Safety Input Display for Dynamic Emergency Stop Coverage
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Solution Overview
Problem
In industrial automation systems, the existing methods for ensuring safety during commissioning, reconfiguration, and operation are inadequate, particularly in dynamic environments where system configurations change, leading to increased safety and accident risks due to rigid labeling and marking of emergency stop buttons, which do not accurately reflect the effective range of safety functions.
Innovation Solution
A safety control system with a safety control and safety input means, equipped with a display device that visualizes the effective range of the safety function based on a predetermined safety configuration, allowing the system operator to recognize the influence area of the safety input means and trigger the safety function from any location within the automation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid labeling or marking of safety input devices is used, then the system structure is simple and easy to manufacture, but the safety reliability deteriorates during commissioning and reconfiguration because the labels do not reflect the actual effective range
Solution Approach 1:
The patent applies dynamics by making the effective range visualization changeable based on system configuration. The safety controller dynamically updates the displayed effective range when components are added, removed, or reconfigured during commissioning and operation. This ensures the visualization always reflects the actual safety coverage, resolving the contradiction between simple labeling and reliable safety indication.
Solution Approach 2:
The patent implements feedback by continuously monitoring the system configuration and updating the effective range visualization accordingly. The safety controller receives feedback about component status and automatically adjusts the displayed safety coverage, ensuring operators always see accurate information without manual intervention, thus improving reliability without proportionally increasing complexity.
2Reliability
If multiple emergency stop buttons are used for different effective ranges, then the safety coverage is improved, but the device complexity increases due to multiple labeled buttons
Solution Approach 1:
The patent applies universality by enabling a single safety input device to serve multiple effective ranges through dynamic visualization. Instead of requiring separate physically distinct buttons for each effective range, one button can visually indicate different coverage areas based on current system configuration, reducing the number of physical components while maintaining comprehensive safety coverage.
Solution Approach 2:
The patent transitions from physical differentiation (multiple buttons) to informational differentiation (visualization display). By adding the dimensional aspect of visual information display, the system can indicate multiple effective ranges without adding multiple physical buttons, thus improving safety coverage while controlling device complexity.
3Stability of the object's composition
If the system configuration is fixed during commissioning, then the safety function coverage is stable, but the adaptability deteriorates when reconfiguration is needed for changing production requirements
Solution Approach 1:
The patent applies dynamics by making the safety system adaptable to configuration changes while maintaining stability of safety coverage. When components are added or removed during commissioning or reconfiguration, the system dynamically updates the effective range visualization to reflect current safety coverage, allowing flexible reconfiguration without compromising safety stability.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the displayed effective range parameters based on system configuration. When production requirements change and reconfiguration occurs, the controller modifies the visualization parameters to show updated safety coverage, enabling the system to adapt to new configurations while maintaining accurate safety information.
Data Source
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AI summary
The invention relates to a safety control system and method for executing a safety function for at least one automation system component, wherein the safety control system comprises a safety controller and one or more safety input means, and wherein the execution of the safety function is triggered by actuating one of the safety input means and a display device is arranged on each of the safety input means, wherein the display device is designed to display an effective range of the safety function according to a predefined safety configuration of the safety controller, if the automation system component is connected to the safety controller.