Optoelectronic Safety Sensor Integrated PLC Logic Evaluation
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Solution Overview
Problem
The implementation of functional safety systems in industrial production plants is complex, error-prone, and requires significant effort due to the need for multiple components and extensive wiring, leading to increased response times and larger safety spacings.
Innovation Solution
An optoelectronic safety sensor with an integrated programmable logic controller that evaluates logic state variables from measured signals, allowing the sensor to control and generate signals independently, reducing the need for a separate safety control and wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate safety control and extensive wiring are used to implement functional safety systems, then the system can provide comprehensive safety monitoring and control functions, but the implementation effort, complexity, and error proneness increase significantly
Solution Approach 1:
The patent combines the safety control functions with the optoelectronic sensor by integrating a programmable logic controller (PLC) directly into the sensor unit. This merging eliminates the need for separate safety control devices and extensive wiring, reducing system complexity while maintaining comprehensive safety monitoring capabilities. The integrated PLC processes safety-relevant signals and controls safety functions within the same device that performs the optical measurement.
Solution Approach 2:
The optoelectronic safety sensor is designed to perform multiple functions: optical measurement of the safety zone, generation of measured signals, logical evaluation of safety conditions, and direct control of safety functions. This multi-functionality allows a single device to replace what would traditionally require multiple separate components including sensors, safety controls, and wiring infrastructure.
2Reliability
If extensive wiring is used to connect safety sensors and components to the safety control, then comprehensive safety coverage can be achieved, but the response time of the safety system increases
Solution Approach 1:
By integrating the programmable logic controller directly into the optoelectronic sensor, the patent eliminates the physical distance and signal transmission delays associated with extensive wiring. The safety control functions are performed locally within the sensor unit, enabling immediate processing of safety-relevant signals and instantaneous control responses without the time delays introduced by long wire runs and multiple connection points.
3Reliability
If multiple components and extensive wiring are used to implement safety systems, then comprehensive safety monitoring is achieved, but the implementation effort and error proneness increase
Solution Approach 1:
The integration of the programmable logic controller into the optoelectronic sensor consolidates multiple components into a single unit. This reduces the number of parts that need to be procured, configured, and wired together, significantly lowering implementation effort. The integrated design also reduces the potential for wiring errors and configuration mistakes that commonly occur when assembling multiple separate components.
Solution Approach 2:
The integrated safety sensor system is designed to be self-configuring and self-diagnosing, reducing the need for manual setup and external calibration. The programmable logic controller within the sensor can automatically configure safety parameters and perform self-diagnostics, minimizing the skill level and time required for implementation while maintaining high safety standards.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces implementation effort, error proneness, and response time by integrating the programmable logic controller within the safety sensor, enabling a more efficient and responsive safety system.
Implementation Method 1
The measuring device (11) transmits electromagnetic radiation (14) into a safety zone (12) and receives returning radiation (16) and generates received signals from it
Implementation Method 2
The application module (22) determines logic state variables from the received signals in dependence on a protected field set at the application module (22)
Data Source
AI summary
The invention relates to an optoelectronic safety sensor comprising an electronic measuring device for generating measured signals which depend on a state of a safety zone observed by the safety sensor and an electronic evaluation unit for evaluating the measured signals. The electronic evaluation unit comprises a programmable logic controller integrated into the optoelectronic safety sensor for the logic evaluation of logic state variables which are derived from the measured signals.