Radio-Location Safety Monitoring for Longer Pre-Warning in Hazard Zones
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Solution Overview
Problem
Current safety systems in factories and logistics sectors rely heavily on local, optical safety sensors with limited range, which restricts machine parameters like travel speed and provides only short pre-warning times, often resulting in emergency stops that disrupt productivity.
Innovation Solution
A safety system that integrates a radio location system with at least three radio stations and a radio transponder on each object, allowing for centralized position determination and bidirectional communication, which merges local sensor information with higher-ranking position data for enhanced safety functions and diagnostic mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If local optical safety sensors are used to secure hazard sites, then safety monitoring is achieved, but the detection range is limited and pre-warning time is short
Solution Approach 1:
The patent combines local optical safety sensors with a central RTLS server to create a hierarchical safety system. The local sensors provide high-resolution environmental monitoring while the RTLS system provides long-range position tracking, merging both approaches to achieve comprehensive safety coverage with extended detection range and adequate pre-warning time.
2Reliability
If local optical safety sensors are used, then safety detection is provided, but machine travel speed must be restricted
Solution Approach 1:
The RTLS system provides early position detection and pre-warning signals to operators before objects enter hazard zones defined by local optical sensors. This preliminary action allows operators to take preventive measures, enabling machines to maintain higher travel speeds while still ensuring safety through advance warning.
3Loss of information
If local optical sensors are deployed, then detailed environmental information is obtained, but this information is not available to central control systems
Solution Approach 1:
The system establishes bidirectional communication between local optical sensors and the central RTLS server. High-resolution environmental information from local sensors is fed back to the central system, enabling comprehensive monitoring and coordinated safety responses while maintaining manageable system integration through standardized communication protocols.
4Reliability
If emergency stop measures are taken frequently, then safety risks are avoided, but productivity is significantly disrupted
Solution Approach 1:
The system provides graduated safety responses starting with early pre-warning signals to operators, allowing them to take voluntary preventive actions before emergency stops are triggered. This preliminary action reduces unnecessary emergency stops and maintains productivity while still ensuring safety through a hierarchy of responses ranging from warnings to emergency stops only when absolutely necessary.
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
This solution enables more effective and targeted safety interventions by providing longer pre-warning times, reducing the need for emergency stops, and allowing for increased machine productivity while maintaining safety standards.
Implementation Method 1
position data of the radio transponder and thus position data of the object can be determined by means of the radio location system
Data Source
AI summary
A safety system for the localization of at least one spatially variable object having at least one control and evaluation unit, having at least one radio location system, having at least one spatially resolving sensor for the detection of an object in a detection zone of the spatially resolving sensor, wherein the radio location system has at least three arranged radio stations, wherein at least one radio transponder is arranged at the object, wherein position data of the radio transponder and thus position data of the object can be determined by means of the radio location system, wherein the position data can be transmitted from the radio station of the radio location system to the control and evaluation unit, wherein the control and evaluation unit is configured to cyclically detect the position data of the radio transponder and information on the object in the detection zone can be determined by means of the spatially resolving sensor.