Robot Controller Safety Function Muting for Networkless Commissioning
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Solution Overview
Problem
Robot controllers in automation systems face challenges in operating safely and efficiently due to the lack of safety information availability when network data connections are not established, posing risks to the robot and its surroundings, especially when safety doors and emergency stop switches are not integrated into the network.
Innovation Solution
A robot controller with an optional deactivation or muting function for safety functions allows operation even without a fully established network data connection, enabling manual or reduced-speed operation by simulating safety information and selectively deactivating safety functions, ensuring safe operation and commissioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If safety functions are implemented via network data connection, then system integration and automation are improved, but operation during commissioning without complete network integration is hindered
Solution Approach 1:
The robot controller is configured to perform preliminary actions by simulating safety information before the network data connection is fully established. This allows the controller to operate in a commissioning mode where safety functions are temporarily simulated, enabling operators to perform initial setup and testing without requiring complete network integration of all safety devices.
Solution Approach 2:
The system dynamically switches between different operational modes depending on network connection status. When the network connection is incomplete, the controller activates a simulation mode that dynamically adjusts safety function behavior. Once the network connection is established, the system transitions to normal operation mode where actual safety device inputs are used.
2Reliability
If safety functions require complete network integration, then safety reliability is improved, but operational flexibility during commissioning is reduced
Solution Approach 1:
The controller changes operational parameters based on network connection status. When simulating safety information, the controller adjusts parameters such as enabling commissioning modes, allowing manual operation, and modifying speed limits. These parameter changes maintain appropriate safety levels while providing the flexibility needed for commissioning operations.
Solution Approach 2:
The simulation of safety information acts as an intermediary between the incomplete network connection and the safety functions. This intermediary allows the safety system to receive and process safety-related data in simulation mode, maintaining safety reliability while accommodating the temporary lack of complete network integration.
3Reliability
If all safety functions are always active, then safety coverage is improved, but operational capability during commissioning is limited
Solution Approach 1:
During commissioning, the system applies partial action by selectively deactivating certain safety functions that require network-connected safety devices. The controller simulates the absence of these safety inputs, allowing commissioning operations to proceed with reduced safety function coverage. Once commissioning is complete and the network is fully integrated, full safety coverage is restored.
4Extent of automation
If network data connection is required for safety information, then system integration is improved, but commissioning time is increased
Solution Approach 1:
The controller performs preliminary commissioning actions by simulating safety information before network integration is complete. This preliminary action allows operators to configure and test robot functions during commissioning without waiting for all safety devices to be integrated into the network, significantly reducing commissioning time.
Solution Approach 2:
The system replaces the physical connection requirement with a simulation mechanism. Instead of requiring actual network connections to all safety devices before commissioning can begin, the controller substitutes the physical safety input signals with simulated safety information, allowing commissioning to proceed in parallel with network integration rather than sequentially.
Data Source
Figure 1
AI summary
A control system (RC) according to the invention for a robot (IR), comprising a receiver (IF) for receiving safety information (NA = 0) via a network data connection (B) and a safety means (SC) for executing at least one safety function based on at least one received safety information, includes a deactivation means (MT, SW) for deactivating at least one safety function.