System for proximity reporting in an assembly environment

Abstract

Systems for proximity reporting in an assembly environment are disclosed. Methods and systems can be used to report proximity between technicians in an assembly environment. The method includes monitoring, by a proximity server, a distance between a first proximity detector and a second proximity detector based on a first signal and a second signal. The first proximity detector is configured to generate the first signal and the second proximity detector is configured to generate the second signal.

Description

Technical Field

[0001] This disclosure relates to the field of assembly, and more specifically, to systems and methods for reporting proximity between people and machines in an assembly environment. Background Technology

[0002] In assembly or other environments, maintaining physical distance between people is desirable to prevent the spread of infectious diseases (such as COVID-19) (or at least minimize its risk). For example, in an assembly environment, a significant number of technicians gather and move within specific areas. Therefore, it is useful to inform those technicians whether they are in close proximity to each other.

[0003] Furthermore, in assembly environments, the desire remains to assemble parts as quickly and efficiently as possible. It is not uncommon for some assembly tasks to be performed by automated machines, while others are handled by human technicians. To ensure safety, access to the operating area of ​​automated machines is restricted when they are in operation. Additionally, to ensure safety, technicians are restricted from getting too close to other technicians (e.g., by maintaining "social distancing") regardless of whether the automated machine is operating within the operating area. This results in "stayout" zones, which reduce the speed and efficiency of technician operations and lead to slower assembly rates, which is undesirable. Meanwhile, best practices remain independent of operator awareness of nearby automated machines or nearby technicians. Therefore, both automated machines and technicians face limitations, and if they both need to utilize the same area, they are forced to use it at separate times.

[0004] To further complicate matters, it can be difficult to determine a technician's presence in an area if they are obstructed by large parts being worked on. For example, composite parts used in aircraft wings or fuselages can span several feet and thus obstruct a technician's view.

[0005] Therefore, it is desirable to have methods and apparatus that take into account at least some of the issues discussed above, as well as other possible issues. Summary of the Invention

[0006] The implementation described herein dynamically senses the proximity of a technician to another technician or machine via multiple sensors (e.g., sensing beacons), which interact with proximity detectors at the machine and technician locations. These sensing beacons are capable of operating in different detection modes (e.g., by utilizing different timing windows or detection methods).

[0007] This disclosure describes a method for reporting proximity between a technician and a machine in an assembly environment. In one aspect of this disclosure, the method includes monitoring the distance between a first proximity detector and a second proximity detector based on a first signal and a second signal by a proximity server. The first proximity detector is configured to generate a first signal, and the second proximity detector is configured to generate a second signal. The method includes determining that the distance between the first proximity detector and the second proximity detector is less than a threshold. The method includes providing a warning to a first technician using the first proximity detector in response to determining that the distance between the first proximity detector and the second proximity detector is less than the threshold.

[0008] The method includes receiving a first signal from a first proximity detector via a plurality of sensing beacons arranged in an assembly environment. The first proximity detector is worn by a first technician. Furthermore, the method includes receiving a second signal from a second proximity detector via the plurality of sensing beacons, wherein the second proximity detector is worn by a second technician.

[0009] As described above, the first proximity detector is worn by the first technician. A warning provided by the first proximity detector is referred to as a first warning. The method includes, in response to determining that the distance between the first proximity detector and the second proximity detector is less than a threshold, providing a second warning to the second technician using the second proximity detector. The first warning and the second warning are provided simultaneously.

[0010] Providing a first warning using a first proximity detector includes indicating the direction of the location of a second proximity detector. Providing a second warning using a second proximity detector includes indicating the direction of the location of the first proximity detector.

[0011] The method includes receiving a third signal from a third proximity detector via a plurality of sensing beacons, the third proximity detector being disposed at a moving machine within a unit of an assembly environment. Furthermore, the method includes determining a distance between the first proximity detector and the third proximity detector based on the first signal and the third signal. This threshold is referred to as a third threshold. The method includes providing a third warning to a first technician using the first proximity detector in response to determining that the distance between the first proximity detector and the third proximity detector is less than the third threshold. The method includes commanding the machine to stop moving in response to determining that the distance between the first proximity detector and the third proximity detector is less than a fourth threshold. The fourth threshold is higher than the third threshold. The machine is referred to as the first machine among a plurality of machines, and the plurality of machines includes at least one of a robot, a benchtop, or an automated device.

[0012] In this method, providing a third warning using a first proximity detector includes indicating the direction of the third proximity detector's location. The warning includes vibration, visual indication, and / or sound. The method includes attaching the first proximity detector to a wearable item. Furthermore, the method includes providing a warning to at least one of a first technician or a second technician in response to determining that the distance between the first and second proximity detectors is less than a threshold. Additionally, the method includes monitoring the distance between the first and second technicians based on a first signal and a second signal to warn at least one of the first or second technicians in response to determining that the distance between the first and second technicians is less than a threshold. Furthermore, the method includes transmitting a first signal from the first proximity detector to a plurality of beacons via at least one reflector. At least one reflector is installed in the infrastructure body of the assembly environment. The method includes storing the paths of the first and second technicians by a proximity server to track movement within the assembly environment. The first and second proximity detectors are part of a plurality of proximity detectors, and the plurality of proximity detectors includes more than two proximity detectors.

[0013] The method includes, in response to determining that the distance between a first proximity detector and a second proximity detector is less than a second threshold, providing a second warning to a first technician using the first proximity detector. The second threshold is less than a first threshold, and the first warning is different from the second warning. At least a portion of an aircraft is assembled according to the method described above.

[0014] This disclosure also describes a system for proximity reporting in an assembly environment. In one aspect of this disclosure, the system includes a first proximity detector. The first proximity detector is configured to be worn by a first technician. The system also includes a second proximity detector. The second proximity detector is configured to be worn by a second technician. Each of the first and second proximity detectors is wearable. The system also includes a proximity server that communicates with the first and second proximity detectors. The proximity server is programmed to monitor the distance between the first and second proximity detectors. Additionally, the proximity server is programmed to determine whether the distance between the first and second proximity detectors is less than a threshold. Furthermore, the proximity server is programmed to, in response to determining that the distance between the first and second proximity detectors is less than the threshold, command the first proximity detector to provide a warning to the first technician.

[0015] The system includes multiple sensing beacons that communicate with a first proximity detector, a second proximity detector, and a proximity server. The first proximity detector includes a first transceiver configured to send a first signal to the multiple sensing beacons. The second proximity detector includes a second transceiver configured to send a second signal to the multiple sensing beacons. The proximity server is programmed to determine, based on the first and second signals, whether the distance between the first and second proximity detectors is less than a threshold. A warning is referred to as a first warning, and the proximity server is programmed to, in response to determining that the distance between the first and second proximity detectors is less than the threshold, command the second proximity detector to provide a second warning to a second technician.

[0016] The first warning includes an indication of the direction of the location of the second proximity detector. The second warning includes an indication of the direction of the location of the first proximity detector. The first and second proximity detectors are configured to provide both the first and second warnings simultaneously.

[0017] The system includes a third proximity detector that communicates with a first proximity detector, a second proximity detector, and a proximity server. The third proximity detector is positioned at a moving machine within a unit of the assembly environment. The machine is referred to as the first machine among a plurality of machines, and the plurality of machines includes at least one of a robot, a bench, or an automated device.

[0018] A first proximity detector includes a first transceiver configured to transmit a first signal to a plurality of sensing beacons. A second proximity detector includes a second transceiver configured to transmit a second signal to the plurality of sensing beacons. A third proximity detector includes a third transceiver configured to transmit a third signal to the plurality of sensing beacons. A proximity server is programmed to determine the distance between the first and third proximity detectors based on the first and third signals. A threshold is referred to as a first threshold, and the proximity server is programmed to, in response to determining that the distance between the first and third proximity detectors is less than the third threshold, command the first proximity detector to provide a third warning to a first technician. The first proximity detector is configured to provide directional indication of the location of the third proximity detector.

[0019] The proximity server is programmed to determine the distance between a second proximity detector and a third proximity detector based on a second and a third signal. The proximity server is programmed to, in response to determining that the distance between the first and third proximity detectors is less than a third threshold, command the first proximity detector to provide a third warning to a first technician. The proximity server is programmed to, in response to determining that the distance between the first and third proximity detectors is less than a fourth threshold, and that the fourth threshold is less than the third threshold, command the machine to stop moving. Warnings include vibration, visual indication, and / or sound. The first proximity detector is attached to a wearable device.

[0020] The system includes multiple reflectors deployed in the assembly environment. A first proximity detector is configured to send a first signal to multiple beacons via the multiple reflectors. At least one of the multiple reflectors is mounted on the infrastructure body. A proximity server is configured to store the paths of a first technician and a second technician to track movement within the assembly environment. The first and second proximity detectors are part of a plurality of proximity detectors, and the plurality of proximity detectors includes more than two proximity detectors.

[0021] A first proximity detector is configured to provide a second warning to a first technician in response to determining that the distance between the first and second proximity detectors is less than a second threshold. The second threshold is less than the first threshold, and the first warning is different from the second warning. At least a portion of the aircraft is manufactured using the system described above.

[0022] This disclosure also describes a wearable article. In one aspect of this disclosure, the wearable article includes an article body and a first proximity detector attached to the article body. The first proximity detector is configured to generate a first signal indicating the location of the first proximity detector. The first proximity detector includes a transceiver configured to transmit the first signal to a plurality of sensing beacons and receive data indicating a distance between the first proximity detector and a second proximity detector. The transceiver is configured to receive data indicating that the distance between the first proximity detector and the second proximity detector is less than a threshold. The wearable article includes an alarm coupled to the transceiver. The alarm is configured to provide a warning in response to receiving data indicating that the distance between the first proximity detector and the second proximity detector is less than the threshold.

[0023] A first proximity detector is configured to indicate the direction of the position of a second proximity detector. Furthermore, the first proximity detector is configured to receive data from a proximity server indicating that the distance between the first and second proximity detectors is less than a threshold. The proximity server is programmed to determine whether the distance between the first and second proximity detectors is less than the threshold based on a first signal and a second signal generated by the second proximity detector. The first proximity detector communicates with a third proximity detector located at a moving machine arranged within a unit of the assembly environment. This threshold is referred to as a first threshold, and the first proximity detector is configured to receive data indicating that the distance between the first and third proximity detectors is less than a third threshold.

[0024] An alarm of the first proximity detector is configured to provide a third warning in response to determining that the distance between the first proximity detector and a third proximity detector is less than a third threshold. The warning includes vibration, visual indication, and / or sound. A transceiver of the first proximity detector is configured to send a first signal to a plurality of beacons via a plurality of reflectors. This threshold is referred to as the first threshold, and the warning is referred to as the first warning. An alarm of the first proximity detector is configured to provide a second warning in response to determining that the distance between the first proximity detector and a second proximity detector is less than a third threshold. The third threshold is less than the first threshold, and the first warning is different from the second warning. Wearable items are used to manufacture at least a portion of an aircraft.

[0025] According to one aspect of this disclosure, a method for reporting proximity between technicians in an assembly environment includes: monitoring the distance between a first proximity detector and a second proximity detector by a proximity server based on a first signal and a second signal, wherein the first proximity detector is configured to generate the first signal and the second proximity detector is configured to generate the second signal.

[0026] Advantageously, the method further includes determining that the distance between the first proximity detector and the second proximity detector is less than a threshold.

[0027] Preferably, the method further includes providing a warning to a first technician using the first proximity detector in response to determining that the distance between the first proximity detector and the second proximity detector is less than a threshold.

[0028] Preferably, the method further includes receiving a first signal from a first proximity detector via a plurality of sensing beacons arranged in the assembly environment, wherein the first proximity detector is worn by a first technician; and receiving a second signal from a second proximity detector via the plurality of sensing beacons, wherein the second proximity detector is worn by a second technician.

[0029] Preferably, the method is a method in which the warning is a first warning, and the method further includes: in response to determining that the distance between the first proximity detector and the second proximity detector is less than a threshold, providing a second warning to a second technician using the second proximity detector, and providing the first warning and the second warning simultaneously.

[0030] Preferably, the method is one in which providing a first warning using a first proximity detector includes indicating the direction of the location of a second proximity detector; and providing a second warning using a second proximity detector includes indicating the direction of the location of the first proximity detector.

[0031] Preferably, the method further includes receiving a third signal from a third proximity detector via a plurality of sensing beacons, the third proximity detector being disposed at a moving machine within a unit of the assembly environment.

[0032] Preferably, the method further includes determining the distance between the first proximity detector and the third proximity detector based on the first signal and the third signal.

[0033] Preferably, the method is a method in which the threshold is a first threshold, and the method further includes: in response to determining that the distance between the first proximity detector and the third proximity detector is less than the third threshold, providing a third warning to the first technician using the first proximity detector.

[0034] Preferably, the method further includes, in response to determining that the distance between the first proximity detector and the third proximity detector is less than a fourth threshold, commanding the machine to stop moving, wherein the fourth threshold is less than the third threshold.

[0035] Preferably, the method is a method in which the machine is a first machine among a plurality of machines, and the plurality of machines includes at least one of a robot, a bench, or an automated device.

[0036] Preferably, the method is one in which providing a third warning using a first proximity detector includes indicating the direction of the location of the third proximity detector.

[0037] Preferably, the method is one in which the warning includes vibration.

[0038] Preferably, the method is one in which the warning includes a visual indication.

[0039] Preferably, the method is one in which the warning includes an audio signal.

[0040] Preferably, the method further includes attaching a first proximity detector to a wearable item.

[0041] Preferably, the method includes, in response to determining that the distance between the first proximity detector and the second proximity detector is less than a threshold, further providing a warning to at least one of the first technician or the second technician.

[0042] Preferably, the method further includes monitoring the distance between the first technician and the second technician based on a first signal and a second signal, and issuing a warning to at least one of the first technician or the second technician in response to determining that the distance between the first technician and the second technician is less than a threshold.

[0043] Preferably, the method is a method in which, preferably, the method further includes transmitting a first signal from a first proximity detector to a plurality of sensing beacons via at least one reflector.

[0044] Preferably, the method is one in which at least one reflector is mounted on the infrastructure body in the assembly environment.

[0045] Preferably, the method further includes tracking movement in the assembly environment by storing the paths of the first technician and the second technician on a proximity server.

[0046] Preferably, the method is one in which the first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors includes more than two proximity detectors.

[0047] Preferably, the method is a method in which the threshold is a first threshold, the warning is a first warning, and the method further includes providing a second warning to a first technician using the first proximity detector in response to determining that the distance between the first proximity detector and the second proximity detector is less than a third threshold, the third threshold being less than the first threshold, and the first warning being different from the second warning.

[0048] Assemble at least a portion of the aircraft according to the above method.

[0049] According to one aspect of this disclosure, a system for proximity reporting in an assembly environment is provided, the system comprising: a first proximity detector configured to be worn by a first technician; a second proximity detector configured to be worn by a second technician, each of the first and second proximity detectors being wearable; and a proximity server communicating with the first and second proximity detectors, wherein the proximity server is programmed to monitor the distance between the first and second proximity detectors.

[0050] Advantageously, the system is a system in which the proximity server is programmed to determine whether the distance between the first proximity detector and the second proximity detector is less than a threshold.

[0051] Preferably, the system is a system in which the proximity server is programmed to: in response to determining that the distance between the first proximity detector and the second proximity detector is less than a threshold, command the first proximity detector to provide a warning to the first technician.

[0052] Preferably, the system also includes multiple sensing beacons that communicate with the first proximity detector, the second proximity detector, and the proximity server.

[0053] Preferably, the system is a system in which the first proximity detector includes a first transceiver configured to send a first signal to a plurality of sensing beacons.

[0054] Preferably, the system is a system in which the second proximity detector includes a second transceiver configured to send a second signal to a plurality of sensing beacons.

[0055] Preferably, the system is a system in which the proximity server is programmed to determine whether the distance between the first proximity detector and the second proximity detector is less than a threshold based on a first signal and a second signal.

[0056] Preferably, the system is a system in which the warning is a first warning, and the proximity server is programmed to, in response to determining that the distance between the first proximity detector and the second proximity detector is less than a threshold, command the second proximity detector to provide a second warning to the second technician.

[0057] Preferably, the system is such that the first warning includes an indication of the direction of the location of the second proximity detector; and the second warning includes an indication of the direction of the location of the first proximity detector.

[0058] Preferably, the system is a system in which a first proximity detector and a second proximity detector are configured to simultaneously provide a first warning and a second warning.

[0059] Preferably, the system further includes a third proximity detector that communicates with the first proximity detector, the second proximity detector, and the proximity server, wherein the third proximity detector is arranged at a moving machine within a unit of the assembly environment.

[0060] Preferably, the system is a system in which the machine is the first of a plurality of machines, and the plurality of machines includes at least one of a robot, a bench, or an automated device.

[0061] Preferably, the system is a system in which a first proximity detector includes a first transceiver configured to transmit a first signal to a plurality of sensing beacons, a second proximity detector includes a second transceiver configured to transmit a second signal to a plurality of sensing beacons, a third proximity detector includes a third transceiver configured to transmit a third signal to a plurality of sensing beacons, and a proximity server is programmed to determine the distance between the first proximity detector and the third proximity detector based on the first signal and the third signal.

[0062] Preferably, the system is a system in which the threshold is a first threshold, and the proximity server is programmed to command the first proximity detector to provide a third warning to the first technician in response to determining that the distance between the first proximity detector and the third proximity detector is less than the third threshold.

[0063] Preferably, the system is a system in which a first proximity detector is configured to provide an indication of the direction of the position of a third proximity detector.

[0064] Preferably, the system is a system in which the proximity server is programmed to determine the distance between the second proximity detector and the third proximity detector based on the second signal and the third signal.

[0065] Preferably, the system is a system in which the proximity server is programmed to command the first proximity detector to provide a third warning to the first technician in response to determining that the distance between the first proximity detector and the third proximity detector is less than a third threshold.

[0066] Preferably, the system is a system in which the proximity server is programmed to command the first machine to stop moving in response to determining that the distance between the first proximity detector and the third proximity detector is less than a fourth threshold, wherein the fourth threshold is less than the third threshold.

[0067] Preferably, the system is a system in which the warning includes vibration.

[0068] Preferably, the system is a system in which the warning includes a visual indication.

[0069] Preferably, the system is a system in which the warning includes sound.

[0070] Preferably, the system is a system in which a first proximity detector is attached to a wearable item.

[0071] Preferably, the system further includes a plurality of reflectors arranged in the assembly environment, wherein the first proximity detector is configured to send a first signal to a plurality of sensing beacons through the plurality of reflectors.

[0072] Preferably, the system is a system in which at least one of a plurality of reflectors is mounted on the infrastructure body.

[0073] Preferably, the system is one in which the proximity server is configured to store the paths of the first technician and the second technician to track movement within the assembly environment.

[0074] Preferably, the system is a system in which the first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors includes more than two proximity detectors.

[0075] Preferably, the system is a system in which the threshold is a first threshold, the warning is a first warning, and the first proximity detector is configured to provide a second warning to a first technician in response to determining that the distance between the first proximity detector and the second proximity detector is less than a third threshold, wherein the third threshold is less than the first threshold and the first warning is different from the second warning.

[0076] The aforementioned system is used to manufacture a part of an aircraft.

[0077] According to one aspect of this disclosure, a wearable article includes: an article body; and a first proximity detector attached to the article body, wherein the first proximity detector is configured to generate a first signal indicating the position of the first proximity detector, and the first proximity detector includes: a transceiver configured to transmit the first signal to a plurality of sensing beacons and receive data indicating the distance between the first proximity detector and a second proximity detector.

[0078] Advantageously, a wearable item is an item in which a transceiver is configured to receive data indicating that the distance between a first proximity detector and a second proximity detector is less than a threshold.

[0079] Preferably, the wearable item further includes an alarm coupled to the transceiver, wherein the alarm is configured to provide a warning in response to receiving data indicating that the distance between the first proximity detector and the second proximity detector is less than a threshold.

[0080] Preferably, the wearable article is an article in which the first proximity detector is configured to indicate the direction of the position of the second proximity detector.

[0081] Preferably, the wearable item is an item in which a first proximity detector is configured to receive data from a proximity server indicating that the distance between the first proximity detector and a second proximity detector is less than a threshold, and the proximity server is programmed to determine whether the distance between the first proximity detector and the second proximity detector is less than the threshold based on a first signal and a second signal generated by the second proximity detector.

[0082] Preferably, the wearable article is an article in which a first proximity detector communicates with a third proximity detector located at a machine moving within a unit of the assembly environment.

[0083] Preferably, the wearable item is an item in which the threshold is a first threshold, and the first proximity detector is configured to receive data indicating that the distance between the first proximity detector and the third proximity detector is less than the third threshold.

[0084] Preferably, the wearable item is an item in which the alarm of the first proximity detector is configured to provide a third warning in response to determining that the distance between the first proximity detector and the third proximity detector is less than a third threshold.

[0085] Preferably, the wearable item is an item in which the warning includes vibration.

[0086] Preferably, the wearable item is an item in which the warning includes visual indications.

[0087] Preferably, the wearable item is an item in which the warning includes sound.

[0088] Preferably, the wearable article is an article in which the transceiver of the first proximity detector is configured to send a first signal to a plurality of sensing beacons via a plurality of reflectors.

[0089] Preferably, the wearable item is an item in which the threshold is a first threshold, the warning is a first warning, and the alarm of the first proximity detector is configured to provide a second warning in response to determining that the distance between the first proximity detector and the second proximity detector is less than a third threshold, the third threshold being less than the first threshold and the first warning being different from the second warning.

[0090] The aforementioned wearable items are used to manufacture part of the aircraft.

[0091] Other illustrative embodiments are described below (e.g., methods and computer-readable media related to the foregoing embodiments). The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, as can be seen in the following description and accompanying drawings for further details. Attached Figure Description

[0092] Some embodiments of this disclosure will now be described by way of example only and with reference to the accompanying drawings. In all the drawings, the same reference numerals denote the same elements or elements of the same type.

[0093] Figure 1 This is a schematic diagram of an proximity reporting system according to an aspect of this disclosure, wherein a technician is within a predetermined distance of another technician.

[0094] Figure 2 yes Figure 1 A schematic block diagram of a proximity reporting system.

[0095] Figure 3 yes Figure 1 A schematic block diagram of a proximity reporting system; wherein the proximity reporting system reports when a technician is within a predetermined distance from the machine.

[0096] Figure 4 yes Figure 1 A schematic block diagram of the proximity detector in a proximity reporting system.

[0097] Figure 5 This is a front view of a technician wearing a helmet coupled to a smart face mask.

[0098] Figure 6A This is the first part of a flowchart for reporting methods of proximity between technicians in an assembly environment.

[0099] Figure 6B This is the second part of a flowchart for reporting methods of proximity between technicians in an assembly environment. Detailed Implementation

[0100] The accompanying drawings and the following description provide specific illustrative embodiments of this disclosure. Therefore, it will be understood that, although not explicitly described or shown herein, those skilled in the art will be able to design various arrangements embodying the principles of this disclosure and included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and should be construed as not being limited to such specific instances and conditions. Consequently, this disclosure is not limited to the specific embodiments or examples described below, but is defined by the technical solutions and their equivalents.

[0101] See Figure 1 and Figure 2 The proximity reporting system 100 is configured to monitor and determine the distance between proximity detectors 160 within the assembly environment 130, and is also referred to as a system for proximity reporting in the assembly environment 130. The proximity reporting system 100 is used in the manufacture of at least a portion of the aircraft and is further enhanced to differentiate between technicians 150 and machines 140, and to provide warnings and / or other mitigation measures based on the distance between technicians 150 and machines 140. This provides technical benefits by ensuring physical distance between technicians 150 and the safety of technicians 150 working near machines 140, while also increasing the working time of machines 140 within the unit. It also ensures that parts within the unit do not obscure technicians 150 and prevent their detection. As used herein, "unit" includes any dedicated workspace or volume in which one or more machines 140 operate.

[0102] The proximity reporting system 100 includes a proximity reporting server 110 and multiple sensing beacons 120 (e.g., radio antennas, ultra-wideband (UWB) transceivers, cameras, etc.) communicating with the proximity reporting server 110. The sensing beacons 120 receive input from one or more proximity detectors 160, which are disposed inside or outside one or more units (e.g., first unit 132 and second unit 133) of the assembly environment 130 (e.g., a factory floor). Therefore, the sensing beacons 120 operate as an interface between the proximity reporting server 110 and the proximity detectors 160. A controller 112 checks the ultra-wideband (UWB) input from the sensing beacons 120. The assembly environment 130 includes one or more infrastructure bodies 131, such as beams, floors, ceilings, walls, etc. The sensing beacons 120 are attached to the infrastructure bodies 131. For example, the sensing beacons 120 are movably coupled to one or more of the infrastructure bodies 131. As a non-limiting example, the pivotable mount interconnects one of the sensing beacons in the infrastructure body 131 and the sensing beacon 120 to facilitate receiving signals from the proximity detector 160.

[0103] The proximity detector 160 can be worn or carried by one or more technicians 150. For example, the proximity detector 160 is carried by the technician 150 via a cellular phone or other similar device. Additionally, the proximity detector 160 is arranged at a portion 142 (e.g., a moving part) of the machine 140. The machine 140 includes robots, benchtops, automated equipment, robotic arms, automated guided vehicles (AGVs), flexible track machines, industrial mobile robots (IMRs), and other automated equipment moving within the first unit 132. A first technician 150a wears the first proximity detector 160a at a first position P1, and a second technician 150b wears the second proximity detector 160b at a second position P2. Both the first technician 150a and the second technician 150b are arranged inside the first unit 132. As a non-limiting example, no technician is present in the second unit 133. Each of the first proximity detector 160a and the second proximity detector 160b is configured to be attached to or as part of a wearable article 161. The wearable article 161 is used to manufacture at least a portion of an aircraft and is a crash helmet 165. Figure 5The proximity detector 160 may be clothing, protective clothing, an application for a smartphone or tablet, or other items that can be worn or carried by a technician 150. A first proximity detector 160a is part of or attached to a first wearable item 161a, and a second proximity detector 160b is part of or attached to a second wearable item 161b. Thus, both the first proximity detector 160a and the second proximity detector 160b are considered wearable. Each proximity detector 160 is configured to generate a signal indicating the location of the proximity detector 160. For example, the first proximity detector 160a is configured to generate a first signal indicating the location of the first proximity detector 160a (i.e., a first location P1), and the second proximity detector 160b is configured to generate a second signal indicating the location of the second proximity detector 160b (i.e., a second location P2). In one aspect of this disclosure, the proximity reporting system 100 includes more than two proximity detectors 160.

[0104] In addition to proximity detector 160, proximity reporting system 100 also includes proximity reporting server 110 that communicates wirelessly with proximity detector 160 via sensing beacon 120. Proximity reporting server 110 includes controller 112 and memory 114 coupled to controller 112. Memory 114 is capable of storing data, and controller 112 is capable of processing data by, for example, executing computer-readable instructions.

[0105] Based on a first signal from a first proximity detector 160a and a second signal from a second proximity detector 160b, the controller 112 of the proximity reporting server 110 determines the position of each of the first proximity detector 160a and the second proximity detector 160b. If the distance from the first proximity detector 160a worn by the first technician 150a to the second proximity detector 160b worn by the second technician 150b (i.e., a first distance D1) is less than a predetermined threshold (i.e., a first threshold) stored in memory 114, the controller 112 provides one or more warnings to the first technician 150a and the second technician 150b respectively using the first proximity detector 160a and the second proximity detector 160b. The controller 112 is implemented as, for example, custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0106] To account for the presence of obstructing objects 170 (e.g., fuselage sections, wing panels, etc.) that block the line of sight to one of the detectors 160 (and thus hinder detection by technician 150 or machine 140), a reflector 180 (such as a mirror) is attached to one of the infrastructure components 131 (e.g., wall, ceiling, floor, etc.) to form a detection path 182. The reflector 180 is capable of reflecting wavelengths of electromagnetic radiation utilized by the sensing beacon 120. Therefore, in embodiments where the sensing beacon 120 includes a camera, the reflector 180 reflects light wavelengths. In embodiments where the sensing beacon 120 detects radio wavelengths, the reflector 180 is capable of reflecting radio wavelengths. As used herein, the term "reflector" refers to an object capable of reflecting and redirecting signals with substantially no signal attenuation (e.g., more than ten percent, more than one percent, etc.).

[0107] refer to Figure 3 A first technician 150a (or any other technician 150) wears or carries a first proximity detector 160a at a first position P1 within the first unit 132, and is at a distance (i.e., a second distance D2) from the machine 140. A second technician 150b wears or carries a second proximity detector 160b at a second position P2. At least one of the machines 140 has a third proximity detector 160c at a third position P3 within the first unit 132. The third proximity detector 160c is located at a moving part of the machine 140, the base of the machine 140, an end effector at the machine 140, etc. (i.e., part 142 of the machine 140). During use, the third proximity detector 160c is configured to generate a third signal indicating the position of the machine 140 (i.e., the third position P3). Furthermore, as described, there is currently no technician or proximity detector within the second unit 133.

[0108] Based on a first signal from a first proximity detector 160a and a third signal from a third proximity detector 160c, the controller 112 of the proximity reporting server 110 determines and monitors the position of each of the first proximity detector 160a and the third proximity detector 160c. If the distance from the first proximity detector 160a to the third proximity detector 160c (i.e., a second distance D2) is less than a predetermined threshold (i.e., a third threshold) stored in the memory 114, the controller 112 provides a warning to the first technician 150a using the first proximity detector 160a. If the distance from the first proximity detector 160a to the third proximity detector 160c (i.e., the second distance D2) is less than a fourth threshold (which is less than the third threshold and is stored in the memory 114), the controller 112 commands the machine 140 to stop moving.

[0109] Based on a second signal from the second proximity detector 160b and a third signal from the third proximity detector 160c, the controller 112 of the proximity reporting server 110 determines the position of each of the second proximity detector 160b and the third proximity detector 160c. If the distance from the second proximity detector 160b to the third proximity detector 160c is less than a predetermined threshold (i.e., the third threshold) stored in the memory 114, the controller 112 provides a warning to the second technician 150b using the second proximity detector 160b. If the distance from the second proximity detector 160b to the third proximity detector 160c is less than a fourth threshold (which is less than the third threshold and is stored in the memory 114), the controller 112 commands the machine 140 to stop moving.

[0110] Based on a first signal from a first proximity detector 160a and a second signal from a second proximity detector 160b, the controller 112 of the proximity reporting server 110 determines the position of each of the first proximity detector 160a and the second proximity detector 160b. If the distance from the first proximity detector 160a worn or carried by the first technician 150a to the second proximity detector 160b worn or carried by the second technician 150b (i.e., a first distance D1) is less than a predetermined threshold (i.e., a first threshold) stored in the memory 114, the controller 112 provides one or more warnings to the first technician 150a and the second technician 150b respectively using the first proximity detector 160a and the second proximity detector 160b.

[0111] The proximity reporting server 110 is configured to adjust the sensing heuristic in response to the presence of an obstructing object 170 in the first unit 132. In this way, the sensing beacon 120 can detect the technician 150 using signaling transmitted along the detection path 182 via the reflector 180. The presence of the obstructing object 170 is detected automatically by the sensing beacon 120 or by input indication provided to the controller 112 from an external source.

[0112] For the omnidirectional sensing beacon 120, the change in sensing probe includes adjusting the timing window in which input is acquired (i.e., taking into account the increased input delay due to the increased path length caused by the reflector). Specifically, the increased path length results in a corresponding delay, and the sampling window used to detect input via the sensing beacon 120 shifts in time by an amount equal to the delay. This change in sampling window timing varies between the sensing beacons 120, but is based on the known position and orientation of the reflector 180 with which each sensing beacon 120 interacts. The sensing beacons 120 are oriented and can be adjusted to point in new directions. The change in sensing probe includes pointing the sensing beacon 120 towards the reflector 180 to receive a signal from the detection path 182. As a non-limiting example, a finite number of sensing beacons 120 adjust their sensing probes. The number of sensing beacons 120 (e.g., three) is chosen to ensure that the technician 150 remains immediately detectable from any position behind the obstructing object 170. Therefore, the positions P1 of the first proximity detector 160a, P2 of the second proximity detector 160b, and P3 of the third proximity detector 160c can be triangulated (after timing the received signals to account for path differences caused by the reflector 180). This allows the technician 150 to remain detected while moving within the first unit 132.

[0113] In short, machine 140 and technician 150 are configured to provide their locations to proximity reporting server 110 and compare these locations with each other. Based on this comparison, different levels of warnings / remedies (e.g., warning personnel and / or shutting down machines) are provided to ensure physical distance and safety between people working together in the same unit / area and between people and machines. The use of reflector 180 ensures that the proximity reporting technology and system discussed herein remain effective regardless of the presence of obstructing object 170.

[0114] Figure 4This is a block diagram of an example of a proximity detector 160. The proximity detector 160 includes a detector controller 310, a detector memory 320, and a main transceiver 330. As a non-limiting example, the main transceiver 330 of a first proximity detector 160a is referred to as a first transceiver (configured to transmit a first signal), the main transceiver 330 of a second proximity detector 160b is referred to as a second transceiver (configured to transmit a second signal), and the main transceiver 330 of a third proximity detector 160c is referred to as a third transceiver (configured to transmit a third signal). In addition to the main transceiver 330, the proximity detector 160 includes an auxiliary transceiver 340. The main transceiver 330 and the auxiliary transceiver 340 operate using different frequency ranges (or communication modes, such as optical and radio) to transmit signals from the proximity detector 160. Thus, if one frequency range experiences interference or noise, the other transceiver still provides a signal in another frequency range. The proximity detector 160 also includes a vibration generator 360 (e.g., a piezoelectric element, vibration motor, etc.), a speaker 350, and / or a visual indicator 361 (e.g., a light, a visual user interface, etc.). The vibration generator 360, speaker 350, and / or visual indicator 361 are collectively or individually referred to as an alarm 349. The vibration generator 360 is configured to generate vibrations. The speaker 350 is configured to emit sound. The visual indicator 361 is configured to generate visual cues, such as light. The alarm 349 is coupled to a main transceiver 330 and an auxiliary transceiver 340. The proximity detector 160 is part of or attached to the body 163 of a wearable article 161 (e.g., a helmet, goggles, clothing, face mask, headset, etc.). Thus, one or more wearable articles 161 include one or more elements of the proximity detector 160 (e.g., a vibration generator, etc.). Specifically, for the first proximity detector 160a and the second proximity detector 160b, worn by the first technician 150a and the second technician 150b respectively, the proximity detector 160 is a wearable product that is part of (or attached to) the article body 163 of the wearable article 161. However, for the third proximity detector 160c arranged at the machine 140, the proximity detector 160 is not wearable and is not attached to (or is not part of) the wearable article 161. Instead, the third proximity detector 160c is arranged on or within a portion 142 of the machine 140.

[0115] When a warning is generated, the detector controller 310 activates one or all of these elements (i.e., vibration generator 360, one or more speakers 350, and / or visual indicator 361) to draw the attention of the technician 150. The visual indicator 361 generates an alarm at the goggles or face shield worn by the technician 150 to elicit a flash, other visual input, or a vibration providing a warning. For example, an audio warning is generated by a portion of the goggles located near the temples of the technician 150 (particularly, the ends of the temples). The speaker 350 is a headset or earpiece. The goggles may, for example, include smart safety glasses with visual, audio, vibration warnings, or any combination thereof. As a non-limiting example, the face shield is configured as a smart face shield 362 with visual, audio, warning, vibration warnings, or any combination thereof. Figure 5 For example, a warning from the first proximity detector 160a includes an indication of the direction of the location of the second proximity detector 160b or another proximity detector 160. Similarly, the second proximity detector 160b includes an indication of the location of the first proximity detector 160a or another proximity detector 160. To provide location indication, one or more speakers 350 (such as headphones) emit verbal utterances indicating the location of the other proximity detector 160. Alternatively (or additionally), a visual indicator 361 activates light at a specific location on goggles or a face shield to indicate the direction of the other proximity detector 160. This light is shaped into arrows to indicate the direction of the other proximity detector among the proximity detectors 160. A warning from the first proximity detector 160a is referred to as a first warning. A warning from the second proximity detector 160b is referred to as a second warning, and a warning from the third proximity detector 160c is referred to as a third warning. To differentiate between warnings, a warning from the proximity of machine 140 has a different pitch or frequency of flashing than a warning from the proximity of another technician 150. The warning also indicates the direction of the proximity detector 160, which is closest to the technician 150.

[0116] The proximity detector 160 is part of or attached to the body 163 of a wearable item 161 (e.g., a helmet, goggles, clothing, face mask, headset, etc.). Therefore, one or more wearable items 161 include one or more elements of the proximity detector 160 (e.g., a vibration generator, etc.). Using Bluetooth technology, a technician 150 wears a base station wearable item 161 that communicates with the proximity detector 160. The wearable item 161 is, for example, a hat, helmet, gloves, glasses, vest, etc., that implements the proximity detector 160. As a non-limiting example, a helmet is configured to provide a warning indicating the approach of a machine, while glasses are configured to provide a warning indicating the approach of a technician.

[0117] The proximity detector 160 includes (or is coupled to) an inertial measurement unit 395, which is capable of detecting accelerations indicating the motion of the proximity detector 160. By integrating these accelerations over a period of time (e.g., once per second, every fraction of a second, at kilohertz, etc.), the movement of the technician 150 or machine 140 can be determined. This information is used to verify or supplement the position data determined via the sensing beacon 120. For example, the inertial measurement unit 395 has a sampling rate that is substantially higher than that of the sensing beacon 120. Therefore, the inertial measurement unit 395 is used to detect rapid movement of the technician 150 or machine 140 between UWB pulses received / transmitted by the sensing beacon 120. This helps to accurately detect the positions of multiple technicians 150 and multiple machines 140, even when the technician 150 or machine 140 is moving rapidly between detection pulses used for the sensing beacon 120.

[0118] The inertial measurement unit 395 provides the controller 112 of the proximity reporting server 110 with position updates for the technician 150 (e.g., first technician 150a and / or second technician 150b). The inertial measurement unit 395 receives information indicating the position of the proximity detector 160. The detector controller 310 then internally updates its position based on the input from the inertial measurement unit 395 during intervals when the sensing beacon 120 is not operating (e.g., within a fraction of a second). Thus, the proximity reporting server 110 stores the paths of the technician 150 (e.g., first technician 150a and / or second technician 150b) and the machine 140 in memory 114 to track the movement of the technician 150 and the machine 140 within the assembly environment 130. If the input from the inertial measurement unit 395 indicates that the proximity detector 300 has moved closer than a threshold distance during the interval, the detector controller 310 generates a warning as described above to alert the technician 150 wearing the proximity detector 160.

[0119] The proximity detector 160 also includes a battery 370 and a sensor 380. The sensor 380 detects the battery level (e.g., by measuring the voltage at the battery 370). The sensor 380 reports the battery level to the detector controller 310. If the battery level is below a predetermined value, the detector controller 310 generates a battery level warning via a speaker 350, a visual indicator 361, and / or a vibration generator 360. The proximity detector 160 also includes a button 390. Pressing the button 390 operates the first proximity detector 160a to issue a command to remotely stop the machine 140, which is in the same unit (e.g., first unit 132) as the technician 150.

[0120] Battery level information is reported to proximity reporting server 110. Each of the first unit 132 and the second unit 133 is associated with a predetermined battery level. This is to ensure that proximity detector 160 continues to operate at the expected battery level when technician 150 performs inspection or maintenance within the unit (e.g., first unit 132). Upon entering the first unit 132 or the second unit 133 as determined by the triangulation position of proximity detector 160, controller 112 of proximity reporting server 110 compares the current battery level with the expected battery level for the first unit 132 or the second unit 133. When technician 150 attempts to enter the first unit 132 or the second unit 133, if the battery level is below the predetermined battery level, controller 112 instructs proximity detector 160 to generate a warning. Proximity reporting server 110 estimates the period of time technician 150 is expected to remain in the first unit 132 or the second unit 133 they currently occupy, and instructs proximity detector 160 to generate a battery level warning if the battery level drops below the expected battery level at that point in time during the inspection or maintenance process.

[0121] The proximity reporting server 110 determines that at least one of the proximity detectors 160 has not sent a signal for a period longer than a predefined duration (e.g., one second, ten seconds, thirty seconds, one minute, etc.). In response to this determination, the proximity reporting server 110 sends a stop command to all machines in the first unit 132 or the second unit 133 where the proximity detector 160 was most recently detected. This ensures safety in the event of an unexpected power outage of the proximity detector and allows the technician 150 to safely leave the unit even in the event of a complete power outage or equipment malfunction.

[0122] The proximity detectors 160, such as those worn or placed at one of the machines 140 by a technician 150, are equipped without all of the aforementioned components (e.g., speaker 350). The proximity detectors 160 are directly attached to the power supply of the machine 140 to which they are attached and have a controller that communicates directly with the controller of the machine 140 to which they are mounted.

[0123] See Figure 5In one aspect of this disclosure, wearable item 161 is a crash helmet 165 worn by technician 150. A visual indicator 361 is configured as a smart mask 362 covering the face of technician 150. In another aspect of this disclosure, the visual indicator 361 is configured as smart goggles covering the eyes of technician 150. The smart mask 362 is coupled to the crash helmet 165 and activates light 364 at a specific location to indicate the direction of another proximity detector 160. These light lights 364 are shaped like arrows to indicate the direction of another proximity detector among the proximity detectors 160. For example, one or more light lights 364 are activated to indicate the direction of the nearest proximity detector among the proximity detectors 160. Alternatively (or additionally), the direction of an adjacent proximity detector among the proximity detectors 160 is indicated via a speaker 350 through a verbal warning. These verbal warnings take the form of verbal warnings stating phrases such as “stop moving forward,” “do not move left,” “do not move south,” or similar phrases.

[0124] Figure 6A and Figure 6B A flowchart illustrating a method 400 for reporting proximity between technician 150 and machine 140 is described together. During method 400, machine 140 is operated to assemble or join composite parts and / or metal parts used in aircraft. (See reference...) Figure 1 The proximity reporting system 100 described herein describes the steps of method 400, but method 400 can be executed in other systems. For example, proximity reporting server 110 is programmed to execute method 400. The steps in the flowchart described herein are not all included, and in one aspect of this disclosure, method 400 includes other steps not shown. In another aspect of this disclosure, the steps described herein are performed in an alternative order.

[0125] Method 400 begins at frame 402. Method 400 then proceeds to frame 404. In frame 404, the first technician 150a is equipped with a first proximity detector 160a. The first proximity detector 160a is wearable because it is carried on the first technician 150a in a hands-free manner. Therefore, the first proximity detector 160a is attached to the body 163 of a wearable item 161 worn by the first technician 150a. For example, the first proximity detector 160a is attached to the technician 150a's headwear (e.g., a helmet), fastened to the fabric of the clothing worn by the first technician 150a by hook-and-loop fasteners, placed in the pocket of the first technician 150a, taken as a pendant or smartwatch worn by the first technician 150a, sewn or integrated into the clothing worn by the first technician 150a, implemented as smart safety glasses or a mask providing visual, audio, or vibration warnings or any combination thereof, or equipped by other means. The first proximity detector 160a includes either a cellular phone or a tablet computer and utilizes technology such as Global Positioning System (GPS). Method 400 then proceeds to box 406.

[0126] In box 406, the second technician 150b is equipped with a second proximity detector 160b. As discussed above, the second proximity detector 160b is wearable because it is carried on the second technician 150b in a hands-free manner. Therefore, the second proximity detector 160b is attached to the body 163 of a wearable item 161 worn by the second technician 150b. For example, the second proximity detector 160b is attached to the technician 150b's headwear (e.g., a helmet), fastened to the fabric of the clothing worn by the first technician 150b by hook and loop fasteners, placed in the technician's pocket, taken as a pendant or smartwatch worn by the second technician 150b, sewn or integrated into the clothing worn by the second technician 150b, implemented as smart safety glasses or a mask providing visual, audio, or vibration warnings or any combination thereof, or otherwise fitted. The second proximity detector 160b may include, for example, a cellular phone or tablet computer and utilizes technology such as Global Positioning System (GPS). Method 400 then continues to box 408.

[0127] In box 408, a third proximity detector 160c is positioned at a portion 142 of a moving machine 140 within assembly environment 130. This includes securing multiple third proximity detectors 160c to each machine 140 within the unit (e.g., the first unit 132) (e.g., positioned on or within it), and performing this during the initial setup and calibration of the machine 140 prior to any desired maintenance or inspection. The third proximity detectors 160c are coupled to the power supply of the machine 140 and communicate with the controller of the machine 140. With the first proximity detector 160a, the second proximity detector 160b, and the third proximity detector 160c in place, a first technician 150a and a second technician 150b are free to move within assembly environment 130 and advance into the first unit 132 to perform, for example, inspections, assist with assembly, or perform maintenance. During this time, the machine 140 within the first unit 132 continues to operate. However, continuous movement of the machine 140 is not required during the placement or use of the first proximity detectors 160a and the second proximity detectors 160b. Conversely, during operation of machine 140 and during pauses in operation of machine 140, the third proximity detector 160c is able to detect the position of machine 140. Method 400 then proceeds to block 410.

[0128] In block 410, a first proximity detector 160a transmits a first signal to one or more sensing beacons 120 in the assembly environment 130 (e.g., sensing beacons 120 arranged outside, inside, etc. of the first unit 132). The first signal includes an ultra-wideband (UWB) radio signal that provides a unique identifier for the first proximity detector 160a to distinguish it from other proximity detectors 160 in the assembly environment 130. The first proximity detector 160a is associated with a specific technician (i.e., a first technician 150a) indicated in the memory 114 of the proximity reporting server 110. Alternatively (or additionally), the first signal explicitly identifies the technician (i.e., the first technician 150a) to whom the first proximity detector 160a is attached. The first signal is transmitted via multiple different radio bands or communication channels. Alternatively (or additionally), in some embodiments, the first signal is transmitted as a visual code via a light-emitting diode (LED). Transmitting the first signal via multiple different communication channels provides the technical benefit of ensuring that the first signal can be received and processed by the sensing beacons 120. The first signal is transmitted continuously or periodically (e.g., once or more per second). Method 400 then proceeds to box 412.

[0129] In block 412, one or more sensing beacons 120 receive a first signal from a first proximity detector 160a. The first signal is received at the sensing beacon 120 either directly from the first proximity detector 160a (i.e., without reflection from reflector 180) or via reflector 180. The controller 112 of the proximity reporting server 110 determines the presence of an obstructing object 170 (e.g., a part being worked on in the assembly environment 130, such as a fuselage section or wing). As a non-limiting example, the controller 112 infers the presence of the obstructing object 170 based on input directly provided by a first technician 150a or based on input from the sensing beacons 120. For example, when the first unit 132 is used to work on a limited selection of parts, each with a desired orientation, the sensing beacons 120 detect the presence of the obstructing object 170 directly based on input from the sensing beacons 120 (e.g., based on sensor readings indicating an obstructing object 170 located within the first unit 132). For example, one or more sensing beacons 120 use laser or acoustic sensors to measure the distance below them. If the distance measured by multiple sensors is less than the known distance to the floor, the controller 112 determines that an obstructing object 170 is present. Alternatively or additionally, the sensing beacon 120 may take the form of a camera to detect the presence of the obstructing object 170.

[0130] When an obstructing object 170 is present, the sensing beacon 120 operates to indirectly detect the position P1 of the first proximity detector 160a via reflectors 180. This includes pointing the sensing beacon 120 towards one or more of the reflectors 180 when the sensing beacon 120 is oriented. The sensing beacon 120 interacts with the reflectors 180 to provide at least three distinct paths to each position for triangulation. Indirect detection requires changing the sensing probe of the sensing beacon 120 when it is omnidirectional. For each sensing beacon 120, there are expected maximum and minimum detection distances, which correspond to the sampling window for examining the input from the sensing beacon 120. Signaling through the detection path 182 alters (e.g., increases) the minimum and maximum detection distances, which in turn alters (e.g., increases) the expected arrival time of the signaling. Therefore, the amount of adjustment to the sampling window for acquiring signals for analysis is equal to the amount of change in the expected signaling timing. Based on the received signaling, the position of the first proximity detector 160a is determined (e.g., via triangulation). Method 400 then continues to box 414.

[0131] In block 414, the second proximity detector 160b sends a second signal to one or more sensing beacons 120 in the assembly environment 130 (e.g., sensing beacons 120 arranged outside, inside, etc. of the first unit 132). The second signal includes an ultra-wideband (UWB) radio signal that provides a unique identifier for the second proximity detector 160b, distinguishing it from other proximity detectors 160 in the assembly environment 130. The second proximity detector 160b is associated with a specific technician (i.e., the second technician 150b) indicated in the memory 114 of the proximity reporting server 110. Alternatively (or additionally), the second signal explicitly lists the technician (i.e., the second technician 150b) to whom the second proximity detector 160b is attached. The second signal is transmitted via multiple different radio bands or communication channels. Alternatively (or additionally), in some embodiments, the second signal is transmitted as a visual code via a light source (such as a light-emitting diode (LED)). Transmitting the second signal via multiple different communication channels provides the technical benefit of ensuring that the second signal can be received and processed by the sensing beacon 120. The second signal is transmitted continuously or periodically (e.g., once or multiple times per second). Method 400 then proceeds to block 416.

[0132] In block 416, one or more sensing beacons 120 receive a second signal from a second proximity detector 160b. The second signal is received directly from the second proximity detector 160b at the sensing beacon 120 (i.e., without reflection away from reflector 180) or via one or more reflectors 180. The controller 112 of the proximity reporting server 110 determines the presence of an obstructing object 170 (e.g., a part being worked on in the assembly environment 130, such as a fuselage section or wing). As a non-limiting example, the controller 112 infers the presence of the obstructing object 170 based on input directly provided by a second technician 150b or based on input from the sensing beacon 120. For example, when the first unit 132 is used to work on a limited selection of parts, each with a desired orientation, the sensing beacon 120 detects the presence of the obstructing object 170 directly based on input from the sensing beacon 120 (e.g., based on sensor readings indicating an obstructing object 170 located within the first unit 132). For example, one or more sensing beacons 120 use laser or acoustic sensors to measure the distance below them. If the distance measured by multiple sensors is less than the known distance to the floor, the controller 112 determines that an obstructing object 170 is present. Alternatively or additionally, the sensing beacon 120 may take the form of a camera to detect the presence of the obstructing object 170.

[0133] When an obstruction 170 is present, the sensing beacon 120 operates to indirectly detect the position P2 of the second proximity detector 160b via reflector 180. This includes pointing the sensing beacon 120 toward one or more reflectors 180 when the sensing beacon 120 is oriented. The sensing beacon 120 interacts with the reflectors 180 to provide at least three distinct paths to each position for triangulation. When the sensing beacon 120 is omnidirectional, indirect detection requires altering the sensing probe of the sensing beacon 120. For each sensing beacon 120, there are expected maximum and minimum detection distances, corresponding to the sampling window for examining input from the sensing beacon 120. Signaling through the detection path 182 alters (e.g., increases) the minimum and maximum detection distances, which in turn alters (e.g., increases) the expected arrival time of the signaling. Therefore, the amount of adjustment to the sampling window for acquiring the signal used for analysis is equal to the amount of change in the expected signaling timing. Based on the received signaling, the position of the first proximity detector 160a is determined (e.g., via triangulation). Method 400 then continues to box 418.

[0134] In block 418, the third proximity detector 160c sends a third signal to one or more sensing beacons 120 in the assembly environment 130 (e.g., sensing beacons 120 arranged at machine 140, etc.). The third signal includes an ultra-wideband (UWB) radio signal that provides a unique identifier for the third proximity detector 160c, distinguishing it from other proximity detectors 160 in the assembly environment 130. The third proximity detector 160c is associated with the machine 140 indicated in the memory 114 of the proximity reporting server 110. Alternatively (or additionally), the third signal explicitly lists the machine 140 to which the third proximity detector 160c is attached. The third signal is transmitted via multiple different radio bands or multiple different communication channels. Alternatively (or additionally), in some embodiments, the third signal is transmitted as a visual code via a light source (such as a light-emitting diode (LED)). Transmitting the third signal via multiple different communication channels provides the technical benefit of ensuring that the third signal can be received and processed by the sensing beacon 120. The third signal is transmitted continuously or periodically (e.g., once or more per second). Method 400 then proceeds to block 420.

[0135] In block 420, one or more sensing beacons 120 receive a third signal from a third proximity detector 160c. The third signal is received at the sensing beacon 120 either directly from the third proximity detector 160c (i.e., without reflection away from reflector 180) or via one or more reflectors 180. The controller 112 of the proximity reporting server 110 determines the presence of an obstructing object 170 (e.g., a part being worked on in the assembly environment 130, such as a fuselage section or wing). As a non-limiting example, the controller 112 makes inferences based on inputs from the sensing beacons 120. For example, when the first unit 132 is used to work on a limited selection of parts, each with a desired orientation, the sensing beacons 120 detect the presence of an obstructing object 170 directly based on inputs from the sensing beacons 120 (e.g., based on sensor readings indicating an obstructing object 170 located within the first unit 132). For example, one or more sensing beacons 120 utilize laser sensors or acoustic sensors to measure the distance below them. If the distance measured by multiple sensors is less than the known distance to the floor, controller 112 determines that an obstructing object 170 is present. Alternatively or additionally, the sensing beacon 120 may take the form of a camera to detect the presence of the obstructing object 170.

[0136] When an obstruction 170 is present, sensing beacon 120 operates to indirectly detect the position P3 of the third proximity detector 160c via reflector 180. This includes pointing sensing beacon 120 towards one or more of reflectors 180 when sensing beacon 120 is oriented. Sensing beacon 120 interacts with reflector 180 to provide at least three distinct paths to each position for triangulation. When sensing beacon 120 is omnidirectional, indirect detection requires altering the sensing probe of sensing beacon 120. For each sensing beacon 120, there are expected maximum and minimum detection distances corresponding to the sampling window examining the input from sensing beacon 120. Signaling through detection path 182 alters (e.g., increases) the minimum and maximum detection distances, which in turn alters (e.g., increases) the expected arrival time of the signaling. Therefore, the amount of adjustment to the sampling window for acquiring the signal used for analysis is equal to the amount of change in the expected signaling timing. Based on the received signaling, the position of the first proximity detector 160a is determined (e.g., via triangulation). Method 400 then continues to box 422.

[0137] In block 422, the controller 112 of the proximity reporting server 110 determines and monitors the positions (i.e., first position P1, second position P2, and third position P3) of the first proximity detector 160a, the second proximity detector 160b, and the third proximity detector 160c based on a first signal, a second signal, and a third signal, respectively. The positions (i.e., first position P1, second position P2, and third position P3) of the first proximity detector 160a, the second proximity detector 160b, and the third proximity detector 160c are stored in memory 114. Knowing the position of the proximity detector 160, the controller 112 determines and monitors the distance (i.e., distance D1) between the first proximity detector 160a and the second proximity detector 160b based on the first and second signals. This is performed by querying information stored in memory 114 indicating the position of each sensing beacon 120, performing triangulation on the first position P1 of the first proximity detector 160a and the second position P2 of the second proximity detector 160b based on the strength of the signal received at each sensing beacon 120, and determining the separation between the first position P1 and the second position P2. Memory 114 stores signals from sensing beacons 120 as part of the process. Sensing beacons 120 include cameras and use angles or techniques of each camera and stereoscopic device to determine position. Controller 112 selects which proximity detectors 160 to determine distances between them. For example, controller 112 selectively waives determining distances between proximity detectors 160 located on the same entity (e.g., the same technician, the same machine, etc.) and proximity detectors 160 located on a machine (e.g., where existing collision avoidance techniques on machine 140 have prevented a collision). This allows controller 112 to make greater resource allocation to perform the most relevant distance determinations (i.e., those most likely to enhance safety and ensure physical distances between technicians 150). Motion detection techniques are used on the distance data acquired over time to determine the current speed and / or orientation of technician 150 or machine 140. Proximity reporting server 110 stores the path of the first technician 150a and the path of the second technician 150b (and any other technicians 150) in its memory 114 to track movement within the assembly environment 130. The stored information is then used to determine which technicians 150 are adhering to physical distancing guidelines. Method 400 then proceeds to box 424.

[0138] Once the distance (i.e., distance D1) between the first proximity detector 160a and the second proximity detector 160b has been determined at box 420, this distance is compared with a threshold (i.e., a first threshold) at box 424. The first threshold is stored in memory 114. If the distance (i.e., distance D1) is not less than the threshold (e.g., a distance at which a safety warning would be issued to a technician), method 400 returns to box 422, and the proximity reporting system 100 determines the new location of the proximity detector 160. Alternatively, if the distance (i.e., distance D1) is less than the first threshold, method 400 continues to box 426.

[0139] Block 426 includes: in response to determining that the distance (i.e., distance D1) between the first proximity detector 160a and the second proximity detector 160b is less than a first threshold, instructing or commanding the first proximity detector 160a to provide a warning (i.e., a first warning) to the first technician 150a, and instructing or commanding the second proximity detector 160b to provide a warning (i.e., a second warning) to the second technician 150b. Both the first and second warnings are provided simultaneously. The described first threshold is either statically defined or dynamically determined based on the movement of the first technician 150a and the second technician 150b. For example, if the future path and speed of technician 150 (e.g., the first technician 150a and / or the second technician 150b) are expected to reduce the distance between the first technician 150a and the second technician 150b, the first threshold is increased to ensure that the first warning to the first technician 150a is issued more quickly.

[0140] If the distance (i.e., distance D1) is less than a first threshold, controller 112 instructs first proximity detector 160a to activate alarm 349 via detection path 182 (e.g., via sensing beacon 120) to provide a warning to first technician 150a. That is, a warning is provided via detection path 182. Specifically, a transmission is provided via detection path 182 to cause first proximity detector 160a to warn first technician 150a via any suitable alarm (e.g., visual indication, sound, and / or vibration, etc.). Thus, alarm 349 is configured to provide a warning in response to receiving data indicating that the distance between first proximity detector 160a and second proximity detector 160b is less than a first threshold.

[0141] The first warning includes an indication of the direction of the second proximity detector 160b, and the second warning includes an indication of the direction of the first proximity detector 160a. Depending on the position of the first technician 150a relative to the second technician 150b, the first and second warnings take the form of verbal warnings stating phrases such as “Stop moving forward,” “Do not move to the left,” “Do not move to the south,” or similar phrases. A speaker 350 provides the verbal warning or sound. The first and second warnings are implemented in the form of flashlights on the technician’s helmet, glasses, mask, or gloves, or as flashlights or suitable visual indicators. A visual indicator 361 flashes at a specific location on the helmet, glasses, mask, or gloves to indicate the direction of the other proximity detector 160. The first and second warnings include vibrations generated by a vibration generator 360. Regardless of their form, the first and second warnings are prompts advising the technician 150 to physically move away. Method 400 then proceeds to block 428.

[0142] In block 428, controller 112 compares the distance (i.e., distance D1) between the first proximity detector 160a and the second proximity detector 160b with a threshold (i.e., a second threshold). The second threshold is less than the first threshold. The second threshold is stored in memory 114. If the distance (i.e., distance D1) is not less than the threshold (e.g., the distance at which a safety warning would be issued to technician 150), method 400 returns to block 422, and proximity reporting system 100 determines the new location of proximity detector 160. Alternatively, if the distance (i.e., distance D1) is less than the second threshold, method 400 continues to block 430.

[0143] In block 430, the first proximity detector 160a and the second proximity detector 160b, in response to determining that the distance between the first proximity detector 160a and the second proximity detector 160b (i.e., distance D1) is less than a second threshold (less than the first threshold discussed above), provide different warnings to the first technician 150a and the second technician 150b, respectively. When provided by both the first proximity detector 160a and the second proximity detector 160b, the warning differs from the first and second warnings described above. For example, the warning includes a vibration of a higher frequency compared to the vibrations of the first and second warnings described above. Furthermore, the warning includes an audible sound that is louder than the vibrations of the first and second warnings described above. Furthermore, the warning includes a visual indicator that is brighter than the visual indicators of the first and second warnings described above. Method 400 further includes block 432.

[0144] In block 432, controller 112 determines the distance (i.e., distance D2) between first proximity detector 160a (or another proximity detector 160 worn by technician 150) and third proximity detector 160c based on a first signal and a third signal. This is performed by querying information stored in memory 114 indicating the position of each sensing beacon 120, triangulating a first position P1 of the first proximity detector 160a and a third position P3 of the third proximity detector 160c based on the strength of the signal received at each sensing beacon 120, and determining the amount of separation between the first position P1 and the third position P3. Memory 114 stores signals from sensing beacons 120 as part of this process. Sensing beacons 120 include cameras, and angles of each camera and stereoscopic device or technology are used to determine position. Motion detection technology is used on the distance data acquired over time to determine the current speed and / or orientation of technician 150 or machine 140. Method 400 then proceeds to block 434.

[0145] Once the distance (i.e., distance D2) between the first proximity detector 160a and the third proximity detector 160c has been determined at box 432, this distance is compared with a threshold (i.e., a third threshold) at box 434. The third threshold is stored in memory 114. If the distance (i.e., distance D2) is not less than the third threshold (e.g., the distance at which a safety warning will be issued to technician 150), method 400 returns to box 432, and proximity reporting system 100 determines the new location of proximity detector 160. Alternatively, if the distance (i.e., distance D2) is less than the third threshold, method 400 continues to box 436.

[0146] Box 436 includes instructing or commanding the first proximity detector 160a to provide a warning (i.e., a first warning) to the first technician 150a in response to determining that the distance between the first proximity detector 160a and the third proximity detector 160c (i.e., distance D2) is less than a third threshold. The distance threshold described herein is either statically defined on a machine-by-machine basis or dynamically determined based on movements indicated in the numerical control (NC) program of machine 140 and / or the position of machine 140 within the NC program as the machine continues to operate. For example, if the future path of machine 140 is expected to reduce its distance from technician 150, the third threshold is increased to ensure a faster warning is issued.

[0147] If the distance is not less than a third threshold, the technician 150 is further away from the machine 140. Therefore, the machine 140 continues to operate. Alternatively, if the distance is less than the third threshold, the controller 112 instructs the first proximity detector 160a (e.g., via sensing beacon 120) to activate the alarm 349 to provide a warning (i.e., a third warning) to the first technician 150a via the detection path 182. That is, a third warning is provided via the detection path 182. Specifically, a transmission is provided via the detection path 182 such that the first proximity detector 160a warns the first technician 150a via any suitable indicator (e.g., visual indicator, sound, vibration, etc.). The operating environment within the first unit 132 includes visual, auditory, and / or other stimuli that diminish the senses of the technician 150. Therefore, a warning is generated to stimulate multiple senses (e.g., via bright light, vibrating motion, and / or distinctive sound).

[0148] The third warning includes an indication of the direction of the third approach detector 160c. This third warning takes the form of a verbal warning stating “Stop moving forward,” “Do not move left,” “Do not move south,” or similar phrases, depending on the position of the first technician 150a relative to the machine 140. A speaker 350 provides the verbal warning or sound. The third warning may also be implemented as a flashing light on the technician’s helmet, glasses, mask, or gloves, or as a flashing light or appropriate visual indication. A visual indicator 361 flashes at a specific location on the helmet, glasses, mask, or gloves to indicate the direction of the location of another approach detector 160. The third warning may include vibration generated by a vibration generator 360. Regardless of its form, the third warning serves as a prompt to the technician 150, reminding them of the position of the machine 140. Method 400 then proceeds to block 438.

[0149] In block 438, the distance between the first proximity detector 160a and the third proximity detector 160c (i.e., distance D2) is compared with a threshold (i.e., a fourth threshold). The fourth threshold is stored in memory 114. If the distance (i.e., distance D2) is not less than the threshold (e.g., the distance at which a safety warning will be issued to technician 150), method 400 returns to block 432, and proximity reporting system 100 determines the new location of proximity detector 160. Alternatively, if the distance (i.e., distance D2) is less than the fourth threshold, method 400 continues to block 440. The fourth threshold is less than the third threshold.

[0150] In box 440, if the distance between the first proximity detector 160a and the third proximity detector 160c (i.e., distance D2) is less than a fourth threshold, the controller 112 instructs the machine 140 to stop moving. This provides a technical benefit by ensuring the safety of technicians, even when they are near the moving machine to actively operate it. It also provides the technical benefit that it eliminates the need for each machine 140 to include its own dedicated technicians to circumvent sensors and logic.

[0151] Method 400 is performed substantially simultaneously and asynchronously for multiple sets of proximity detectors 160. For example, method 400 is performed to determine additional distances between proximity detectors 160 at technician 150 and proximity detectors 160 at machine 140 or technician 150. This makes it possible to perform proximity detection for all relevant entities within a manufacturing cell or even across an entire factory site. Method 400 further provides technical benefits by preventing obstruction of objects 170 (e.g., large parts) that render technician 150 undetectable.

[0152] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, the element is implemented as dedicated hardware. Dedicated hardware elements are referred to as “processors,” “controllers,” or similar terms. When provided by a processor, functionality is provided by a single dedicated processor, a single shared processor, or by multiple separate processors (some of which may share resources). Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as specifically referring to hardware capable of executing software, and may imply, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or certain other physical hardware components or modules.

[0153] Furthermore, control elements are implemented as instructions executable by a processor or computer to perform the functions of that element. Some examples of instructions are software, program code, and firmware. Instructions are operable when executed by a processor to instruct the processor to perform the functions of the element. Instructions can be stored on a storage device that can be read by a processor. Some examples of storage devices are digital or solid-state memories, magnetic storage media (e.g., hard disks and magnetic tapes), hard disk drives, or optically readable digital data storage media.

[0154] Although specific embodiments are described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the appended technical solutions and any equivalents thereof.

Claims

1. A method for reporting proximity between technicians in an assembly environment, comprising: Multiple first detection pulses are sent from a first proximity detector to multiple sensing beacons; Multiple second detection pulses are sent from the second proximity detector to the multiple sensing beacons; A proximity server monitors the first distance between the first proximity detector and the second proximity detector based on a first triangulation of the plurality of first detection pulses and a second triangulation of the plurality of second detection pulses. A plurality of first position pulses are transmitted based on a plurality of first positions of the first proximity detector measured by a first inertial measurement unit in the first proximity detector, wherein the plurality of first position pulses are transmitted at a sampling rate higher than the plurality of first detection pulses; Multiple second position pulses are transmitted based on multiple second positions of the second proximity detector measured by the second inertial measurement unit in the second proximity detector, wherein the multiple second position pulses are transmitted at a sampling rate higher than the multiple second detection pulses; as well as During multiple intervals between multiple receptions of the plurality of first detection pulses and the plurality of second detection pulses at the sensing beacon, the proximity server monitors the first distance between the first proximity detector and the second proximity detector based on the plurality of first position pulses and the plurality of second position pulses.

2. The method according to claim 1, further comprising: It is determined that the first distance between the first proximity detector and the second proximity detector is less than a threshold.

3. The method according to claim 2, further comprising: In response to determining that the first distance between the first proximity detector and the second proximity detector is less than the threshold, a warning is provided to the first technician using the first proximity detector.

4. The method according to claim 3, in, The first proximity detector is worn by the first technician; The second proximity detector is worn by a second technician.

5. The method according to claim 4, wherein, The warning is a first warning, and the method further includes: in response to determining that the first distance between the first proximity detector and the second proximity detector is less than the threshold, providing a second warning to the second technician using the second proximity detector, and the first warning and the second warning are provided simultaneously.

6. The method according to claim 1, further comprising: The first proximity detector is attached to the wearable device.

7. The method according to claim 2, further comprising: In response to determining that the first distance between the first proximity detector and the second proximity detector is less than the threshold, a warning is provided to at least one of the first technician and the second technician.

8. The method according to claim 1, wherein, The first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors includes more than two proximity detectors.

9. A system for proximity reporting in an assembly environment, the system comprising: Multiple sensing beacons; A first proximity detector, configured to be worn by a first technician, and to send a plurality of first detection pulses to the plurality of sensing beacons, and to send a plurality of first position pulses based on a plurality of first positions of the first proximity detector measured by a first inertial measurement unit in the first proximity detector, wherein the plurality of first position pulses are sent at a higher sampling rate than the plurality of first detection pulses; A second proximity detector, configured to be worn by a second technician, transmits a plurality of second detection pulses to the plurality of sensing beacons and transmits a plurality of second position pulses based on a plurality of second positions of the second proximity detector measured by a second inertial measurement unit in the second proximity detector, wherein the plurality of second position pulses are transmitted at a higher sampling rate than the plurality of second detection pulses; and A proximity server, communicating with the first proximity detector and the second proximity detector, wherein the proximity server is programmed to: monitor a first distance between the first proximity detector and the second proximity detector based on a first triangulation of the plurality of first detection pulses and a second triangulation of the plurality of second detection pulses; and monitor the first distance between the first proximity detector and the second proximity detector based on the plurality of first position pulses and the plurality of second position pulses during a plurality of intervals between a plurality of receptions of the plurality of first detection pulses and the plurality of second detection pulses at the plurality of sensing beacons.

10. The system according to claim 9, wherein, The proximity server is programmed to: Determine whether the first distance between the first proximity detector and the second proximity detector is less than a threshold.

11. The system according to claim 10, wherein, The proximity server is programmed to: In response to determining that the first distance between the first proximity detector and the second proximity detector is less than the threshold, the first proximity detector is commanded to provide a warning to the first technician.

12. A wearable article comprising: The main body of the item; as well as A first proximity detector attached to the body of the article, wherein the first proximity detector includes a first inertial measurement unit configured to measure a plurality of first positions of the first proximity detector; and The transceiver is configured to transmit a plurality of first detection pulses to a plurality of sensing beacons and to transmit a plurality of first position pulses based on the plurality of first positions of the first proximity detector measured by the first inertial measurement unit, wherein the plurality of first position pulses are transmitted at a sampling rate higher than the plurality of first detection pulses.

13. The wearable article according to claim 12, wherein, The transceiver is configured to receive data indicating that the distance between the first proximity detector and the second proximity detector is less than a threshold.

14. The wearable article of claim 13 further includes an alarm coupled to the transceiver, wherein, The alarm is configured to provide a warning in response to receiving data indicating that the distance between the first proximity detector and the second proximity detector is less than the threshold.

15. The wearable article according to claim 13, wherein, The first proximity detector is configured to receive data from a proximity server indicating that the distance between the first proximity detector and the second proximity detector is less than the threshold, and the proximity server is programmed to determine whether the distance between the first proximity detector and the second proximity detector is less than the threshold based on a first triangulation of the plurality of first detection pulses and a second triangulation of the plurality of second detection pulses generated by the second proximity detector.

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