Interlocked Device Operation Prediction for Safer Control Changes
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Solution Overview
Problem
In facilities with multiple interlocked devices, operators often lack comprehensive knowledge of all devices, leading to unpredicted outcomes when changing operation states, potentially causing accidents due to unrecognized impacts on interconnected systems.
Innovation Solution
An operation prediction system that includes a controller, prediction input unit, state prediction unit, and information acquisition units to forecast the impact of control changes on multiple devices by analyzing real-time state information and historical operation records, using simulators when necessary, and displaying predicted outcomes to the user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If workers operate devices based on their personal knowledge, then operation simplicity is maintained, but prediction accuracy of device behavior deteriorates
Solution Approach 1:
The system creates a virtual copy (digital twin) of the physical device that replicates its behavior and state. This virtual model can be manipulated and observed without affecting the actual device, allowing workers to predict outcomes of operational changes safely. The virtual copy maintains the same structural and behavioral characteristics as the real device, enabling accurate prediction while keeping the actual operation simple.
Solution Approach 2:
The system performs preliminary simulations and predictions before actual operational changes are made. By using the virtual device model to pre-test operational scenarios and predict outcomes, the system allows workers to make informed decisions about actual device operations. This preliminary action prevents unexpected behaviors while maintaining ease of operation through guided decision-making.
2Ease of operation
If workers focus on devices they are responsible for, then operational control is simplified, but awareness of interlocked devices deteriorates
Solution Approach 1:
The system implements comprehensive feedback mechanisms that continuously monitor and display the state of all interlocked devices to the worker. When a worker operates a device, the system provides immediate feedback showing how this operation affects other interlocked devices through the virtual model. This feedback loop maintains operational control simplicity while preventing information loss about interdevice relationships.
Solution Approach 2:
The system adds a virtual dimension to the physical operational space. By displaying the state and interrelationships of multiple devices in a virtual environment, workers can perceive connections between devices that are not obvious in the physical workspace. This additional dimensional representation preserves simple operational control while enhancing awareness of interlocked device relationships.
Data Source
AI summary
An operation prediction system for multiple devices, according to one embodiment of the present invention, comprises: a control unit; a first device of which the operation state is changed by being controlled by the control unit; a second device which is linked to the first device; a prediction input unit which receives a prediction input which is an input for predicting the operation state to be changed of the first device; and a state prediction unit which predicts operation prediction information including information on the operation state of the first device, which is to be changed by the controlling of the control unit, and information on the impact on the second device as a result of the operation state to be changed of the first device.