Integrated PLC Safety Relay for Shock-Resistant Emergency Stop
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Solution Overview
Problem
Existing programmable logic controllers for mobile working machines face challenges in meeting safety standards due to environmental conditions like extreme temperatures, shock, and vibration, and require complex assembly efforts, often relying on error-prone electromechanical components.
Innovation Solution
A programmable logic controller with an integrated safety relay function, featuring two safety circuits and an emergency stop function, designed to be compact, mobile, and flexible, with no moving mechanical components, housed in a robust and watertight enclosure resistant to shock, vibration, and dust, ensuring safe state de-energization of outputs within milliseconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electromechanical safety relays are used in mobile machinery control systems, then safety functions can be implemented, but the system becomes vulnerable to shock, vibration, and mechanical failures in harsh environmental conditions
Solution Approach 1:
The patent replaces electromechanical safety relay components with a fully electronic control unit that integrates safety monitoring functions. The control unit uses electronic circuits and software-based safety monitoring instead of mechanical relays, eliminating moving parts that are susceptible to shock and vibration in mobile machinery environments while maintaining safety function reliability
2Reliability
If separate safety relay components are integrated into the control system, then safety monitoring is achieved, but assembly complexity and the number of components increase
Solution Approach 1:
The patent merges the safety monitoring functions into the existing control unit, combining the safety relay functionality with the programmable logic controller in a single integrated device. This eliminates the need for separate safety relay components and reduces assembly complexity while maintaining comprehensive safety monitoring capability through unified hardware and software integration
3Reliability
If safety functions are implemented using traditional control systems in mobile machinery, then safety requirements can be met, but the system lacks adaptability to harsh environmental conditions like extreme temperatures, dust, and water
Solution Approach 1:
The patent implements safety functions through software-based monitoring and electronic control parameters that can be adapted to various environmental conditions. The control unit uses configurable safety parameters, diagnostic routines, and electronic protection mechanisms that maintain safety standard compliance across different temperatures, dust levels, and moisture conditions without requiring mechanical adjustments
Data Source
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AI summary
Programmable logic controller (PLC) with integrated safety relay function, wherein the controller (PLC) includes an emergency stop (NH) function, and the controller (PLC) includes at least one output (A), wherein the relay function is designed as a safety function, wherein the safety function includes two safety circuits (S1, S2), wherein the first safety circuit can be switched via a first channel of the safety function (K1) and the second safety circuit via a second channel of the safety function (K2), wherein by activating a channel (K1, K2) the output (A) can be switched to a safe state and the first channel of the safety function (K1) and the second channel of the safety function (K2) can be switched simultaneously via the emergency stop (NH) function, wherein a control output (SA) is provided by which the at least one output (A) can be switched.wherein the control output (SA) is logically AND connected to the first channel of the safety function (K1), and wherein at least one individual control output (Q) is provided through which the at least one output (A) can be individually switched, so that the output (A) can be switched by the individual control output (Q), and wherein the at least one individual control output (Q) is logically AND connected to the second channel of the safety function (K2).