Torsional Material Testing System Virtual Interlock Safety
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Solution Overview
Problem
Conventional material testing systems often fail to comply with international safety standards and require additional, costly safety components to ensure operator safety during mechanical testing.
Innovation Solution
The integration of a safety system within the material testing system, which includes machine state indicators, monitored activation mechanisms, and compliance with ISO safety standards, to ensure safe operation and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional external safety components are added to conventional material testing systems, then operator safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges the safety system with the existing control system by integrating a safety processor that communicates through the existing fieldbus network. The safety processor is coupled to the actuator controller and shares communication infrastructure, eliminating the need for separate safety cables and external safety components while maintaining ISO 13849-1 compliance.
Solution Approach 2:
The safety processor is designed to perform multiple functions: it monitors actuator operations, determines machine states, controls virtual interlocks, and manages safety functions all through a single integrated unit. This multi-functional approach replaces what would traditionally require multiple separate safety components.
2Reliability
If additional external safety components are added to conventional material testing systems, then operator safety is improved, but cost increases
Solution Approach 1:
The patent merges the safety system with the existing control system by integrating a safety processor that communicates through the existing fieldbus network. The safety processor is coupled to the actuator controller and shares communication infrastructure, eliminating the need for separate safety cables and external safety components while maintaining ISO 13849-1 compliance.
Solution Approach 2:
The control system performs its own safety functions through the integrated safety processor, eliminating the need for separate external safety components. The system self-monitors and self-regulates safety-critical parameters using existing infrastructure, reducing both component costs and integration complexity.
3Device complexity
If safety functions are integrated into existing electronics, then device complexity is reduced, but safety reliability may be compromised
Solution Approach 1:
The safety processor acts as an intermediary between the actuator controller and the final control elements. It receives control signals, determines appropriate machine states, and controls virtual interlocks accordingly. This intermediary layer ensures that safety functions are properly isolated and managed even within the integrated system.
Solution Approach 2:
The safety processor continuously monitors actuator operations and machine state through feedback from the fieldbus network. It dynamically adjusts virtual interlock control based on real-time conditions, ensuring ISO 13849-1 compliance while maintaining system integration. The feedback mechanism allows the integrated system to respond safely to changing operational conditions.
Data Source
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AI summary
Methods and systems are provided for a torsional material testing system, which includes a rotatable actuator, such as a motor, configured to perform a torsional material testing operation. During a torsional material testing operation, a virtual interlock is configured to engage or disengage with the actuator to prevent or allow rotational movement of the actuator (e.g., during a setup state or during a torsional material testing operation, respectively). A control circuitry is employed to control the virtual interlock as well as the torsional testing system based on one or more operational states before, during, or after a material testing process.