Crush Avoidance Device

Abstract

A crush avoidance device 100,200,300 (n00) for attachment to an elevated work platform (EWP) 10. The EWP 10 includes a machine control system (MCS) 20 adapted to be operated by an operator to be located on an operator support 50 comprising an operator cage 52. The positioning and movement of the operator support 50 is operable to be controlled by the MCS 20 on or in the support 50. The EWP 10 also includes a drive mechanism 62,72 adapted to effect movement of the support 50 by alternatively engaging a base vehicle drive 72 for land-based movement of the EWP 10 and a height adjustment ram 62 for elevating or lowering the support 50. The MCS 20 is adapted to immediately enact a safety response on receiving a signal from a crush avoidance device (CAD) n00. The crush avoidance device n00 includes a motion detector 120,220,320 that is adapted to detect the operator's movement in or on the support 50 without physical contact with the operator. On detecting a movement of the operator that is associated with a crush event, the crush avoidance device 100,200 is adapted to actuate the safety response.

Claims

1. A crush avoidance device for attachment to an elevated work platform (EWP), the EWP including: (a) a machine control system (MCS) adapted to be operated by an operator; (b) an operator support, the position of which is adapted to be controlled by the MCS on or in the support; and (c) a drive mechanism adapted to effect movement of the operator support and to immediately react to a safety response, wherein the crush avoidance device: (i) includes a motion detector that is adapted to detect the operator's movement in or on the support without physical contact with the operator; and (ii) on detecting a movement of the operator that is associated with a crush event or anticipation of a crush event, the crush avoidance device is adapted to enact the safety response, wherein the crush event or anticipation of the crush event is characterized by a sudden acceleration of the operator's torso.

2. (canceled)

3. The crush avoidance device as claimed in claim 1, further including a processor that is adapted to: (a) sense that an operator is present on or in the support; (b) identify at least one anatomical parameter of the operator; and (c) detect at least one characterizing movement of the operator that is associated with preparatory to, or predictive of, a crush event.

4. The crush avoidance device as claimed in claim 3, wherein the processor includes an algorithm to perform steps (a) to (c) in claim 3, and a further algorithm to map the simple dimensions and shape of the support on or within which the operator is intended to be confined during the operation of the EWP.

5. The crush avoidance device as claimed in claim 3, wherein the motion detector uses LIDAR (Light Detection and Ranging) technology to map the size, dimensions, profile and/or body shape of the operator and to feed such data to the crush avoidance device processor as variables.

6. The crush avoidance device as claimed in claim 5, wherein the crush avoidance device further includes a support motion detector configured to measure amplitude, direction of acceleration, velocity and/or position of the operator support using a “nine degrees of freedom inertial motion unit” (9DOF).

7. The crush avoidance device as claimed in claim 6, wherein the 9DOF includes an accelerometer, gyroscope and/or magnetometer.

8. The crush avoidance device as claimed in claim 6, wherein the 9DOF includes 3 accelerometers, 3 gyroscopes and 3 magnetometers configured to measure the amplitude and direction of acceleration, velocity and/or position of the support.

9. (canceled)

10. The crush avoidance device as claimed in claim 1, further adapted to predict or detect a crush event characterized characterized by: sudden acceleration of the operator's torso toward a side or end of the operator support; or movement of the operator out of a defined normal workspace with respect to a motion detector mounting point; or acceleration of the operator outside predetermined expected parameters; or the operator moving to a position relative to the motion sensor that is lower than a predetermined height parameter.

11. A method of avoiding a crush hazard using the crush avoidance device as claimed in claim 1 involving the detection of at least one input to the MCS by the operator to estimate or calculate the amplitude and direction of acceleration, velocity and/or position of the support.

12. A method of avoiding a crush hazard using the avoidance device as claimed in claim 6, wherein the safety response involves immediately redirecting the movement of the drive mechanism or the movement of the supporting vehicle and further involves the actuation of a kill switch capable of immediately stopping the operation of the drive mechanism.

13. The crush avoidance device as claimed in claim 3, wherein the processor is housed in a housing together with the motion detector.

14. The crush avoidance device as claimed in claim 12, wherein the EWP is mounted to a vehicle and the actuation of the kill switch is adapted to disengage the EWP and vehicle drives or to switch off associated motors, to immediately halt both the operation of the drive mechanism and the motion of the vehicle.

15. The crush avoidance device as claimed in claim 14, wherein the kill switch is an electronic circuit breaker that electronically stops the operation of drive mechanism to freeze movement of the support and stop land-based movement of the vehicle.

16. The crush avoidance device as claimed in claim 12, wherein the support has a cage to support the operator, and the processor is configured to use measurements from the 9DOF and the LIDAR to detect a potential crush event where it involves the support moving backward and the operator rapidly moving a certain distance and/or acceleration forward in a pattern characterizing movement preparatory to a crush event of the operator against a front rail of the cage.

17. The crush avoidance device as claimed in claim 16, wherein the current position of the operator is measured via the LIDAR motion detector and the current spatial position of the EWP is measured by the 9DOF to provide an initial starting or base-line condition, and an IMU (Inertia Measurement Unit) provides cost-effective spatial positioning information using a triad of accelerometers and gyroscopes in the form of the 9DOF.

18. The crush avoidance device as claimed in claim 14, wherein the drive mechanism includes a drive switch, the EWP includes an elevate switch, and the processor further receives digital inputs from the drive and elevate switches and analogue inputs from a joystick (hand lever) for estimating or determining acceleration, velocity and change in position of the EWP, whereby the processor is configured to estimate or calculate the acceleration, velocity and change in position of the EWP from the digital and analogue inputs and the 9DOF.

19. The crush avoidance device as claimed in claim 1, further including an alert device and an enable switch that is configured to turn the crush avoidance device on or off through an “on” and “off” position of the enable switch respectively, wherein, if the enable switch is held in the “on” position and the kill switch is in an “on” position, the alert device is adapted to sound to remind the operator that the kill switch is still on.

20. The crush avoidance device as claimed in claim 1, further including an override mode adapted to be activated with the enable switch by pressing the enable switch multiple times.

21. The crush avoidance device as claimed in claim 5, wherein the processor uses motion detection data to determine whether or not the operator is operating within a safe positional envelope (operator safety envelope) using the following criteria: (a) the operator is no further than 200 mm from where the operator was when the dead man switch was activated by the operator; and (b) the velocity of any motion by the operator is lower than a safety threshold.

22. The crush avoidance device as claimed in claim 19, wherein the alert device projects voice outputs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0077] The invention may be better understood from the following non-limiting description of preferred embodiments, in which:

[0078] FIG. 1 is a perspective view of a scissor lift incorporating a crush avoidance device according to a first embodiment of the invention;

[0079] FIG. 2 is a perspective view of a portion of a crow's nest incorporating the crush avoidance device shown in FIG. 1;

[0080] FIG. 3 is a perspective view of a console incorporating the crush avoidance device shown in FIG. 1;

[0081] FIGS. 4a-f show the crush avoidance device shown in FIG. 1 from (a) right side, (b) underside, (c) front, (d) left side, (e) upper perspective and (f) top plan views, respectively;

[0082] FIG. 5 is a schematic diagram of hardware and interactions between hardware of the crush avoidance device according to the first or second embodiment of the invention;

[0083] FIG. 6 is a schematic diagram of software and interactions between software processes according to the first or second embodiment of the invention;

[0084] FIG. 7 is an isometric view of a motion detector and motion detector housing of the crash avoidance device according to the second or third embodiment of the invention;

[0085] FIG. 8 is a right-side view of the motion detector and motion detector housing of the crush avoidance device according to the second or third embodiment of the invention;

[0086] FIG. 9 is a left-side view of an alert device and motion detector housing of the crush avoidance device according to the second or third embodiment of the invention;

[0087] FIG. 10 is a rear view of the motion detector housing of the crush avoidance device according to the second or third embodiment of the invention;

[0088] FIG. 11 is a front view of the motion detector housing of the crush avoidance device according to the second or third embodiment of the invention;

[0089] FIG. 12 is a front cross-sectional view of the motion detector, alert device and motion detector housing of the crush avoidance device according to the second or third embodiment of the invention;

[0090] FIG. 13 is an isometric view of a processor housing according to the second or third embodiment of the invention;

[0091] FIG. 14 is a right-side view of the processor housing according to the second or third embodiment of the invention;

[0092] FIG. 15 is a left-side view of the processor housing according to the second or third embodiment of the invention;

[0093] FIG. 16 is a front view of the processor housing according to the second or third embodiment of the invention;

[0094] FIG. 17 is a rear view of the processor housing according to the second or third embodiment of the invention;

[0095] FIG. 18 is a bottom view of the processor housing according to the second or third embodiment of the invention;

[0096] FIG. 19 is a top view of the processor housing according to the second or third embodiment of the invention;

[0097] FIG. 20 is a front cross-sectional view of a processor and processor housing according to the second or third embodiment of the invention;

[0098] FIG. 21 is an isometric view of the motion detector and motion detector housing mounted to a console according to the second or third embodiment of the invention;

[0099] FIG. 22 is a schematic diagram of circuitry of a real time clock of the crush avoidance device according to the first or second embodiment of the invention;

[0100] FIG. 23 is a schematic diagram of circuitry of an audio interface of the crush avoidance device according to the first or second embodiment of the invention;

[0101] FIG. 24 is a schematic diagram showing an overview of circuitry of the crush avoidance device according to the first or second embodiment of the invention;

[0102] FIG. 25 is a schematic diagram of circuitry for a sensor, output and input interface plug of the crush avoidance device according to the first or second embodiment of the invention;

[0103] FIG. 26 is a schematic diagram of an audio and sensor circuit of the crush avoidance device according to the first or second embodiment of the invention;

[0104] FIG. 27 is a schematic diagram of an input circuit of the crush avoidance device according to the first or second embodiment of the invention;

[0105] FIG. 28 is a schematic diagram of an output circuit of the crush avoidance device according to the first or second embodiment of the invention;

[0106] FIG. 29 is a schematic diagram of wires connected to a computer processing unit of the processor of the crush avoidance device according to the first or second embodiment of the invention;

[0107] FIG. 30 is a schematic diagram of circuitry of a power supply of the crush avoidance device according to the first or second embodiment of the invention;

[0108] FIG. 31 is a schematic diagram of two printed circuit boards of the circuitry and computer hardware components shown in FIGS. 22-30;

[0109] FIG. 32 is a schematic diagram of circuitry of the crush avoidance device according to the third embodiment of the invention;

[0110] FIG. 33 is flow chart of an overview of functions and programming of software programmed into a processor of the crush avoidance device according to the third embodiment of the invention; and

[0111] FIG. 34 is a schematic diagram showing interactions between sensors, processors and other devices of the crush avoidance device according to the third embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0112] Preferred features of the present invention will now be described with particular reference to the accompanying drawings. However, it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. In describing the various embodiments of the invention, like features will be referred to using like references, with references for features of each embodiment generally preceded by 1, 2, 3, or followed by a Roman numeric sequence, such as i, ii, iii, etc. or an alphabetical sequence such as a, b, c, relative to the corresponding feature of the first embodiment. For example, a feature 10 of the first embodiment may represented as 110, 210, 310, (or n10), or 10a, 10b, 10c, (or 10x) or 10i, 10ii, 10iii, (or 10r) etc. in second, third and fourth embodiments, respectively.

[0113] Referring to the drawings, there is shown a crush avoidance device 100,200,300 (n00) for attachment to an elevated work platform (EWP) 10. The EWP 10 includes a machine control system (MCS) 20 adapted to be operated by an operator to be located on an operator support 50 comprising an operator cage 52.

[0114] The positioning and movement of the operator support 50 is operable to be controlled by the MCS 20 on or in the support 50. The EWP 10 also includes a drive mechanism 62,72 adapted to effect movement of the support 50 by alternatively engaging a base vehicle drive 72 for land-based movement of the EWP 10 and a height adjustment ram 62 for elevating or lowering the support 50. The MCS 20 is adapted to immediately enact a safety response on receiving a signal from a crush avoidance device (CAD) n00.

[0115] The CAD 100 according to a first embodiment of the invention is shown in FIGS. 1-6 and 22-31. The CAD 200 according to a second embodiment of the invention is shown in FIGS. 5-31. The CAD according to a third embodiment of the invention is shown in FIGS. 7-21 and 32-34. The second embodiment of the CAD 200 is identical to the first embodiment of the CAD 100 except for the housings 102,202a,b. The third embodiment of the CAD 300 is identical to the second embodiment of the CAD except for circuitry and a processor 210,310 of the CAD 200,300. The housings 102, 202a,b include a housing 102 of the first embodiment of the invention. The housings 102, 202a,b further include a motion detector (LIDAR) housing 202a and a processor housing 202b of the second embodiment of the invention. The housings 202a-b,302a-b of the second and third embodiment of the CAD are identical. In this specification, features or components with reference numbers between 100-138b are features or components of the first embodiment of the CAD 100. Furthermore, in this specification, features or components with reference numbers between 200-238b are features or components of the second embodiment of the CAD 200. In this specification, features or components with reference numbers between 300-342 are features or components of the third embodiment of the CAD 300. In this specification, features or components with reference numbers between 0-74 are features or components which can be used with the CAD n00 of the first, second or third embodiment of the invention.

[0116] Unless otherwise stated the following passages refer to the first, second and third embodiments of the invention.

[0117] The CAD n00 includes a motion detector 120,220,320 (n20) that is adapted to detect the operator's movement in or on the support 50 without physical contact with the operator. On detecting a movement of the operator that is associated with a crush event, the CAD n00 is adapted to actuate the safety response.

[0118] Enacting the safety response involves engaging a kill switch to disengage the scissor lift and vehicle drives 62,72 or to switch off the associated motors, so that height and land-based movement is immediately stopped with a view to avoiding the crush event. The actuation of the kill switch is adapted to fix the support in place before the crush event occurs. The kill switch is adapted, on actuation, to immediately halt both the operation of the scissor lift drive mechanism 62 and the motion of the vehicle 70, applying vehicle brakes, if applicable, but not suddenly whereby to risk destabilising the support 50. The kill switch is an electronic circuit breaker that electronically stops the operation of the drive mechanisms 62,72 to freeze movement of the support and stop land-based movement of the vehicle 70 on which the EWP is mounted.

[0119] The EWP 10 in the embodiment shown is a scissor lift. The support 50 includes a work platform 54 and the peripheral cage 52 that can be a crush hazard if the operation of the drives 62,72 proceeds unchecked as conditions for a potential crush event emerge.

[0120] The operator is typically instructed to standard in an orthodox and predictable position in front of the console 20, within arm's reach of the joystick 22. This predictability allows the CAD n00 to be configured to detect an operator, identify the operator's operational position, and to detect movements forward, back or to the side that may be associated with a sequence of movements preparatory to a crush event.

[0121] As is standard for EWPs, the MCS 20 includes a computer processor and a manual control device in the form of a toggle button 21 and a joystick or hand lever 22 that form part of a console 24. The console 24 is mounted on the support 50 within the confines of the cage 52. By engaging the toggle button or switch 21, the operation of the hand-lever 22 can be toggled between alternative vertical scissor lift 60 and/or lateral vehicle 70 or support 50 movements.

[0122] The manual control device 20 may sit in a cradle 26 in the console 20 and be detached for remote operation by the operator as a vehicle 70 pilot. For example, when proceeding through narrow entrances such as doorways, the operator is required to alight the vehicle 70 (including the support 50) and to remotely operate the vehicle 50 until it is moved safely through the entrance or otherwise passed a hazardous obstacle, situation or location.

[0123] The CAD n00 is adapted to be installed either during manufacture of the EWP 10 as an after-sales service or retrofit. The CAD n00 is in wireless communication with the MCS 20 and the kill switch.

[0124] The CAD n00 includes a housing 102,202a,b,302a,b that contains internal component parts. The housing 102,202a,b,302a,b is mountable to a side of the console 24 by means of fasteners extending through registered apertures 104,204,304 (n04) formed in mounting flanges 106,206,306 (n06) and a side wall of the console 24.

[0125] A combination of predetermined algorithms are used by a processor of the CAD n00 such that it is adapted to: [0126] (e) Sense that an operator is present on or in the support 50; and/or [0127] (f) Map the simple dimensions and shape of the support 50 on or within which the operator is intended to be confined during the operation of the EWP 10; and/or [0128] (g) Determine the parameters of the operator, including body shape and/or dimensions; and [0129] (h) Detect one or more of the movements of the operator that is/are associated with a crush event.

[0130] The motion detector n20 is operable to detect movement of the operator that is associated with the crush event without physical contact with the operator.

[0131] The motion detector n20 is mounted or located in or on the housing 102,202a,b,302a,b. The motion detector includes a pair of small adjacent panels 122,222,322 (n22),124,224,324 (n24) including a transmitter n22 and a receiving sensor n24.

[0132] The motion detector n20 uses LIDAR (Light Detection and Ranging) technology that is capable of measuring a distance to a target by using the transmitter n22 to project laser light onto the target and measuring the reflected light with the receiving sensor n24. The laser emitter or transmitter n22 is configured to emit light of between 800 nanometres (nm) and 900 nm. The power usage of the laser emitter n22 is 550 milliwatts. The laser emitter n22 includes a light emitting diode (LED). A field of view of the motion detector n20 is 4.2°.

[0133] The motion detector n20 is configured to obtain data to map the size, dimensions, profile and/or body shape of the operator. The data is fed to the crush avoidance device processor 110,210,310 (n10) as variables. The processor n10 is able to calibrate the motion sensor n20 by the application of the data and variables to the combination of predetermined algorithms. The motion detector n20 is configured to individually measure amplitude and direction of acceleration and velocity as well as the position of parts of the operator and the operator's clothing relative to the position of the motion detector n20. The algorithms involve variable data input, such as acceleration, velocity and vector orientation. The processor may incorporate adaptive technology to refine the algorithms, by operator and real event feedback, to progressively avoid false positives (i.e. false triggering of the kill switch).

[0134] The CAD n00 is configured to calibrate the motion detector n20 for different sized and shaped operators. The MCS 20 includes a touch screen 28 which is used to monitor and control a “dead man switch”. The dead man switch 27 can be located on the operator hand-lever 22. Pushing this switch 27 allows the operator to use the EWP's 10 controls on the console 24 to operate the EWP 10 because the crush avoidance device's n00 processor n10 detects the activation of the dead man switch 27. Once the dead man switch 27 is activated, the CAD n00 is configured to take measurements of the position of parts of the operator to calibrate the CAD n00 and to adjust to limits of the movement of the operator that is associated with a crush event.

[0135] The one or more movements of the operator that are associated with a crush event or anticipation thereof include the following: [0136] Sudden acceleration of the operator's torso toward a side or end of the support 50; [0137] Operator moves out of the defined normal workspace with respect to the motion detector n20 mounting point; [0138] Operator's acceleration is high; or [0139] Operator's position relative to the motion sensor n20 is low.

[0140] The CAD n00 may further include a support motion detector configured to measure amplitude and direction of acceleration and velocity and position of the support 50. The support motion detector includes a “nine degrees of freedom inertial motion unit” (9DOF). The 9DOF includes an accelerometer, a gyroscope and/or a magnetometer. The 9DOF advantageously includes 3 accelerometers, 3 gyroscopes and 3 magnetometers. The 9DOF is configured to measure the amplitude and direction of acceleration and velocity and position of the support 50. The 9DOF may be configured to measure whether the support is moving in any direction, such as backward or forward, left or right, and/or up or down. The processor n10 is configured to use measurements from the 9DOF and the LIDAR to detect a potential crush event. For example, if the support 50 is moving backward, it is more likely that the operator will be hit on the opposite side to the LIDAR and therefore move towards the LIDAR motion detector n20. Therefore, movement of the operator associated with a crush event may include the support 50 moving backward and the operator rapidly moving a certain distance and/or acceleration forward in a pattern characterising movement preparatory to a crush event of the operator against a front rail of the cage 52.

[0141] The CAD n00 is configured such that to first operate the EWP 10, the dead man switch 27 of display 28 must be pressed and therefore the CAD n00 must be calibrated to the operator. The current position of the operator is measured via the LIDAR motion detector n20 and the current spatial position of the scissor lift 60 and EWP 10 is measured by the 9DOF to provide stat for the initial starting or base-line condition. The IMU (Inertia Measurement Unit) provide cost-effective spatial positioning information using a triad of accelerometers and gyroscopes. The CAD n00 is configured to start detecting movement of the operator after the CAD n00 has been calibrated. Operation of the vehicle 70 and the scissor lift 60 is only enabled when this process is completed. When a crush event (or the parameters predictive of a crush event) is detected, the dead man switch 27 circuit will be opened, stopping the EWP 10 (including the vehicle 70 and the scissor lift 60), and the CAD's n00 horn 126,226,326 (n26) is sounded, together with a visual alert, such as a flashing blue strobe light 125.

[0142] The LIDAR motion sensor n20, 9DOF and/or processor n10 may include Wi-Fi communication devices 114,214 configured for the LIDAR n20 and 9DOF to communicate with an internal web server in the processor n10 for calibration, diagnostic reporting, configuring and viewing of logs of measurements taken form the LIDAR n20 and 9DOF.

[0143] The CAD n00 can include an alert device n26 that is configured to generate an audible and/or visual alert to warn the operator and others of an impending crush event and/or other events detected by the processor n10, LIDAR n20 and 9DOF. The other events may include system errors. The alert device 125,n26 includes a speaker n26 and/or a light 125, including a preferably blue strobe light. The speaker n26 may project voice outputs such as “lift stopped due to crush event detected from rear”. The alert device 125,n26 and/or the processor n10 can include an audio voice output CODEC via the speaker n26. Advantageously, the voice outputs are pre-configured to communicate any actions taken by the CAD n00 to an operator without training in or having in-depth knowledge of the CAD n00. The CODEC messages communicated through the audio output n26 to the operator to inform the operator as to the perceived crush event and instructions for proceeding, for example: “Hazardous Operator Movement Detected; Release Dead Man Switch to Restore Operation or Await Assistance”. Preferably, the CAD n00 initiates a timing sequence of, for example, 10 seconds, before the operator can resume control of the CAD n00, after releasing the dead man switch 27.

[0144] Preferably, the CODEC messages communicated through the audio output n26 to the operator to inform the operator of a perceived crush event include the following: [0145] The phrase “operator movement” or synonymous phrases indicating that the reason for detecting a crush event is that the operator moved too suddenly or erratically; and [0146] The phrase “operator position” or synonymous phrases indicating that the operator has moved too far from the calibration area or the operator is not within line of sight of the sensor.

[0147] If the operator continues to hold the dead man switch 27 after the CAD n00 has detected a crush event, the speaker n26 or a horn projects or sounds at least once, preferably 3 times. To move or operate the vehicle 70 and/or EWP 10 again, the operator must release the dead man switch 27, wait a time period, and then press the dead man switch 27 again. The time period may be less than 3 seconds.

[0148] The CAD n00 is adapted such that the speaker n26 also announces a movement mode of the EWP 10 and/or vehicle 70. Advantageously, this feature audibly reminds the operator of expected movement of the EWP 10 and/or vehicle 70. The CAD n00 is adapted such that the speaker n26 projects the following movement modes: [0149] The speaker n26 announces the word “elevate” or synonymous words when the EWP 10 is set to move up or down; and/or [0150] The speaker n26 announces the word “drive” or synonymous words when the EWP 10 is set to move forward or backward.

[0151] The hardware and mechanical design of the CAD 100,200 according to the first and second embodiments of the invention is best represented in FIGS. 4a-f and the flowchart of FIG. 5, also shown below:

[0152] The CAD n00 is a stand-alone system that is configured to be mounted onto the side of the MCS in the form of a scissor lift control box (console) 24 and via a hardwire terminal 108,208,308 (n08) connects into the scissor lift control box 24 for power and to utilise the existing cutout (or dead man switch) 27 functionality of the control box 24.

[0153] The LIDAR movement sensor n20 is designed to be IP67 rated, robust, small, streamlined and non-intrusive to the scissor lift support 50 workspace. The LIDAR sensor n20 has smooth flush surfaces to resist gathering dust/detritus build up on a LIDAR sensor n20 face.

[0154] The CAD n00 includes within its housing 102,202a,b,302a,b its internal hardware components. The CAD 100 includes an external M12 screw lock connector 108 for the CAD's 100 wiring requirements.

[0155] The LIDAR sensor n20 is a time of flight distance sensor that uses infrared (850 nm) laser to measure the distance from the sensor n20 to the target. In the present invention, the target is the operator who preferably stands on the platform 54 within about 200 millimetres (mm) in front of the sensor n20. The set up or baseline information derived by the CAD n20 is subsequently used in operation to determine if the operator moves forward or backward from the LIDAR sensor n20.

[0156] The LIDAR sensor n20 is also used to measure the operator's movement speed and acceleration relative to the console 24. When the operator presses the dead man switch 27 on the manual joystick lever 22 the CAD n00 takes a measurement via the LIDAR sensor n20 for the distance to the operator at periodic intervals (say every 100 ms). This allows for real time calibration of the and each individual operator, depending on the operator's height and size, etc., and adapts to the dimensions of each new operator who takes control of the EWP 10.

[0157] The 9DOF sensor provides information on the supports 50 position in space. The 9DOF sensor also provides information on the various movement directions. This sensor data is used to determine which way the EWP 10 vehicle 70 and scissor lift 60 is moving. This sensor information is fed into the CAD's n20 firmware and fuses or is processed with the LIDAR sensor n20 derived data, to determine if the operator is in danger by virtue of an impending crush event.

[0158] The following passages refer to the first and second embodiments of the invention. Input 112,212 is a VCC (higher voltage) or GND (ground) switching digital input which is linked to the dead man switch 27. The operator must hit the dead man switch 27 in order to operate the EWP 10. When this input 112,212 is active, the CAD 100,200 will calibrate the position of the operator, the EWP's 10 current spatial orientation, and then start the main process/crush event detection routines.

[0159] The processor 110,210 includes a microprocessor chip which serves as the CAD's 100,200 processor for the main computational functions.

[0160] Wi-Fi 114,214 connectivity is coupled to the processor 110,210 and is used for the CAD's 100,200 calibration, diagnostic reporting, configuration and viewing of log data. The processor 110,210 and/or an external internet server may be adapted to record and playback the data logs such as crash event history. The processor 110,210 includes an internal clock 130,230 to record the time of each event or data of the data log. The Wi-Fi 114,214 provides access to an internal web server located in code on the processor 110,210.

[0161] Firmware 116,216 is programmed into the processor 110,210 and provides the main system functionality code.

[0162] Power supply 118,218 supplies rails for the various sensors 120,220 etc.

[0163] FET (field-effect transistor) outputs 111,211 are used to control the EWP 10 dead man cutout, the EWP's horn and an optional external blue strobe light 125,225.

[0164] Software and firmware of the CAD 100,200 is represented in the flowchart of FIG. 6.

[0165] A more detailed representation of the electronic hardware of the CAD 100,200 is shown in schematic diagrams in FIGS. 22-30. An overview of how the circuit schematic diagrams of FIGS. 22-23 and 25-30 connect together to form schematic diagrams of circuitry for the CAD 100,200 is shown in FIG. 24. The rectangles 131,231 shown in FIG. 24 represent circuitry and computer hardware components and the lines 132,232 in FIG. 24 represent wires or interfaces 132a-f,232a-f. The computer processing unit (computer processor) 110,210 represented by a rectangle in FIG. 24 performs calculations and may store data for the CAD 100,200. The interfaces 132a-f,232a-f also represented in part by a rectangle in FIG. 24 include wires and plugs to send and/or receive data from CAD 100,200 components such as the speaker 126,226 (through the audio interface 132b,232b), the LIDAR 120,220 (through the sensor interface 132c,232c), input devices such as buttons 21,22 and the dead man switch 27 (through the inputs interface 132d,232d) and output devices such as the EWP 10 (through the outputs interface 132e,232e).

[0166] FIG. 22 shows a schematic diagram of circuitry of a real time clock 130,230 with it's own back up battery 130a,230a. A real time clock interface 132f,232f is shown in FIGS. 22 and 24. FIG. 23 shows a schematic diagram of circuitry of the audio interface 132b,232b with the speaker 126,226 and the LIDAR 120,220. The sensor interface 132c,232c connector is shown in FIGS. 23-25. A sensor interface plug 138a,238a shown in FIG. 25 includes the sensor interface 132c,232c and the audio/speaker interface 132b,232b. An output and input interface plug 138b,238b shown in FIG. 25 includes the outputs interface 132e,232e and the inputs interface 132d,232d.

[0167] FIG. 26 shows an expanded view of an audio and sensor circuit 131c represented by a rectangle in FIG. 24. FIG. 27 shows an expanded view of an input circuit 131d,231d represented by a rectangle in FIG. 24. FIG. 28 shows an expanded view of an output circuit 131e,231e represented by a rectangle in FIG. 24.

[0168] FIG. 29 shows an expanded view of wires connected to the computer processing unit (CPU) 110,210. Wires or interfaces 132h,232h connect the input circuit 131d,231d to the CPU 110,210. Wires or interfaces 132i,232i connect the audio and sensor circuit 131c,231c to the CPU 110,210. Wires or interfaces 132j,232j connect the output circuit 131e,231e to the CPU 110,210. FIG. 30 shows a schematic diagram of a power supply circuit 135,235. Wires and interfaces labelled the same and shown in FIGS. 22-30 are connected to each other. FIG. 31 is a schematic diagram of two printed circuit boards (PCB's) 137,237 for the circuitry and computer hardware components shown in FIGS. 22-30.

[0169] The following passages refer to the third embodiment of the invention. Schematic diagrams of electronic hardware and software of the CAD 300 according to the third embodiment of the invention are shown in FIGS. 32-34. FIG. 32 shows circuitry between a processor 310, MCS 20 and motion detector (LIDAR) 320. The third embodiment of the invention is the same as the second embodiment of the invention accept that the processor 310 of the CAD 300 according to the third embodiment of the invention additionally receives digital inputs from the drive and elevate switches 330a,b and analogue inputs from the joystick (hand lever) 22 for estimating or determining acceleration, velocity and change in position of the EWP 10. The processor 310 is configured to estimate or calculate the acceleration, velocity and change in position of the EWP 10 from the digital and analogue inputs and the 9DOF.

[0170] The processor 310 may include memory storage devices such as random-access memory (RAM) and solid-state drives (SSD) as well as a central processing unit (CPU). The processor 310 includes programming outlined by the flow chart in FIG. 33. After turning on or starting, the processor 310 is configured to first run all hardware of the CAD 300. If the processor 310 detects that the hardware is not running normally, the processor engages the kill switch (cutout) 340 and sounds an alarm with the speaker. If the processor 310 detects that the hardware is working properly, the processor 310 proceeds to read measurements from sensors including the motion detector 320, a 9DOF, digital inputs from the elevate switches 330a,b and the analogue inputs from the joystick 22. In this specification, the digital inputs are some of a discrete set of data points and analogue inputs are some of a large number of discrete or a continuous set of data points.

[0171] If the processor 310 detects that the sensors are not communicating with the processor 310, the processor engages the kill switch (cutout) 340 and sounds an alarm with the speaker. If the processor 310 detects that the sensors are communicating with the processor 310, the processor 310 runs the predetermined algorithm (process safety algorithm). If the processor 310 determines that the kill switch 340 should not be engaged based on the predetermined algorithm, the processor 310 proceeds to detect whether the sensors are communicating with the processor 310 to repeat the loop as seen in FIG. 33.

[0172] If the processor 310 determines that the kill switch 340 should be engaged based on outputs from the predetermined algorithm, the processor 310 engages the kill switch. The processor 310 then detects whether an enable switch 341 is pressed. The enable switch 341 may be a foot pedal or button 341. If the enable switch is pressed, the kill switch 340 remains engaged and the alarm continues to project sound. If the enable switch 341 is not pressed, the processor 310 proceeds to detect whether the sensors are communicating with the processor 310 to repeat the loop as seen in FIG. 33.

[0173] The enable switch 341 is configured to turn the CAD 300 on or off through an “on” and “off” position of the enable switch respectively. The CAD 300 is configured such that if the enable switch is held or pressed and the kill switch 340 is in an “on” position, the alert device 326 will sound to remind the operator that the kill switch 340 is still on. The alert device 326 may sound 3 times. The “on” position of the kill switch 340 is after the kill switch 340 has been actuated and is stopping operation of the drive mechanism or not moving the support. When the CAD 300 is “on”, the CAD 300 is configured to detect movement of the operator and perform other functions mentioned in this specification. When the CAD 300 is “off”, the CAD 300 is configured not to detect movement of the operator.

[0174] The enable switch 341 may be a button, switch, touchscreen or voice input.

[0175] The CAD further includes an override mode. The override mode is activated with the enable switch 341. The override mode is activated by pressing the enable switch 341 sequentially two times and then holding the enable switch 341 down on a third press for a time period. The CAD is adapted to turn off the override mode in 15 seconds after activating the override mode. After the override mode has been turned off or expired, the override mode cannot be turned on again for 60 seconds. The override mode, when activated, temporarily enables movement of the EWP for the 15 seconds.

[0176] FIG. 34 shows a simplified schematic diagram of circuitry of the CAD. FIG. 34 shows that the motion detector 320, kill switch 340, enable switch 341, joystick 22, elevate switches 330a,b and alert device 326 all communicate with the processor 310. FIG. 34 also shows that the processor 310 and sensors 320 are powered by a battery 342.

[0177] Throughout the specification and claims the word “comprise” and its derivatives are intended to have an inclusive rather than exclusive meaning unless the contrary is expressly stated or the context requires otherwise. That is, the word “comprise” and its derivatives will be taken to indicate the inclusion of not only the listed components, steps or features that it directly references, but also other components, steps or features not specifically listed, unless the contrary is expressly stated or the context requires otherwise.

[0178] In the present specification, terms such as “apparatus”, “means”, “device” and “member” may refer to singular or plural items and are terms intended to refer to a set of properties, functions or characteristics performed by one or more items or components having one or more parts. It is envisaged that where an “apparatus”, “means”, “device” or “member” or similar term is described as being a unitary object, then a functionally equivalent object having multiple components is considered to fall within the scope of the term, and similarly, where an “apparatus”, “assembly”, “means”, “device” or “member” is described as having multiple components, a functionally equivalent but unitary object is also considered to fall within the scope of the term, unless the contrary is expressly stated or the context requires otherwise. In the present specification, the phrase “and/or” refers to severally or any combination of the features. For example, the phrase “feature 1, feature 2 and/or feature 3” includes within its scope any one of the following combinations: Feature 1 or feature 2 or feature 3; feature 1 and feature 2 or feature 3; feature 1 or feature 2 and feature 3; feature 1 and feature 2 and feature 3.

[0179] Orientational terms used in the specification and claims such as vertical, horizontal, top, bottom, upper and lower are to be interpreted as relational and are based on the premise that the component, item, article, apparatus, device or instrument will usually be considered in a particular orientation, typically with the manual lever 22 and railing 52 uppermost.

[0180] It will be appreciated by those skilled in the art that many modifications and variations may be made to the methods of the invention described herein without departing from the spirit and scope of the invention.