Wireless Emergency Stop Linking for Secure Mobile Machine Control

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Solution Overview

Problem

Hardwired emergency stop devices increase cost and complexity, limit operator movement, and may not provide sufficient security for reliable emergency stop functionality in machine control systems.

Innovation Solution

A wireless emergency stop system using a mobile device controller, such as a tablet, tethered to a safety stop device via near-field communication, provides secure emergency stop functionality without wires, utilizing a linking protocol to ensure safety category compliance and reliable machine control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hardwired emergency stop devices are used, then reliability of emergency stop functionality is improved, but device complexity and cost increase

Engineering Contradiction:

Improveemergency stop functionalityVSAvoidmachine control complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical hardwired connection system with a wireless communication system. The mobile device controller communicates with the machine safety device via wireless protocols (Bluetooth, Wi-Fi, or other short-range wireless communications), eliminating the need for physical wire connections while maintaining the emergency stop functionality. This substitution reduces device complexity and installation requirements while preserving reliability through multiple verification mechanisms including authentication protocols and signal integrity checks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If hardwired emergency stop devices are used, then reliability of emergency stop functionality is improved, but operator mobility is limited

Engineering Contradiction:

Improveemergency stop functionalityVSAvoidoperator movement freedom

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the mechanical constraint of hardwired connections with wireless communication technology. Operators can carry mobile devices (smartphones, tablets, or dedicated handheld controllers) that maintain wireless communication with the machine safety device, allowing free movement within the operational area while preserving emergency stop capability through continuous wireless signal transmission and reception.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If wireless communication is used for emergency stop, then operator mobility is improved, but security and reliability may be compromised

Engineering Contradiction:

Improveoperator movement freedomVSAvoidemergency stop security

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent introduces an intermediary authentication and verification system between the mobile device controller and the machine safety device. This includes authentication protocols that verify the legitimacy of control signals, encryption methods to protect communication channels from unauthorized access, and verification mechanisms that ensure the integrity of emergency stop commands. The system acts as a trusted intermediary that maintains security while enabling wireless communication.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent implements feedback mechanisms that continuously monitor the wireless communication link quality, signal strength, and system status. The machine safety device receives and verifies authentication tokens from the mobile device, and the system provides feedback on connection status and security verification results. This feedback loop ensures that emergency stop functionality remains secure and reliable by detecting and responding to potential communication issues or unauthorized access attempts.

Inventive Principle:

Principle #23Feedback

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 secure, reliable, and cost-effective emergency stop operations with enhanced operator mobility by eliminating the need for hardwired connections, ensuring rapid machine shutdowns and maintaining safety protocols through wireless communication.

Implementation Method 1

transmit an emergency stop signal to a machine safety device to trigger an emergency stop of the machine

Methodology Applied

Scientific EffectWireless communication: Electromagnetic Induction

Implementation Method 2

A wireless emergency stop system using a mobile device controller, such as a tablet, tethered to a safety stop device via near-field communication

Methodology Applied

Scientific EffectNear-field communication: Electromagnetic Induction

Data Source

PatentEP4094128B1Wireless emergency stop systems including mobile device controllers linked with safety stop devices

Publication Date: 2026.03.04 CATTRON NORTH AMERICA INC

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AI summary

A wireless emergency stop system includes a machine safety device connected 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 a mobile device controller configured to control operation of the machine, and a safety stop device. The safety stop device includes a wireless communication interface for wireless communication with the machine safety device, and an emergency stop switch configured to, when activated, transmit an emergency stop signal to the machine safety device to trigger an emergency stop of the machine. The mobile device controller is configured to link with the safety stop device via short-range wireless communication.