Construction Machine Control Panel Redundancy for Safe Emergency Operation
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Solution Overview
Problem
The increasing safety requirements for construction machines necessitate improved control systems that ensure proper functioning of components and prevent operation in case of safety-related malfunctions, while existing systems lack redundancy and operator confirmation of component functionality.
Innovation Solution
A control system with at least two signal transmission paths between operating elements and the control and monitoring unit, where control signals are checked for plausibility, and the system prompts the operator to confirm component functionality before switching to emergency operation, ensuring safe operation by deactivating one path if the other fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single signal transmission path is used between operating elements and control unit, then the device complexity is reduced, but the reliability and safety of the construction machine deteriorates
Solution Approach 1:
The patent applies local quality by implementing different levels of signal transmission paths for different operating elements. Critical safety-related controls have redundant signal paths (first and second transmission paths), while non-critical controls use single paths. This selective approach enhances safety where needed without uniformly increasing complexity across the entire system.
Solution Approach 2:
The control system is segmented into multiple independent signal transmission paths. The first signal transmission path carries control signals from operating elements to the control unit, while a second redundant path provides backup transmission. This segmentation ensures that if one path fails, the other can maintain safe operation.
2Reliability
If redundant signal paths are implemented for safety, then the reliability improves, but the device complexity and cost increase
Solution Approach 1:
The system dynamically switches between single-path and dual-path operation modes. The control unit monitors the status of both signal transmission paths and automatically activates redundancy only when a fault is detected in the primary path. This dynamic adaptation maintains high reliability while minimizing complexity during normal operation.
Solution Approach 2:
The control system performs self-diagnosis by monitoring its own signal transmission paths. When a fault is detected, the system automatically activates the redundant path without external intervention, and can even prompt the operator to confirm component functionality. This self-service capability reduces the need for complex external monitoring systems.
3Reliability
If operator confirmation of component functionality is required, then the safety improves, but the productivity and ease of operation deteriorates
Solution Approach 1:
The system performs preliminary fault detection and assessment before requiring operator confirmation. The control unit monitors signal transmission paths continuously and only prompts the operator when a specific fault condition is detected. This preliminary action filters out normal variations and only requires operator intervention for actual safety-critical issues.
Solution Approach 2:
The system provides feedback to the operator through the display unit when a fault is detected, explaining the nature of the issue and requesting confirmation of component functionality. This structured feedback process ensures operator awareness and confirmation only when necessary, maintaining productivity while enhancing safety through verified operational status.
Data Source
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AI summary
The invention relates to a construction machine with a device for controlling at least one component of the construction machine. The control device comprises a control panel 8, which has at least one operating element 9 that can assume several switching states or positions, and a control and monitoring unit 15 for controlling at least one component of the construction machine depending on a control signal indicating the switching state or position of the at least one operating element 9, as well as a display and/or signaling unit 20 that interacts with the control and monitoring unit 15. Furthermore, the invention relates to a method for controlling a component of the construction machine.The control device provides a first and a second signal transmission path 17, 18 for signal transmission. A first control signal indicating the switching state or position of an operating element 9 is transmitted via the first signal transmission path 17, and a second control signal indicating the switching state or position of an operating element 9 is transmitted via the second signal transmission path 18. The first and second control signals are checked for plausibility. If the plausibility criterion is not met, signal transmission via one or the other signal transmission path 17 or 18 is deactivated, and the functionality of the respective component is checked. Emergency operation can only be activated after the functionality of the respective component has been confirmed.