Safety Detector Terminal Reconfiguration for Emergency Stop Integration

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Solution Overview

Problem

Conventional safety detectors with only eight electrical terminals are not suitable for connecting an emergency stop device while maintaining their current functionalities, as they lack the necessary terminals required for this additional safety function.

Innovation Solution

A safety detector with a detection module that includes a test module configured to perform specific test sequences and a control and processing unit to manage the emergency stop functionality, allowing the connection of an emergency stop device using existing terminals by reconfiguring the wiring and adding a test software module.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional safety detectors with eight terminals are used, then the detector maintains its current size and terminal configuration, but it cannot connect an emergency stop device while maintaining existing functionalities

Engineering Contradiction:

Improveability to connect emergency stop deviceVSAvoidterminal configuration complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent makes the existing eight terminals multi-functional by dynamically reconfiguring their roles. Terminals can switch between serving safety outputs, control inputs, emergency stop connections, and test functions depending on the operational mode. This allows the detector to connect emergency stop devices without adding physical terminals, resolving the contradiction between adaptability and terminal configuration complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements dynamic terminal reconfiguration where the function of each terminal changes based on the operational state. During normal operation, terminals serve safety functions; during test mode, they switch to test signal transmission. This dynamic behavior enables the system to accommodate emergency stop connections while maintaining existing functionalities, solving the adaptability-complexity contradiction.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If additional terminals are added to connect emergency stop device, then the detector can support emergency stop function, but the detector size and terminal count increase

Engineering Contradiction:

Improveemergency stop functionalityVSAvoiddetector size

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If a safety logic block is added to manage emergency stop functionality, then the detector can support emergency stop, but the device complexity and size increase

Engineering Contradiction:

Improveemergency stop control capabilityVSAvoiddevice structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent enables the safety detector to perform self-testing and self-diagnosis functions through integrated test modules that use the existing terminals. The detector autonomously configures terminals for test modes, transmits test signals, and validates emergency stop functionality without requiring external safety logic blocks. This self-service capability resolves the contradiction by eliminating the need for additional complexity-adding components.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent merges the emergency stop control functionality, test functions, and safety output management into a single integrated safety detector unit. By combining these functions and using dynamic terminal reconfiguration, the system eliminates the need for separate safety logic blocks, resolving the contradiction between adaptability and device structure complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If terminals are reconfigured for emergency stop connection, then the detector can support emergency stop device, but the original safety functionalities may be compromised

Engineering Contradiction:

Improveterminal usage flexibilityVSAvoidsafety output reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent implements dynamic terminal reconfiguration where the function of each terminal changes based on the operational state. During normal operation, terminals serve safety functions with guaranteed reliability; during test mode, they switch to test signal transmission. This temporal separation ensures that safety functionalities are never compromised, as terminals are only reconfigured when safety operations are not active, resolving the contradiction between flexibility and reliability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs periodic test sequences where the system alternates between normal safety operation and test modes. During test periods, terminals are reconfigured for testing; during normal operation periods, they return to safety functions. This periodic switching ensures safety reliability is maintained while enabling terminal flexibility for emergency stop connections and testing.

Inventive Principle:

Principle #19Periodic action

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

Enables the integration of an emergency stop device with the safety detector, maintaining the detector's original functionalities and size, without the need for additional terminals or a safety logic block, by utilizing the existing eight terminals effectively.

Implementation Method 1

The use of radio frequency technology (RFID) allows communication between the sensor and the transponder

Methodology Applied

Scientific EffectRadio frequency technology: Electromagnetic Induction

Data Source

PatentEP3835645B1Safety detector and safety detection system including said safety detector

Publication Date: 2021.11.24 SCHNEIDER ELECTRIC IND SAS

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Figure 2B~3

AI summary

The invention relates to a safety detector (20) comprising a detection module (IN) configured to read a control signal (S_IN) as input, said detector having two power supply terminals, a first control input (I1) and a first control output (C1), a first safety output (OSSD1) and a second safety output (OSSD2), and a first free terminal and a second free terminal, said detector having: - A second control input (I2) connected to the first free terminal and a second control output (C2) connected to the second free terminal, - A test module configured to apply in particular a first test sequence comprising a deactivation of the first control output (C1) and a test of a start loop (B_ST) connected between the second control output (C2) and the first control input (I1).