Safety check method for modular safety controller

Abstract

The present invention relates to a method for performing safety checks of a modular safety controller (1) having a number of electronic modules (10.1 to 10.n) implementing safety functions for the safe operation of at least one machine (2) connected to the modular safety controller (1), in which all safety checks to be processed are performed and, after completion of the checks, are confirmed and recorded.

Description

[Technical field]

[0001] The present invention relates to a safety checking method for a modular safety controller, which comprises a number of electronic modules in which safety functions for the safe operation of at least one machine or technical system connected to the modular safety controller are implemented. [Background technology]

[0002] Modular safety controllers are known from the prior art in various embodiments. In particular, they are used to safely put machines or technical systems into a state that is not dangerous for people in the event of a dangerous situation. For this purpose, on the input side, corresponding signals are received from a signaling device, which may be an emergency stop switch, an emergency stop switch, a light grid, a light curtain, a safety mat, a safety door position switch, a 3D laser scanner, etc., and safely evaluated. On the output side, one or more safety output contacts of an output circuit are activated. In the event of a dangerous situation, these output contacts are used to control actuators such as contactors, valves, etc., so that machines or technical systems connected to them can be switched into a state that is safe for people.

[0003] Such a modular safety controller comprises several electronic modules, which are arranged in at least one module row and have a specific function. The modular structure of the safety controller allows the possibility of application-specific configurations, where several electronic modules are individually assembled, wired and configured to provide the modular safety controller with the desired safety function. Examples of electronic modules that can be used to build modular safety controllers with widely different safety functions are input modules, which can receive and, if necessary, process input signals from one or more signaling devices, such as input signals from sensors or emergency command devices, output modules, which can provide output signals to one or more connected actuators, modules that combine input and output modules (so-called I / O modules), control modules that can control the allocation of input and output modules, as well as interface modules, communication modules, fieldbus controllers, fieldbus couplers, etc.

[0004] The configuration of the modular safety controller can be performed by a user, for example, using a configuration tool with a graphical user interface, which allows the user to select from a large number of electronic modules those that are required for a specific application purpose of the safety controller. The configuration is stored in a configuration database as a configuration data set.

[0005] In the manufacture of a modular safety controller, electronic modules are stitched together based on configuration data set in at least one bank of modules, wired accordingly, and configured to provide the functionality required for the purpose of a particular application from a safety perspective.

[0006] After the modular safety controller has been installed at the point of use, a safety check must be performed to ensure that the safety controller functions correctly when interacting with the machine or technical system that is connected to the safety controller.

[0007] EP 3 499 324 A1 discloses a method for validating the configuration of a safety controller. The configuration is created on an external input device, such as a computer or a smartphone, and transferred to the safety controller. The configuration thus implemented is displayed on the input device for a user to check. The configuration is divided into sub-configurations and validated. Summary of the Invention

[0008] The present invention aims to provide a method for performing safety checks of a modular safety controller, which allows the check process to be performed by a user in a particularly simple, intuitive and safe manner.

[0009] A solution to this problem is provided by a method having the features of claim 1. The dependent claims relate to advantageous further embodiments of the invention.

[0010] A method according to the invention for carrying out a safety check of a modular safety controller having a plurality of electronic modules in which safety functions for the safe operation of at least one machine connected to said modular safety controller are implemented comprises the steps of: S1) establishing a communication link between a modular safety controller and a test device providing a human-machine interface; S2) providing a configuration data set, the configuration data set being processed by the test device and including information about the electronic module and about the safety functions of the modular safety controller implemented by the electronic module; S3) generating a test data set comprising a number of predefined user instructions which are executed in sequence to test the functionality, in particular the safety functionality, of the electronic module; S4) visualizing one of the user instructions, executing the corresponding user instruction, and verifying the execution of the user instruction; S5) recording and verifying at least one machine intervention resulting from the execution of a user instruction in process step S4); S6) repeating steps S4) and S5) until execution of all user instructions and resulting machine interventions has been confirmed; S7) automatically generating a digital test report from verification of executed user instructions and resulting machine interventions, and storing the test report together with the unique identification code of the safety controller in a non-volatile memory device.

[0011] By means of the method according to the invention, the user is guided through all test steps required for a safety check of the modular safety controller in an automated process in the form of a sequentially processed digital checklist. The execution of all user instructions and the resulting machine interventions are automatically logged and stored, so that in the form of a digital test log they can form at least part of the digitally searchable machine documentation.

[0012] The term "machine intervention" here should be understood to mean all reactions of at least one machine or technical system connected to the safety controller and its actuators and signalling devices to the execution of user instructions specified by the test data set.

[0013] The test device can be, for example, a computer, in particular a portable computer, a tablet computer or a mobile phone (smartphone). Corresponding test software is executed by the test device, which executes parts of the method according to the invention. The test device can optionally be designed to execute a software-based configurator for configuring the modular safety controller and / or to program the modular safety controller.

[0014] In a preferred embodiment, it is proposed to visualize the user instructions by means of a display device of the man-machine interface, so that the user instructions can be recognized and executed by the user in a particularly simple manner.

[0015] In a particularly preferred embodiment, it is proposed that the execution of user instructions and machine interventions is confirmed by the user by input into the input means of the man-machine interface, in this way all instructions executed by the user which trigger machine interventions are confirmed.

[0016] The man-machine interface may for example comprise a touch-sensitive display device with integrated input means, which allows the man-machine interface to be operated particularly simply and intuitively.

[0017] In one embodiment, at least some of the user instructions may include setting a potentiometer position on the electronic module, and / or reading a preset potentiometer position on the electronic module, and / or triggering at least one signaling device.

[0018] In one embodiment, at least one machine intervention resulting from the execution of a user instruction in process step S4) can be detected by the user and confirmed by the man-machine interface.

[0019] In an alternative embodiment, at least one machine intervention resulting from the execution of a user instruction in process step S4) can also be automatically detected and confirmed by the modular safety controller, this confirmation being preferably transmitted to the test device via a communication link.

[0020] In an advantageous embodiment, it is proposed to automatically generate the test data set from the configuration data set by the test device.

[0021] To further simplify the implementation of the method, in one embodiment, the establishment of a communication link between the modular safety controller and the test device may be initiated by scanning an optoelectronically readable code attached to the modular safety controller by a camera of the test device. This embodiment is particularly advantageous when the test device is a tablet computer or a mobile phone (smartphone) with a built-in camera. The optoelectronically readable code may in particular be a two-dimensional code.

[0022] In one embodiment, when one of the electronic modules is replaced, a replacement verification can be performed.

[0023] The method presented here for performing a safety check of a modular safety controller makes it possible, among other things, to check all potentiometer settings, wiring and safety functions of the modular safety controller. [Brief description of the drawings]

[0024] Further features and advantages of embodiments of the present invention are described below with reference to the drawings. [Figure 1] FIG. 1 is a schematic diagram of a system for performing safety checks on a modular safety controller. [Diagram 2] FIG. 1 is a schematic diagram showing a basic process flow. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Before describing in detail below how the safety checks of the modular safety controller 1 are performed, the basic structure of the modular safety controller 1 will first be described with reference to Figure 1. The modular safety controller 1 is connected to at least one machine 2 (or technical system) which has at least one actuator 20 and at least one signaling device 21. An example of a machine 2 which can be operated using the modular safety controller 1 is an industrial robot.

[0026] The machine 2 will also often have a number of actuators 20 and a number of signalling devices 21 connected to the modular safety controller 1. In many applications, a number of machines 2 will also be connected to the modular safety controller 1 and controlled by it.

[0027] The modular safety controller 1 comprises a plurality of n electronic modules 10.1 to 10.n, which are arranged in at least one module row and accordingly electrically wired with each other and connected to the machine 2. The first electronic module 10.1 preferably forms the central control module of the modular safety controller 1 and is often also called the head module. The other electronic modules 10.2 to 10.n are selected from a number of different types of electronic modules depending on the application. The other electronic modules 10.2 to 10.n can be, for example, input modules capable of safely receiving and, if necessary, processing input signals from one or more signalling devices 21, such as input signals from sensors, signalling devices or emergency command devices, output modules capable of safely outputting output signals to one or more connected actuators 20, combined input-output modules having inputs and outputs (so-called I / O modules), as well as interface modules, fieldbus controllers, fieldbus couplers, etc. The number and type of electronic modules used in the modular safety controller 1 can vary depending on the application. The number and type of electronic modules 10.1 to 10.n used depends directly on the planned application and intended use of the modular safety control device 1 and in particular on the safety level to be achieved.

[0028] In general, the task of the modular safety controller 1 is to switch off the actuators 20 connected to the modular safety controller 1 in a safety-relevant manner upon the occurrence of a dangerous situation detected by at least one of the signaling devices 21, i.e. by at least one of a sensor, a signaling device or an emergency command device, and to activate the actuators 20 again after the dangerous situation has ended.

[0029] At least some of the electronic modules 10.1-10.n of the modular safety controller 1 are equipped with one or more potentiometers 11.1-11.n, in particular latching potentiometers, by means of which electrical resistance values ​​can be set or changed which influence the functioning, in particular the safety-related functions, of the modular safety controller 1 and of the machine 2 connected thereto. For example, the potentiometers 11.1-11.n can be used to set or change the switch-on and / or switch-off delays of the machine 2.

[0030] For simplicity and to avoid overcomplicating the following description, in accordance with this general functional description of the modular safety controller 1, it is assumed that the actuators 20 and signaling devices 21 of one machine 2 are connected to the modular safety controller 1.

[0031] The modular safety controller 1 is configured by the user depending on the intended use, preferably using a software-based configurator. The configuration process can be carried out, for example, using a web-based configurator. The configuration of the modular safety controller 1 is stored as a configuration data set in the non-volatile memory device 3 and can be retrieved. The modular safety controller 1 is manufactured based on the configuration data set which contains all the configuration information. The potentiometers 11.1 to 11.n can be preset during manufacturing to facilitate the installation of the modular safety controller 1 at the place of use.

[0032] After delivery of the modular safety controller 1 and after connecting the modular controller 1 to the machine 2, the safety functions of the modular controller 1 have to be checked before starting a production run. This check of the safety functions is performed by a test device 4. The test device 4 is, for example, a stationary or portable computer, in particular a laptop computer, a tablet computer, a smartphone, etc. The test device 4 can be used to run corresponding test software that supports a user in checking the safety functions of the modular safety controller 1 and ensures that all safety checks performed are performed, verified and recorded after the test is completed. The test device 4 can optionally be designed in such a way that it can also run a software-based configurator and / or program the modular controller 1.

[0033] The test device 4 comprises a man-machine interface 40 which allows a dialogue with a user carrying out a safety check. The man-machine interface 40 has a display device 41 by means of which various kinds of information and data can be visualized to the user. Furthermore, the man-machine interface 40 comprises at least one input means 42 by means of which the user can make various user inputs. The display device 41 can be designed to be touch-sensitive, such that the functionality of the at least one input means 42 is integrated in the display device 41, in particular if the test device 4 is designed as a tablet computer or a smartphone.

[0034] In the present embodiment, the configuration data sets of the modular safety controller 1 are stored in a distributed manner in a non-volatile storage device 3 designed as a cloud memory. In principle, the configuration data sets of the modular safety controller 1 can also be stored elsewhere. In this context, non-volatile storage means should be mentioned, which can be integrated in the test device 4 or at least temporarily connected to the test device 4 via an interface. Furthermore, the configuration data sets can also be saved on a local server accessible from the test device 4 via a wired or wireless network connection.

[0035] The test device 4 is designed to read and process a configuration data set which defines the configuration of the modular safety controller 1 and generate therefrom a configuration-specific test data set. The test data set comprises the operational inputs made by the user during a safety check of the modular safety controller 1, e.g. the settings made to the potentiometers of the electronic modules 10.1 to 10.n of the modular safety controller 1 in order to perform the safety check. If the settings of the potentiometers, in particular latching potentiometers, have already been made by the manufacturer of the modular safety controller 1, the test data set may comprise information regarding the setting positions of the potentiometers.

[0036] With further reference to FIG. 2, details of a method for performing a safety check of a modular safety controller 1 connected to at least one machine 2 will now be described.

[0037] In step S1) a communication link is established between the modular safety controller 1 and the test device 4. This can be a wired or wireless communication connection. The establishment of the communication link between the modular safety controller 1 and the test device 4 can be initiated, for example, by scanning an optoelectronically readable code 12 attached to the modular safety controller 1 with a camera 43 of the test device 4. This makes the establishment of the communication link particularly simple and intuitive.

[0038] It is processed by the test device 4 and contains information about the electronic modules 10.1-10.n and about the safety functions of the modular safety controller 1 implemented by the electronic modules 10.1-10.n. The configuration data set can for example be stored in the non-volatile memory device 3 together with a unique identification code of the modular safety controller 1, in particular a unique serial number, making it retrievable.

[0039] In step S3) a test data set is generated which comprises a number of predefined user instructions which are executed sequentially to test the safety functions of the electronic modules 10.1 to 10.n. Preferably, the test data set is generated automatically by the test device 4 from a configuration data set of the modular safety controller 1 previously loaded by the storage device 3. The user instructions which are executed sequentially specify to the user in the form of a digital checklist how to perform safety checks of the modular safety controller 1.

[0040] In step S4), one of the user instructions is visualized by the display device 41 of the man-machine interface 40. The corresponding user instruction is executed by the user. Afterwards, the execution of this user instruction is confirmed.

[0041] At least some of the user instructions may include setting potentiometer positions of the electronic modules 10.1-10.n and / or reading preset potentiometer positions, in particular manufacturer preset potentiometer positions, of the electronic modules 10.1-10.n and / or activating the signaling device 21.

[0042] At least one machine intervention resulting from the execution of the user instructions in process step S4) is detected and confirmed by the user in step S5), or alternatively, it is also possible that at least one machine intervention resulting from the execution of the user instructions in process step S4) is detected by the modular safety controller 1 in step S5) and confirmed to the test device 4 via an existing communication link.

[0043] In step S6), steps S4) and S5) are repeated until all user instructions and all resulting machine interventions have been verified.

[0044] In step S7), a digital test protocol is automatically generated as a result of the validation of the executed user instructions and of the machine intervention by the test device 4. This test protocol, together with the unique identification code of the modular safety controller 1, in particular the unique serial number of the modular safety controller 1, is stored and retrievable in the non-volatile memory device 3 or other non-volatile memory means. The test log forms part of the machine documentation.

[0045] The method provided herein for performing a safety check of the modular safety controller 1 allows for checking of all potentiometer settings, wiring and safety functions of the modular safety controller 1.

[0046] If one of the electronic modules 10.1 to 10.n is replaced, the method can also be used to perform replacement verification.

Claims

1. A safety check method for a modular safety controller (1) having a number of electronic modules (10.1 to 10.n) in which safety functions for the safe operation of at least one machine (2) connected to the modular safety controller (1) are implemented, comprising: S1) establishing a communication link between a modular safety controller (1) and a test device (4) providing a man-machine interface (40); S2) preparing a configuration data set, which is processed by the test device (4) and contains information about the electronic modules (10.1-10.n) and about the safety functions of the modular safety controller (1) implemented by the electronic modules (10.1-10.n); S3) generating a test data set comprising a number of predefined user instructions which are executed in sequence to test the functions, in particular the safety functions, of the electronic modules (10.1-10.5); S4) visualizing one of the user instructions, executing the corresponding user instruction, and confirming the execution of the user instruction; S5) recording and verifying at least one machine intervention resulting from the execution of a user instruction in process step S4); S6) repeating steps S4) and S5) until the execution of all user instructions and all resulting machine interventions have been confirmed; S7) automatically generating a digital test report from validation of executed user instructions and resulting machine interventions, and storing the test report together with a unique identification code of the safety controller (1) in a non-volatile memory device (3).

2. 2. The method according to claim 1, characterized in that the user instructions are visualized by means of a display device (41) of the man-machine interface (40).

3. 3. A method according to claim 1 or 2, characterized in that the execution of user instructions and machine interventions are confirmed by the user by input into the input means (42) of the man-machine interface (40).

4. The method according to any one of claims 1 to 3, characterized in that at least some of the user instructions comprise setting potentiometer positions of the electronic modules (10.1-10.n) and / or reading preset potentiometer positions of the electronic modules (10.1-10.5) and / or activating at least one signaling device (21) of the machine (2).

5. Method according to any one of the preceding claims, characterised in that at least one machine intervention resulting from the execution of a user instruction in method step S4) is detected and confirmed by the user.

6. 5. The method according to claim 1, wherein at least one machine intervention resulting from the execution of a user instruction in method step S4) is detected and verified by a modular safety controller (1).

7. Method according to any one of the preceding claims, characterized in that the test data set is generated automatically by the test device (4) from the configuration data set.

8. The method according to any one of claims 1 to 7, characterized in that the establishment of a communication link between the modular safety controller (1) and the test device (4) is initiated by scanning an optoelectronic readable code attached to the modular safety controller (1) by a camera (43) of the test device (4).

9. Method according to any one of the preceding claims, characterized in that when one of the electronic modules (10.1 to 10.n) is replaced, a replacement verification is carried out.

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