Remote Wireless Lockout System for Machine Safety Verification
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Solution Overview
Problem
Current lock-out/tag-out procedures for large machines are unsafe due to the risk of injury from personnel accessing manual locks or lockout mechanisms, as they do not ensure the machine is in a safe location prior to maintenance and lack effective remote control options.
Innovation Solution
A system and method for remotely initiating and managing Lock Out/Tag Out (LO/TO) procedures using wireless control devices, allowing service technicians to safely shut down and secure machines from a distance, with features like GPS-based location verification and safety zone detection to prevent unauthorized access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual lockout mechanisms are accessed physically, then the lockout procedure can be completed, but personnel are exposed to injury risk due to required proximity to the machine
Solution Approach 1:
The patent replaces manual mechanical lockout operations with an automated electronic system. The control device automatically engages lockout mechanisms and monitors machine state through sensors, eliminating the need for personnel to physically access hazardous areas. This substitution of mechanical manual operations with automated electronic control directly resolves the contradiction by maintaining operational completeness while removing personnel exposure to injury risks.
Solution Approach 2:
The patent introduces a control device as an intermediary between personnel and the machine lockout mechanism. This intermediary automatically performs lockout engagement, state verification, and monitoring functions, allowing personnel to initiate and oversee the process from a safe distance without direct physical contact with hazardous components. The intermediary resolves the contradiction by mediating the interaction between human operators and dangerous machinery.
2Reliability
If lockout procedures are performed manually, then the process can be completed, but the machine may not be verified to be in a safe location or state prior to maintenance
Solution Approach 1:
The patent implements continuous feedback loops where sensors monitor machine state parameters (position, operational status, environmental conditions) and automatically report to the control device. The system verifies safe state through this feedback mechanism before allowing lockout completion, ensuring the machine is in a verified safe location and condition. This automated feedback system resolves the contradiction by providing reliable verification without requiring complex manual checking procedures.
Solution Approach 2:
The patent enables the machine system to self-verify its own safe state through integrated sensors and control logic. The machine automatically monitors its own parameters, determines whether it is in a safe configuration for maintenance, and communicates this status to the control device. This self-service verification capability resolves the contradiction by providing reliable safety confirmation without adding external complexity to the lockout procedure.
3Ease of operation
If technicians approach the machine for lockout operations, then they can manually secure the machine, but they are exposed to hazardous conditions and potential injury
Solution Approach 1:
The patent replaces manual mechanical lockout operations with an automated electronic system. The control device automatically engages lockout mechanisms and monitors machine state through sensors, eliminating the need for personnel to physically access hazardous areas. This substitution of mechanical manual operations with automated electronic control directly resolves the contradiction by maintaining operational completeness while removing personnel exposure to injury risks.
Solution Approach 2:
The patent extracts the hazardous element of physical proximity from the lockout procedure. By implementing remote automated control, the system separates the personnel from the dangerous machine environment while maintaining full functional capability to perform lockout operations. This extraction of the hazardous proximity requirement resolves the contradiction by allowing complete lockout execution without exposing technicians to machine hazards.
Data Source
AI summary
A remote lock-out/tag-out system and method allow a remote service technician to remotely lock-out a machine via a remote wireless control device. In one aspect, the lock-out initiation request is sent from the remote wireless control device to the machine. The remote wireless control device then receives from the machine an indication that the machine location and state are suitable for lock-out. In response, the remote wireless control device sends a lock-out command to the machine.