Field of the invention

[001 ] The present invention relates to a personnel detection system, a port and or mobile machinery safety system, and safety structure or humpy for an automated personnel detection system. The present invention further relates to safety systems for workers working in ports and working with cranes. In particular the invention relates to the use of RFID tags to assist in the working of such safety systems, to assist in protecting the safety of pin men, wharf workers, stevedores, ground foremen working with cranes or working on the ground in port areas.

Background of the invention

[002] Prior art safety systems have not been successful on the uptake in the market place, as they have tended to be cumbersome in operation.

[003] Ports have historically isolated personnel from contact with straddle carriers or crane lifted spreaders by setting up two separate areas. When a container is loaded or unloaded from a ship the quay crane first drops or picks up the container from the middle of the crane where personnel (known as 'pinmen') add or remove twistlocks. The container is then taken to the back of the crane leg for straddle carriers separate from pinmen. This process known as 'double hopping' and leads to decreased efficiency as a quay crane must drop and pick up a container twice.

[004] Alternatively, if the quay crane picks or drops off a container only once out at the back leg it would be able to return for the next container quicker, saving roughly 40 seconds per load & unload. This is known as 'single hopping'.

[005] Ports are currently using the single hopping process to increase efficiency. A key issue to utilising a single hopping process, is that the process requires pinmen to be identified by straddle carriers as they may share the same workspace.

[006] Pinmen and ground foremen work out of a pinning station or hut referred to as a 'humpy'. When the pinmen need to enter the shared work space and leave the humpy pinning station they must activate a switch which produces a red light above the station. This indicates to the straddle drivers not to enter the shared work space. When the pinmen re-enter their humpy they activate a switch to make a green light glow above the humpy, visually allowing the straddle drivers to then enter the shared work space.

[007] It has been identified that pinmen fail to hit the light switch when they leave or enter the humpy, and with the need to enter or leave every 2 minutes in some cases, the switches are never activated, which makes the situation dangerous for the pinmen, as the common work area safety condition is in an unknown state.

[008] Attempts have been made in prior art systems to address these issues. Prior art systems include RFID 'Radio Frequency Identification Devices' which are used for in a wide array of applications including surveillance, motor vehicle identification, electronic access control, automatic identification of cars on tolls. An 'RFID' system usually includes RFID reader and an RFID device. The RFID reader may transmit an Radio frequency carrier signal to the RFID device. The RFID device may respond to the carrier signal with a data signal encoded with information stored by the RFID device.

[009] RFID devices have decreased in size, and weight as the technology has improved. Such RFID devices can now be printed in a label. This practicality has meant RFID devices can be attached to articles of clothing and on a person without adversely impacting that person's functionality or comfort.

[010] The problem or limitation of prior art devices and methods is that an RFID device is only tracked when it passes across a reader. In a port area for example, where there is a large amount of metal and various obstructing objects, then the signals get distorted and then the detection of a signal is readily compromised. The interference of the signal then makes prior art systems problematic and unsafe when it comes to common work areas. If a site based reader cannot read the RFID device due to the interference, then the reader cannot relay the signal to the processor unit, and so either alert the machinery operator or operators of the impending danger.

[01 1 ] Another limitation is the accuracy of the distance the reader can read the tag.

[012] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application. Summary of the invention

[013] The present invention provides an automated personnel detection system, the system including a designated area for workers to be safely located, identification means for identifying when predetermined personnel are located in the designated area, the system giving to machinery operators a signal as to whether the predetermined personnel are in the designated area, whereby when one or more of the personnel are detected as not being in the designated area, the system indicates to the driver that an unsafe condition exists.

[014] The system can include two or more designated areas, wherein when the one or more personnel are not detected in any of the two or more areas, the system indicates to the driver that an unsafe condition exists.

[015] The designated area can be contained within a structure which is adapted to be one or more than one, or has one or more than one, of the following: free standing; removably mountable to a crane foundation or support structure; removably mountable to a mobile crane foundation or support structure; packable in multiples in a standard transport container; formed in a container type structure; windows are provided which have mesh in the window openings; fork lift tynes are provided in a base or roof area for moving the structure about; formed with hooks to releasably mount the structure to a crane structure; an RFID detector mounted in the roof; a metal awning, flap or shield to interact with an RFID detector to control the extent of the detection field possibly for the detector; a seat for the personnel; an insulated cooler chamber or refrigeration device for the personnel; constructed from a generally 6 sided structure, of which one whole side is left in an open condition.

[016] The identification means can includes at least one RFID antenna or detector.

[017] The personnel can be included in their clothing footwear or headgear, or otherwise on their person, one or more RFID tag that has been pre-allocated to a specific person.

[018] The RFID tag can be located in a safety helmet of the personnel. [019] The system can include a log-in mechanism whereby the specific personnel must acknowledge their being located in the designated area, when they are first detected in that area.

[020] The log-in of specific personnel can be done by means of inputting their employment identifier.

[021 ] A worker can login at either designated area if there is more than one designated area.

[022] The present invention also provides a port and or work area and or mobile machinery safety system, the system comprising:

[023] a) an automated personnel detection system as described above;

[024] b) building structure into which the automated personnel detection system as described above is installed;

[025] c) a machinery operator notification system.

[026] The port and or work area and or mobile machinery safety system, can also include a data entry module to allow personnel to login and enter their employee details to link to their detected RFID tag.

[027] The data module can update a database in a location away from the building structure.

[028] The automated personnel detection system can be connected by wireless or wired means to said machinery operator notification system.

[029] The notification system can include a red light and green light, to indicate to the machinery operator whether the specific personnel are in a safe or unsafe condition or whether the shared work zone is in a safe or unsafe condition.

[030] The port and or work area and or machinery safety system can be synchronised with a controller for a vehicle which will in operation enter the port or work area, whereby the notification system will only signal a safe condition if the vehicle can enter the port or work area. [031 ] The port and or work area and or machinery safety system can include a detection system adapted to detect the presence of a moving vehicle in the shared work zone.

[032] The detection system can have at least one detection unit which is adapted to emit a signal and receive a reflected signal, being a reflection of said emitted signal off said moving vehicle.

[033] The detection unit can be a laser detection unit, placed onto a crane.

[034] The moving vehicle whose presence is detectable by the detection system can include a reflector adapted to reflect the emitted signal from the detection unit.

[035] The reflector can be a reflective metal panel which is placed at the same height as the or each detection unit.

[036] The or each detection unit only accounts for a detected presence of said moving vehicle, if said moving vehicle is determined to be located within a range of distance.

[037] The range can be between 6 to 20 metres.

[038] The or each detection unit can be adapted to send a signal to a controller of said moving vehicle after detecting that the moving vehicle has entered an unsafe zone or caused an unsafe condition in a shared work zone.

[039] The or each detection unit can send a signal to the automated personnel detection system to notify the automated personnel detection system of a detected presence of a moving vehicle into the shared work zone.

[040] The automated personnel detection system can trigger a warning signal, such as a siren or light if a trigger condition is met.

[041 ] The trigger condition can be met if the laser units detect a moving object, and either of the two following conditions are met: said automated personnel detection system detects an unsafe condition (e.g. a checked in personnel is outside the safe zone); an unsafe condition exists regarding the structure on which the humpy or laser units are mounted (e.g. the crane spreader is in an unsafe position in relation to the straddle carrier). [042] The structure can be a crane, and the detection units can be mounted on crane legs. The moving object can be a straddle carrier

[043] The present invention further provides a safety structure or pinning station for an automated personnel detection system as described above, wherein the safety structure is characterized in that it is one or more than one of the following: free standing; removably mountable to a crane foundation or support structure; removably mountable to a mobile crane foundation or support structure; packable in multiples in a standard transport container; assembled from steel components; formed in a container type structure; windows are provided which have mesh in the window openings; fork lift tynes are provided in a base or roof area for moving the structure about; formed with hooks to releasably mount the structure to a crane structure; an RFID detector mounted in the roof; a metal awning, flap or shield to interact with an RFID detector to control the extent of the detection field possibly for the detector; a seat for the personnel; an insulated cooler chamber or refrigeration device for the personnel; constructed from a generally 6 sided structure, of which one whole side is left in an open condition.

[044] The control system can be adapted to directly or indirectly receive a signal from a detection system for detecting a presence of a moving object in a zone associated with said building structure.

[045] The detection system can be a laser detection system comprising one or more laser units each emitting a laser beam which is adapted to be reflected by a moving vehicle which passes said laser beam, and a sensor which senses any reflected beam.

[046] The detection system can output a signal to identify that the moving vehicle is detected, if the moving vehicle passes within a certain range of distance from said detection system.

[047] The range of distance can be between about 6 and 20 metres.

[048] The control system can trigger a warning if the detection system detects the presence of a moving vehicle and either of the two following conditions are met: said control system determines that personnel is outside the building structure; the control system determines that an associated vehicle or structure in a work area where the building structure is located is not correctly or safely positioned. Brief description of the drawings

[049] A detailed description of a preferred embodiment will follow, by way of example only, with reference to the accompanying figures of the drawings, in which:

[050] Fig.1 Illustrates a perspective schematic view of s safety structure or humpy;

[051 ] Fig. 2 illustrates a safety structure similar to Fig.1 ;

[052] Fig.3 illustrates a rear view of the structure of Fig.2;

[053] Fig.4-1 illustrates an underneath perspective view of structure similar to Figs 1 to 3, showing more detail;

[054] Fig.4-2 is a perspective view of a humpy similar to that of Fig.4-1 , the figure is annotated;

[055] Fig 4-3 is perspective view of the humpy of Fig 4-2;

[056] Fig.5 illustrates a plan view of the structure of Figs 1 to 4 and how their detection systems operate;

[057] Fig 6. Illustrates a lateral cross section through the humpy of Figs 1 to 4;

[058] Fig.7 illustrates a longitudinal cross section through the humpy of Figsl to 4;

[059] Fig.8 is a perspective view of a hook arrangement for use with the humpy to mount the humpy to a crane structure;

[060] Fig.9 is a perspective view of a sleeve arrangement to mount to the humpy so that the humpy can hang from the hook of Fig.8;

[061 ] Fig.10 illustrate and underneath view of a safety helmet in which RFID tags have been located;

[062] Fig.1 1 illustrates a flow diagram of the operations needed to initialise the safety system;

[063] Fig.12 illustrates a flow diagram of an algorithm for the control system of said safety system;

[064] Fig.13 illustrates a flow diagram of the algorithm which is used when a worker or site personnel have to leave the area covered by the safety system; [065] Fig. 14-1 depicts a logic flow employed by the humpy system to output a "safe" or "unsafe" status;

[066] Fig. 14-2 depicts a fault-detection logic flow used by the humpy system;

[067] Fig. 15 depicts a logic flow of how the headquarters computer uses its local database to control the humpy and employee registration;

[068] Fig. 16-1 shows a flow chart depicting how the tablet determines whether a tag is absent or present within the detection range of a corresponding antenna.

[069] Fig. 16-2 depicts a logic flow used by the humpy system to determine whether a detection of a helmet is successful;

[070] Fig.17 illustrates a safety structure or humpy controller hardware architecture for the system described herein;

[071 ] Fig. 18-1 schematically illustrates the main software modules included in the humpy system;

[072] Fig.18-2 illustrates a flow diagram of a safety structure or humpy controller software architecture;

[073] Figure 19 is a schematic diagram depicting a laser detection system for a straddle carrier;

[074] Figure 20 is a schematic diagram depicting a radar detection system from a straddle carrier;

[075] Figure 21 is a flow chart depicting the detection process using the radar detection system; and

[076] Figure 22 is a schematic diagram detecting the positioning of a radar detection system for a straddle carrier.

Detailed description of the embodiment or embodiments

[077] The present in invention is embodied in a humpy 10, which is illustrated in Figs 1 to 5. The humpy 10, which can also be called a smart pinning station, is a device, which together with a method and arrangement of both an RFID reader and RFID device array, and a control process in which the device and method interacts. [078] In general, the embodiments provide a system and method for alerting operators of mobile equipment, such as straddle carriers or crane operators to the presence of people in monitored areas around the periphery of the mobile equipment they are operating. The system includes an RFID detection system which is installed in a 'Smart Station' device or unit 10 which alerts the operator of machinery to the presence of people wearing Personal Protection Equipment containing RFID safety tags.

[079] The problems of accuracy with regards to prior art systems, being a limitation as to the range in which they work, is addressed by embodiments of the invention in that the embodiments are able to provide a 'safe zone' with a relatively high degree of accuracy, say to within up to 5 cm.

[080] OVERVIEW

[081 ] The smart station 10 has RFID readers which constantly read for signals from RFID tags carried by workers. Instead of the processor relaying an alert when the tag is in the monitored zone, the processor relays an alert when the tag is 'Not' in the monitored zone. When the RFID tag is read in the safe zone it is safe, when it is not read in the safe zone it is not safe.

[082] The metal interference to the signal detection of the prior art is overcome with the creation of the Smart Station 10' in which is located a designated or monitored area which is confined to the area within an internal designated area within the 'smart station' or humpy 10.

[083] The accuracy of the signal being detected is controlled in the Smart station or humpy 10 through the unique method of controlling the RFID signal, through the positioning of the readers, the materials used in installation and array of the tags in the helmet.

[084] Generally, an automated personnel detection system has a designated area for workers to be safely located, the designated area being defined by the floor space of the humpy 10. Identification means in the form of antennae 15, which are housed in purpose built cavities or box like structure 45, for identifying the presence of predetermined personnel or workers, are located in the designated area defined by the humpy 10. The system gives to machinery operators a signal, in the form of a red light or green light, as to whether the predetermined personnel are in the designated area, whereby when one or more of the personnel are detected as not being in the designated area, the system indicates to the driver that an unsafe condition exists, by a red light being illuminated. Optionally the signal can be light of a further colour, such as amber, which indicates faults in the humpy components. The lights are essentially a detection output device which produces appropriate alarm signals for different situations.

[085] The system can include two or more designated areas for each crane, wherein when the one or more personnel are not detected in any of the two or more areas, the system indicates to the driver that an unsafe condition exists. However each humpy or pinning station 10 can alternatively operate to cover one designated area, independent to another humpy in the port.

[086] The designated area, as defined by the humpy 10, is contained within the humpy structure 10 which is adapted to be one or more than one, or has one or more than one, of the following: free standing; removably mountable to a crane foundation or support structure; removably mountable to a mobile crane foundation or support structure; packable in multiples in a standard transport container; assembled from steel components; formed in a container type structure; windows are provided which have mesh in the window openings; fork lift tynes are provided in a base or roof area for moving the structure about; formed with hooks to releasably mount the structure to a crane structure; an RFID detector mounted in the roof; a metal awning, flap or shield to interact with an RFID detector to control the extent of the detection field possibly for the detector; a seat for the personnel; an insulated cooler chamber or refrigeration device for the personnel; constructed from a generally six sided structure, of which one whole side is left in an open condition.

[087] HUMPY

[088] The humpy 10 is a roofed structure. The humpy 10 uses several RFID antenna 15, which can also be called or termed an RFID detector, located in the roof of the humpy 10 as illustrated in Figs. 1 to 4, and also on an undersurface of an awning or shielding formation, which is securely connected to the structure of the humpy 10. The antenna 15 in the smart station 10 structure, track the locations of the personnel by reading the signal from the RFID tags that are embedded within their helmets.

[089] As will be explained, the plurality of RFID antennas 15 are intended to work with helmets with RFID tags mounted on them. Preferably each helmet will have a plurality of, tags 1 1 at a variety of locations. The plurality of tags are provided so that at any location and or orientation, within the humpy 10, they will have one of their number detected by the RFID readers. The inclusion of more tags 1 1 will help ensure the detection of at least one of the tags 1 1 when a worker wearing the helmet enters the safe zone. However, the efficiency of the processing of the RFID data will decrease when more RFID tags are provided. Therefore, the number of tags 1 1 will be chosen to maximise the efficiency of data processing. The orientations of the tags will be chosen to spatially arrange them to maximally allow for the detection of the worker.

[090] As shown in Figure 10, in a preferred embodiment, six tags 1 1 are included in each helmet. These include one tag 1 1 -1 provided in a front zone (i.e. near the forehead area) of the helmet, one tag 1 1 -2, 1 1 -3 on each lateral side (i.e. near the sides of the head) of the helmet, one tag 1 1 -4 provided in an occipital or rear zone (i.e. near the back of head area) of the helmet, one tag 1 1 -5 provided near the top of the helmet (i.e. the top of the head), and one tag 1 1 -6 provided near the crown of the helmet (i.e. near the crown of the head). The tag 1 1 -5 provided near the top of the helmet is generally oriented along the midline M of the helmet. The tag 1 1 -4 provide near the rear of the helmet is generally perpendicular to the top tag 1 1 -5. The side tags 1 1 -2, 1 1 -3 are oriented so that they are each angled in relation to the midline, where the side tags 1 1 - 2, 1 1 -3 tend to converge toward the front of the helmet. The front tag 1 1 -1 and the tag 1 1 -6 provided near the crown of the helmet are generally parallel to each other and oriented at an acute angle to the rear tag 1 1 -4.

[091 ] By using this technology, the smart station 10 can automatically determine when personnel are within the safe zone (inside the humpy 10) and then relay that information using a Wi-Fi network to the straddle carriers informing them that it is safe to enter the workspace. Alternatively the smart station provides the information of whether all personnel are in a safe zone to the crane's programmable logic controller, to display or activate a warning light on the crane. The display or activation of the warning light alerts the straddle carrier driver that it is safe (or unsafe) to enter the work zone. By alerting the straddle carriers to the presence of the personnel, it allows the workspace to be safely shared and eliminates the need to have two separate workplaces and thereby enables the process of single hopping (i.e. the use of a single pickup and drop off zone at the back of the crane).

[092] The humpy 10 can have a wall, roof or shield embedded RFID portal - antenna 15, in a front roof extension, shield, flap, or awning 1 1 .2, operatively connected to a touch screen tablet 12, either by a wiring harness or by wired connection. The humpy 10 in this embodiment includes within it a humpy seat 32 which is made from 30mm treated plywood, which provides seating and also storage. Antennas 15 are connected to an RFID reader 35 (See Fig 15) by wires, through a wired connection, but the reader 35 can be connected to the tablet 12 either through wired connection over ethernet or wirelessly connected through WIFI. Preferably a casing is also provided that cannot be tampered with or seen by pinmen, stevedores, or ground foremen working in the area whilst providing strong RFID reading within the entire humpy 10.

[093] An electrical cabinet 33 is also provided within the humpy 10, at a location adjacent one of the sidewalls 16, 17 (see Figs 1 and 2) or the rear wall 18 (see Fig.2) of the humpy 10. The electrical cabinet 33 houses electrical components including, but not limited to, the RFID reader 35, a general purpose input-output (GPIO) box which controls the lighting system of the humpy and/or the crane, network switches, and the like. For instance, the GPIO relays the status of the automated personnel detection system (i.e. whether it detects a safe or unsafe condition) to the crane's programmable logic controller. For example, the GPIO transmits a green signal when it is safe, a red signal when it is not safe, and amber signal when there is a fault in the system. The crane's programmable logic controller is then used to control the crane light, which signals to the driver of the straddle carrier (or other moving vehicle) whether it is safe to enter the work zone.

[094] The electrical cabinet 33 also houses one or more fan to cool the cabinet and the electrical components. Four fans can be provided. The humpy wall 17 (see Fig 2) adjacent the electrical cabinet 33 includes air vents 37.1 , 37.2, including one or more fresh air vents 37.1 through which air is drawn into the electrical cabinet 33, and one or more exhaust air vents 37.2 via which air exits the electrical cabinet 33.

[095] Within the humpy 10, cables connecting different devices such as the tablet to the RFID reader(s) 35 are protected within ducts 34 of a 50mm x 50mm cross section, which can be shown in Fig.1 as leading into the electrical cabinet 33. Plastic ducts 34 are used in a preferred embodiment to minimise RFID signal reflections from the metal surfaces from the humpy structure. The ducts 34 are mounted along a corner of the humpy structure and near or adjacent the location where the antennas are mounted.

[096] Side windows 20 (upper and lower, are provided with customised metal mesh screens 21 , allowing crossflow and full visibility, whilst still making sure the RFID signal is contained within the humpy 10, creating a safe zone 105 within the humpy 10. The mesh screens are made of mesh of the size 25 mm x 25 mm wire strand spacing, with wires of 3mm in diameter.

[097] The humpy 10 of Fig.1 includes the front roof extension or shield 1 1 .2 and side roof extensions or shields 1 1 .1 and 1 1 .3, which can be angled from horizontal or in line with the roof, to a position to perpendicular thereto, that is, in line with the walls, or at incremental or indexed or predetermined angles or locations there between. This allows cross flow ventilation across the humpy 10 when the flaps 1 1 .1 , 1 1 .3 are flat; when they are perpendicular the side flaps 1 1 .1 , 1 1 .3 cover side windows to prevent rain entering the structure from the sides.

[098] The humpy 10 can be mounted onto the crane, using a 'hook and sleeve' attachment 1 10 (see Fig.3) whereby the hook is welded onto the humpy structure and a sleeve is welded onto the crane leg. This allows for the humpy 10 to be lifted and slotted into place and detached as required, in order to perform maintenance works or to replace the structure with a new unit, or to be moved to another crane. Furthermore, by mounting the humpy 10 to the crane structure, it moves with the crane, thereby providing a safe zone adjacent to the workspace.

[099] Embedded into at least one wall of the humpy 10 is a 10 inch (300mm) "industrialised" touchscreen tablet with an employee card reader 12. The touchscreen being embedded within a custom built tablet mount allows for no movement or disruption to the screen in any condition. The tablet or computer 12 is in wireless communication with a central computer or database.

[0100] The identification means is an RFID reader 35 with an antenna 15 which is located within box like pockets 45 on the owning or shield 1 1 .2.

[0101 ] As is best illustrated in Figs 1 to 4, the roof of the humpy 10, includes two antenna boxes 45 in which are each located an RFID detector antenna, for detection of workers in the floor space 31 of the humpy 10. As can be seen from the cross section of Fig.6, the detection signal does not proceed outside of the humpy 10 through the window 20 because the mesh 221 prevents this from happening.

[0102] If desired or required, some of the front opening of the humpy 10, as indicated in Figs 1 , 2, 4 and 7, can be closed off by mesh panels 21 , which form an openwork wall preventing passage through them and directing workers out through the door opening.

[0103] As illustrated in Fig 4, the humpy 10 has a base constructed of ribs or beams 1 17, over which an expanded mesh floor 31 is located. The humpy is of the order of 1750 mm wide, by 1050mm deep by 2400mm in height.

[0104] As further shown in Fig. 4, the touch screen or computer 1 2 can be mounted on the rear wall, allowing upper side window 20 opening to be almost the full width of the side, allowing maximum flow through of air, unlike the version of Figs 1 to 3, where a lesser width of window 20 was provided. But depending upon climates where the humpy 10 will be used the window 20 arrangement can be selected according to need.

[0105] Tyne pockets 30 (see Figs. 1 to 4) are provided to allow easy movement of the humpy 10 throughout the port. The humpy 10 is multi-purpose in that it can provide a safe zone which is readily connected to a crane, or situated at a base of a crane, or completely independent thereto if required.

[0106] Chequered steel floor plates can be located in the floor of the humpy 10 to provide grip during all weather conditions, together with a timber seat 32 (see Figsl and 2) for comfort with an integrated storage box beneath for storing tools and equipment, and a refrigerator device and or an insulated storage container can also or be alternatively provided. [0107] A 'hook and sleeve' attachment 1 10 (see for example Figs 3 and 14) to allow the humpy 10 to be mounted on and off a crane's structure, derrick or system.

[0108] Referring to Fig 3, the hook arrangement 1 10 of Fig 8 is welded to the rear wall 18 of the Humpy 10, which provides two spaced apart hooks 1 1 1 for carrying the weight of the humpy 10 and its occupants. The sleeve 1 14 of Fig .9 is mounted to a crane structure, and has a pocket 1 12 into which the hooks 1 1 1 can enter. By the sleeves 1 14 being firmly welded or secured by bolts to the crane structure, the lifting of the humpy 10 by the fork lift pockets 30, so that the hooks 1 1 1 engage the pockets 1 14, can be readily performed.

[0109] The humpy 10 provides significant safety benefits by minimising collisions between straddle carrier and pin-men. This is because it alerts the straddle carriers to the presence of pin-men, via the activation of traffic lights mounted on the humpy and/or the crane. Optionally, a list of the names of the pin-men who are inside and outside the humpy is displayed on the screen of the straddle carrier, hence if a pin-men exits the unit while the straddle carrier is in the area, the technology allows the driver to contact the pin-men in the unsafe area to coordinate the safe passage of that pin-men to the designated safe zone (i.e. the humpy 10) avoiding a potential collision.

[01 10] The choice of materials and design of the structure of the humpy 10 are selected to optimise the function of RFID systems 20. This includes the use of 2mm thick steel on all walls and metal mesh 21 on the windows 20 to prevent RFID signal penetration and hence prevent readings from outside the humpy 10, thus creating a "not safe zone" 100 (see Fig. 5). The metal mesh 21 serves a second purpose of allowing cross flow ventilation across the humpy 10 to reduce the temperatures within the humpy 10. As further shown in Fig. 5, the RFID antennas 15 are positioned to reduce the distance between the antennas 15 and the edges 1 1 .4, 1 1 .5, 1 1 .5 of the awnings 1 1 .1 , 1 1 .2, 1 1 .3, to create safe zones 105 (see also Fig. 6). The safe zones 105 are approximately bound or partially bound by the edges 1 1 .4, 1 1 .5 and will be within signal reach to the antennas 15. The roof of the humpy 10 is preferably constructed from the same as that used for shipping containers, to prevent the possibility of falling objects breaking past the roof and into the humpy. [01 1 1 ] Power supply from an independent source, or from the crane to which the humpy 10 is connected to provide an external power source to the safety system. Built in wiring capability to connect electrical equipment without affecting the structure will also be provided and advantageous.

[01 12] In the preferred construction, the corner posts used to construct the humpy are continuous. A marine-grade paint is applied to the humpy. Unless otherwise specified, the humpy is made from Cor-Ten® steel, which is the material used to construct shipping containers.

[0113] DETECTION OVERVIEW

[01 14] As illustrated in Fig. 10, metallic weatherproof RFID tag stickers 1 1 in Fig.10 are preferably added to the inside of the existing safety helmets. This is a preferred option as they do not need their own battery and battery management system.

[01 15] The smart station 10 uses software to constantly identify the presence of the personnel based on the signal strength received by the antenna from the tags 1 1 on the personnel's helmet.

[01 16] The humpy 10 identifies the locations of the pin-men. This is based on the signal strength received by the antenna from the tag on the worker's helmet. The signal strength can be correlated or calibrated, so that a certain range of signal strength is identified as being within the humpy 10.

[01 17] There can be two or more humpy units per crane, each with its own signal read range, each with access to a database which is accessed by the system software which controls the pair of humpies 10 together so that a worker can go to either humpy and be identified as within a shared safe zone.

[01 18] The humpy 10 can be configured so that it is connected to a tablet, computer or controller 12 inside the humpy 10. The humpy 10 further has an employee card or ID reader 35. Each humpy 10 has its control or computer system linked to a port's network, preferably by means of a wireless network.

[01 19] The humpy 10 and the control system will also be linked to a red-green light system attached to either the top of the humpy or to the back of the quay crane leg. Preferably each quay crane back leg has two humpies 10, one on the left and one on the right. The humpies 10 will be linked together and act as one for each crane back leg. Each straddle carrier will be fitted with an industrial computer linked to the system over a wireless network.

[0120] As each pinman enters the port they will be required to wear their assigned helmet, pre-fitted with one or more RFID Tag. As the pinmen are dropped off at the quay crane they will be required to enter the humpy 10 from the safe side.

[0121 ] Upon entering the humpy 10, the pinmen's RFID tag will be identified by the humpy 10 antenna/receiver 15 and the worker's identity will be displayed on the mounted computer screen 13.

[0122] The workers, who may be pinmen, stevedores, ground foremen or other, will be required to "check in" on the mounted computer screen 13. Every worker can only checkin/checkout themselves. As a security measure the worker must swipe their employee ID card on an employee ID card reader next to the screen 13, to confirm their initial presence within the humpy 10. This is discussed in more detail in relation to Fig. 12.

[0123] The light fitted above the humpies 10 or on the crane leg will not go green until all checked in workers are located within one of the two humpies stationed for that crane leg.

[0124] A central organisation control centre will have a computer setup to monitor and view all checked in personnel, installed within existing control centre system.

[0125] When the pinmen or workers leave for a break or at the end of a shift, they must "check out' and then "check in" when they are to re-enter the humpy 10, all via the screen touch 12 and an employee ID card reader.

[0126] Once successfully checked out, that pinman or worker will no longer be required to be back in the humpy for the area to be deemed safe.

[0127] The control system, in the situation where there are two humpies 10 per crane, is integrated so that all pinmen checked into either designated area 10 must be back within one of the two humpies for the shared work zone to be deemed safe. The system's integration also allows for a central operation management centre (and straddle drivers in another version of the system) to view from within their own remotely located screens.

[0128] The system provides a touch screen 13 (see Fig.2) inside the humpy 10, so that a worker can, when their helmet is first detected by the RFID system, login to the system, by having their employee security card swiped or scanned by the touch screen or related camera. Firstly this ensures that another person is not using the helmet other than the designated worker, as the RFID tag IDs are allocated to each worker. When there are two humpies 10 per crane, the worker can login at either humpy 10 and they will be registered for both designated areas.

[0129] Fig. 1 1 illustrates the process required to ready a humpy 10 for use with the designated RFID tags, for corresponding personnel and their helmets. The humpy or humpies are made ready during the initial preparation stage 1 100, where the humpy is prepared or constructed or attached to the designated crane or other mobile vehicle, with powering and data circuitry wired. At the completion of the preparation stage 1 100, the humpy is registered and assigned at the "humpy registration and assignment" step 1 105. During the "humpy registration and assignment" step 1 105, each humpy is issued with its unique ID. As mentioned before, two or more humpies can be assigned to a shared work zone.

[0130] Another step that is required is RFID tag assignment and registration 1 1 10. In step 1 1 10, multiple RFID tags will be issued, their particulars recorded and assigned to a helmet (i.e. a worker). The tag IDs, the worker's name, and the date of the assignment or any replacement of the tags will be recorded in the system database, which may be located within the humpy computer, or at a remote computer away from the humpy.

[0131 ] Once the RFID tag assignment and registration 1 1 10 is complete, each helmet will be verified 1 1 15. That is, before each worker goes on site, their helmet will be verified by a test station to ensure that all of the tags in the helmet are readable, and faulty helmet will be replaced. The verification is done daily.

[0132] The registration steps (see Fig. 1 1 ) will enable the worker to check into and check out of the humpy. [0133] Fig. 12-1 is a flow chart generally outlining the check in procedure and safety lighting 1200. When a worker enters a humpy wearing their assigned helmet in step 1205, the humpy will detect one or more RFID tags in the helmet in step 1210. The worker swipes their employee identification card at the card reader inside the humpy to "check in" 1215. The humpy computer or the remote computer will determine whether the check in is successful 1220. A successful "check in" means that the identity of the worker is verified by the reader, and matches the identity of the worker to whom the detected tag is assigned. If the check in is not successful 1225, the display within the humpy will show that an error has occurred 1230. If the check in is successful 1235, the system will then determine whether the worker, along with any other worker that is checked in, is within the humpy safe zone 1240. This determination is made by checking whether the RFID tags in the helmet(s) of the worker(s) are still being detected by the humpy. If all of the checked in workers are within the safe zone 1245, then the system causes the green light to be lit 1250. If any of the checked in workers is not in the safe zone 1255, then the system causes the red or alarm light to be lit 1260.

[0134] Figure 13 is a flow chart generally outlining the check out procedure 1300. When a worker wishes or needs to leave a humpy 1305, they swipe their employee card at the card reader to check out 1310. The humpy computer (or remote computer with the correct registration data) will determine the check out is successful 1315, by determining whether the swiped card is assigned to a worker who is detected as being present in the humpy. If check out is successful 1320, the process is finished 1325 and the computer will not check for the presence of the checked out worker within the safe zone. If check out is not successful 1330, the display will show a check out error 1335 to notify the worker.

[0135] Figure 14-1 depicts a logic flow 1400 employed by the humpy system to output a "safe" or "unsafe" status. The humpy system regularly checks to see if any helmet RFID tags have been detected 1405. If not, the checking continues until a presence of any RFID tags is detected. Upon detection of the tags, the humpy system or controller checks for information regarding the detected tag (i.e. to identify the employee) 1410, by looking up the local humpy database 1410. If the employee or user is identified 1420, the humpy system checks to see whether the employee has "checked-in" 1425 . If the user is not checked in, then the humpy system will display an error message to notify the person that he or she has not checked in 1430 The humpy system will then keep checking for the presence of tags 1405. If the user is checked in, the humpy system will determine whether the checked in user is inside the safe zone 1435. If the checked in user is inside the safe zone, then the traffic light will output a "green" or "safe" condition status 1445, and then keep checking for the presence of any helmet tags 1405 as per usual. If the checked in user is not inside the safe zone (e.g. if the user leaves the safe zone after checking in), the humpy system will output a "red" or "unsafe" condition status 1450, and then keep checking for the presence of any helmet tags 1405 as per usual.

[0136] Figure 14-2 depicts a logic flow 1455 for fault-detection, employed by the humpy system. As an initial step, the system, which runs on a humpy tablet or computer with batter power, will check that there is a power supply to the humpy 1460. If there is no power, the humpy system will communicate with the GPIO box to turn on a warning light (e.g. "amber light") to indicate a system fault 1495. Upon making sure the humpy has power, the humpy system checks that its software applications are operational 1465. In the negative, the humpy system preferably will notify the programmable logic controller of a crane or a headquarters computer of that its applications are not operational 1470. As will be discussed later, one way this is done is to interrupt a "heart beat" signal, the continuous transmission of which indicates normal humpy software operations. If the applications are verified to be operational, the humpy system checks that it can connect to the card reader and the RFID reader 1475. If the system cannot connect to any reader, the system displays on the tablet that it cannot connect to the reader(s) 1480, and the fault is reported 1470. If the system can connect to the readers, the system next checks whether it can connect to the local database in the humpy 1485. If there is no connection to the local database 1410, the system displays an appropriate error message, and causes the warning signal to be activated 1495. If the connection to the database is detected per normal, the system will keep checking that the humpy is connected to power 1460.

[0137] Figure 15 depicts a logic flow 1500 which shows how the headquarters computer uses its local database to control the humpy and employee registration. To change the detail of a humpy 1 505, the headquarters computer or controller will check that the changes are correct 1510. The requirements are that each humpy can only be assigned to one location, and the humpy must have an IP address that is known to and searchable by the headquarters computer. For any given crane to which two humpies can be assigned, there cannot two slaves, or two masters. If any of these conditions are not met, the changes made in the registration and assignment step will be rejected 1515. If all of the conditions are met, then the changes will be made 1520 to the database at the headquarters 1525.

[0138] To create a user (i.e. employee) or change the detail of an existing user 1 530, again the headquarters computer 1525 will check that the changes are permissible 1535. The system will require that no two users are registered under the same name or be assigned the same user ID. All of the tags issued to a particular person's helmet will have same tag ID, but no tags issued to different users will have the same ID. If any of the requirements are not met, the changes to the database 1 525 are rejected 1515. If all of the requirements are made, the changes are made 1 540 to the database at the headquarters 1525.

[0139] The changes made to the headquarters database 1525 will be synched with the data residing in the relevant humpy that the changes concern. Before this is done, the system checks whether the headquarters database is in communication with the humpy 1545. If the headquarters database can communicate with the humpy 1 550, the data will be synched 1555. If there is a communication fault and the data cannot be synched 1560, the communications check will be conducted again after the issue has been examined and repaired.

[0140] Upon the synching of the headquarters database and the humpy database 1 555, the humpy is able to display the employee information and checked in/out status for the added user 1565. The humpy can now check for the activity, i.e. RFID detection for a user assigned to the humpy 1570. Upon the detection of any activity of the worker (i.e. entering or leaving a safe zone) 1 575, the detected activity will be logged 1 580 to the headquarters database. Every time the humpy checks in or checks out a user 1 585, the humpy and headquarters databases are synched 1 555 so that the successful checking in/out is logged to the headquarters database 1 525.

[0141] RFID DETECTION [0142] In a particular embodiment, for security purposes when a pin-men enters the humpy 10 they are required to swipe/scan their employee card on the employee identification via the card reader and select a person to log in as on the tablet. The tablet is connected to the RFID antenna mounted on the roof of the humpy 10, so that when a pin-men is within reading distance of the RFID antenna on either humpy 10, the RFID antenna reads the signal from the RFID tag on the helmet and this information is initially used to activate a red light/green light indicator on the or near the humpy 10.

[0143] When the worker walks into the area related to an RFID antenna 15 which is transmitting radio waves in the UHF frequency around 916 MHz, this signal is retransmitted by the tags on the workers helmet back to the RFID antenna 15 in the humpy 10. The RFID antenna 15 transmits this signal at 30 milliseconds (ms) cycles, to closely monitor the movement of the workers. These readings are then transmitted by the antenna 15 to the RFID reader. The reader then processes how quickly the antenna is reading the tags to identify whether the worker is inside or outside based on how long since the tags on the workers helmets have been read. This information is transmitted to the software and then onto the associated database 1 120 (see Fig 1 1 ), which triggers a green or red light.

[0144] The flow chart shown in Fig 16-1 depicts this process. In step 1605, when the RFID reader first receives the retransmitted signal from a particular tag, it waits for a detection condition 1610 to occur - that is, for the retransmitted signal to be consistently detected at every signal cycle over a detection period or a first time threshold of 800ms. If the retransmitted signal is consistently detected for each of the signal cycle during the 800ms period 1615, then the software will identify this particular tag as being present or detected in step 1620. That is, the worker to whom the tag is assigned is considered to be inside the humpy. If the detection condition is considered not met 1625, then the system will keep checking for the detection condition 1605. The detection condition 1605 is typically not met 1625, if the time threshold has not been reached, or if the worker steps away from the corresponding RFID antenna causing an interruption in the retransmitted signal for a particular tag. If the latter case occurs, the detection period will restart. [0145] Once a tag is detected 1620, the system will keep transmitting the RFID signal and checking for the retransmitted signal 1630. If the retransmitted signal continues to be received 1635 then the tag remains "detected" 1620. If the retransmitted signal is not received 1640, the system will start a time counter for a signal absent period 1645. If the absence of a retransmitted signal persists for at least the signal absent period 1650, then the system will identify this particular tag as not being detected 1655. If the retransmitted signal is not yet absent for the entirety of a "signal absent period", then the system will keep checking for the absence of the tag 1630. The "signal absent period" can be of the order of about 2000 ms. Different time thresholds may be used, but they need to be chosen to realistically correspond with the possible movement of a worker into and out of the detection range of an RFID antenna. The requirements of a consistent detection, or absence, of the retransmitted signal over the lengths of time help reduce the occurrence of false "red" or false "green" conditions.

[0146] Figure 16-2 depicts a further logic 1660 that the system may employ to ensure the successful detection the presence of a helmet and hence the employee to whom it is assigned, to ensure that it has correctly detected the presence of the helmet (and thus employee). When a helmet is initially detected 1665, the system will read the helmet tags for a period of time, e.g. 3 seconds 1670, to try to detect all of the tags. The system next checks whether it has detected the correct number of tags known to be attached to the helmet (e.g. 6) 1675. If it detects more tags then there are supposed to be, an appropriate error message is displayed 1680. Similarly if the system detects fewer tags than there are supposed to be, then it displays an error message 1685. Provided it detects the right number of tags, the system checks if all of the tags is assigned with the same employee or user ID 1690. If all of the tags are assigned to the same person, the system notifies the user that the reading of the helmet tags is successful 1695. Otherwise it can optionally display an error message.

[0147] In another version of this safety system, the retransmitted information or tag signal will be transmitted to a tablet which calculates the location of the worker based on the signal strength and then determines whether they are within either of the smart station units, if they are, the system adds their name to the list of people inside the humpy column, else their name appears in the outside humpy column. This information is relayed to tablets on the straddle carriers or other machinery which are linked through a Wi-Fi network to the tablets on the humpy 10. These tablets on the straddle carriers displays a list of the pin-men who are inside and outside the humpy, therefore informing the drivers when it is safe to enter the shared workspace. By using this system, the straddle carriers are alerted to when a pin-men is outside the humpy which informs them not to enter the workspace. This can be linked to a red light and green light system so that the machinery operator is able to make a speedy decision on the issue of the safety of the shared work zone.

[0148]A feature of the humpy of the embodiment of the invention, is preferably standardised so that the RFID systems can be readily calibrated and initialised for operation. That is, the humpies for use will be of the same size, material, and shape. The number and placement of the RFID antennas that are required to effectively cover all of the humpy interior and "safe zones" under the awnings will therefore be the same for standardised humpies. The calibration of the RFID system in the humpies will be readily producible.

[0149] A worker can log in at either designated area or humpy 10, if there is more than one designated area or humpy 10.

[0150] The present invention also provides a port and or work area and or mobile machinery safety system, the system comprising: a) an automated personnel detection system as described above; b) building structure or humpy 10 into which the automated personnel detection system as described above is installed; c) a machinery operator notification system.

[0151 ] The port and or work area and or mobile machinery safety system, can also include a data entry module to allow personnel to login and enter their employee details to link to their detected RFID tag. In other embodiments, the data entry module is only accessible by authorised personnel or "super users" from a central computer located at the headquarter.

[0152] The automated personnel detection system can be connected by wireless or wired means to the machinery operator notification system. [0153] The notification system can include a red light and green light, to indicate to the machinery operator whether the specific personnel are in a safe or unsafe condition or whether the shared work zone is in a safe or unsafe condition.

[0154] The present invention further provides a safety structure or humpy for an automated personnel detection system as described above, wherein the safety structure is characterized in that it is one or more than one of the following: free standing; removably mountable to a crane foundation or support structure; removably mountable to a mobile crane foundation or support structure; packable in multiples in a standard transport container; formed in a container type structure; windows are provided which have mesh in the window openings; fork lift tynes are provided in a base or roof area for moving the structure about; formed with hooks to releasably mount the structure to a crane structure; an RFID detector mounted in the roof; a metal awning, flap or shield to interact with an RFID detector to control the extent of the detection field possibly for the detector; a seat for the personnel; an insulated cooler chamber or refrigeration device for the personnel; constructed from a generally 6 sided structure, of which one whole side is left in an open condition.

[0155] HARDWARE OVERVIEW

[0156] Figs 17 illustrates the hardware architecture employed by an embodiment of the invention. The RFID antennas 15 mounted on the humpy 10 detect the retransmitted ultra high frequency signals from the RFID tags 25 located in the workers helmets. The antennas 15 provide their output via coaxial cables 16 to the RFID reader 35, which then provides the information to the relevant database in a central control location via wireless communication. It is also a viable option to provide the database within the humpy 10, if for example, the safe zone includes only one humpy or multiple humpies which are near each other and between which data is routed. In the embodiment of Fig. 17, the RFID reader 35 further serves as part of the circuit between the humpy tablet or computer 12 to a general purpose input output (GPIO) box 40, via a dedicated GPIO cable 41 .

[0157] The tablet 12 takes information from an employee card reader 43, which reads an employee card 43.1 swiped by the worker and populates the relevant employee table in a database. The database is located in the tablet or in a central database away from the humpy 10. The tablet 12 processes the information in the database in order to determine an output for the general purpose input output (GPIO) controller 40 which outputs signals appropriate to turn on the required light signal. The output will be routed through the RFID reader 35. The GPIO box 40, upon receiving the output, will cause the humpy traffic light 42 and/or the crane traffic light 44 to emit the appropriate light signal.

[0158] In embodiments where the crane traffic light 44 and the humpy traffic light 42 are integrated, the lights 42, 44 are green and red at the same time. A two-way communication between the GPIO box 40 and the crane is depicted in Fig 17. In a particular embodiment, there is a programmable logic controller in the crane which communicates with the GPIO box in the humpy. When there is a crane malfunction or the crane is in a particular mode of operation which requires the worker or other vehicles to stay away, the programmable logic controller from the crane sends a signal to the GPIO box. The GPIO will cause the tablet display to show a warning signal to alert the worker as to the state of the crane. In this embodiment, both the crane light 44 and the humpy traffic light 42 will be green only if the safe conditions are detected and the crane is not malfunctioning or in a state of operation which requires the absence of workers or other vehicles from an area around the crane. The skilled readers will however appreciate that the lights 42, 44 need not be synchronised.

[0159] In one embodiment where the crane light 44 and humpy light 42 are integrated, the GPIO box 40 which controls the humpy traffic light 42 will have at least three outputs - one output each for the red and green lights of the traffic light 42, and one output to the crane's traffic light 44. The GPIO controller 40 will have at least four outputs if the traffic light 42 further has a third, e.g. amber, light. The amber light can be used to, e.g. indicate a hardware failure or fault within the humpy. The GPIO box can have a further output which is regularly or continuously sent to the crane's programmable logic controller. The further output can be a pulse signal, e.g. a 3 second pulse signal. The pulse signal can be considered a "heartbeat" of the humpy which is regularly or continuously sent to the crane. Therefore, if there is an issue with the humpy software (e.g. software freezing) or with any controls within the humpy (e.g. GPIO control signals become degraded or unreliable), then the heartbeat signal will not be transmitted as expected to the crane's controller. If the crane's programmable logic controller stops receiving this "heartbeat" signal, it will cause a warning light such as the amber light to be activated.

[0160] The GPIO box or controller 40 also receives input from the crane's programmable logic controller. If the humpy detection system determines that a worker is in an unsafe zone, then the GPIO controller 40 will send outputs to both the humpy light 42 and the crane light 44, to cause red light to be activated in both. If the crane's programmable logic controller determines that the crane is malfunctioning or not in the right position for e.g. the straddle carrier to move in, the crane's programmable logic controller will provide a "red light" input to the GPIO controller 40, causing both the humpy traffic light 42 to be red along with the crane light 44.

[0161 ] Further, in Fig 17, the RFID reader 35 is depicted as accepting an output from the tablet 12. However the RFID reader 35 does not process the GPIO information from the tablet 12. Rather, in this embodiment the RFID reader 35 forms a part of the circuit between the tablet 12 and the GPIO box. The RFID reader 35 has the physical port to accept an Ethernet cable from the tablet 12, which has a LAN connection with the RFID reader 35. The RFID reader 35 also has the physical port to connect with a GPIO cable that is accepted by the GPIO box 40.

[0162] Preferably passive RFID Tags are utilised such as by means of Zebra UHF RFID Label printer and Encoder. The touch screen 12 is preferably a Panasonic FZ-G1 Ruggedised tablet with dock and power supply, while the RFID reader 35 is preferably a Impinj brand Portal Passive UHF RFID Reader. The tags are e.g. Alien Squiggle ® tags.

[0163] SOFTWARE OVERVIEW

[0164] As shown in Fig. 18-1 , the humpy software 1600 generally includes at least three control modules which may reside in different components physically or which may reside in the tablet 12. These include a hardware control module 161 which controls the configuration of the RFID reader 35 and also the control for the GPIO which determines the lighting output. An RFID card reader module 162 employs the logic and processes prior discussed with respect to the RFID tag detection procedure. A worker status or check-in/check-out module 163 controls the employee card reader and oversees the cross match between the card reader and the personnel detection by the RFID card reader. [0165] The humpy software 1800 is discussed in more detail with reference to Fig. 18-2. The software 1800 preferably at least partially resides within each humpy 10, to avoid the additional lag time that would have been caused if the control modules were located in a central head quarter. As shown in Fig 18-2, the software 1600.1 includes the reader controller or reader module 1805.1 which interfaces with the RFID reader (see Figure 17), to take the input from the RFID reader. The tag event handler 1815.1 includes the processes and algorithms to determine whether a particular tag has been read. The determination is populated into the database 1 620.1 , which is located in a central control away from the humpy, but could be situated locally in the humpy, e.g. within the tablet.

[0166] There is a connection configuration module 1810.1 between the reader module 1805.1 and other modules in the humpy software 1800.1 . The connection configuration module 1810.1 is a communications driver which determines the way in which various modules takes and outputs information, but does not process the input beyond ensuring communication can be achieved.

[0167] The database 1820 includes a "tag read table" 1825 and an "employee information table" 1830. The "tag read table" 1825 and "employee information table" 1830 are sub-tables which form a larger table structure. As the helmets are each assigned to specific workers, the tags are also assigned to specific workers. The "tag read" data, i.e. data showing whether a particular tag has been read or detected, is populated into specific parts of the "tag read table" 1625 which corresponds to a particular worker.

[0168] The humpy software 1800.1 also includes a check in/check out controller module 1835.1 . As described in the previous paragraphs, when a worker enters a humpy or leaves a scheduled shift, he or she scans an employee access or identity card. The scan information is read by the check in/check out controller module 1 635.1 , which provides input for the "employee information table" 1830. Under normal circumstances, it is expected that once an employee checks into the humpy 10, the information read by the check in/check out controller module 1835.1 will be in concordance with the result from the tag event handler 1815.1 to identify the same worker(s). [0169] The database 1820 is monitored by a display warning controller module 1840.1 , which will determine whether conditions are met for a "safe" or "unsafe" signal. The display warning controller module 1840.1 outputs this determination to a General Purpose Input Output (GPIO) controller module 1845.1 , which controls the humpy traffic light, and optionally also the crane traffic light, as described before with reference to the inputs and outputs for the GPIO controller 40.

[0170] In Fig 18-2 it can further be seen that both humpies 10.1 , 10.2 associated with a crane can be provided with the ability to communicate with each other. The output from the check in/check out controller module 1835.2 and the tag event handler module 1815.2 in humpy 10.2 are also communicated and added to the database 1820. In the depicted embodiment, one of the humpies 10.1 takes the "master" role and the other humpy 10.2 takes the "slave" role. That is, the software 1800.1 in humpy 10.1 is used to provide input for the display warning controller module 1840.2 in humpy 10.2. The roles may be reversed, if, for example, a software or hardware issue arises with humpy 10.1 . It is also possible, depending on customer preference, for there to be no connection between the humpies 10.1 , 10.2.

[0171 ] Optionally, the humpy software further includes a hardware monitoring module 1650, to detect any hardware failure or fault in the humpy. On the detection of a fault or failure, the module communicates to the GPIO controller module 1645 to output a warning light of a distinct colour, such as amber.

[0172] Furthermore, each humpy 10.1 , 10.2 may also communicate to a central or headquarters computer 1900 located in a central location or in a "headquarters" location which oversees the humpies' operation. The headquarters computer 1900 will have the capability to add, remove, or update user details in the database 1820. Any changes made by the central or headquarters computer 1900 to the database 1820 will either be synched to all of the databases of the humpies that are linked together, or the controllers of the linked humpies will have access to the same master database which is being updated by the headquarters computer 1900. Therefore a user will be able to log into any humpy that is linked to the same network.

[0173] The central computer further has the capability to remotely check in or check out workers at each linked humpy. With this capability, in the event that a worker forgets to check in or check out, port operations will not be impacted. Therefore, the central computer 1900 would also have the capability to remotely read the list of checked in workers - i.e. it can read the tag read table 1825 and employee information table 1830 within the database 1820.

[0174] The hardware monitoring function performed by the hardware monitoring module 1850 can in addition or alternatively be performed by the headquarters computer. That is, the hardware monitoring module may reside in the headquarters computer 1900 as well as, or instead of, within the humpy software 1800.

[0175] LASER DETECTION SYSTEM

[0176] As shown in Figure 19, the above personnel detection system can further be incorporated with or used alongside a laser detection system for detecting whether a straddle carrier 46 has entered a zone adjacent or associated with the humpy or pinning station. The laser detection system 50 is used to define an "unsafe zone". It also identifies to a straddle carrier driver when the straddle carrier has entered the unsafe zone, by triggering a warning siren or light.

[0177] The laser detection system 50 includes at least two laser units 52, 54, one mounted on each end of the crane 48. The laser units 52, 54 are placed so that they are oriented toward or face the straddle carrier(s). For instance they are mounted on each of the two crane legs, on the side or face of the crane legs that faces the straddle carriers. In Figure 19 only one laser unit 52 is visible. A reflector, such as a reflective metal panel 56, is mounted on the straddle carrier 46, covered by the laser detection system 50. The reflective metal panel 56 is mounted at the same height as the laser unit 52, 54.

[0178] The laser units 52, 54 transmit a constant laser signal toward the reflective metal panel 56. The placement of the two laser units 52, 54 and the resulting constant laser signals they emit will define a range. When the straddle carrier 46 moves across the laser signal of either laser unit 52, 54 and into range, the emitted laser signal will be reflected by the reflective metal panel 56. This reflected signal will be detected by a sensor of the laser unit 52, 54, thus identifying that the straddle carrier 46 has passed into the range of the laser unit 52, 54. [0179] The laser units 52, 54 are calibrated to only recognise reflected signals off a reflective metal panel 56 and thus a straddle carrier 46 located at a certain range of distance, e.g. between 6 to 20 metres, away. The laser units 52, 54 do so by measuring the time it takes for the reflected signal to be detected. If either laser unit 52 (54) detects that the straddle carrier 46 is within this range of distance, it sends a signal to the crane's programmable logic controller (PLC). The crane's PLC will then send a signal to the humpy 10, where the software within the humpy will record this event.

[0180] In a preferred embodiment, the crane's PLC triggers a warning audio siren when the laser system has detected an object within the specified range of distance, and when either or both of the following conditions are satisfied: 1 . the humpy light is red; 2 the crane light is red. A red humpy light signals that a checked in personnel is in an unsafe zone. A red crane light means that the crane is in an unsafe position. Similarly the an equivalent traffic light system can be mounted on another machinery or structure in the shared work zone, and will have the same function in the overall safety system as the crane light.

[0181 ] The laser units 52, 54 can alternatively connect directly to the GPIO box on the humpy or pinning station 10. The software container within the humpy architecture processes the signals from the laser units 52, 54 to determine if two or more of the above conditions are satisfied. If so, the humpy software 1900 sends a signal through its GPIO box 40, which then communicates to the crane PLC to trigger a warning.

[0182] In the above, the laser units 52, 54 are said to be placed on a crane. However this system can be generalised to detect the present of any moving object or vehicle into a particular zone around any structure. Depending on the configuration of the structure and object to be detected, it is envisioned that only one laser unit may be needed.

[0183] RADAR DETECTION SYSTEM

[0184] As an alternative to the laser detection system discussed in relation to Figure 19, the above personnel detection system can instead be incorporated with or used alongside a radar detection system for detecting whether a straddle carrier 46 or another vehicle has entered an "unsafe" zone adjacent or associated with the humpy or pinning station. [0185] As shown in Figure 20, the pinning station or humpy 10 is fitted with a FMCW (Frequency Modulated Continuous Wave) Radar detection system 58. Radar signals of frequency between, for example, 24.068GHz to 24.218GHz are transmitted and reflected off surfaces of passing vehicles back to the radar antenna. Information of the presence & distance of detected vehicle is extracted from the reflected signal and analysed. If the vehicle is found to be within a specified Detection Zone 60, the system generates a first signal that is fed into the Humpys' General Input & Output (GPIO) unit 40. For example this will be a "high" voltage signal of e.g. 24 volts.

[0186] Figure 21 is a flow chart depicting how the radar detection system determines it has detected a vehicle. The humpy controller software will check for the detection signal to the GPIO unit at regular time intervals 2105, for example every 500 millisecond. If a signal is detected 21 10, a configurable timer is turned on 21 15. The timer is configured to wait for a predetermined waiting period, and at the end of the waiting period trigger the software to check for the signal again 2120. If GPIO again detects the signal generated by the radar detection system, the presence of the vehicle is confirmed 2125. If the radar system generated signal is not again detected 2130, the process reverts to the start where the software checks for the radar system signals at regular intervals 2105.

[0187] The purpose of the timer and the double-checking is to avoid the radar from detecting objects other than the vehicles (e.g. a bird). Once it is confirmed that a vehicle has been detected 2125, the software will check whether all personnel that are checked into the Humpy are in the safe zone, and also the status of the Crane. This is done by checking whether either of the humpy light or the crane light is red, indicating an unsafe condition 2135. If either light is red, then the software will cause an audio siren to sound or a visual warning to be displaced 2140. In addition, a specified GPIO pin will be set high (+24V) to inform external control units (e.g. Programmable Control Unit) that a vehicle has been detected by the radar 2145. If neither light is red, the system keeps checking for the signal from the radar detection system 2105.

[0188] The dimension of the specific Detection Zone 60 is configurable (i.e. can be set by software) to allow flexibility in the detection range. A user has the ability to adjust the radar mount to change the vertical pitch (maximum 45°) & horizontal direction of the Radar (Between 0° to 180°). Adjusting vertical pitch allows the radar to detect objects of different height and adjustment in horizontal direction permits positioning of the detection zone.

[0189] Figure 22 depicts an example of the positioning and configuration of the radar system. Two humpies 10 are mounted to the crane 48. Each humpy 10 is outfitted with a radar system 58. Each radar system 58 creates one detection zone 60. The dimension of the detection zones is configured to be, for example, 20m x 6m. The vertical pitch of the radar is optionally adjusted to an angle which allows the radar to only detect a certain type of vehicle. For example, vertical pitch of the radar is adjusted to about 10 degrees, so that the radar is suited to detect straddle carriers.

[0190] The detection zones 60 are located one adjacent each side of a cargo to be carried, such as a container 62, so as to each sufficiently cover a respective area within the travel path 80 of the straddle carrier 46. The direction of travel of the straddle carrier 46 is shown by the arrow 68. One detection zone 60 detects the presence of the carrier 46 into an entry zone 64 where the carrier 46 prepares to accept or pick up the container 62. Therefore this detection zone 60 needs to cover the entire width of entry zone 64, as measured in the direction of travel. The carrier 46 leaves the entry zone 64 to go to the correct position to accept or pick up the container 62. When the pick-up is complete, the carrier 46 continues to drive in the direction of the arrow 68 and enters the exit zone 66.

[0191 ] The other detection zone 60 detects the presence of the carrier 46 into an exit zone 66, and no longer detects the presence of the carrier 46 when the carrier clears the exit zone 66. Therefore the other detection zone 60 preferably covers the entire width of the exit zone 66. The radar detection systems will be located a distance 70 from the travel path of the carrier 46. The distance 70 is preferably chosen to be sufficient so that the radar of each radar detection system 58 is able to create a detection zone 60 which will cover its respective travel path area (i.e. entry zone 64 or exit zone 66).

[0192] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of". A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[0193] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[0194] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.