Magnetic Proximity Detection for Mining Machine Safety
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Solution Overview
Problem
Industrial machines, such as continuous mining machines, pose safety risks due to their large size and unstructured operating environments, making it difficult to implement traditional safety systems like light fences or sonar/laser sensors, which are often unreliable and impractical in noisy, dusty conditions. Existing magnetic field-based systems lack geometric control over safety perimeters, leading to inefficient operation and potential hazards.
Innovation Solution
A system comprising a first transmitter unit carried by the operator, transmitting a magnetic proximity signal, and multiple receiver units on the machine, which determine the signal strength and location of the transmitter unit relative to the machine, allowing for precise definition of safety boundaries and automatic machine shutdown if the operator is too close, using a processing unit to output warning or control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional operator protection systems (light fences, guard rails) are implemented, then operator safety is improved, but the system cannot be deployed in unstructured environments and requires environmental structures that are difficult to install
Solution Approach 1:
The patent replaces mechanical protection systems (light fences, guard rails) with a magnetic field-based detection system. The machine is equipped with magnetic field sensors that detect the operator's proximity through magnetic field distortion, eliminating the need for physical environmental structures and enabling deployment in unstructured environments.
Solution Approach 2:
The patent introduces magnetic field sensors as an intermediary detection mechanism. These sensors detect the operator's presence by sensing distortions in the magnetic field caused by the operator's body, serving as a mediator between the operator and the machine's safety system without requiring direct line-of-sight or environmental structures.
2Measurement precision
If sonar and laser time-of-flight sensors are used, then proximity detection capability is improved, but the sensors become dirty and non-operational quickly in noisy, dusty, wet environments
Solution Approach 1:
The patent substitutes optical sensors (sonar, laser) with magnetic field sensors. Magnetic field sensors are not affected by dust, noise, or moisture, eliminating the reliability issues associated with optical sensors in harsh environments while maintaining proximity detection capability.
3Reliability
If radar is used for proximity detection, then durability in harsh environments is improved, but the short distances between operator and machine make the sensor impractical and unreliable
Solution Approach 1:
The patent employs multiple magnetic field sensors positioned at different locations on the machine (e.g., boom, stick, bucket). Each sensor provides localized proximity detection data, and the system integrates these local measurements to achieve accurate overall proximity assessment at short distances.
Solution Approach 2:
The patent divides the detection system into multiple segmented magnetic field sensors distributed across different parts of the machine. This segmentation allows each sensor to cover a specific zone, improving overall detection accuracy at short distances while maintaining durability.
4Measurement precision
If magnetic field generator and sensor system is used, then operator location detection is improved, but the safety perimeter is limited to a circular shape, preventing arbitrary definition of safety boundaries
Solution Approach 1:
The patent uses multiple magnetic field sensors positioned at different locations and orientations on the machine. By combining data from these segmented sensors, the system can calculate the operator's position relative to different parts of the machine and define complex, arbitrary safety boundaries rather than being limited to circular perimeters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise determination of the operator's location relative to the machine, providing effective safety warnings and controlling machine operation to maintain safe distances, enhancing operational efficiency and safety without requiring environmental structures.
Implementation Method 1
The first transmitter unit transmitting a magnetic proximity signal
Data Source
AI summary
A system and method for detecting a proximity of a person to a machine includes a first transmitter unit carried by the person, a plurality of receiver units located on the machine at know locations, and a processing unit including data defining a first boundary around the machine. The first transmitter unit transmits a magnetic proximity signal having a predetermined signal strength and a predetermined signal frequency. Each of the plurality of receiver units is for determining a received signal strength of the received magnetic proximity signal. The processing unit: determines a location of the first transmitter unit relative to the machine based on the received signal strength of the magnetic proximity signal and the known location of the plurality of receiver units; and outputs a proximity warning signal if the location of the transmitter relative to the machine is within the first boundary around the machine.