Intelligent personal protection system in vertical work structures

Abstract

The present invention relates to an intelligent safety harness system comprising a primary control unit (PCU) 110 integrated into the safety harness (on the connectors 111 to safety structures) worn by an operator 10 in elevated work structures. The PCU 110 comprises a plurality of sensors for monitoring the connectors 111 and thus the operator's attachment to metal anchor points 20. A virtual gate 130 identifies the entry / exit points of the operator 10 to the elevated structures, selecting or deselecting a "work at height" mode and transmitting commands to a secondary control unit, SCU, 120, which activates this mode. The secondary control unit (SCU) 120 is worn by the operator 10 and receives data from the PCU 110 and the virtual gate 130, distinguishes between open and closed connectors, detects the coupling of one or more PCUs 110 to a metal element, and measures the difference in height between the PCU 110 via corresponding pressure sensors. The SCU 120 can send the data to a server 160 that is able to process it and establish the level of danger. A dashboard and a mobile application in the central unit 160 allow for the monitoring and remote control of the "work at height" mode. The invention also relates to a corresponding method of operating the system.

Description

Intelligent personal protection system in vertical work structures

[0001] This invention concerns an intelligent personal protection system in vertical work structures .Field of the Invention

[0002] This invention concerns an intelligent personal protection system, in particular a safety harness, designed to improve safety measures for workers operating at height . The system is particularly suitable for use on construction sites, prefabrication yards, and offshore installations .Description of the State of the Art :

[0003] Based on a report published in 2019, the construction industry accounts for 50% of all fatal accidents in industries, of which about 40% are related to falls from work at height . When working at height, for example on construction sites, workers are required to wear safety harnesses to prevent falls .

[0004] Work at height often takes place on so-called scaffolding, temporary modular structures that create a primary barrier against falls . However, the complexity of modern construction sites makes it difficult to always guarantee the integrity of these primary barriers . For this reason, work situations with a potential risk of falling (for example, scaffolding with a "yellow tag" ) require the use of secondary barriers, such as safety harnesses (Personal Protective Equipment, PPE) fixed toanchor points .

[0005] Safety harnesses typically include force distribution straps, safety ropes (or lanyards) , mechanical connectors (hooks or safety hooks) for connection to anchor points or lines, and sometimes energy absorption systems . Correct use requires the worker to attach the connector to a secure anchor point before exposing themselves to risk . The potential fall energy is linked to the "fall factor" (f) , defined as the ratio between the fall height (h) and the length of the rope (L) . A high fall factor (f>l, and especially f>2) can generate dangerous impact forces for the worker .

[0006] Despite the regulatory obligation and the vital importance of these devices, numerous accidents occur due to misuse, incorrect perception of risk, complexity of the construction site, or simple negligence . A common and particularly dangerous violation is the so-called "low hang, high use", where the anchor point is below the worker ' s position, dramatically increasing the potential fall factor.

[0007] To overcome these problems, intelligent systems have been proposed to monitor the use of harnesses . Some systems are based on the sensorization of mechanical connectors to detect their status (open / closed) or the coupling. For example, US 2021 / 106855 Al describes sensors placed on the harness and rope fasteners to verify that both are closed. Other systems, such as the one described in JP 2022 139618 A, combine a hook status sensor with atmospheric pressure sensors (one mobile on the worker, integrated with thehook, and other fixed reference points on the building floors) to determine whether the worker is at a height ("high place" ) and, if so, to check whether the hook is connected. These systems, however, are limited to a binary control (hooked / unhooked) and a static evaluation of the position with respect to fixed references, without considering the dynamic geometry of the connection .

[0008] Other approaches specifically aim to detect the violation of the "low hang, high use" rule . Systems such as those described in CN 217 612 572 U, CN 214 050 239 U, and CN 113 842 570 B typically employ two height or distance sensors : one associated with the anchor point (or the fixed end of the rope) and one associated with the worker (or the movable end of the rope / harness connection point) . By comparing the readings of the two sensors, these systems determine whether the worker is above the anchor point and trigger an alarm. CN 116 236 720 A also includes multiple height sensors (on hook, vest, and rope) for this purpose, integrated into a more complex environmental monitoring system. Although useful for this specific violation, these systems have limitations :~ They focus on a single rule (low hang, high use) and do not evaluate other dynamic risks .- The position of the sensors (e . g. , rope end, along the rope, connection point to the harness) often does not allow a direct measurement of the vertical distance between the actual anchorage and the worker ' s body ( ' h' ) , a fundamental measure for assessing fall energy . For example, the necessarypresence of an extension rope in CN 217 612 572 U introduces an indirect mode in the measurement . ~ They do not consider the length of the rope ( ' L ' ) and therefore cannot calculate critical parameters such as the fall factor (f=h / L) or the excessive slack (SL) of the rope .

[0009] Different technologies have been proposed for localization and contextual monitoring. The article by G6mez-de-Gabriel et al . ("Monitoring harness use in construction with BLE beacons", Measurement 131 (2018) 329-340) uses Bluetooth Low Energy (BLE) beacons to delimit risk areas and verify the proximity between a worn receiver and a beacon placed on the lifeline hook, based on the power of the received signal (RSSI) . This approach is useful for proximity detection and zone entry, but the RSSI is notoriously inaccurate for exact distance measurements and not suitable for determining the relative vertical height ' h' needed to assess fall energy risks .

[0010] Other systems are based on motion detection using inertial sensors . JP 7502925 B2 describes the use of an accelerometer placed on the hook or rope, whose data is analyzed by machine learning (SVM) to recognize movement patterns associated with the correct or incorrect use of the hook . Similarly, US 2024 / 033545 Al describes a Motion Detector Module (MDM) , typically with an accelerometer or gyroscope, attached to the equipment to infer compliance of use from the presence or absence of movement . These systems can indicate whether the equipment is likely in use, but they do not directlymeasure the geometry of the connection or assess energy risks such as the fall factor or slack state . US 2024 / 033545 Al also mentions the optional use of barometric or GPS sensors to determine the elevation or plane on which the worker is located, but not for the differential anchor-body measurement or the evaluation of f and SL .

[0011] Therefore, several problems emerge from the existing solutions :- Many systems only perform static checks or verify compliance with individual specific rules (closed hook, not "low hang, high use" ) , neglecting other hazards .- There is no quantitative dynamic assessment of the risks related to the potential energy of the fall, such as the fall factor (f) and the excessive slack state (SL) of the rope .~ Sensor architectures and positions often provide only an indirect or potentially inaccurate measurement of the critical vertical anchor-body distance ( ' h ' ) .-Some approaches require complex processing (e . g. , machine learning) or additional infrastructures (e . g. , multiple reference stations, beacons to delimit zones) .- The integration of advanced electronics can be invasive on critical components such as hooks, potentially compromising their reliability or increasing their complexity.~ Automatic identification of the specific riskcontext is often lacking, limiting the effectiveness of monitoring.~ The accuracy of localization in complex environments can be insufficient, leading to false positives or negatives .

[0012] There is therefore a need to provide an intelligent personal protection system that overcomes these drawbacks . Ideally, such a system should automatically identify at-risk work situations, monitor the correct use of the harness and connectors, and, crucially, provide a dynamic and accurate assessment of the real risks associated with the potential fall, such as the fall factor and the slack state of the rope, activating timely alarms in the event of non-compliance . It is also important that the system is reliable, non-invasive, energy efficient, and sufficiently accurate to avoid false alarms in complex construction site environments .Purpose and object of the invention

[0013] The purpose of this invention is to provide an intelligent personal protection system that solves the problems and overcomes the drawbacks of the known technique .

[0014] The object of this invention is a system according to the attached claims .Detailed description of examples of the inventionList of Figures

[0015] The invention will now be described by way of non-limiting example, with particular reference to the accompanying drawings, in which:- Figure 1 shows an example of fall factors, according to a form of embodiment of the invention;- Figure 2 shows a simplified diagram of the architecture of the System according to the invention according to a different embodiment;- Figure 3 shows a block diagram of the SCU according to a specific embodiment;- figure 4 shows a state diagram of the SCU according to a specific embodiment;- figure 5 shows an exemplary diagram of the virtual gate, according to one aspect of the present invention;- figure 6 shows a state diagram of the SCU logic, according to a specific aspect of the present invention;- Figure 7 shows a state diagram of the PCU according to a specific aspect of the present invention .

[0016] It is specified here that elements of different embodiments can be combined together to provide further embodiments without limits while respecting the technical concept of the invention, as the average technician in the field understands without problems from what has been described.

[0017] This description also refers to the technique known for its implementation, with regard to the detailed features not described, such as, for example, elementsof minor importance usually used in the technique known in solutions of the same type .

[0018] When an element is introduced, it is always understood that it can be "at least one" or "one or more" .

[0019] When a list of elements or features is listed in this description, it is understood that the finding according to the invention "comprises" or alternatively "is composed of" such elements .

[0020] When listing features within the same sentence or bulleted list, one or more of the individual features may be included in the invention without connection to the other features in the list .Forms of construction

[0021] The system is suitable for use on construction sites, prefabrication yards, and offshore installations / vessels in various geographical areas . The main use case concerns the assembly, use, and disassembly of scaffolding. The professional of reference who will have to use the device is the scaffolder; other workers who work at height on construction sites / sites will still be able to wear it and be monitored during activities at height . The system must be able to function properly even in situations where the use of scaffolding is not planned (e .g. work / inspection on large equipment involving work at height) as long as metal or rigid attachment elements such as lifelines, anchor points, etc . are present .

[0022] In the following, explicit reference will bemade to the safety harness equipped with one or more connectors, but what has been said applies to a generic personal safety device (for example, but not limited to, shoes or gloves or helmets or headphones) , not necessarily equipped with connectors but worn by an operator .

[0023] Referring to Fig. 2, the 100 intelligent safety harness system according to the invention offers several combinable features :1. Primary Control Unit (PCU) 110 with Sensor Integration : the PCU incorporates advanced sensor technology, e . g. one or more of kinetic, pressure, induction and capacitive sensors, to monitor the status of the (one or more) mechanical connectors 111 of the PPE (or the status of other PPE even without connectors) and / or the attachment of the operator 10 to anchorage points (one or more elements) of a safety structure 20 (in particular metal, e . g. certified lifeline; this applies only where the PPE has mechanical connectors) with the one or more mechanical connectors, possibly the position of the mechanical connectors (e . g. placed on the chest or pelvis attached to the metal or plastic rings installed on the harness worn by the operator) . The PCU may also process data, for example by distinguishing between open and closed connectors, identifying secure and unsecure anchor points, or identifying other PPE statuses . In the case of a mechanical connector (111) , the PCU may comprise a respective PCU atmospheric pressuresensor . The PCU comprises a PCU communication unit for transmitting said PCU data .Secondary Control Unit (SCU) 120 : the SCU, worn by the operator, processes information from one or more PCUs with or without mechanical connectors (e . g. helmets, gloves, and shoes) . The SCU can be equipped with its own sensors, such as a pressure sensor for altitude detection . Based on the processing of such data, the SCU can detect falls (or other states) of the operator wearing the SCU / PCU and can provide data on the dynamics of the fall (or other change of state) . In the case of the atmospheric pressure sensor, the SCU also measures the difference in height between itself and the PCU 110 (receiving from the latter a pressure datum on the PCU itself) , and on this basis can emit corresponding alarms (for example through a speaker integrated in the SCU) . The SCU can also transmit the collected data to a server 160, directly or through a "concentrator" (router) 150 that collects data from various (one or more) SCUs in the site of operations that includes the structure . The SCU includes a data reception module for receiving the data of PCU 110 and possibly the data and / or commands from at least one virtual gate 130 (optional) ;Virtual Gate 130 (optional) for selecting or deselecting the "Work at Height" Mode (or other safety mode) : the virtual gate (comprising one or more beacons placed at a height in the elevatedstructure) identifies and circumscribes (dynamically) the spatial extension of the entry / exit points to / from the elevated structures . The system selects or deselects the "work at height" mode (or other safety mode) when the operator passes through the virtual gate (for example, after a predefined time from the passage) . The virtual gate 130 can also deactivate this mode when the operator exits the safety structure (for example, an elevated structure) . The virtual gate (s) transmit data and / or commands relating to said security mode to the SCU.Real-Time Monitoring and Alarm System: the SCU provides real-time monitoring of the status of the PPE (for example, the hooking of the operator) and activates local alarms, for example, through means of which the same SCU is equipped (alarms that may include one or more of vibration, optical and / or sound signal) if the status of the operator ' s PPE is not the one expected in that position, for example, if the operator does not secure one or both mechanical connectors to a secure anchorage point . The alarm signals can also be transmitted to a work area supervisor and to a control dashboard for immediate action .Concentrator for Aggregation and Data Analysis : The concentrator is only optional and is a router positioned within or near the work area, and collects information from all the SCUs present in the monitored work environment . The concentratorprovides data on the positions of the workers, the coupling status, and the manual deactivation of the "work at height" mode, having collected them from the SCUs and preferably also from the virtual gates .6. Remote Monitoring Server 160 (optional, the SCU can also act alone) : a remote server 160 (also mobile) , possibly connected to the concentrator, and preferably with a graphical interface equipped with a dashboard, allows remote monitoring of the "work at height" conditions . A supervisor can check the status of the PCU-SCU pairs, check which PCUs are in the correct state (e . g. , hooked) , manage the alarms and control the activation and deactivation / reactivation of the "work at height" mode by sending commands to the SCU. The application also supports the transmission and analysis of data in real time, including statistical analysis (e . g. , number of workers working at height in a given work area, % of time spent in a compliant / non-compliant situation, % of time spent with one or two connectors attached) and predictive risk assessments based on the data collected (e . g. , with the fall factor shown in Fig.1) •

[0024] The SCU comprises an electronic processing unit configured to process said PCU data 110 and / or said data and / or commands, determine the status of said one or more personal safety devices 111, activate or deactivate said safety mode based on said data and / orcommands and also based on the relative height between each PCU 110 and the SCU 120 determined as a function of the measurements of said atmospheric pressure sensor of the PCU 110 and of said atmospheric pressure sensor of the SCU 120, and wherein said safety mode is a working at height mode of said one virtual gate 130. The SCU also comprises an alarm module configured to emit one or more alarms based on said correspondence . The SCU may also comprise a gyroscope to detect the orientation of the operator 10, an orientation that can be used by the supervisor . According to one aspect of the invention, the SCU 120 may include an emergency button configured to allow the operator 10 to manually activate an alarm. Optionally, the PCU may comprise a GPS module to determine the precise position of the operator 10 and possibly provide it to a central control unit (also optional) .

[0025] One aspect of the invention concerns the two-stage synergistic logic made possible by the distributed architecture of the system. The system is designed to be both highly effective and energy efficient . In a first stage, contextual activation occurs through virtual gates . The virtual gates 130, generated by low-consumption beacons, function as intelligent triggers . Their sole purpose is to detect the passage of an operator inside or outside a predefined high-risk area . It is an event-based mechanism. Upon detection of the entrance, the gate transmits a command to the operator ' s SCU 120, activating the "work at height" safety mode . This contextual activation ensures that the system' smost energy-intensive monitoring functions are used only when strictly necessary, preserving battery life and preventing false alarms in safe areas . In a second stage, a dynamic risk assessment takes place . The "work at height" safety mode, activated by the gate, is defined by the SCU that performs a dynamic and continuous risk assessment . This is made possible by the physical separation between the PCU 110 placed on the rope connector (at the anchor point) and the SCU 120 worn by the operator . The SCU constantly compares the atmospheric pressure readings from both units to determine the precise relative vertical distance ( ' h' ) between the anchor and the operator . The technical means for this measurement are well established; modern MEMS barometric sensors offer resolutions capable of detecting altitude variations of less than 5 centimeters . Using two of these sensors in a differential configuration, the system eliminates common atmospheric drifts (for example, due to meteorological changes) , allowing an accurate and reliable measurement of ' h' . This dynamically monitored ' h' value is used to assess a number of fall-related risks that static systems are unable to detect . The SCU is configured to check if ' h' corresponds to a risk condition, including but not limited to :- High fall factor : A high positive ' h' value (operator well below the anchor) or negative (operator above the anchor) can lead to a fall factor (f = h / L) above the safety limits (forexample, > 1 or in general at a first predetermined threshold) .- Excessive rope slack: A high ' h' value (compared to a second predetermined threshold) , even when the operator is under the anchor, indicates a dangerous slack that would increase the fall distance and the impact force ."Low Hang, High Use" Violation : A significant negative ' h' value (compared to a third predetermined threshold, where the anchor point is below the operator .

[0026] The fall factor and the slack state of the SL rope can generally be functions of the relative height h and the length of the rope L . If one or more of these three risk conditions is verified, the alarm module is activated. This two-stage synergistic operation— which uses a simple trigger to activate sophisticated dynamic analysis— of fers a much higher level of safety monitoring than the known technique .

[0027] The determination of the fall factor f based on the relative height h measured is not simply an abstract risk index, but is directly related to the physical forces to which the operator would be subjected in the event of a fall . As is known from the physics of falls with arrest systems, the maximum arrest force (F_stop) depends critically on the fall factor (f = h / L) . An excessive stopping force can cause serious injury even if the fall is stopped. Therefore, the system' s ability to calculate f in real time based on the direct measurement of h (vertical anchor-operator distance)allows for a quantitative and dynamic assessment of the impact risk, solving a fundamental technical problem for safety that systems based on simple status checks (closed / open hook) or binary rules (low hang / high use) do not address .

[0028] The specific architecture of the system, with the PCU (110) associated with the connector (111) and the SCU (120) worn on the body (10) , is designed to provide a direct and continuous measurement of the relative vertical height h between the actual anchor point and the operator ' s torso, through differential atmospheric pressure measurements . This h value, continuously updated, serves as a primary and direct input for the assessment of the potential instantaneous fall height . It is precisely this continuous and direct measurement of h that enables the SCU processing unit to perform the specific calculations of the fall factor (f = h / L) and the slack state (SL = function (h, L) ) , thus providing an accurate physical basis for verifying the unsafe conditions related to potential energy.

[0029] The monitoring performed by the SCU processing unit is inherently dynamic and continuous . The determination of the relative height h does not occur at discrete intervals or only in response to specific events, but is a constant process during active safety mode . This continuous measurement of h allows the processing unit to constantly recalculate and verify the values of the fall factor f and the slack state SL with respect to the predetermined thresholds . Consequently, the system provides a continuous assessment of the riskrelated to the geometry of the anchor-operator connection, allowing the immediate identification of the onset of an unsafe condition (such as an increase in slack or positioning above the anchor) and the activation of the alarm in a timely manner, rather than relying on static controls or post-event surveys .

[0030] The system can be configured for use in various geographical locations (e . g. remote sites in the desert or offshore) and in general in operating sites with potentially limited connectivity or in areas where the use of mobile phones is prohibited. Below is an example of communication modes between the various (sub-) systems :- Communication between PCU and SCU : BLE 5.0;- Communication between SCU and Concentrator : TBD (depending on the work area) ;- 4G / 5G (e . g. with physical SIM) ;- Wi-Fi;- Communication between concentrator and dashboard: 4G / 5G / Cable .

[0031] The system can be designed to operate in extreme temperatures, high humidity and environments with limited connectivity. Communication between PCU and SCU can use BLE 5.0, while communication between SCU and concentrator can use 4G / 5G or Wi-Fi or similar, depending on the work area . The system can ensure compliance with relevant safety and certification standards .

[0032] In particular, the PCU 110 may be a first electronic control unit integral with a sensorized hook fixed to a harness (not shown) . The first control unitcan be connected to or comprise one or more transducers, including at least one barometer and an antenna, thus representing a node of a digital network architecture . The first electronic control unit can be equipped with hardware / software means for a first processing of the data to be transmitted to the SCU.

[0033] Referring to Fig. 3, in a specific embodiment the SCU 130 may comprise the following components :- a back-up battery 120-a (optional) ;- one or more primary batteries lOd, 120c chargeable through USB port 120-b;- an RTC, Real Time Clock, 102-e;- an LDO, Low Dropout Regulator, 120-f which supplies voltage to a BLE module (or other connectivity module) 120-q;- an LDO, Low Dropout Regulator, 120-g which supplies voltage to one or more of an IMU module 120-r, a barometer 120-s, a memory (EEPROM) 120- t ;- an LDO with active antenna 120-h, which supplies voltage to a GPS antenna 120-n, which is connected to an LTE / GPS module 120-O, possibly connected to a SIM card 120-p;- a DC-DC 120-m transformer that supplies voltage to the LTE / GPS 120-0 module;- an LTE antenna possibly connected to the LTE / GPS module 120-O.

[0034] The virtual gate 130 may comprise a second electronic control unit that couples with the firstcontrol unit to identify the passage, distance and movement of the first control unit in relation to the second control unit . The second control unit simultaneously sends a command to the first control unit (of the SCU) by modifying a status parameter of the latter ( "Gate_status " ) . The virtual gate may include a pressure sensor .

[0035] Referring to Fig. 5, thanks to the positioning of a plurality of virtual gates 130 within a work area, it is therefore possible to detect the passage and the direction / travel direction 133 of the operator from these virtual gates 130 and therefore model the movement of people . This is possible, for example, by detecting the passage of the operator through at least two virtual gates 130, for example according to an interference logic 132 between configurable coverage areas 131 of two successive virtual gates (thus also determining the direction 133 of the passage) . It is also possible to determine a security mode based on the passage through three or more virtual gates .

[0036] The server or central electronic unit 160 (optional) collects the information received and / or processed by the nodes constituted by the various SCUs, including for example the status of parameters such as the status of the gate, of the work at height, of the harness hook (open / closed) , the safe / unsafe security status of the PPE (anchored or other) , or other physical parameters (environmental and / or biometric of the operator) acquired from corresponding SCU sensors, and can possibly perform the following operations :- correlate the parameters, for example the status of the "Work at height" GATE with the status of the hook (safe / not safe) or other PPE and therefore with the correct use of personal safety devices, alerting in case of anomalies; and / or- estimating the risk of falling from a height, calculating on the basis of the two height measurements, the relative distance between the primary PCU unit and the secondary SCU unit and then calculating a fall factor value, for example as f = h / L, where h is the relative distance and L the length of the rope (e . g. rope 115 in cf . Figure 1 ) ; and / or- to verify the correspondence between one or more PCU states, said safety mode and said further one or more physical parameters, the alarm module being configured to emit one or more alarms based on said correspondence ;- send commands to the various SCUs 120.

[0037] The Gate_status determines whether the person has crossed the gates and whether he / she is currently enabled to access the work area, for example enabling the WORK_at_HEIGHT status in the SCU in the risk areas, and in this case evaluates whether the hook has been attached (if so, no alarm is triggered) . If the hook (s) has / have not been attached, the status parameter enters ALARM mode, which provides a local alarm (for the person, through an alarm emitting device, for example integrated in the SCU) and an alarm in the user interface 160 of the remote server 160.

[0038] In one embodiment, each coupling device 110, such as the sensorized hook, and each first control unit 120 are equipped with a precision pressure sensor, so as to be able to calculate the fall factor based on the detected pressure difference (which corresponds to a difference in altitude) . The pressure sensor can be suitable for providing extreme accuracy, for example it can be capable of measuring height variations of 8 cm.

[0039] In a different embodiment, which can be combined with the other embodiments in this description, the sensor-equipped hook uses sensors to detect the open or closed state of the hook and is configured to detect whether the closed hook encloses a cable or a tube or other structural element within its perimeter and therefore if there is a connection to an anchor point .

[0040] In all embodiments, other monitored PCUs may have other sensors for their monitoring. In all embodiments, the working at height mode can be a different working mode, not necessarily linked to height, but linked to another safety parameter (such as the risk of falling objects from above with respect to a helmet worn) . Within the monitored work structure, PCU / SCU / gate related to height and PCU / SCU / gate related to another safety parameter can coexist .

[0041] In one embodiment, the first control unit or SCU 120 comprises an antenna for communicating with the control panel 160, and / or one or more accelerometers (e . g. integrated on inertial platforms, IMU - Inertial Measurement Unit) , and / or a GPS, and / or acoustic alarm devices .

[0042] The working method of the system described above may comprise the execution of the following steps : A. providing an intelligent personal protection system 100 in vertical work structures, described above;B . transmitting, by each of said one or more PCUs 110, said PCU data to said SCU 120;C . Continuously determining a relative height between the PCU 110 associated with said at least one mechanical connector 111 and the SCU 120 based on measurements of the PCU atmospheric pressure sensor and the SCU atmospheric pressure sensor, and verifying whether said relative height corresponds to a fall risk condition, verifying the difference between a fall factor and a slack state of the rope SL, calculated as functions of the relative height h and the length of the rope L, and respective predetermined thresholds;D . activating or deactivating, by the SCU 120, said alarm module on the basis of said fall risk condition .

[0043] According to one aspect of the invention, the following further steps are performed:E . providing one or more of the aforementioned virtual gates 130;F . selecting or deselecting, by at least one virtual gate (130) , a predetermined safety mode based on an operator (10) passing through at least one virtual gate (130) ;G. transmitting, by said at least one virtual gate(130) , data and / or commands relating to said predetermined safety mode to the SCU (120) ;H. verifying, by the SCU (120) , the correspondence between said state and said predetermined safety mode, wherein said predetermined safety mode is a working at height mode;I . activating or deactivating, by the SCU, the predetermined safety mode based on said correspondence and said data and / or commands .

[0044] According to a further aspect of the invention, in phase F the predetermined safety mode is selected or deselected based on the operator 10 passing through at least two virtual gates 130 in sequence .

[0045] According to a further aspect of the invention, the SCU 120 comprises one or more SCU sensors configured to detect one or more additional physical parameters, and wherein in phase I the SCU 120 verifies the correspondence between said state, said safety mode, and said one or more additional physical parameters .

[0046] According to a further aspect of the invention, said PCU 110 comprises a coupling sensor of said mechanical connector 111 to an element 20 of the elevated structure, and in phase C the SCU 120 further verifies the coupling of said mechanical connector to said element 20 on the basis of the data of said coupling sensor, in order to determine said fall risk condition .

[0047] In particular, with regard to the operating states activated by the SCU, in the WORK_AT_HEIGHT state :- if the operator attaches the safety hooks before the activation time of the Safety Mode alarm haselapsed, it switches to the SAFE state, otherwise Safety Mode switches to the ALARM state;- if the remote deactivation command is sent, the Safety Mode returns to the ENABLED state .

[0048] In the SAFE state, the Safety Mode remains in the SAFE state until the remote deactivation command (PAIRED) is sent or the operator does not fall below the activation height (ENABLED) or at least one hook is released for a predetermined time or both carabiners are released (ALARM) , or another safety parameter related to the PPE is changed.

[0049] In the ALARM state, the Safety Mode remains in this state until the remote deactivation command is sent or until both carabiners are hooked (or another PPE state is restored) . The alarm is activated by local buzzers and / or sent via the network to the software of the first control unit .

[0050] From an operational point of view, the system of the invention can be operated as follows .

[0051] Before starting operations at height, each worker 10 must wear the personal protective equipment of the invention (with at least one PCU and one SCU) . To access the scaffolding or a vertical structure where there is a danger of falling from a height, a virtual gate 130 can be provided (which can be used to control different safety areas with different safety parameters over time, by the management of the construction site or other structure, for example as the floors of a building are added) that can communicate with the device worn by the operator (s) (SCU 120) .

[0052] The "work at height" mode (or other predetermined safety mode) will be activated when the following conditions occur :1) Passage of the device 120 worn by the operator near the entrance area to the scaffolding where a virtual gate 130 will be installed (with the possibility of setting an activation delay after the passage) ; and optionally :2) Detection of an absolute difference in altitude (calibratable, understood as meters above sea level) between the virtual gate 130 and the SCU device 120 worn by the operator . The detection must also work in the case of work that is carried out at height even below sea level (e . g. , inside excavations) .

[0053] Once the "work at height" mode (or other predetermined safety mode) has been activated or selected, the worker 10 must secure both hooks 110 (coupling elements) to a safe anchorage point 20 (e . g. , metal) (e . g. , certified lifeline) . If the worker wearing the device fails to secure himself with one or two hooks to the support structure, a local alarm signal must be triggered with the SCU 120 (via vibration and optical / audible warning) . The signal must also reach the team supervisor and a control panel 160 located in a control room available to site management .

[0054] In one embodiment, if the worker wearing the PCU / SCU 110 / 120 requests it (for example, by pressing a request key) , the team supervisor can deactivate the activated safety mode . The supervisor will then be ableto restore the safety mode on the same device, via the graphical interface described above .

[0055] The virtual gate allows the "work at height" mode to be activated or deactivated depending on whether the operator accesses or leaves the scaffolding or elevated structure .

[0056] For some types of work (e . g. , where there is no scaffolding) , site management can activate the safety mode for specific needs, regardless of the passage of the virtual gate .

[0057] According to one aspect of the invention, once the safety mode is activated, the PCU / SCU device will transmit the information in real time to the control center .

[0058] According to a preferred embodiment of the invention, the operator ' s actions on the PPE are not monitored, but the SCU sends generic alarms relating to the selected safety mode .

[0059] According to a preferred embodiment, the operational logic according to which the SCU activates the "work at height" mode is based on the passage of the operator through a virtual gate, which corresponds to the entry of the operator into the risk zone of falling from a height .

[0060] Consequently, in this as in the other embodiments, there is a difference between enabling operator monitoring, carried out by the gate, and the actual activation of a safety mode, which can be work at height or another mode as described above .

[0061] Referring to Fig. 4, reference is made to an embodiment of the method that models the movement of an operator 10 within the elevated structure and that determines the activation of the SCU 120.

[0062] The purpose of this method is achieved, for example, through a GATE parameter that changes dynamically, for example, when the operator passes through the multiplicity of virtual gates and optionally on the basis of the operator ' s distance with respect to this multiplicity of virtual gates; this distance is identified by the status of the parameter (ADV) detected by the SCU 120 on the basis of the signal emitted by the virtual gate 130.

[0063] The relationship 200 between movement and GATE and ADV parameters is described by way of non-limiting example as follows :- At the initial position 201, the operator is outside the work area : the GATE parameter in 204 is set to zero and the SCU is deactivated in 202;- if the operator passes through the first virtual gate, the ADV1 parameter, corresponding to the signal received from the first virtual gate, passes in 207 to 1 and the GATE state passes to GATE1; In the GATE1 state :- if the operator goes back through the first virtual gate in 206, the ADV1 parameter returns to 0 and the GATE state returns to zero,- if the operator moves forward with respect to the first virtual gate and reaches in 211 the area of influence of both the first and the second virtualgate, then the ADV2 parameter, corresponding to the signal received from the second virtual gate, passes to 1 and the GATE state passes to GATE1_2 in 213,In the GATE 1_2 state :- If the operator returns in 210 with respect to the area of influence of the first and second virtual gates, then the ADV2 parameter, corresponding to the signal received from the second virtual gate, passes to 0 and the GATE state returns to GATE1, - if the operator continues forward with respect to the area of influence of the first and second virtual gates in 215, then the ADV1 parameter, corresponding to the signal received from the first virtual gate, passes to 0 and the GATE state passes to GATE2 in 216,In the GATE2 state :- if the operator continues forward in 221 with respect to the area of influence of the second virtual gate, then the ADV2 parameter, corresponding to the signal received from the second virtual gate, passes to 0 and the GATE state passes to ENABLE in 219, which corresponds to the activation of the SCU;- if the operator returns in 218 to the area of influence of the second virtual gate, then the ADV2 parameter, corresponding to the signal received from the second virtual gate, switches to 1 and the ENABLE state switches to GATE2 in 216, which corresponds to the SCU not yet activated.

[0064] Referring now to Fig. 6, an embodiment of the invention is illustrated by way of non-limiting example, in which there is a possible succession of states 400 of the SCU towards the activation (and not only the enabling) of the working at height mode (or in general of any safe working mode) , as follows (the previous states of Fig. 7 concern the enabling of the SCU and not the activation of the safety mode) :- from the connection state 413, it is possible to switch to the enabled or disabled gate state (see Fig. 4) 418 by setting a GATE_EN parameter to 1 or 0 respectively;- from the enabled state 418 it is possible to pass to the working at height state in 419 if Ascu > AEN, i . e . if the height of the SCU relative to the gate is greater than a predetermined threshold or simply based on the positioning of the worker with respect to the gate or by remote control after a certain time from the enabling, or this state can be deactivated in 420 when this condition no longer occurs or there is a remote deactivation; this working at height mode can be confirmed or not on the basis of a time parameter that runs from the activation;- in the work at height safety mode in 421, it is possible to switch in 426 to an alarm state 430 if, for example, the time elapsed since activation exceeds an alarm time limit or based on another parametric determination based on sensor data (see above) ; alternatively, in 422, the system canswitch to the safe state 424 if the operator engages the hook before this alarm time limit;- from the alarm state 430, it is possible to pass in 427 to a safe state 424 under certain conditions such as a remote command or if the operator engages the hook; if these conditions no longer exist, the state in 429 passes back to the alarm state 430.

[0065] Referring to Fig. 7, the PCU, for its part, moves between a possible series of states 300, by way of example and not limited to the following:- starting from a starting state 301, the PCU can be brought to a standby state 304, and this can be reconfirmed if a time parameter t is less than a coupling time threshold with the SCU;- if, on the other hand, the condition on the time parameter is opposite, it passes in 305 to the inactive state 308;- if then the data of the accelerometer Acc is greater than a certain IDLE threshold, the state returns in 306 to the standby state 304;- from the standby state 304, the coupling parameter PAIR_EN can be set equal to 1 in 310 and the state can become the enabled state 312, and can return the inactive one by setting in 309 PAIR_EN=0; the enabled state can be confirmed in 312.

[0066] Two or more of the parts (elements, devices, systems) described above can be freely associated and considered as a kit of parts according to the invention .Advantages of the invention

[0067] The intelligent personal protection system according to the present invention offers significant advantages over the solutions known in the state of the art, directly addressing the inherent limitations of existing systems and providing a higher level of dynamic safety for workers at height .

[0068] Optimized Distributed Architecture for Direct Measurement : Unlike systems that use a single mobile unit or sensors positioned only on the ends of the main rope or along the rope or only at the connection points to the harness, the invention employs a specific architecture with two physically separate units : a PCU (110) associated with the mechanical connector (111) (therefore positioned near the anchor point when in use) and an SCU (120) worn directly on the operator ' s body (10) . Both units are equipped with an atmospheric pressure sensor . This targeted architecture is the essential technical prerequisite that allows the direct and continuous measurement of the relative vertical distance ( ' h' ) between the anchor point and the operator ' s body.

[0069] Accurate Measurement of Relative Height 'h' via Differential Pressure: The system continuously determines ' h' based on differential atmospheric pressure measurements between the PCU sensor (at the anchor point) and the SCU sensor (on the operator ' s body) . As described, this method eliminates common drifts due to atmospheric changes, providing an accurate and reliable measurement of ' h' in real time . This contrasts with systems based on different principlessuch as RSSI, accelerometers, or simple height sensors not specifically configured for this direct differential measurement .

[0070] Dynamic Assessment of Fall Energy Risks (Fall Factor and Slack) : This is the fundamental technical advantage . Unlike the known technique, which is limited to static controls (such as DI which verifies the height with respect to the plane and the state of the hook) or to binary controls for specific rules (such as D4, D7, D8 which only verify the "low hang, high use" violation) , the system of the invention uses the dynamically measured ' h' value, together with the known length of the rope ’ L’ , to explicitly calculate the fall factor (f) and the slack state of the rope (SL) . The SCU processing unit then checks whether these calculated values exceed predetermined thresholds, thus identifying unsafe conditions directly related to the potential energy of the fall . This allows for the detection of previously unidentifiable critical dynamic hazards, such as :

[0071] High fall factor (f > threshold) : Situations in which the operator could fall for an excessive distance with respect to the length of the rope (for example, f > 1, or f > 2 if the operator is above the anchor) , with consequent dangerous impact forces .

[0072] Excessive slack rope state (SL > threshold) :Situations in which a high positive ' h' value indicates a dangerous slack in the rope, increasing the potential fall distance even if f < 1.

[0073] This ability to dynamically quantify and verify specific risks related to fall energy, based onthe actual anchor-operator geometry ( ' h' ) and the length of the rope ( ' L ' ) , represents a qualitative leap compared to the simple status or rule checks of the prior art .

[0074] Increased Accuracy and Reduction of False Alarms : The direct measurement of ' h' (anchor-body) and the specific evaluation of f and SL allow for a more accurate discrimination of real danger situations compared to systems based on indirect measurements or binary rules, thus reducing false positives and negatives .

[0075] Continuous Monitoring and Immediate Alarm: The continuous determination of ' h' and the verification with respect to the thresholds of f and SL guarantee constant monitoring of dynamic risks during work, with timely activation of the local alarm on the SCU in case of detection of an unsafe condition .

[0076] (Optional - Relating to virtual gates) Intelligent Contextual Activation: The optional use of virtual gates (as described in claim 5) allows the dynamic monitoring mode (based on ’h’ , f, SL) to be activated only when the operator enters a defined risk zone . This two-stage approach optimizes the energy consumption of wearable units (PCU / SCU) , avoids spurious alarms in safe areas, and focuses advanced monitoring only where and when needed, improving the overall reliability of the system.

[0077] Scalability and Integration: The architecture allows integration with remote monitoring systems (via concentrator 150 and server 160) for centralized supervision and analysis of collected safety data . Thesystem is scalable to cover different work areas and multiple operators .

[0078] In summary, the invention overcomes the limitations of traditional systems by providing an optimized architecture for the direct measurement of the vertical anchor-operator geometry and by introducing a dynamic quantitative assessment of the specific risks related to fall energy (fall factor and slack) , thus offering more accurate, reliable, and comprehensive safety monitoring.

[0079] In the foregoing, the preferred embodiments have been described and variants of the present invention have been suggested, but it is to be understood that those skilled in the art will be able to make modifications and changes without thereby departing from the relative scope of protection, as defined by the attached claims .

Claims

CLAIMS1. An intelligent system (100) for protecting operators (10) in an elevated structure, comprising: one or more personal safety devices (111, 115) wearable by an operator (10) , each comprising a rope (115) of length L and at least one mechanical connector (111) at one end of the rope, with a harness connected to the other end of the rope, wherein each of the one or more personal safety devices (111, 115) further comprises :- a primary control unit (110) , PCU, physically associated with said mechanical connector (111) , the PCU (110) comprising one or more PCU sensors selected from the group consisting of kinetic sensors, induction sensors, pressure sensors and capacitive sensors, configured to measure PCU data relating to a state of said personal safety device, wherein the PCU comprises at least one respective PCU atmospheric pressure sensor, as well as- a PCU communication unit for transmitting said PCU data;a secondary control unit (120) , SCU, physically separated from said PCU (110) and configured to be worn directly on the operator ' s body (10) , the SCU (120) comprising :an SCU atmospheric pressure sensor;a data reception module for receiving the PCUdata (110) ;- an SCU electronic processing unit configured to o continuously determine a relative height h between the PCU (110) associated with said at least one mechanical connector (111) and the SCU (120) based on differential atmospheric pressure measurements of the PCU atmospheric pressure sensor and the SCU atmospheric pressure sensor,o verify whether said relative height corresponds to a fall risk condition, verifying the difference between a fall factor and a slack state of the rope SL, calculated as functions of the relative height h and the length of the rope L, and respective predetermined thresholds;- an alarm module configured to emit one or more alarms based on said fall risk condition .

2. The system according to claim 1, wherein a central electronic unit (160) is further included, configured for the monitoring and remote control of said fall risk condition through the reception of data from said SCU (120) and the sending of commands to said SCU (120) .

3. The system according to claim 2, wherein said central electronic unit (160) is configured for monitoring and remotely controlling the fall risk condition of a plurality of operators (10) .

4. The system according to claim 2 or 3, wherein an electronic concentrator device (150) is further included, arranged in an area around the structure and configured to receive information from all the SCUs (120) present in said area, and transmit them to said central electronic unit (160) .

5. The system according to one of claims 1 to 4, wherein one or more virtual gates (130) are further included, generated by respective one or more beacons placed at respective heights in the elevated structure, the one or more virtual gates being configured and arranged to :- identify and circumscribe the spatial extension of respective entry or exit points in the elevated structure;- select or deselect a predetermined safety mode based on the operator (10) passing through at least one virtual gate (130) of the one or more virtual gates;- transmit data and / or commands relating to said safety mode;wherein the data reception module of the SCU is configured to receive data and / or commands from said at least one virtual gate (130) .

6. The system according to claim 5, wherein the predetermined security mode is selected or deselected based on an operator (10) passing through at least two virtual gates (130) in sequence through the one or morevirtual gates .

7. The system according to claim 6, wherein said at least two virtual gates (130) have respective coverage areas (131) that interfere (132) .

8. The system according to one of the claims from 1 to 7, wherein the SCU (120) includes an integrated speaker for audio alarms .

9. The system according to one of the claims from 1 to 8, wherein the SCU (120) includes a gyroscope for detecting the orientation of the operator (10) and / or an accelerometer for detecting the movement and / or orientation of the operator (10) and / or a GPS module for determining the precise position of the operator (10) .

10. The system according to one of the claims from 1 to 9, wherein the SCU (120) includes an emergency button configured to allow the operator (10) to manually activate an alarm.

11. The system according to one of claims 5 to 10, wherein the SCU (120) comprises one or more SCU sensors configured to detect one or more additional physical parameters, and wherein the SCU (120) is configured to verify the correspondence between said state, said safety mode, and said one or more additional physical parameters, the alarm module being configured to emit one or more alarms based on said correspondence .

12. The system according to one of claims 1 to 11, wherein the PCU (110) comprises a coupling sensor of said mechanical connector to an element (20) of the structure, for example a metal element .

13. A method of individual protection in vertical work structures, comprising the execution of the following steps :A. providing an intelligent personal protection system (100) in vertical working structures according to one of claims 1 to 12;B . transmitting, by each of said one or more PCUs (110) , said PCU data to said SCU (120) ;C . Continuously determining a relative height between the PCU (110) associated with said at least one mechanical connector (111) and the SCU (120) based on differential atmospheric pressure measurements of the PCU atmospheric pressure sensor and the SCU atmospheric pressure sensor, and verifying whether said relative height corresponds to a fall risk condition, verifying the difference between a fall factor and a slack state SL of the rope, calculated as functions of the relative height h and the length of the rope L, and respective predetermined thresholds ;D . activating or deactivating, by the SCU (120) , said alarm module on the basis of said fall risk condition .

14. The method according to claim 13, wherein the following further steps are performed:E . providing one or more virtual gates (130) of claim 5;F . selecting or deselecting, by at least one virtual gate (130) , a predetermined safety mode based on an operator (10) passing through at least one virtual gate (130) ;G. transmitting, by said at least one virtual gate (130) , data and / or commands relating to said predetermined safety mode to the SCU (120) ;H. verifying, by the SCU (120) , the correspondence between said state and said predetermined safety mode, wherein said predetermined safety mode is a working at height mode .I . activating or deactivating, by the SCU, the predetermined safety mode based on said correspondence and said data and / or commands .

15. Method according to claim 14, wherein in step F the predetermined safety mode is selected or deselected based on the operator (10) passing through at least two virtual gates (130) in sequence .

16. Method according to claim 14 or 15, wherein the SCU (120) comprises one or more SCU sensors configured to detect one or more additional physical parameters, and wherein in phase I the SCU (120) verifies the correspondence between said state, said safety mode, and said one or more additional physical parameters .

17. Method according to one of claims 15 to 16, wherein said PCU (110) comprises a coupling sensor of said mechanical connector (111) to an element (20) of the elevated structure, and in step C the SCU (120) further verifies the coupling of said mechanical connector to said element (20) on the basis of the data of said coupling sensor, in order to determine said fall risk condition.

Images