AI Worker Count Control for Industrial Work Area Safety
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Solution Overview
Problem
Existing buddy systems in industrial sites are inefficient due to decreased work efficiency and lack of supervision, leading to potential accidents and additional costs.
Innovation Solution
An AI-based system that monitors worker presence using cameras and controls equipment operation based on real-time image data, ensuring a minimum number of workers is present, with notifications and emergency responses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the buddy system is implemented to ensure worker safety, then safety reliability is improved, but work efficiency deteriorates and additional supervision costs are incurred
Solution Approach 1:
The patent replaces the manual buddy system with an automated image recognition system using cameras and AI algorithms to monitor worker presence. The system automatically detects the number of workers in the area and controls equipment operation, eliminating the need for manual supervision and additional personnel while maintaining safety requirements.
Solution Approach 2:
The system enables self-service monitoring where the equipment itself participates in safety verification. The equipment receives control signals based on automated worker detection, creating a self-regulating mechanism where the system automatically ensures safety conditions are met without external supervision.
2Reliability
If the buddy system is implemented to prevent accidents, then safety reliability is improved, but device complexity increases due to additional supervision requirements
Solution Approach 1:
The complex manual supervision process is replaced with an automated image recognition system. Cameras capture images, AI algorithms process them to count workers, and control units automatically manage equipment. This substitution eliminates the need for supervisor personnel and simplifies the overall system structure.
Solution Approach 2:
The patent introduces an intermediary image recognition system between the workers and the equipment control. This intermediary automatically verifies safety conditions and transmits control signals, eliminating the need for direct human-to-human supervision and reducing system complexity.
3Reliability
If manual supervision is added to enforce the buddy system, then safety reliability is improved, but additional costs are incurred
Solution Approach 1:
The patent replaces human supervisors with an automated image recognition and control system. Cameras and AI algorithms perform the supervision function that previously required human personnel, eliminating ongoing labor costs while maintaining continuous safety monitoring.
Solution Approach 2:
The system uses image copies (photographs) of the work area to monitor worker presence instead of requiring physical human supervisors. The AI system processes these visual copies to determine safety conditions, replacing the need for additional personnel with automated visual analysis.
Data Source
AI summary
An artificial intelligence based industrial site work area minimum number-of-people control system according to an exemplary embodiment includes a camera which captures equipment which performs a process of producing products in an industrial site in real time to acquire real-time image data, a control unit which turns on or off the equipment, an image collection unit which collects the real-time image data acquired by the camera, an artificial intelligence inference unit which establishes an industrial site image dataset based on the real-time image data and trains, validates, and tests an artificial intelligence model to monitor a worker in the real-time image data based on the industrial site image dataset and calculate the number of workers detected by the monitoring, and a worker count unit which displays the real-time image data on a screen, sets an actual work area on the real-time image data displayed on the screen.