Electronic Hinged Safety Switch Barrier Position Detection
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Solution Overview
Problem
Hinged safety switches with mechanical commutators struggle to generate additional electric signals regarding the position or state of the barrier, leading to installation complexities and increased costs when integrated with digital communication systems, as they cannot detect inconsistent switching states or contact failures.
Innovation Solution
An electronic hinged safety switch with a sensor and electronic control unit that generates actuation signals for electric safety circuits, allowing connection to digital communication systems and enabling quick, automatic enabling/disabling during maintenance, using a microprocessor to process signals and interface with data buses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a mechanical commutator is used in the safety switch, then the switch can reliably open and close electrical contacts, but it cannot generate additional electric signals concerning the position or state of the barrier
Solution Approach 1:
The patent replaces the mechanical commutator with an electronic sensor system that includes a sensor (6) and an electronic control unit (8). The sensor detects the position and state of the barrier, and the electronic control unit processes this information to generate multiple electric signals (SA, SC) that convey comprehensive status information, thereby eliminating the information limitations of mechanical commutators while reducing mechanical complexity.
Solution Approach 2:
The electronic control unit (8) is designed to perform multiple functions: it receives signals from the sensor, processes the information, generates actuation signals for safety circuits, and provides additional signals about barrier position and switch state. This multi-functional approach allows a single electronic system to replace what would otherwise require multiple separate mechanical components.
2Adaptability or versatility
If a mechanical commutator is used in the safety switch, then the switch structure remains simple, but it cannot be easily integrated with digital communication systems like data buses or field buses
Solution Approach 1:
By replacing the mechanical commutator with an electronic control unit, the system gains native compatibility with digital communication systems. The electronic control unit can directly interface with data buses and field buses, enabling seamless integration with modern digital control architectures without requiring additional analog-to-digital conversion interfaces.
Solution Approach 2:
The patent changes the signal parameters from mechanical contact states to electronic signals that can be transmitted in various formats (analog, digital, serialized). This parameter transformation allows the safety switch to communicate effectively with different types of control systems and digital communication protocols.
3Reliability
If an analog contact unit is used in the safety switch, then the switch can operate reliably, but it requires an analog-to-digital conversion interface to connect to digital buses, increasing installation costs and circuit complexity
Solution Approach 1:
The patent replaces the analog contact unit with an electronic sensor and control unit system that natively generates digital-compatible signals. This substitution maintains the reliability of safety circuit operation while eliminating the need for separate analog-to-digital conversion interfaces, thereby reducing both installation costs and circuit complexity.
4Reliability
If a mechanical commutator is used in the safety switch, then the switch can be manufactured cost-effectively, but it cannot detect inconsistent switching states or contact unit failures
Solution Approach 1:
The electronic control unit implements feedback mechanisms that continuously monitor the state of the sensor and the generated signals. This feedback system enables the detection of inconsistent switching states, contact unit failures, and other anomalies, providing enhanced reliability while the integrated electronic design keeps manufacturing costs competitive.
Solution Approach 2:
The electronic sensor and control unit system performs self-diagnosis and self-monitoring, automatically detecting its own operational status and potential failures. This self-service capability enhances reliability without requiring additional external monitoring equipment, thereby controlling manufacturing costs.
Data Source
AI summary
An electronic hinged safety switch adapted for installation on protection barriers (B) of machines and/or automatic plants having one or more electric safety circuits (S). The switch comprises a substantially box-like fixed member (2) designed to be secured to a stationary part (M) of a protection barrier (B) and a movable member (3) designed to be secured to a pivotal part (P) of the protection barrier (B) and coupled to the fixed member (2) through hinge means (4). Sensing means (5) are housed in said box-like fixed member (2) for interacting with the hinge means (4) to send an electric control signal (SC) to one or more electric safety circuits (S) at a predetermined switching angle (α). The sensing means (5) comprise at least one sensor for generating a corresponding actuation signal (SA) at the switching angle (α), and an electronic control unit (8) operatively connected to at least one sensor (6). The electronic control unit (8) has at least one input (9) electrically connected to said sensor (6) for receiving the actuation signal (SA) and at least one output (10) connected to the electronic safety circuits (S) for generating the electric control signal (SC) in response to the actuation signal (SA).