A security door lock contact configuration adaptive control system and method

Abstract

The application discloses a safety door lock contact configuration adaptive control system and method, and belongs to the technical field of industrial safety control. The system comprises a multi-channel isolation contact state acquisition circuit, a main control unit meeting the functional safety level, mapping configuration data for defining contact functions, a redundancy channel consistency verification module, a contact health state evaluation module based on multi-dimensional historical data for evaluation, an adaptive de-bouncing filter and a redundant safety output interface. The method comprises the following steps: acquiring contact states, applying mapping configuration, performing adaptive de-bouncing and redundancy channel verification, evaluating contact health states and finally controlling safety output. The application has the beneficial effects that contact functions are flexibly defined through software configuration, cross verification and self-diagnosis are built-in, contact health conditions are predicted based on historical data, de-bouncing parameters are adaptively adjusted, the generality of the hardware platform is realized while the high safety level is ensured, and data support is provided for state maintenance.

Description

Technical Field

[0001] This invention relates to the field of industrial safety control technology, and more specifically, to a smart monitoring and adaptive configuration control system and method for the contact status of industrial safety door locks. Background Technology

[0002] Industrial safety door locks are critical devices for ensuring personnel safety in automated production lines and machinery. They detect the position and locking status of the safety door and provide signals to the safety control system to prevent accidental activation or operation in hazardous areas. Relevant international standards such as ISO 13849-1 specify clear functional and performance level requirements for control systems of such safety-related components.

[0003] Currently, mainstream security door lock control solutions typically connect the signals of their safety contacts directly to external safety relays or security programmable logic controllers (PLCs). These external devices are responsible for implementing safety logic such as dual-channel redundancy judgment, inter-channel consistency verification, and fault detection. While this solution is structurally simple, placing all the safety logic judgment burden on the external controller leads to complex system wiring, and the door lock itself lacks any diagnostic information reporting capabilities, making status monitoring and fault diagnosis difficult.

[0004] To address these issues, some high-end security door locks integrate dedicated integrated circuits (ASICs) or main control units, capable of preliminary processing of contact states and outputting security signals via an OSSD (Output Signal Switching Device) interface. However, in these solutions, the functions of the physical contacts (e.g., which contact is used for door position monitoring and which for lock status monitoring) are fixed in the hardware design or at the factory, preventing users from flexibly adjusting them according to actual application needs. For instance, on complex new energy vehicle production lines, different workstations may have different requirements for door lock functions, making it difficult for locks with fixed functions to adapt. When the security architecture changes, it often requires replacing the entire lock model, lacking flexibility and increasing maintenance costs.

[0005] Furthermore, the mechanical contacts in security door locks are vulnerable components that gradually deteriorate over long-term use due to arc erosion, mechanical wear, and other factors. This manifests as increased contact resistance and exacerbated bounce during closing or opening. Existing technologies typically use fixed-time debounce filters to handle bounce, but fixed parameters cannot adapt to changes in bounce characteristics caused by contact aging, potentially leading to prolonged safety response times or misjudgments during severe bounce. Simultaneously, existing technologies lack effective monitoring and prediction methods for contact health status. Maintenance relies heavily on periodic, reactive inspections or replacements, failing to achieve condition-based predictive maintenance, thus posing safety hazards and wasting resources. Summary of the Invention

[0006] To overcome the problems of fixed contact functions, reliance on external devices for verification, inability to predict contact aging, and poor debouncing capabilities in existing security door lock technologies, this invention provides a security door lock contact configuration adaptive control system and method, comprising: a multi-channel isolated contact status acquisition circuit for acquiring at least one electrical signal reflecting the physical state of each channel in multiple physical contact channels; a main control unit, integrated within the security door lock housing, for executing control logic, the main control unit being configured to meet a preset functional safety level; the main control unit being coupled to the acquisition circuit for processing the electrical signals; mapping configuration data stored in a memory managed by the main control unit, the mapping configuration data being used to map the multiple physical contact channels to one or more logical function roles; and a redundant channel consistency verification module running on the main control unit for... Based on the mapping configuration data, the status of multiple physical contact channels mapped to the same safety function is compared in real time, and a fault is determined when the duration of inconsistency in status exceeds a preset tolerance. A contact health status assessment module running on the main control unit generates indication information characterizing the health status of the physical contact channels based on multi-dimensional historical operating data, including at least the cumulative number of operations and contact resistance, using a preset model. An adaptive debouncing filter running on the main control unit dynamically adjusts the debouncing parameters used to stabilize the status signal of the physical contact channels based on the historical operating data of the physical contact channels. A redundant safety output interface, whose output status is determined by the main control unit based on the status of all safety functions and the verification results of the consistency verification module, provides the final safety signal to an external safety controller. By decoupling physical contacts from logical functions and incorporating an intelligent processing module, the same hardware platform can flexibly adapt to different applications and achieve proactive health management.

[0007] Furthermore, the system also includes a power-on self-diagnostic module running on the main control unit. This module performs a self-test on key hardware, including the acquisition circuit, power supply, memory, and main control unit kernel, each time the system is powered on. If the self-test fails, the redundant safety output interface enters a safe state. This configuration proactively detects potential faults before the system is put into operation, preventing "operation with defects" and thus improving the overall safety of the system.

[0008] Optionally, the system further includes an industrial communication interface for bidirectional communication of non-secure data with a host computer or programmable logic controller; wherein the main control unit is configured to report indication information of the health status through the industrial communication interface, and / or receive configuration instructions for updating the mapping configuration data. This configuration provides a channel for realizing digital operation and maintenance, facilitating remote monitoring, diagnosis, and configuration, and reducing the complexity of on-site maintenance.

[0009] In one embodiment, each detection channel of the multi-channel isolation contact status acquisition circuit is equipped with a constant current source excitation circuit to apply a constant test current to the physical contact channel being detected. This method not only avoids damage to the contacts from large currents but also provides a stable prerequisite for accurately estimating contact resistance.

[0010] Preferably, the redundant safety output interface is a dual-channel OSSD safety output interface. Using an OSSD interface provides a fault-safe output that meets industrial safety standards and has pulse self-diagnostic capabilities, allowing for seamless integration with mainstream safety controllers.

[0011] Furthermore, the redundant channel consistency verification module is configured to perform dual-channel cross-validation. This method is a classic and effective approach for detecting inconsistencies between redundant security function channels, and it can reliably detect the failure of a single channel.

[0012] Optionally, the multidimensional historical operating data includes at least one of the following: cumulative number of operations, time series of contact resistance, and contact bounce width. By fusing data from multiple dimensions, the actual health status of the contacts can be assessed more comprehensively and accurately, improving the reliability of predictions.

[0013] In one implementation, the adaptive debouncing filter employs a variable-window majority voting algorithm, and the debouncing parameter is the window size of the algorithm. This algorithm can dynamically adapt to changes in touch bounce characteristics by adjusting the window size while ensuring filtering stability.

[0014] Preferably, the main control unit is a dual-core lockstep microcontroller. A microcontroller employing a dual-core lockstep architecture provides a solid foundation for the realization of system functional safety at the hardware level, helping the system achieve a higher level of security integrity.

[0015] This invention also provides an adaptive control method for contact configuration of a security door lock. This method is executed by a main control unit integrated within the security door lock housing and conforming to a preset functional safety level. The method includes the following steps: cyclically acquiring at least one electrical signal reflecting the physical state of each of multiple physical contact channels through a multi-channel isolated contact state acquisition circuit; determining the logical function roles corresponding to the multiple physical contact channels based on pre-stored mapping configuration data; applying adaptive debouncing filtering and dynamically adjusting debouncing parameters based on historical operating data of the physical contact channels to stabilize the state indicated by the electrical signals; performing redundant channel consistency verification, comparing the stabilized states of multiple physical contact channels mapped to the same safety function in real time based on the mapping configuration data, and determining a fault when the states are inconsistent; updating and evaluating the health status, generating indication information characterizing the health status of the physical contact channels based on multi-dimensional historical operating data and a preset model; and controlling the output state of a redundant safety output interface based on the states of all safety functions and the results of the consistency verification.

[0016] Beneficial effects: The beneficial effects of adopting the technical solution of this invention are as follows: (1) By introducing mapping configuration data, the present invention realizes the software definition of physical contact channels and logical function roles, enabling the same door lock hardware platform to flexibly adapt to different security architecture requirements, such as upgrading from a single channel to dual-channel redundancy, or adjusting the definition of auxiliary signals, which significantly reduces the user's spare parts inventory and system transformation costs, and realizes "one platform for multiple uses".

[0017] (2) This invention integrates security logic such as dual-channel cross-checking into the door lock controller, enabling "on-site judgment" at the source of a fault, shortening fault detection and response time, and reducing the logical burden and configuration complexity of the external security controller. At the same time, the power-on self-diagnosis function ensures that the system is in a healthy state at startup, further improving the reliability of the system.

[0018] (3) This invention achieves the transformation from "periodic maintenance" to "state-based predictive maintenance" by establishing a contact health status assessment model based on multidimensional historical data and an adaptive debouncing mechanism. The system can dynamically adjust control parameters according to the actual aging degree of the contacts and issue an early warning before its performance degrades to the point of affecting safety functions, thereby effectively avoiding unexpected shutdowns or safety function degradation caused by contact aging, and achieving a good balance between safety and economy. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a block diagram of the overall architecture of the contact configuration adaptive control system in an embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of the principle of a single detection channel in the multi-channel isolation contact status acquisition circuit of this invention.

[0022] Figure 3 This is a schematic diagram of the touch function mapping configuration table in an embodiment of the present invention.

[0023] Figure 4 This is a flowchart of the dual-channel cross-validation logic in an embodiment of the present invention.

[0024] Figure 5 This is a schematic diagram illustrating the working principle of the adaptive debouncing filter in an embodiment of the present invention.

[0025] Figure 6 This is a schematic diagram of the contact health scoring model in an embodiment of the present invention.

[0026] Figure 7 This is a flowchart of the power-on self-diagnosis module in an embodiment of the present invention.

[0027] Figure 8 This is a flowchart of the system control method in an embodiment of the present invention.

[0028] Figure 9 This is a schematic diagram of the IO-Link communication data frame structure in an embodiment of the present invention.

[0029] Figure 10 This is an integrated schematic diagram of a typical application system in an embodiment of the present invention. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In existing security door lock control schemes, there are common defects such as fixed contact function allocation, reliance on external equipment for dual-channel cross-verification, unpredictable contact aging, lack of adaptive debouncing capability, and lack of integrated self-diagnostic function, resulting in complex system integration, high maintenance costs, and insufficient intelligence. To solve the above problems, the present invention proposes an intelligent control system integrated inside the door lock, possessing software-defined functions, self-diagnostic capabilities, and health prediction capabilities.

[0031] In the description of this invention, it should be understood that the term "mapping configuration data" refers to a data structure stored in non-volatile memory, whose core function is to establish the correspondence between physical contact channels and logical functional roles, thereby realizing the software definition of hardware functions. "Redundant channel consistency verification" refers to software logic running on the main control unit, used to compare in real time whether the states of multiple physical contact channels mapped to the same safety function are consistent; it is key to realizing built-in fault detection. "Contact health status assessment" refers to an intelligent diagnostic process that assesses the health status of physical contacts based on multi-dimensional historical operating data through a preset model and generates warnings or maintenance suggestions. "Adaptive debouncing filter" is a digital signal processing algorithm that can dynamically adjust its filtering parameters (such as time windows) according to changes in the historical bounce characteristics of the contacts, aiming to balance response speed and signal stability. The technical solution of this invention will be described in detail below.

[0032] Reference Figure 1This document illustrates the overall architecture of a safety door lock contact configuration adaptive control system 100 according to one embodiment of the present invention. The safety door lock contact configuration adaptive control system 100 is integrated within the housing of the safety door lock, forming a highly integrated intelligent safety component. The safety door lock contact configuration adaptive control system 100 includes a main control unit 110, which serves as the control core of the entire system, responsible for executing complex control logic and algorithms. The main control unit 110 is coupled to a multi-channel isolated contact status acquisition circuit 120 for real-time monitoring of the status of multiple physical contacts within the safety door lock. The main control unit 110 is also connected to a redundant safety output interface 130 for outputting the final safety decision signal to an external safety controller (such as a safety PLC or safety relay). Furthermore, the system may also include an industrial communication interface 140 for data exchange with a host system; an LED diagnostic indicator system 150 for visually displaying the system status to on-site personnel; and a system power supply module 160 for providing a stable and reliable power supply to the entire system. This highly integrated architecture incorporates many functions that were traditionally performed by external devices into the door lock, greatly simplifying system wiring and configuration.

[0033] The main control unit 110 is configured to meet a preset functional safety level, such as IEC 61508 SIL 2 or ISO 13849-1 PL d. To achieve this, in a preferred embodiment, the main control unit 110 is a dual-core lockstep microcontroller. The dual-core lockstep microcontroller contains two identical CPU cores that execute the same instruction set synchronously in lockstep mode and perform a hardware comparison of their respective calculation results after each clock cycle. If any inconsistency occurs in the calculation results of the two cores, the hardware comparison logic immediately detects the fault and triggers an interrupt or reset, bringing the system to a preset safe state. By employing a dual-core lockstep microcontroller, the coverage and response speed of fault detection can be greatly improved, effectively preventing the loss of safety functions due to random hardware failures within the CPU. This is a key technical means to meet high functional safety level certification requirements.

[0034] The safety door lock contact configuration adaptive control system 100 internally stores mapping configuration data 200, such as... Figure 3 As shown. The mapping configuration data 200 is preferably stored in a non-volatile memory (NVM) managed by the main control unit 110, such as EEPROM or Flash memory, to ensure that the configuration information is not lost after power failure. The core function of the mapping configuration data 200 is to flexibly map the N physical contact channels connected to the multi-channel isolated contact status acquisition circuit 120 to one or more logical function roles. For example... Figure 3As shown in the example, a 6-channel system can map channels 1 and 2 as a door monitoring security channel pair (DM_A, DM_B), channels 3 and 4 as a lock monitoring security channel pair (LM_A, LM_B), channel 5 as an auxiliary signal (AUX), and channel 6 as a spare (SPARE). This software-defined approach allows the same hardware platform to adapt to different security application requirements. For example, when upgrading from single-channel monitoring to dual-channel redundant monitoring, users only need to modify the configuration without replacing the hardware, thus achieving the beneficial effect of "one platform for multiple uses" and significantly reducing spare parts inventory and system upgrade costs.

[0035] A redundant channel consistency verification module runs on the main control unit 110. This module's function is to perform real-time comparison of the status of two physical contact channels (such as DM_A and DM_B) mapped to the same security function (e.g., door monitoring) according to the definition of the mapping configuration data 200. Figure 4 As shown, this verification logic continuously monitors the status of the two channels. When the two channels are inconsistent (e.g., one is closed while the other is open), the module starts a timer. If the duration of this inconsistent state exceeds a preset tolerance window T_tol, the module determines that a "channel inconsistency fault" has occurred. This tolerance window T_tol is configurable, with a typical value ranging from 50ms to 500ms, and can be set by the user according to the actual operating time of the mechanical device and the allowable response delay. By incorporating this verification module, the system can immediately determine the source of the fault and quickly report the fault through the redundant safety output interface 130. This not only shortens the fault response time but also reduces the logical burden on the external safety controller 300.

[0036] To enable predictive maintenance of physical contact lifecycles, a contact health status assessment module also runs on the main control unit 110. The core idea of ​​this module is to quantify the health status of the contacts based on multi-dimensional historical operational data and a preset model. For example... Figure 6 As shown, these multidimensional historical operating data include at least the cumulative number of operations N_op, the time series of contact resistance Rc(t), and the sequence of contact bounce width W_bounce(t). The cumulative number of operations reflects the degree of mechanical wear, the increasing trend of contact resistance is a direct manifestation of contact surface oxidation or ablation, and the increase in bounce width indicates the deterioration of contact elasticity. This module uses a preset weighted scoring model, for example, H=w1f(N_op)+w2g(Rc(t))+w3 The system uses h(W_bounce(t)) to calculate a comprehensive health score H (0-100). Based on the score H, the system can generate different levels of indications, such as H≥70 for healthy, 40≤H<70 for caution, and H<40 for warning. This state-based maintenance (CBM) approach allows users to receive accurate replacement recommendations before significant degradation in touchpoint performance, thus avoiding safety risks caused by under-maintenance and resource waste caused by over-maintenance.

[0037] To address the bounce phenomenon generated by the mechanical contacts during switching operations, an adaptive debouncing filter operates on the main control unit 110. Unlike traditional methods that use a fixed debouncing time, this filter dynamically adjusts the debouncing parameters used to stabilize the state signal based on historical operating data of the physical contact channels. In one specific implementation, such as... Figure 5 As shown, this adaptive debouncing filter employs a variable window majority voting algorithm. Its working principle is as follows: within a time window T_debounce, the contact state is continuously sampled at a fixed period Ts (e.g., 1ms). If the percentage of sampled points for a certain state (closed or open) exceeds the confirmation threshold R_confirm (e.g., 70%), the confirmation state switches. Crucially, the debouncing parameter, i.e., the window size T_debounce, is dynamically variable. The system continuously calculates the bounce width of each contact switch. When the average bounce width of the most recent K (e.g., 100) switches exceeds 50% of the current T_debounce, the system automatically extends T_debounce by a step ΔT (e.g., 2ms). This design allows new contacts to use a shorter debouncing window to ensure fast response, while aging contacts automatically use a longer window to suppress false triggering, thus achieving a dynamic balance between safe response speed and signal reliability.

[0038] To further enhance the reliability and security of the system, in a preferred embodiment, the system also includes a power-on self-diagnostic module running on the main control unit 110. For example... Figure 7As shown, this module automatically executes a comprehensive self-diagnostic sequence (POST) each time the system is powered on. This sequence includes, but is not limited to: checking whether the constant current source excitation current of each channel in the multi-channel isolated contact status acquisition circuit 120 is within the nominal range (e.g., ±5%); checking whether the isolation power supply voltages provided by the system power supply module 160 are normal; verifying the logic function of the dual threshold voltage comparator 123 in the acquisition circuit through internal test signals; reading and verifying the CRC check value of the mapped configuration data 200 stored in non-volatile memory; and checking whether the internal resources of the main control unit 110, such as RAM, Flash, clock, and watchdog hardware, are functioning correctly. If any self-test fails, the system will proactively enter a safe state, i.e., drive the redundant safety output interface 130 to output a safety signal (e.g., disconnect), and flash a specific fault code through the LED diagnostic indicator system 150. This design ensures that the system will not "operate with defects," proactively detecting potential hardware or configuration faults before deployment, greatly enhancing the overall system safety.

[0039] To achieve integration with industrial automation networks and digital operation and maintenance, in a preferred embodiment, the system further includes an industrial communication interface 140. This interface can be an IO-Link interface, implemented, for example, through an IO-Link transceiver, compatible with the IO-Link V1.1.3 standard. Figure 10 As shown, the main control unit 110 can communicate bidirectionally with an IO-Link master station 400 for non-secure data via this interface, thereby connecting to a host computer or programmable logic controller (PLC), i.e., an external safety controller 300. The main control unit 110 is configured to periodically report health status indication information (such as health scores, fault logs, remaining life predictions, etc.) generated by the contact health status assessment module to the host system via this industrial communication interface 140. Simultaneously, it can also receive configuration commands from the host system for remotely and securely updating the mapped configuration data 200 stored in non-volatile memory. Figure 9 As shown, this information can be organized within the IO-Link process data frame. Specifically, Figure 9 This diagram illustrates a possible structure for an IO-Link process data frame, which includes multiple fields for real-time transmission, such as status bits indicating door and lock status, bytes for transmitting contact health scores, fault codes indicating specific fault types, and configuration CRC values ​​for verifying configuration integrity. Through this structured data frame, the host computer can efficiently parse the complete operating status and diagnostic information of the door lock. This communication capability provides robust data support for remote monitoring, predictive maintenance, and flexible production line adjustments.

[0040] In the specific implementation of the acquisition circuit, in order to achieve accurate and low-damage detection of the contact state, in a preferred embodiment, a constant current source excitation circuit 122 is provided in each detection channel of the multi-channel isolated contact state acquisition circuit 120. For example... Figure 2 As shown, the constant current source excitation circuit 122 applies a constant, weak test current to the physical contact being tested, with a value configurable between 1mA and 5mA. When the contact is closed, the main control unit 110 measures the voltage drop Vdrop across the contact via a contact resistance estimation circuit 124 (typically a high-precision ADC) and calculates the contact resistance Rc according to Ohm's law (Rc = Vdrop / Itest). Since the test current Itest is constant and known, the value of Rc can be estimated very accurately. Using a weak current for testing effectively avoids the accelerated oxidation and ablation of the contact material caused by arcing when a large current passes through the contact, thereby extending the contact's lifespan. Simultaneously, the accurate contact resistance measurement provides crucial input data for the subsequent contact health status assessment module.

[0041] Regarding safety outputs, to ensure compatibility with standard safety controllers and a high level of safety output integrity, in a preferred embodiment, the redundant safety output interface 130 is a dual-channel OSSD (Output Signal Switching Device) safety output interface. This interface includes two independent output channels, OSSD1 and OSSD2, implemented using P-type MOSFETs or PNP transistors. Under normal safety conditions, both channels output a high level (e.g., +24V). The main control unit 110 periodically applies brief low-level test pulses with a width of 100μs to 500μs to both output channels, and the test pulses for the two channels are interleaved. The external safety controller monitors these two test pulses; if the pulses disappear or are abnormal, a line fault is identified. Simultaneously, the main control unit 110 also monitors the feedback from the output stage to detect short-circuit or open-circuit faults in the output transistors themselves. When the system detects any unsafe condition or internal fault, it immediately shuts down both OSSD1 and OSSD2 simultaneously (outputting 0V), thereby providing a clear and reliable safety signal to the external safety controller 300. This design complies with industrial safety standards and can effectively prevent a single failure from causing a dangerous output state.

[0042] The present invention also provides a corresponding adaptive control method for contact configuration of a security door lock, which is executed by a main control unit 110 integrated within the security door lock housing and conforming to a preset functional safety level. (Refer to...) Figure 8The method includes the following steps: First, after the system is powered on, a power-on self-diagnosis is performed, and the pre-stored mapping configuration data 200 is loaded after passing the self-diagnosis. Next, the main loop is entered, and the electrical signals reflecting the status of multiple physical contact channels are collected cyclically through the multi-channel isolated contact status acquisition circuit 120. Then, adaptive debouncing filtering is applied to the collected raw signals, and the debouncing parameters are dynamically adjusted according to the historical operating data of each channel to output a stable contact status. Subsequently, according to the mapping configuration data 200, redundant channel consistency verification is performed on multiple channels mapped to the same safety function, and a fault is determined when the status is inconsistent. After each status switch, the system updates and evaluates the health status of the contacts, and generates health indication information through a preset model based on multi-dimensional historical data such as cumulative operation count and contact resistance. Finally, the main control unit 110 makes a comprehensive decision and controls the output status of the redundant safety output interface 130 based on the status of all safety functions (such as door monitoring and lock monitoring) and the results of the consistency verification. At the same time, the system periodically refreshes and reports diagnostic data through the industrial communication interface and processes possible remote configuration change requests. This series of steps constitutes a closed-loop intelligent control process, realizing adaptive control throughout the entire process from signal acquisition, processing, decision-making to health management.

[0043] To more clearly illustrate the technical solution of the present invention, a basic embodiment is described below. This embodiment describes a basic control system. In terms of hardware, the system includes a general-purpose main control unit that meets functional safety requirements, a multi-channel isolated contact status acquisition circuit with six channels, and a general-purpose redundant safety output interface. In terms of software, the main control unit has embedded mapping configuration data; for example, mapping physical channels 1 and 2 to logical function roles for door monitoring, and mapping channels 3 and 4 to logical function roles for lock monitoring. The main control unit runs core software modules, including a redundant channel consistency verification module, a basic contact health status assessment module (this module only evaluates based on the cumulative number of operations and whether the contact resistance exceeds a fixed threshold, such as 500mΩ), and an adaptive debouncing filter that dynamically adjusts its debouncing time window according to changes in the number of contact bounces.

[0044] The workflow of this basic embodiment is as follows: After the system is powered on, the main control unit 110 initializes and loads the preset mapping configuration data. Subsequently, the system enters an infinite loop. In each loop, the main control unit 110 acquires the original status signals of all six physical contact channels through the multi-channel isolated contact status acquisition circuit 120. The acquired signals are sent to their respective independent adaptive debouncing filters for processing to filter out noise caused by mechanical bounce and output a stable "closed" or "open" state. Next, the redundant channel consistency verification module compares the states of the door monitoring channel pairs (channels 1 and 2) and the lock monitoring channel pairs (channels 3 and 4) according to the mapping configuration. If the states of any channel pair are still inconsistent after exceeding the preset tolerance time, it is determined to be a fault. Finally, the main control unit 110 controls the on / off state of the redundant safety output interface based on the comprehensive state of all safety functions (door monitoring and lock monitoring) and the result of the consistency verification. For example, the safety output is only turned on when both door monitoring and lock monitoring are in a safe state and there is no channel inconsistency fault. This embodiment fully demonstrates the core concepts of software-defined touch functionality, built-in consistency verification, adaptive debouncing, and health assessment based on historical data.

[0045] As a preferred implementation, the main control unit 110 employs a commercially available dual-core lockstep microcontroller based on the ARM Cortex-R4F, whose hardware design itself meets the certification requirements of IEC 61508 SIL 3. Upon power-up, the system executes a comprehensive Power-On Self-Diagnosis (POST) procedure to thoroughly check the integrity of critical hardware. Furthermore, the system integrates an IO-Link communication interface, through which it can upload detailed contact health scores and fault history logs calculated by the contact health status assessment module to the PLC or HMI in real time. Simultaneously, authorized users can remotely modify the mapped configuration data stored in non-volatile memory via the IO-Link master station tool after entering the correct PIN code, achieving high flexibility and maintainability.

[0046] In another embodiment, the acquisition circuitry and safety output interface are further refined. In this embodiment, each detection channel of the multi-channel isolated contact status acquisition circuit 120 employs a 1mA constant current source excitation circuit 122. By applying a precise 1mA constant current and using a 12-bit resolution ADC to measure the voltage drop when the contact is closed, the system can accurately estimate the contact resistance value of the contact, providing a reliable data source for health assessment. On the output side, the redundant safety output interface 130 is specifically implemented as an industry-standard dual-channel OSSD safety output interface. This OSSD interface not only provides fail-safe switching signals but also has a dynamic test pulse function, which can be monitored by an external safety controller to detect short circuits, open circuits, or cross-circuit faults, further enhancing the integrity of the entire safety loop.

[0047] To further improve the accuracy and adaptability of the control algorithm, another embodiment specifically implements the verification, evaluation, and debouncing algorithms. In this embodiment, the redundant channel consistency verification module executes dual-channel cross-validation logic, and its tolerance window T_tol is configured to 100ms. For the contact health status evaluation module, the multi-dimensional historical operating data used is explicitly defined as the cumulative number of operations, the time series of contact resistance, and the contact bounce width. The evaluation model adopts a weighted scoring method, with the specific weight allocation as follows: cumulative number of operations accounts for 30%, contact resistance change trend accounts for 40%, and average bounce width accounts for 30%. For the adaptive debouncing filter, a variable window majority voting algorithm is adopted, and the initial value of its debouncing window T_debounce is set to 10ms. When the system detects that the average bounce width of the most recent 100 operations exceeds 5ms (i.e., 50% of the current window), the window size will automatically increase by 2ms until it reaches the upper limit T_max of 50ms.

[0048] To fully demonstrate the comprehensive application value of this invention, a complete embodiment applied in an automated production line is described below. This embodiment describes an enhanced controller incorporating all the technical features of this invention, applied to a large automated production line with five protective doors. Each protective door is equipped with a security door lock integrating the control system of this invention. In terms of controller hardware, the main control unit 110 employs a secure MCU integrating an EtherNet / IP communication protocol stack and a dual-port switch to support a device-level ring network (DLR) topology. During operation, each controller performs a complete power-on self-diagnosis (POST) process upon power-up. During operation, it acquires contact status through a 2mA constant current source excitation circuit 122. The acquired signal is processed by an adaptive debouncing filter with an initial window of 10ms, and then undergoes dual-channel cross-validation with a tolerance window T_tol set to 150ms.

[0049] In this complete application embodiment, each door lock controller reports its security status to the external safety controller 300 in two ways: one is through a hard-wired dual-channel OSSD safety output interface, and the other is through the CIP Safety security protocol transmitted over an EtherNet / IP network. This redundant communication method ensures extremely high security and reliability. Simultaneously, the external safety controller 300 periodically polls for detailed diagnostic data from each door lock controller via standard Ethernet communication (non-secure communication). This data includes, but is not limited to, real-time contact resistance values, health scores, cumulative number of operations, average bounce width, and remaining useful life (RUL) values ​​predicted based on a lightweight neural network model for each physical contact. This rich data is centrally displayed on the production line's central HMI (Human-Machine Interface), allowing maintenance personnel to easily grasp the health status of all security door locks. When the system detects that the health score of any contact of any door lock is lower than a preset threshold of 40, the system automatically generates a maintenance work order through the MES (Manufacturing Execution System), precisely indicating the specific door lock and contact that needs replacement, achieving a leap from passive maintenance to proactive predictive maintenance. This embodiment makes full use of all the key parameters described in this invention, such as a safety response time strictly controlled within 20ms, system power consumption below 2W, and an operating temperature range covering -25℃ to 70℃.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A safety door lock contact configuration adaptive control system, characterized in that, include: A multi-channel isolated contact status acquisition circuit is used to acquire at least one electrical signal that reflects the physical status of each channel in multiple physical contact channels. The main control unit, integrated within the housing of the security door lock, is used to execute control logic. The main control unit is configured to meet a preset functional safety level. The main control unit is coupled to the acquisition circuit and is used to process the electrical signals; The mapping configuration data is stored in the memory managed by the main control unit, and the mapping configuration data is used to map the plurality of physical contact channels to one or more logical function roles; The redundant channel consistency verification module running on the main control unit is used to compare the status of multiple physical contact channels mapped to the same security function in real time according to the mapping configuration data, and to determine a fault when the duration of inconsistent status exceeds the preset tolerance. The contact health status assessment module running on the main control unit generates indication information characterizing the health status of the physical contact channel based on multi-dimensional historical operating data, including at least the cumulative number of operations and contact resistance, through a preset model. An adaptive debouncing filter runs on the main control unit. This filter dynamically adjusts the debouncing parameters used to stabilize the status signal of the physical contact channel based on the historical operating data of the physical contact channel. A redundant security output interface, the output state of which is determined by the main control unit based on the status of all security functions and the verification result of the consistency verification module, is used to provide the final security signal to the external security controller.

2. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The system also includes a power-on self-diagnostic module running on the main control unit. This module performs a self-test on key hardware, including the acquisition circuit, power supply, memory, and main control unit kernel, after each power-on of the system, and puts the redundant safety output interface into a safe state if the self-test fails.

3. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The system further includes an industrial communication interface for bidirectional communication of non-secure data with a host computer or programmable logic controller; wherein the main control unit is configured to report indication information of the health status through the industrial communication interface, and / or receive configuration instructions for updating the mapping configuration data.

4. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, In each detection channel of the multi-channel isolation contact status acquisition circuit, a constant current source excitation circuit is provided to apply a constant test current to the physical contact channel being detected.

5. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The redundant security output interface is a dual-channel OSSD security output interface.

6. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The redundant channel consistency verification module is configured to perform dual-channel cross-verification.

7. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The multidimensional historical operation data includes at least one of the following: cumulative number of operations, time series of contact resistance, and contact bounce width.

8. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The adaptive debouncing filter employs a variable window majority voting algorithm, and the debouncing parameter is the window size of the algorithm.

9. The adaptive control system for security door lock contact configuration according to claim 1, characterized in that, The main control unit is a dual-core lockstep microcontroller.

10. An adaptive control method for contact configuration of a security door lock, characterized in that, This method is executed by a main control unit integrated within the housing of the security door lock, conforming to a preset functional safety level, and includes the following steps: The multi-channel isolation contact status acquisition circuit cyclically acquires at least one electrical signal that reflects the physical status of each channel in multiple physical contact channels. Based on the pre-stored mapping configuration data, determine the logical function roles corresponding to the multiple physical contact channels; An adaptive debounce filter is applied, and the debounce parameters are dynamically adjusted based on the historical operating data of the physical contact channel to stabilize the state indicated by the electrical signal. Perform redundant channel consistency verification. Based on the mapping configuration data, compare the stable state of multiple physical contact channels mapped to the same security function in real time, and determine the fault when the state is inconsistent. Update and assess the health status, and generate indication information to characterize the health status of the physical contact channel based on multidimensional historical operating data and a preset model; Based on the status of all security functions and the results of the consistency check, control the output status of a redundant security output interface.

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