Wireless Emergency Stop Interface for Multi-Operator Machine Shutdown
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Solution Overview
Problem
Hardwired emergency stop stations require time for operators to reach and activate, which can be hazardous and inefficient, especially when the station is out of reach or in a hazard zone.
Innovation Solution
A wireless emergency stop system comprising personal safety devices with emergency stop switches and machine safety devices connected via a radio interface, allowing instant activation of the emergency stop from a distance and maintaining machine operation unless specific safety conditions are compromised.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardwired emergency stop stations are used, then machine safety is ensured, but operator response time increases and accessibility is reduced
Solution Approach 1:
The patent replaces the mechanical hardwired emergency stop system with a wireless communication system. Personal safety devices communicate with the machine safety device via radio frequency, eliminating the need for physical contact with hardwired stations. This substitution maintains safety reliability while dramatically reducing operator response time by allowing emergency stops to be triggered from any location within wireless range.
Solution Approach 2:
The patent introduces a wireless communication intermediary (radio frequency transmission) between the operator's personal safety device and the machine safety device. This intermediary enables remote activation of emergency stops without requiring direct mechanical connection, thus resolving the contradiction between maintaining safety and reducing response time.
2Reliability
If hardwired emergency stop stations are used, then safety control is maintained, but accessibility is reduced when stations are out of reach or in hazard zones
Solution Approach 1:
The patent replaces the mechanical constraint of fixed hardwired stations with wireless communication capability. Operators can trigger emergency stops from any location within radio range, eliminating the accessibility problems associated with reaching distant or hazardous hardwired stations while maintaining safety control through the wireless link.
Solution Approach 2:
The patent transitions the emergency stop system from a spatially constrained mechanical system (fixed locations) to a wireless system that operates in the electromagnetic dimension. This allows operators to activate emergency stops from any position within the wireless coverage area, dramatically improving accessibility without compromising safety control.
3Loss of time
If wireless communication is implemented for emergency stops, then operator response time is reduced, but system complexity increases
Solution Approach 1:
The patent employs universal wireless communication interfaces and standardized protocols that allow the same communication infrastructure to serve multiple functions (emergency stops, status monitoring, device identification). This multi-functionality reduces overall system complexity despite the addition of wireless capabilities, as the same hardware and software components handle multiple tasks.
Solution Approach 2:
The patent uses wireless communication to create a virtual copy of the hardwired emergency stop functionality. The personal safety devices replicate the emergency stop activation capability remotely, eliminating the need for additional complex hardware while maintaining the essential safety function through software-based wireless communication.
4Ease of operation
If multiple personal safety devices are connected wirelessly, then accessibility and response time are improved, but communication reliability requirements increase
Solution Approach 1:
The patent implements feedback mechanisms where the machine safety device continuously monitors communication status with all connected personal safety devices. The system provides status information back to operators and automatically manages device connections, ensuring that communication reliability is maintained even as the number of connected devices increases. This feedback loop allows the system to adapt to changing communication conditions while maintaining safety.
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
Enables rapid and safe shutdown of machines without operator delay, reducing risk and increasing efficiency by allowing multiple operators to trigger stops remotely and maintaining machine operation until valid communication and safety conditions are met.
Implementation Method 1
a machine safety device (102) having a wireless communication interface (106) for wireless communication with multiple personal safety devices (108)
Data Source
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AI summary
Exemplary embodiments are provided of wireless emergency stop systems. In an exemplary embodiment, a wireless emergency stop system includes a machine safety device wired 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 multiple personal safety devices. Each personal safety device includes a wireless communication interface for wireless communication with the machine safety device, and an emergency stop switch. The emergency stop switch is configured to, when activated, transmit an emergency stop signal to the machine safety device to trigger an emergency stop of the machine. The machine safety device is configured to maintain wireless connections with more than one of the multiple personal safety devices at the same time. Example methods of operating a wireless emergency stop system are also disclosed.