Dynamic Machine Risk Assessment Using Real-Time Sensor Data
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Solution Overview
Problem
Current risk assessment methods for machines are largely manual, subjective, and inadequate for dynamic and flexible production environments, leading to incomplete risk reduction and inefficiencies in adapting to changing production conditions and interfaces.
Innovation Solution
A dynamic risk assessment system that uses a computer with a control and evaluation unit to collect and analyze data for formalized risk parameter classification, enabling continuous assessment and adaptation of risk reduction measures, and automatically adjusts risk assessments based on real-time data and changing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual risk assessment methods are used, then the process is simple to implement, but the assessment is highly subjective and may miss risks
Solution Approach 1:
The patent replaces manual mechanical risk assessment processes with an automated computer-based system that uses sensors, data processing, and algorithms to identify and evaluate risks objectively, eliminating human subjectivity while maintaining ease of use through automated workflows
Solution Approach 2:
The system enables machines to self-assess their own risk profiles by automatically collecting operational data, analyzing it through predefined criteria, and generating risk assessments without requiring external manual intervention, thereby improving both reliability and ease of implementation
2Productivity
If simple risk assessment methods are used, then the process can be implemented quickly, but the risk assessment is inaccurate due to limited parameters
Solution Approach 1:
The patent segments the risk assessment process into multiple independent evaluation dimensions including safety risks, quality risks, delivery risks, and financial risks, each assessed with specific parameters, allowing comprehensive evaluation to be performed systematically and efficiently in parallel
Solution Approach 2:
The system creates a universal risk assessment framework that can evaluate multiple types of risks across different machines and production scenarios using a standardized multi-dimensional model, enabling accurate assessments to be performed quickly across diverse applications
3Reliability
If strict machine limits are defined, then legal certainty is achieved, but flexibility and adaptability to dynamic production environments are reduced
Solution Approach 1:
The patent implements dynamic risk assessment that continuously monitors machine operational parameters and automatically adjusts risk evaluations in real-time based on actual conditions, allowing the system to maintain legal compliance while adapting flexibly to changing production environments without requiring manual reassessment
4Adaptability or versatility
If frequent risk assessments are performed to adapt to dynamic manufacturing, then adaptability improves, but time expenditure increases
Solution Approach 1:
The system performs continuous risk assessment by continuously collecting operational data from sensors and machine systems, automatically analyzing this data in real-time, and maintaining up-to-date risk evaluations without interruption, thereby achieving high adaptability while eliminating the time loss associated with periodic manual reassessments
Data Source
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AI summary
System and method comprising a system (1) with at least one machine (2) and at least one protective device, sensor (3) or sensor system for safety-related safeguarding of the machine (2), wherein the system (1) performs the following steps: - Cyclic reading and acquisition of machine characteristics and machine descriptions (5) of the machine (2), - Cyclic reading and acquisition of protective device characteristics, protective device descriptions, sensor characteristics, sensor descriptions (6) and application data of the protective device, sensor (3) or sensor system, - Cyclic reading of application data and application descriptions (7) of an application for the machine (2), - Identification of hazards (9) emanating from the machine (2) and identification of associated hazardous situations at the respective machine (2),- wherein a risk assessment and a risk evaluation (13) for a user (10) of the machine is carried out cyclically by the system (1) and decisions on the need for risk minimization are made cyclically, whereby the system (1) is trained to automatically and dynamically create a risk evaluation (13) of the at least one machine (2).