Personnel Key Tracking System for Automated Work Cells
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Solution Overview
Problem
Existing safety control systems for automated work cells require complete shutdown of machinery when a worker enters, lacking means to track the worker's location and allowing resumption of automation only after the worker exits, leading to inefficiencies in processes where frequent entry is needed.
Innovation Solution
A safety system with controlled access points, secondary and tertiary key receptacles, and optional light barriers and fingerprint scanners, allowing workers to enter and work within a safety sub-cell while automation continues, ensuring safety through failsafe mechanisms and authorization for resuming automation only when all access points are secure and workers are authenticated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional trapped key systems are used to ensure worker safety in automated cells, then safety is improved by requiring key removal to enter, but productivity deteriorates because automation must be completely shut down whenever a worker enters
Solution Approach 1:
The automated work cell is divided into multiple zones with different safety requirements. The key tracking system segments the cell into areas where automation can continue operating while workers are present in designated safe zones, rather than requiring complete shutdown. This allows partial automation operation while maintaining safety protocols.
Solution Approach 2:
The system continuously tracks the location and status of keys in real-time using sensors and communication protocols. This feedback mechanism allows the control system to make informed decisions about which automation functions can safely operate while workers are present, enabling dynamic adjustment of automation operation based on current safety conditions.
2Reliability
If complete automation shutdown is implemented when workers enter the cell, then worker safety is ensured, but time is lost due to repeated shutdowns and restarts during frequent entries
Solution Approach 1:
The system performs preliminary safety assessments and authorizations before allowing workers to enter specific zones. By pre-establishing safe entry conditions and authorized zones, the system avoids repeated shutdowns when workers enter pre-approved areas, reducing the time loss associated with frequent entries and exits.
Solution Approach 2:
The automation system dynamically adjusts its operation based on real-time worker location and key status. Rather than static complete shutdowns, the system dynamically allows automation to continue in areas where workers are not present, optimizing the balance between safety and productivity during entry/exit cycles.
3Productivity
If key tracking and location monitoring systems are added to trapped key systems, then productivity can be improved by allowing automation to resume, but device complexity increases due to additional sensors and tracking mechanisms
Solution Approach 1:
The key tracking system is designed to serve multiple functions: it tracks key location, monitors worker presence, authorizes zone entry, and controls automation operation. By making the tracking system multi-functional, the patent reduces the need for separate dedicated systems for each function, thereby limiting the increase in overall device complexity while achieving productivity improvements.
4Productivity
If frequent worker entry into automated cells is permitted, then productivity is improved by reducing shutdown time, but safety risk increases without proper tracking of worker location
Solution Approach 1:
The system continuously monitors worker location and key status through real-time feedback from sensors and tracking devices. This feedback enables the control system to dynamically assess safety conditions and allow automation to operate in areas where workers are not present, permitting frequent entries while maintaining safety by preventing hazard exposure through informed control decisions.
Data Source
AI summary
A safety system comprising a work area having a perimeter and hazardous automated machinery within the perimeter, wherein access by workers to the work area within the perimeter is controlled by one or more controlled access points; at least one safety work cell within the perimeter, each safety work cell having no hazardous automated machinery within or accessible from the safety work cell; a primary key-secondary key system which includes a tertiary key receptacle within the safety work cell; an optional light barrier surrounding each safety work cell; optional fingerprint scanners to authenticate authorized persons, and a controller programmed to permit operation of the hazardous automated machinery only when all controlled access points are closed, all secondary keys are placed within either a secondary key receptacle or a tertiary key receptacle, any light barrier has not been tripped by interruption of the light barrier, and any fingerprint scanners have authenticated a person.