Monitoring Tool Usage

Abstract

Methods and systems for monitoring tool device usage and, in particular, methods and systems including at least one sensor mechanism configured to detect at least one operational parameter of the tool device. Information regarding usage of the tool device may be communicated to a processing unit and further communicated to a network-connected storage and/or to a display device.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of co-pending U.S. provisional application No. 62/149,496, filed on Apr. 17, 2015, the entire disclosure of which is incorporated by reference as if set forth in its entirety herein.

FIELD

[0002] This disclosure relates to methods and systems for monitoring usage of a tool device and, in particular, methods and systems including at least one sensor mechanism operably connected to a tool device to detect at least one operational parameter of the tool device.

BACKGROUND

[0003] Modern factories and other types of manufacturing facilities are increasingly connected with automated technologies. Although certain steps of manufacturing processes are automated, human operators are nonetheless still involved. For example, it is often impractical for robotic systems or machines to perform every step of a manufacturing process, and it may be more effective for a human operator to perform a certain step. These human operators may rely on various tool devices to perform the step(s).

[0004] It may therefore be desirable to monitor tool device usage. Information regarding tool device usage may be helpful to, for example, ensure that users are being productive and/or consistently following a standard set of work instructions, ensure that users are using the tool device in a safe manner, ensure that the tool devices are functioning properly, to recognize when a tool device needs replacement (e.g., due to a malfunction or a low power level), and to provide other forms of preventive maintenance.

[0005] However, current precision tools with feedback loops are expensive and complicated to use. These existing tools may require training to use and may rely on complex processing steps that are difficult to implement.

[0006] Simpler sensing mechanisms that are decoupled from tool device exist, but do not provide much information regarding tool device usage. For example, simple torque meters are available, but they only provide single, non-continuous readings. In other words, they do not provide a feedback loop and only provide information regarding torque at a single point in time. These existing sensor mechanisms are not modular and are typically not able to be used across multiple types of tool devices.

[0007] A need exists, therefore, for methods and systems for monitoring tool device usage that overcome these disadvantages.

SUMMARY

[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0009] In one aspect, embodiments of the present invention relate to a system for monitoring tool usage, the system including at least one sensor mechanism operably and externally connected to a tool device such that the at least one sensor mechanism is able to detect at least one operational parameter of the tool device in substantially real time; a network-connected storage for storing information regarding the operational parameter of the tool device detected by the at least one sensor mechanism; and a communication mechanism configured to communicate information regarding the operational parameter of the tool device detected by the at least one sensor mechanism to the network-connected storage.

[0010] In one embodiment, the at least one operational parameter includes movement of the tool device, and the at least one sensor mechanism is selected from the group consisting of an accelerometer, magnetometer, photodetector and a gyroscope to measure the movement of the tool device.

[0011] In one embodiment, the at least one operational parameter includes power consumption of the tool device and the at least one sensor mechanism is a power meter mechanism.

[0012] In one embodiment, the at least one operational parameter includes electrical signals communicated from the tool device.

[0013] In one embodiment, the system further comprises a processing unit configured to determine a state of the tool device based on the information regarding the at least one operational parameter of the tool device. In one embodiment, the state of the tool device is a function of at least one of orientation of the tool device, location of the tool device, temperature of the tool device, power level of the tool device, and operation of the tool device. In one embodiment, the system further comprises a control unit configured to prevent use of the tool device upon the processing unit determining the tool device is in a certain state.

[0014] In one embodiment, the at least one sensor mechanism is configured as a deformable and extendable substrate to be removably connected to different types of tool devices.

[0015] In one embodiment, the tool device is selected from the group consisting of a machine, an actuator, a hand tool, and a power tool.

[0016] In another aspect, embodiments of the invention relate to a method for monitoring tool usage. The method includes operably connecting at least one sensor mechanism to a tool device; detecting, via the at least one sensor mechanism and in substantially real time, at least one operational parameter of the tool device; and communicating, via a communication mechanism, information regarding the at least one operational parameter of the tool device to a network-connected storage.

[0017] In one embodiment, the at least one operational parameter includes movement of the tool device, and the at least one sensor mechanism is selected from the group consisting of an accelerometer, magnetometer, photodetector and a gyroscope to measure the movement of the tool device.

[0018] In one embodiment, the at least one operational parameter includes power consumption of the tool device and the at least one sensor mechanism is a power meter mechanism.

[0019] In one embodiment, the at least one operational parameter includes electrical signals communicated from the tool device.

[0020] In one embodiment, the method further comprises the step of determining, via a processing unit, a state of the tool device based on the information regarding the at least one operational parameter of the tool device. In one embodiment, the state of the tool device is a function of at least one of orientation of the tool device, location of the tool device, temperature of the tool device, power level of the tool device, and operation of the tool device. In one embodiment, the method further comprises the step of changing a parameter of the tool device upon the processing unit determining the tool device is in a certain state. This may involve, e.g., preventing, via a control unit, use of the tool device.

[0021] In one embodiment, the at least one sensor mechanism is configured as a deformable and extendable substrate to be removably connected to different types of tool devices.

[0022] In one embodiment, the tool device is selected from the group consisting of a machine, an actuator, a hand tool, and a power tool.

[0023] In yet another aspect, embodiments of the present invention relate to a sensor mechanism for monitoring usage of a tool device. The sensor mechanism is configured as a deformable and extendable substrate to be removably connected to different types of tool devices, the sensor mechanism further configured to detect at least one operational parameter of a tool device and to communicate information regarding the at least one operational parameter of the tool device to a network-connected storage.

[0024] These and other features and advantages, which characterize the present non-limiting embodiments, will be apparent from a reading of the following detailed description and a review of the associated drawings. It is to be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of the non-limiting embodiments as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Various embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:

[0026] FIG. 1 illustrates a system for monitoring tool device usage in accordance with one embodiment;

[0027] FIG. 2 illustrates a system for monitoring tool device usage in accordance with another embodiment;

[0028] FIG. 3 illustrates a system for monitoring tool device usage in accordance with yet another embodiment;

[0029] FIG. 4 illustrates multiple views of a sensor mechanism in accordance with one embodiment;

[0030] FIG. 5 illustrates a sensor mechanism in accordance with another embodiment;

[0031] FIG. 6 illustrates a sensor mechanism operably connected to a drill press in accordance with one embodiment;

[0032] FIG. 7 depicts a flowchart of a method of monitoring tool device usage in accordance with one embodiment;

[0033] FIG. 8 depicts a flowchart of a method of monitoring tool device usage in accordance with another embodiment; and

[0034] FIG. 9 depicts a flowchart of a method of monitoring tool device usage in accordance with yet another embodiment.

[0035] In the drawings, like reference characters generally refer to corresponding parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed on the principles and concepts of operation.

DETAILED DESCRIPTION

[0036] Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, the concepts of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure, to fully convey the scope of the concepts, techniques and implementations of the present disclosure to those skilled in the art. Embodiments may be practiced as methods, systems or devices. Accordingly, embodiments may take the form of a hardware implementation, an entirely software implementation or an implementation combining software and hardware aspects. The following detailed description is, therefore, not to be taken in a limiting sense.

[0037] Reference in the specification to "one embodiment" or to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one example implementation or technique in accordance with the present disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.

[0038] Some portions of the description that follow are presented in terms of symbolic representations of operations on non-transient signals stored within a computer memory. These descriptions and representations are used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. Such operations typically require physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical, magnetic or optical signals capable of being stored, transferred, combined, compared and otherwise manipulated. It is convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. Furthermore, it is also convenient at times, to refer to certain arrangements of steps requiring physical manipulations of physical quantities as modules or code devices, without loss of generality.

[0039] However, all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as "processing" or "computing" or "calculating" or "determining" or "displaying" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system memories or registers or other such information storage, transmission or display devices. Portions of the present disclosure include processes and instructions that may be embodied in software, firmware or hardware, and when embodied in software, may be downloaded to reside on and be operated from different platforms used by a variety of operating systems.

[0040] The present disclosure also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, application specific integrated circuits (ASICs), or any type of media suitable for storing electronic instructions, and each may be coupled to a computer system bus. Furthermore, the computers referred to in the specification may include a single processor or may be architectures employing multiple processor designs for increased computing capability.

[0041] The processes and displays presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may also be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus to perform one or more method steps. The structure for a variety of these systems is discussed in the description below. In addition, any particular programming language that is sufficient for achieving the techniques and implementations of the present disclosure may be used. A variety of programming languages may be used to implement the present disclosure as discussed herein.

[0042] In addition, the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the disclosed subject matter. Accordingly, the present disclosure is intended to be illustrative, and not limiting, of the scope of the concepts discussed herein.

[0043] Features of the present invention relate generally to a sensor mechanism configured to operably connect with a plurality tool devices to gather information regarding at least one operational parameter of the tool device. Features of the present invention also relate to methods and systems for monitoring usage of the tool device.

[0044] In various embodiments, the sensor mechanism may be elastic and extendable to change shape and size to connect to a variety of different types of tool devices and to different portions of said tool devices. In these embodiments, the sensor mechanism may act as a "wearable" sensor device for a particular tool device and may gather information regarding the tool device's usage in real time.

[0045] In the context of the present application, the term "tool device" may refer to any type of machine (e.g., used in manufacturing processes), power tool, hand tool, tool actuator, or the like.

[0046] In the context of the present application, the term "tool topology" may refer to characteristics of a tool device such as how it is grasped by users, how it is used, how it is actuated, how it is powered, how safety is provided, how the tool device interacts with a workpiece, etc. This discussion is not limited to a single type of tool. Topology may be relevant for single-hand tools, two-hand tools, spindles (rotary tools), triggered devices, or the like.

[0047] In the context of the present application, the term "operational parameter" may refer to how the tool device is operated. Operational parameters may refer to whether the tool device is on/off, whether the tool device is active, how long the tool device has been used, the orientation of the tool device, how the tool device is held by a user, the location of the tool device, the power level of the tool device, the power consumption of the tool device, the movement of the tool device, or physics of the tool device (e.g., displacement, velocity, acceleration, illuminance or irradiance (or other information regarding incident light on a surface), etc.). This list is non-exhaustive and it is contemplated that other types of operational parameters may be detected without departing from the scope of the invention.

[0048] In the context of the present application, the term "state" of the tool device may refer to a characteristic or mode of the tool device that is dependent on at least one operational parameter of the tool device. For example, if an operational parameter of a tool device is rotations per minute (RPM), and the RPM is above a certain level, the state of the tool device may be "active" or "in use." As another example, if the detected operational parameter indicates that the tool device is upside down or otherwise oriented in an unsafe orientation, the state may be "unsafe for use." As yet another example, if the detected operational parameter indicates a power level that is below a certain level, the state may be "in need of charging or battery replacement." The tool device state may also provide manufacturing process context when combined with work instructions. For example, a state could report events such as "tool picked up by operator at a certain work step."

[0049] Features of the present invention therefore enable feedback regarding tool device usage, along with user action, in real time and in a non-invasive manner. It may be desirable to have this type of information to, for example, ensure users are being productive, ensure users are following a standard set of work instructions, ensure users are using the tool device in a safe manner, ensure the tool devices are functioning properly, and to recognize when a tool device may need replacement (e.g., due to low power level). This type of feedback may be made available to Manufacturing Execution Systems (MESs), human-machine interfaces (HMIs), and/or other interfaces used to in turn guide an operator to perform a certain step in the manufacturing process.

[0050] Although the features of the invention are described as being implemented in manufacturing facilities such as factories, it is contemplated that the features of the invention may be used in other applications. Applications such as those in farming, medicine, and construction, for example, may benefit from the features of the invention.

[0051] FIG. 1 illustrates components of a system 100 for non-invasively monitoring tool device usage in accordance with one embodiment. In this particular embodiment, an operator (user) 102 may operate an actuator 104 to actuate a tool device (e.g., a machine) 106. When the tool device 106 is actuated, power is drawn and measured by the power meter 108. Specifically, when the tool device 106 is actuated, current flows in a loop from the power source and returned during operation of the tool device 106. This current draw can fluctuate depending on the operation of the tool device 106. Additionally, voltage (in conjunction with the DC and AC components can be used to calculate power (W) and other similar calculations such as, but limited to, RMS power, peak power, or the like. Further, by measuring the AC and digitizing this signal via an analog-to-digital converter, digital techniques, such as moving from the time-domain to frequency domain, are possible. The power meter 108 may report the power draw to the cell 110. The cell 110 serves as a gateway device that connects existing and new hardware (i.e., tool devices 106) to the network-connected storage 114. The cell 110 collects information from the factory floor (such as power drawn by the tool device) and communicates that information to the network-connected (e.g., cloud-based) storage 114. The cell 110 may also include processing components to determine the state of the tool device 106 based on the measured operational parameters.

[0052] This information is further communicated, via an i/net connection 112 (i.e., a local area network connection, wireless connection, internet connection, etc.) to a network-connected storage 114 and/or may be presented on display device 116.

[0053] In this embodiment, the operator (user) 102 may be located a manufacturing facility such as a factory or the like. The actuator 104 may be any type of device operably connected to any type of tool device 106 to control operation of the tool device 106.

[0054] In this embodiment, tool device 106 usage is monitored based on the measurement of the power drawn by the tool device 106. Information regarding the power drawn may be communicated to the cell 110.

[0055] The cell 110 can connect to existing factory-floor equipment in a variety of ways. For example, the cell 110 can connect using an existing industrial network protocol such as MTConnect, OPC-UA, Modbus, CAN bus, and others. The cell 110 can also connect to standard peripheral devices such as RFID readers and/or barcode scanners that have standard operating-systems such as HID implemented thereon. In addition to these methods, the cell 110 can also be implemented as a simpler interface by, for example, detecting the voltage level or switching to a binary output. This is an example of a parallel input via field-conditioned inputs and outputs (and a non-serialized data input or output stream).

[0056] The cell 110 may communicate information regarding the tool device usage, via an i/net connection 112 to the network-connected storage 114. Information regarding usage of the tool device 106 may also be communicated to and presented on a display device 116. The display device 116 may be configured as a PC, laptop, tablet, smartphone, smartwatch, or the like, and may allow a viewer to view information regarding tool device 106 in substantially real time. Information may be communicated to (and from) the display device 116 via any type of hardwired or wireless connection, e.g., Ethernet, 802.11x, Bluetooth, etc.

[0057] FIG. 2 presents another embodiment of a system 200 for monitoring tool device usage. Similar to the system 100 of FIG. 1, an operator 202 may operate an actuator 204 to control a tool device 206. In this embodiment, however, a cell 208 provides a bypass 214 to the actuator 204 by virtue of the actuator's connection to a tool device controller 210. The cell 208 may read the actuator's communications with the tool device controller 210 to obtain information regarding usage of the tool device 206.

[0058] Communication link 212 represents an original communication path between the actuator 204 and the tool device controller 210. The system 200, however, replaces this path with a bypass 214 that allows the system 200 to intercept information transmitted between the actuator 204 and the tool device controller 210 using the cell 208. Thus, data concerning the usage of the tool device 206 becomes available to the cell 208 in the context of a specific step in a particular manufacturing process.

[0059] In this embodiment, the cell monitors an existing tool device by connecting to the tool device's 206 output lines (e.g., those used to actuate relays, valves, etc.), communication lines (such as, e.g., RS-232 serial communication lines), or by monitoring power consumption by the tool device 206 and/or its components.

[0060] As in the system 100 of FIG. 1, information regarding usage of the tool device 206 may be communicated via an i/net connection 216 to a network-connected storage 218 and also communicated to and presented on a display device 220. The display device 220 may be configured as a PC, laptop, tablet, smartphone, smartwatch, or the like, and may allow a viewer to view information regarding tool device 206 in substantially real time.

[0061] FIG. 3 presents a system 300 for monitoring tool device usage in accordance with another embodiment. Similar to FIGS. 1 and 2, an operator 302 may actuate an actuator 304 to operate a tool device 306 (illustrated as a power drill). In this embodiment, the tool device 306 may include a tool latching mechanism 308 to attach at least one sensor 310 (discussed below) to the tool device 306. The at least one sensor 310 may non-invasively monitor the movement(s) and operation of the tool device 306 so that the state of the tool device 306 may be determined.

[0062] The tool device 306 may include or otherwise be in communication with a tool sensor controller 312, which in turn may be in communication with a battery 314 to monitor power levels of the tool device 306, a wireless radio interface 316 to wirelessly communicate information regarding the tool device 306, and at least one sensor device 310. The at least one sensor device 310 may be, for example, an accelerometer 320, a gyroscope 322, a magnetometer 324, and/or a photodetector 326. The type of sensor device(s) used may vary and may depend on the type of tool device along with the operational parameter(s) to be measured.

[0063] The components of the system 300 may be in communication with the cell 328 via any hardwired or wireless connection. Communications regarding tool device 306 usage and other information may be communicated from the wireless radio interface 316 to the cell 328, for example. As in the embodiments of FIGS. 1 and 2, the cell 328 may process the obtained information to determine the state of the tool device. This information may be further communicated via an i/net communication 330 to a network-connected storage 332. This information may also be communicated to and presented on a display device 334.

[0064] FIGS. 4A-C illustrate multiple views of an attachable sensor mechanism 400 in accordance with one embodiment. The term "attachable" simply refers to the sensor mechanism's ability to directly connect to or otherwise interface with a tool device, such as in the embodiment illustrated in FIG. 3, and without adversely affecting the tool device's ability to function.

[0065] The sensor mechanism 400 may include an elastic portion 402 with all necessary electronics and circuitry printed or otherwise included thereon. The elastic portion 402 may further include a connection mechanism like buckles 404a and 404b with pins 406, or be attached to a tool device via an adhesive.

[0066] The sensor mechanism 400 may include a housing portion 408 that includes components such as a battery 410, transceiver 412, vibration sensor 414, gyroscope 416, acceleration sensor 418, and GPS sensor 420. These types of components are merely exemplary and it is contemplated that other types of components may be configured as part of the sensor mechanism 400 depending on the application (e.g., depending on the type of tool device, the operational parameter being measured, etc.).

[0067] Regardless of the exact configuration of the sensor mechanism 400, it is contemplated that the sensor mechanism 400 is length-adjustable and configurable so it can connect to different types of tool devices and at different locations on said tool devices, depending on the topology of the tool device. FIG. 4B shows the sensor mechanism 400 extending in length (indicated by arrows) by virtue of the elastic portion 402. The elastic portion 402 may extend under tensile stress (e.g., as a user pulls on the ends of the sensor mechanism 400), and then return to its original shape and size when the stress is removed.

[0068] FIG. 4C illustrates the sensor mechanism 400 in a closed position. The buckles 404a and 404b may connect with each other via pins 406 or another connection mechanism so that the sensor mechanism 400 can securely attach to or otherwise connect with a tool device (not shown in FIG. 4C).

[0069] Additionally or alternatively, the length of the sensor mechanism may be adjusted via a spool and spring configuration; or a configuration of straps and ratchets that enable the strap to be pulled to a certain length and then locked at a certain length, or any of a variety of mechanism for adjusting length known to one of ordinary skill.

[0070] FIG. 5, for example, illustrates a sensor mechanism 500 in accordance with another embodiment of the invention. The sensor mechanism 500 may be similar to the sensor mechanism 400 of FIG. 4 in that it may include a housing 502 with various sensor devices. However, in this embodiment, the sensor mechanism 500 may include straps 504 (e.g., made of leather or neoprene foam) extendable by a buckle 506. Also in this embodiment, the sensor mechanism 500 may be secured around a tool device via connection mechanisms 508a and 508b.

[0071] FIG. 6 illustrates a sensor mechanism attached to a tool device in accordance with one embodiment of the invention. FIG. 6 illustrates a drill press machine 600 with a sensor mechanism 602 such as the one illustrated in FIG. 4 or 5 attached. In this particular embodiment, the sensor mechanism 602 is secured to a spindle portion 604 of the drill press 600. The sensor mechanism 602 may therefore be configured to detect the RPM of the spindle 604 during operation of the drill press 600 and/or detect when the spindle portion 604 is lowered/raised during operation of the drill press 600.

[0072] FIG. 7 depicts a flowchart of a method 700 of monitoring tool device usage in accordance with one embodiment. Step 702 involves operably connecting at least one sensor mechanism to a tool device. The sensor mechanism may be operably connected to a tool device by any of the techniques previously described or other analogous techniques apparent to one of ordinary skill.

[0073] If the sensor mechanism is going to be attached to the tool device (as in FIG. 6), the sensor mechanism may be operably connected to the tool device in a variety of ways based on the topology of the tool device. For example, the sensor mechanism may be connected to a spindle of the tool device (as in FIG. 6) or a trigger of the tool device. The sensor mechanism may also be connected to a handle of the tool device to, for example, ensure the operator is using the tool device with two hands. In these embodiments, the sensor mechanism may be configured as an elastic and adjustable article to change shape and size to be able to connect to a variety of tool devices.

[0074] Step 704 involves detecting, via the at least one sensor mechanism and in substantially real time, at least one operational parameter of the tool device. The terms "in substantially real time" may mean in real time or with some minimal delay that does not significantly diminish the value of the obtained information regarding the operational parameter of the tool device.

[0075] The operational parameter detected may depend on the type of tool device, the type of sensor mechanism, and the location of the sensor mechanism on the tool device. For example, if the tool device is a power drill such as the one of FIG. 3, there may be at least one piezoelectric element located at various positions on the power drill. These piezoelectric elements may detect, for example, pressure applied by the operator's hands when holding and operating the tool device. This information may be used to determine whether the operator is holding the tool device in the correct location(s) and/or holding the tool device with two hands.

[0076] Similarly, a tool device such as a power drill may be equipped with gyroscope devices. These gyroscopes may detect whether an operator is using the tool device in the correct orientation (i.e., holding it correctly), for example. Or, these gyroscope devices may simply detect whether the tool device is being used and/or how long it has been used.

[0077] As another example, the sensor mechanism may be operably connected to, for example, the trigger, spindle, and/or a bit device to detect, e.g., the RPM of a moving part. If the sensor mechanism is attached to a spindle, it may include a gyroscope and/or an accelerometer. This information may be used to determine whether the operator is actually using the power drill, for example.

[0078] Step 706 involves communicating, via a communication mechanism, information regarding the at least one operational parameter of the tool device to a network-connected storage. This information may be communicated wirelessly, for example. Information regarding the tool device usage may be stored for later analysis, and/or may be displayed on a display device. Therefore, an operator or other interested party (such as an operator's supervisor) may monitor usage of the tool device in substantially real time.

[0079] FIG. 8 depicts a flowchart of a method 800 of monitoring tool device usage in accordance with another embodiment. Steps 802, 804, and 806 are similar to steps 702, 704, and 706, respectively, of FIG. 7 and are not repeated here.

[0080] Step 808 involves, determining, via a processing unit, a state of the tool device based on the information regarding the at least one operational parameter of the tool device. The state of the tool device may depend on the type of tool device, the type of sensor mechanism, and the location of the sensor mechanism on the tool device.

[0081] As mentioned previously, the "state" as it relates to a tool device, may refer to whether the tool device is: on or off; operating above or within safe speed range; short circuiting; operating at or above a safe power level; being held correctly, etc. The tool device state may be determined by a processing unit and is based on the at least one operational parameter of the tool device.

[0082] The processing unit (e.g., the cells 110, 208, and 328 of FIGS. 1, 2, and 3, respectively) may be any specifically configured processor or hardware device capable of analyzing the operational parameter(s) to determine the state of the tool device. The processing unit may include a microprocessor, a field programmable gate array (FPGA), application-specific integrated circuit (ASIC), or other similar device. In some embodiments, such as those relying on one or more ASICs, the functionality described as being provided in part via software may instead be configured into the design of the ASICs, and as such, any associated software may be reduced or omitted.

[0083] The processing unit may, for example, analyze information obtained by piezoelectric elements positioned on a power drill (if applicable). In this embodiment, the "state" of the tool device may be whether the tool device is being held by the user correctly or incorrectly. Any class of transducers that convert mechanical signals into electrical signals may be used as they are computationally simple and power-efficient. For example, these types of transducers can be used to "wake" any applicable processing devices and/or connect any applicable sensor devices, thereby lengthening battery life, among other features.

[0084] Information regarding the state of the tool device may be communicated to storage and/or communicated to a display device. Information regarding the state of the tool device may be presented on the display device in variety of ways. For example, if the tool device is in a potentially dangerous state (e.g., overheating, being held incorrectly), the display device may communicate a message to that effect in a variety of ways. The display device may issue an audio alert, a visual alert (e.g., in the form of color patterns), and/or a haptic-based alert, along with recommendations of how to make the tool device return to a safe state.

[0085] FIG. 9 depicts a flowchart of a method 900 of monitoring tool device usage in accordance with one embodiment. Steps 902, 904, 906, and 908 are similar to steps 802, 804, 806, and 808, respectively, of FIG. 8 and are not repeated here.

[0086] Step 910 is optional and involves preventing, via a control unit, use of the tool device upon the processing unit determining the tool device is in a certain state. For example, if the state of the tool device is "held incorrectly," the control unit may prevent power from being supplied to the tool device until the tool device is held correctly. As another example, if the state of the tool device is "overheated," the control unit may prevent operation of the tool device until the state of the tool device is no longer "overheated." This control unit may be configured as part of the cell, or as a separate device in communication with the cell and in connection with the tool device.

[0087] In other embodiments, other parameters of the tool may be varied if the processing unit determines the tool device is in a certain state. For example, an orientation behavior could change a speed setting of a drill.

[0088] The methods, systems, and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, in alternative configurations, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims.

[0089] Embodiments of the present disclosure, for example, are described above with reference to block diagrams and/or operational illustrations of methods, systems, and computer program products according to embodiments of the present disclosure. The functions/acts noted in the blocks may occur out of the order as shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially concurrent or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Additionally, or alternatively, not all of the blocks shown in any flowchart need to be performed and/or executed. For example, if a given flowchart has five blocks containing functions/acts, it may be the case that only three of the five blocks are performed and/or executed. In this example, any of the three of the five blocks may be performed and/or executed.

[0090] A statement that a value exceeds (or is more than) a first threshold value is equivalent to a statement that the value meets or exceeds a second threshold value that is slightly greater than the first threshold value, e.g., the second threshold value being one value higher than the first threshold value in the resolution of a relevant system. A statement that a value is less than (or is within) a first threshold value is equivalent to a statement that the value is less than or equal to a second threshold value that is slightly lower than the first threshold value, e.g., the second threshold value being one value lower than the first threshold value in the resolution of the relevant system.

[0091] Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, configurations may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the configurations. This description provides example configurations only, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations will provide those skilled in the art with an enabling description for implementing described techniques. Various changes may be made in the function and arrangement of elements without departing from the spirit or scope of the disclosure.

[0092] Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of various implementations or techniques of the present disclosure. Also, a number of steps may be undertaken before, during, or after the above elements are considered.

[0093] For example, the following exemplary user scenarios may be realized by incorporating the above-discussed features. As mentioned previously, the features of the invention may be used to determine whether the correct tool was picked up, and may be measured in a variety of ways. For example, there may be a sensor package on a hand-held tool such as the drill of FIG. 3C that contains an accelerometer and a gyroscope. An on-board processing device may watch for changes in the sensor values and transmit an event indicating that the tool was picked up.

[0094] Or, each tool device may include, on the handle, a pressure sensor that is connected to a circuit that transmits a unique ID when a hand presses or otherwise engages it, and a remote (or local) hub may receive that information and pass it along with a timestamp to the internet. In another embodiment, a user wear may a band on their wrist that continuously measures local electromagnetic noise. When the user picks up a device, the band may measure a change in the noise spectrum, and then transmit the event to a base station elsewhere to be forwarded to the internet.

[0095] In yet another embodiment, a device embedded in the wiring of a tool device may monitor the operation of the tool device and communicate the activity along with IDs to an internet-connected base station. Or, each tool device may be outfitted with an RFID tag and the operator may wear an RFID reader. When the tool device is picked up, the RFID reader may read the tag and communicate the event over the internet.

[0096] Features of the present invention may also be used to gather information regarding anomalous events. For example, a sensor for augmenting a tool may include or otherwise be configured with a small camera that is instructed to take/record imagery of the workpiece upon the occurrence of an unexpected event for later debugging. This imagery may be transmitted over the internet in at least substantially real time for analysis.

[0097] Features of the present invention may also be used to determine variation in an operator's operation of a tool device (e.g., for quality control purposes). Specifically, features of the invention may be used to detect (and quantify) variations in tasks such as cutting, rolling, pressing, etc. A strain-gauge or a flexible combination of strain gauges may measure, via a trivial amount of support/conditioning circuitry, the variation in torque during operation of a tool device. The velocity of certain tool devices may also be monitored. For example, velocity of a drill press may be monitored to ensure it is applied at a constant speed to minimize risk of potential component failure. This may be accomplished by an optical encoder and/or a gyroscope that measures the velocity or angular momentum of the moving part. In other embodiments, voltage due to movement of a tool device may be detected. It is contemplated that thresholds may be applied along with feedback/control mechanisms to halt operation of the tool device upon certain parameters being exceeded.

[0098] Features of the present invention may also be used to determine how long tool devices are idle between processes (i.e., how much they're being used). As mentioned previously, this may be done by the amount of power drawn or measured passively via a transducer that converts mechanical energy (vibrations) into an electrical signal to be measured.

[0099] The features of the present invention may also include log-in systems to monitor which operator(s) are using the tool devices.

[0100] Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the general inventive concept discussed in this application that do not depart from the scope of the following claims.

Claims

1. A system for monitoring tool usage, the system comprising: at least one sensor mechanism operably and externally connected to a tool device such that the at least one sensor mechanism is able to detect at least one operational parameter of the tool device in substantially real time; a network-connected storage for storing information regarding the operational parameter of the tool device detected by the at least one sensor mechanism; and a communication mechanism configured to communicate information regarding the operational parameter of the tool device detected by the at least one sensor mechanism to the network-connected storage.

2. The system of claim 1, wherein the at least one detected operational parameter is movement of the tool device.

3. The system of claim 2, wherein the at least one sensor mechanism is selected from the group consisting of an accelerometer, magnetometer, photodetector, transducer, and a gyroscope to measure the movement of the tool device.

4. The system of claim 1, wherein the at least one operational parameter includes power consumption of the tool device and the at least one sensor mechanism is a power meter mechanism.

5. The system of claim 1, wherein the at least one operational parameter includes electrical signals communicated from the tool device.

6. The system of claim 1, further comprising a processing unit configured to determine a state of the tool device based on the information regarding the at least one operational parameter of the tool device.

7. The system of claim 5, wherein the state of the tool device is a function of at least one of orientation of the tool device, location of the tool device, temperature of the tool device, power level of the tool device, and operation of the tool device.

8. The system of claim 6, further comprising a control unit configured to change a parameter of the tool device upon the processing unit determining the tool device is in a certain state.

9. The system of claim 1, wherein the at least one sensor mechanism is configured as a deformable and extendable substrate to be removably connected to different types of tool devices.

10. The system of claim 1, wherein the tool device is selected from the group consisting of a machine, an actuator, a hand tool, and a power tool.

11. A method for monitoring tool usage, the method comprising: operably connecting at least one sensor mechanism to a tool device; detecting, via the at least one sensor mechanism and in substantially real time, at least one operational parameter of the tool device; and communicating, via a communication mechanism, information regarding the at least one operational parameter of the tool device to a network-connected storage.

12. The method of claim 11, wherein the at least one operational parameter includes movement of the tool device, and the at least one sensor mechanism is selected from the group consisting of an accelerometer, magnetometer, photodetector and a gyroscope to measure the movement of the tool device.

13. The method of claim 11, wherein the at least one operational parameter includes power consumption of the tool device and the at least one sensor mechanism is a power meter mechanism.

14. The method of claim 11, wherein the at least one operational parameter includes electrical signals communicated from the tool device.

15. The method of claim 11, further comprising determining, via a processing unit, a state of the tool device based on the information regarding the at least one operational parameter of the tool device.

16. The method of claim 15, wherein the state of the tool device is a function of at least one of orientation of the tool device, location of the tool device, temperature of the tool device, power level of the tool device, and operation of the tool device.

17. The method of claim 15, further comprising preventing, via a control unit, use of the tool device upon the processing unit determining the tool device is in a certain state.

18. The method of claim 11, wherein the at least one sensor mechanism is configured as a deformable and extendable substrate to be removably connected to different types of tool devices.

19. The method of claim 11, wherein the tool device is selected from the group consisting of a machine, an actuator, a hand tool, and a power tool.

20. A sensor mechanism for monitoring usage of a tool device, the sensor mechanism configured as a deformable and extendable substrate to be removably connected to different types of tool devices, the sensor mechanism further configured to detect at least one operational parameter of a tool device and to communicate information regarding the at least one operational parameter of the tool device to a network-connected storage.