Wireless Sensor Lockout Tagout Disconnect
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Solution Overview
Problem
Current lockout tagout systems in electrical systems rely on manual logging, which is prone to human error and lacks efficient data assimilation and communication, especially in multi-worker scenarios, making it difficult to manage and analyze lockout operations effectively.
Innovation Solution
A manually operated disconnect with integrated sensors and processing circuitry that automatically detects locks and tags via wireless communication, storing lockout data including user information, time, and machine details, enabling automated logging and real-time monitoring and reporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual logging is used for lockout tagout operations, then the system is simple to implement, but human error increases and data accuracy deteriorates
Solution Approach 1:
The patent replaces manual logging (mechanical/human process) with an automated sensor-based system that uses wireless communication to detect lock status and automatically log data. The sensor detects the lock state and transmits information wirelessly to a receiver, eliminating manual data entry and reducing human error while improving data accuracy.
Solution Approach 2:
The system enables self-service by allowing the lockout tagout process to automatically record and report its own status without requiring human intervention for data collection. The sensor autonomously detects lock application/removal and the system automatically logs the information, making the system record itself.
2Productivity
If automated sensor-based logging is implemented, then data accuracy and real-time monitoring improve, but device complexity increases
Solution Approach 1:
The patent replaces complex manual logging procedures with a streamlined automated system using sensors and wireless communication. This substitution improves productivity by enabling real-time monitoring and automatic data collection, while the wireless nature of the system keeps the added complexity relatively low compared to wired alternatives.
Solution Approach 2:
The system achieves multi-functionality by combining lock detection, automatic logging, real-time monitoring, and reporting capabilities into a single integrated system. This universal approach improves operational efficiency across multiple functions while avoiding the need for separate systems for each task.
3Loss of time
If wireless communication is used for automatic lock detection, then real-time data collection is achieved, but energy consumption increases
Solution Approach 1:
The patent employs periodic action by having the sensor transmit lock status information only when changes occur (lock applied or removed) rather than continuously. This event-triggered communication approach achieves real-time data collection when needed while minimizing energy consumption by keeping the system in a low-power state between events.
Solution Approach 2:
The wireless communication system replaces continuous manual monitoring with event-driven automatic detection. The sensor only activates and transmits data when a lock state change occurs, achieving real-time response to critical events while consuming minimal energy during idle periods.
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 enhances data accuracy and efficiency by reducing human error, providing real-time insights into lockout operations, and facilitating better management and safety through automated logging and customizable reports and graphs.
Implementation Method 1
a sensor retrofittable onto an in-service manual disconnect and configured to automatically detect via wireless communication a lock affixed to the disconnect
Data Source
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Figure 2A~2D
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AI summary
A manually operated disconnect maintains a machine/process in a de-energized state. The disconnect employs a sensor that automatically detects, via wireless communication, a lock affixed to the disconnect that locks the disconnect in an open state. Processing circuitry coupled to the sensor determines lockout tagout data, such as identification of a user associated with the lock, a time of application of the lock, and data identifying and/or locating the disconnect or a machine/process to which the disconnect provides power when in a closed state. Memory circuitry coupled to the processing circuitry stores the lockout tagout data, and holds it available for user review, transmission, analysis, reporting, and so forth