An occupational safety system and a detection method therefor

Abstract

The invention relates to an occupational safety system which has been developed for use in machines that may be dangerous while operating (a press machine, a bending machine, a sawbench, etc.) and quickly stops the operation of the machine in certain situations such as absent-mindedness, carelessness, etc., and a detection method therefor, wherein the occupational safety system (1) and a detection method therefor operate with the following operating principle: a detecting member (20) detects a capacitive value of the components, such as a machine, a material, an operator (40),etc., and transmits that value to a control unit (30), then said control unit (30) processes the values obtained and calculates a threshold value (X1, X2, X3), the detecting member (20) and the control unit (30) constantly communicate with each other in order to instantly transmit the detected values, the detecting member (20) detects the capacity change and transmits the same to the control unit (30) when the operator (40) approaches a dangerous part (10) of the machine in a way that he could harm himself, the control unit (30) compares the instant capacity data with the previously calculated threshold values (X1, X2, X3), the control unit (30) commands the machine to stop its operation in case that any of the threshold values (X1, X2, X3) are exceeded, and the machine stops itself.

Description

[0001] DESCRIPTION

[0002] AN OCCUPATIONAL SAFETY SYSTEM AND A DETECTION METHOD THEREFOR

[0003] Technical Field

[0004] The invention relates to an occupational safety system which has been developed for use in machines that may be dangerous while operating (a press machine, a bending machine, a sawbench, etc.) and stops the operation of the machine when an operator is absent-minded, careless, etc. while using the machine, and to a detection method therefor.

[0005] More particularly, an occupational safety system and a method therefor are disclosed, in which after a detecting member measures the capacitive values of components such as a machine, a material, an operator, etc., if any one of the thresholds is exceeded, which are calculated as a result of a comparison of the threshold values calculated by a control unit by processing said measurements with the capacitive values detected instantly by said detecting member when an operator approaches the machine at a dangerous distance, then the operation of the machine is stopped.

[0006] State of the Art

[0007] Nowadays, various work tools / machines are used, mostly in industry. Said machines are used in various tasks, sometimes automatically or by means of an operator. In particular, the machines that are used to cut, bend and shape materials have dangerous parts in order to perform their functions. Examples of said dangerous parts include the operation of the circular gear of a sawbench so as to protrude from the bench, the application of very high pressures by a press machine to process a material, etc. Said machines should be used with caution, as these parts may easily damage any extremity of a person in case of contact.

[0008] Occupational accidents may occur when the operator acts carelessly while using said machines. Various methods have been developed to detect such a situation and stop the machine. In the patent document no. US6376939B1 , two plates placed relative to the machine and a sensor group facing said plates are used. Sensors detect the capacitive change between the plates and proceed depending on the detected value. Said solution detects situations when the operator is approaching. Here we encounter a problem. As said document detects based on approaching, the machine may be stopped unnecessarily even if the operator approaches the machine in a way that does not pose a danger. This causes unnecessary turning on and off the machine and disruption of the work being performed.

[0009] In the document no. US11413717B2, a method for detecting a human tissue is disclosed. Said method is characterized by a process in which a value of a capacitance formed by a tool and a counterpart electrode that is electrically insulated from the tool is measured for a period, a substance is arranged in a region relative to the tool, and the geometrical property of the tool changes periodically within the region upon movement of the tool.

[0010] Consequently, factors such as the inability of the detection systems used to react quickly enough for a solution and, as mentioned above, some solutions set forth in the prior art cannot fully detect the normal working procedure of the operator with the machine, and therefore stop the machine, have revealed the necessity of our invention in question.

[0011] Object and Summary of the Invention

[0012] An object of the invention is to provide a system that quickly stops the machine in case that an operator approaches a dangerous part of the machine that may pose a safety risk.

[0013] Another object of the invention is to ensure that various capacitive values are detected by the detecting member and transmitted to a control unit.

[0014] The invention relates to an occupational safety system which has been developed for use in machines that may be dangerous while operating (a press machine, a bending machine, a sawbench, etc.) and stops the operation of the machine in certain situations such as absent-mindedness, carelessness, etc., and a detection method therefor, wherein the occupational safety system and a detection method therefor operate with the following operating principle: a detecting member detects a capacitive value of the components, such as a machine, a material, an operator, etc., and transmits that value to a control unit, then said control unit processes the values obtained and calculates a threshold value, the detecting member and the control unit constantly communicate with each other in order to instantly transmit the detected values, the detecting member detects the capacity change and transmits the same to the control unit when the operator approaches a dangerous part of the machine in a way that he could harm himself, the control unit compares the instant capacity data with the previously calculated threshold values, the control unit commands the machine to stop its operation in case that any of the threshold values are exceeded, and the machine stops itself.

[0015] Brief Description of the Figures

[0016] Fig.-1 : Shows a representative graph drawing indicating the peaks of the capacitive values and the threshold values that determine the operating limits of the system.

[0017] Fig. -2: Shows a representative view of the elements of the system.

[0018] Fig. -3: Shows a representative view of the operating principle of the system.

[0019] Fig. -4: Shows a view of the elements of the system, and the capacitance sensor.

[0020] Reference Numerals

[0021] 10 Dangerous part (a saw, a press end, etc.)

[0022] 20 Detecting member

[0023] 30 Control unit

[0024] 30.1 Screen

[0025] 40 Operator

[0026] 50 Capacitance sensor

[0027] C1 Machine capacitive value

[0028] C2 Starting capacitive value

[0029] C3 Working and material capacitive value

[0030] C4 Environment capacitive value

[0031] X1 First threshold value

[0032] X2 Second threshold value

[0033] X3 Third threshold value

[0034] Detailed Description of the Invention The invention is an occupational safety system (1) which has been developed for use in machines that may be dangerous while operating (a press machine, a bending machine, a sawbench, etc.), characterized in that it is configured to capacitively detect when an operator (40) approaches a dangerous part (10) of the machine in a way that a safety risk may occur in cases of absent-mindedness, carelessness, etc., and to quickly stop the operation of the machine.

[0035] More particularly, the occupational safety system (1) and a detection method therefor operate with the following operating principle: a detecting member (20) detects a capacitive value of the components, such as a machine, a material, an operator (40), etc., and transmits that value to a control unit (30), then said control unit (30) processes the values obtained and calculates a threshold value (X1 , X2, X3), the detecting member (20) and the control unit (30) constantly communicate with each other in order to instantly transmit the detected values, the detecting member (20) detects the capacity change and transmits the same to the control unit (30) when the operator (40) approaches a dangerous part (10) of the machine in a way that he could harm himself, the control unit (30) compares the instant capacity data with the previously calculated threshold values (X1 , X2, X3), the control unit (30) commands the machine to stop its operation in case that any of the threshold values (X1 , X2, X3) are exceeded, and the machine stops itself. Our invention, as described, may be used in any metal processing machines, any wood processing machines, any circular and band saws, any press machines and any bending machines. In addition, said dangerous part (10) is the metallic parts of said machines, which fulfill the main function of the machine.

[0036] The present invention makes different threshold value calculations and ensures that the machine operates between the calculated threshold values. The machine is stopped when one of the calculated threshold values (X1 , X2, X3) is exceeded. The point to be considered here is that the machine will be stopped only when a human extremity approaches to the machine in a way that pose a danger. For all other cases the machine will continue to operate.

[0037] Our invention essentially consists of at least one detecting member (20) which makes various capacitive measurements for calculating a threshold value and transmits (30) the peak values of the capacitive values measured / detected in an analog manner to a control unit via a data pin, wherein said data pin is connected to an A / D pin located on said control unit (30); at least one control unit (30) which stores the machine capacitive value (C1) detected by said detecting member (20), the starting capacitive value (C2), the working and material capacitive value (C3) and the environment capacitive value (C4) in the memory thereof, calculates a first threshold value (X1), a second threshold value (X2) and a third threshold value (X3), respectively, using said values, compares the capacitance values obtained instantly and constantly from said capacitance sensor (50) with the threshold values (X1 , X2, X3) stored in its memory, and if the instant capacitance data is greater than any threshold value (X1 , X2, X3), commands the machine to stop for a dangerous situation; and at least one capacitance sensor (50) which consists of two parts, i.e., said detecting member (20) and a dangerous part (10) of a machine with a metallic surface and instantly and constantly transmits the capacitive changes it detects to said control unit (30) via the data pin of said detecting member (20) in order to make a dangerous situation comparison. s

[0038] Said detecting member (20) has a data pin to transmit the peak value of the capacity it detects analogously to said control unit (30). Furthermore, said control unit (30) is a microcontroller, and the data pin of the detecting member (20) is connected to an A / D pin on the microcontroller. Thus, the analog values obtained from the data pin are transmitted to the control unit (30) via the A / D pin. Said control unit (30) has a memory. The machine capacitive value (C1), the starting capacitive value (C2), the working and material capacitive value (C3), the environment capacitive value (C4), which are to be used when calculating the threshold values (X1 , X2, X3), and the threshold values (X1 , X2, X3) calculated using these values are saved in said memory. In this way, data may be retrieved from the memory and processed at any time.

[0039] Said detecting member (20) and the dangerous part (10) of the machine with a metallic surface acts as a capacitance sensor (50). The dangerous part (10) mentioned here refers to metallic and functional structures, such as a circular saw of a sawbench, abending end of a bending machine, a press end of a press machine, a cutting / drilling end of a wood or metal processing machine, etc. When the capacitance sensor (50) shown in Fig. 4 detects any capacitive change, the detecting member (20) transmits the peak value of the detected capacitance as an analog signal to the A / D pin of the control unit (30) via the data pin. Said transmission continues instantly and constantly. The control unit (30) determines the dangerous or non-dangerous situation by instantly and constantly comparing the capacitive values transmitted thereto in an instant and constant manner with the threshold values (X1 , X2, X3) previously calculated and stored in its memory. Here, if the instan capacitance value is greater than a threshold value (X1 , X2, X3), a dangerous situation is meant, if it is lower, a non-dangerous situation is meant.

[0040] The system is optimized-fine-tuned so that the machine can only understand a human extremity. Said control unit (30) has a screen (30.1) for fine-tuning for the sensitivity optimization of the threshold values (X1 , X2, X3) calculated by said control unit (30) so as not to stop the machine unnecessarily and only to stop in case of a danger. In a preferred embodiment of the invention, said screen (30.1) may be a touch screen. Said touch screen (30.1) has an interface which is integrated thereto and operates simultaneously with said control unit (30). The user / operator (40) performs fine-tuning by touching the screen (30.1) in accordance with the instructions on said interface. In another preferred embodiment of the invention, said screen (30.1) operates as integrated with the control unit (30) and a keypad. Fine tuning may be made by managing the instructions on the screen (30.1) by said keypad. More specifically, said capacitance sensor (50) detects the capacitance changes for an operator (40) continuing to work regularly with the machine (e.g. cutting a material on a sawbench) or for being therearound in a non-hazardous way, for both two screen (30.1) combinations. The peak values of the detected capacitance changes are transmitted to the control unit (30) as an analog signal by the detecting member (20). Said control unit (30) processes the analog signals obtained and saves them in its memory as a non-dangerous situation.

[0041] Fine-tuning can be understood more clearly from the graph given in fig. 1. The capacitive values shown in the graph with ascending and descending lines may vary depending on the material and machine. Furthermore, as the threshold values (X1 ,X2,X3) shown with dashed lines are determined according to capacitance values, their values may change on the graph. The most important characteristic of fine-tuning process here that the threshold values (X1 ,X2,X3) may vary depending on the capacitance values and the machine is ensured to be operated in the range of the threshold values (X1 ,X2,X3). The threshold values are calculated by a fine-tuning process, and a sealing process - restricting the operating range - is performed. As the fine-tuning process also includes operations such as data detection interval and data detection frequency, these operations are carried out via said screen (30.1). Hereinafter, the system, the operating principle of which is shown in Fig. 3, will be examined in more detail. Said detecting member (20) detects the capacitive value (C1) of the machine to which the system is connected and the starting capacitive value (C2) of the machine. The detected machine capacitive value (C1) and the starting capacitive value (C2) are analog signals and are transmitted to the control unit (30) to calculate the first threshold value (X1) via a data pin. The control unit (30) processes the analog values obtained, calculates the first threshold value (X1) and saves it in its memory. Then, the general structure containing said detecting member (20) and control unit (30) is mounted on the machine to be used. After said mounting process, the detecting member (20) makes a series of measurements, which we can call a second step, and transmits the detected values to the control unit (30). More particularly, the detecting member (20) detects the working - an operator working with the machine - and material capacitive value (C3) and transmits it to said control unit (30). Said control unit (30) processes the first threshold value (X1) saved previously and the working and material capacitive value (C3), and calculates and saves a second threshold value (X2) in its memory. Here, fine- tuning process is performed via said screen (30.1) as the capacity changes are detected for the operator (40) continuing to work regularly with the machine (e.g. cutting a material on a sawbench), or for being therearound in a non-dangerous manner. Subsequently, said detecting member (20) detecs the environment capacitive value (C4) and transmits it to the control unit (30). The control unit (30) processes the calculated first threshold value (X1), the second threshold value (X2) and the environment capacitive value (C4), and calculates and saves a third threshold value (X3) in its memory. As a result of these processes, limits within which the machine may operate safely - a non-dangerous situation - are determined. Hereinafter, the system will continue to operate for detecting dangerous situations. The capacitance values mentioned here are detected as analog signals.

[0042] The process of detecting dangerous situations is carried out by said capacitive sensor (50) continuing to instantly detect capacitive values and transmitting the detected values to the control unit (30) via the data pin of the detecting member (20), followed by comparing the instant capacitive values with the threshold values (X1 , X2, X3) by the control unit (30). If the capacitive value obtained from the comparisons is greater than any threshold value (X1 , X2, X3), the control unit (30) commands the machine to stop and the machine stops quickly. Said machine continues to operate in the range of the threshold values explained in the previous paragraphs. This is indicated by dashed lines in fig. 1. In addition, the values indicated with solid lines in fig.1 represent the instantly detected capacitance values. The point to be considered here is that said control unit (30) uses the peak values of said data when calculating the threshold value and comparing the calculated threshold values

[0043] (X1 , X2, X3) with the instantly detected capacitive value, as shown in fig.1. On the other hand, said detecting member (20) and the control unit (30) are in constant communication so that said detecting member (20) constantly detects the capacitive value and transmits it to the control unit (30), and the control unit (30) constantly compares the obtained values with the threshold values (X1 , X2, X3).

[0044] Our invention, as described, may be used in any metal processing machines, any wood processing machines, any circular and band saws, any press machines and any bending machines.

Claims

CLAIMS1. An occupational safety system (11 which has been developed for use in machines that may be dangerous while operating (a press machine, a bending machine, a sawbench, etc.), characterized in that in order to capacitively detect when an operator (40) approaches a dangerous part (10) of the machine in a way that a safety risk may occur in cases of absent-mindedness, carelessness, etc., and to quickly stop the operation of the machine, it comprises: at least one detecting member (20) which makes various capacitive measurements for calculating a threshold value and transmits (30) the peak values of the capacitive values measured / detected in an analog manner to a control unit via a data pin, wherein said data pin is connected to an A / D pin located on said control unit (30), at least one capacitance sensor (50) which consists of two parts, i.e., said detecting member (20) and a dangerous part (10) of a machine with a metallic surface and instantly and constantly transmits the capacitive changes it detects to said control unit (30) via the data pin of said detecting member (20) in order to make a dangerous situation comparison, at least one control unit (30) which stores the machine capacitive value (C1) detected by said detecting member (20), the starting capacitive value (C2), the working and material capacitive value (C3) and the environment capacitive value (C4) in the memory thereof; calculates a first threshold value (X1), a second threshold value (X2) and a third threshold value (X3), respectively, using said values; compares the capacitance values obtained instantly and constantly from said capacitance sensor (50) with the threshold values (X1 , X2, X3) stored in its memory; and if the instant capacitance data is greater than any threshold value (X1 , X2, X3), commands the machine to stop for a dangerous situation.

2. An occupational safety system according to claim 1 , characterized in that said control unit (30) has at least one screen (30.1) for fine-tuning for the sensitivity optimization of the threshold values (X1 , X2, X3) calculated by said control unit(30) so as not to stop the machine unnecessarily and only to stop in case of a danger.

3. An occupational safety method which has been developed for use in machines that may be dangerous while operating, characterized in that in order to detect an operator (40) approaching a dangerous part (10) of the machine in a dangerous way in cases of absent-mindedness, carelessness, etc., and to quickly stop the operation of the machine, it comprises the following process steps: detecting the capacitive value (C1) of the machine to which the system is connected and the starting capacitive value (C2) of the machine and transmitting them to said control unit, by said detecting member (20), by said control unit (30), processing the values obtained, and calculating and saving the first threshold value (X1), detecting the working - an operator working with the machine - and material capacitive value (C3) and transmitting it to said control unit (30), by said detecting member (20), by said control unit (30), processing the first threshold value (X1) saved previously and the working and material capacitive value (C3), and calculating and saving a second threshold value (X2), detecting the environment capacitive value (C4) and transmitting it to the control unit (30), by said detecting member (20), by said control unit (30), processing the calculated first threshold value (X1), the calculated second threshold value (X2) and the environment capacitive value (C4), and calculating and saving a third threshold value (X3), continuing to instantly detect the capacitive value and transmitting the detected values to the control unit (30), by said detecting member (20), by said control unit (30), obtaining constantly the capacitive value from the detecting member (20) and comparing the obtained capacitive values with the threshold values (X1 , X2, X3), if the capacitive value obtained from these comparisons is greaterthan any threshold value (X1 , X2, X3) - a dangerous situation - commanding the machine to stop by the control unit (30) and then stopping the machine quickly.

4. An occupational safety method according to claim 3, characterized in that said control unit (30) uses the peak values of said data when calculating the threshold value and comparing the calculated threshold values (X1 , X2, X3) with the instantly detected capacitive value.

5. An occupational safety method according to claim 3, characterized in that said detecting member (20) and the control unit (30) are in constant communication so that said detecting member (20) constantly detects the capacitive value and transmits it to the control unit (30), and the control unit (30) constantly compares the obtained values with the threshold values (X1 , X2, X3).

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