Automated Machine Configuration Checking Against Safety Rules
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Solution Overview
Problem
Current automated machine systems lack effective methods to ensure safety compliance with evolving safety standards and detect malfunctions or changes in technical devices and safety sensors, which can lead to safety breaches and inefficiencies.
Innovation Solution
A system comprising a control device that retrieves and analyzes safety sensor and technical device description data against predefined safety rules, using machine learning and expert systems to monitor and adjust configurations to ensure compliance with safety standards, and detect potential safety issues or malfunctions, thereby issuing warnings or initiating corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated machines operate without continuous safety monitoring, then productivity increases, but safety compliance deteriorates
Solution Approach 1:
The system performs preliminary safety assessments by retrieving safety rules and comparing them against current machine configurations before operations proceed. This proactive approach ensures safety compliance is established in advance, allowing continuous operation without interruptions while maintaining safety standards.
Solution Approach 2:
The control device continuously monitors machine operation by retrieving current configuration data and comparing it against stored safety rules. When deviations are detected, the system provides feedback through alerts and warnings, enabling real-time corrective actions while maintaining continuous operation and productivity.
2Reliability
If safety rules are manually updated to reflect evolving standards, then safety compliance improves, but device complexity increases
Solution Approach 1:
Safety rules are pre-stored in the control device's memory, allowing the system to automatically reference and enforce current safety standards without requiring manual configuration during operation. This preliminary preparation simplifies the operational complexity while maintaining compliance with evolving standards.
Solution Approach 2:
The control device automatically retrieves and applies safety rules from its internal storage without requiring manual intervention or complex configuration procedures. This self-service capability maintains safety compliance while minimizing the complexity burden on operators and system administrators.
3Reliability
If comprehensive safety monitoring is implemented, then safety compliance improves, but loss of time increases
Solution Approach 1:
The safety monitoring system operates continuously in the background during machine operation, retrieving and comparing configuration data without interrupting production workflows. This continuous passive monitoring ensures comprehensive safety compliance while minimizing time loss by avoiding repeated manual checks and maintaining operational flow.
Data Source
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AI summary
Aspects of operating an automated machine (1) include: a database device (101) for storing a plurality of machine safety rules (SRj) in terms of relationships between safety-sensor devices (6, 7, 8, 9) and technical devices (2, 3, 4, 5), in particular requirements between safety-sensor device description data (DSDi) and technical-device description data (DDi); and a control device (102) implemented: to retrieve the safety-sensor device description data (DSDi) and the technical-device description data (DDi) associated to the technical devices (2, 3, 4, 5) and the safety-sensor devices (6, 7, 8, 9) comprised in the automated machine (1), to retrieve, from the database device (101), safety rules (SRj) corresponding to the retrieved safety-sensor device description data (DSDi) and the technical-device description data (DDi), to determine as to whether the retrieved safety-sensor device description data (DSDi) and the technical-device description data (DDi) comply with retrieved safety rules (SRj).