Location of the user for the control of machines and systems with mobile operating devices

Status:

completed 12/2024

Aims:

Wireless remote controls are now widely used to control machinery, systems, and equipment mounted on vehicles. The forms of wireless link used for this purpose include WLAN, Bluetooth, infrared and radio. In principle, wireless remote controls facilitate safer and more ergonomic working. For example, tripping accidents caused by control unit cables can be avoided. Wireless remote controls also provide their users with greater choice in the position from which to operate the equipment, for example by facilitating a better view of danger points or hazardous areas.

At the same time, the facility to initiate hazardous movements from almost any position also gives rise to new hazards. This is the case, for example, when care is not taken when movements on mobile machinery are being controlled. The hazards in question are mainly mechanical in nature. Serious and in some cases fatal accidents involving the use of wireless remote controls reveal a need for action. For example, the operator may themselves be located on a vehicle when controlling equipment mounted on it, or may be within the danger zone when loads are being tipped. During the operation of machinery or systems, the operator’s location must also enable them to view the danger zone without actually being within it.

The aim of this project is for technical measures to be used to specify a particular position at which the operator of a wireless remote control must be located. A machine or system can then be operated only if the operator is at a location specified beforehand; should they move away from it, they will no longer be able to operate the machinery or system. This project does not address the safety of other parties.

Activities/Methods:

The project examined safety concepts and technologies by which operation by means of wireless remote controls could be made dependent on the operator being at a specific location.

A number of different technologies were analysed for their suitability for requiring operators of wireless remote controls to be at a specific location. Procedural aspects for requiring the operator to be at a specified location in a range of applications were also taken into account, as were the safety requirements to be met by the corresponding functionality.

Examples of these aspects are the use of conventional equipment or technologies, and also functionally safe technology and the potential for a required operating location to be classified as a safety function.

The project considered RFID, ultrasound, UWB (ultra-wide band) and distance measurement by WLAN as technologies for implementing a specified operating location.

Results:

Concepts for suitable model applications were developed. These are to be trialled in a further phase by the German Social Accident Insurance Institutions involved in the project. The project’s findings are to be made available to parties formulating technical design rules, test specifications and standards. During revision of certain standards, sections were added containing requirements relating to this subject.

Manufacturers are beginning to place wireless remote controls on the market that feature integral systems specifying the position at which the operator must be located in order for the device to be used.

The DGUV Expert Committee Traffic and Environment is currently planning to develop a model application for operating vehicle-mounted equipment by means of a wireless remote control. The start of development is scheduled for the beginning of July 2025. In cooperation with a manufacturer of vehicle-mounted equipment and the manufacturer of a collision warning system, a concept for this purpose is to be implemented and tested in a master’s thesis. The IFA will be involved in the work.

Last Update: