RFID Padlock for Industrial Switch Monitoring

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Solution Overview

Problem

Existing padlocks for securing industrial plant switches lack a reliable and efficient method for monitoring and documenting their usage, particularly in ensuring the switch remains in a safe position during service work, and do not provide adequate protection against mechanical damage or contamination.

Innovation Solution

A padlock with a plastic lock housing containing a displaceable hoop and a lock cylinder, integrated with an RFID transponder for secure radio communication, allowing for the identification and documentation of the padlock's presence and position, and providing protection against mechanical stress and contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a padlock is used to secure a switch in the OFF position, then the switch is protected against accidental activation, but there is no reliable method for monitoring and documenting the padlock's usage

Engineering Contradiction:

Improveswitch safetyVSAvoidusage documentation

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent replaces the purely mechanical padlock system with an electronic monitoring system using RFID technology. The RFID transponder integrated into the padlock enables automatic documentation of usage data, eliminating the need for manual recording and providing reliable electronic tracking of padlock attachment and removal events.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a feedback mechanism where the RFID transponder continuously communicates usage information to a central system. This feedback loop provides real-time monitoring of padlock status, enabling automatic documentation of service work duration and switch security state without requiring manual intervention.

Inventive Principle:

Principle #23Feedback

2Loss of information

If an RFID transponder is integrated into the padlock for monitoring, then usage documentation is improved, but the padlock becomes more susceptible to mechanical damage and contamination

Engineering Contradiction:

Improveusage documentationVSAvoidmechanical damage and contamination

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The patent embeds the RFID transponder within the internal structure of the padlock housing, nesting the electronic component inside the protective mechanical shell. This nested arrangement protects the sensitive RFID electronics from external mechanical damage, contamination, and environmental factors while maintaining RFID signal transmission capability.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent uses a composite structure combining the mechanical padlock housing with integrated RFID electronics. The durable outer housing provides mechanical protection while the embedded RFID transponder adds electronic monitoring functionality, creating a composite system that benefits from both mechanical strength and electronic intelligence.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If multiple service engineers need to secure the switch independently, then service flexibility is improved, but the monitoring system complexity increases

Engineering Contradiction:

Improveservice flexibilityVSAvoidmonitoring system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates a universal padlock system where each padlock contains an RFID transponder that can be independently identified and tracked. Multiple service engineers can use identical padlocks with unique RFID identifiers, allowing the system to handle multiple users simultaneously without requiring different types of locks or complex user-specific configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables reliable and efficient monitoring and documentation of the padlock's usage, ensuring the switch remains securely locked, while the RFID transponder's protection against damage and contamination ensures reliable operation and data integrity.

Implementation Method 1

integrated with an RFID transponder for secure radio communication, allowing for the identification and documentation of the padlock's presence and position

Methodology Applied

Scientific EffectRFID (Radio Frequency Identification): Electromagnetic Induction

Data Source

PatentUS10119303B2Padlock for securing and monitoring a switch

Publication Date: 2018.11.06 ABUS AUGUST BREMICKER SOEHNE KG

AI summary

A padlock for securing and monitoring a switch of an industrial plant has a lock housing of plastic, furthermore a hoop which is displaceably held at the lock housing and a lock cylinder which is arranged in the lock housing and can selectively be brought from an open position into a locked position to lock the hoop to the lock housing. An RFID transponder is arranged in the lock housing. A securing and monitoring system for a switch of an industrial plant includes at least one such padlock and a mobile RFID reading device or an RFID reading device permanently attached in the environment of the switch, said RFID reading device being configured to read out the RFID transponder of the padlock.