Construction Machine Control Panel Redundancy for Safe Emergency Operation
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Solution Overview
Problem
Existing construction machines lack robust safety controls to ensure correct functioning of components during operation, particularly in cases of malfunctions, which can lead to unsafe conditions.
Innovation Solution
The implementation of a dual signal transmission path system for operating elements, where both paths are checked for plausibility criteria, and emergency operation is activated only after confirmation of component functionality by the operator, ensuring safe operation by deactivating faulty paths and allowing control through a single path if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single signal transmission path is used for controlling construction machine components, then the device complexity is reduced, but the reliability of safe operation decreases
Solution Approach 1:
The control system is segmented into multiple independent signal transmission paths (first and second paths) that operate in parallel. Each path can independently transmit control signals from operating elements to the control unit, allowing the system to maintain functionality even if one path fails, thus improving reliability without excessive complexity increase
Solution Approach 2:
The system performs preliminary checks of signal transmission paths before critical failures occur. The control unit continuously monitors the status of each path and can detect malfunctions early, allowing for preventive switching to backup paths or activation of safety protocols before unsafe conditions develop
2Reliability
If multiple signal transmission paths are implemented for safety checks, then the reliability of operation is improved, but the device complexity increases
Solution Approach 1:
Multiple signal transmission paths are merged into a unified control architecture where the control unit receives and evaluates signals from both paths simultaneously. This merging allows for cross-validation of signals and coordinated response to failures, improving reliability while managing complexity through integrated control logic
Solution Approach 2:
The control unit implements feedback mechanisms that continuously monitor the status of each signal transmission path. When a malfunction is detected in one path, the feedback system triggers appropriate responses such as switching to the other path or activating safety protocols, ensuring reliable operation while maintaining manageable system complexity through automated monitoring and response
3Reliability
If plausibility checks are performed on control signals from multiple paths, then the safety of operation is enhanced, but the productivity decreases due to additional verification time
Solution Approach 1:
The system performs plausibility checks selectively rather than uniformly on all signals at all times. Under normal operating conditions, the system may use simplified validation to maintain productivity. However, when anomalies are detected or during critical operations, more extensive plausibility checks are activated to ensure safety, thus balancing productivity and safety requirements
4Ease of operation
If the system switches to emergency operation mode with single path control, then the ease of operation is improved, but the reliability decreases
Solution Approach 1:
The system prepares for potential failures by having emergency operation modes pre-configured with appropriate safety measures in place. Before switching to single-path emergency operation, the system ensures that necessary safety protocols are activated and that the operator is alerted to the reduced redundancy, thus cushioning the transition and maintaining an acceptable level of safety assurance while improving ease of operation
Data Source
AI summary
A construction machine is provided with a control device having an operating panel with operating elements, which can assume numerous switching states/positions, a control and monitoring unit for controlling machine components via control signals signalling the switching state/position of associated operating elements, and a display/signal unit interacting with the control and monitoring unit. The control device provides first and second signal transmission paths for transmitting a first control signal signalling the switching state/position of a first operating element and a second control signal signalling the switching state/position of a second operating element, respectively. The control signals are checked for the existence of a plausibility criterion. If the plausibility criterion is not met, signal transmission over one or the other signal transmission path is deactivated, wherein the functionality of the relevant component is checked. Switching to emergency operation is only possible after confirmation of the functionality of the relevant component.