Wireless Emergency Stop Pairing for Secure Mobile Machine Control
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Solution Overview
Problem
Hardwired emergency stop devices increase cost and complexity in machine control systems, limit operator movement, and lack sufficient security for reliable emergency stop functionality, while mobile device controllers may not provide adequate security without hardwired panels.
Innovation Solution
A wireless emergency stop system using a mobile device controller, such as a tablet, tethered to a safety stop device via near-field communication (e.g., Bluetooth), which detects the safety stop device's identifier to provide a secure emergency stop functionality without hardwired cables, utilizing a microcontroller architecture with wireless communication protocols to ensure machine safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardwired emergency stop devices are used, then machine safety and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces hardwired mechanical emergency stop systems with a wireless system using mobile devices (smartphones, tablets) running safety applications. The mobile device communicates wirelessly with the machine control system, eliminating the need for physical hardwired panels and cables while maintaining emergency stop functionality. This substitution reduces installation complexity and allows operator movement without compromising safety reliability.
2Reliability
If hardwired emergency stop devices are used, then emergency stop security is improved, but operator movement is limited
Solution Approach 1:
The patent implements a dynamic emergency stop system where the safety control point moves with the operator via mobile device. The system continuously tracks the mobile device's location and maintains wireless communication links, allowing operators to move freely around the machine while keeping the emergency stop function accessible. The system adapts to changing positions by maintaining active wireless connections, unlike static hardwired systems.
3Ease of operation
If mobile device controllers are used, then operator movement freedom is improved, but emergency stop security deteriorates
Solution Approach 1:
The patent implements multiple feedback mechanisms to ensure security: the system continuously monitors wireless signal strength and connection status, provides visual and audible alerts when approaching communication limits, and automatically triggers emergency stop if the connection is lost or signal becomes too weak. This continuous feedback loop maintains security by detecting potential failures before they occur, allowing mobile operation without compromising emergency stop reliability.
4Reliability
If hardwired emergency stop panels are used, then emergency stop reliability is improved, but installation cost and complexity increase
Solution Approach 1:
The patent leverages the universality of mobile devices that operators already possess (smartphones, tablets). Instead of requiring specialized hardwired control panels, the system uses commercially available mobile devices running safety-critical applications. This approach eliminates the need for expensive specialized hardware installation while maintaining emergency stop functionality through software-based control and wireless communication protocols.
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
The system allows for secure and reliable emergency stop functionality with reduced complexity and cost, enabling operators to control machines with sufficient safety ratings without hardwired cables, while maintaining normal operation unless unsafe conditions are detected.
Implementation Method 1
transmit an emergency stop signal to a machine safety device to trigger an emergency stop of the machine
Implementation Method 2
establish a short-range wireless communication link with the safety stop device
Data Source
AI summary
A wireless emergency stop system includes a machine safety device connected to a machine stop circuit for stopping operation of a machine when the machine stop circuit is activated. The machine safety device includes a wireless communication interface. The system also includes a mobile device controller configured to control operation of the machine, and a safety stop device. The safety stop device includes a wireless communication interface for wireless communication with the machine safety device, and an emergency stop switch configured to, when activated, transmit an emergency stop signal to the machine safety device to trigger an emergency stop of the machine. The mobile device controller is configured to link with the safety stop device via short-range wireless communication.