Wireless Emergency Stop Pairing for Secure Mobile Machine Shutdown
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Solution Overview
Problem
Hardwired emergency stop devices increase cost and complexity, limit operator movement, and lack 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 (e.g., Bluetooth), which detects the safety stop device's identifier to provide secure emergency stop functionality without hardwired cables, ensuring high safety category compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardwired emergency stop devices are used, then reliable emergency stop functionality is achieved, but device complexity and cost increase
Solution Approach 1:
The patent replaces hardwired mechanical connections with wireless communication technology. The mobile device controller communicates with the machine control system via wireless protocols (Bluetooth, Wi-Fi, cellular), eliminating the need for physical cables and hardwired emergency stop circuits while maintaining emergency stop functionality through software-based communication channels.
Solution Approach 2:
The patent introduces a mobile device controller as an intermediary between the operator and the machine control system. This mobile device acts as a mediator that receives emergency stop inputs from the operator and transmits stop commands to the machine control system wirelessly, replacing direct hardwired connections with an intermediate communication device.
2Reliability
If hardwired emergency stop devices are used, then emergency stop functionality is provided, but operator movement is limited
Solution Approach 1:
The patent replaces mechanical cable connections with wireless communication fields. The mobile device controller uses wireless protocols to transmit emergency stop signals without requiring physical cable connections, allowing operators to move freely within wireless communication range while maintaining reliable emergency stop capability.
3Reliability
If hardwired emergency stop devices are used, then safety functionality is ensured, but cost increases
Solution Approach 1:
The patent replaces expensive hardwired safety systems with cost-effective wireless communication technology. By using mobile devices with existing wireless capabilities (Bluetooth, Wi-Fi, cellular) to communicate with the machine control system, the patent eliminates costs associated with physical cables, connectors, and hardwired safety circuits while maintaining safety functionality through software-based emergency stop commands.
4Ease of operation
If wireless mobile device controllers are used, then operator movement freedom and reduced complexity are achieved, but security and reliability concerns arise
Solution Approach 1:
The patent implements feedback mechanisms where the mobile device controller and machine control system verify each other's identity and maintain authenticated communication sessions. The system continuously monitors wireless signal integrity and authentication status, providing feedback to ensure that only authorized emergency stop commands are executed, thereby maintaining security and reliability despite using wireless technology.
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 and reliable emergency stop functionality with reduced complexity and cost, allowing operators to control machines safely without the constraints of hardwired connections, while maintaining safety standards through verified connectivity and identity verification protocols.
Implementation Method 1
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, a mobile device controller configured to control operation of the machine, and a safety stop device. The mobile device controller establishes a short-range wireless communication link with the safety stop device and wirelessly transmits one or more instructions to control operation of the machine.
Data Source
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.