Industrial Machine Image-Zone Monitoring for Operator Proximity Stops
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Solution Overview
Problem
Conventional industrial machines lack effective safety monitoring systems to prevent operator injury from sudden workpiece movements, as they rely on manual restraints and procedures rather than automated detection of operator proximity.
Innovation Solution
A system that defines an image zone around the machine, using image recognition to detect predefined colors, patterns, or shapes, such as a colored glove, to automatically halt the machine when the operator enters the zone, incorporating redundant relay modules for safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual safety restraints and procedures are used to protect operators, then device complexity is reduced, but safety reliability deteriorates due to reliance on human compliance rather than automated detection
Solution Approach 1:
The patent replaces manual mechanical safety restraints and procedures with an automated optical detection system using cameras and image processing. The system automatically detects operator presence in the image zone and triggers machine halting, eliminating reliance on human compliance while maintaining safety functionality.
Solution Approach 2:
The patent introduces an intermediary automated monitoring system between the operator and the machine. The camera system and image processing algorithms act as intermediaries that detect operator presence and communicate with the machine control system, providing automated safety mediation without direct human intervention.
2Reliability
If automated image recognition systems are implemented to detect operator presence, then safety reliability improves, but device complexity increases due to additional monitoring components
Solution Approach 1:
The patent implements a multi-functional system where the camera and image processing algorithms serve multiple purposes: detecting operator presence, identifying specific body parts through color/pattern/shape recognition, and providing data for safety decisions. This consolidates multiple safety functions into a single integrated system.
Solution Approach 2:
The system employs self-service through automated image processing algorithms that automatically analyze captured images, identify operators based on predefined color/pattern/shape criteria, and trigger appropriate safety responses without requiring manual intervention or complex external control systems.
3Object-affected harmful factors
If the machine is halted automatically when an operator enters the image zone, then operator safety improves, but productivity decreases due to machine stoppages
Solution Approach 1:
The patent applies partial action by halting the machine only when an operator is detected in the specific image zone, rather than implementing continuous or excessive stoppages. The system monitors continuously but acts selectively based on actual detection events, minimizing unnecessary productivity loss while maintaining safety.
Solution Approach 2:
The system implements feedback through continuous monitoring of the image zone and real-time communication between the detection system and machine control. When an operator is detected, the system provides feedback to halt the machine; when the zone is clear, normal operation resumes, creating a responsive safety system that adapts to actual conditions.
Data Source
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AI summary
A control system for monitoring operation of an industrial machine includes a processor and a tangible, non-transitory, computer-readable memory communicating with the processor. The tangible, non-transitory computer-readable memory includes instructions that, in response to execution by the processor, cause the processor to perform operations including: receiving image data from an imaging device that monitors an image zone around the industrial machine, analyzing the image data, generating, based upon the analyzing, operational data associated with the industrial machine, and transmitting the operational data to a display that is communicatively coupled to the control system.