Actuator Safety Switching Assembly With Reduced Wiring Complexity
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Solution Overview
Problem
Current systems for providing functional safety in industrial settings with actuators require complex cabling and multiple components, leading to increased assembly time, manufacturing costs, and space requirements, while also necessitating extensive coordination of components to ensure the desired safety level.
Innovation Solution
A simplified system with a control and actuator assembly that integrates a switching unit and control device, where the switching unit is actuated by the control unit to manage electrical current flow, reducing the number of connections and cabling needed, and incorporating redundant components and sensors for enhanced safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual switches and circuit breakers are installed in the power supply line to ensure functional safety, then the desired safety level is achieved, but the assembly time increases and manufacturing costs increase
Solution Approach 1:
The patent combines multiple individual switches (first switch, second switch) and circuit breaker into a single integrated assembly that is inserted as one unit into the actuator's power supply line. This merging of previously separate safety components into a single modular unit directly reduces assembly time while maintaining the required functional safety level through coordinated operation of all switching elements within the integrated assembly.
2Reliability
If multiple individual switches and circuit breakers are installed in the power supply line to ensure functional safety, then the desired safety level is achieved, but the manufacturing costs increase
Solution Approach 1:
The patent integrates multiple switching elements and circuit protection into a single manufactured assembly, reducing manufacturing costs through economies of scale and simplified production. The coordinated design of multiple switches and circuit breaker within one unit eliminates the need for separate procurement, coordination, and installation of individual components, thereby reducing overall manufacturing expenses while ensuring functional safety.
3Reliability
If multiple individual switches and circuit breakers are installed in the power supply line to ensure functional safety, then the desired safety level is achieved, but a comparatively large number of different wires/cables are needed
Solution Approach 1:
The patent consolidates multiple wiring connections into a single integrated assembly that interfaces with the actuator's power supply line through one unified connection point. This merging of wiring requirements into a single modular unit significantly reduces wiring complexity and the number of cables needed, while the internal coordination of multiple switching elements within the assembly maintains the required functional safety level.
4Reliability
If individual components are coordinated with each other for the intended application, then the desired safety level is achieved, but the design time increases
Solution Approach 1:
The patent pre-coordinates multiple switching elements and circuit protection within a single integrated assembly during the manufacturing phase, eliminating the need for time-consuming coordination of individual components during system design. The unified assembly ensures functional safety through internally coordinated operation of all switching elements, thereby reducing design time while maintaining the desired safety level.
5Adaptability or versatility
If a comparatively large number of interfaces for the switches are provided on the controller, then multiple actuators can be controlled, but the manufacturing costs significantly increase
Solution Approach 1:
The patent designs the integrated assembly with universal interfaces that can control multiple actuators through a single controller interface. The modular assembly incorporates multiple switching elements that can be configured to control different actuators, providing multi-functionality that reduces the number of controller interfaces needed and thereby significantly reduces manufacturing costs while maintaining adaptability.
6Adaptability or versatility
If a comparatively large number of interfaces for the switches are provided on the controller, then multiple actuators can be controlled, but the required space significantly increases
Solution Approach 1:
The patent implements a universal interface design in the integrated assembly that allows a single controller interface to control multiple actuators. The modular assembly contains multiple switching elements that can be configured for different actuators, providing multi-functional control that reduces the number of physical interfaces needed on the controller, thereby reducing the required controller space while maintaining the ability to control multiple actuators.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a system (2) having a controller (16) and having an actuator (4) and also having an assembly (18) for providing functional safety. The assembly (18) has a switching unit (24), introduced into an electrical supply line (8) of the actuator (4), that is operated by means of a control unit (22) of the assembly (18), which control unit is connected to the controller (16) for signal transmission purposes. The invention further relates to an assembly (18) and a switching unit (24).