Maintenance Controller for Hazard-Mode Machine Speed Reduction
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Solution Overview
Problem
Heavy equipment with control systems that include personnel or object detection sensors often prevent movement during service or troubleshooting, as sensors detect hazards and trigger disablement, hindering maintenance and calibration processes.
Innovation Solution
A maintenance-service system with a controller that enables movement of heavy equipment at a reduced speed when authorization data is received, allowing operation in a hazard detected mode without full disablement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hazard detection sensors are activated to ensure safety, then safety is improved, but machine movement is prevented during maintenance and troubleshooting
Solution Approach 1:
The system dynamically adjusts the operational state based on authorization input. When authorized, the control system transitions from a disabled state to an enabled state, allowing machine operation despite detected hazards. This dynamic response resolves the contradiction by making the safety system adaptable rather than static.
Solution Approach 2:
An authorization mechanism acts as an intermediary between the hazard detection system and the machine control system. This intermediary layer allows authorized personnel to override the hazard-induced disablement, enabling movement when appropriate while maintaining safety for unauthorized operations.
2Reliability
If the control system disables machine movement when hazards are detected, then safety is improved, but maintenance and troubleshooting time increases
Solution Approach 1:
The control system transitions dynamically between disabled and enabled states based on authorization. This allows maintenance personnel to quickly enable the machine for troubleshooting when hazards are present, reducing downtime while maintaining safety through the authorization requirement.
Solution Approach 2:
The authorization mechanism is prepared in advance, allowing authorized personnel to quickly override the hazard detection disablement when maintenance is needed. This preliminary preparation of the authorization system reduces the time penalty associated with safety interlocks.
3Reliability
If hazard detection sensors are activated to ensure safety, then safety is improved, but machine speed must be reduced during authorized operation
Solution Approach 1:
The system applies different operational characteristics to different operational contexts. When operating with detected hazards present, the machine runs at reduced speed under authorization, while normal speed is available when no hazards are detected. This local differentiation resolves the contradiction by applying speed restrictions only where necessary.
Solution Approach 2:
The control system changes the speed parameter based on the operational context and authorization state. When hazards are detected and authorization is received, the system adjusts the speed parameter to a reduced value, allowing operation while maintaining enhanced safety margins in hazardous conditions.
Data Source
AI summary
A maintenance-service system and method for controlling a machine that includes a plurality of operational modes is disclosed. The plurality of operational modes including a normal mode and a hazard detected mode. The maintenance-service system may comprise a controller configured to receive authorization data when machine is in the hazard detected mode, and enable movement of the machine at a reduced machine speed based on the authorization data, wherein the reduced machine speed is less than 50% of a normal machine speed available to the machine when the operational mode is the normal mode, wherein, the hazard detected mode precludes movement of the machine.