FIELD OF INVENTION
The present invention relates to the field of industrial safety and maintenance by
providing safety sensors for workers in hazardous areas and enabling assistance
to them in case of mishap by monitoring their activities remotely through video
as well as tracking their location indoors/outdoors and underground. The
invention also endeavors to increase worker productivity and a reduction in
equipment downtime by providing equipment specific maintenance data based
upon proximity to the equipment.
BACKGROUND OF THE INVENTION
In a manufacturing industry such as steel industry carrying out maintenance
work is fraught with hazards. The common Hazards which are encountered are
falling /tripping /slipping over obstacles, electrocution and exposure to poisonous
gases. Moving in unknown areas where moving machinery and conveyors are in
operation, may cause serious injuries or even fatalities. It is also desired to track
the work team if they are working in such hazardous locations. While doing
maintenance work to improve productivity it is desirable to provide the correct

documents and SOP (Standard Operating procedure) for the specific equipment.
The maintenance history of the equipment and location and availability of spares
and replacement schedules etc. This can improve the productivity of the
equipment and maintenance teams by reducing maintenance times. It is also
desirable to track the people working in underground cable tunnels for their
safety.
There are certain work stations in a plant, where round the clock vigilant
monitoring of the equipment is required. In case personnel leave their station for
any reason, a reliever should be present or the system should be shut down
safely, examples being conveyors and crushers in mining industry.
This invention attempts to address these problems by devising a system where in
wearable sensors are incorporated in the mandatory safety equipment worn by
the workers. The sensors on the invention can detect when the worker is
approaching a hazard or leaving a work station.
It alerts the central control also when the person has fallen, or becomes
incapacitated.
It provides live video for remote assistance and monitoring of the work by
experts. It tracks people when they are working under ground by means of

various beacons and above ground by GPS, the invention alerts the person and
the control room if the person is exposed to poisonous gases.
During maintenance work the pertinent and relevant maintenance manuals and
documentation are made available to the team when in proximity of equipment
by means of this invention.
Beacons and Tags mounted on equipment enable transmission of relevant
maintenance data to the workers enabling rapid trouble shooting and repairs.
By means of Beacons and Wireless Networks location of persons working
underground or indoors can be tracked, while movement outside can be tracked
using GPS sensors. These sensors stitched on the High Visibility jackets of the
workers. Accelerometer, Gyroscope, pulse sensors indicate to the control room if
the person has fallen or incapacitated in any way. Carbon Monoxide detectors
alert the wearer and control room of gas leakage.
A micro CCTV system enables live video transmission to a safe location from
where assistance or expert help can be provided.
This system thus provides methods and apparatus for enhancing safety and
productivity or workers in a hazardous environment.

RELATED PRIOR ARTS
Inductive fencing systems have been developed by companies for controlling live
stocks and pets. Companies such as ‘Pet Safe’ market products in which a wire
buried underground transmits a signal which is received by a receiver mounted
in a dog collar. Such receivers have an audio alarm and contacts, which generate
a high voltage low power shock to the animal.
These collars are powered by batteries while the transmitter with the buried
antenna wire is powered through the mains. One example of the method in
which a wire is installed for sending a signal is disclosed in U.S. Pat. No.
5,967,094.
More recently wireless systems which are located centrally and radiate an Omni
directional signal. These do not require the cumbersome process of burying an
antenna wire. Such systems work on the Chirp spread spectrum technology
implementation, such as disclosed in prior art US6404338. A radio method, as
another method, was devised. In this method, a transmitter that radiates radio
signals though an antenna is placed in the centre of the pet's activity area. If a
pet goes far away from the antenna, out of a predetermined range, a radio
signal is no longer received and a receiver attached to the pet generates an

electrical shock to the pet so that it may not escape from the designated area.
Such a radio method is disclosed in U.S. Pat. No. 5,381,129
Wearable sensors such as products from ‘Adafruit’ and ‘Grover’ provide low cost
wearable wireless sensors used in this system which can be stitched into clothes
using conductive wires and fabric. These low powered devices use connect to
micro controllers using the Arduino programming environment. These micro
controllers can be stacked with various devices and modules known as shields
which range from sensors to WiFi, Zigbee, Blue tooth or other communication
modules as well. These are open source systems and are available for integration
into systems such as described in this patent.
Blue tooth beacons using the “Eddystone” profile developed by Google with
vendors such as kontakt.io and “I beacon” patented by Apple provide similar
location and beacon functionality which is being used. These are used to
broadcast advertisements and store locations and special offers inside shopping
malls or location of booths in a conference with many stalls. These beacons can
deliver advertisements to the Bluetooth enabled smart phones of passer-by’s.
Other person tracking or locating technologies such as “Nanoloc” use chirp
spread spectrum in 2.4 ghz to measure distance between a transmitter to the

receiver measuring the time of flight and intensity of the radiated signals
between the transmitter and receiver.
Micro CCTV system with head tracking and First Person viewing using 5 Ghz or
2.4 Ghz band have been developed by Aero modelling companies for hobbyists
flying drones and remote control air crafts. These devices are marketed by
companies such as Boscam and Fatshark. The GoPro Company manufactures
cameras and gimbals which can be mounted on helmets and mountain bikes or
skate boards while playing adventure sports or even for water sports but do not
have a video transmission or pan tilt facility.
Helmet mounted devices and wearable sensors have been used in various
applications.
Such a wearable sensor is mentioned in the prior art US20150212057, where
wearable sensor alert the individual to hazardous gases. Helmet mounted
proximity detectors have been used for various applications. Fire fighters have
helmet which incorporate Radio Frequency Voice communication and sensors to
ensure their safety inside buildings on fire. Similar systems are available for
Military and emergency response teams, underwater scuba divers etc which
provide wireless means of audio and video communication among team
members.

Another system which requires placement of a RFID tag at hazardous locations
and a RFID reader mounted on the Helmet is described in prior art KR816555B1.
This invention requires that RFID tags be affixed to the dangerous facilities such
as water pipelines and structures at the construction site. The information of the
RFID tag is read by a RFID reader mounted on the side of the protective helmet
of the operator and the RFID reader senses this signal and provides an alert to
the operator as he approaches the unsafe regions and structures of the
construction site.
The helmet of the operator has a collision sensor, and radio frequency
identification (RFID) reader attached to a front side of the helmet to read the
RFID tag information.
A speaker generates a sound signal of different volumes based on the
information. The volume of the audio alert depends on the proximity to the
hazard. Depending on the hazard classification the alarm intensity changes. For
minor hazards such as low clearance intensity is low and for serious hazard
which may cause fatality such as electric hazards, intensity classification is high.
Another Prior Art for a similar application US3309690A wherein in combination,
helmet to be placed upon the head of a wearer having mounted thereupon a

portable multistage miniaturized detection circuit means for detecting a radiated
inductive field and giving a warning to the wearer when 'the detection circuit
means approaches closer than a variable-pre-determined distance to an
energized power line, the detection circuit means including an energizing means,
a normally closed switch means for completing the circuit, an antenna means
mounted on the helmet and connected to the circuit means for receiving. the
inductive electric field input signal, a high impedance amplification means
coupled to the antenna means to receive the input signal and to direct the input
signal to a gain control stage having manually adjustable means for setting a
pre-determined signal level, audio-amplification to raise the input signal to a pre-
determined voltage value, rectifying means connected to the output of the audio
amplification means to convert the input signal voltage to a D.C. signal voltage,
switching means coupled to the rectifying means and operative in response to a
pre-determined voltage value therefrom, an oscillating means controlled by the
switching means adapted to operate at such times as a pre-determined voltage
value is received by the switching means from the rectifying means, audible
signal means mounted on the helmet and connected to the oscillating means so
as to transmit an audible signal to the wearer responsive to the setting of the
gain control adjustable means.

The operator will normally move to the vicinity of the power lines with which he
will work and then adjust the gain control by manipulating the serrated knob 14
so as to calibrate the circuit to operate at a distance from the power line the
operator feels to be safe. Each time the operator approaches a new area, he
moves his own adjustment of the safety detector, making this instrument very
versatile in its operation.
In prior art CN201700461U it is described that when the operator is in the
vicinity of energized lines or appliances, the sensing electrode senses the
charged field, the field input to the electronic trigger circuit, electronic trigger
circuit will be triggered, the voice module will output an alarm voice.
The utility program uses new technologies: it includes helmet cap, characterized
in that the cap is installed in the helmet sensing electrode, electronic trigger
circuit, voice alarm circuit, speaker, power amplifier, power switch, Rechargeable
batteries and charging socket; their connection relationship is: sensing electrode
connected to the electronic trigger circuit input terminal, an electronic trigger
circuit output sequentially connected voice alarm circuit, amplifier circuit and
speaker

The working principle is: When the operator is in the vicinity of energized lines or
appliances, the sensing electrode senses the charged field, the field input to the
electronic trigger circuit, electronic trigger circuit will be triggered, the voice
module will output an alarm voice.
All the prior art discussed here do not address the need of a holistic system
which monitors the health of the person, makes him aware of the hazard of his
workplace, provides remote technical assistance during maintenance, and alerts
emergency teams when person is incapacitated in any way for quick rescue.
These conventional prior arts do not make use of combining video technology
and methods of generating beacons to track the movement of the persons
underground.
The conventional prior art using RFID presupposes the placement of RFID tags
at various locations. The RFID tags have limited battery life and needs to be
replaced. The RFID tags have to be collected and reused after work is finished at
any site. This invention has a collision sensor which will generate false positive
alarm when a person is approached by another person or walks towards a large
body even in safe conditions.

The Audio alarm in such prior will not be audible in noisy industrial environment.
False positive signals will irritate the wearer. No provision of transmission of
health data and alerts to a central station is available in such conventional
systems. No mechanism of switching off the circuitry when helmet is removed is
envisaged and alerting the control station when helmet is removed does not
exist.
In other conventional Helmet mounted systems relying on Inductive and Radio
Frequency detection to the alert the wearer of proximity to electric hazard, does
not have means for differentiating Hazardous and deemed non-hazardous power
lines. Such as power line for operating a power tool will also set off the alarm as
will proximity to high voltage power lines.
Such systems again do not have mechanisms or conceived application to cordon
“IN” or confine a person to their workstation in Hazardous area. No means of
sending alert to a central control room when a person approaches a hazard or
when a work station is left unmanned.
These conventional Helmet mounted systems do not conceive of an integrated
system which enables, a combination of health, safety, person tracking, and
improvement in productivity and maintenance.

Alarms envisaged in these conventional inventions are audio/voice based. These
do not take into account that at several industrial processes the ambient noises
are exceeding 100 decibels and ear plugs are mandatorily worn at these
locations. Audio alarm of any intensity will remain unheeded in such situations.
These inventions have not conceived of a Piezo electric buzzer or vibrator which
will vibrate with escalating urgency along with an audible feedback to work in
noisy and noiseless ambient.
SUMMARY OF THE INVENTION AND OBJECTS
In view of the foregoing, one object of the present invention is to implement a
positive isolation system whereby hazardous areas are demarcated with a buried
conductor or a conductor used in a rope or inserted in a cordon, which acts as an
antenna. The buzzer vibrates to alerts the wearer of the receiver when it nears
this cordon. This antenna may also be a centrally located Omni directional
radiator without requiring a need for burying a conducting cable.
Another objective is this invention is to provide variable lengths of cordoned area
possible by enabling transmission of a proportional frequency through the
tunable Signal generator depending on cordon length which is the antenna,
(antenna length being a function of frequency) and thereby reception of several

frequencies by the receiver simultaneously through mechanisms of filters and
associated circuitry.
A further objective of this invention is to generate alarm for the worker, only
from those area/power lines considered as hazardous. Power lines of power tools
being used by the worker or deemed non-hazardous should not activate the
alerting circuitry and create false positive alerts.
Another object of the present invention is to provide live video transmission to an
expert located at a safe distance. The expert can remotely control the pan tilt of
the camera and can have an immersive viewing experience by using immersive
viewing goggles. This live video can also be seen on a video monitor and
recorded.
Yet another object of this invention is to utilize solar power to charge the
batteries used for powering the sensors and devices.
Another objective of this invention is to implement a mechanism which turns of
the battery circuit when the helmet is removed to conserve power.
Still another objective of the present invention is to provide alerts to the wearer
and a control station if the wearer falls, is incapacitated or is exposed to
poisonous carbon monoxide gases using WiFi network.

Still another objective of the present invention is to provide the location of the
wearer to the control station using GPS sensor when outdoors or a beacon based
location while working indoors or in a tunnel. This location is transmitted to a
control station over WiFi or Cellular network or other means and the location is
indicated on a Map.
Another objective of this invention is to also indicate when the wearer has left
the designated post or work area without authorization.
A further objective of this invention is to provide relevant maintenance manuals
of equipment including its schematics, maintenance history and spares
availability to the worker. This is accomplished by using near field tags or
beacons and the WiFi network to transmit the data on the workers smart phone.
In accordance with these and other objects, the present invention is directed to
a System consisting of methods and apparatus for enhancing safety of an
industrial worker and providing assistance by monitoring the workers
environment over video and through the sensors worn by the worker. The
system also envisaged to increase the workers’ productivity by providing relevant
technical assistance and expertise for specific equipment using proximity sensing
technology over a Wireless Data network.

These together with other objects and advantages which will become
subsequently apparent reside in the details of construction and operation as
more fully hereinafter described and claimed, reference being had to the
accompanying drawings forming a part hereof, wherein like numerals refer to
like parts throughout.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.1 - Shows a Schematic of a Safety Helmet with Wearable Sensors and
battery pack to power these devices.
Fig.2 - is the Schematic of a High Visibility Jacket with Wearable Sensors,
micro controller and battery pack
Fig.3 - Schematic of an indoor Location Tracking system and proximity
based maintenance system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE
INVENTION
In describing a preferred embodiment of the invention illustrated in the
drawings, specific terminology will be resorted to for the sake of clarity.

However, the invention is not intended to be limited to the specific terms so
selected, and it is to be understood that each specific term includes all technical
equivalents which operate in a similar manner to accomplish a similar purpose.
According to the present invention generally designated by reference numerals 1
to 32 in figures 1 to 3, a safety helmet is generally embodied by reference
numeral 14 in Schematic designated as Figure 1.
The Helmet incorporates a battery pack 11 which has a USB charging port 11, an
on off switch 8 a battery indicator 9 and charging port 10.This battery pack
contains a suitable Lithium polymer battery which powers the other devices a
micro cctv camera 13 with pan tilt features and a proximity sensor/receiver 6.
This battery pack 11 is so designed that it can be installed and removed easily
for replacement.
The devices 6 and 13 are connected with wires which run flush with the band
across the helmet periphery. The battery pack also has an USB port 12 to charge
smart phones if required.
The cctv camera 13 is connected to a clover leaf antenna which is used to
transmit and receive video and data respectively from an Immersive viewing
goggles 4 and a LCD monitor with Diversity antenna 15, over a 5ghz frequency
band free for use in industrial, scientific and military applications.

The video monitors can be powered by mains power or batteries. The range of
this system is typically 300 meters in line of sight outdoors or about 50-75
meters indoors.
A signal generator 2 generating a variable frequency is connected to one free
core of a multi core power cable1 which acts as the antenna for this illustration.
In industrial applications multi core power cables are available with 2 cores for
carrying power while the third core 3 is used for grounding and also a central
metal cable is available to provide mechanical strength to these cables.
Alternatively a single strand conducting cable such as made of copper can be
used as the transmitting antenna 3 or the said signal generator2 can be
connected to a transmitting antenna 3 which transmits the frequency radially
from a central location.
The signal generator 2 can be battery operated or connected to the mains
power. The receiver 6 denoted as an inductive proximity sensor mounted on the
said helmet 14 receives this transmitted frequency when it nears the radiating
antenna 3 which earmarks the boundary or fence of the hazard area. An
amplifier circuit embodied in the receiver 6 and induction coil amplify the signal
as the fence is neared. Depending upon the proximity of the receiver 6 an
escalating level of vibration and buzzer intensity can be provided to the wearer.

The micro cctv camera 13 can be controlled independently by the remote
operator and can be panned 180 from left to right and tilted from 30 to 150
degrees through a remote control or movement of the head of the person
wearing the immersive goggles 4.
The chin strap of the helmet14 incorporates pressure sensor which can detect if
the helmet if removed from the persons head and turn off the system to
conserve power, while sending an alert message to control room.
As summarized in figure 2 a high visibility jacked enumerated with numeral 22
has incorporated within several wearable sensors. These sensors known as
shields are stitched using conducting thread and cloth. The sensors such as
Accelerometer, CO gas detector, Gyroscope, pulse monitor etc. enumerated as
numeral 19 are connected to the input ports of a micro controller 21 such as
made by companies like Adafruit or Linkit using arm chipset and Arduino
programming environment. This micro controller 21 is enabled with a WiFi/GSM
module which is used to transmit the sensor data to the control station. A GPS
sensor 20 is also incorporated in the jacket and connected to the micro controller
21. These devices are powered by a battery pack enumerated as numeral 23.
This battery pack is embodies a trickle charger and is connected with a solar
panel 18 stitched into the said jacket 22.

The micro controller 21 is programmed with control software which monitors the
threshold level readings from the sensors 19 and 20. The GPS sensor 20
transmits its data to the micro controller 21 input ports which in turns transmits
it using inherent WiFi or Cellular network to the Nearest WiFi Access point 24
connected to the LAN 17. The control system is centrally located on the LAN 17
and proprietary software denotes the sensor status, location data received from
each person wearing the Invention.
The micro controller 21 also monitors the data from the sensors 19 and when a
threshold value is exceeded, it alerts the wearer by an alarm embodied in the
micro controller 21 and transmits this data using WiFi access point 24 to the LAN
17 and displayed at the central computer 16.
As shown in figure 3 when the worker is moving indoors in a cable tunnel or
confined space, Blue tooth beacons enumerated as 25 in fig.3 will be used to
track the persons location. The beacon 25 based on the Eddystone profile
developed by Google Inc. are devices which can detect blue tooth low energy
beacons and transmit the same over a WiFi network 27 or transmit a beacon
with parameters such as location id, signal and health of the device and other
messages. A person can be tracked in such locations by either carrying a beacon
25 which is detected and transmitted over WiFi network 27 to the central station

29 and displayed on the map of the location 28 or by carrying a smart phone
enumerated as numeral 32 which can receive these beacons 25. These beacons
25 can be received by the blue tooth enabled smart phone 32 and use the
smartphones 32 WiFi to transmit location data to central station 29.
Also as indicated in the figure 3 the beacon 25 when located near any equipment
can enable the smart phone 32 to connect to the WiFi network 27 and connect
to the central computer 29.From the central computer 29, and other repositories
on the company LAN 30 the maintenance data specific to the aforesaid
equipment can be transmitted to the smartphone over WiFi Network 27. This
data can enable the worker to service the equipment correctly and efficiently.
The foregoing descriptions and drawings should be considered as illustrative only
of the principles of the invention. The invention may be configured in a variety of
ways and is not limited by the dimensions of the preferred embodiment.
Numerous applications of the present invention will readily occur to those skilled
in the art. Therefore, it is not desired to limit the invention to the specific
examples disclosed or the exact construction and operation shown and
described. Rather, all suitable modifications and equivalents may be resorted to,
falling within the scope of the invention.

WE CLAIM
1) A system of safety package comprising,
safety helmet with wearable sensors, battery pack;
high visibility jacket with wearable sensors, micro controller, battery pack;
indoor location tracking system;
2) a) A safety helmet as claimed in claim 1, wherein a cctv camera mounted on
the base of the helmet, characterized by servo motors enabling pan-tilt
capability of the said camera
b) A proximity sensor receiver transmitting video images to remote location,
wherein, sensor receiver is connected with the cctv camera with wires which
run flush with the band across the helmet periphery.
c) A clover leaf antenna on the helmet connected to cctv camera to transmit
and receive video images and data
d) Immersive viewing goggles with head tracking circuitry or hand held
monitor with video recording capability
e) LCD monitor with diversity antenna over high frequency band
f) Signal generator generating signal to connect to free core of multi core
power cable

g) Piezo electric buzzer alarm on the helmet to detect the radiated signal
characterized by varied intensity of the vibration and sound of the buzzer
h) Pressure sensor on the chin strap of the helmet to detect whether the
helmet is removed from head and switching off to conserve power.
i) Battery pack with USB charging port, on-off switch, indicator to provide
power to the system and accessories
3) a) A high visibility jacket as claimed in claim 1, wherein, sensors such as
accelerometer, CO gas detector, Gyroscope, pulse monitor which are stitched
using conducting thread and cloth in the jacket
b) A micro controller enabled with WiFi/GSM module, connected to the
sensors through input ports to transmit sensor data to control station
c) A GPS sensor to transmit data to the micro controller
d) A battery pack to provide power to the system through trickle charging
e) Solar panel connected to the trickle charger for recharging
f) Wi Fi cellular network to the nearest Wi Fi access point connected to the
LAN
g) Central computer monitor to display the status and threshold level
readings

4) a) A blue tooth beacon tracking the location of the person by detecting low
energy and transmitting the same over a WiFi network or transmitting a
beacon with parameters, i.e location id, signal, health of the device, other
messages to the central station.
b) A blue tooth enabled smart phone to receive the beacons and using wi fi
network and transmitting location data at the central station
5) A positive isolation or cordoning system preventing a person approaching
electrical or structural hazard , alerting a remote control room while person
leaves or enters a designated area of work, wherein, a receiver tuned to
detect a RF frequency in a conductor used for fencing a hazardous area.
6) The said battery as claimed in claim 1, housed in a fireproof and waterproof
housing to protect the wearer and the system