Fall Protection Monitoring for Crane and Safety Line Interference
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Solution Overview
Problem
Manufacturing operations often involve personnel working at elevated positions with safety lines that can interact with moving manufacturing equipment, such as overhead cranes, posing a risk of accidents due to the lack of effective automated monitoring systems.
Innovation Solution
A fall-protection monitor system using sensors and wireless communication to detect the operation and location of safety lines and manufacturing equipment, automatically preventing equipment movement when safety lines are in use to avoid interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual observation methods are used to monitor safety lines and equipment, then device complexity is reduced, but reliability of accident prevention deteriorates
Solution Approach 1:
The patent replaces manual observation (mechanical/human system) with an automated electronic monitoring system comprising sensors, wireless communication devices, and a controller. The sensor detects safety line status, the wireless device transmits data, and the controller automatically prevents equipment movement when safety lines are in use, thereby improving reliability while accepting increased system complexity.
Solution Approach 2:
The monitoring system operates autonomously without requiring continuous human intervention. The sensor automatically detects when a safety line is in use, the wireless communication device self-transmits this information, and the controller automatically generates alerts or prevents equipment movement, making the system self-sufficient in monitoring and preventing accidents.
2Reliability
If automated monitoring systems are implemented to detect safety line operation and equipment location, then reliability of accident prevention is improved, but device complexity increases
Solution Approach 1:
The monitoring system is divided into distinct functional modules: a sensor component for detecting safety line operation, a wireless communication device for data transmission, and a controller for processing information and preventing equipment movement. This segmentation allows each component to perform its specific function independently, making the overall complex system manageable and maintainable.
3Object-affected harmful factors
If the controller prevents movement of manufacturing equipment within predetermined distance from safety line, then safety of personnel is improved, but productivity of manufacturing operations deteriorates
Solution Approach 1:
The controller proactively prevents equipment movement before a hazardous interaction can occur. When the sensor detects that a safety line is in use, the controller automatically restricts equipment movement within a predetermined distance, thereby preemptively eliminating the safety risk rather than reacting after an incident occurs.
Solution Approach 2:
The system establishes a feedback loop where the sensor continuously monitors safety line status, the wireless communication device transmits this information to the controller, and the controller adjusts equipment movement restrictions based on real-time data. This feedback mechanism ensures that productivity is maximized when safety lines are not in use while automatically restricting operations when they are, balancing safety and productivity dynamically.
Data Source
AI summary
Personnel working at elevated positions use safety lines to prevent falls. Equipment being used in proximity to the personnel may interfere with the safety lines presenting a potential hazard. A fall protection monitor provides an automated and wireless sensor system for avoiding interactions between equipment and safety lines. The fall-protection monitor includes a first sensor for monitoring whether a safety line is in operation. A second sensor monitors a location of a moveable device being used in the vicinity of the safety line. A controller determines the location of the moveable device and whether the safety line is in operation. The controller prevents movement of the moveable device within a predetermined distance from an operational safety line.