Safety Controller Commissioning Verification for Functional Integrity
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Solution Overview
Problem
Existing safety controllers lack a reliable method to verify if the mandatory commissioning test has been successfully executed by the user before the safety controller goes into productive operation, which can lead to inadequate safety function execution.
Innovation Solution
A method involving automatic verification of the functional integrity of a safety controller through a verification routine that checks the execution of safety functions, visualizes the need for a commissioning test, and ensures its completion before productive operation, with optional user intervention or automatic initiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a commissioning test is required to verify functional integrity of the safety controller, then the safety reliability is improved, but there is no verification mechanism to ensure the user actually executed the test, leading to potential inadequate safety function execution
Solution Approach 1:
The patent implements a feedback mechanism where the safety controller automatically verifies whether the commissioning test has been executed by checking for specific conditions (e.g., test mode activation, safety function responses). The controller stores verification status information and provides feedback indicators to show whether the test has been completed, thereby ensuring the reliability improvement is actualized.
Solution Approach 2:
The safety controller performs self-verification of the commissioning test execution status. The controller automatically checks whether safety functions respond correctly when activated during commissioning, and stores this verification information in its memory, eliminating the need for external verification mechanisms.
2Reliability
If automatic verification of commissioning test execution is implemented, then the functional integrity verification is improved, but the device complexity increases due to additional verification routines and storage requirements
Solution Approach 1:
The verification routine leverages the existing safety function activation mechanisms and response evaluation capabilities of the safety controller. The same hardware and software components used for normal safety function execution are reused for verification purposes, avoiding the need for separate dedicated verification hardware and reducing overall device complexity.
Solution Approach 2:
The verification of commissioning test execution is performed automatically as part of the initial startup sequence or commissioning process. By conducting the verification preliminarily before normal operation begins, the patent ensures functional integrity without requiring complex continuous verification mechanisms during operation.
Data Source
AI summary
Described is a method for verifying the functional integrity of a safety controller that provides safety functions for one or more machines and has a central evaluation and control unit for operating the safety controller. The method comprises: powering on the safety controller; verifying a stored machine-readable instruction as to whether a commissioning test is to be executed; if verified, displaying information indicating that the commissioning test is to be executed; initiating a verification routine executable by the safety controller, the evaluation and control unit automatically verifying via the verification routine whether a user has successfully verified each of the safety functions; if all of the safety functions are successfully verified, deleting the machine-readable instruction that the commissioning test is to be executed; and if not all of the safety functions are successfully verified, storing the machine-readable instruction, indicating that the commissioning test is to be executed anew.