Embedded Safety Laser Scanner Simulation for PLC-Free Testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Safety laser scanners require expert configuration and complex setup processes, especially with fieldbus protocols, making them difficult for untrained operators to use effectively.
Innovation Solution
An embedded solution within the safety laser scanner device that emulates the behavior of an external controller, allowing users to test and validate configurations through a graphical user interface without the need for external equipment, such as a programmable logic controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fieldbus protocol is used for safety laser scanner, then system integration capability is improved, but device complexity increases
Solution Approach 1:
The patent introduces a simulation mode that acts as an intermediary between the safety laser scanner and external fieldbus controllers. This simulation mode emulates controller behavior, allowing the scanner to be tested and configured independently without requiring actual external controller connections, thereby reducing the complexity barrier while maintaining fieldbus integration capabilities.
Solution Approach 2:
The simulation mode enables preliminary testing and validation of scanner configurations before actual deployment with external controllers. Users can pre-configure and test safety zones, response behaviors, and communication protocols in isolation, reducing the complexity of on-site setup and integration.
2Manufacturing precision
If expert configuration is required for safety laser scanner, then configuration precision is improved, but ease of operation deteriorates
Solution Approach 1:
The simulation mode enables self-service configuration and testing by providing built-in test capabilities that guide users through configuration validation without requiring external equipment or expert intervention. The system performs self-diagnosis and configuration verification through integrated simulation functions.
Solution Approach 2:
The simulation mode provides immediate feedback on configuration validity by testing scanner responses to simulated controller signals. This real-time feedback mechanism helps untrained operators verify their configurations correctly without needing deep expertise, while maintaining configuration precision through systematic validation.
3Measurement precision
If external controller is required for testing, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a virtual copy of the external controller's behavior within the scanner's simulation mode. This digital twin emulates the controller's signal patterns and response characteristics, enabling accurate testing of scanner configurations without requiring physical external controller equipment, thereby maintaining measurement precision while reducing testing complexity.
Data Source
AI summary
The disclosure includes a safety laser scanner device having a features simulator embedded thereon. One or more processors having one or more embedded software applications may be operable to connect with an external controller during an operational mode, and to emulate behavior of the external controller during a test mode that is configured to test the SLS device and validate configuration settings without the use of an external controller. A related method includes operating a safety laser scanner to communicate input process images and output process images between a programmable logic controller (PLC) and the safety laser scanner during an operational mode, communicate input process images and output process images between an external computer running a graphical user interface (GUI) during a test mode, and operate embedded logic within the safety laser scanner operable to emulate behavior of the PLC during test mode without a connection to the PLC.