Modular Safety Controller Checks With Guided Digital Test Logging
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Solution Overview
Problem
Existing methods for safety checks of modular safety controllers are complex and not intuitive, making it difficult for users to ensure the correct functioning of safety functions in machines or technical systems.
Innovation Solution
A method that establishes a communication link between the modular safety controller and a test device with a human-machine interface, generates a test data set with user instructions, and automatically logs and confirms machine interventions, producing a digital test report for verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods for safety checks are used, then safety verification can be performed, but the checking process is complex and not intuitive
Solution Approach 1:
The patent introduces a test device as an intermediary between the user and the modular safety controller. This test device provides a human-machine interface that guides users through the safety check process, automatically generates test data sets from configuration data, and presents results in an intuitive manner. The intermediary handles the complexity of safety verification internally while presenting a simplified interface to the user.
Solution Approach 2:
The safety check process is designed to be largely automated and self-guiding. The test device automatically generates test data sets based on the configuration data, executes safety checks without requiring deep user expertise, and automatically documents results. The system serves itself by using its own configuration data to generate appropriate test scenarios.
2Reliability
If manual safety checking is performed, then users can verify safety functions, but the process requires extensive user knowledge and effort
Solution Approach 1:
The system performs preliminary actions by automatically generating the test data set before the actual safety check execution. The test device reads the configuration data in advance, processes it to create appropriate test scenarios, and prepares all necessary test parameters. This preliminary generation of test data eliminates the need for users to manually design test cases.
Solution Approach 2:
The patent replaces manual mechanical processes of safety checking with automated electronic and software-based systems. Instead of manual configuration verification and test execution, the system uses automated data processing, electronic communication between devices, and software-driven test execution to verify safety functions.
3Reliability
If comprehensive safety checks are performed, then all safety functions can be verified, but documentation and verification become time-consuming
Solution Approach 1:
The test device implements feedback mechanisms by automatically capturing and documenting the results of safety checks. As safety functions are verified, the system automatically records the outcomes, generates test reports, and stores documentation. This automated feedback loop ensures comprehensive documentation without requiring manual time investment.
Solution Approach 2:
The system creates digital copies of safety verification results automatically. The test device generates electronic test reports that document all safety function verifications, which can be stored and archived. This digital copying and storage of results eliminates the need for manual documentation processes.
Data Source
AI summary
A method for carrying out a safety check of a modular safety controller having electronics modules in which safety functions for the safe operation of at least one machine connected to the modular safety controller are implemented, includes: establishing a communication link between the modular safety controller and a test device having a human-machine interface; providing a configuration data set processed by the test device and has information about the electronics modules and about the safety functions of the modular safety controller implemented by the electronics modules; generating a test data set with a plurality of user instructions to be executed sequentially for testing the safety functions of the electronics modules; and, for each of the user instructions, visualizing the user instruction, executing the user instruction, confirming execution of the user instruction, and recording and confirming a machine intervention resulting from the execution of the user instruction.