Drei nachhaltige Verbesserungen, getrieben durch die Bremse-Benchmark-
Faelle GT 1.4, GT 1.30 und GT 7.4. Die Engine erfindet weiterhin
keine Fachmann-Kommentare — Kommentare bleiben aus, weil sie ein
Verstaendnis der konkreten Anlage erfordern, das die Engine nicht
hat. Statt dessen liefert die Engine norm-basierte Klaerungsfragen
und ein praeziseres Pattern-Vokabular.
A) HazardPattern.ClarificationQuestionsDE — neues optionales Feld:
- Pattern hinterlegt prueffaehige Fragen, die der Bediener mit dem
Anlagenbauer abklaert. Beispiele:
- HP1640: "Liegt ein Pruefprotokoll nach EN 60204-1 vor?"
- HP1666: "Ist die WZM als CE-konformes Subsystem integriert?"
- HP1604: "Ist DCS am Roboter konfiguriert und validiert?"
- Init-Handler haengt die Fragen an Hazard.Description an mit dem
Marker "Mit Anlagenbauer zu klaeren:". Kein DB-Schema-Aenderungs-
bedarf.
- 11 Patterns mit Klaerungsfragen versehen (HP1602, HP1604, HP1611,
HP1612, HP1620, HP1622, HP1637, HP1640, HP1641, HP1666, HP1685).
B) HP1632 "Bersten druckbeaufschlagter Pneumatik-Komponente" — neues
Pattern, semantisch DISTINKT zu HP1630 "Abspringen":
- Bersten = Material-/Druckversagen der Komponente, Mediumaustritt
- Abspringen = Verbindung loest sich, Peitscheneffekt
Bremse-Benchmark GT 1.4 sprach von Bersten, HP1630 nur von
Abspringen — ein 66%-Frontend-Match war eine Sackgasse. Mit
HP1632 feuert die Engine ein eigenes Hazard, das auf GT 1.4
einen sauberen Volltreffer liefert.
C) HP1637 "Einatmen von KSS-Aerosolen" — Massnahmen vervollstaendigt:
Vorher nur M141 (Sicherheitszeichen), neu zusaetzlich M405 (KSS-
Aerosolabsaugung), M418 (AGW-Ueberwachung), M526 (WZM-Tueren
geschlossen waehrend Bearbeitung), M408 (Hautschutzplan).
Klaerungsfrage: "Wurde die Aerosolkonzentration nach Bearbeitungs-
ende messtechnisch ermittelt und mit dem AGW verglichen?"
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
HP1671 "Druckluft-Verletzung in Bearbeitungszelle" matched zwar das
GT-1.30 Szenario "Einstich, Augenverletzung in Bearbeitungszelle" exakt
nach Name und Scenario, hatte aber nur eine einzige Massnahme M061
"Feste trennende Schutzeinrichtung". Die drei spezifischen Massnahmen
des Fachmanns (Reinigungsduese in Zelle integriert / Druckluft bei
Tueroeffnung aus / Einhausung-Lastbemessung) blieben unsichtbar, weil
mein neuer GT-Bremse-Pattern HP1712 zwar diese Massnahmen kennt, aber
durch RequiredEnergyTags=["pneumatic"] in diesem Projekt nicht feuert.
Fix: HP1671 SuggestedMeasureIDs ["M061"] -> ["M504", "M505", "M501",
"M061", "M141"]. EN 12417 Kap. 5.2 / Pos. 1.1.4 ist jetzt durch
M504/M505 abgedeckt. HP1712 bleibt als Backup-Pattern fuer Projekte
mit explizitem pneumatic-Tag bestehen.
Followup: HP1671 und HP1712 sind semantisch redundant — Konsolidierung
ist Teil der naechsten Pattern-Hygiene-Iteration.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Background: hazard_patterns_extended.go (HP045-074) and _extended2.go
(HP074-102) shared their entire ID range with the semantically-different
patterns in hazard_patterns_cobot.go, hazard_patterns_press.go,
hazard_patterns_operational.go and hazard_patterns_extended_dguv.go.
The collision had lived unnoticed because TestGetBuiltinHazardPatterns_-
UniqueIDs only checks the 44 builtin patterns (HP001-HP044).
Examples of the collision:
- HP059 = "Kollision Mensch-Roboter" (cobot.go) vs "Kupplung — mechanisch" (extended.go)
- HP060 = "Quetschen durch Werkzeug am Cobot" (cobot.go) vs "Diagnosemodul — Software" (extended.go)
- HP073 = "Wartung ohne LOTO" (operational.go) vs "Hydraulikventil — hydraulisch" (extended.go)
At runtime collectAllPatterns() returned both patterns under the same ID
which made downstream lookups (e.g. hazardPatternMeasures map keyed by
pattern_id) non-deterministic — last-loaded wins, dropping the other
pattern's mitigation set silently.
Rename strategy (no deletes — both patterns are real and earn their
SuggestedMeasureIDs after the category-filter work):
extended.go HP045..HP073 -> HP1800..HP1828 (29 IDs)
extended2.go HP074..HP102 -> HP1830..HP1858 (29 IDs)
cobot/press/operational/extended_dguv keep their original IDs because:
- compliance_triggers.go references HP059/HP060 with the cobot meaning
- pattern_engine_test.go references HP073 with the LOTO/maintenance meaning
- phase3_4_test.go references HP073 the same way
New regression test:
- TestAllPatterns_UniqueIDs runs over collectAllPatterns() and fails if
ANY pattern in the runtime set duplicates an ID. The old
TestGetBuiltinHazardPatterns_UniqueIDs stays for the builtin subset.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Two-part nachhaltiger fix replacing the previous "fill to 5 mitigations
no matter what" behavior that the GT-Bremse benchmark proved
unfaithful (e.g. HP1625 "scharfe Kanten" returning M005 "Rotations-
bewegung vermeiden" via category fallback; HP1651 "Wiederanlauf
Roboter" returning M054 "Sichere thermische Auslegung" via
mismatched pattern reference).
PART A — Set-based category filter (handlers package):
- acceptableMeasureCategories: replaces 1:1 patternCatToMeasureCat
with a curated set per pattern category, so e.g.
safety_function_failure now accepts software_control measures
(watchdogs, plausibility checks) and emc_hazard accepts both
electrical and software_control measures
- isCategoryCompatible: gate every measure id against the accepted
set before creating a mitigation; mismatches log MEASURE-SKIP
- The old category fallback is REMOVED. A hazard whose pattern has
no category-compatible measure is now created with zero mitigations
and logged as COVERAGE-GAP — the operator must consult an expert.
No more silent invention of generic defaults.
PART B — 235 pattern author-error fixes across 26 files:
- HP040-HP044 (AI): M101/M102/M103 (Auffangwanne/Absauganlage) ->
M133 Anomalieerkennung + M214 Plausibilitaet + M213 Sensor-Redundanz
+ M044 Zweikanalige Steuerung + others
- HP011-HP015, HP104-HP109, HP1085-HP1095, HP1281-HP1334 (electrical):
M001-M005/M054/M061 placeholders -> M481/M482 Isolation +
M511-M522 PE/Schutzleiter/RCD/Hauptschalter
- HP110-HP1331 (material_environmental): M101-M103 -> M384-M395
Brandschutz/Laserschutz + M533/M408 SDB/PSA
- HP800-HP858, HP1178-HP1264 (software/sensor/hmi):
M101/M104 -> M105/M106/M107/M214 SPS/Watchdog/Plausibilitaet
- HP026, HP611-HP1690 (ergonomic): M001/M082 -> M353-M360 +
M530-M532 Hebehilfe/ergonomische Hoehe
- HP201-HP1697 (mechanical): M054/M051 -> M002/M008/M061/M141 +
M487/M488 Tueroeffnung-Stillsetzung/Wiederanlauf
- Plus EMF/Strahlung/Brand/Lärm/Vibration/Kommunikation/Cyber
Coverage shift (Pattern-Author-Fehler bei aktiviertem Set-Filter):
start: 237 patterns with zero category-compatible measures
after Stufe 1A: 5 (AI)
after Stufe 1B: 20 (mechanical Bestand)
after Stufe 1C: 35 (electrical Bestand)
after Stufe 1D: 29 (material_environmental)
after Stufe 1E: 29 (software/sensor/hmi)
after Stufe 1F: 20 (ergonomic)
after Stufe 1G: 80 (thermal/comm/radiation/fire/safety)
final: 0 (28 extended.go/extended2.go duplicates fixed)
New regression tests:
- TestEveryPattern_HasCategoryCompatibleMeasure: every pattern in
collectAllPatterns() must reference at least one category-compatible
measure; gaps must be explicitly listed in AllowlistKnownGaps
(currently empty). Fails CI for any new pattern that drifts.
- TestAcceptableMeasureCategories: pins the set-mapping for the
7 most-bug-prone pattern categories.
- TestIsCategoryCompatible_EmptyMeasureCat: protects legacy entries.
A separate task #11 tracks 58 HP-ID duplicates between
extended.go/extended2.go and cobot.go/press.go/operational.go —
patterns are semantically different and TestGetBuiltinHazardPatterns_-
UniqueIDs misses them because it only checks HP001-HP044.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
6 supplementary measures (M410-M420) were silently overwritten by
metalworking duplicates in measureByID lookups, so robot-cell electrical
patterns resolved to chip-extraction/cleaning fallbacks instead of
equipotential bonding, creepage, EMC, or hose-burst protection. Rename
supplementary IDs to M475-M480 and rewire 13 affected pattern references
in robot_cell + robot_cell_ext.
HP1640 (direct contact with live parts, GT 2.2): priority 98->99, drop
RequiredEnergyTags gate so it fires in robot cells without an electrical
tag, expand mitigations to 5 concrete TRBS 2131 / IEC 60204-1 / EN 61140
measures (basic protection, double insulation, earthing, insulation
monitoring, equipotential bonding) — was previously losing to HP1688
even though HP1688 describes a different scenario.
HP1688 (touch voltage from potential differences): priority 98->96 so it
no longer outranks HP1640 for the direct-contact case; mitigations
expanded from M410-only to 4 concrete electrical measures.
Add regression tests pinning HP1640 contact-protection resolution and
M475 = Potentialausgleich. Existing TestGetProtectiveMeasureLibrary_-
UniqueIDs now actually enforces uniqueness (previously masked by
last-wins map override).
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
Robot cell patterns now fire BEFORE generic patterns (Priority 96-99
vs generic 85-95). This ensures pattern-specific SuggestedMeasureIDs
(M420 for KSS, M410 for Potentialausgleich) reach the hazard.
Removed debug fmt.Println statements.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Each hazard now gets measures from its SOURCE PATTERN first
(SuggestedMeasureIDs), then category fallback for remaining slots.
Previously all mechanical hazards got the same generic top-5 measures
(Gefahrstelle eliminieren, Sicherheitsabstaende, Scharfe Kanten...).
Now a KSS-Schlauch hazard gets M420 (Druckfeste Auslegung) first.
SuggestedMeasureIDs added to PatternMatch struct and passed through
from pattern definition to hazard creation to measure assignment.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Every ScenarioDE now describes how a PERSON is affected, not just
what happens to the machine. Every HarmDE describes the INJURY,
not just the technical effect.
Examples:
- "Peitscheneffekt des Schlauchs" → "Person wird von abspringendem
Schlauch getroffen. KSS-Spritzer verletzen Haut und Augen."
- "Kurzschluss, Brand" → "Person wird durch Brand oder toxische
Rauchgase verletzt. Verbrennungen, Rauchvergiftung."
Rule: Risikobeurteilung bewertet Gefahr fuer PERSONEN.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
HP1606: Quetschen/Scheren durch Greifer im Einrichtbetrieb (GT 1.14)
HP1634: KSS-Pumpe spritzt bei geoeffneter Schutztuer (GT 1.38)
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
HP1605: Stoss durch Werkzeug/Greifer im Einrichtbetrieb (GT 1.14)
HP1633: KSS-Versorgungsschlauch platzt oder reisst ab (GT 1.35)
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Energy tag "electrical" doesn't match resolved tags (which are
"high_voltage", "electrical_part", etc.). Patterns HP1685-HP1699
now fire without energy tag requirement — they fire for any
project that has the right component tags.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
When GT has two entries for the same zone with different scenarios
(e.g. "eingeklemmt" vs "getroffen"), we need separate engine patterns.
HP1700: Getroffen von bewegtem Werkzeug/Greifer (vs HP1652 eingeklemmt)
HP1701: Greifer/Werkzeug durchschlaegt Zaun (vs HP1654 Werkstueck)
HP1702: KSS-Schlauch platzt (vs HP1675 springt ab)
HP1703: KSS-Bettspuelung bei offener Tuer (vs HP1670 allgemein)
HP1704: Brand durch KSS auf elektrische Komponenten
Extended synonym sets for potential/EMV matching.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
scenarioSimilarity now uses synonym-set cross-matching: if GT says
"durchschlaegt" and Engine says "schleuder", the synonym set recognizes
them as related. Added significantWordOverlap fallback when no action
words found. Extended action terms: schlauch/druck/kuehlschmierstoff,
pumpe/bettspuel, potential/bezugspotential, stoerung/emv.
Moved extractActionWords to benchmark_synonyms.go (458+119 lines).
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
4-signal matcher: category (0.2), keywords (0.2), zone (0.3),
scenario similarity (0.3). Scenario signal extracts action words
(eingeklemmt vs herabfallend vs durchschlaegt) to differentiate
similar-looking hazards at the same component.
Split benchmark_synonyms.go (70 lines) from benchmark_matcher.go
(516→450 lines) to stay under 500-line cap.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Sort matches by specificity first (zone overlap), then by score.
Prevents generic matches from consuming specific Engine patterns
that should match more specific GT entries.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Threshold 0.25→0.20 to recover matches lost by keyword penalty.
New synonym sets: eingeschlossen/wiederanlauf, zentriergreifer,
beladetuer/schutztuer, ergonom/bedienelemente, spritzer/auge, bersten.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Patterns for playground, escalator, wind turbine, glass washing,
laundry, crane, lathe, rotary transfer, press now require matching
MachineTypes — they no longer fire for unrelated projects.
Neutralized zone texts in base patterns HP006/HP008 (removed
"Pressenraum", "Kran-/Hebezeugbereich").
Fixes: Spielplatz, Fahrtreppe, Windturbine etc. appearing in robot cell.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Backend: HazardSummary now includes lifecycle_phase and affected_person
Frontend: Engine detail column shows Lebensphasen and Betroffene Personen
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Systematic refactoring of all hazard_patterns_*.go files:
- Removed lifecycle phase words from NameDE and ScenarioDE
(67 fixes across 20 files)
- Phases belong in ApplicableLifecycles, not in text
- "bei Wartung/Reinigung/Montage/..." removed from names
- Scenarios rewritten to be phase-neutral
- Lifecycle-specific concepts preserved when they define the hazard
(e.g. LOTO, Betriebsartenwahlschalter)
Rule: Gefaehrdung + Szenario NEUTRAL, Lebensphasen SEPARAT.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Removed HP1601 (duplicate of HP1600 with narrower scope)
- HP1600 now covers ALL lifecycle phases, not just teach mode
- All pattern texts neutral: no lifecycle phase references in
NameDE, ScenarioDE, TriggerDE — phases only in ApplicableLifecycles
- Formulierungsregel documented in file header
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- ApplicableLifecycles field in HazardPattern: patterns now declare which
lifecycle phases the hazard applies to (Output, not just filter)
- Init handler writes first applicable lifecycle into Hazard.LifecyclePhase
- Robot cell patterns HP1600-1601 broadened: "Betrieb, Einrichten, Reinigung,
Wartung, Fehlersuche" instead of only "Teach-Betrieb"
- All robot cell patterns get ApplicableLifecycles for proper phase display
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Backend: HazardSummary now includes description, scenario, possible_harm,
trigger_event, and mitigations[] for side-by-side comparison.
Frontend: Each matched pair row is now clickable/expandable showing
two-column detail view:
- Left (GT): hazard type, cause, zone, lifecycle phases, risk values
(F/W/P/S->R), residual risk, measures, type (KM/TM/BI), norms, comment
- Right (Engine): name, scenario, zone, possible harm, trigger, measures
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Backend:
- hazard_blocks.go: ComputeHazardBlocks() groups hazards by category +
component + zone. Parent = highest risk in group. Children covered by
parent's measures are flagged (no separate assessment needed).
- iace_handler_blocks.go: GET /projects/:id/hazard-blocks endpoint
with summary stats (blocks, covered children, assessments saved)
Frontend:
- HazardBlockView.tsx: Expandable block view with summary cards,
parent-child hierarchy, coverage badges, and "abgedeckt" indicators
- hazards/page.tsx: New "Bloecke" tab alongside "Hazard-Liste" and
"Risikobewertung"
No database schema changes — grouping is computed at runtime.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Add synonym sets for isolation/grounding, creepage/surface, EMV/radiation
to improve matching of GT entries 2.5, 2.6, and 6.1.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- Erklaerteil-Template fuer Risikobeurteilungen (risk_assessment_template.go)
in PDF-Export, Markdown-Export und Frontend ReportPrintView eingebaut
- Ground Truth Benchmark-System: Datenmodell, Fuzzy-Matching-Engine,
3 API Endpoints (import-gt, benchmark, benchmark/summary)
- Frontend Benchmark-Tab mit Score-Cards, Kategorie-Breakdown,
Hazard-Vergleichstabelle (Zugeordnet/Fehlend/Extra), Business Impact
- Erster Benchmark: 13.3% Coverage (Baseline) gegen 60 GT-Eintraege
- Dedup-Fix: seenCat[cat] -> seenCatZone[cat+zone] erlaubt mehrere
Gefaehrdungen pro Kategorie an verschiedenen Gefahrenstellen
- Komponenten-spezifische Hazard-Namen und Zone-basierte Zuordnung
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Neues Feld "Einsatzbereich" auf Interview-Seite (Sektion 7) mit 15 Branchen.
Pattern Engine bekommt MachineTypes aus MatchInput → branchenfremde Patterns
(Medizin, Aufzug, Bau etc.) feuern nur wenn die Branche ausgewählt ist.
Refactoring: iace_handler_init.go aufgeteilt in init + init_helpers (LOC-Limit).
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Medizin (25), Laser-Medizin (15), Aufzuege (25), Lebensmittel (20),
Bau (20), Forst/Foerderband (31) — alle Patterns feuern jetzt NUR
wenn der Maschinentyp passt. Verhindert Infusionspumpen-Szenarien
bei einem Cobot-Projekt.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
- POST /initialize?force=true loescht bestehende Hazards + Mitigations
und erstellt sie neu mit aktuellen Betriebszustaenden
- Orange "Neu initialisieren" Button auf Interview-Seite (mit Confirm-Dialog)
- DeleteHazard Store-Methode (kaskadiert Risk Assessments)
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Hazards zeigen jetzt farbige Badges mit den Betriebszustaenden die sie
ausgeloest haben (z.B. "Wartung", "Not-Halt"). Mitigations erben die
States ihrer verknuepften Hazards.
Backend: OperationalStates im Function-Feld encodiert (kein DB-Schema),
beim Lesen als operational_states[] JSON-Feld zurueckgegeben.
Frontend: Indigo-Badges in HazardTable + MitigationCard.
Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
Benjamin Admin