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With the rapid development of industrial automation, equipment safety has become an increasingly important issue in enterprise operations. In a high-risk, high-intensity production environment, how to effectively avoid operational errors, ensure employee safety, and achieve linkage protection between devices is a common challenge faced by many companies. Among many security solutions, Trapped key interlocking has become one of the preferred security control solutions in many industries due to its simple structure, strong reliability, and intuitive operation.

So, in which industries is trapped key interlocking suitable? This article will start from its principle, combine actual application scenarios, and deeply analyze the specific applications and unique advantages of the system in multiple industries to help companies deploy and select security systems more scientifically.

1. Introduction to the principle of trapped Key Interlocking system

Trapped key interlocking is a physical interlocking mechanism that controls the startup and operation sequence of the equipment through "locking and releasing the key" to ensure the safety of the operation process. Its working logic is: when a device or area is not in a safe state, the corresponding key is locked and cannot be transferred to the next step; only after confirming safety can the key be released and subsequent operations activated.

This operation mode avoids human errors or illegal operations by "physical behavior constraining logical processes", and is particularly suitable for industries that rely on processes, have strict steps, and have high accident costs.

2. Trapped key interlocking is applicable to industries

Power and energy industry

In substations, distribution rooms, high-voltage switch cabinets and other environments, there are a large number of high-voltage current equipment, and once misoperated, it may cause serious personal injury or even system paralysis. Trapped key interlocking can be used in scenarios such as electrical isolation, grounding switch operation, and cable interlocking.

Application example:

The electrical cabinet must be powered off and grounded before the cabinet door can be opened.

The key of the grounding knife switch can only be taken out when the isolation switch is disconnected.

Advantages:

Provide multiple operation confirmations;

Effectively prevent the door from being opened by mistake when high voltage is energized;

Meet the strict safety regulations of the power industry.

Machinery manufacturing and processing industry

During the operation of heavy machinery such as lathes, milling machines, and hydraulic presses, operators must enter the dangerous area in a completely stopped state for maintenance or debugging. At this time, Trapped key interlocking can ensure that the machine cannot be restarted before the main power supply and mechanical linkage are turned off.

Application examples:

Maintenance personnel need to pull out the key to enter the equipment. The system cannot be re-energized before the key is returned.

Linked with the safety door to force entry into the maintenance process.

Advantages:

Enforce shutdown procedures;

Mechanically reliable, not dependent on electronic systems;

Prevent misoperation and accidental restart.

Petrochemical industry

Petrochemical plants often involve high temperature, high pressure, flammable and explosive substances. A slight error in the operation sequence may lead to explosion or leakage accidents. Trapped key interlocking systems are widely used in key links such as valve control and process locking in the petrochemical industry.

Application examples:

During pipeline switching, valve operation must be strictly carried out in sequence;

Pressure release and removal of related keys must be completed before cleaning or repairing equipment.

Advantages:

Achieve mandatory process control;

Ensure the safety of special media operations;

Improve the level of accident prevention and control.

Mining and metallurgical industry

Mines and smelters are complex and harsh environments, accompanied by high temperatures, dust, toxic gases and large mobile equipment. Trapped key interlocking can interlock the conveyor belt, lifting system, ventilation system, etc.

Application examples:

The mine hoist cannot be started before the personnel confirm to leave the mine;

Before the conveyor belt is opened in the maintenance area, the interlocking key must be obtained first.

Advantages:

Ensure the safe isolation of personnel and equipment;

Adapt to high-impact and high-pollution environments;

Reduce the risk of human negligence.

Transportation and rail systems

In the railway and subway industries, ensuring the dynamic safety of personnel and trains is a top priority. Trapped key interlocking plays an important role in track switching, locomotive maintenance, vehicle parking and other links.

Application examples:

All protection procedures must be completed before the vehicle enters the maintenance track;

The switch switching and signal system must be synchronized by interlocking keys.

Advantages:

Achieve high-security interlocking;

Comply with rail transit industry specifications;

Prevent train conflicts and mis-dispatching.

Food and pharmaceutical industry

Although the risk of safety accidents in these industries is slightly lower than that in industry, the processes such as equipment cleaning, maintenance and mold replacement also require strict operation control. Trapped key interlocking can help enterprises improve production safety and hygiene management.

Application examples:

Before mold replacement, the machine must be shut down and safety confirmation must be completed;

During the cleaning process, the equipment must be prevented from starting by key control.

Advantages:

Comply with GMP specifications;

Improve operation traceability;

Prevent accidental startup during cleaning.

Logistics and automatic storage system

In highly automated storage systems, equipment such as robotic arms, rail cars, and automatic lifting platforms operate frequently, and personnel may need to enter the operating area for maintenance. The interlocking system can force shutdown protection.

Application examples:

Before entering the automatic sorting channel, the equipment must be locked and the key must be removed;

When the shelf lifting system is overhauled, the key interlock is enabled to prevent misoperation.

Advantages:

Enhance the collaborative safety of people and machines;

Prevent injuries caused by misactivation of the system;

Easy to use with existing WMS systems.

Regardless of the industry, the trapped Key Interlocking system has the following general advantages:

High reliability: pure mechanical structure, no power supply required, and extremely low failure rate;

Anti-misoperation: mandatory execution of the operation sequence to prevent human negligence;

Flexible configuration: key paths and interlocking logic can be customized according to the process;

Strong traceability: key records can help with accident tracing and process improvement;

Compliance with multiple international standards: such as IEC 60947, ISO 14119, etc.

Safety is the cornerstone of production efficiency. Choosing a suitable safety system is an important manifestation of every enterprise manager's responsibility for employees and the future. If your industry has the characteristics of personnel and equipment interaction, operation sequence dependence, and high risk of misoperation, then the introduction of the trapped key interlocking system will greatly improve the company's inherent safety level. If you want to know more about the structure, solution design or industry cases of trapped key interlocking products, please contact us for customized suggestions.

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