TRAFFIC FLOW CONTROL SAFETY SYSTEM

Field of the Invention

This invention relates to safety equipment and procedures in the workplace, and in particular, to a modular traffic flow control safety system which utilises physical barriers and presence-sensing technotog including integrated yet flexible bolt- together components for assembly in multiple configurations designed to create a system of pedestrian/vehicle barriers with gates interlocks, lights and sensors providing a safety system for preventing injury in the workplace

Whilst the invention may be applied to any hazardous environment requiring some kind of separation of a person(s) from an area in order to aid safety, for convenience, sake it shall be described herein in terms of a traffic flow control safety system for use in a workplace using mobile lifting equipment.

Background to the Invention

Broadly speaking, a safety barrier may be defined as a physical or non-physical means to prevent or control access by a pe son, object or substance to a dangerous area. Most commonly they are used to mitigate the risk of people encountering physical harm by preventing them from entering a dangerous area.

Safety barriers may be classified according to their materials, dimensions, whether they are passive or active barriers, and whither they are physical, computerised, or human operated barriers. Examples of soft barriers includes devices such as light curtains which detect the presence of a foreign body and are tied into the control circuit to stop machinery. Hard barriers, such as a fence on a swimming pool, may be fixed In place or be temporary and i

The use of barriers to separate pedestrians and mobile plant/machinery or the protection of equipment from mobile plant/machinery is common in the workplace, and in most circumstances, is also a safety requirement Traffic control management, particularly for the separation of fonrkifts and pedestrians, is a priority safety issue for any workplace with mobile lifting equipment. Barriers are often used to prevent workers from accidentally entering a dangerous area, such as a large machinery

area or the designated driving area of vehicles. These barriers are often temporary. The issue with previous barriers is that they only provide a safety rail, or alternatively, a complete fence and are cumbersome and time-consuming to install. In addition, the fail to provide a complete system for controlling traffic flow by pedestrians and vehicles within an area with the ability to automate components.

Accordingly, it Is an object of the present invention to overcome or substantially ameliorate the disadvantages of the prior art by providing a modular traffic flow control safety system which utilises physical barriers and presence-sensing technology including integrated yet flexible bolt-together components for assembly in multiple configurations designed to create a system of pedestrian/vehicle barriers with gates interlocks, lights and. sensors providing a safety system for preventing injury in the workplace.

Summary of the Invention

The present invention provides a traffic flow control safety system for controlling traffio between pedestrians and vehicles including: a modular barrier system having at least two support posts, at least one rail extending between said support posts and at least one interchangeable bracket member for connecting said rail to said support post in various configurations; at least one gate for allowing the passage of pedestrians and/or vehicles through the barrier system; at least one sensor for detecting the presence of a pedestrian and/or vehicle within the surrounding area; and a control box for controlling operation of required components in response to signal received from the sensors and/or transmitters/receivers on the vehicle and barrier components.

The bracket members are preferably providec in different forms to enable the rails to be connected to the post in alternate configurations including, but not limited to, an L- shape member for a comer attachment, a H-shape member for attaching the rails in a straight and/or continuous manner and a hinged bracket member for following a curved pathway. The barrier components are connected together using a "bolt together system which enables the bracket to be positioned in the correct location every time, and also in the event of alteration, allows a current bracket to be removed and a different bracket to be fitted.

Preferably, the sensor may be a dedicated detection sensor, motion or beam type sensor or combination thereof. A sensor detection analyser can receive and analyse signals received from one or more sensors to control the traffic flow control safety system components.

It is preferred that the gates includes pedestrian gates controlling the passage of pedestrians and boom gates cofrtrσing the passage of vehicles through the barrier system, wherein opening and closing of the gates is automated and connected to a timer which ensures the gates remain open and doses after a predetermined time. The boom gates preferably have an etectro-mechanical gear motor for raising and lowering the boom gate and may be controfled via a remote control or push-button control to allow boom gate to be raised according to an inbuilt-timer. The gates or a workplace roller preferably ha« a magnetic interlock to prevent the gate or door from opening when the other is in an open position.

The invention preferably has at least one warning light for indicating the passage of a pedestrian or vehicle. A yellow light preferably indicates the passage of a pedestrian and a red light indicates the passage of a vehicle.

An "activate crossing* button may be provided to indicate a pedestrian is ready to cross and allow the gates to be opened once the area is clear.

In order that the invention may be more readily understood we will describe by way of non-limiting example of a specific embodiment thereof.

Brief Description of the Drawing Figures

Figure 1 shows an exploded view of a mounting/support post of the safety barrier system according to an embodiment of the invention.

Figure 2 shows a perspective view of two possible bracket members for connecting rails at an angled position (shown left) and in a straight configuration (shown right) according (o an embodiment of the invention.

Figure 3 shows a top view of base plate for anchoring a support post according to an embodiment of the invention.

Figure 4 shows a schematic view of the traffic flow control safety system according to an embodiment of the invention having pedestrian gates and boom gates.

Figure 5 shows a schematic view of the traffic flow control safety system according to an embodiment of the invention having pedestrian gates and a rapid roller door.

Description of a Preferred Embodiment of the Invention

Figures 1 to 5 show the traffic flow control safety system and its components according to various embodiment of the Invention.

The invention provides a modular traffic flow control safety system which utilises physical barriers and presβπce-senalng technology including Integrated yet flexible bolt-together components for assembly in multiple configurations designed to create a system of pedestrian/vehicle barriers with gates interlocks, lights and sensors providing a safety system for preventing injury in the workplace. The safety barrier system is ideally adapted for use in environments, such as a workplace, requiring either a permanent or temporary barrier system for the purpose of safety. In use, the invention preferably provides the user the ability to assemble the safety barrier system by removing or adding components, without the need for engaging In cutting, welding, painting and other traditional services as the components are pre- manufactured to meet the requirements for a particular application. The components can then be bolted together In multiple configurations to provide greater flexibility to the user. Components may preferably be added either initially or at a later date. It is envisaged that modifications to the safety system and/or Its components can be made during construction and/or at any time as required to meet different requirements. It is envisaged that the shape, size and dimensions of the traffic flow control safety system and/or its components may also be varied to suit different workplace layouts or requirements and/or applications.

The traffic flow control safety system, and/or its components, can preferably be made of any suitable material, such as metal or the like. The material should be strong, durable, weather-resistant and meet the requirements of the invention. The components are preferably powder-coated to provide a finish which is bright, long- lasting, easy to keep clean and easy to replace. In a preferred embodiment, the

components of a safety barrier system, providing the physical barrier for the system, are preferably made of treated steel, n is envisaged that the safety barrier system may be powder-coated for further durability and longevity. It Is preferred that the components of the safety system may come in various prefabricated lengths and widths, made to order or supplied In different sizes, which may then be assembled by the user to suit their particular application or workplace layout.

The safety barrier system has provided at least one safety rail member 10 which is adapted to be positioned between at least one mounting-suport post 20 to provide a physical barrier to a person. The safety rail(s) 10 provides a designated and separate walkway far pedestrians which is/are readily identifiable by drivers. Preferably, the rail(s) 10 is/are provided in lengths from 300 millimeters to 2400 millimeters, in increments of 25 millimeters. Preferably, the rail (s) is/are rectangular in shape. However, ft is envisaged that any other shape or dimensions may be employed to better suit the particular application/workplace environment, preferably one which is modular for ease of assembly in multiple configurations. In an alternate embodiment, it Is envisaged a chain or other suitable member may be used. The outer surface of the rail component(s) 10 is/are slightly rounded edges along their edges so that they are less likely to cause injury than sharp, jagged, or pointed components. The rate 10 have at least one mounting hole which is adapted to be complimentary and align with a mounting hole provided on a bracket member 30 into which the rail 10 is received. The mounting holes are preferably adapted to be pre-drilled to provide simple installation and are adapted to receive a suitable fastening member such as a bolt or nutsert or the like therethrough,

A kick rail may be provided which is a bolt-in guard to protect against valuable equipment from being damaged when pallets, or other items, are being located by forklifts. The kick rail is suitable In various applications such as;

• - Protection to machinery or equipment where pallets are being loaded

• Protection to machinery or equipment against general vehicle operations

• Protection against waits (especially sandwich panel, etc) against general vehicle movement

• Around edges or similar where vehicles are not permitted access

- Car-park of similar vehicle areas to protect the facility against vehicles striking walls, etc when parking.

The safety barter system has provided at least one mounting/support post 20 adaptdd to provide structural support for the safety system. The ρost(s) 20 is/are rectangular in shape. However, it is envisaged that any other shape or dimensions may be employed to better suit the type of application/workplace requirements. The outer surface of the post component(s) 20 is/are preferably adapted to have slightly rounded edges so that they are less likely to cause injury than sharp, jagged, or pointed components. Each post 20 has a rounded cap portion 21 which is adapted to be positioned over the top end of the vertical post(s) 20 to prevent exposure of the - lop edge. Each post 20 component has provided a series of attachment points along the length of the post adapted to provide several different positions along the length of the post to which one or more bracket members 30 or other components can be mounted. The attachment points are preferably in the form of an aperture which is adapted to receive a suitable fastening means such as a bolt or the like therethrough.

Provided on a base portion 22 of the post 20 is preferably at least one slot 23. In a preferred embodiment, each side of the post 20 has a slot provided. The slot(s) 23 is/are adapted to enable the post 20 to be received over a base portion 22 which can be in the form of a base ptate 22 and is adapted to support the post 20 and/or provide a means for securing the post 20 to a ground surface. It is envisaged that the shape and dimensions of the bottom portion of the post 20 may be varied to be complimentary to an attachment portion of a base support plate 40. The bottom portion of the post 20 is adapted to be open-ended 90 that the post 20 can be received over the base support plate 22.

The safety barrier system has provided at least one interchangeable bracket member 30 which is adapted to receive and enable a rail 10 to be attached to a post 20. The bracket members 30 are preferably provided in different forms to enable the rails 10 to be; connected to the post in alternate configurations to suit different applications/workplaoe requirements. A first bracket member may have an L-shape configuration for a corner attachment A second bracket member may be provided in a H-shaρe configuration for attaching the rails in a straight and/or continuous manner, it is envisaged that a hinged bracket member may be provided to provide a means for constructing the safety system to follow a curved pathway. The brackets 30 have provided at least one aperture 31. The apertures 31 are adapted to receive a fastening means, such as a bolt or the Ike therethrough, to secure the bracket to the post. Preferably, the fastening means is adapted to enable the brackets 30 to be interchangeable and be easily removed or added to a constructed safety barrier

system as required at any time. The brackets 30 to be attached to the post 10 can be provided in multiple configurations to allow the rails to slot and be secured therein in different arrangements to make the system flexible enough to go around corners and meet various angles. .

Preferably, there ie provided an anchoring means. Preferably, the anchoring means is in the form of a base plate 40. The base plate(s) 40 is/are adapted to enable the post(s) 20 to stand upright securely. The base plate(s) 40 consist of a base plate and an attachment portion. The base plate 40 has provided attachment points at which ft may preferably be secured to the floor via an attachment means such as a bolt or the like.The attachment portion has at least one upwardly extending portion which is adapted to be integrally formed with the base plate 40 and be adopted to be received within a slot 23 provided on the bottom of a post 20 to be secured and provide support to the base of the post

The modular "bolt together" system of the invention using nutserts or bolts or similar fastening means provides flexibility for completed structures that are later required to be modified for various reasons. H enables the bracket 30 to be positioned In the correct location every time, and also in the event of alteration, allows a current bracket to be removed and a different bracket to be fitted. Furthermore, the different variations of brackets 30 provide the ability to make additional configurations.

The traffic flow control safety system has provided at least one traffic flow control feature which assists in guiding a person or vehicle through and around the safety system. A first pedestrian traffic control feature is preferably at least one gate. The gate(s) is/are adapted to be able to be attached to the safety barrier system at any stage .during construction or thereafter. In a preferred embodiment, the system includes pedestrian gates 50 which allow or prevent the passage of pedestrians through the path of the safety system and boom gates 51 which allow or prevent the passage of vehicles through the safety system, The pedestrian gate 50 is preferably attached to the traffic flow oontrol safety system via a hinge means. The hinge means can be attached using pre-drilled holes in the post 20 or alternatively new holes may be bored. The pedestrian gates 50 can open inwardly so that the pedestrian is required to take a step back and be more aware of the crossing. A boom gate 51 can be added to provide additional control in which case the pedestrian gates 50 wwll preferably open on the same side opposite to the boom gate 51 to provide a barrier on both sides. The boom gates 51 have an electro-mechanical

gear motor for raising and lowering the boom gate 61. The boom gate 51 can also be controlled via a remote control or push-button control to allow boom gate 51 to be raised according to an inbuilt-time The sensors will check that the surrounding area is clear prior to raising the boom gate 51.

The gates 50, 51 may be automated to open and dose in response to signals received from a sensor(s) 60 and/or tr ansmitters located on the vehicle and receivers on the barrier components/sensors. In a shared intersection, it will be possible to nominate whether vehicles or pedestrians will be given the right of way. Where vehicles are given right of way, the boom gate will always be raised. When a vehicle is detected in the area, the red lights will flash and the pedestrian gates 50 will close. When a pedestrian approaches the crossing, sensors 50 wil detect the direction in which they are travelling to activate the yellow lights and lower the boom gates 51. The pedestrian gates 50 will automatically open to allow pedestrian thoroughfare without the need for stopping. The pedestrian gates 50 can open outwardly to provide a physical barrier to vehicles from both sides, one side with the boom gate 51 (where a boom gate is used) and the other side with the pedestrian gate 50. Once clear, the gates 50 will dose, boom 51 raise and yellow lights cease flashing allowing vehicle access again.

Automation of the pedestrian gates 50 and opening and closing and boom gates 51 raising or lowering in response to the presence of a pedestrian or vehicle is preferably controlled via an actuator kit The actuator kit has provided at least one sensor 60. The sensor(s) 60 can be a dedicated detection sensor and/or motion sensor or combination thereof. The sensor can be mounted on various angles for a shorted or longer detection range. A sensor detection analyser is preferably provided to receive and analyse signals received from one or more sensors to control the traffic flow control safety system components. The sensors which may be utilised preferably, indude but are not limited to, the following: Microwave Sensor

The MD1-1 Sensor is a "state of the art" programmable microwave sensor and has the ability to not only detect an object, but also to: º Determine the direction of a detected object (i.e. coming towards or moving away)

• Discriminate between a pedestrian and a vehicle

• Has a built-in relay to activate a warning light or siren when an object is detected

• Able to hold a detected signal for up to 9-seconds to allow a warning to continue to provide a buffer zone for the detected object to be well dear of an area

• Low Voltage operation of 12/24V DC

• Programmable via a Hand-Held programmer to eliminate unnecessary working at heights for tuning the sensor

Dedicated Detection System (DDS)

The Dedicated Detection System (DDS) is designed to enable a warning or function to occur when a vehicle fitted with the transmitter comes into range of a receiver. By using this method of detection, a warning or type of control can be provided to ensure that only certain types of vehicles are abte to activate the required function. The DDS is suitable for areas such as;

• Blind Corners

• Traffic Management to ensure only authorised vehicles can access a particular area (cool room, boom gate, doorway access, etc).

• Controlled crossing points (interlinked with the pedestrian gates)

• Anywhere that a specific control is required, or where staff & other vehicles need to know a particular type of vehicle Is in the vicinity.

The dedicated signal transmitter & receiver operate vie an Infra-Red (IR) signal, and therefore is based on "direct line of sight". By using this method, false warning are reduced as this method does not permeate through wade or other objects as is found with RF (Radio Frequency). Benefits of this type of detection include:

• Improved occupation health and safety standards

• Supplements normal driver warnings

• Extremely good for noisy plants where forklift warnings are hard to hear

• Reduces the risk of pedestrian death or injury

• Reduces the likellhood that operations will be disrupted

• Reduces Liability

• No false triggers or false alarms (as with Radio Frequency systems)

• Predictable range and coverage

• Line of Sight

• Not affected by other plant or equipment (as with Radio Frequency systems)

• Easy to Install

• Modular for future expansion

• No licensee or permits required to operate the system.

Radar Sensor

The Proximity Warning Kits are designed to give a warning when a vehicle is approi chjng a certain area. The Radar Senior is programmable to detect, mass or object size, and with the added advantage of detecting directional movement, a suitable warning can be provided when the vehicle is approaching an area. The warning provided can be in areas such as; Blind Corners

• Inside/Outside of a dispatch office or other room

• Near pedestrian crossing areas

• Anywhere that staff & other vehicles need to know a vehicle is approaching.

Digital Motion Detector

Digital Motion Detector combines a special outdoor use weatherproof design.

Resistant to water, insects, dust, wind, sunlight and other outdoor disturbances due to its tjpecially designed casing. Advanced optics and digital processing technologies. These photoelectric sensors provide the ability to monitor when an object has crossed a certain point and can be configured through the various controls to provide a warming light or to activate a crossing or almost any other function required.

Direction Detection

The Objet Direction Detection sensor is designed to provide a warning when an object is moving in a certain direction. By utilizing 2 sensors, when an object passes the first sensor, then the second sensor, the control box can activate a warning light or alarm to notify that something is travelling towards them. This can also be provided in the opposite direction of setting of the second sensor and then the first sensors. The Control Box can be configured in various ways, and include (note: "output " means the type of device that the control box is activating such as a light, siren, etc);

• Output on-off for a timed period (0-80 seconds)

* Output latched on until an object has reversed the sensor detection sequence (i.e. an object passes sensor 1 then sensor 2 and the output is switched on until an object passes sensor 2 then sensor 1).

This method of detection is useful In many areas where traditional types of monitoring may not be suitable. Benefits of this type of detection include:

• Pedestrian walkways where a. pre-warning of a pedestrian heeding towards a crossing is required.

• Activating the Pedestrian Automated Gate system by detecting when a pedestrian is heading towards the crossing and then starting the crossing sequence without having to press a button. This is suited to areas where a pedestrian is wheeling a trottey, carrying items, etc end the pressing of a button may be awkward.

• Driveways or entry points where the notice that α vehicle is heading to or from an area.

• Providing a warning when over-height vehicles are heading towards an area can also be achieved if the sensors are mounted in at ft height that is the required notice level.

The gates can operate in the following ways:

Option 1 (Vehicle Priority)

This option provides vehicle priority which means the pedestrian gates are normally closed. When a pedestrian wishes to cross, they press an "activate crossing" button 70. If the sensors don't detect any vehicles the yellow LEO lights start flashing and the gates 60 open to alow the pedestrians to cross. When the sensors on the crossing confirm that there are no pedestrians, the gates dose and the Yelow LED lights turn off, allow vehicte access. When a vehicle is detected by the sensors, the red LED lights are activated and if a pedestrian presses the "activate crossing" button, the yellow LED lights will activate, but system will not allow the gates 50 to open until the vehicle is longer being detected.

Potion 2 (Pedestrian Priority)

This option provides pedestrian priority which means the pedestrian gates 50 are normally open. When a vehicle is detected by the sensors, the red LED rights activate and the gates 60 close. Once the vehicle is longer detected in the area, the gates 50 open and the red LED Dghts turn off. allowing pedestrian access. If a pedestrian is crossing, the yellow LED lights are activated for around 3-5 seconds (adjustable) to provide a warning that pedestrians are crossing. If a vehicle is detected white a pedestrian is crossing, the red LEO lights are activated, but the

gates 50 will not dose until the system has confirmed that there are no pedestrians crossing.

A second pedestrian traffic control feature is preferably at least one warning, light The warning light 80 may be mounted to a light post which is adapted to attach to the safety barrier system at any stage during construction or thereafter or alternatively, be mounted to a support post 20 or other suitable position. The light post 81 is preferably attached to the system via an attachment means. The attachment means is preferably a "hammer-on" installation that provides that the light post will fit onto the top of a post 20. However, it could also be mounted via a bolt or other suitable fastening mechanism. It is envisaged that the base of the light post 81 may have the same configuration as the cap member 21 so that the light post 81 can be used as an alternative to the cap member 21 to be placed on top of a support post 20. The LED light 80 is adapted to indicate via flashing whan a gate 50, 51 is open to a vehicle or pedestrian. In a preferred embodiment, there are yellow lights for indicating that a pedestrian is crossing or intending to cross and red lights for indicating that a vehicle is crossing or Intending to cross. Lights 80 are preferably positioned on both sides of a roller door so that vehicles and pedestrians, can see that there is a vehicle/pedestrian on the other side of the roller door. It is envisaged that the traffic control features may be integraly formed with and/or or provided as separate components which can be fitted and installed as part of, or separate to, the traffic flow control safety system as required.

The traffic flow control safety system has provided at least one magnetic intertock. The magnetic interlock is adapted to control the traffic flow through the barrier system by allowing the passage of pedestrians or vehicles and preventing the passage of the other. The interlocksare particularly useful near rapid roller doors 90. The gates 50 will be magnetically locked when a vehicle is within a prescribed distance of the crossing with the red lights 80 flashing, and unlocked once the path is dear. When a pedestrian is σroeβiπg, the rapid roller door 90 will be magnetically locked with the yellow light 80 flashing. The pedestrian crossings have a time-out circuit for the gate which will unlock the gates 90 once the pedestrians have crossed. The timer function allows a predefined time, preferably eight to ten seconds, for a pedestrian to cross one the pedestrian gate 50 is opened. In this embodiment, the traffic flow control control box will be integrated with the rapid rotter door control box. Where a magnetic interlocking kit is utilised and the vehicles are nominated for priority to pass through the system, the pedestrian gates 50 wiH normally be dosed, so when a pedestrian Is

wanting to cross, they must press the "activate crossing" button. If the sensom dont detect any vehicles either in the loading bay or outside the loading bay, the yellow LED lights 80 start flashing and the gates 50 will open to allow the pedestrians to cross. The gates 50 operate on a timer function and allow ten seconds for the pedestrian to cross. Once the timer has elapsed, the gates 50 will dose and the yellow LED lights will turn off, allowing vehicle access. When a vehicle is detected by the sensors, the reed LED lights are activated and if a pedestrian presses the "activate crossing" button, the yellow LED lights will activate, but system will not allow the gates 50 to open until the vehicle is longer being detected. The lights preferably use long-life LEDS and are high dust, moisture and vibration resistant.

The Timer Control Box provides the ability to turn on a light, siren or other warning devices when the pedestrian/boom gate is opened. The bunt in timer will keep the warning device on for an adjustable period of 1-60 seconds. Uses include:

• Providing a warning to notify when a pedestrian is crossing at a designated point º Providing a warning when a gate, or any other switch connected to the

Control Box is activated

The timer control box has an indicator for showing activation of the unit and power supply to the unit The Control Boxes are configured on the number of zones that are being monitored by the DOS Receiver, A zone is an area being monitored that when a signal is received (from a vehicle fitted with the Transmitter), a function occurs (a function may be a warning light, siren, gate Interlock, etc). Each zone may also have a number of Receivers connected so that when arty of the Receivers are activated, the same function occurs.

The advantage of the safety barrier system is that it provides a complete solution by the use of different brackets to be Installed in a straight-line, or angled at 90-degrees, or to have a multi-angle bracket installed providing a 180-degrees axis for the rail to be positioned. The provision of various additional devices such as gates and light posts provide further flexibility to the system to not only provide a physical barrier but to assist in directing human traffic through the baπier system. In addition, it is envisaged that the components of the baπier system may be adapted to that it can be adopted for any flat or inclined surface and/or straight or angled pathway. The invention provides a safe and dearly separated working environment eliminating the risk of uncontrolled vehicle and pedestrian interaction.

While we have described herein a particular embodiment of a safety barrier system, it is further envisaged that other embodiments of the invention could exhibit any number and combination of any one of the features previously described. However, it is to be understood that any variations and modifications can be made without departing from the spirit and scope thereof.