Handheld Control Device Safety Circuit Bridging
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Solution Overview
Problem
Existing control systems for technical systems face challenges in safely managing the connection and disconnection of handheld control devices, leading to potential unintended shutdowns due to unclear cable states, which can result in operational disruptions and safety hazards.
Innovation Solution
A control system with a wireless communication interface and a wired plug-in interface that includes a termination identifier detection mechanism to differentiate between intentional disconnection and cable faults, automatically bridging the safety circuit to prevent unwanted shutdowns and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a handheld control device is disconnected from the technical system, then the operator can move to another machine or location, but the safety circuit is interrupted causing unintended shutdown of the machine
Solution Approach 1:
The patent introduces a bridging contact as an intermediary element that compensates for the interrupted safety circuit when the handheld control device is disconnected. This bridging contact acts as a mediator between the disconnected safety circuit contacts, allowing the safety circuit to remain closed and functional even when the handheld device is removed from the machine
Solution Approach 2:
The patent implements preliminary detection of the disconnection state through coupling state detection means before the shutdown occurs. By detecting that the handheld control device has been disconnected and that the safety circuit is interrupted, the system can proactively activate the bridging contact to prevent the unintended shutdown, rather than reacting after the shutdown has occurred
2Reliability
If the safety circuit is monitored continuously, then cable faults can be detected, but the system complexity increases
Solution Approach 1:
The patent combines multiple detection functions into a single integrated monitoring approach. The coupling state detection means serves dual purposes: it detects both the disconnection of the handheld control device and the interruption of the safety circuit, eliminating the need for separate detection systems for each function
Solution Approach 2:
The safety circuit monitoring leverages the existing safety circuit infrastructure and components already present in the system. Rather than introducing a completely new monitoring system, the patent uses the existing safety circuit contacts and detection means to perform self-diagnosis of cable faults and disconnection states
3Reliability
If manual checks are performed to distinguish intentional disconnection from cable faults, then shutdown accuracy improves, but operational time increases
Solution Approach 1:
The patent implements an automated feedback mechanism where the coupling state detection means continuously monitors the connection state and provides real-time information to the control device. This feedback loop enables the system to automatically distinguish between intentional disconnection and cable faults based on the detection of the bridging contact state, eliminating the need for manual checks
Data Source
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AI summary
The invention relates to a control system (1) for technical systems (2). The control system (1) comprises at least one electronic handheld operating device (9) which can be carried by an operator (11) and which can be used in a mobile manner for influencing and monitoring the control system (1) with respect to a technical system (2) linked to the control system. The handheld operating device (9) has a wireless communication interface (16) and a communication interface (18) which can be established via a connection cable (17). At least one safety switch element (15), which can be actuated by an operator (11), on the handheld operating device (9) is provided at least for ending potentially safety-critical control commands or movement patterns. The cable-connected communication interface (18) comprises a contact-based plug interface (20) on the handheld operating device (9), said plug interface (20) having a first coupling element (21) on the handheld operating device (9) and a second coupling element (22) which can be coupled to and uncoupled from the first coupling element (21) as required. At least one termination characteristic (27) which can be electronically detected by a termination characteristic detection means (28) is formed directly in the second coupling element (22) or in the direct vicinity of the second coupling element (22) on or in the connection cable (17).