feat(iace): Sprint 3A — Operational State Graph + fix(ucca) flaky keyword sort

State Graph:
- 9 Standard-Betriebszustaende (startup, homing, automatic_operation, manual_operation, teach_mode, maintenance, cleaning, emergency_stop, recovery_mode)
- 20 State-Transitions als gerichteter Graph
- OperationalStates + StateTransitions Felder in HazardPattern, MatchInput, PatternMatch
- patternMatches() filtert Patterns nach Betriebszustand (nil = feuert immer)
- Narrative-Parser extrahiert States aus Maschinenbeschreibung (22 Keywords + 4 Transition-Keywords)
- 27 bestehende Patterns mit State-Einschraenkungen annotiert (10 operational, 15 maintenance, 2 cobot)
- MatchReason um operational_state + state_transition Typen erweitert (Explainability)
- 6 neue Tests: NilFiresAlways, MaintenanceFilter, StateTransition, MatchReasons, Count, TransitionValid

UCCA fix:
- Stabiler Tiebreaker (Pattern-ID aufsteigend) bei gleichem Keyword-Score in MatchByKeywords
- Behebt flaky TestControlPatternIndex_MatchByKeywords (1/10 Failure-Rate durch Go map iteration order)

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

ai-compliance-sdk/internal/api/handlers/iace_handler_init.go

@@ -102,6 +102,8 @@ func (h *IACEHandler) InitializeProject(c *gin.Context) {
 		EnergySourceIDs:     energyIDs,
 		LifecyclePhases:     parseResult.LifecyclePhases,
 		CustomTags:          parseResult.CustomTags,
+		OperationalStates:   parseResult.OperationalStates,
+		StateTransitions:    parseResult.StateTransitions,
 	})
 	steps = append(steps, InitStep{
 		Name:   "Patterns abgeglichen",

ai-compliance-sdk/internal/api/handlers/iace_handler_parser.go

@@ -73,6 +73,8 @@ func (h *IACEHandler) ParseNarrative(c *gin.Context) {
 		EnergySourceIDs:     energyIDs,
 		LifecyclePhases:     parseResult.LifecyclePhases,
 		CustomTags:          parseResult.CustomTags,
+		OperationalStates:   parseResult.OperationalStates,
+		StateTransitions:    parseResult.StateTransitions,
 	}
 	matchOutput := engine.Match(matchInput)
 

ai-compliance-sdk/internal/iace/hazard_pattern_types.go

@@ -32,4 +32,14 @@ type HazardPattern struct {
 	// project's machine_type is in this list. Prevents e.g. press-specific
 	// patterns from firing for a cobot project.
 	MachineTypes []string `json:"machine_types,omitempty"`
+	// OperationalStates restricts this pattern to specific operational states.
+	// Empty/nil = fires in ALL states (backwards compatible). If set, the pattern
+	// only fires when the project declares at least one matching state.
+	// Standard states: startup, homing, automatic_operation, manual_operation,
+	// teach_mode, maintenance, cleaning, emergency_stop, recovery_mode.
+	OperationalStates []string `json:"operational_states,omitempty"`
+	// StateTransitions restricts to specific state transitions (format: "from→to").
+	// Hazards at transitions are critical — e.g. "maintenance→automatic_operation"
+	// is where "unexpected restart" fatalities occur. Empty = no transition filter.
+	StateTransitions []string `json:"state_transitions,omitempty"`
 }

ai-compliance-sdk/internal/iace/hazard_patterns_cobot.go

@@ -63,7 +63,7 @@ func GetCobotHazardPatterns() []HazardPattern {
 			DefaultSeverity: 4, DefaultExposure: 3,
 		},
 		{
-			ID: "HP062", NameDE: "Fehlprogrammierung Kraft-/Geschwindigkeitsgrenzwerte", NameEN: "Misprogramming of force/speed limits",
+			ID: "HP062", OperationalStates: []string{"teach_mode"}, NameDE: "Fehlprogrammierung Kraft-/Geschwindigkeitsgrenzwerte", NameEN: "Misprogramming of force/speed limits",
 			RequiredComponentTags: []string{"programmable", "force_limited"},
 			RequiredEnergyTags:    []string{},
 			GeneratedHazardCats:   []string{"safety_function_failure"},
@@ -94,7 +94,7 @@ func GetCobotHazardPatterns() []HazardPattern {
 			DefaultSeverity: 3, DefaultExposure: 3,
 		},
 		{
-			ID: "HP064", NameDE: "Quetschen im Roboter-Arbeitsraum (nicht-kollaborierend)", NameEN: "Crushing in robot workspace (non-collaborative)",
+			ID: "HP064", OperationalStates: []string{"automatic_operation"}, NameDE: "Quetschen im Roboter-Arbeitsraum (nicht-kollaborierend)", NameEN: "Crushing in robot workspace (non-collaborative)",
 			RequiredComponentTags: []string{"moving_part", "high_force", "sensor_part"},
 			RequiredEnergyTags:    []string{},
 			ExcludedComponentTags: []string{"collaborative_operation"},

ai-compliance-sdk/internal/iace/hazard_patterns_maintenance_ext.go

@@ -5,70 +5,70 @@ package iace
 func GetMaintenanceExtPatterns() []HazardPattern {
 	return []HazardPattern{
 		// — Wartung allgemein (HP700-HP709) —
-		{ID: "HP700", NameDE: "LOTO-Fehler: Maschine nicht freigeschaltet", NameEN: "LOTO failure: not locked out",
+		{ID: "HP700", OperationalStates: []string{"maintenance"}, NameDE: "LOTO-Fehler: Maschine nicht freigeschaltet", NameEN: "LOTO failure: not locked out",
 			RequiredComponentTags: []string{"moving_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"mechanical_hazard", "safety_function_failure"},
 			SuggestedMeasureIDs: []string{"M054", "M082"}, SuggestedEvidenceIDs: []string{"E08", "E20"}, Priority: 95,
 			ScenarioDE: "Arbeit ohne Freischaltung der Maschine", TriggerDE: "Fehlende LOTO-Prozedur",
 			HarmDE: "Erfassen durch anlaufende Teile, Tod", AffectedDE: "Instandhalter", ZoneDE: "Gesamte Maschine",
 			DefaultSeverity: 5, DefaultExposure: 3},
-		{ID: "HP701", NameDE: "Restenergie trotz Abschaltung", NameEN: "Residual energy after shutdown",
+		{ID: "HP701", OperationalStates: []string{"maintenance"}, NameDE: "Restenergie trotz Abschaltung", NameEN: "Residual energy after shutdown",
 			RequiredComponentTags: []string{"moving_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"mechanical_hazard", "pneumatic_hydraulic"},
 			SuggestedMeasureIDs: []string{"M054", "M082"}, SuggestedEvidenceIDs: []string{"E08"}, Priority: 90,
 			ScenarioDE: "Gespeicherte Energie entlaedt sich bei Wartung", TriggerDE: "Nicht abgelassener Druckspeicher",
 			HarmDE: "Unkontrollierte Bewegung, Quetschung", AffectedDE: "Instandhalter", ZoneDE: "Antriebe, Speicher",
 			DefaultSeverity: 5, DefaultExposure: 3},
-		{ID: "HP702", NameDE: "Falsches Werkzeug bei Wartung", NameEN: "Wrong tool during maintenance",
+		{ID: "HP702", OperationalStates: []string{"maintenance"}, NameDE: "Falsches Werkzeug bei Wartung", NameEN: "Wrong tool during maintenance",
 			RequiredComponentTags: []string{"structural_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M082"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 50,
 			ScenarioDE: "Ungeeignetes oder defektes Werkzeug", TriggerDE: "Falscher Schraubenschluessel",
 			HarmDE: "Abrutschen, Quetschung", AffectedDE: "Instandhalter", ZoneDE: "Wartungszugang",
 			DefaultSeverity: 3, DefaultExposure: 4},
-		{ID: "HP703", NameDE: "Fehlende Qualifikation des Instandhalters", NameEN: "Insufficient maintainer qualification",
+		{ID: "HP703", OperationalStates: []string{"maintenance"}, NameDE: "Fehlende Qualifikation des Instandhalters", NameEN: "Insufficient maintainer qualification",
 			RequiredComponentTags: []string{"electrical_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"electrical_hazard", "safety_function_failure"},
 			SuggestedMeasureIDs: []string{"M082", "M141"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 70,
 			ScenarioDE: "Unqualifiziertes Personal an Elektrik", TriggerDE: "Keine Elektrofachkraft",
 			HarmDE: "Stromschlag, Fehlverdrahtung", AffectedDE: "Instandhalter", ZoneDE: "Schaltschrank",
 			DefaultSeverity: 4, DefaultExposure: 3},
-		{ID: "HP704", NameDE: "Herabfallen schwerer Teile bei Demontage", NameEN: "Heavy parts falling during disassembly",
+		{ID: "HP704", OperationalStates: []string{"maintenance"}, NameDE: "Herabfallen schwerer Teile bei Demontage", NameEN: "Heavy parts falling during disassembly",
 			RequiredComponentTags: []string{"structural_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M082", "M141"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 75,
 			ScenarioDE: "Schwere Teile fallen bei Demontage herab", TriggerDE: "Fehlende Abstuetzung",
 			HarmDE: "Quetschung, Frakturen, Tod", AffectedDE: "Instandhalter", ZoneDE: "Wartungsbereich",
 			DefaultSeverity: 5, DefaultExposure: 3},
-		{ID: "HP705", NameDE: "Vergessenes Werkzeug in Maschine", NameEN: "Forgotten tool in machine",
+		{ID: "HP705", OperationalStates: []string{"maintenance"}, NameDE: "Vergessenes Werkzeug in Maschine", NameEN: "Forgotten tool in machine",
 			RequiredComponentTags: []string{"moving_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M082"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 65,
 			ScenarioDE: "Zurueckgelassenes Werkzeug wird Geschoss", TriggerDE: "Keine Werkzeugkontrolle",
 			HarmDE: "Herausgeschleudertes Teil, Verletzungen", AffectedDE: "Bedienpersonal", ZoneDE: "Arbeitsraum",
 			DefaultSeverity: 4, DefaultExposure: 2},
-		{ID: "HP706", NameDE: "Schnittwunden an scharfkantigen Teilen", NameEN: "Cuts on sharp-edged parts",
+		{ID: "HP706", OperationalStates: []string{"maintenance"}, NameDE: "Schnittwunden an scharfkantigen Teilen", NameEN: "Cuts on sharp-edged parts",
 			RequiredComponentTags: []string{"structural_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M005", "M082"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 45,
 			ScenarioDE: "Scharfe Kanten und Grate verletzen", TriggerDE: "Fehlende Schutzhandschuhe",
 			HarmDE: "Schnittwunden, Abschuerfungen", AffectedDE: "Instandhalter", ZoneDE: "Blechverkleidungen",
 			DefaultSeverity: 2, DefaultExposure: 4},
-		{ID: "HP707", NameDE: "Verbrennung an heissen Teilen bei Wartung", NameEN: "Burn on hot parts during maintenance",
+		{ID: "HP707", OperationalStates: []string{"maintenance"}, NameDE: "Verbrennung an heissen Teilen bei Wartung", NameEN: "Burn on hot parts during maintenance",
 			RequiredComponentTags: []string{"high_temperature"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"thermal_hazard"},
 			SuggestedMeasureIDs: []string{"M005", "M082"}, SuggestedEvidenceIDs: []string{"E10"}, Priority: 60,
 			ScenarioDE: "Maschine nicht abgekuehlt vor Wartung", TriggerDE: "Zu kurze Abkuehlzeit",
 			HarmDE: "Kontaktverbrennungen", AffectedDE: "Instandhalter", ZoneDE: "Heizplatten, Motorgehaeuse",
 			DefaultSeverity: 3, DefaultExposure: 4},
-		{ID: "HP708", NameDE: "Fehlende Wartungsfreigabe", NameEN: "Missing maintenance permit",
+		{ID: "HP708", OperationalStates: []string{"maintenance"}, NameDE: "Fehlende Wartungsfreigabe", NameEN: "Missing maintenance permit",
 			RequiredComponentTags: []string{"structural_part"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"safety_function_failure"},
 			SuggestedMeasureIDs: []string{"M082", "M141"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 70,
 			ScenarioDE: "Wartung ohne formale Freigabe", TriggerDE: "Fehlender Erlaubnisschein",
 			HarmDE: "Unerwarteter Maschinenbetrieb", AffectedDE: "Instandhalter", ZoneDE: "Gesamte Maschine",
 			DefaultSeverity: 5, DefaultExposure: 3},
-		{ID: "HP709", NameDE: "Biologische Gefaehrdung bei KSS-Wartung", NameEN: "Biological hazard MWF maintenance",
+		{ID: "HP709", OperationalStates: []string{"maintenance"}, NameDE: "Biologische Gefaehrdung bei KSS-Wartung", NameEN: "Biological hazard MWF maintenance",
 			RequiredComponentTags: []string{"chemical_risk"}, RequiredLifecycles: []string{"maintenance"},
 			GeneratedHazardCats: []string{"material_environmental"},
 			SuggestedMeasureIDs: []string{"M005", "M082"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 50,
@@ -76,35 +76,35 @@ func GetMaintenanceExtPatterns() []HazardPattern {
 			HarmDE: "Hautinfektionen, Atemwegsbeschwerden", AffectedDE: "Instandhalter", ZoneDE: "KSS-System",
 			DefaultSeverity: 2, DefaultExposure: 3},
 		// — Einrichten / Umruesten (HP710-HP719) —
-		{ID: "HP710", NameDE: "Falsche Parameter nach Umruestung", NameEN: "Wrong parameters after changeover",
+		{ID: "HP710", OperationalStates: []string{"teach_mode"}, NameDE: "Falsche Parameter nach Umruestung", NameEN: "Wrong parameters after changeover",
 			RequiredComponentTags: []string{"programmable"}, RequiredLifecycles: []string{"setup"},
 			GeneratedHazardCats: []string{"safety_function_failure"},
 			SuggestedMeasureIDs: []string{"M106", "M082"}, SuggestedEvidenceIDs: []string{"E08"}, Priority: 75,
 			ScenarioDE: "Falsche Maschinenparameter nach Produktwechsel", TriggerDE: "Falsche Rezeptnummer",
 			HarmDE: "Uebergeschwindigkeit, Werkzeugbruch", AffectedDE: "Einrichter", ZoneDE: "Bedienterminal",
 			DefaultSeverity: 4, DefaultExposure: 3},
-		{ID: "HP711", NameDE: "Quetschung bei Werkzeugwechsel", NameEN: "Crushing during tool change",
+		{ID: "HP711", OperationalStates: []string{"maintenance"}, NameDE: "Quetschung bei Werkzeugwechsel", NameEN: "Crushing during tool change",
 			RequiredComponentTags: []string{"moving_part", "high_force"}, RequiredLifecycles: []string{"setup"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M003", "M054"}, SuggestedEvidenceIDs: []string{"E08"}, Priority: 80,
 			ScenarioDE: "Schwere Werkzeuge manuell gewechselt", TriggerDE: "Kein Hebezeug, Finger eingeklemmt",
 			HarmDE: "Quetschung, Amputation", AffectedDE: "Einrichter", ZoneDE: "Werkzeugaufnahme",
 			DefaultSeverity: 4, DefaultExposure: 4},
-		{ID: "HP712", NameDE: "Unkontrollierte Bewegung bei Testlauf", NameEN: "Uncontrolled movement test run",
+		{ID: "HP712", OperationalStates: []string{"teach_mode", "manual_operation"}, NameDE: "Unkontrollierte Bewegung bei Testlauf", NameEN: "Uncontrolled movement test run",
 			RequiredComponentTags: []string{"moving_part", "programmable"}, RequiredLifecycles: []string{"setup"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M106", "M054"}, SuggestedEvidenceIDs: []string{"E08"}, Priority: 80,
 			ScenarioDE: "Testlauf mit Person im Gefahrenbereich", TriggerDE: "Volle Geschwindigkeit, kein Schutz",
 			HarmDE: "Erfassen, Quetschen", AffectedDE: "Einrichter", ZoneDE: "Arbeitsraum",
 			DefaultSeverity: 5, DefaultExposure: 3},
-		{ID: "HP713", NameDE: "Einrichtbetrieb ohne reduzierte Geschwindigkeit", NameEN: "Setup without reduced speed",
+		{ID: "HP713", OperationalStates: []string{"teach_mode"}, NameDE: "Einrichtbetrieb ohne reduzierte Geschwindigkeit", NameEN: "Setup without reduced speed",
 			RequiredComponentTags: []string{"moving_part", "programmable"}, RequiredLifecycles: []string{"setup"},
 			GeneratedHazardCats: []string{"mechanical_hazard", "safety_function_failure"},
 			SuggestedMeasureIDs: []string{"M106", "M082"}, SuggestedEvidenceIDs: []string{"E08"}, Priority: 85,
 			ScenarioDE: "Volle Geschwindigkeit im Einrichtmodus", TriggerDE: "Defekter Betriebsartschalter",
 			HarmDE: "Erfassen bei voller Geschwindigkeit", AffectedDE: "Einrichter", ZoneDE: "Werkzeugbereich",
 			DefaultSeverity: 5, DefaultExposure: 3},
-		{ID: "HP714", NameDE: "Werkstueck faellt bei Aufspannung", NameEN: "Workpiece falls during clamping",
+		{ID: "HP714", OperationalStates: []string{"teach_mode", "maintenance"}, NameDE: "Werkstueck faellt bei Aufspannung", NameEN: "Workpiece falls during clamping",
 			RequiredComponentTags: []string{"structural_part"}, RequiredLifecycles: []string{"setup"},
 			GeneratedHazardCats: []string{"mechanical_hazard"},
 			SuggestedMeasureIDs: []string{"M082"}, SuggestedEvidenceIDs: []string{"E20"}, Priority: 55,

ai-compliance-sdk/internal/iace/hazard_patterns_operational.go

@@ -41,7 +41,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 4, DefaultExposure: 3,
 		},
 		{
-			ID: "HP068", NameDE: "Unerwarteter Wiederanlauf nach Stoerung", NameEN: "Unexpected restart after fault",
+			ID: "HP068", NameDE: "Unerwarteter Wiederanlauf nach Stoerung", OperationalStates: []string{"recovery_mode", "emergency_stop"}, StateTransitions: []string{"maintenance→automatic_operation", "emergency_stop→recovery_mode"}, NameEN: "Unexpected restart after fault",
 			RequiredComponentTags: []string{"moving_part", "programmable"},
 			RequiredLifecycles:    []string{"fault_clearing"},
 			GeneratedHazardCats:   []string{"mechanical_hazard", "safety_function_failure"},
@@ -57,7 +57,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 5, DefaultExposure: 3,
 		},
 		{
-			ID: "HP069", NameDE: "Restenergie nach Abschaltung (gespeichert)", NameEN: "Residual stored energy after shutdown",
+			ID: "HP069", NameDE: "Restenergie nach Abschaltung (gespeichert)", OperationalStates: []string{"maintenance", "emergency_stop"}, NameEN: "Residual stored energy after shutdown",
 			RequiredComponentTags: []string{"stored_energy"},
 			RequiredLifecycles:    []string{"maintenance", "fault_clearing"},
 			GeneratedHazardCats:   []string{"mechanical_hazard", "electrical_hazard"},
@@ -72,7 +72,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 4, DefaultExposure: 3,
 		},
 		{
-			ID: "HP070", NameDE: "Eingriff in laufende Maschine bei Stoerung", NameEN: "Intervention in running machine during fault",
+			ID: "HP070", NameDE: "Eingriff in laufende Maschine bei Stoerung", OperationalStates: []string{"recovery_mode"}, NameEN: "Intervention in running machine during fault",
 			RequiredComponentTags: []string{"moving_part"},
 			RequiredLifecycles:    []string{"fault_clearing"},
 			ExcludedComponentTags: []string{"interlocked"},
@@ -120,7 +120,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 		// Wartung / Instandhaltung (HP073-HP079)
 		// ================================================================
 		{
-			ID: "HP073", NameDE: "Wartung ohne LOTO (Lockout/Tagout)", NameEN: "Maintenance without LOTO",
+			ID: "HP073", NameDE: "Wartung ohne LOTO (Lockout/Tagout)", OperationalStates: []string{"maintenance"}, NameEN: "Maintenance without LOTO",
 			RequiredComponentTags: []string{"moving_part"},
 			RequiredLifecycles:    []string{"maintenance"},
 			GeneratedHazardCats:   []string{"maintenance_hazard"},
@@ -136,7 +136,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 5, DefaultExposure: 3,
 		},
 		{
-			ID: "HP074", NameDE: "Sturz von Wartungsbuehne / Leiter", NameEN: "Fall from maintenance platform / ladder",
+			ID: "HP074", OperationalStates: []string{"maintenance"}, NameDE: "Sturz von Wartungsbuehne / Leiter", NameEN: "Fall from maintenance platform / ladder",
 			RequiredComponentTags: []string{"structural_part"},
 			RequiredLifecycles:    []string{"maintenance", "cleaning"},
 			GeneratedHazardCats:   []string{"mechanical_hazard"},
@@ -150,7 +150,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 4, DefaultExposure: 2,
 		},
 		{
-			ID: "HP075", NameDE: "Kontakt mit heissen Teilen bei Wartung", NameEN: "Contact with hot parts during maintenance",
+			ID: "HP075", OperationalStates: []string{"maintenance"}, NameDE: "Kontakt mit heissen Teilen bei Wartung", NameEN: "Contact with hot parts during maintenance",
 			RequiredComponentTags: []string{"high_temperature"},
 			RequiredLifecycles:    []string{"maintenance"},
 			GeneratedHazardCats:   []string{"thermal_hazard"},
@@ -165,7 +165,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 3, DefaultExposure: 3,
 		},
 		{
-			ID: "HP076", NameDE: "Kontakt mit Gefahrstoffen bei Wartung", NameEN: "Contact with hazardous substances during maintenance",
+			ID: "HP076", OperationalStates: []string{"maintenance"}, NameDE: "Kontakt mit Gefahrstoffen bei Wartung", NameEN: "Contact with hazardous substances during maintenance",
 			RequiredComponentTags: []string{"chemical_risk"},
 			RequiredLifecycles:    []string{"maintenance", "cleaning"},
 			GeneratedHazardCats:   []string{"material_environmental"},
@@ -179,7 +179,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 3, DefaultExposure: 3,
 		},
 		{
-			ID: "HP077", NameDE: "Elektrischer Schlag bei Wartungsarbeiten", NameEN: "Electric shock during maintenance",
+			ID: "HP077", OperationalStates: []string{"maintenance"}, NameDE: "Elektrischer Schlag bei Wartungsarbeiten", NameEN: "Electric shock during maintenance",
 			RequiredComponentTags: []string{"high_voltage"},
 			RequiredLifecycles:    []string{"maintenance", "fault_clearing"},
 			GeneratedHazardCats:   []string{"electrical_hazard"},
@@ -195,7 +195,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 			DefaultSeverity: 5, DefaultExposure: 3,
 		},
 		{
-			ID: "HP078", NameDE: "Ergonomische Belastung bei Wartungszugang", NameEN: "Ergonomic strain at maintenance access",
+			ID: "HP078", OperationalStates: []string{"maintenance"}, NameDE: "Ergonomische Belastung bei Wartungszugang", NameEN: "Ergonomic strain at maintenance access",
 			RequiredComponentTags: []string{"structural_part"},
 			RequiredLifecycles:    []string{"maintenance"},
 			GeneratedHazardCats:   []string{"ergonomic"},
@@ -228,7 +228,7 @@ func GetOperationalHazardPatterns() []HazardPattern {
 		// Einrichten / Umruesten / Werkzeugwechsel (HP080-HP085)
 		// ================================================================
 		{
-			ID: "HP080", NameDE: "Quetschen bei Werkzeugwechsel", NameEN: "Crushing during tool change",
+			ID: "HP080", NameDE: "Quetschen bei Werkzeugwechsel", OperationalStates: []string{"maintenance", "teach_mode"}, NameEN: "Crushing during tool change",
 			RequiredComponentTags: []string{"crush_point", "high_force"},
 			RequiredLifecycles:    []string{"changeover", "setup"},
 			GeneratedHazardCats:   []string{"mechanical_hazard"},

ai-compliance-sdk/internal/iace/narrative_parser.go

@@ -40,6 +40,8 @@ type ParseResult struct {
 	CustomTags        []string         `json:"custom_tags"`
 	TechSpecs         []TechSpec       `json:"tech_specs"`
 	Confidence        float64          `json:"confidence"`
+	OperationalStates []string         `json:"operational_states,omitempty"`
+	StateTransitions  []string         `json:"state_transitions,omitempty"`
 }
 
 // techSpecPattern matches numeric values with engineering units.
@@ -91,6 +93,40 @@ var roleKeywords = map[string]string{
 	"leiharbeiter":    "temp_worker",
 }
 
+// operationalStateKeywords maps German text patterns to operational state IDs.
+var operationalStateKeywords = map[string]string{
+	"hochfahren":          "startup",
+	"anlauf":              "startup",
+	"anfahren":            "startup",
+	"referenzfahrt":       "homing",
+	"referenzpunkt":       "homing",
+	"automatikbetrieb":    "automatic_operation",
+	"automatisch":         "automatic_operation",
+	"handbetrieb":         "manual_operation",
+	"manuell":             "manual_operation",
+	"tippbetrieb":         "manual_operation",
+	"teach":               "teach_mode",
+	"einrichtbetrieb":     "teach_mode",
+	"programmier":         "teach_mode",
+	"wartung":             "maintenance",
+	"instandhaltung":      "maintenance",
+	"reinigung":           "cleaning",
+	"not-halt":            "emergency_stop",
+	"nothalt":             "emergency_stop",
+	"notabschaltung":      "emergency_stop",
+	"wiederanlauf":        "recovery_mode",
+	"wiederinbetriebnahme":"recovery_mode",
+	"quittier":            "recovery_mode",
+}
+
+// stateTransitionKeywords maps keyword combinations to state transitions.
+var stateTransitionKeywords = map[string]string{
+	"unerwarteter wiederanlauf": "maintenance→automatic_operation",
+	"wiederanlauf nach not":     "emergency_stop→recovery_mode",
+	"automatischer anlauf":      "startup→automatic_operation",
+	"betriebsartwechsel":        "manual_operation→automatic_operation",
+}
+
 // ParseNarrative extracts components, energy sources, lifecycle phases,
 // roles, and tags from a machine description text. Fully deterministic,
 // no LLM required.
@@ -221,12 +257,37 @@ func ParseNarrative(text string, machineType ...string) ParseResult {
 		}
 	}
 
-	// 6. Collect all tags
+	// 6. Extract operational states
+	stateSet := make(map[string]bool)
+	for kw, state := range operationalStateKeywords {
+		kwNorm := strings.ReplaceAll(kw, "ä", "ae")
+		kwNorm = strings.ReplaceAll(kwNorm, "ö", "oe")
+		kwNorm = strings.ReplaceAll(kwNorm, "ü", "ue")
+		if strings.Contains(lower, kwNorm) {
+			if !stateSet[state] {
+				stateSet[state] = true
+				result.OperationalStates = append(result.OperationalStates, state)
+			}
+		}
+	}
+
+	// 7. Extract state transitions
+	transSet := make(map[string]bool)
+	for kw, trans := range stateTransitionKeywords {
+		if strings.Contains(lower, kw) {
+			if !transSet[trans] {
+				transSet[trans] = true
+				result.StateTransitions = append(result.StateTransitions, trans)
+			}
+		}
+	}
+
+	// 8. Collect all tags
 	for t := range tagSet {
 		result.CustomTags = append(result.CustomTags, t)
 	}
 
-	// 7. Calculate overall confidence
+	// 9. Calculate overall confidence
 	if len(result.Components) > 0 {
 		result.Confidence = float64(len(result.Components)) / 15.0 // Normalize to ~1.0 for 15 components
 		if result.Confidence > 1.0 {

ai-compliance-sdk/internal/iace/pattern_engine.go

@@ -8,6 +8,12 @@ type MatchInput struct {
 	EnergySourceIDs     []string `json:"energy_source_ids"`
 	LifecyclePhases     []string `json:"lifecycle_phases"`
 	CustomTags          []string `json:"custom_tags"`
+	// OperationalStates are the active operational states of the machine.
+	// Used to filter patterns that only apply in specific states (e.g. teach_mode, maintenance).
+	OperationalStates []string `json:"operational_states,omitempty"`
+	// StateTransitions are active state transitions (format: "from→to").
+	// Used to detect transition-specific hazards like unexpected restart.
+	StateTransitions []string `json:"state_transitions,omitempty"`
 }
 
 // MatchOutput contains the results of pattern matching.
@@ -45,6 +51,8 @@ type PatternMatch struct {
 	HazardCats        []string `json:"hazard_categories,omitempty"`
 	ExpertHintDE      string   `json:"expert_hint_de,omitempty"`
 	RequiresExpert    bool     `json:"requires_expert,omitempty"`
+	OperationalStates []string `json:"operational_states,omitempty"`
+	StateTransitions  []string `json:"state_transitions,omitempty"`
 }
 
 // HazardSuggestion is a suggested hazard from pattern matching.
@@ -141,7 +149,7 @@ func (e *PatternEngine) Match(input MatchInput) *MatchOutput {
 	evidenceSources := make(map[string][]string)     // evidence ID → pattern IDs
 
 	for _, p := range patterns {
-		if !patternMatches(p, tagSet, input.LifecyclePhases) {
+		if !patternMatches(p, tagSet, input) {
 			continue
 		}
 
@@ -175,6 +183,18 @@ func (e *PatternEngine) Match(input MatchInput) *MatchOutput {
 				reasons = append(reasons, MatchReason{Type: "lifecycle_match", Tag: lc, Met: found})
 			}
 		}
+		if len(p.OperationalStates) > 0 {
+			stateSet := toSet(input.OperationalStates)
+			for _, s := range p.OperationalStates {
+				reasons = append(reasons, MatchReason{Type: "operational_state", Tag: s, Met: stateSet[s]})
+			}
+		}
+		if len(p.StateTransitions) > 0 {
+			transSet := toSet(input.StateTransitions)
+			for _, t := range p.StateTransitions {
+				reasons = append(reasons, MatchReason{Type: "state_transition", Tag: t, Met: transSet[t]})
+			}
+		}
 
 		matchedPatterns = append(matchedPatterns, PatternMatch{
 			PatternID:       p.ID,
@@ -192,6 +212,8 @@ func (e *PatternEngine) Match(input MatchInput) *MatchOutput {
 			HazardCats:      p.GeneratedHazardCats,
 			ExpertHintDE:      p.ExpertHintDE,
 			RequiresExpert:    p.RequiresExpertCalculation,
+			OperationalStates: p.OperationalStates,
+			StateTransitions:  p.StateTransitions,
 		})
 
 		for _, cat := range p.GeneratedHazardCats {
@@ -259,8 +281,9 @@ func (e *PatternEngine) Match(input MatchInput) *MatchOutput {
 	}
 }
 
-// patternMatches checks if a pattern fires given the resolved tag set and lifecycle phases.
-func patternMatches(p HazardPattern, tagSet map[string]bool, lifecyclePhases []string) bool {
+// patternMatches checks if a pattern fires given the resolved tag set, lifecycle phases,
+// operational states, and state transitions.
+func patternMatches(p HazardPattern, tagSet map[string]bool, input MatchInput) bool {
 	// All required component tags must be present (AND)
 	for _, t := range p.RequiredComponentTags {
 		if !tagSet[t] {
@@ -283,9 +306,9 @@ func patternMatches(p HazardPattern, tagSet map[string]bool, lifecyclePhases []s
 	}
 
 	// If pattern requires specific lifecycle phases, at least one must match
-	if len(p.RequiredLifecycles) > 0 && len(lifecyclePhases) > 0 {
+	if len(p.RequiredLifecycles) > 0 && len(input.LifecyclePhases) > 0 {
 		found := false
-		phaseSet := toSet(lifecyclePhases)
+		phaseSet := toSet(input.LifecyclePhases)
 		for _, lp := range p.RequiredLifecycles {
 			if phaseSet[lp] {
 				found = true
@@ -297,6 +320,37 @@ func patternMatches(p HazardPattern, tagSet map[string]bool, lifecyclePhases []s
 		}
 	}
 
+	// If pattern requires specific operational states, at least one must match.
+	// nil/empty OperationalStates on pattern = fires in ALL states (backwards compatible).
+	if len(p.OperationalStates) > 0 && len(input.OperationalStates) > 0 {
+		found := false
+		stateSet := toSet(input.OperationalStates)
+		for _, s := range p.OperationalStates {
+			if stateSet[s] {
+				found = true
+				break
+			}
+		}
+		if !found {
+			return false
+		}
+	}
+
+	// If pattern requires specific state transitions, at least one must match.
+	if len(p.StateTransitions) > 0 && len(input.StateTransitions) > 0 {
+		found := false
+		transSet := toSet(input.StateTransitions)
+		for _, t := range p.StateTransitions {
+			if transSet[t] {
+				found = true
+				break
+			}
+		}
+		if !found {
+			return false
+		}
+	}
+
 	return true
 }
 
@@ -317,3 +371,54 @@ func maxInt(a, b int) int {
 	}
 	return b
 }
+
+// ── Operational State Graph constants ──────────────────────────────
+
+// Standard operational states for machinery (ISO 12100 + BetrSichV).
+const (
+	StateStartup            = "startup"
+	StateHoming             = "homing"
+	StateAutomaticOperation = "automatic_operation"
+	StateManualOperation    = "manual_operation"
+	StateTeachMode          = "teach_mode"
+	StateMaintenance        = "maintenance"
+	StateCleaning           = "cleaning"
+	StateEmergencyStop      = "emergency_stop"
+	StateRecoveryMode       = "recovery_mode"
+)
+
+// AllOperationalStates returns the 9 standard operational states.
+func AllOperationalStates() []string {
+	return []string{
+		StateStartup, StateHoming, StateAutomaticOperation,
+		StateManualOperation, StateTeachMode, StateMaintenance,
+		StateCleaning, StateEmergencyStop, StateRecoveryMode,
+	}
+}
+
+// StandardStateTransitions returns the valid transitions between states.
+// Format: "from→to". These represent the directed edges of the state graph.
+func StandardStateTransitions() []string {
+	return []string{
+		"startup→homing",
+		"homing→automatic_operation",
+		"automatic_operation→manual_operation",
+		"manual_operation→automatic_operation",
+		"automatic_operation→teach_mode",
+		"teach_mode→automatic_operation",
+		"automatic_operation→maintenance",
+		"manual_operation→maintenance",
+		"maintenance→automatic_operation",
+		"maintenance→manual_operation",
+		"automatic_operation→cleaning",
+		"cleaning→automatic_operation",
+		"automatic_operation→emergency_stop",
+		"manual_operation→emergency_stop",
+		"teach_mode→emergency_stop",
+		"maintenance→emergency_stop",
+		"cleaning→emergency_stop",
+		"emergency_stop→recovery_mode",
+		"recovery_mode→homing",
+		"recovery_mode→manual_operation",
+	}
+}

ai-compliance-sdk/internal/iace/pattern_engine_test.go

@@ -215,3 +215,219 @@ func TestPatternEngine_SafetyDevice_HighPriority(t *testing.T) {
 		t.Error("expected safety_function_failure for Not-Halt-Taster")
 	}
 }
+
+// ── Operational State Graph tests ──────────────────────────────────
+
+func TestPatternEngine_OperationalState_NilFiresAlways(t *testing.T) {
+	// Patterns with nil OperationalStates should fire regardless of input states
+	engine := NewPatternEngine()
+	result1 := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001"},
+		EnergySourceIDs:     []string{"EN01"},
+	})
+	result2 := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001"},
+		EnergySourceIDs:     []string{"EN01"},
+		OperationalStates:   []string{"automatic_operation"},
+	})
+
+	if len(result1.MatchedPatterns) == 0 {
+		t.Fatal("expected patterns to fire without operational states")
+	}
+	if len(result2.MatchedPatterns) == 0 {
+		t.Fatal("expected patterns to fire with automatic_operation state")
+	}
+	// nil-state patterns should fire in both cases
+	if len(result1.MatchedPatterns) != len(result2.MatchedPatterns) {
+		t.Logf("patterns without states: %d, with automatic_operation: %d", len(result1.MatchedPatterns), len(result2.MatchedPatterns))
+		// This is OK — some patterns may have OperationalStates set and filter differently
+	}
+}
+
+func TestPatternEngine_OperationalState_MaintenanceFilter(t *testing.T) {
+	// HP073 (LOTO) has OperationalStates: ["maintenance"]
+	// It should only fire when maintenance is in the input states
+	engine := NewPatternEngine()
+
+	// Without maintenance state — HP073 should still fire if no states in input
+	// (because empty input states = no filtering)
+	resultNoState := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001"},
+		EnergySourceIDs:     []string{"EN01"},
+		LifecyclePhases:     []string{"maintenance"},
+	})
+
+	// With maintenance state — HP073 should fire
+	resultMaint := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001"},
+		EnergySourceIDs:     []string{"EN01"},
+		LifecyclePhases:     []string{"maintenance"},
+		OperationalStates:   []string{"maintenance"},
+	})
+
+	// With only automatic_operation — HP073 should NOT fire
+	resultAuto := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001"},
+		EnergySourceIDs:     []string{"EN01"},
+		LifecyclePhases:     []string{"maintenance"},
+		OperationalStates:   []string{"automatic_operation"},
+	})
+
+	// HP073 should be in resultMaint but not in resultAuto
+	hasHP073Maint := false
+	for _, p := range resultMaint.MatchedPatterns {
+		if p.PatternID == "HP073" {
+			hasHP073Maint = true
+			break
+		}
+	}
+
+	hasHP073Auto := false
+	for _, p := range resultAuto.MatchedPatterns {
+		if p.PatternID == "HP073" {
+			hasHP073Auto = true
+			break
+		}
+	}
+
+	if !hasHP073Maint {
+		t.Error("HP073 should fire with maintenance operational state")
+	}
+	if hasHP073Auto {
+		t.Error("HP073 should NOT fire with automatic_operation operational state")
+	}
+
+	_ = resultNoState // HP073 fires here too because empty input states = no filter
+}
+
+func TestPatternEngine_StateTransition_UnexpectedRestart(t *testing.T) {
+	// HP068 has StateTransitions: ["maintenance→automatic_operation", "emergency_stop→recovery_mode"]
+	engine := NewPatternEngine()
+
+	// HP068 requires moving_part + programmable — C001 (Roboterarm) + C071 (SPS)
+	// With matching transition
+	resultMatch := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001", "C071"},
+		EnergySourceIDs:     []string{"EN01"},
+		LifecyclePhases:     []string{"fault_clearing"},
+		OperationalStates:   []string{"recovery_mode", "emergency_stop"},
+		StateTransitions:    []string{"maintenance→automatic_operation"},
+	})
+
+	// With non-matching transition
+	resultNoMatch := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001", "C071"},
+		EnergySourceIDs:     []string{"EN01"},
+		LifecyclePhases:     []string{"fault_clearing"},
+		OperationalStates:   []string{"recovery_mode", "emergency_stop"},
+		StateTransitions:    []string{"startup→homing"},
+	})
+
+	hasHP068Match := false
+	for _, p := range resultMatch.MatchedPatterns {
+		if p.PatternID == "HP068" {
+			hasHP068Match = true
+			// Verify explainability reasons include state transition
+			hasTransReason := false
+			for _, r := range p.MatchReasons {
+				if r.Type == "state_transition" {
+					hasTransReason = true
+					break
+				}
+			}
+			if !hasTransReason {
+				t.Error("HP068 match should include state_transition reason")
+			}
+			break
+		}
+	}
+
+	hasHP068NoMatch := false
+	for _, p := range resultNoMatch.MatchedPatterns {
+		if p.PatternID == "HP068" {
+			hasHP068NoMatch = true
+			break
+		}
+	}
+
+	if !hasHP068Match {
+		t.Error("HP068 should fire with matching state transition")
+	}
+	if hasHP068NoMatch {
+		t.Error("HP068 should NOT fire with non-matching state transition")
+	}
+}
+
+func TestPatternEngine_MatchReasons_IncludeOperationalState(t *testing.T) {
+	// Verify that MatchReasons include operational_state entries
+	engine := NewPatternEngine()
+	result := engine.Match(MatchInput{
+		ComponentLibraryIDs: []string{"C001"},
+		EnergySourceIDs:     []string{"EN01"},
+		LifecyclePhases:     []string{"maintenance"},
+		OperationalStates:   []string{"maintenance"},
+	})
+
+	for _, p := range result.MatchedPatterns {
+		if p.PatternID == "HP073" {
+			hasStateReason := false
+			for _, r := range p.MatchReasons {
+				if r.Type == "operational_state" && r.Tag == "maintenance" && r.Met {
+					hasStateReason = true
+					break
+				}
+			}
+			if !hasStateReason {
+				t.Error("HP073 MatchReasons should include operational_state:maintenance with Met=true")
+			}
+			return
+		}
+	}
+	t.Error("HP073 not found in matched patterns")
+}
+
+func TestAllOperationalStates_Count(t *testing.T) {
+	states := AllOperationalStates()
+	if len(states) != 9 {
+		t.Errorf("expected 9 operational states, got %d", len(states))
+	}
+}
+
+func TestStandardStateTransitions_Valid(t *testing.T) {
+	transitions := StandardStateTransitions()
+	if len(transitions) < 15 {
+		t.Errorf("expected at least 15 state transitions, got %d", len(transitions))
+	}
+	// Verify all transitions reference valid states
+	stateSet := make(map[string]bool)
+	for _, s := range AllOperationalStates() {
+		stateSet[s] = true
+	}
+	for _, tr := range transitions {
+		// Format: "from→to" (→ is multi-byte UTF-8)
+		parts := splitTransition(tr)
+		if len(parts) != 2 {
+			t.Errorf("invalid transition format: %q", tr)
+			continue
+		}
+		if !stateSet[parts[0]] {
+			t.Errorf("transition %q references unknown state: %q", tr, parts[0])
+		}
+		if !stateSet[parts[1]] {
+			t.Errorf("transition %q references unknown state: %q", tr, parts[1])
+		}
+	}
+}
+
+func splitTransition(tr string) []string {
+	// Split on → (UTF-8: 0xE2 0x86 0x92)
+	idx := 0
+	for i := 0; i < len(tr); i++ {
+		if tr[i] == 0xE2 && i+2 < len(tr) && tr[i+1] == 0x86 && tr[i+2] == 0x92 {
+			return []string{tr[:i], tr[i+3:]}
+		}
+		idx = i
+	}
+	_ = idx
+	return []string{tr}
+}

ai-compliance-sdk/internal/ucca/pattern_loader.go

@@ -219,9 +219,14 @@ func (idx *ControlPatternIndex) MatchByKeywords(text string) []PatternMatch {
 		})
 	}
 
-	// Simple insertion sort (small N)
+	// Sort by keyword hits descending, then by pattern ID ascending (stable tiebreaker)
 	for i := 1; i < len(matches); i++ {
-		for j := i; j > 0 && matches[j].KeywordHits > matches[j-1].KeywordHits; j-- {
+		for j := i; j > 0; j-- {
+			higher := matches[j].KeywordHits > matches[j-1].KeywordHits
+			sameTie := matches[j].KeywordHits == matches[j-1].KeywordHits && matches[j].Pattern.ID < matches[j-1].Pattern.ID
+			if !higher && !sameTie {
+				break
+			}
 			matches[j], matches[j-1] = matches[j-1], matches[j]
 		}
 	}