Safety Switch Signal Emulation for Receiving Circuit Testing
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Solution Overview
Problem
Existing safety switches for monitoring the position of protective arrangements in automatically operating technical installations lack comprehensive testing capabilities, particularly for safety-relevant components like transceivers and storage units, limiting their reliability in safety-critical applications.
Innovation Solution
A device with a sensor and actuator system that includes a receiving circuit with a sensor element, detector element, signal emulator, and switch-over element, allowing for both normal and test operating states, enabling comprehensive testing of components and emulation of sensor signals to assess the functionality of the receiving circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a microprocessor and network connection are used for self-diagnosis, then basic functional testing is enabled, but comprehensive testing of safety-relevant components (transceiver, storage unit) is insufficient
Solution Approach 1:
The patent implements a signal emulator that generates test signals mimicking actual sensor signals, allowing the receiving circuit to be tested without requiring the physical sensor. This copying approach enables comprehensive testing of the receiving circuit's signal processing capabilities, including the transceiver and storage unit, resolving the limitation of insufficient testing coverage while maintaining manageable device complexity.
2Reliability
If the sensor element is permanently connected to the detector element, then normal operation is ensured, but testing of the receiving circuit is limited
Solution Approach 1:
The patent introduces a switch-over element that dynamically changes the connection configuration between sensor element and detector element. During normal operation, the sensor element is connected to the detector element for stable sensing. During testing, the switch-over element disconnects the sensor element and connects the signal emulator instead, enabling comprehensive receiving circuit testing without compromising operational stability.
3Reliability
If the device is switched between normal and test operation, then comprehensive testing is enabled, but operational availability is reduced
Solution Approach 1:
The patent enables periodic switching between normal operation and test operation through the switch-over element. The device can perform self-diagnosis at predetermined intervals or upon request, allowing comprehensive testing of the receiving circuit while maintaining high operational availability. The periodic testing approach ensures fault detection capability without continuously reducing productivity.
Data Source
AI summary
A device includes a sensor and an actuator. The sensor has a receiving circuit with a sensor and a detector, as well as a computer connected to the detector. The sensor cooperates with the actuator to generate a first receiving circuit signal during a normal operation when a switching distance between the sensor and the actuator is undershot. The detector generates a first output signal as a function of the first receiving circuit signal, and to transmit transmits the first output signal to the computer. The receiving circuit includes a signal emulator and a switch-over element. The signal emulator generates a second receiving circuit signal during a test operation. The detector generates a second output signal as a function of the second receiving circuit signal and transmits the second output signal to the computer. The device can repeatedly switch between normal operation and test operation.