Phase 16 of the Klaerungen / risk-assessment polish. Sources from
EN ISO 12100 Anhang B Tabelle B.1 are now first-class:
A) HazardPattern.ISO12100Section identifier (string), persisted only as
the section number (e.g. "6.3.5.5") — not the norm text. Keeps the
library urheberrechtlich neutral (DIN/Beuth license). 57 patterns
labeled today; rest will follow on touch.
B) Category split per ISO 12100 Nr. 4 vs Nr. 5:
- 16 patterns reclassified noise_vibration -> noise_hazard
- 7 patterns reclassified noise_vibration -> vibration_hazard
- 1 pattern (HP228 UV-/Laermexposition) kept multi-cat
acceptableMeasureCategories now accepts both new aliases plus the
legacy noise_vibration. Coverage test recognises both as valid.
C) 5 new ISO-12100-Annex-B gap patterns (HP1900-HP1904):
- HP1900 Vakuum-Verletzung (6.3.5.5)
- HP1901 Federenergie / elastische Elemente (6.2.10)
- HP1902 Rutschen/Stolpern auf rauer Oberflaeche (6.3.5.6)
- HP1903 Hochdruckinjektion (6.3.5.4) — includes clarifying
"no hand-locating of leaks" question
- HP1904 Ersticken durch Brustkorbquetschung (6.3.5.2)
The library now mirrors the ISO 12100 Annex B structure for the gaps
the Bremse benchmark surfaced.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
ZoneDE 'Pneumatikkomponenten der Anlage' kollidiert nach normalizeZoneKey
mit HP1630 'Pneumatikschlaeuche der Automation' im 3-signifikante-Wort-
Vergleich. Neue Zone 'Berstgefaehrdete Druckwandungen Pneumatik (Leitungs-
wand, Dichtung, Verschraubung)' hat semantisch eigenstaendige Schluessel-
woerter — Dedup mergt nicht mehr in HP1630.
Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
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>
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>
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>
- 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>
Benjamin Admin