Machine Vision Safety Interlock for Industrial Machine Operation
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Solution Overview
Problem
Industrial machines pose safety risks due to the potential for workpieces to shift or move during operation, necessitating effective monitoring and control systems to ensure operator safety and prevent accidents.
Innovation Solution
A control system that utilizes an imaging device to monitor an image zone around the machine for predefined colors, patterns, or shapes, transmitting signals to relay modules to halt or permit machine operation based on the presence of these indicators, ensuring operator safety and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional safety systems (arm restraint straps, safety procedures) are used to protect operators, then operator safety is improved, but operator convenience and ease of operation deteriorate
Solution Approach 1:
The patent replaces mechanical safety systems (arm restraint straps, physical safety procedures) with an optical sensing system using imaging devices and image processing algorithms. The system uses color, pattern, and shape recognition to detect operator presence and machine zone proximity, automatically controlling machine operation without requiring physical safety equipment from the operator.
Solution Approach 2:
The patent introduces an intermediary image processing system that acts as a mediator between the operator and the machine. This system processes visual information about operator presence and machine zone status, then automatically controls machine operation based on safety conditions, eliminating the need for direct operator interaction with safety mechanisms.
2Reliability
If image processing is used to detect operator presence and control machine operation, then operator safety is improved, but device complexity increases
Solution Approach 1:
The imaging device serves multiple functions: it detects operator presence, determines proximity to machine zones, identifies operator intent through gesture recognition, and provides visual feedback. This multi-functionality reduces the need for separate sensors and control systems, thereby managing complexity while enhancing safety capabilities.
Solution Approach 2:
The system creates a visual copy or representation of the physical workspace through imaging, allowing the control system to analyze and respond to operator presence and machine zone status without requiring complex physical sensors. This virtual model simplifies the control logic by working with image data rather than multiple physical sensor inputs.
3Reliability
If the machine halts operation frequently to ensure safety, then operator safety is improved, but productivity decreases
Solution Approach 1:
The system applies partial action by halting machine operation only when and where necessary - specifically when the operator is in dangerous proximity zones or when safety conditions are not met. When safety conditions are satisfied, the machine operates normally without interruption, thus maintaining productivity while providing targeted safety protection.
Solution Approach 2:
The system continuously monitors operator presence and machine zone status through imaging, providing real-time feedback to the control system. This feedback loop allows the machine to operate safely and efficiently by automatically adjusting operation based on current safety conditions, minimizing unnecessary halts while maintaining safety standards.
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
The system effectively differentiates between material and operator presence, halting the machine when necessary to prevent accidents and allowing operation when safety conditions are met, thereby enhancing operational safety and efficiency.
Implementation Method 1
receiving image data from an imaging device that monitors an image zone around the industrial machine
Data Source
AI summary
A control system for operation of an industrial machine includes a processor and a tangible, non-transitory, computer-readable memory communicating with the processor. The tangible, non-transitory computer-readable memory includes instructions that, in response to execution by the processor, cause the processor to perform operations including: receiving image data from an imaging device that monitors an image zone around the industrial machine, and analyzing the image data. The processor further performs operations including determining, based upon the analyzing, that the control system is functional, determining, based upon the analyzing, that the image data includes at least one of a predefined color, a predefined pattern, and a predefined shape, and transmitting a proximity signal to at least one relay module coupled between the processor and the industrial machine to halt operation of the industrial machine.