Zone-Based Safety Module for Predictive Machine Braking
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Solution Overview
Problem
Existing processing machines, such as sawing tools, pose a risk of harming operators due to potential accidental activation or contact with moving parts, necessitating improved safety mechanisms.
Innovation Solution
A safety module incorporating a visual element that defines safety and danger zones, a brake, and a controller to manage power source operation, preventing accidental start-up and stopping the power source when objects enter the danger zone or are at risk of entering it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a visual element and control system are added to prevent accidental start-up and detect danger zones, then operator safety is improved, but device complexity increases
Solution Approach 1:
The space around the processing machine is segmented into distinct safety zones and danger zones using the visual element. This spatial segmentation allows the system to selectively monitor and respond to objects in specific areas, improving safety without requiring complex system-wide changes. The controller receives signals from the visual element about object positions in different zones and triggers appropriate responses (preventing start-up in safety zone, activating brake in danger zone).
Solution Approach 2:
The visual element acts as an intermediary between the operator environment and the controller. It captures images, processes them to identify objects and their positions, and transmits this information to the controller. This intermediary component simplifies the overall system architecture by centralizing the detection and decision-making functions, rather than requiring multiple distributed sensors and control points throughout the machine.
2Reliability
If the brake is activated immediately when an object enters the danger zone, then operator safety is improved, but productivity decreases due to operational interruptions
Solution Approach 1:
The system performs preliminary monitoring and detection using the visual element before triggering the brake. The visual element continuously captures images and identifies objects in the danger zone in advance, allowing the controller to prepare for potential brake activation. This preliminary detection phase enables selective braking only when necessary, rather than continuous or preemptive braking that would unnecessarily interrupt operations.
Solution Approach 2:
The system implements a feedback loop where the visual element continuously monitors the environment, the controller processes the visual information to determine object positions and potential hazards, and the brake is activated only when the feedback indicates a genuine danger. This closed-loop feedback system ensures that braking actions are taken only when truly necessary for safety, minimizing unnecessary operational interruptions while maintaining high safety standards.
Data Source
AI summary
A safety module, which is applied to a processing machine including a processing member and a power source connected with the processing member, includes a visual element, a brake and a controller. The visual element defines safety and danger zones for the processing scope of the processing member. The brake is connected with the power source for providing a brake effect to the power source. The controller is connected with the power source, the visual element and the brake. When capturing that an object is located in the danger zone or determining that an object is about to enter the danger zone according to the movement trajectory of the object, the visual element transmits a brake signal to the controller to make the controller drive the brake to control the power source to stop operating. The safety module improves the safety of the operator operating the processing machine.