Intelligent Lockout Control for Verified Power Source Isolation

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Solution Overview

Problem

Current equipment management and de-energization systems in industries, particularly in the mining sector, are prone to human errors and inefficiencies, lacking automated checks and requiring extensive manual processes, which can lead to safety risks and increased downtime during maintenance.

Innovation Solution

An automated equipment management and de-energization system comprising an intelligent lock with a communication interface, a control device, and a central server that identifies and verifies the power source, ensures correct locking and unlocking, and remotely monitors the process, reducing human intervention and enhancing safety and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual identification and locking of power sources is used, then device complexity is reduced, but reliability and safety deteriorate due to human errors

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical identification and locking processes with an automated system using mobile devices, sensors, and communication interfaces. The system automatically identifies power sources, verifies their status, and controls locking mechanisms, eliminating human error while maintaining manageable complexity through software-based solutions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service functionality where the mobile device automatically performs identification, verification, and locking control without requiring manual intervention. The power source identification and status verification are handled autonomously by the system, improving reliability while reducing operational complexity.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual power source identification is performed, then device complexity is reduced, but loss of time increases due to excessive manual checking

Engineering Contradiction:

ImproveefficiencyVSAvoidtime

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces time-consuming manual identification processes with automated digital identification using mobile devices and communication interfaces. The system quickly identifies power sources and verifies their status through electronic communication, dramatically reducing the time required while improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If manual locking and key management is used, then device complexity is reduced, but reliability deteriorates due to human errors in key deposition and transport

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual key management with an automated electronic locking system controlled by mobile devices. The system electronically verifies lock status, controls key access, and monitors the entire locking process, eliminating human errors in key deposition and transport while maintaining manageable system complexity through software control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If automated system with communication interface is implemented, then reliability and productivity are improved, but device complexity increases

Engineering Contradiction:

ImprovesafetyVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a universal mobile device that performs multiple functions: identification, verification, locking control, and communication. This multi-functional approach improves reliability and productivity while managing device complexity by consolidating multiple specialized components into a single versatile platform.

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Productivity

If automated verification system is implemented, then loss of time is reduced through faster identification, but device complexity increases

Engineering Contradiction:

ImproveefficiencyVSAvoidcomplexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements self-service functionality where the mobile device automatically performs verification and identification without requiring additional specialized equipment or complex external systems. The automated verification is handled by the device itself, reducing time loss while managing complexity through autonomous operation.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11749037B2Locking and de-energization management system and locking and de-energization management method

Publication Date: 2023.09.05 BOSCH SOLUCOES INTEGRADAS BRASIL LTDA

AI summary

An equipment locking and de-energization management system (7) is configured to guarantee safety during the locking and de-energization of a power source (6) of an item of equipment (7) during maintenance thereof. The system includes an intelligent lock (1) to be inserted into the power source (6) and perform the locking thereof, a control device (2) configured to manage and sort the locking steps and a central server (15) to assist with the communication between the elements of the locking and de-energization management system. Also described is an equipment locking and de-energization management method (7) which makes use of the locking and de-energization management system, enhancing the safety, efficiency and productivity during locking and de-energization of the power source (6) of an item of equipment (7) undergoing maintenance.