Monitoring Unit Control for Dual-Use Safety Inputs
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Solution Overview
Problem
Existing control systems for machines and systems lack the ability to seamlessly integrate non-safety-relevant and safety-relevant functions, limiting the flexibility and efficiency of operation, particularly in scenarios where safety functions are activated.
Innovation Solution
A control device comprising a first control unit for non-safe technology to handle non-safety-relevant functions and a second control unit for safe technology to manage safety-relevant functions, with a monitoring unit to monitor the state of safety-relevant inputs, allowing non-safety functions to be triggered when safety functions are activated, thereby expanding operational capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety-relevant input means are dedicated solely to safety functions, then safety reliability is improved, but operational flexibility deteriorates
Solution Approach 1:
The input means associated with the second control unit are designed to serve dual purposes: they function as safety-relevant switching means when the second control unit is inactive, and as non-safety-relevant input means when the second control unit is active and has taken over their control. This multi-functionality allows the same physical input means to adapt its function based on the operational state of the control units, thereby maintaining both safety reliability and operational flexibility.
2Reliability
If separate control units are used for safety and non-safety functions, then functional separation is improved, but device complexity increases
Solution Approach 1:
The patent combines the first control unit (non-safe technology) and the second control unit (safe technology) into a single integrated control device. The monitoring unit detects when the second control unit has taken over control of input means, and automatically connects these input means to the first control unit for non-safety functions. This merging approach maintains functional separation for safety purposes while reducing overall device complexity through integration.
Solution Approach 2:
The control device employs dynamic reconfiguration where the connection between input means and control units changes based on operational state. The monitoring unit continuously monitors whether the second control unit has taken over control, and dynamically switches the connection between the first and second control units accordingly. This dynamic adaptability allows the system to maintain optimal functionality without requiring permanently separate physical control devices.
Data Source
AI summary
A control device for controlling a machine or system includes a monitoring unit designed and configured to monitor the functional state of a second control unit such that, when the second control unit is in an activated functional state, by which the machine or system is put into a safe state, the monitoring unit connects at least one input means associated with the second control unit to a first control unit such that non-safety-relevant functions of the machine or system can be triggered by manual actuation of the input means, as long as the second control unit is in its activated functional state in which the input means is not connected to the machine or system as a proper safety switching means.