Solid-State Safety Controller Logic for Wiring Reduction
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Solution Overview
Problem
Existing safety controller systems for machine equipment and industrial robots require complex wiring and are difficult to modify, leading to increased time and manpower for system changes and expansions.
Innovation Solution
A safety controller system using solid-state outputs and logical connections between safety controllers, allowing for reduced wiring and easy system modifications through software changes, with features like self-diagnosis and logical correlation of safety and connection outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If relay units with electromagnetic relays are used to form safety circuits, then reliable safety control is achieved, but the wiring becomes complex and the system becomes difficult to modify
Solution Approach 1:
The patent replaces electromagnetic relays (mechanical/electromagnetic system) with solid-state output circuits and microcontroller-based control logic. This substitution eliminates the need for complex relay wiring while maintaining safety control reliability through electronic logic operations and software-based safety monitoring.
Solution Approach 2:
The safety controller is designed with multiple functions integrated into a single device: it performs safety monitoring, logic processing, output control, and system configuration. This multi-functionality consolidates what would previously require multiple relay units and extensive wiring into one universal control unit, reducing overall system complexity.
2Reliability
If relay sequences are used to control multiple fabrication machines, then safety monitoring is achieved, but the number of wires increases and system design becomes difficult
Solution Approach 1:
The patent merges multiple safety monitoring functions and control logic into a single integrated safety controller. Instead of using separate relay units for each machine with individual wiring, the controller consolidates all safety inputs, processing logic, and outputs in one device, dramatically reducing the total number of wires required.
Solution Approach 2:
The controller uses software-based logic copies to replicate safety monitoring functions across multiple machines. Rather than physically replicating relay circuits for each machine, the same safety logic is implemented through software programs that can be easily copied and modified, eliminating the need for extensive physical wiring to each device.
3Reliability
If wiring-based logic is used to control system operations, then safety control logic is implemented, but system modification requires long time and large amount of manpower
Solution Approach 1:
The patent implements dynamic, reconfigurable control logic through software programming rather than fixed wiring. The safety control logic can be dynamically modified by changing software parameters and programs, allowing rapid system adaptation without physical rewiring. This dynamic approach enables quick response to production changes while maintaining safety requirements.
Solution Approach 2:
The system allows modification of safety control logic by changing software parameters and configuration settings rather than altering physical wiring. This parameter-based approach enables rapid system reconfiguration for different production scenarios, machine configurations, or safety requirements without time-consuming rewiring work.
4Reliability
If electromagnetic relays are used for safety control, then dependable shutdown is achieved, but the system cannot be easily restarted after abnormal conditions
Solution Approach 1:
The safety controller incorporates feedback mechanisms that continuously monitor system status, safety conditions, and abnormal states. When an abnormal condition occurs, the controller maintains shutdown status through feedback loops until the issue is resolved. Once normal conditions are restored, the feedback system automatically enables system restart, providing both dependable shutdown and easy restart capabilities.
Data Source
AI summary
A safety controller provides a safety output to a target controlled system such as a magnet contactor based on an input from an input device such as a safety door switch to thereby control operation of machine equipment. Safety output parts serve to transmit a solid-state output as the safety output and a connection output part transmits a connection output to another safety controller. A control part having two CPUs controls the safety output and the connection output according to a program based on the input from the input device. Two or more of such safety controllers are connected through their connecting output parts and the connecting input parts to together form a safety system.