Modular Safety Controller Configuration Detection by Image Recognition
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Solution Overview
Problem
Current modular safety controllers face challenges in efficiently and error-free detection and documentation of configuration changes and parameterizations, particularly due to the precise determination of configuration and parameterization changes during their life cycle.
Innovation Solution
A method involving a camera-based image generating device to capture a digital image of the module block, with an evaluation device using image recognition to generate an unambiguous logic code representing the current configuration and parameterization, and comparing it to stored codes to identify the correct configuration or detect errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual detection and documentation methods are used for configuration changes, then device complexity is reduced, but measurement precision and reliability of configuration detection deteriorate
Solution Approach 1:
The patent uses image copying technology to create a digital visual record of the module block configuration. A camera captures an image of the physical modules, and image recognition algorithms process this copy to extract configuration information, replacing manual detection methods and improving precision without requiring direct physical interaction with the hardware.
Solution Approach 2:
The patent replaces manual mechanical detection methods with an automated optical system. Instead of physically examining and recording configuration parameters by hand, the system uses a camera-based image capture and automated image recognition processing to detect and document module types, positions, and parameterizations, thereby improving measurement precision while managing system complexity through automation.
2Productivity
If automated image recognition is implemented for configuration detection, then productivity is improved, but device complexity increases
Solution Approach 1:
The system implements self-service through automated image recognition. The evaluation device automatically processes captured images, identifies module configurations, and generates documentation without requiring manual intervention. This automation improves productivity by enabling rapid, consistent configuration detection while the modular architecture manages complexity through standardized processing routines.
Solution Approach 2:
The evaluation device serves multiple functions: it captures images, processes them through recognition algorithms, identifies various module types, determines their positions, extracts parameterization information, and generates documentation. This multi-functionality improves productivity by consolidating multiple detection tasks into a single integrated system, while the standardized evaluation algorithms help manage the inherent complexity.
3Loss of information
If comprehensive configuration parameters are detected and documented, then loss of information is reduced, but device complexity increases
Solution Approach 1:
The patent segments the configuration detection process into distinct components: identifying module types, determining module positions, extracting parameterization settings, and generating documentation. The image recognition system processes different aspects of the configuration separately and integrates them into a complete record, reducing information loss while managing complexity through modular processing steps.
Solution Approach 2:
The patent transitions from physical configuration to digital representation by capturing images and processing them through image recognition. This dimensional transformation from physical space to digital image space allows comprehensive extraction of configuration parameters (module types, positions, settings) without directly complicating the physical detection system, as all information is extracted from the visual domain.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables automated, efficient, and error-proof detection of module types, sequence, and parameterization, ensuring up-to-date documentation and compliance with safety and quality management requirements.
Implementation Method 1
generating a digital image of the module block of the modular safety controller by a camera-based image generating device on the basis of one or a plurality of images or image sequences
Implementation Method 2
an evaluation algorithm is executed by the evaluation device, which algorithm captures, through image recognition, the selected module types, the positions of the central control module and of the electronic modules within the module block
Data Source
AI summary
A method for detecting a configuration of a modular safety controller includes generating a digital image of a module block of the modular safety controller, and evaluating the digital image with an evaluation device using image recognition. A logic code is generated which is compared with a plurality of configuration codes in order to determine the current configuration of the modular safety controller.