Safety Control Evaluation Unit for Dynamic Danger Zone Setting
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Solution Overview
Problem
Existing safety-relevant function control systems for machines face challenges with fast movements, requiring generously sized danger zones and error-free machine recognition, which can lead to inefficiencies and reduced precision in safety assessments.
Innovation Solution
Direct communication between the machine control and evaluation unit allows for precise setting of danger zones using control signals, enabling smaller, dynamically defined zones even at high speeds, and consideration of object and machine data for tailored safety measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor measures position and speed to set the danger zone, then the danger zone can be dynamically adjusted, but at high machine speeds the measurement time causes delays that require generously sized danger zones
Solution Approach 1:
The control unit receives future position and/or speed data from the machine control in advance before the machine actually reaches those positions. This allows the evaluation unit to pre-calculate and set the danger zone based on anticipated machine states, eliminating the time delay associated with real-time measurement and ensuring the danger zone is already properly configured when the machine arrives at high speeds.
Solution Approach 2:
The system dynamically adjusts the danger zone size based on the machine's future speed and position data. When high speeds are anticipated, the danger zone is automatically enlarged in advance; when lower speeds are expected, the danger zone is reduced. This dynamic adaptation resolves the contradiction by making the danger zone size responsive to actual machine conditions rather than using fixed conservative margins.
2Device complexity
If the sensor is used to sense machine data for danger zone setting, then the system can operate with existing components, but the machine must be recognized error-free by the sensor which reduces reliability at high speeds
Solution Approach 1:
The invention introduces the machine control as an intermediary between the machine and the evaluation unit. Instead of the sensor directly measuring machine position and speed, the machine control receives future position and speed data from the machine control unit and transmits this information to the evaluation unit. This intermediary approach improves reliability because control systems are designed to handle high-speed data accurately, whereas sensors may struggle with error-free recognition at high speeds.
3Reliability
If generously sized danger zones are used to ensure safety at high speeds, then safety is maintained, but the working zone utilization is reduced
Solution Approach 1:
The system applies local quality by setting different danger zone sizes in different spatial locations and time moments based on the machine's specific future position and speed data. Instead of using a uniformly generous danger zone throughout the working area, the evaluation unit calculates precise, location-specific danger zones that are only enlarged where and when actually needed for safety, thereby maximizing working zone utilization while maintaining safety.
Data Source
AI summary
An apparatus for the control of at least one safety-relevant function of a machine is described having a machine control for the control of the movements of the machine, having at least one sensor for the sensing of an object inside a monitored zone and having an evaluation unit for the setting of a danger zone and for the triggering of the safety-relevant function on the intrusion of the sensed object into the danger zone. To set the danger zone, the evaluation unit is coupled to the machine control and the evaluation unit is designed for the derivation of the parameters required for the setting of the danger zone starting from the control signals used by the machine control for the movement control of the machine. A corresponding method is furthermore described.