Wireless Proximity Stop Using Beacon-Based RF Diagnostic Coverage
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Solution Overview
Problem
Standard wireless Emergency Stop systems are inadequate for large installations and mobile machines, as they require continuous communication between personal safety devices (PSDs) and machine safety devices (MSDs), leading to unreliable operation and unnecessary machine shutdowns when out of range.
Innovation Solution
Integration of diagnostic coverage into the radio frequency (RF) systems of PSDs and MSDs, allowing them to operate in a non-continuous communication mode with Category 3 architecture, enabling PSDs to function as beacons that trigger MSDs to stop when within a defined proximity, maintaining functional safety levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous communication mode is used between PSD and MSD, then functional safety is maintained, but unnecessary machine shutdowns occur when out of range and system reliability decreases
Solution Approach 1:
The patent implements periodic diagnostic coverage checks instead of continuous communication. The system performs diagnostic coverage verification at specific intervals to determine if the PSD is within the functional safety zone, allowing the machine to operate continuously unless a diagnostic failure occurs. This periodic verification eliminates unnecessary shutdowns while maintaining safety.
Solution Approach 2:
The system performs preliminary diagnostic coverage verification to establish whether the PSD is within range before triggering a shutdown. By checking diagnostic coverage status in advance and maintaining operation when coverage is confirmed, the system avoids reactive shutdowns and enables more reliable operation.
2Productivity
If diagnostic coverage is integrated into RF systems, then unnecessary shutdowns are prevented, but device complexity increases
Solution Approach 1:
The patent integrates diagnostic coverage functionality into the existing RF communication infrastructure. The same RF system used for communication also performs diagnostic coverage verification, eliminating the need for separate dedicated diagnostic hardware. This multi-functional approach increases productivity while minimizing the increase in device complexity.
Solution Approach 2:
The RF system performs self-diagnosis by verifying its own communication capability and diagnostic coverage status. The system monitors its own functional safety zone detection without requiring external diagnostic equipment, thereby maintaining operational continuity while adding minimal complexity through self-monitoring capabilities.
Data Source
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AI summary
A wireless Proximity Stop system includes one or more Machine Safety Devices (MSDs) and one or more Personal Safety Devices (PSDs). Each MSD includes a wireless communication interface with Diagnostic Coverage (DC). Each PSD includes a wireless communication interface with Diagnostic Coverage (DC) for wireless communication with the one or more MSDs. Each PSD is configured to be operable for initiating and safely terminating a Proximity Stop signal to the one or more MSDs to trigger a Proximity Stop function of the one or more MSDs for stopping operation of a connected machine(s). Each PSD includes a transmitter and separate receiver operable for verifying that the transmitter is transmitting with the correct data and power level. Each MSD includes a receiver and a separate transmitter or local transmitting beacon usable by the receiver for verifying that the receiver is capable of receiving with the correct data and power level.