Position based machine control in an industrial automation environment

• US 7,272,456 B2
• Filed: 01/24/2003
• Issued: 09/18/2007
• Est. Priority Date: 01/24/2003
• Status: Active Grant

• Current Assignee: Xenogenic Development Limited Liability Company (Intellectual Ventures LLC)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Brandt, David D., Farchmin, David W., Vasko, David Alan
• Primary Examiner(s): Knight; Anthony
• Assistant Examiner(s): Norton; Jennifer L.
• Application Number:
  US10/351,572
• Publication Number:
  US 20040148039A1
• Time in Patent Office: 1,698 Days
• Field of Search: 455/456.2, 455/404.2, 455/456.1, 700/9, 700/17, 700/65, 700/66, 700/23, 700/79, 702/94, 702/95, 715/700, 715/864, 340/5.62, 709/208
• US Class Current: 700/66
• CPC Class Codes: G05B 19/122 using cards, tapes or discs having conductive paths G05B19/128 takes precedence
• CPC Class Codes: G05B 19/4061 Avoiding collision or forbidden zones
• CPC Class Codes: G05B 2219/25196 Radio link, transponder
• CPC Class Codes: G05B 2219/40202 Human robot coexistence
• CPC Class Codes: G05B 2219/40203 Detect position of operator, create non material barrier to protect operator
• CPC Class Codes: G05B 2219/49152 Feedhold, stop motion if machine door is open, if operator in forbidden zone
• CPC Class Codes: G05B 2219/49302 Part, workpiece, code, tool identification
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A method and apparatus for controlling machine operations in an automated industrial facility including at least one machine, the method for restricting machine operation when a wireless information device associated with a facility user is within a restricted facility location and comprising the steps providing at least one wireless information device, determining if the at least one wireless information device is within a restricted facility location and, where the at least one wireless information device is within a restricted facility location, regulating operation of the at least one machine.

Claims

1. A method for controlling machine operation in an automated industrial facility including at least one machine, the method for regulating machine operations as a function of location of a wireless information device (WID), the method comprising the steps of:

providing at least one WID;

monitoring a location of at least one WID;

determining if at least one WID is at a restricted facility location; and

when at least one WID is at a restricted facility location, automatically changing a mode of operation of at least one machine.

2. The method of claim 1 further including the steps of monitoring for user presence at the restricted location and when only a user is present at the restricted location, automatically changing operation of the at least one machine from a normal mode of operation to a first reduced mode of operation and when both a user and a WID are present at the restricted location, automatically changing operation of the at least one machine to a second reduced mode of operation, wherein the first reduced mode of operation is more restrictive than the second reduced mode of operation.

3. The method of claim 2 wherein the first reduced mode of operation includes one of halting machine operations and causing machines to assume fail-safe operating modes.

4. The method of claim 3 wherein, when neither a user nor a WID is present at the restricted location after detecting at least one of the user and the WID at the restricted location, automatically returning the at least one machine to the normal mode of operation.

5. The method of claim 4 wherein the return to the normal mode of operation occurs upon detecting the absence of the user and the WID within the restricted location.

6. The method of claim 1 further including the step of associating at least one machine zone with at least one facility machine and wherein the step of determining if at least one WID is within a restricted facility location includes determining if at least one WID is within the at least one machine zone.

7. The method of claim 1 wherein the step of automatically changing the mode of operation includes regulating machine operation as a function of the specific WID located in the restricted location.

8. The method of claim 7 wherein the WIDs include first and second WID types, the first WID type including WIDs that have a first authorization clearance and the second type including WIDs that have a second authorization clearance, the first and second clearances associated with different sets of machine operations that may be performed when a WID having the clearance is within the restricted location, the step of automatically changing the mode of operation further including the step of determining the type of WID within the restricted location and automatically changing the mode of operation of the at least one machine as a function of the clearance associated with the identified WID type.

9. The method of claim 8 wherein WIDs of the first type include first type identifiers and, wherein the step of determining WID type includes attempting to obtain a first type identifier and, when a first type identifier is obtained, determining that the WID is of the first type, else, determining that the WID is of the second type.

10. The method of claim 9 wherein, when the WID type is the second type, the step of changing the mode of operation includes halting machine operations.

11. The method of claim 10 wherein the step of automatically changing the mode of operation further includes the step of indicating via the WID that machine operations have been changed.

12. The method of claim 7 wherein the step of automatically changing the mode of operation further includes the steps of obtaining information from the WID, using the obtained information to identify an authorization specification for the specific WID, the authorization specification specifying machine operations that can be performed when the WID is within each restricted location, and regulating machine operation in a manner consistent with the identified authorization specification.

13. The method of claim 12 further including the steps of providing a unique WID identifier in each WID, providing a database linked to a processor and separate from the WIDs, at least one authorization specification stored in the database and, wherein, the step of obtaining information includes obtaining the WID identifier stored in the WID that resides at the restricted location and the step of using including accessing the authorization specification stored in the database that is associated with the WID identifier.

14. The method of claim 13 wherein the step of providing the processor includes providing a processor capable of communicating with at least one machine for controlling machine operations and wherein the processor regulates machine operations as a function of the authorization specification.

15. The method of claim 14 wherein the step of providing at least one WID includes providing at least one WID with a transmitter and wherein the step of obtaining the WID identifier includes transmitting the WID identifier from the WID to the processor.

16. The method of claim 12 further including the steps of storing an authorization specification in each of the WIDs and wherein the step of obtaining includes obtaining an authorization specification from the WID located at the restricted location.

17. The method of claim 16 further including the steps of providing a processor capable of communicating with the at least one machine for controlling machine operations and wherein the step of obtaining includes transmitting at least a portion of the authorization specification from the WID to the processor.

18. The method of claim 7 further including the step of storing an authorization specification in each of the WIDs, each authorization specification specifying machine operations that can be performed when the associated WID is within each restricted location, providing a system processor linked to the at least one machine for controlling the at least one machine, transmitting a location identifier to the WID, accessing the authorization specification in the WID to identify a machine operations that can be performed when the WID is within the specific restricted location and transmitting an operations specification from the WID to the system processor, the system processor regulating machine operations as a function of the received operations specification.

19. The method of claim 6 further including the steps of providing an operator that may be activated by a facility user, when a WID is within a machine zone, monitoring operator activation and, when the operator is deactivated and the WID is in a machine zone, limiting operation of the machine associated with the zone.

20. The method of claim 19 wherein the step of limiting includes one of halting machine operation and causing machines to assume fail safe operating modes.

21. The method of claim 19 wherein the step of providing an operator includes providing an operator that is separate from the at least one WID.

22. The method of claim 19 wherein the step of providing an operator includes providing an operator as part of the WID.

23. The method of claim 22 further including the steps of enabling at least one WID, when a WID is located within a machine zone, determining if the WID is enabled and, when the WID is enabled, regulating machine operations as a function of the specific WID within the machine zone, else, halting machine operation.

24. The method of claim 23 further including the steps of, after the WID is enabled, monitoring physical proximity of the WID to a WID user and, when the WID is outside a proximity range of the WID user, disabling the WID.

25. The method of claim 24 wherein the step of determining if the WID is enabled includes periodically determining if the WID is enabled and, if the WID becomes disabled, further regulating machine operations.

26. The method of claim 25 wherein the step of further regulating includes one of halting machine operations and causing machines to assume fail safe operating modes.

27. The method of claim 23 wherein the step of enabling at least one WID includes the steps of obtaining user information from the WID user that uniquely identifies the user and storing the user information in the WID.

28. The method of claim 27 wherein the step of obtaining user information includes identifying biometric indicia of the user.

29. The method of claim 23 wherein the step of enabling at least one WID includes the steps of storing biometric indicia of authorized facility users, identifying biometric indicia of a facility user, comparing the user'"'"'s biometric indicia to the stored indicia and, where the user'"'"'s indicia matches at least one of the stored indicia, enabling the WID.

30. The method of claim 21 further including the steps of enabling at least one WID, when a WID is located within a zone, determining if the WID is enabled and, when the WID is enabled, regulating the machine as a function of the specific WID within the machine zone, else, halting machine operation.

31. The method of claim 30 further including the steps of, after the WID is enabled, monitoring physical proximity of the WID to a WID user and, when the WID is outside a proximity range of the WID user, disabling the WID and, wherein the step of enabling at least one WID includes the steps of obtaining user information from the WID user that uniquely identifies the user and storing the user information in the WID.

32. The method of claim 1 further including the steps of enabling at least one WID, when a WID is located at a restricted location, determining if the WID is enabled and, when the WID is enabled, automatically changing a mode of operation of the at least one machine to a reduced mode of operation.

33. The method of claim 32 further including the steps of, after the WID is enabled, monitoring physical proximity of the WID to a WID user and, when the WID is outside a proximity range of the WID user, disabling the WID.

34. The method of claim 33 wherein the step of monitoring physical proximity includes the steps of providing a user proximity sensor on the WID and using the WID to monitor user proximity.

35. The method of claim 34 wherein the step of providing a proximity sensor includes providing a capacitive coupling sensor.

36. The method of claim 32 wherein the step of enabling at least one WID includes the steps of obtaining user information from the WID user that uniquely identifies the user and storing the user information in the WID.

37. The method of claim 36 wherein the step of obtaining user information includes identifying biometric indicia of the user.

38. The method of claim 37 wherein the step of identifying biometric indicia includes the step of providing at least one of a thumb print reader, an eye scanner and a voice recognition sensor as part of the WID.

39. The method of claim 6 wherein, for at least one machine there are at least first and second different machine zones and wherein the step of automatically changing a mode of operation of the at least one machine includes regulating machine operation differently depending on which of the first and second zones the WID is located in.

40. The method of claim 39 wherein the first zone is inside the second zone and is more proximate the at least one machine than the second zone, the step of automatically changing a mode of operation of the at least one machine includes allowing more machine operations to be performed when the WID is in the second zone than when the WID is in the first zone.

41. The method of claim 6 wherein the step of automatically changing a mode of operation of the at least one machine includes changing a mode of operation of the at least one machine as a function of WID location within the machine zone and wherein the step of determining if a WID is within the machine zone includes determining the location of the WID within the machine zone.

42. The method of claim 41 wherein the step of automatically changing a mode of operation of the at least one machine includes regulating machine operations in one of several different ways as a function of WID location.

43. The method of claim 1 further including the step of using past WID location information to predict a future WID location and automatically changing a mode of operation of the at least one machine as a function of the predicted future WID location.

44. The method of claim 43 wherein the step of using past WID location information includes storing machine location information, using the stored machine information to determine current direction of WID travel and current travel rate and using the current direction and current rate information to predict future WID location.

45. The method of claim 1 wherein the step of determining if the WID is located at a restricted location includes the steps of providing wireless access points within the facility and transmitting signals from one of the WID and the access points to the other of the WID and the access points and using the received signals to determine WID location.

46. The method of claim 1 wherein machine operations include machine cycles and wherein the step of automatically changing a mode of operation of the at least one machine includes the steps of monitoring machine cycles and regulating machine operation as a function of both WID location and the extent of machine cycle completion.

47. The method of claim 1 further including the step of providing at least a second WID, the step of determining if a WID is at a restricted location includes determining if the first WID is at a restricted location and the method further includes the step of, when the first WID is located at a restricted location, determining the location of the second WID and, the step of automatically changing a mode of operation of the at least one machine includes regulating machine operation as a function of the second WID location.

48. The method of claim 47 further including the step of associating at least one machine zone with at least one machine and, wherein, the step of determining if at least one WID is at a restricted location includes the step of determining if the first WID is within the at least one machine zone and the step of determining the location of the second WID includes determining if the second WID is within the at least one machine zone.

49. The method of claim 48 wherein the step of automatically changing a mode of operation of the at least one machine as a function of the second WID location includes halting operations of machines associated with the machine zone when the second WID is within the machine zone.

50. A method for use in an automated industrial facility including at least one machine, the method for controlling machine operations as a function of location of a facility user, the method comprising the steps of:

specifying at least one restricted location associated with the at least one machine;

providing at least one wireless information device (WID);

monitoring for facility user presence at the at least one restricted location;

monitoring for WID presence at the at least one restricted location;

controlling machine operations according to a first regimen when only a user is present at the restricted location;

controlling machine operations according to a second regimen when both a user and a WID are present at the restricted location, wherein the first and second regimens are different; and

wherein changes in operation between at least the first regimen and the second regimen occur automatically based on the monitored user location and the monitored WID location.

51. The method of claim 50 wherein the first regimen is more restrictive than the second regimen.

52. The method of claim 50 wherein the step of monitoring WID presence includes the steps of providing wireless access points within the facility, transmitting signals from one of the WID and the access points to the other of the WID and the access points and using the received signals to determine WID location within the facility.

53. The method of claim 52 wherein the step of monitoring user presence includes the step of providing at least one of a motion sensor, a light sensor, a pressure sensor and a thermal sensor.

54. The method of claim 53 wherein the step of monitoring for user presence further includes the step of physically restricting access to the restricted location to along access paths and using the at least one sensor to identify movement along any of the access paths.

55. The method of claim 50 wherein the step of specifying at least one restricted facility location includes the step of specifying at least one machine zone associated with the at least one machine and wherein the step of monitoring for WID presence includes monitoring for WID presence anywhere within the machine zone.

56. The method of claim 55 wherein the step of monitoring for user presence includes monitoring for user presence anywhere within the machine zone.

57. The method of claim 55 further including the step of, when a WID is present in the machine zone, tracking WID location within the machine zone.

58. The method of claim 57 further including the steps of altering machine operations as a function of WID location within the machine zone.

59. A system for controlling machine operation in an automated industrial facility comprising:

at least one machine and at least one machine zone associated with the machine;

a wireless information device (WID) associated with a facility user;

an operator device; and

a processor linked to the at least one machine for controlling operations of the at least one machine, the processor configured to automatically;

(a) determine if a facility user is located within the machine zone;

(b) if a user is located within the machine zone, determine if the operator device is activated, else regulating operation of the at least one machine according to a first regimen;

(c) if the operator is activated, determine if a WID is located within the machine zone, else regulating operation of the at least one machine according to a second regimen;

(d) if a WID is located within the machine zone;

(i) regulate machine operations according to a third regimen; and

(ii) repeat steps (a) through (d).

60. The system of claim 59 wherein the first regulating regimen includes halting operation of the at least one machine.

61. The system of claim 60 wherein, to determine if a user is within the machine zone, the processor is further configured to restrict access to the machine zone to at least one zone access path and further comprising a sensor within each of the zone access paths configured to identify user passage therethrough and provide feedback to the processor.

62. The system of claim 61 wherein, to regulate machine operations according to the third regimen, the processor is further configured to identify at least one characteristic of the WID within the machine zone and regulate machine operations as a function of the identified WID characteristic.

63. The system of claim 62 wherein, to identify at least one characteristic of the WID, the processor is further configured to identify the specific WID within the machine zone.

64. The system of claim 59 wherein the processor is further caused to enable at least one WID and, wherein, to regulate according to a third regimen, the processor is caused to determine if the WID in the machine zone is enabled and, where the WID is enabled, the processor is caused to regulate machine operations according to a second protocol, else regulate machine operations according to a first protocol.

65. The system of claim 64 wherein the first protocol is more restrictive than the second protocol.

66. The system of claim 65 wherein regulating according to a first protocol includes halting machine operations.

67. The system of claim 59 wherein, to regulate operation of the at least one machine according to the third regimen includes regulating operation of the at least one machine as a function of WID location within the machine zone.

68. The system of claim 59 wherein the machine operations include machine cycles and wherein the processor is further caused to regulate operations according to the third regimen by regulating operations as a function of the extent of machine cycle completion.

69. A system for controlling machine operation in an automated industrial facility comprising:

at least one machine that performs machine operations including machine cycles;

a wireless information device (WID) associated with a facility user;

a controller in communication with the WID and the at least one machine and configured to;

identify at least one restricted facility location associated with at least one machine;

determine if the WID is within a restricted facility location;

where the WID is within a restricted facility location automatically;

(i) identify the extent of machine cycle completion of the at least one machine; and

(ii) regulate operation of at least one machine as a function of the extent of machine cycle completion.

70. The system of claim 69 wherein the controller is further configured to identify at least one machine zone associated with the at least one machine and including the at least one restricted location and wherein, to determine if the WID is located within a restricted location, the controller is configured to determine if the WID is located within the machine zone.

71. The system of claim 70 wherein the controller is further caused to determine the location of the WID within the machine zone.

72. The system of claim 71 wherein, to regulate operations, the controller is further configured to regulate operations as a function of both the extent of machine cycle completion and WID location within the machine zone.

73. A system for controlling machine operation in an automated industrial facility comprising:

at least one machine;

a wireless information device (WID);

a controller in communication with the at least one machine and the WID and configured to automatically;

monitor a location of the WID within the facility;

predict a future location of the WID within the facility; and

regulate operation of the at least one machine as a function of the predicted WID location.

74. The system of claim 73 wherein, to predict a future location, the controller is further configured to periodically determining WID location, store WID location information, and, using the stored WID location information, predict a future WID location.

75. The system of claim 74 wherein, to use the stored location information, the controller is further configured to use the stored location information to determine a current travel direction and a current travel rate and combine the current direction and current rate information to predict the future location.

76. The system of claim 73 wherein the controller is further configured to identify at least one restricted location within the facility and determine if the predicted location includes the restricted location and, if the predicted location includes the restricted location, regulate operation of the at least one machine according to a first regimen, else regulate operation of the at least one machine according to a second regimen.

77. A controller for controlling machine operation in an automated industrial facility including at least one machine, the controller configured to:

(a) automatically identify at least one machine zone associated with at least one facility machine;

(b) automatically monitor at least first and second wireless information devices (WIDs);

(c) automatically determine if the first and second WIDs are located within the machine zone;

(d) when both the first and second WIDs are located within the machine zone, automatically regulate machine operations according to a first regimen; and

(e) when only the first WID is located in the machine zone, automatically regulate machine operation according to a second regimen that is different than the first regimen.

78. The system of claim 77 wherein the first regimen is more restrictive than the second regimen.

79. The system of claim 78 wherein the first regimen includes causing the machine to assume a safe operating condition.

80. The system of claim 77 wherein, when only the second WID is located in the machine zone, the controller is configured to regulate the machine according to a third regimen that is different than each of the first and second regimens.

81. The system of claim 77 wherein the controller is configured to repeat (c), (d) and (e).

82. A system for controlling machine operation in an automated industrial facility comprising:

at least one machine and at least one associated machine zone;

a controller configured to restrict machine operation as a function of juxtaposition of a facility user with respect to the at least one machine by performing the steps of;

determining if a facility user is within the at least one machine zone;

where a user is within the machine zone, determining user location within the machine zone; and

automatically adjusting operation of the at least one machine as a function of user location within the at least one machine zone.

83. The system of claim 82 wherein the step of adjusting includes the steps of determining the user'"'"'s identity and changing machine operation as a function of the user'"'"'s identity.

84. The system of claim 82 wherein the step of adjusting includes regulating operation of the at least one machine according to a second regimen and, wherein the controller is further configured to perform the steps of determining if a second facility user is within the machine zone and, where a second user is located within the machine zone, regulating machine operation operations according to a first regimen that is more restrictive than the second regimen.

85. The system of claim 82 further comprising an operator that is associated with the at least one machine and, wherein, the controller is further configured to perform the steps of, when a user is located within the machine zone, monitoring for activation of the operator, and the step of adjusting including operation includes the steps of, where the operator is activated, regulating machine operations according to a second regimen and, where the operator is not activated, regulating machine operations according to a first regimen.

86. The system of claim 85 wherein the step of adjusting according to a first regimen includes halting machine operations.

87. The system of claim 82 wherein the step of determining if a user is within the machine zone includes the step of monitoring a wireless information device (WID) associated with the user and monitoring the machine zone for presence of the WID.

88. A system for controlling machine operations in an automated industrial facility including at least one machine, the system for controlling machine operations as a function of the location of facility users, the system comprising:

at least one wireless information device (WID);

a monitor for obtaining information usable to determine if at least one WID is at a restricted facility location; and

a controller linked to the monitor and also to the at least one machine, the controller receiving the information from the monitor and determining if the at least one WID is at the restricted location and automatically changing operations of the machine associated with the restricted location when the WID is at the restricted location.

89. The system of claim 88 wherein the monitor is a first monitor and the system further includes a second monitor for obtaining information useable to determine if a user is present at the restricted location, the controller receiving information from the second monitor and using the information from the second monitor to determine if a user is present at the restricted location and wherein, when only a user is present at the restricted location, the controller regulates machine operation according to a first regimen and when both a user and a WID are present at the restricted location, the controller automatically regulates machine operation according to a second regimen that is less restrictive than the first regimen.

90. The system of claim 89 wherein the first regimen includes one of halting machine operations and causing the machine to assume a fail safe operating mode.

91. The system of claim 90 wherein, when neither a user nor a WID is present at the restricted location the controller regulates the machine to perform a first set of operations and wherein the second regimen includes a second set of operations that is a sub-set of the first set of operations.

92. The system of claim 88 wherein at least one machine zone is associated with at least one facility machine and wherein the controller determines if at least one WID is within the at least one machine zone.

93. The system of claim 88 wherein the controller identifies at least one characteristic of a WID present at the restricted location and regulates operations as a function of both the identified WID characteristic and the WID location.

94. The system of claim 93 wherein the characteristic includes WID type.

95. The system of claim 93 wherein the characteristic includes specific identity of the WID.

96. The system of claim 95 wherein the at least one WID includes a WID identifier and wherein the controller obtains the WID identifier via the monitor.

97. The system of claim 96 wherein the WID includes a transmitter and the monitor includes a receiver linked to the controller and wherein the transmitter transmits WID identifier signals to the controller via the receiver.

98. The system of claim 93 wherein the WID may be enabled and wherein the controller identifies whether or not the WID is enabled.

99. The system of claim 92 further including an operator activatable by a facility user when the user is in a machine zone and wherein the controller monitors operator activation and, when the operator is deactivated and a WID is located within the machine zone, limits machine operations.

100. The system of claim 99 wherein the operator is separate from the at least one WID.

101. The system of claim 99 wherein the operator is part of the WID.

102. The system of claim 93 wherein the WID may be enabled by a user and wherein the characteristic includes enablement, the controller controlling machine operations according to a second regimen when the WID is enabled and otherwise controlling machine operations according to a first regimen that is more limited than the second regimen.

103. The system of claim 102 wherein the at least one WID further includes a proximity sensor for monitoring proximity of the WID to a user after the WID is enabled and, wherein, the proximity sensor disables the WID when the WID is removed from proximity of a user.

104. The system of claim 103 wherein the proximity sensor includes a capacitive coupling sensor.

105. The system of claim 102 further including an input device for receiving user information useable to enable the at least one WID.

106. The system of claim 105 wherein the input device is a biometric indicia reader.

107. The system of claim 106 wherein the WID includes the reader.

108. The system of claim 106 wherein the reader includes at least one of a thumb print reader, an eye scanner and a voice recognition sensor.

109. The system of claim 92 wherein the controller tracks WID location within the machine zone and regulates machine operations as a function of WID location within the machine zone.

110. The system of claim 109 wherein, for at least one machine there are at least first and second different machine zones and wherein the controller determines if the WID is within the first or the second zone and regulates machine operations according to a first regimen when the WID is within the first zone and according to a second regimen when the WID is within the second zone.

111. The system of claim 110 wherein the first zone is inside the second zone and is more proximate the machine than the second zone and wherein the first regimen is more restrictive than the second regimen.

112. The system of claim 93 wherein the characteristic includes predicted future WID location and wherein the controller uses past WID location information to predict future WID location.

113. The system of claim 112 wherein the controller stores machine location information, uses the stored information to determine current direction of WID travel and current travel rate and uses the current direction and current rate information to predict future WID location.

114. The system of claim 88 wherein the at least one WID includes a transmitter and the monitor includes wireless access points linked to the controller and, wherein, the transmitter transmits at least some signals to the access points that are used by the controller to determine WID location.

115. The system of claim 93 wherein machine operations include machine cycles, the characteristic includes the extent of cycle completion and wherein the controller monitors machine cycles.

116. The system of claim 88 further including at least a second WID, the monitor also obtaining information useable to determine if the at least second WID is at the restricted facility location and the controller regulating operation of the at least one machine associated with the restricted location differently when more than one of the WIDs are at the restricted location at he same time.

117. An system for use in an industrial automation facility including at least one machine, the system for controlling machine operation as a function of location of a facility user, the system comprising:

at least one wireless information device (WID);

a first monitor for obtaining information useable to determine if a user is present at a restricted facility location;

a second monitor for obtaining information useable to determine if at least one WID is at a restricted facility location;

a controller linked to the at least one machine and also linked to the first and second monitors, the controller using information from the first and second monitors to determine if a user and a WID are present at the restricted location, respectively;

wherein the controller is configured to automatically change machine operations from a normal operational mode to a first regimen when only a user is present at the restricted location and change machine operations from the normal operational mode to a second regimen when both a user and a WID are present at the restricted location; and

wherein the first regimen is more restrictive than the second regimen.

118. The system of claim 117 wherein the second monitor includes wireless access points within the facility that are linked to the controller, the WID includes a transmitter that transmits signals from the WID to the access points.

119. The system of claim 118 wherein the first monitor includes at least one of a motion sensor, a light sensor, a pressure sensor and a thermal sensor.

120. The system of claim 117 wherein the restricted location includes a machine zone and the controller tracks WID location within the machine zone.

121. The system of claim 120 wherein the controller alters machine operations as a function of WID location within the machine zone.

122. A system for controlling machine operations in an automated industrial facility including at least one machine and at least one machine zone associated with the machine, the system for restricting machine operation when a wireless information device (WID) associated with a facility user is within the machine zone, the system comprising:

at least one WID;

an operator device that may be activated by a system user;

a first monitor for obtaining information for determining if a user is present in the at least one machine zone;

a second monitor for obtaining information for determining if a WID is present within the at least one machine zone;

a controller linked to the machine for controlling machine operations and linked to the first and second monitors and to the operator, the controller programmed to carry out a plurality of steps automatically, the plurality of steps including;

(a) determining if a user is located in the machine zone;

(b) if a user is located within the machine zone, determining if the operator is activated;

(c) if the operator is activated, determining if a WID is located within the machine zone;

(d) if a WID is located within the machine zone;

(i) regulating machine operations according to a third regimen; and

(ii) repeating steps (a) through (d);

else regulating machine operations according to a second regimen;

else regulating machine operations according to a first regimen.

123. The system of claim 122 wherein the first regulating regimen includes halting machine operations.

124. The method of claim 122 wherein the controller regulates machine operations according to the third regimen by identifying at least one characteristic of the WID within the machine zone and regulating machine operations as a function of the identified WID characteristic.

125. The system of claim 124 wherein the characteristic includes WID identity and the second monitor receives information from the WID useable to identify the specific WID.

126. The system of claim 122 wherein the WID may be enabled by a user and wherein the controller regulates according to a third regimen by determining if the WID in the machine zone is enabled and, where the WID is enabled, regulating machine operations according to a second protocol, else regulating machine operations according to a first protocol wherein the first protocol is more restrictive than the second protocol.

127. A system for controlling machine operation in an automated industrial facility including at least one machine and an associated machine zone, the system comprising:

at least first and second wireless information devices (WIDs);

a monitor for obtaining information useable to determine when each of the first and second WIDs is located within the machine zone;

a controller for receiving the monitor information and determining when each of the first and second WIDs is within the machine zone, when both the first and second WIDs are located within the machine zone, automatically regulating machine operations according to a first regimen without prompting and when only the first WID is located in the machine zone, automatically regulating machine operations according to a second regimen that is less restrictive than the first regimen without prompting.

128. The system of claim 127 wherein the controller further, when only the second WID is located in the machine zone, regulates the machine according to a third regimen without prompting that is different than each of the first and second regimens.

129. A system for controlling machine operations in an automated industrial facility including at least one machine, the system for controlling machine operations as a function of the location of facility users, the system comprising:

at least one wireless information device (WID);

a plurality of monitors configured to determine if the at least one WID is at a restricted facility location;

a controller linked to the monitor to receive location feedback indicating a current location of the at least one WID and control operation of the at least one machine without prompting based on the location feedback from the plurality of monitors to;

(i) automatically reduce operation of the at least one machine to a first reduced operational mode when the at least one WID enters the restricted facility location;

(ii) automatically reduce operation of the at least one machine to a second reduced operational mode that is a subset of the first reduced operational mode when the at least one WID enters a predetermined proximity of the at least one machine within the restricted facility location; and

(iii) automatically disable the at least one machine when the at least one WID enters another predetermined proximity of the at least one machine within the predetermined proximity.

130. The system of claim 129 wherein the controller is further configured to store machine location information and, using the stored machine information, determine a current direction of at least one WID travel and current travel rate within the automated industrial facility using the location feedback indicating the current location of the at least one WID from the plurality of monitors and, using the current direction and current rate information, predict a future location of the at least one WID.

131. The system of claim 130 wherein the controller is further configured to automatically change the operational mode of the at least one machine to one of the first reduced operational mode, the second reduced operational mode, and disabled upon determining a future location of the at least one WID that is located in at least one of the restricted facility location, the predetermined proximity of the at least one machine within the restricted facility location, and the another predetermined proximity of the at least one machine within the predetermined proximity.