Wireless Mobile Control Unit With Distance-Limited Safety Pairing
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Solution Overview
Problem
Existing control devices for technical installations, such as machine tools, often rely on wired connections that can be cumbersome, prone to damage, and may lead to confusion or incorrect operation of neighboring machines, compromising safety.
Innovation Solution
A control device featuring a mobile control unit with wireless energy and signal transmission capabilities, utilizing a supply unit that can be assigned to the installation in a fixed manner, ensuring energy and safety protocols are transmitted only within a predetermined distance, thereby enhancing safety and preventing unauthorized control of neighboring machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired connections are used for control devices, then reliability and safety are improved, but ease of operation and flexibility deteriorate due to cumbersome cables that can be damaged or cause confusion
Solution Approach 1:
The patent replaces the mechanical wired connection system with a wireless communication system. The control device communicates with the machine tool via wireless signals, eliminating physical cables while maintaining control functionality. This substitution resolves the contradiction by removing the mechanical constraints (cables) that limited flexibility while preserving the control reliability through validated wireless communication protocols.
Solution Approach 2:
The patent introduces a wireless communication intermediary (radio frequency signals) between the control device and the machine tool. This intermediary enables energy and data transmission without direct physical contact, allowing the control device to be moved freely while maintaining reliable communication. The wireless intermediary resolves the contradiction by providing both the flexibility of movement and the reliability of controlled transmission.
2Ease of operation
If wireless control devices are used, then ease of operation and flexibility are improved, but reliability and safety deteriorate due to potential confusion with neighboring machines and incorrect operation
Solution Approach 1:
The patent implements local quality by providing each machine tool with a unique identification code and establishing a localized wireless communication field. The control device is programmed to recognize and communicate only with the specific machine tool whose identification code it has been assigned. This localizes the control authority to each specific machine, preventing confusion with neighboring machines while maintaining the flexibility of wireless operation.
Solution Approach 2:
The patent incorporates feedback mechanisms where the machine tool transmits identification signals and status information back to the control device. The control device continuously verifies the identity of the target machine and confirms proper connection before allowing control operations. This feedback loop ensures that the control device is always communicating with the intended machine, preventing incorrect operation while maintaining wireless flexibility.
3Reliability
If wired control devices are used, then reliability is improved, but device complexity increases due to cable management and physical connections
Solution Approach 1:
The patent replaces the mechanical cable connection system with an electromagnetic wireless communication system. This substitution eliminates the physical infrastructure (cables, connectors, cable management hardware) while maintaining the essential function of controlled signal transmission. The complexity of managing physical connections is replaced by the simpler electronic implementation of wireless communication protocols.
Solution Approach 2:
The patent extracts and removes the cable infrastructure from the control system. By taking out the physical wiring and replacing it with wireless communication, the system eliminates the complexity associated with cable routing, connection management, and physical maintenance. The essential control function is preserved while the complicating mechanical elements are completely removed.
4Ease of operation
If mobile control units with wireless transmission are used, then ease of operation is improved, but energy consumption increases due to continuous wireless transmission requirements
Solution Approach 1:
The patent implements periodic action by establishing discrete communication intervals between the mobile control device and the machine tool. Instead of continuous transmission, the system uses periodic signal exchanges triggered by specific events (control commands, status updates, acknowledgment signals). This periodic communication pattern maintains the mobility advantage while significantly reducing energy consumption compared to continuous wireless transmission.
Solution Approach 2:
The patent applies dynamics by adapting the wireless transmission characteristics based on operational needs. The transmission power, frequency, and duration are dynamically adjusted according to the operational state, distance between devices, and communication requirements. This dynamic adjustment optimizes energy consumption while maintaining reliable communication for the mobile control unit.
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 solution promotes safety by allowing secure, wireless energy and signal transmission, reducing the risk of incorrect operation and confusion, and adhering to safety standards like the C standard for hydraulic press brakes, while enabling flexible operation and reduced risk of damage from wiring.
Implementation Method 1
the at least one mobile control unit and the at least one supply unit have a device for wireless energy transmission with a transmission frequency within a predetermined distance between the supply unit and the mobile control unit
Data Source
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AI summary
A control device for at least one technical installation is provided, having at least one mobile control unit for controlling the at least one technical installation; and having at least one supply unit, which can be assigned in a fixed manner to the technical installation and can be connected thereto in an energy- and signal-transmitting manner, for supplying the at least one mobile control unit with energy; wherein the at least one mobile control unit and the at least one supply unit have a device for wireless energy transmission with a transmission frequency within a predetermined distance between the supply unit and the mobile control unit and for wireless transmission of a safety protocol in the course of the energy transmission. Furthermore, a technical installation and a method for controlling a technical installation are specified.