FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION
Device to monitor machine and operator performance
2. APPLICANT
1. (a) NAME Evincere Software Solutions Pvt Ltd.
(b) NATIONALITY. A Company Registered under Indian Companies
Act 1956
2. (C) ADDRESS 26, Electronic Sadan 1, Bhosari MJ.D.C.,Pune -
411026, Maharashtra, India
3. PREAMBLE TO THE DESCRIPTION
Provisional Complete
The following Specification particularly describes the invention and the manner in which it is to be performed

Title of Invention: Device to monitor machine and operator performance
Field Of Invention: The present invention is related to devices used for supervision of the machines in industry and the alertness of the operators operating the machines. More particularly the present invention relates to device which monitors important machine parameters comprising of electric current, speed, pressure, temperature, process stability and utility.
Prior Art: To the best of the belief and information of the applicant, he could not find prior art relevant to the present invention.
Deficiencies of Prior Art: At present, according to the knowledge of the applicant, the machines in industry are run by the operators and they are manually supervised. Difficulties are faced by the supervisors and management as to keep a watch on every machine and operator. The operators may inadvertently set the machine to wrong parameters incurring losses due to waste of material, due to rejection and loss of productive time of that machine and operator. In case the operator purposely sets the machine wrongly to cause fosses he must be stopped before such losses occur beyond some limits.
At present there is no prior art device available to address above problem. Need is felt by the industry for a device to address the above problem at an early date.

Object of Invention and summary:
The objective of the present invention is to provide a device to monitor machine parameters and operator's attendance and watchfulness at machine.
Another object of the present invention is to provide a device which provides information about the machine parameters, process stability and utility.
Yet another object of the present invention is to provide data useful for planning preventive maintenance of the machine.
Yet another object of the present invention is to provide a device which indicates and prevents the operator from playing mischief like running the machine idle or running it at lower or higher speed than the recommended speed.
The present invention comprises a housing which contains an electronic circuit comprising of a pre programmed microprocessor with input devices comprising of current sensor for sensing the machine current, RF interface to report emergency and failure to supervisor console and other devices, a matrix key board to facilitate inputting data and machine parameters comprising speed, pressure, temperature and other important parameters pertaining to the machine to be set. The maximum and minimum permissible values of the machine parameters are inputted using the keyboard. An acknowledgement key and panic switch are provided on the said matrix key board. An LCD display is provided on fascia of the housing for verifying data while setting as well as for

inspection of stored data at the machine. Memory device for storage of data together with a RTC (real time clock) device is provided as reference real time and date for logging errors and abnormalities.
Output devices comprise of a buzzer' to give signal to the operator working on machine. Auxiliary inputs comprises of data coming from speed, pressure and temperature sensors provided on machine. If the machine is idle or any of said parameters go beyond the permissible range set, the event is logged in the memory device as an error with date and time. Logging includes Machine parameters comprising of Current, temperature, pressure and other set parameters. If the operator takes immediate action and brings machine parameters in permissible range the operator alertness cycle continues. In case of emergency, operator presses the panic switch which switches the hooter ON signaling the supervisor. Alternatively operator uses RF interface to communicate with supervisor consol. The supervisor uses pen drive which is inserted in a USB interface provided on the device to download the error data stored in memory for diagnosis. Said stored data comprises of current, temperature, pressure and other set parameters of the machine in real time when the error occurred. This data is protected by a password and only on inputting the password the supervisor is enabled to download data.
When the device is started, time cycle of the buzzer is set. The time cycle comprises of buzzer ON time and buzzer OFF time in sequence. This cycle goes on continuously over the time. The

operator should press the acknowledgement key while the buzzer remains ON. In case the operator does the same he has acknowledged his alertness and he is at his machine, the event is called acknowledgement and logged in the memory. If the operator fails to successfully acknowledge his alertness due to any reason, the event is called an error and is logged in the memory. The said real time clock device enables logging all the events of acknowledgements and errors in real time.
The data about the machine parameters in the events of errors is valuable for planning the preventive maintenance.
Two arrow keys provided on the key board enables the supervisor to observe data at the machine station. Same keys can be used to scroll the data up and down.
It is evident from above that the present invention overcomes the limitation of the prior art where such device is not available and achieves the objectives as mentioned above.
Statement of invention:
Device to monitor machine and operator performance comprises of a housing (not shown in figures) which contains an electronic circuit comprising of a pre programmed microprocessor with input devices comprising of current sensor for sensing the machine current, RF interface to report emergency and failure to supervisor console at remote place, matrix key board to facilitate inputting data and machine parameters comprising of speed, pressure, temperature and other important parameters pertaining to the machine. The

maximum and minimum permissible values of the machine parameters are inputted using the keyboard, an LCD display provided enables verification and observation of data at machine station; an acknowledgement key and panic switch are provided on the said matrix key board. A memory device to store inputted parameters and logging generated data, a real time computing device to initiate action and record data in real time, a buzzer to give a beep for set time for alerting the operator, auxiliary inputs for inputting the signals coming from sensors provided on machine, a hooter alarm with its activating relay and USB interface facilitating down load of data stored in the memory are provided.
When the device is started, time cycle of the buzzer is set which is said to be the alertness cycle, the time cycle comprises of buzzer ON time and buzzer OFF time in sequence. The buzzer remains on for 120 seconds on completion of 120 seconds the Hooter goes ON for set time. The operator should press the acknowledgement key while the buzzer remains ON, in case the operator does the same he has acknowledged his alertness, the event is logged in the memory as acknowledgement, if the operator fails to successfully acknowledge his alertness, the event is logged in the memory as error. Said real time clock device enables logging all the events of acknowledgements and errors in real time.
If the machine is idle or any of said parameters go beyond the permissible range set, the event is logged in the memory device as an error with date and time, logging includes machine parameters comprising of Current, temperature,

pressure and other set parameters. If the operator takes immediate action and brings machine parameters in permissible range the operator alertness cycle continues. In case of emergency, operator presses the panic switch which switches the hooter ON signaling the supervisor. Alternatively operator uses RF interface to communicate with supervisor consol, the supervisor presses the acknowledgement key to put OFF the hooter. He uses pen drive which is inserted in a USB interface provided on the device to download the error data stored in memory for diagnosis. Said stored data comprises of date, time, current, temperature, pressure and other set parameters of the machine in real time when the error occurred.
This download of the data from memory is password protected and only on inputting correct password an authorized person is enabled to download this data.
Two arrow keys provided on keyboard enables supervisor to observe data by scrolling up and down by choosing error mode or acknowledgements mode.
Description of figures:
Fig 1 shows block diagram of hardware set up according to present invention.
Fig 2a to Fig 2j taken together, represent the flow chart according to which the present invention works.

Description:
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention as described below in the preferred embodiment.
This invention is illustrated in the accompanying drawings, through out which, like reference fetters indicate corresponding parts in the various figures.
The present invention "Device to monitor machine and operator performance" comprises a housing (not shown in figures) which contains and electronic circuit comprising a pre programmed microprocessor (1) with input devices comprising current sensor (2) for sensing the machine current, RF interface (3) to report emergency and failure to supervisor console at remote place, and other devices; a matrix key board (4) to facilitate inputting data and machine parameters comprising speed, pressure, temperature and other important parameters pertaining to the machine to be set. The maximum and minimum permissible values of the machine parameters are inputted using the keyboard (4). A permissible range of the said parameters is between the maximum and the minimum limiting values. An acknowledgement key and panic switch are provided on the said matrix key board (4).
When the device is started, time cycle of the buzzer (7) is set which is said to be the alertness cycle. The time cycle comprises buzzer (7) ON time and buzzer (7) OFF time in sequence. The buzzer remains OFF for 120 seconds on

completion of 120 seconds it the Hooter goes ON for set time. This cycle goes on continuously over the time. The operator should press the acknowledgement key while the buzzer (7) remains ON. In case the operator does the same he has acknowledged his alertness and he is at his machine, the event is called acknowledgement and logged in the memory (5). If the operator fails to successfully acknowledge his alertness due to any reason, the event is called an error and is logged in the memory (5). The said real time Clock (6) enables logging all the events of acknowledgements and errors in real time.
An LCD display (13) is provided on fascia of the housing for verifying data while setting as well as for inspection of stored data at the machine. Memory device (5) for storage of data together with a RTC (real time clock) device (6) is provided as reference real time (and date) for logging errors and abnormalities and maintaining the accuracy of the logged data. Output devices comprise of a buzzer (7) to give signal to the operator working on machine. Auxiliary inputs (8) comprise of data coming from speed, pressure and temperature and other sensors provided on machine. If the machine is idle or any of said parameters go beyond the permissible range set, the event is logged in the memory device (5) as an error with date and time. Logging includes Machine parameters comprising Current, temperature, pressure and other set parameters. If the operator takes immediate action and brings machine parameters in permissible range the operator alertness cycle continues. In case of emergency, operator presses the panic switch which switches the hooter (12) ON through relay (10)

signaling the supervisor. Alternatively subject device uses RF interface (3) to communicate with supervisor consol. He uses pen drive which is inserted in a USB interface (9) provided on the device to download the error data stored in memory for diagnosis. Said stored data comprises current, temperature, pressure and other set parameters of the machine in real time when the error occurred.
The data about the machine parameters in the events of errors is valuable for planning the preventive maintenance.
This download of the data in memory (5) is password protected and only on inputting correct password the authorized person is enabled to download this data.
A two way toggle key switch is provided on the key board (4). This switch is used to observe the data at the machine station. Pressing the toggle key to up position, acknowledgement data is displayed on the LCD display (13). Pressing the toggle key to down position error data is displayed on the LCD display. In both the cases there is provided a facility to scroll the data up and down.
The algorithm according to which the present invention works is given below with reference to the flow chart provided from the Fig 2a to Fig 2j.
Algorithm
1 : Power on the system.
2 : Initialize Input- output ports, ADC, RTC, LCD, RF, ,
USB, Keyboard etc.

3 : Calculate all stored settings, Acknowledge (ACK)
Start time & End time, etc
4 : Read & display RTC
5 : Check Machine Current if yes then go to 6 else
Store Time and Date.
6 : Check ACK Time, If ACK start time matches with
current time, and then countdown starts from 120 sec, buzzer stars alarming and LED flash
6(a): Check for ACK switch press, if yes, then store ACK
Time and Date & Calculate
Next ACK Time, then go to 7
6(b): Else Store Error Time & Date and also Calculate
Next ACK Time then go to 7
7 : Check panic switch pressed, if yes then, go to 7 (a)
else go to 8
7(a): Hooter and Relay gets ON,
then Check for ACK Key Press, if yes then Hooter and Relay gets OFF then go to 8
8 : Check Pen Drive Inserted if yes go to 8 (a) else go
to 9
8(a): USB device Detected, then Enter Password if
correct, Download data to USB device

8(b): Check USB device removed if no, then download
data, if yes then go to 9
9 : Check for UP Key Press, if yes go to 9 (a) else go to
10
9(a): Display Acknowledge Records, Use UP/DOWN Key
for Scrolling Records,
Check Auto Return if yes then go to 4, else go to 10
10 : Check for DOWN Key Press, if yes go to 10 (a) else
go to 11
10(a): Display Error Records, Use UP/DOWN Key for
Scrolling Records,
Check Auto Return if yes then go to 4, else go
to 11
11 : Check Enter key pressed, if yes then go to 11(a),
else go to 12
11(a): Enter password, Check Password, if correct Enter
into Setting Mode then go to 12 else go to 11(b)
11(b): Invalid password, press backspace key for auto
return then go to 11(a) & 12
12 : Check Valid RF Data if yes Take Action else go to 4

Advantages of present invention:
1. Large 20x4 line LCD backlight display to provide all necessary information
2. Large memory to hold data equivalent to

2.1 5000 Acknowledgements
2.2 1000 Acknowledgement failures

3. Built-in hooter with sound output of 80 db.
4. Flexibility to acknowledge either by a single key press or by entering a unique 4 digit numeric code. 10 such codes can de set by user.
5. Built in battery backup up to 6 hours.
6. The acknowledgement frequency can be set from 10 to 99 minutes.
7. A set of potential free contacts are provided as auxiliary output to activate additional hooter or flood light along with the built in hooter.
8. RF communication with supervisor's console to report emergency.
9. The ranges of parameters and acknowledgement cycles are Programmable
10. Error and acknowledgement log is provided with date and time
11. Logging of Machine parameters comprising Current, temperature, pressure and other parameters pertaining to the machine.
12. USB connectivity to download / transfer data(Error and acknowledgement Log)

The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment.
Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or matter,
The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention; which is defined by the scope of the following claims.

Claims:
1. Device to monitor machine and operator performance comprises a housing (not shown in figures) which contains an electronic circuit comprising of a pre programmed microprocessor with input devices comprising current sensor for sensing the machine current, RF interface to report emergency and failure to supervisor console at remote place, matrix key board to facilitate inputting data and machine parameters comprising of speed, pressure, temperature and other important parameters pertaining to the machine; the maximum and minimum permissible values of the machine parameters are inputted using the keyboard, an LCD display provided enables verification and observation of data at machine station; an acknowledgement key and panic switch are provided on the said matrix key board; a memory device to store inputted parameters and togging generated data, a real time clock to initiate action and record data in real time, a buzzer to give a beep for set time for alerting the operator, auxiliary inputs for inputting the signals coming from sensors provided on machine, a hooter alarm with its activating relay and USB interface facilitating down load of data stored in the memory;
when the device is started, time cycle of the buzzer is set which is said to be the alertness cycle, the time cycle comprises buzzer ON time and buzzer OFF time in sequence the buzzer remains OFF for 120 seconds on completion of 120 seconds it the Hooter goes ON for set time, the operator should press the acknowledgement key while the buzzer remains ON,

in case the operator does the same he has acknowledged his alertness, the event is logged in the memory as acknowledgement, if the operator fails to successfully acknowledge his alertness, the event is logged in the memory as error; said real time computing deice enables logging all the events of acknowledgements and errors in real time;
if the machine is idle or any of said parameters go beyond the permissible range set, the event is logged in the memory device as an error with date and time, logging includes machine parameters comprising Current, temperature, pressure and other set parameters, if the operator takes immediate action and brings machine parameters in permissible range the operator alertness cycle continues; if operator alertness is not confirmed the device checks for panic switch, in case of emergency, operator presses the panic switch which switches the hooter ON signaling the supervisor; alternatively the subject device uses RF interface to communicate with supervisor consol He uses pen drive which is inserted in a USB interface provided on the device to download the error data stored in memory for diagnosis; said stored data comprises current, temperature, pressure and other set parameters of the machine in real time when the error occurred;
this download of the data from memory is password protected and only on inputting correct password an authorized person is enabled to download this data;

two arrow keys provided on keyboard enables supervisor to observe data by scrolling up and down by choosing error mode or acknowledgements mode.
2. Device to monitor machine and operator performance as claimed in claim 1 as substantially described hereinbefore, with reference to the accompanying drawings.