Dynamic Protective Field Control for Movable Machine Safety
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Solution Overview
Problem
Existing protective field-based safeguarding for movable machines is inflexible and does not dynamically adapt to the current state of the machine, compromising safety and productivity in dynamic applications.
Innovation Solution
A method involving a control unit, sensor apparatus, and two adaptation apparatuses that determine dynamic protective fields based on real-time state data of the movable machine, using redundant and diverse algorithms to ensure safe operation by dynamically adapting protective fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a static initial protective field is used for safeguarding the movable machine, then the safety device is simple to implement, but it cannot dynamically adapt to the current state of the machine, leading to unnecessary shutdowns and reduced productivity
Solution Approach 1:
The patent implements dynamic protective fields that automatically adjust their spatial configuration based on real-time state data from the movable machine's control unit. Two independent adaptation apparatuses continuously modify the protective field boundaries according to the machine's current position, speed, and operational state, enabling the safety system to adapt dynamically without manual intervention and avoid unnecessary shutdowns
Solution Approach 2:
The system establishes a feedback loop where state data from the movable machine's control unit is continuously fed to the adaptation apparatuses. These apparatuses process the feedback information and adjust the protective field configuration accordingly, creating a closed-loop control system that responds to changing machine states in real-time
2Productivity
If speed-and-separation monitoring is used to allow dynamic operation, then productivity is improved, but the safety requirements become more complex and difficult to meet
Solution Approach 1:
The patent divides the safety function into separate modular components: a sensor apparatus for detecting object engagement, an evaluation apparatus for assessing safety conditions, and adaptation apparatuses for adjusting protective fields. This segmentation allows each component to be optimized independently while working together to meet complex safety requirements
Solution Approach 2:
The system dynamically changes the spatial parameters of the protective field based on the movable machine's state data. The adaptation apparatuses modify field boundaries, distances, and coverage areas according to real-time parameters such as machine position, speed, and operational mode, enabling flexible safety monitoring that adapts to varying productivity requirements
3Reliability
If redundant and diverse adaptation apparatuses are used to determine the protective field, then safety and reliability are improved, but the device complexity increases
Solution Approach 1:
The safety function is divided into separate modular components: sensor apparatus, evaluation apparatus, and adaptation apparatuses. This segmentation allows independent optimization and validation of each component while maintaining overall system reliability through their coordinated operation
Solution Approach 2:
Different regions of the protective field are assigned different safety characteristics and monitoring requirements. The adaptation apparatuses create non-uniform protective field configurations where certain zones have enhanced monitoring based on local risk assessment, allowing tailored safety measures rather than uniform complexity throughout the entire field
Data Source
AI summary
A method for the safe operation of a movable machine comprises: that the movable machine is controlled by a control unit; that a sensor apparatus determines a 3D representation of an environment of the movable machine; that an initial protective field is predefined that is a defined spatial region within the environment of the movable machine; that a first adaptation apparatus and a second adaptation apparatus receive state data about the movable machine from the control unit, wherein the first adaptation apparatus, starting from the initial protective field, determines a first adapted protective field in dependence on the state data and the second adaptation apparatus, starting from the initial protective field, determines a second adapted protective field in dependence on the state 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 apparatus evaluates the determined 3D representation with respect to whether an object engages into the relevant protective field, and outputs a result signal in dependence on the result of the evaluation; and that the control unit triggers a safety-related reaction if the result signal corresponds to an engagement of an object into the relevant protective field.