Dynamic Protective Field Control for Mobile Machine Safety
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Solution Overview
Problem
Existing protective field-based safety systems for mobile machines are inflexible and do not dynamically adapt to the current state of the machine, leading to unnecessary restrictions in dynamic applications where high process speeds are desired.
Innovation Solution
A method that dynamically adapts the protective field in real-time based on the current state of the mobile machine using redundant and diverse adaptation devices, determining a relevant protective field by combining first and second adapted protective fields derived from an initial protective field and status data of the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a static protective field is used for safety monitoring, then safety is ensured, but process speed and flexibility are reduced due to unnecessary shutdowns
Solution Approach 1:
The protective field is transformed from a static to a dynamic system that adapts in real-time to the mobile machine's state. The control unit continuously receives status data from the mobile machine and adjusts the protective field parameters accordingly, allowing the safety system to respond dynamically to changing conditions rather than operating with fixed, overly conservative parameters
Solution Approach 2:
The system changes the parameters of the protective field based on the mobile machine's status data. By receiving real-time information about the machine's position, speed, and operational state, the control unit modifies the protective field's extent and monitoring sensitivity, enabling safer operation at higher speeds when conditions permit
2Reliability
If the protective field is extended to cover larger areas, then safety coverage is improved, but false detections and unnecessary shutdowns increase
Solution Approach 1:
The protective field is configured with varying monitoring characteristics across different spatial regions. The control unit determines region-specific protective field parameters based on the mobile machine's status, applying stricter monitoring where risks are higher and more lenient monitoring where risks are lower, thereby reducing false detections while maintaining comprehensive safety coverage
Solution Approach 2:
The protective field's spatial extent and monitoring intensity are dynamically adjusted based on real-time status data. When the mobile machine is stationary or moving slowly, the protective field extends further; when the machine is moving quickly or in safe conditions, the field contracts, preventing unnecessary shutdowns while maintaining safety
3Reliability
If speed and separation monitoring is implemented, then safety is maintained, but the system complexity and monitoring requirements increase
Solution Approach 1:
The control unit performs multiple functions: it controls the mobile machine's operation, receives status data from various sensors, determines the appropriate protective field parameters, and monitors for interventions. This multi-functional approach consolidates what would otherwise require separate systems, reducing overall complexity while maintaining comprehensive safety monitoring
Data Source
Figure 1
Figure 2~3
AI summary
A method for the safe operation of a mobile machine comprises: the mobile machine being controlled by a control unit; a sensor device determining a 3D representation of an environment of the mobile machine; an initial protective field being specified, which is a defined spatial area within the environment of the mobile machine; a first adaptation device and a second adaptation device receiving status data about the mobile machine from the control unit, wherein the first adaptation device determining a first adapted protective field based on the initial protective field in dependence on the status data, and the second adaptation device determining a second adapted protective field based on the initial protective field in dependence on the status data;that a relevant protective field is determined on the basis of both the first adapted protective field and the second adapted protective field; that an evaluation device evaluates the determined 3D representation with regard to whether an object intervenes in the relevant protective field and outputs a result signal depending on the result of the evaluation; and that the control unit triggers a safety-related reaction if the result signal corresponds to an intervention of an object in the relevant protective field.