Proximity notification system in assembly environments

Abstract

To provide a system and a method for reporting proximity of a person and a machine in an assembly environment.SOLUTION: A method can be used for reporting proximity between technicians (150a, 150b) in an assembly environment (130). The method includes monitoring, by a proximity reporting server (110), a distance between a first proximity detector (160a) and a second proximity detector (160b) based on a first signal and a second signal. The first proximity detector (160a) is configured to generate the first signal, and the second proximity detector (160b) is configured to generate the second signal.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to the field of assembly, and more particularly, to systems and methods for reporting the proximity of people and machines in an assembly environment.

Background Art

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

[0003] Moreover, in an assembly environment, it is desirable to assemble parts as quickly and efficiently as possible. It is not uncommon for certain assembly operations to be performed by automated machines and other assembly operations to be performed by technicians. To ensure safety, technicians are restricted from entering the operating area of an automated machine while it is operating. Further, to ensure safety, technicians are restricted from getting too close to other technicians (as is referred to as the "social distance" interval), regardless of whether an automated machine is operating within the operating area. This results in "stayout zones" where the speed and efficiency of the technicians' work are reduced, leading to an undesirable situation where the assembly speed decreases. At the same time, it remains best practice not to rely on an operator noticing machines and technicians that are in close proximity. Therefore, when both an automated machine and a technician use the same area, they are restricted and forced to divide the time of use.

[0004] Furthermore, as a cause complicating this problem, when technicians are hidden by large parts being assembled in a certain area, it becomes difficult to determine whether there are technicians in that area. For example, composite parts of an aircraft wing or fuselage can be several feet long and may block the view of technicians.

[0005] Therefore, it is desirable to provide methods and apparatus that take into account at least some of the above-mentioned matters and other potential matters. [Overview of the project]

[0006] Embodiments described herein dynamically detect when an engineer is approaching another engineer or machine through a plurality of sensors (e.g., sensing beacons) that interact with machine and engineer proximity detectors. These sensing beacons can operate in various detection modes (e.g., by using various timing windows and detection methods).

[0007] This disclosure describes a method for notifying of proximity between a technician and a machine in an assembly environment. In one embodiment 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, upon determining that the distance between the first proximity detector and the second proximity detector is less than the threshold, issuing a warning to a first technician using the first proximity detector.

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

[0009] As described above, the first proximity detector is worn by the first technician. The warning given by the first proximity detector is referred to as the first warning. The method includes, upon determining that the distance between the first proximity detector and the second proximity detector is less than the threshold, giving the second warning to the second technician using the second proximity detector. The first warning and the second warning are given simultaneously.

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

[0011] The method includes using the plurality of sensing beacons to receive a third signal from a third proximity detector positioned on a machine moving within a cell of the assembly environment. The method also includes determining the distance between the first proximity detector and the third proximity detector based on the first and third signals. This threshold is referred to as the third threshold. The method includes, upon determining that the distance between the first proximity detector and the third proximity detector is less than the third threshold, giving the first technician a third warning using the first proximity detector. The method includes, upon 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 operating. The fourth threshold is less than the third threshold. The machine is referred to as the first machine among a plurality of machines, and the plurality of machines include at least one of a robot, a gantry, or an automated device.

[0012] In the method, providing the third warning using the first proximity detector includes indicating the direction of the third proximity detector's location. The warning includes vibration, a visual display, and / or sound. The method includes attaching the first proximity detector to a wearable device. The method also includes providing a warning to at least one of the first or second technician upon determining that the distance between the first and second proximity detectors is less than a threshold. Furthermore, the method includes monitoring the distance between the first and second technicians based on the first and second signals and providing a warning to at least one of the first or second technicians upon determining that the distance between them is less than a threshold. Furthermore, the method includes transmitting the first signal from the first proximity detector to the plurality of beacons through at least one reflector. At least one reflector is attached to an infrastructure structure within the assembly environment. The method includes tracking movement within the assembly environment by storing the paths of the first and second technicians using the proximity server. The first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors includes three or more proximity detectors.

[0013] The method includes determining that the distance between the first proximity detector and the second proximity detector is less than a second threshold, and then using the first proximity detector to give a second warning to the first technician. 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 assembled by the method described above.

[0014] This disclosure also describes a proximity notification system in an assembly environment. In one embodiment of this disclosure, the system includes a first proximity detector, which is configured to be worn by a first technician. The system further includes a second proximity detector, which is configured to be worn by a second technician. Each of the first and second proximity detectors is wearable. The system further includes a proximity server that communicates with the first and second proximity detectors. The proximity detectors are programmed to monitor the distance between the first and second proximity detectors. The proximity server is programmed to determine whether the distance between the first and second proximity detectors is less than a threshold. The proximity server is also programmed to instruct the first proximity detector to issue a warning to the first technician if it has determined that the distance between the first and second proximity detectors is less than the threshold.

[0015] The system includes a first proximity detector, a second proximity detector, and a plurality of sensing beacons that communicate with the proximity server. The first proximity detector includes a first transceiver configured to transmit a first signal to the plurality of sensing beacons. The second proximity detector includes a second transceiver configured to transmit a second signal to the plurality of sensing beacons. The proximity server is programmed to determine, based on the first and second signals, whether the distance between the first proximity detector and the second proximity detector is less than the threshold. The warning is referred to as the first warning, and the proximity server is programmed to instruct the second proximity detector to give the second warning to the second technician after determining that the distance between the first proximity detector and the second proximity detector is less than the threshold.

[0016] The first warning includes an indication of the direction of the second proximity detector's position. The second warning includes an indication of the direction of the first proximity detector's position. The first and second proximity detectors are configured to give the first and second warnings simultaneously.

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

[0018] The first proximity detector includes a first transceiver configured to transmit a first signal to the plurality of sensing beacons. The second proximity detector includes a second transceiver configured to transmit a second signal to the plurality of sensing beacons. The third proximity detector includes a third transceiver configured to transmit a third signal to the plurality of sensing beacons. The proximity server is programmed to determine the distance between the first proximity detector and the third proximity detector based on the first and third signals. The threshold is referred to as the first threshold, and the proximity server is programmed to command the first proximity detector to give a third warning to the first technician when it determines that the distance between the first proximity detector and the third proximity detector is less than the third threshold. The first proximity detector is configured to provide an indication of the direction of the location of the third proximity detector.

[0019] The proximity server is programmed to determine the distance between the second proximity detector and the third proximity detector based on the second and third signals. Upon determining that the distance between the first proximity detector and the third proximity detector is less than the third threshold, the proximity server is programmed to instruct the first proximity detector to issue a third warning to the first technician. Upon determining that the distance between the first proximity detector and the third proximity detector is less than the fourth threshold, the proximity server is programmed to instruct the machine to cease operation. The warning includes vibration, a visual display, and / or sound. The first proximity detector is attached to a wearable device.

[0020] The system includes a plurality of reflectors placed in the assembly environment. The first proximity detector is configured to transmit a first signal to the plurality of beacons through the plurality of reflectors. At least one of the plurality of reflectors is attached to an infrastructure structure. The proximity server is configured to store the route of the first technician and the route of the second technician and to track their movement within the assembly environment. The first proximity detector and the second proximity detector are part of a plurality of proximity detectors, the plurality of proximity detectors including three or more proximity detectors.

[0021] The first proximity detector is configured to issue a second warning to the first technician upon determining that the distance between the first proximity detector and the second proximity detector 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 an aircraft is manufactured using the system described above.

[0022] This disclosure also describes wearable devices. According to one aspect of this disclosure, a wearable device 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 to receive data indicating the 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 device includes an alarm connected to the transceiver. The alarm is configured to give a warning upon receiving data indicating that the distance between the first proximity detector and the second proximity detector is less than the threshold.

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

[0024] The alarm of the first proximity detector is configured to issue a third warning upon determining that the distance between the first proximity detector and the third proximity detector is less than the third threshold. The warning includes vibration, a visual display, and / or sound. The transceiver of the first proximity detector is configured to transmit the first signal to the plurality of beacons through a plurality of reflectors. The threshold is referred to as the first threshold, and the warning is referred to as the first warning. The alarm of the first proximity detector is configured to issue a second warning upon determining that the distance between the first proximity detector and the second proximity detector is less than the third threshold. The third threshold is less than the first threshold, and the first warning is different from the second warning. The wearable device is used to manufacture at least a part of an aircraft.

[0025] According to one aspect of the present disclosure, a method for notifying proximity between technicians in an assembly environment 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, 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, upon determining that the distance between the first proximity detector and the second proximity detector is less than the threshold, using the first proximity detector to give a warning to the first technician.

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

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

[0030] Preferably, giving the first warning using the first proximity detector includes indicating the direction of the position of the second proximity detector, and giving the second warning using the second proximity detector includes indicating the direction of the position of the first proximity detector.

[0031] Preferably, the method further includes receiving a third signal from a third proximity detector arranged on a machine moving within a cell of the assembly environment using the plurality of sensing beacons.

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

[0033] Preferably, the threshold value is a first threshold value, 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 a third threshold value, giving a third warning to the first technician using the first proximity detector.

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

[0035] Preferably, the method is such that the machine is the first machine among a plurality of machines, and the plurality of machines include at least one of a robot, a gantry, or an automated device.

[0036] Preferably, the method includes indicating the direction of the position of the third proximity detector by using the first proximity detector to give the third warning.

[0037] Preferably, the method includes vibration as the warning.

[0038] Preferably, the method includes a visual indication for the warning.

[0039] Preferably, the method includes an audible warning.

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

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

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

[0043] Preferably, the method further includes transmitting the first signal from the first proximity detector to the plurality of beacons through at least one reflector.

[0044] Preferably, the method involves the at least one reflector being attached to an infrastructure structure within the assembly environment.

[0045] Preferably, the method further includes the proximity server storing the route of the first technician and the route of the second technician to track their movement within the assembly environment.

[0046] Preferably, the method is such that the first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors include three or more proximity detectors.

[0047] Preferably, the method is such that the threshold is a first threshold and the warning is a first warning, and the method further includes, upon determining that the distance between the first proximity detector and the second proximity detector is less than a third threshold, giving the first technician a second warning using the first proximity detector, wherein the third threshold is less than the first threshold and the first warning is different from the second warning.

[0048] At least a portion of the aircraft may be assembled by the method described above.

[0049] According to one aspect of the present disclosure, a proximity notification system in an assembly environment is provided, the system comprising a first proximity detector configured to be worn by a first technician and a second proximity detector configured to be worn by a second technician, each of the first and second proximity detectors being wearable, and further comprising a proximity server that communicates with the first and second proximity detectors, the proximity server being programmed to monitor the distance between the first and second proximity detectors.

[0050] Advantageously, the system is programmed so that the proximity server determines whether the distance between the first proximity detector and the second proximity detector is less than a threshold.

[0051] Preferably, the system is programmed to instruct the first proximity detector to issue a warning to the first technician when the proximity server determines that the distance between the first proximity detector and the second proximity detector is less than the threshold.

[0052] Preferably, the system further includes a plurality of sensing beacons that communicate with the first proximity detector, the second proximity detector, and the proximity server.

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

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

[0055] Preferably, the system is programmed so that the proximity server determines, based on the first signal and the second signal, whether the distance between the first proximity detector and the second proximity detector is less than the threshold.

[0056] Preferably, the system is programmed to instruct the second proximity detector to give a second warning to the second technician when the warning is a first warning and the proximity server has determined that the distance between the first proximity detector and the second proximity detector is less than the threshold.

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

[0058] Preferably, the system is configured such that the first proximity detector and the second proximity detector simultaneously issue the first and second warnings.

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

[0060] Preferably, the system is such that the machine is the first machine among a plurality of machines, and the plurality of machines include at least one of a robot, a gantry, or an automated device.

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

[0062] Preferably, the system is programmed to instruct the first proximity detector to give the first technician a third warning when the threshold is a first threshold and the proximity server determines that the distance between the first proximity detector and the third proximity detector is less than the third threshold.

[0063] Preferably, the system is configured such that the first proximity detector provides an indication of the direction of the position of the third proximity detector.

[0064] Preferably, the system is programmed so that the proximity server determines 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 programmed to instruct the first proximity detector to give the third warning to the first technician when the proximity server determines that the distance between the first proximity detector and the third proximity detector is less than the third threshold.

[0066] Preferably, the system is programmed so that when the proximity server determines that the distance between the first proximity detector and the third proximity detector is less than a fourth threshold, it commands the first machine to stop operating, and the fourth threshold is less than the third threshold.

[0067] Preferably, the system includes vibration as part of the warning.

[0068] Preferably, the system includes a visual display for the warning.

[0069] Preferably, the system includes an audible warning.

[0070] Preferably, the system is such that the first proximity detector is attached to a wearable device.

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

[0072] Preferably, the system is such that at least one of the plurality of reflectors is attached to an infrastructure structure.

[0073] Preferably, the system is configured such that the proximity server stores the route of the first technician and the route of the second technician and tracks their movement within the assembly environment.

[0074] Preferably, the system is such that the first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors include three or more proximity detectors.

[0075] Preferably, the system is configured such that the threshold is a first threshold, the warning is a first warning, and the first proximity detector determines that the distance between the first proximity detector and the second proximity detector is less than a third threshold, and the third threshold is less than the first threshold, and the first warning is different from the second warning.

[0076] At least a portion of the aircraft manufacturing can be carried out using the system described above.

[0077] According to one aspect of the present disclosure, a wearable product is provided which 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 location 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 to receive data indicating the distance between the first proximity detector and a second proximity detector.

[0078] Advantageously, the wearable device is configured such that the transceiver receives data indicating that the distance between the first proximity detector and the second proximity detector is less than a threshold.

[0079] Preferably, the wearable device further includes an alarm connected to the transceiver, the alarm being configured to give a warning upon receiving data indicating that the distance between the first proximity detector and the second proximity detector is less than the threshold.

[0080] Preferably, the wearable device is configured such that the first proximity detector indicates the direction of the second proximity detector's position.

[0081] Preferably, the wearable device is configured such that the first proximity detector receives data from the 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 the first signal and the second signal generated by the second proximity detector.

[0082] Preferably, the wearable device is configured such that the first proximity detector communicates with a third proximity detector located on a machine moving within a cell in the assembly environment.

[0083] Preferably, the wearable device is configured such that the threshold is a first threshold, and the first proximity detector receives 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 device is configured such that the alarm of the first proximity detector determines that the distance between the first proximity detector and the third proximity detector is less than the third threshold, and issues a third warning.

[0085] Preferably, the wearable device provides a warning that includes vibration.

[0086] Preferably, the wearable device includes a visual display for the warning.

[0087] Preferably, the wearable device includes an audible warning.

[0088] Preferably, the wearable device is configured such that the transceiver of the first proximity detector transmits the first signal to the plurality of sensing beacons through a plurality of reflectors.

[0089] Preferably, the wearable device is configured such that the threshold is a first threshold, the warning is a first warning, and the alarm of the first proximity detector gives a second warning when it determines that the distance between the first proximity detector and the 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.

[0090] At least a portion of the aircraft's manufacture could be carried out using the aforementioned wearable devices.

[0091] Other exemplary embodiments (e.g., methods and computer-readable media related to the embodiments described above) are described below. The features, functions, and advantages described above can be achieved individually in various embodiments and can also be incorporated into yet another embodiment, the details of which will become apparent with reference to the following description and drawings. [Brief explanation of the drawing]

[0092] Hereinafter, several embodiments of the present disclosure will be described as illustrative examples with reference to the accompanying drawings. In all drawings, the same reference numerals represent the same element or element of the same type.

[0093] [Figure 1] This is a schematic diagram of a proximity notification system according to one aspect of the present disclosure, showing one technician within a predetermined distance from another technician. [Figure 2]Figure 1 is a schematic block diagram of the proximity notification system. [Figure 3] Figure 1 is a schematic block diagram of the proximity notification system that alerts the system when a technician enters a predetermined distance from the machine. [Figure 4] Figure 1 is a schematic block diagram of the proximity detector in the proximity notification system. [Figure 5] This is a front view of a technician wearing a bump cap connected to a smart face shield. [Figure 6A] This is the first part of a flowchart for how to notify engineers of proximity in an assembly environment. [Figure 6B] This is the second part of the flowchart for how to notify engineers of proximity in an assembly environment. [Modes for carrying out the invention]

[0094] The drawings and the following description illustrate specific exemplary embodiments of the Disclosure. While not expressly described or illustrated herein, various modifications embodying the principles of the Disclosure and falling within its scope may be conceived by those skilled in the art. Furthermore, the embodiments described herein are intended to aid in understanding the principles of the Disclosure, and these specifically described embodiments or conditions are not limiting. Accordingly, the Disclosure is not limited to the specific embodiments or examples described below, but is limited only by the claims and their equivalents.

[0095] Referring to Figures 1 and 2, the proximity notification system 100 is configured to monitor and identify the distance between proximity detectors 160 within the assembly environment 130 and is referred to as the proximity notification system in the assembly environment 130. The proximity notification system 100 is used to manufacture at least a portion of an aircraft and has been further advanced to identify technicians 150 and machines 140 and to take warnings or other avoidance measures based on the distance between the technicians 150 and machines 140. This provides the technical advantages of ensuring physical distance between technicians 150 and the safety of technicians 150 working near machines 140, as well as increasing the uptime of machines 140 within a cell. Furthermore, the detection of technicians 150 is not obstructed by parts within the cell. Here, “cell” includes any dedicated workspace or space in which one or more machines 140 are to operate.

[0096] The proximity notification system 100 includes a proximity notification server 110 and a plurality of sensing beacons 120 (e.g., wireless antennas, UWB (ultra-wideband) transceivers, cameras, etc.) that communicate with the proximity notification server 110. The sensing beacons 120 receive input from one or more proximity detectors 160 located inside or outside one or more cells (e.g., first cell 132 and second cell 133) of the assembly environment 130 (e.g., a factory floor). Thus, the sensing beacons 120 function as an interface between the proximity notification server 110 and the proximity detectors 160. A controller 112 evaluates the ultra-wideband (UWB) input from the sensing beacons 120. The assembly environment 130 includes one or more infrastructure structures 131, such as beams, floors, ceilings, and walls. The sensing beacons 120 are attached to the infrastructure structures 131. For example, the sensing beacon 120 is movably attached to one or more of the infrastructure structures 131. In a non-limiting example, the infrastructure structures 131 and one of the sensing beacons 120 are interconnected by a pivotable mount to facilitate the reception of signals from the proximity detector 160.

[0097] The proximity detector 160 can be worn or carried by one or more technicians 150. For example, the proximity detector 160 can be carried by a technician 150 in a mobile phone or other similar device. Furthermore, the proximity detector 160 can be placed on a part 142 (e.g., a movable component) of a machine 140. The machine 140 includes robots, gantry, automated equipment, robotic arms, automated guided vehicles (AGVs), flex-track machines, industrial mobile robots (IMRs), and other automated equipment that moves within the first cell 132. The first technician 150a is wearing the first proximity detector 160a at the first position P1, and the second technician 150b is wearing the second proximity detector 160b at the second position P2. Both the first technician 150a and the second technician 150b are located within the first cell 132. In a non-limiting example, there are no technicians in the second cell 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 part of an aircraft and is a bump cap 165 (Figure 5), clothing, protective clothing, a smartphone or tablet app, or other article that can be worn or carried by a technician 150. The first proximity detector 160a is part of or attached to the first wearable article 161a, and the second proximity detector 160b is part of or attached to the second wearable article 161b. Thus, each of the first proximity detector 160a and the second proximity detector 160b is 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 position of the first proximity detector 160a (i.e., first position P1), and the second proximity detector 160b is configured to generate a first signal indicating the position of the second proximity detector 160b (i.e., second position P2). According to aspects of the present disclosure, the proximity notification system 100 includes three or more proximity detectors 160.

[0098] The proximity notification system 100 includes, in addition to the proximity detector 160, a proximity notification server 110 that communicates wirelessly with the proximity detector 160 via a sensing beacon 120. The proximity notification server 110 includes a controller 112 and a memory 114 connected to the controller 112. The memory 114 can store data, and the controller 112 can process the data, for example, by executing computer-readable instructions.

[0099] Based on a first signal from the first proximity detector 160a and a second signal from the second proximity detector 160b, the controller 112 of the proximity notification server 110 determines the respective locations 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., first distance D1) is less than a predetermined threshold (i.e., first threshold) stored in memory 114, the controller 112 uses the first proximity detector 160a and the second proximity detector 160b, respectively, to issue one or more warnings to the first technician 150a and the second technician 150b. The controller 112 may be implemented, for example, as a custom circuit, as a hardware processor that executes programmed instructions, or as any combination thereof.

[0100] Taking into account the presence of an obstruction 170 (e.g., part of the fuselage, wing panel, etc.) that obstructs the line of sight to one of the proximity detectors 160 (thus preventing detection by the technician 150 or machine 140), a reflector 180, such as a mirror, is attached to one of the infrastructure structures 131 (e.g., a wall, ceiling, floor, etc.) to form a detection path 182. The reflector 180 can reflect the wavelength of electromagnetic radiation used by the sensing beacon 120. Thus, in embodiments in which the sensing beacon 120 includes a camera, the reflector 180 reflects the wavelength of light. In embodiments in which the sensing beacon 120 detects the wavelength of radio waves, the reflector 180 can reflect the wavelength of radio waves. In this specification, the term “reflector” means an object that can reflect and redirect a signal without substantially attenuating the signal (e.g., more than 10 percent, more than 1 percent, etc.).

[0101] Referring to Figure 3, a first technician 150a (or any other technician 150) is wearing or carrying a first proximity detector 160a at a first position P1 in the first cell 132, away from the machine 140 (i.e., at a second distance D2). A second technician 150b is wearing or carrying 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 in the first cell 132. The third proximity detector 160c is located on a moving part of the machine 140, the base of the machine 140, an end effector provided on the machine 140, etc. (i.e., a part 142 of the machine 140). When in 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 already mentioned, at this stage, there are no technicians or proximity detectors inside the second cell 133.

[0102] Based on the first signal from the first proximity detector 160a and the third signal from the third proximity detector 160c, the controller 112 of the proximity notification server 110 identifies and monitors the respective locations 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., the second distance D2) is less than a predetermined threshold (i.e., the third threshold) stored in memory 114, the controller 112 uses the first proximity detector 160a to issue a warning to the first technician 150a. 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 stored in memory 114, the controller 112 commands the machine 140 to stop operating, provided that the fourth threshold is less than the third threshold.

[0103] Based on the second signal from the second proximity detector 160b and the third signal from the third proximity detector 160c, the controller 112 of the proximity notification server 110 determines the respective locations 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 memory 114, the controller 112 uses the second proximity detector 160b to issue a warning to the second technician 150b. If the distance from the second proximity detector 160b to the third proximity detector 160c is less than a fourth threshold stored in memory 114, the controller 112 commands the machine 140 to stop operating, and the fourth threshold is less than the third threshold.

[0104] Based on the first signal from the first proximity detector 160a and the second signal from the second proximity detector 160b, the controller 112 of the proximity notification server 110 determines the respective locations 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., the first distance D1) is less than a predetermined threshold (i.e., the first threshold) stored in the memory 114, the controller 112 uses the first proximity detector 160a and the second proximity detector 160b, respectively, to issue one or more warnings to the first technician 150a and the second technician 150b.

[0105] The proximity notification server 110 is configured to adjust its sensing heuristic upon detecting the presence of an obstruction 170 within the first cell 132. This allows the sensing beacon 120 to detect the technician 150 by a signal transmitted along the detection path 182 via the reflector 180. The presence of the obstruction 170 is detected automatically by the sensing beacon 120 or is communicated to the controller 112 by an input from an external source.

[0106] If the sensing beacon 120 is omnidirectional, modifying the sensing heuristic involves adjusting the timing window in which the input is acquired (i.e., taking into account the increased input delay due to the increased path length caused by the mirror). That is, the increased path length causes a corresponding delay, which in turn shifts the sampling window for detecting input via the sensing beacon 120 in time by an amount equal to this delay. This change in the timing of the sampling window differs among the sensing beacons 120, but can be determined from the position and orientation of the reflector 180 with which each sensing beacon 120 interacts. The sensing beacon 120 is directional and can be adjusted to point in a new direction. Modifying the sensing heuristic involves orienting the sensing beacon 120 toward the reflector 180 to receive signals from the sensing path 182. As a non-limiting example, only a limited number of sensing beacons 120 may adjust the sensing heuristic. The number of sensing beacons 120 (e.g., 3) is selected so that the technician 150 can be immediately detected from any position behind an obstruction. This allows the positions P1 of the first proximity detector 160a, P2 of the second proximity detector 160b, and P3 of the third proximity detector 160c to be triangulated (after converting the timing of the received signals to account for path differences caused by the reflector 180). This ensures that the technician 150 remains detectable while moving within the first cell 132.

[0107] In short, the machine 140 and the technician 150 are configured to provide their respective locations to the proximity notification server 110, and these locations are compared with each other. Based on this comparison, various levels of warning / response measures (e.g., warning people or shutting down machines) are provided to ensure physical distance and safety between people working together in the same cell / area, and between people and machines. By using the reflector 180, the proximity notification methods and systems described herein can maintain their effectiveness with or without the presence of the shield 170.

[0108] Figure 4 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 primary transceiver 330. As a non-limiting example, the primary transceiver 330 of the first proximity detector 160a is referred to as the first transceiver (configured to transmit a first signal), the primary transceiver 330 of the second proximity detector 160b is referred to as the second transceiver (configured to transmit a second signal), and the primary transceiver 330 of the third proximity detector 160c is referred to as the third transceiver (configured to transmit a third signal). In addition to the primary transceiver 330, the proximity detector 160 includes a secondary transceiver 340. The primary transceiver 330 and the secondary transceiver 340 operate using different frequency ranges (or different communication modes such as optical communication and wireless communication) to transmit signals from the proximity detector 160. Therefore, even if interference or noise occurs in one frequency range, the other transceiver will provide a signal in a different frequency range. The proximity detector 160 also includes a vibration generator 360 (e.g., a piezoelectric element, a 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 the 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 a visual display such as light. The alarm 349 is connected to a primary transceiver 330 and a secondary transceiver 340. The proximity detector 160 is part of or attached to the article body 163 of a wearable item 161 (e.g., a bump cap, helmet, eyewear, clothing, face shield, headphones, etc.). Therefore, one or more wearable items 161 include one or more elements of the proximity detector 160 (e.g., a vibration generator). Specifically, in the case of 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 that is part of (or attached to) the article body 163 of the wearable item 161.However, in the case of the third proximity detector 160c located in machine 140, this proximity detector 160 is not wearable and is not attached to (or part of) the wearable device 161. The third proximity detector 160c is located in or inside a part 142 of machine 140.

[0109] When issuing a warning, the detector controller 310 activates one or all of these elements (i.e., the vibration generator 360, one or more speakers 350, and / or visual indicators 361) to attract the attention of the technician 150. The visual indicators 361 alert the eyewear or face shield worn by the technician 150 by generating flashing lights, other visual input, or vibrations that give a warning. For example, an audible warning is generated by a part of the eyewear located near the technician 150's temples, particularly near the edges of the temples. The speakers 350 are headphones or earphones. The eyewear includes, for example, smart safety glasses with visual warnings, audible warnings, vibration warnings, or any combination thereof. In a non-limiting example, the face shield is configured as a smart face shield 362 (Figure 5) with visual warnings, audible warnings, vibration warnings, or any combination thereof. For example, the 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 warning from the second proximity detector 160b includes an indication of the direction of the location of the first proximity detector 160a or another proximity detector 160. To provide the location indication, one or more speakers, such as headphones, emit words indicating the location of another proximity detector 160. Alternatively (or in addition to this), a visual indicator 361 activates lights at specific points on eyewear or a face shield to indicate the direction of another proximity detector 160. These lights are in the shape of an arrow indicating the direction of another proximity detector 160. The warning from the first proximity detector 160a is referred to as the first warning. The warning from the second proximity detector 160b is referred to as the second warning, and the warning from the third proximity detector 160c is referred to as the third warning. To distinguish between the warnings, the approach warning for machine 140 differs from the approach warning for another technician 150 in terms of flashing pitch or frequency. The warning also indicates the direction of the nearest approach detector 160 to the technician 150.

[0110] The proximity detector 160 is part of or attached to the main body 163 of a wearable item 161 (e.g., a bump cap, helmet, eyewear, clothing, face shield, headphones, etc.). Thus, one or more wearable items 161 include one or more elements of the proximity detector 160 (e.g., a vibration generator, etc.). Bluetooth technology is used, and the technician 150 wears a base station that communicates with the wearable item 161, such as a hat, helmet, gloves, glasses, or vest, which implements the proximity detector 160. In a non-limiting example, the helmet may be configured to give a warning indicating the approach of a machine, while the glasses may be configured to give a warning indicating the approach of a technician.

[0111] The proximity detector 160 includes (or is connected to) an inertial measurement unit (IMU) 395 that can detect acceleration indicating the movement of the proximity detector 160. By integrating these accelerations over a set period of time (e.g., once per second, once every few minutes, several 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 identified via the sensing beacon 120. For example, the inertial measurement unit 395 has a substantially higher sampling rate than the sensing beacon 120. Therefore, by using the inertial measurement unit 395, rapid movements of the technician 150 or machine 140 between UWB pulses transmitted and received by the sensing beacon 120 can be detected. This helps to accurately determine the positions of multiple technicians 150 and multiple machines 140, even if the technicians 150 or machine 140 move more rapidly between the sensing pulses of the sensing beacon 120.

[0112] The inertial measurement unit 395 provides the controller 112 of the proximity notification server 110 with the latest location information of the technicians 150 (e.g., first technician 150a and / or second technician 150b). The inertial measurement unit 395 receives information indicating the location of the proximity detector 160. The detector controller 310 then internally updates its own position based on input from the inertial measurement unit 395 during a brief pause period when the sensing beacon 120 is not operating (e.g., a fraction of a second). This allows the proximity notification server 110 to store the paths of the technicians 150 (e.g., first technician 150a and / or second technician 150b) and the machine 140 in memory 114 to track the movement of the technicians 150 and the machine 140 within the assembly environment 130. If input from the inertial measuring unit 395 indicates that the proximity detector 300 has moved closer than the threshold distance during the pause period, the detector controller 310 issues the warning described above to alert the technician 150 wearing the proximity detector 160.

[0113] The proximity detector 160 also includes a battery 370 and a sensor 380. The sensor 380 detects the battery level (for example, by measuring the voltage of the battery 370). The sensor 380 reports this battery level to the detector controller 310. If the battery level is below a threshold, the detector controller 310 issues a battery level warning via the speaker 350, the visual indicator 361, and / or the vibration generator 360. The proximity detector 160 further includes a button 390. When the button 390 is pressed, the first proximity detector 160a is activated and commands the machine 140, which is in the same cell (e.g., the first cell 132) as the technician 150, to be stopped remotely.

[0114] Battery level information is reported to the proximity notification server 110. Each of the first cell 132 and the second cell 133 is associated with a predetermined battery level. This is the desired battery level to ensure that the proximity detector 160 continues to operate while the technician 150 is performing inspection or maintenance in that cell (e.g., the first cell 132). When entry into the first cell 132 or the second cell 133 is determined based on the triangulation position of the proximity detector 160, the controller 112 of the proximity notification server 110 compares the current battery level with the desired battery level for the first cell 132 or the second cell 133. If the battery level is lower than the predetermined battery level when the technician 150 attempts to enter the first cell 132 or the second cell 133, the controller 112 instructs the proximity detector 160 to issue a warning. The proximity notification server 110 estimates how long the technician 150 will remain in the first cell 132 or the second cell 133 where he is currently located, and instructs the proximity detector 160 to issue a battery level warning if the battery level falls below the required level at that time during the inspection or maintenance process.

[0115] The proximity notification server 110 determines that at least one of the proximity detectors 160 has not transmitted a signal for a period longer than a predetermined time (e.g., 1 second, 10 seconds, 30 seconds, 1 minute, etc.). Upon this determination, the proximity notification server 110 sends a stop signal to all machines in the first cell 132 or second cell 133 where the proximity detector 160 was last detected. This ensures safety in the event of an unexpected power loss of the proximity detector, allowing the technician 150 to safely leave the cell even in the event of a complete battery failure or device malfunction.

[0116] The proximity detector 160, which may be worn by the technician 150 or placed in one of the machines 140, does not necessarily have to be equipped with all of the above-mentioned elements (e.g., the speaker 350). The proximity detector 160 is directly attached to the power supply of the machine 140 to which it is attached and has a controller that communicates directly with the controller of the machine 140 to which it is attached.

[0117] Referring to Figure 5, in one embodiment of the present disclosure, the wearable item 161 is a bump cap 165 worn by a technician 150. The visual indicator 361 is configured as a smart face shield 362 that covers the face of the technician 150. In one embodiment of the present disclosure, the visual indicator 361 is configured as smart eyewear that covers the eyes of the technician 150. The smart face shield 362 is connected to the bump cap 165 and activates lights 364 located at specific points to indicate the direction of another proximity detector 160. These lights 364 are shaped like arrows to indicate the direction of another proximity detector 160. For example, one or more lights 364 are activated to indicate the direction of the nearest proximity detector 160. Alternatively (or in addition), the direction of an adjacent proximity detector 160 is indicated by verbal warnings via a speaker 350. 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 other similar phrases.

[0118] Figures 6A and 6B together show a flowchart of method 400 for notifying proximity between engineer 150 and machine 140. During method 400, machine 140 is operating to assemble or join composite and / or metal parts for use in an aircraft. The steps of method 400 are described with reference to the proximity notification system 100 of Figure 1, but method 400 can also be performed in other systems. For example, proximity notification server 110 is programmed to perform method 400. The steps in the flowchart described herein are not necessarily all, and in one aspect of this disclosure, method 400 includes other steps not shown. According to another aspect of this disclosure, the steps described herein are performed in a different order.

[0119] Method 400 begins in block 402. Next, Method 400 proceeds to block 404. In block 404, the first technician 150a is equipped with the first proximity detector 160a. The first proximity detector 160a is wearable in that it is carried by the first technician 150a hands-free. Thus, the first proximity detector 160a is attached to the main body 163 of the wearable item 161 worn by the first technician 150a. For example, the first proximity detector 160a may be attached to the headwear (e.g., helmet) of the technician 150, or attached with hook-and-loop fasteners to the fabric of clothing worn by the first technician 150a, or placed in the pocket of the first technician 150a, or in the form of a pendant or smart wristwatch worn by the first technician 150a, or sewn or glued to clothing worn by the first technician 150a, or implemented as smart safety glasses or face shield that provide warnings by visual, audible, or vibration, or any combination thereof, or equipped by other means. The first proximity detector 160a may include a mobile phone or tablet and utilize technologies such as GPS (Global Positioning System) technology. Method 400 continues in block 406.

[0120] In block 406, the second technician 150b is equipped with a second proximity detector 160b. As described above, the second proximity detector 160b is wearable in that it is carried by the second technician 150b hands-free. Thus, the second proximity detector 160b is attached to the main body 163 of a wearable item 161 worn by the second technician 150b. For example, the second proximity detector 160b may be attached to the second technician 150b's headwear (e.g., a helmet), fastened with hook-and-loop fasteners to the fabric of clothing worn by the second technician 150b, placed in the technician's pocket, in the form of a pendant or smart wristwatch worn by the second technician 150b, sewn or glued to clothing worn by the second technician 150b, implemented as smart safety glasses or a face shield that provides visual, auditory, or vibrational warnings or any combination thereof, or equipped by other means. The second proximity detector 160b includes a mobile phone or tablet and utilizes technologies such as GPS (Global Positioning System) technology. Method 400 continues in block 408.

[0121] In block 408, the third proximity detector 160c is placed on part 142 of the machine 140 moving within the assembly environment 130. This involves mounting multiple third proximity detectors 160c on each machine 140 within a cell (e.g., the first cell 132) (e.g., on the surface or internally) and is performed during the initial setup and calibration of the machine 140 before maintenance or inspection is required. The third proximity detector 160c is connected to the power supply of the machine 140 and communicates 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, the first technician 150a and the second technician 150b move freely within the assembly environment 130 and enter the first cell 132, for example, to perform inspections or assist with assembly or maintenance. During this time, the machine 140 within the first cell 132 continues to operate. However, the machine 140 does not necessarily need to be operating continuously when the first proximity detector 160a and the second proximity detector 160b are placed or used. The third proximity detector 160c can detect the position of the machine 140 both while the machine 140 is operating and when the machine 140 is not operating. Method 400 then continues to block 410.

[0122] In block 410, the first proximity detector 160a transmits a first signal to one or more sensing beacons 120 within the assembly environment 130 (e.g., sensing beacons 120 located outside or inside the first cell 132). The first signal includes an ultra-wideband (UWB) radio signal that gives the first proximity detector a unique identifier that distinguishes it from other proximity detectors 160 within the assembly environment 130. The first proximity detector 160a is associated with a specific technician (i.e., first technician 150a) indicated in the memory 114 of the proximity notification server 110. Alternatively (or in addition), the first signal explicitly represents the technician (i.e., first technician 150a) to whom the first proximity detector 160a is installed. The first signal is transmitted on multiple different radio bands or communication channels. Alternatively (or in addition to this), the first signal is transmitted via a light-emitting diode (LED) as a visual code in certain embodiments. Transmitting the first signal via multiple separate communication channels provides the technical advantage that the first signal is reliably received and processed by the sensing beacon 120. The first signal is transmitted continuously or periodically (e.g., once or more times per second). Method 400 then proceeds to block 412.

[0123] In block 412, one or more of the sensing beacons 120 receive a first signal from the first proximity detector 160a. The first signal is received by the sensing beacons 120 either directly from the first proximity detector 160a (i.e., without reflection by the reflector 180) or via the reflector 180. The controller 112 of the proximity notification server 110 determines whether an obstruction 170 (for example, a component such as a conductor or part of a wing being handled in the assembly environment 130) is present. In a non-limiting example, the controller 112 infers the presence of the obstruction 170 based on input directly from the first technician 150a or based on input from the sensing beacons 120. For example, if the first cell 132 is used for working with a limited number of parts whose orientations are predicted, the sensing beacon 120 detects the presence of an obstruction 170 based directly on input from the sensing beacon 120, for example, on sensor measurements indicating that the obstruction 170 is located within the first cell 132. For example, one or more sensing beacons 120 utilize laser or acoustic sensors to measure the distance below them. If the distance measured by multiple sensors is less than a known distance to the floor, the controller 112 determines that an obstruction 170 is present. Alternatively, or in addition to this, the sensing beacon 120 may take the form of a camera to detect the presence of an obstruction 170.

[0124] If an obstruction 170 is present, the sensing beacon 120 operates to indirectly detect the position P1 of the first proximity detector 160a via the reflector 180. If the sensing beacon 120 is directional, this involves orienting the sensing beacon 120 towards one or more of the reflectors 180. The sensing beacon 120 interacts with the reflectors 180 such that at least three distinct paths are provided for each position to enable triangulation. If the sensing beacon 120 is omnidirectional, indirect detection involves modifying the sensing heuristic of the sensing beacon 120. For each sensing beacon 120, a maximum detection distance and a minimum detection distance are expected, which correspond to the sampling window over which input from the sensing beacon 120 is evaluated. Signal transmission through the detection path 182 alters (e.g., increases) this maximum and minimum detection distances, and consequently alters (e.g., increases) the timing over which signal reception is expected. Therefore, the sampling window for acquiring the signal for analysis is adjusted by the same amount as the predicted change in signal transmission timing. Based on the received signal, the position of the first proximity detector 160a is determined (for example, by triangulation). Method 400 then proceeds to block 414.

[0125] In block 414, the second proximity detector 160b transmits a second signal to one or more sensing beacons 120 within the assembly environment 130 (e.g., sensing beacons 120 located outside or inside the first cell 132). The second signal includes an ultra-wideband (UWB) radio signal that gives the second proximity detector a unique identifier that distinguishes it from other proximity detectors 160 within the assembly environment 130. The second proximity detector 160b is associated with a specific technician (i.e., second technician 150b) indicated in the memory 114 of the proximity notification server 110. Alternatively (or in addition to this), the first signal explicitly represents the technician (i.e., second technician 150b) to whom the second proximity detector 160b is installed. The second signal is transmitted on multiple different radio bands or communication channels. Alternatively (or in addition to this), the second signal is transmitted, in certain embodiments, via a light source such as a light-emitting diode (LED) as a visual code. Transmitting the second signal via multiple separate communication channels provides the technical advantage that the second signal is reliably received and processed by the sensing beacon 120. The second signal is transmitted continuously or periodically (e.g., once or more times per second). Method 400 then proceeds to block 416.

[0126] In block 416, one or more sensing beacons 120 receive a second signal from the second proximity detector 160b. The second signal is received by the sensing beacons 120 either directly from the second proximity detector 160b (i.e., without reflection by the reflector 180) or via one or more reflectors 180. The controller 112 of the proximity notification server 110 determines whether an obstruction 170 (for example, a part such as a fuselage or wing being handled in the assembly environment 130) is present. In a non-limiting example, the controller 112 infers the presence of the obstruction 170 based on input directly from the second technician 150b or based on input from the sensing beacons 120. For example, if the first cell 132 is used for working with a limited number of parts whose orientations are predicted, the sensing beacon 120 detects the presence of an obstruction 170 based directly on the input from the sensing beacon 120, for example, on sensor measurements indicating that the obstruction 170 is located within the first cell 132. For example, one or more sensing beacons 120 utilize laser or acoustic sensors to measure the distance below them. If the distance measured by multiple sensors is less than a known distance to the floor, the controller 112 determines that an obstruction 170 is present. Alternatively (or in addition to this), the sensing beacon 120 may take the form of a camera to detect the presence of an obstruction 170.

[0127] If an obstruction 170 is present, the sensing beacon 120 operates to indirectly detect the position P2 of the second proximity detector 160b via the reflector 180. If the sensing beacon 120 is directional, this involves orienting the sensing beacon 120 towards one or more of the reflectors 180. The sensing beacon 120 interacts with the reflectors 180 such that at least three distinct paths are provided for each position to enable triangulation. If the sensing beacon 120 is omnidirectional, indirect detection involves modifying the sensing heuristic of the sensing beacon 120. For each sensing beacon 120, a maximum and minimum detection distance are expected, which correspond to the sampling window over which input from the sensing beacon 120 is evaluated. Signal transmissions passing through the detection path 182 change (e.g., increase) this maximum and minimum detection distance, and consequently change (e.g., increase) the timing over which the signal is expected to be received. Therefore, the sampling window for acquiring the signal for analysis is adjusted by the same amount as the predicted change in signal transmission timing. Based on the received signal, the position of the first proximity detector 160a is determined (for example, by triangulation). Method 400 then proceeds to block 418.

[0128] In block 418, the third proximity detector 160c transmits a third signal to one or more sensing beacons 120 (e.g., sensing beacons 120 located on machine 140, etc.) within the assembly environment 130. The third signal includes an ultra-wideband (UWB) radio signal that gives the third proximity detector a unique identifier that distinguishes it from other proximity detectors 160 within the assembly environment 130. The third proximity detector 160c is associated with machine 140 as shown in the memory 114 of the proximity notification server 110. Alternatively (or in addition), the third signal explicitly represents the machine 140 to which the third proximity detector 160c is attached. The third signal is transmitted over multiple different radio bands or communication channels. Alternatively (or in addition), in certain embodiments, the third signal is transmitted as a visual code via a light source such as a light-emitting diode (LED). By transmitting the third signal via multiple separate communication channels, a technical advantage is obtained in that the second signal is reliably received and processed by the sensing beacon 120. The third signal is transmitted continuously or periodically (e.g., once or multiple times per second). Method 400 then proceeds to block 420.

[0129] In block 420, one or more sensing beacons 120 receive a third signal from a third proximity detector 160c. The third signal is received by the sensing beacons 120 either directly from the third proximity detector 160c (i.e., without reflection by the reflectors 180) or via one or more reflectors 180. The controller 112 of the proximity notification server 110 determines whether an obstruction 170 (e.g., a part such as a fuselage or wing part being handled in the assembly environment 130) is present. In a non-limiting example, the controller 112 infers based on input from the sensing beacons 120. For example, if the first cell 132 is used for working with a limited number of parts whose orientations are predicted, the sensing beacons 120 detect the presence of an obstruction 170 based directly on input from the sensing beacons 120, for example, based on sensor measurements indicating that the obstruction 170 is located within the first cell 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 obstruction 170 is present. Alternatively (or in addition to this), the sensing beacon 120 may take the form of a camera to detect the presence of the obstruction 170.

[0130] If an obstruction 170 is present, the sensing beacon 120 operates to indirectly detect the position P3 of the third proximity detector 160c via the reflector 180. If the sensing beacon 120 is directional, this involves orienting the sensing beacon 120 towards one or more of the reflectors 180. The sensing beacon 120 interacts with the reflectors 180 such that at least three distinct paths are provided for each position to enable triangulation. If the sensing beacon 120 is omnidirectional, indirect detection involves modifying the sensing heuristic of the sensing beacon 120. For each sensing beacon 120, a maximum and minimum detection distance are expected, which correspond to the sampling window over which input from the sensing beacon 120 is evaluated. Signal transmissions passing through the detection path 182 change (e.g., increase) this maximum and minimum detection distances, and consequently change (e.g., increase) the timing over which signal reception is expected. Therefore, the sampling window for acquiring the signal for analysis is adjusted by the same amount as the predicted change in signal transmission timing. Based on the received signal, the position of the first proximity detector 160a is determined (for example, by triangulation). Method 400 then proceeds to block 422.

[0131] In block 422, the controller 112 of the proximity notification server 110 identifies and monitors the positions of the first proximity detector 160a, the second proximity detector 160b, and the third proximity detector 160c (i.e., first position P1, second position P2, and third position P3) based on the first signal, second signal, and third signal, respectively. The positions of the first proximity detector 160a, the second proximity detector 160b, and the third proximity detector 160c (i.e., first position P1, second position P2, and third position P3) are stored in memory 114. With the positions of each proximity detector 160 known, the controller 112 identifies and monitors the distance between the first proximity detector 160a and the second proximity detector 160b (i.e., distance D1) based on the first and second signals. This is done by examining the positional information from each sensing beacon 120 stored in memory 114, triangulating the first position P1 of the first proximity detector 160a and the second position P2 of the second proximity detector 160b based on the signal strength received by each sensing beacon 120, and determining the distance between the first position P1 and the second position P2. As part of this process, memory 114 stores the signals from the sensing beacons 120. The sensing beacons 120 include cameras, and their position is determined using the angles of each camera and stereoscopic equipment or technology. The controller 112 selects which proximity detectors 160 to determine the distance between. For example, the controller 112 selectively skips determining the distance between proximity detectors 160 located on the same physical object (e.g., the same technician, the same machine, etc.) and proximity detectors 160 located on the machine (e.g., in situations where a collision has already been prevented by existing collision avoidance techniques for the machine 140). This allows the controller 112 to allocate more resources to identifying the most important distances (i.e., the distances most likely to improve safety and ensure physical distance between technicians 15). By using motion detection technology on distance data acquired over time, the current speed and / or direction of the technician 150 or machine 140 is determined. The proximity notification server 110 tracks movement within the assembly environment 130 by storing the paths of the first technician 150a and the second technician 150b (and any other technicians 150) in memory 114.This stored information will later be used to determine which technicians 150 are adhering to the physical distance guidelines. Method 400 then proceeds to block 424.

[0132] In block 420, once the distance between the first proximity detector 160a and the second proximity detector 160b (i.e., distance D1) is determined, in block 424, this distance is compared to a threshold (i.e., a first threshold), which is stored in memory 114. If this distance (i.e., distance D1) is greater than or equal to the threshold (e.g., the distance at which a safety warning is given to a technician), method 400 returns to block 422, and the proximity notification system 100 determines the new location of the proximity detector 160. If, however, this distance (i.e., distance D1) is less than the first threshold, method 400 continues to block 426.

[0133] Block 426 includes, upon determining that the distance between the first proximity detector 160a and the second proximity detector 160b (i.e., distance D1) is less than a first threshold, instructing or commanding the first proximity detector 160a to give a warning (i.e., a first warning) to the first engineer 150a, and instructing or commanding the second proximity detector 160b to give a warning (i.e., a second warning) to the second engineer 150b. The first and second warnings are given simultaneously. The first threshold is either fixedly set or dynamically determined based on the movement of the first engineer 150a and the second engineer 150b. For example, if, based on the future path and speed of the engineers 150 (e.g., the first engineer 150a and / or the second engineer 150b), it is expected that the first engineer 150a will decrease the distance to the second engineer 150b, the first threshold is increased so that the first warning to the first engineer 150a is issued more quickly.

[0134] If the distance (i.e., distance D1) is less than the first threshold, the controller 112 warns the first technician 150a by instructing the first proximity detector 160a to activate the alarm 349 via the detection path 182 (e.g., via the sensing beacon 120). In other words, the warning is given via the detection path 182. Specifically, by transmission given through the detection path 182, the first proximity detector 160 warns the first technician 150a using any appropriate alert (e.g., a visual display, sound, and / or vibration). Thus, the alarm 349 is configured to give a warning upon receiving data indicating that the distance between the first proximity detector 160a and the second proximity detector 160b is less than the first threshold.

[0135] 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. The first and second warnings take the form of verbal warnings stating phrases such as “Stop moving forward,” “Do not move left,” “Do not move south,” or other similar phrases, depending on the relative position of the first technician 150a to the second technician 150b. The speaker 350 provides such verbal or audible warnings. The first and second warnings are implemented in the form of flashing lights on the technician’s helmet, goggles, face shield, or gloves, or as flashing lights or appropriate visual indicators. The visual indicator 361 is a flashing light located at a specific point on the helmet, goggles, face shield, or gloves to indicate the direction of the location of another proximity detector 160. The first and second warnings include vibrations generated by the vibration generator 360. The first and second warnings, in whatever form, are cues prompting the technician 150 to maintain physical distance. Method 400 then proceeds to block 428.

[0136] In block 428, the controller 112 compares the distance between the first proximity detector 160a and the second proximity detector 160b (i.e., distance D1) to a threshold (i.e., a second threshold). The second threshold is smaller than the first threshold. The second threshold is stored in memory 114. If this distance (i.e., distance D1) is greater than or equal to the threshold (for example, the distance at which a safety warning is given to the technician 150), method 400 returns to block 422, and the proximity notification system 100 identifies the new location of the proximity detector 160. If, however, this distance (i.e., distance D1) is smaller than the second threshold, method 400 continues to block 430.

[0137] In block 430, upon determining that the distance between the first proximity detector 160a and the second proximity detector 160b (i.e., distance D1) is less than the second threshold which is less than the first threshold described above, the first proximity detector 160a and the second proximity detector 160b give different warnings to the first technician 150a and the second technician 150b, respectively. This warning is provided by both the first proximity detector 160a and the second proximity detector 160b, but is different from the first and second warnings described above. For example, this warning includes vibrations of a higher frequency than the vibrations of the first and second warnings described above. Also, this warning includes a louder audible sound than the vibrations of the first and second warnings described above. Furthermore, this warning includes a clearer visual display than the visual displays of the first and second warnings described above. Method 400 further includes block 432.

[0138] In block 432, the controller 112 determines the distance (i.e., distance D2) between the first proximity detector 160a (or other proximity detector 160 worn by the technician 150) and the third proximity detector 160c based on the first and third signals. This is done by examining the positional information of each sensing beacon 120 stored in memory 114, triangulating the first position P1 of the first proximity detector 160a and the second position P3 of the third proximity detector 160c based on the signal intensity received by each sensing beacon 120, and determining the separation between the first position P1 and the second position P3. As part of this process, memory 114 stores the signals from the sensing beacons 120. The sensing beacons 120 include cameras, and their position is determined using the angles of each camera and stereoscopic equipment or technology. By using motion detection technology on distance data acquired over time, the current speed and / or direction of the engineer 150 or machine 140 is determined. Method 400 then proceeds to block 434.

[0139] In block 432, once the distance between the first proximity detector 160a and the third proximity detector 160c (i.e., distance D2) is determined, in block 434, this distance is compared to a threshold (i.e., a third threshold), which is stored in memory 114. If this distance (i.e., distance D2) is greater than or equal to the third threshold (e.g., the distance at which a safety warning is given to the technician 150), method 400 returns to block 432, and the proximity notification system 100 determines the new location of the proximity detector 160. If, however, this distance (i.e., distance D2) is less than the third threshold, method 400 continues to block 436.

[0140] Block 436 includes instructing or commanding the first proximity detector 160a to give a warning (i.e., a first warning) to the first technician 150a after it has been determined 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 is either fixed for each machine or dynamically determined based on the movement shown in the numerical control (NC) program for that machine 140, and / or the position of machine 140 in the NC program as the machine continues to operate. For example, if the future path of machine 140 is expected to cause machine 140 to decrease its distance to technician 150, the third threshold may be increased so that a warning is issued more quickly.

[0141] If the distance is less than the third threshold, the technician 150 is away from the machine 140. Therefore, the machine 140 continues to operate. In contrast, if the distance is less than the third threshold, the controller 112 warns the first technician 150a by instructing the first proximity detector 160a to activate the alarm 349 via the detection path 182 (e.g., via the sensing beacon 120). That is, the third warning is given via the detection path 182. Specifically, by transmission given via the detection path 182, the first proximity detector 160a warns the first technician 150a using any appropriate notification means (e.g., visual display, sound, vibration, etc.). The working environment within the first cell 132 contains visual, auditory, and other stimuli that dull the senses of the technician 150. Therefore, the warning is issued in a way that stimulates multiple senses (e.g., by bright light, vibration-generating movement, characteristic sound, etc.).

[0142] The third warning includes an indication of the direction of the third proximity detector 160c. Depending on the relative position of the first technician 150a with respect to the machine 140, the third warning takes the form of a verbal warning stating phrases such as “Stop moving forward,” “Do not move left,” “Do not move south,” or other similar phrases. The speaker 350 provides such verbal or audible warnings. The third warning is implemented in the form of a flashing light on the technician’s helmet, goggles, face shield, or gloves, or as a flashing light or appropriate visual indicator. The visual indicator 361 is a flashing light located at a specific point on the helmet, goggles, face shield, or gloves to indicate the direction of the location of another proximity detector 160. The third warning includes vibrations generated by the vibration generator 360. Regardless of its form, the third warning is a cue prompting the technician 150 to be vigilant about the location of the machine 140. Method 400 then proceeds to block 438.

[0143] In block 438, the distance between the first proximity detector 160a and the third proximity detector 160c (i.e., distance D2) is compared to a threshold (i.e., a fourth threshold). The fourth threshold is stored in memory 114. If this distance (i.e., distance D2) is greater than or equal to the threshold (for example, the distance at which a safety warning is given to the technician 150), method 400 returns to block 432, and the proximity notification system 100 identifies the new location of the proximity detector 160. If, however, this 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.

[0144] In block 440, if the distance between the first proximity detector 160a and the third proximity detector 160c (i.e., distance D2) is less than the fourth threshold, the controller 112 commands the machine 140 to stop operating. This provides the technical advantage of ensuring the safety of technicians even when they approach a machine that is actually in operation. Furthermore, this eliminates the need to equip each machine 140 with dedicated sensors or logic for technician avoidance, thus providing another technical advantage.

[0145] Method 400 is performed substantially simultaneously and asynchronously for multiple sets of proximity detectors 160. For example, Method 400 is performed to determine the additional distance between the proximity detector 160 of the technician 150 and the machine 140 or the proximity detector 160 of the technician 150. This allows for proximity detection to be performed for all relevant physical objects within the manufacturing cell or across the entire factory floor. Method 400 also offers the technical advantage of preventing the technician 150 from being unable to detect objects due to obstructions 170, such as large parts.

[0146] Any of the various control elements (e.g., electrical or electronic components) illustrated or described herein may be implemented as hardware, a processor implementing software, a processor implementing firmware, or any combination thereof. For example, an element may be implemented as dedicated hardware. Dedicated hardware elements are referred to as “processors,” “controllers,” or similar terms. Where provided by processors, the functionality may be provided by a single dedicated processor, a single shared processor, or multiple individual processors, some of which may be shared. Furthermore, where the terms “processors” or “controllers” are explicitly used, they should not be interpreted as referring only to hardware capable of executing software, but implicitly include, for example, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuits, field-programmable gate arrays (FPGAs), read-only memory (ROM) for software storage, random-access memory (RAM), non-volatile memory, logic circuits, or other physical hardware components or modules.

[0147] Furthermore, control elements are implemented as instructions that can be executed by a processor or computer to perform the function of that element. Examples of instructions include software, program code, and firmware. When an instruction is executed by a processor, it operates and instructs the processor to perform the function of the element. Instructions are stored in a memory device that can be read by the processor. Examples of memory devices include digital memory, solid-state memory, magnetic storage media such as magnetic disks and magnetic tapes, hard disks, or optically readable digital data storage media.

[0148] While this specification describes specific embodiments, the scope of this disclosure is not limited to these specific embodiments. The scope of the disclosure is defined by the following claims and their equivalents.

Claims

1. A method for notifying proximity between engineers in an assembly environment, The first position signal generated by the first proximity detector is transmitted to the sensing beacon. The second position signal generated by the second proximity detector is transmitted to the sensing beacon. The proximity server monitors the distance between the first proximity detector and the second proximity detector based on the first position signal and the second position signal. The first acceleration signal from the first inertial measurement unit in the first proximity detector is transmitted to the sensing beacon at a sampling rate higher than the sampling rate at which the sensing beacon receives the first position signal from the first proximity detector and the second position signal from the second proximity detector. The second acceleration signal from the second inertial measurement unit in the second proximity detector is transmitted to the sensing beacon at a sampling rate higher than the sampling rate at which the sensing beacon receives the first position signal from the first proximity detector and the second position signal from the second proximity detector. A method for updating the distance between the first proximity detector and the second proximity detector based on the first acceleration signal and the second acceleration signal using the proximity server.

2. Furthermore, the method according to claim 1, wherein it is determined whether the distance between the first proximity detector and the second proximity detector is less than a threshold.

3. Furthermore, the method according to claim 2, wherein, upon determining that the distance between the first proximity detector and the second proximity detector is smaller than the threshold, the first proximity detector is used to give a warning to the first technician.

4. The first proximity detector is worn by the first technician, The method according to claim 3, wherein 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 determines that the distance between the first proximity detector and the second proximity detector is less than the threshold, and the second warning is given to the second technician using the second proximity detector, and the first and second warnings are given simultaneously.

6. Furthermore, the method according to any one of claims 1 to 5, wherein the first proximity detector is attached to a wearable device.

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

8. The method according to any one of claims 1 to 7, wherein the first proximity detector and the second proximity detector are part of a plurality of proximity detectors, and the plurality of proximity detectors include three or more proximity detectors.

9. A proximity notification system in an assembly environment, Sensing beacons and A first proximity detector configured to be worn by a first technician, the first proximity detector configured to transmit a first position signal to a sensing beacon and to transmit a first acceleration signal from a first inertial measurement unit to the sensing beacon at a sampling rate higher than the sampling rate at which the sensing beacon receives the first position signal, A second proximity detector, configured to be worn by a second technician, which transmits a second position signal to the sensing beacon and transmits a second acceleration signal from a second inertial measurement unit to the sensing beacon at a sampling rate higher than the sampling rate at which the sensing beacon receives the second position signal; The system includes the sensing beacon, the first proximity detector, and the proximity server that communicates with the second proximity detector, The proximity server is programmed to monitor the distance between the first proximity detector and the second proximity detector based on the first position signal and the second position signal, and is configured to update the distance between the first proximity detector and the second proximity detector based on the first acceleration signal and the second acceleration signal.

10. The system according to claim 9, wherein 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.

11. The system according to claim 10, wherein the proximity server is programmed to instruct the first proximity detector to issue a warning to the first technician when it determines that the distance between the first proximity detector and the second proximity detector is less than the threshold.

12. The item itself and A wearable product comprising a first proximity detector attached to the main body of the article, wherein the first proximity detector is configured to generate a first position signal indicating the position of the first proximity detector, and the first proximity detector is A first inertial measuring unit configured to generate a first acceleration signal representing the movement of the first proximity detector, The system includes a transceiver connected to the first inertial measuring unit, the transceiver being: A wearable device configured to transmit the first position signal to a plurality of sensing beacons, transmit the first acceleration signal from the first inertial measurement unit to the sensing beacons at a sampling rate higher than the sampling rate at which the sensing beacons receive the first position signal, and further receive data indicating the distance between the first proximity detector and the second proximity detector, which is determined based on the first position signal and the first acceleration signal.

13. The wearable product 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 product according to claim 13, further comprising an alarm connected to the transceiver, wherein the alarm is configured to give a warning upon receiving the data indicating that the distance between the first proximity detector and the second proximity detector is less than the threshold.

15. The wearable device according to claim 13 or 14, wherein the first proximity detector is configured to receive data from the 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 the first position signal and the second position signal generated by the second proximity detector.

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