Safety Controller Diagnostics Adaptation
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Solution Overview
Problem
Existing safety controllers are not optimal in terms of information transfer regarding system and process states, lacking flexibility in adapting diagnostic information to external circumstances and user roles, which complicates effective communication and response to malfunctions.
Innovation Solution
A safety controller with an operating state data record that includes diagnostic information, a Boolean status indicator, and a user program capable of processing both safety and standard control tasks, allowing for flexible display and selection of diagnostic information and targeted reactions, with access authorization and operating mode influencing the content of diagnostic messages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diagnostic information is displayed solely based on detected malfunctions, then the safety controller ensures reliable malfunction detection, but the flexibility in adapting diagnostic information to external conditions and user roles is limited
Solution Approach 1:
The patent implements dynamic adaptability by allowing the diagnostic information display to change based on external conditions. The safety controller can adapt the content, detail level, and presentation of diagnostic messages according to the current operating mode, user access authorization, and external conditions, while maintaining reliable malfunction detection through the same diagnostic evaluation unit.
Solution Approach 2:
The patent applies local quality by providing different levels of diagnostic information to different users or under different conditions. The diagnostic information is tailored to the specific needs, roles, and authorization levels of users, with more detailed information provided to authorized personnel and simplified information to general users, while all users receive accurate malfunction detection.
2Adaptability or versatility
If multiple control devices are used to achieve flexible diagnostic information display, then the adaptability improves, but the device complexity and wiring increase
Solution Approach 1:
The patent makes the safety controller multi-functional by integrating both the diagnostic evaluation capabilities and the flexible display control functions into a single device. The safety controller can evaluate malfunctions, determine diagnostic information, assess user authorization, select appropriate display content, and control the display output, thereby eliminating the need for multiple separate control devices and reducing wiring complexity.
Solution Approach 2:
The patent combines previously separate functions into a unified safety controller system. The diagnostic information generation, user authorization verification, display content selection, and output control are merged into a single integrated system, simplifying the overall device architecture and reducing the number of components and connections required.
Data Source
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AI summary
The invention relates to a safety control for controlling an automated system (14), comprising a plurality (18) of sensors and a plurality (16) of actuators, having a control unit (22) to which a plurality (32) of control input signals are fed from the sensors, wherein the control unit (22) is designed to create, in an automatic mode, a plurality (34) of control output signals in dependence on the control input signals according to a user program (38) running within it, wherein the plurality (16) of actuators are activated by the plurality (34) of control output signals, having a diagnostics evaluation unit (64) that is fed a number (66) of diagnostics input signals, wherein the diagnostics evaluation unit (64) is designed to determine which of several operating conditions (122) is present at a defined point in time in dependence on the diagnostics input signals, wherein the diagnostics evaluation unit (64) creates an operating condition data set (68) that is designed to display diagnostics messages, wherein the operating condition data set (68) exhibits a variety of diagnostics data and a boolean status indicator, and wherein the control unit (22) is designed to activate at least one actuator in dependence on the boolean status indicator.