Construction Machine Operator Monitoring With Sensor-Based Servo Interlocks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing safety mechanisms in construction machinery, such as safety levers, can be easily bypassed, leading to potential accidents due to unintentional or untrained operator actions, and there is a need for improved safety systems to detect and prevent hazardous operating conditions.
Innovation Solution
A device comprising sensors (seat contact, door close, grip, driving function, seatbelt buckle, selector, and emergency stop switches) connected to an evaluation unit that limits or stops the construction machine's functions based on detected states, providing visual warnings and restricting capabilities to prevent accidents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional safety levers are used to prevent unauthorized operation, then operator safety is improved, but the system complexity increases and the levers can be easily bypassed by untrained operators
Solution Approach 1:
The patent replaces the mechanical safety lever system with an electronic sensor-based monitoring system. The evaluation unit uses sensor signals (seat contact, door close, grip detection) to electronically control servo circuit activation, eliminating the need for physical safety levers and reducing mechanical complexity while maintaining safety functionality.
Solution Approach 2:
The system automatically monitors operator presence and control lever manipulation through sensors, and the evaluation unit autonomously determines whether to activate or deactivate the servo circuit based on detected states. This self-monitoring and self-decisioning capability eliminates the need for manual safety lever operation by untrained personnel.
2Measurement precision
If multiple sensors are implemented to detect operator states, then measurement precision of operator behaviour is improved, but device complexity increases
Solution Approach 1:
The evaluation unit serves multiple functions: it processes signals from various sensors (seat contact switch, door close switch, grip sensor), determines operator states, controls servo circuit activation, and provides visual warnings. This multi-functional approach consolidates complexity into a single control unit rather than requiring separate systems for each function.
Solution Approach 2:
The patent combines multiple sensor inputs (seat contact, door close, grip detection) into a unified evaluation system that processes all signals together to determine overall operator state. This merging of sensor functions into a single evaluation unit reduces system complexity compared to having separate monitoring systems for each sensor.
3Reliability
If the servo control is immediately deactivated when safety conditions are not met, then safety is improved, but productivity decreases due to operational restrictions
Solution Approach 1:
The evaluation unit provides visual warnings before fully deactivating the servo control, giving the operator a chance to correct their behavior. This partial action (warning first) allows continued operation if the operator complies with safety requirements, thereby maintaining productivity while still ensuring safety through progressive intervention.
Solution Approach 2:
The system provides visual feedback through warning signals that inform the operator when safety conditions are not met. This feedback loop allows the operator to understand the safety issue and correct their behavior, enabling continued operation when appropriate and only restricting productivity when necessary for safety.
Data Source
AI summary
The disclosure relates to a device for monitoring and assisting an operator of a construction machine, which comprises a seat contact switch for detecting whether an operator is sitting in a seat of the construction machine, a door close switch for detecting whether a door of a driver's cab of the construction machine is closed, a grip sensor for detecting whether an operating lever arranged to the left of the seat and/or an operating lever arranged to the right of the seat for controlling a servo circuit of the construction machine is actuated by an operator, and an evaluation unit designed to limit or stop a capacity of the construction machine depending on the detected states of the seat contact switch, the door close switch and the grip sensor.