Safety Interlock Failure Prediction Using Real-Time Alarm Data

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Solution Overview

Problem

Existing safety interlock devices in roll package production equipment are not effectively monitored for failures, leading to potential safety risks due to manual inspection inadequacies.

Innovation Solution

A method and system for predicting safety interlock failure using real-time operation data analysis, including training a model to identify fault and non-fault alarm information, and generating early warning information when failure is predicted.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If operator-based point inspection and safety personnel-based routing inspection are used to judge safety interlock device failures, then the inspection process is simple and does not require complex monitoring systems, but the safety interlock device may actually fail without being detected, resulting in potential safety problems

Engineering Contradiction:

Improvesafety detection reliabilityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual inspection methods (operator-based point inspection and safety personnel-based routing inspection) with an automated monitoring system that collects alarm information and operates the prediction model electronically. This substitution of mechanical/manual processes with automated electronic monitoring improves detection reliability while managing system complexity through software-based solutions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The monitoring system enables the safety interlock device to self-monitor through automated collection of alarm information and self-diagnosis via the prediction model. The system performs self-assessment of its own safety status without requiring external manual inspection, thereby improving reliability while keeping the system architecture relatively simple.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If manual inspection methods are used to monitor safety interlock devices, then the system complexity is low, but the detection accuracy is insufficient leading to undetected failures

Engineering Contradiction:

Improvefailure detection accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary prediction model that processes alarm information between the raw data collection and the final failure detection. This intermediary layer analyzes alarm patterns and provides more accurate failure predictions than direct manual inspection, improving measurement precision while adding only moderate system complexity through software processing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The monitoring system implements feedback mechanisms by continuously collecting alarm information, analyzing it through the prediction model, and using the results to improve future detections. The system learns from historical alarm patterns and adjusts its prediction accuracy over time, enhancing detection precision without proportionally increasing system complexity.

Inventive Principle:

Principle #23Feedback

3Reliability

If real-time operation data analysis with prediction models is implemented, then the failure detection accuracy is significantly improved, but the device complexity increases due to data collection and processing requirements

Engineering Contradiction:

Improvesafety interlock failure prediction reliabilityVSAvoiddata collection and processing system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The monitoring system is designed with multi-functionality to handle multiple tasks within a unified architecture: collecting alarm information, storing historical data, operating the prediction model, and generating warnings. This universal approach improves reliability through comprehensive monitoring while managing complexity by consolidating functions into a single integrated system rather than separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system performs preliminary actions by pre-collecting and storing alarm information and historical operation data before failures occur. The prediction model is pre-trained with historical data to enable accurate real-time predictions. This preliminary preparation improves reliability by ensuring data is ready for analysis while organizing system complexity through structured data management procedures.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12579453B2Safety interlock failure prediction method and roll production system

Publication Date: 2026.03.17 ZHANGJIAKOU CIGARETTE FACTORY

AI summary

The present disclosure provides a method for predicting safety interlock failure and a system for producing a roll package. The method for predicting safety interlock failure includes: obtaining, by a model for predicting safety interlock failure, real-time operation data of the production equipment to perform prediction; predicting, by the model for predicting safety interlock failure, whether the safety interlock device fails according to fault shutdown alarm information and non-fault shield alarm information in the real-time operation data, and generating a prediction result; and if the prediction result indicates that the safety interlock device fails, generating early warning information, wherein the fault shutdown alarm information is alarm information generated when the safety shield is opened to shut down the production equipment, and the non-fault shield alarm information is alarm information generated when the safety shield is opened or closed after the production equipment is shut down.