Industrial Machine Control Using Worker Safety Level Assessment
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Solution Overview
Problem
Industrial machines at manufacturing sites face risks of erroneous manipulation due to changes in worker physical conditions and environmental factors, which can lead to reduced attention and concentration, potentially causing accidents and decreasing production efficiency.
Innovation Solution
A controller and control system that monitor worker biometric and environmental information to determine a safety level, implementing partial work restrictions and activating safety functions based on this assessment to ensure continuous operation while minimizing error and accident risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operation of the industrial machine is stopped to restrict worker work due to poor physical condition, then worker safety is improved, but production efficiency suddenly decreases
Solution Approach 1:
The patent applies dynamics by making the control state of the industrial machine changeable based on worker condition. The controller dynamically adjusts between normal operation, restricted operation, and stopped operation modes according to the assessed safety level, allowing flexible adaptation rather than fixed stoppage or continuous operation
Solution Approach 2:
The patent changes operational parameters by adjusting drive restriction levels and safety function activations based on the determined safety level. Instead of binary stop/go decisions, the system modifies operational parameters such as drive permission, speed limits, and safety function activation to balance safety and productivity
2Productivity
If the operation of the industrial machine is continued without restriction, then production efficiency is maintained, but the risk of manipulation error and accident increases
Solution Approach 1:
The patent implements feedback by continuously monitoring worker biometric information and environmental conditions, assessing safety level, and adjusting machine operation accordingly. The system creates a closed-loop control where operation status is continuously adjusted based on real-time worker state feedback
Solution Approach 2:
The patent applies preliminary action by assessing worker safety level before allowing operation and continuously monitoring during operation. The system proactively determines safety level based on biometric and environmental data before permitting machine operation, and prepares appropriate control measures in advance
Data Source
AI summary
A controller acquires biometric information of a worker and environmental information related to work environment and determines a safety level of the worker in a plurality of steps according to a safety level determination condition stored in advance on the basis of the acquired biometric information and environmental information. Then, the controller continuously controls an operation of an industrial machine in a state of a predetermined restriction being applied to a driving unit of the industrial machine and in a state of a predetermined safety function being activated on the basis of the determined safety level.