Body-Worn Safety Control for Barrier-Free Autonomous Machines
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Solution Overview
Problem
Existing safety measures for autonomously operating machines in industrial environments are costly, inflexible, and reduce machine availability, as they require static barriers and frequent shutdowns when operators are present, limiting the machines' potential and operator safety.
Innovation Solution
A body-worn device with safety means that generates an input signal only when correctly locked and arranged on the person, interacting with a safety controller to dynamically manage the safety environment, allowing machines to operate safely alongside operators without static barriers, enhancing flexibility and availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed installations such as fences or barriers are used to isolate autonomously operating machines, then safety performance is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical safety barriers (fences, barriers) with an electronic/optical safety system consisting of body-worn devices, safety controllers, and signal processing units. This substitution eliminates the need for physical isolation structures while maintaining safety performance through electronic monitoring and control mechanisms.
Solution Approach 2:
The safety controller serves multiple functions: it receives signals from body-worn devices, processes safety information, controls autonomously operating machines, and coordinates safety operations across multiple devices. This multi-functional approach consolidates what would otherwise require separate safety systems into a single integrated controller.
2Reliability
If fixed installations are used to ensure safety, then safety performance is improved, but productivity decreases due to machine shutdowns when operators are present
Solution Approach 1:
The safety system transitions from a static barrier-based approach to a dynamic body-worn device system. The safety status changes dynamically based on the operator's position, movement, and interaction with the machine, allowing the machine to operate continuously while maintaining safety through real-time monitoring rather than requiring shutdowns.
Solution Approach 2:
The body-worn device continuously provides feedback signals to the safety controller about the operator's status and position. This feedback mechanism enables real-time safety assessment, allowing the machine to maintain operation when safe and shut down only when necessary, thereby preserving productivity while ensuring safety.
3Reliability
If each autonomously operating machine is equipped with its own safety equipment, then safety performance is improved, but device complexity and cost increase
Solution Approach 1:
The safety controller serves multiple functions: it receives signals from body-worn devices, processes safety information, controls autonomously operating machines, and coordinates safety operations across multiple devices. This multi-functional approach consolidates what would otherwise require separate safety systems into a single integrated controller.
4Ease of operation
If body-worn devices are used without failsafe locking mechanisms, then ease of operation is improved, but reliability decreases
Solution Approach 1:
The failsafe locking mechanism ensures that the body-worn device is properly secured to the operator's body before it can generate valid safety signals. This preliminary action of locking prevents signal generation until correct wear is confirmed, ensuring reliability without significantly impacting ease of operation since the locking process is automatic and quick.
Data Source
AI summary
System for safeguarding a person from an autonomously operating machine. The system comprises a safety controller for asserting control over the autonomously operating machine based on an input signal generated by a body-worn. The body-worn device comprises safety means for ensuring failsafe locking and arrangement of the body-worn device on the person in a predefined manner. Furthermore, the body-worn device is configured to generate the input signal only when the body-worn device is locked and arranged in said predefined manner.