Production Safety Decision Hardware for Multi-Factor Risk Analysis

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Solution Overview

Problem

Intelligent manufacturing lacks an effective and reliable safety production risk decision-making system for comprehensive multi-factorial models across various production line aspects, particularly in rapidly changing environments, leading to high misjudgment rates and time delays in safety decisions.

Innovation Solution

An intelligent hardware system for production safety decision-making, incorporating data acquisition, processing, and analysis modules, utilizing subjective and objective risk factor analyses with intuitionistic fuzzy numbers and grey prediction models to predict bottlenecks and schedule maintenance, integrating temperature, pressure, and gas sensors for real-time data collection and processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional sensor-based monitoring and alarm systems are used for safety production risks, then basic safety monitoring is achieved, but misjudgment rates are high and time delays occur due to lack of comprehensive multi-factorial analysis

Engineering Contradiction:

Improvesafety production risk decision reliabilityVSAvoidtime delay in safety decisions

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system segments the risk assessment into multiple independent modules: subjective risk factor analysis module, objective risk factor analysis module, and their integration. Each module processes specific aspects of risk information separately before combining results, enabling comprehensive multi-factorial analysis without overwhelming processing delays.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by pre-processing sensor data, pre-calculating risk probabilities, and establishing baseline safety parameters before actual risk events occur. This advance preparation enables faster decision-making when risks materialize, reducing response time while maintaining accuracy.

Inventive Principle:

Principle #10Preliminary action

2Measurement precision

If comprehensive multi-factorial models are implemented for safety risk assessment, then decision accuracy improves, but system complexity increases and processing time delays occur

Engineering Contradiction:

Improvesafety risk assessment precisionVSAvoiddecision-making system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The complex risk assessment model is segmented into distinct processing stages: data collection, subjective risk factor analysis, objective risk factor analysis, and integrated decision-making. Each stage handles specific computational tasks independently, making the overall complex system manageable and scalable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system introduces intermediary processing layers including data preprocessing modules and risk probability calculation units that mediate between raw sensor data and final risk decisions. These intermediaries simplify the relationship between complex input data and decision outputs, reducing direct system complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Quantity of substance

If real-time data collection from multiple sensors is implemented, then monitoring coverage is improved, but data processing burden increases and decision-making speed decreases

Engineering Contradiction:

Improveamount of safety monitoring dataVSAvoidsafety decision-making speed

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The system extracts and isolates critical safety parameters from the vast amount of sensor data, focusing processing resources on the most relevant risk indicators. By filtering out redundant information and concentrating on key safety metrics, the system maintains comprehensive monitoring while reducing processing burden.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system performs preliminary data processing and risk probability calculations in advance, preparing processed information for rapid decision-making. This pre-processing of critical safety data enables fast response when decisions are needed, maintaining both comprehensive data collection and quick decision-making speed.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20260105392A1Intelligent hardware for production safety decision-making

Publication Date: 2026.04.16 XIANGFU LABORATORY

AI summary

An intelligent hardware for production safety decision-making comprises a data acquisition module for real-time acquisition of physical quantities in the production environment and production equipment; a data processing module, used to pre-process the collected physical quantity data and predict production bottlenecks; an intelligent analysis and decision-making module, used to analyze the failure risk of production equipment based on the collected physical quantity and production bottleneck data, and to perform scheduling process based on the production bottleneck data and failure risk analysis results; the fault risk analysis is divided into the subjective risk factor analysis and objective risk factor analysis, the subjective risk factor analysis in this invention uses intuitionistic fuzzy numbers to assign specific risk values, which can handle the uncertainty and fuzziness in the evaluation process, making the evaluation results closer to the actual situation.