Embedded Safety Control for Material Testing Actuators
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Solution Overview
Problem
Conventional material testing systems often fail to comply with international safety standards and incur significant costs due to the use of off-the-shelf safety components, which can compromise operator safety and system reliability.
Innovation Solution
Integration of a safety system within the material testing system, utilizing embedded safety processors, redundant monitoring, and direct hardware control to ensure compliance with ISO and European Machinery Directive standards, reducing the need for external wiring and off-the-shelf components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If off-the-shelf safety components are used, then safety coverage is provided, but system cost increases significantly
Solution Approach 1:
The patent merges the safety system with the existing material testing system by integrating safety processors, monitoring circuits, and control logic into the universal testing machine's existing architecture. This consolidation eliminates the need for separate off-the-shelf safety components while maintaining ISO 13849-1 compliance, thereby reducing system cost without compromising operator safety.
Solution Approach 2:
The safety system is designed to perform multiple functions within the material testing system, including monitoring machine state, detecting operator presence, controlling actuator movement, and providing safety interlocks. This multi-functionality allows a single integrated system to replace multiple dedicated safety components, reducing overall system complexity and cost.
2Device complexity
If integrated safety system is implemented, then costs are reduced, but safety monitoring capability must be maintained
Solution Approach 1:
The patent replaces traditional mechanical safety components with electronic and software-based monitoring systems. The integrated safety system uses electronic sensors, processors, and control circuits to monitor machine state and operator presence, substituting mechanical interlocks and physical guards with intelligent electronic monitoring that maintains safety capabilities while reducing system cost.
3Reliability
If conventional mitigation techniques are used, then operator safety is improved, but ease of operation decreases
Solution Approach 1:
The integrated safety system dynamically adjusts safety parameters based on the current operating state of the universal testing machine. The system automatically modifies monitoring thresholds, actuator speed limits, and force constraints according to the testing phase and machine configuration, maintaining operator safety while adapting to operational requirements without requiring manual intervention.
Data Source
AI summary
Safety systems and material testing systems including safety systems are disclosed. An example material testing system includes: at least one actuator configured to control one or more operator-accessible components of the material testing system; an actuator disabling circuit configured to disable the at least one actuator; and one or more processors configured to: control the at least one actuator based on a material testing process; monitor a plurality of inputs associated with operation of the material testing system; determine, based on the plurality of inputs and the material testing process, a state of the material testing system from a plurality of predetermined states, the predetermined states comprising one or more unrestricted states and one or more restricted states; and control the actuator disabling circuit based on the determined state.