Wireless-Powered Exchanger Safety Circuit for Fast Emergency Stops
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Solution Overview
Problem
Existing production line safety systems with wireless power supply experience delays in emergency stops due to temporary power outages or noise, and require time-consuming permissions for wireless communication, leading to potential collisions and safety risks.
Innovation Solution
A safety system with a work device equipped with a monitoring section to detect objects, a safety circuit to immediately cut power to the driving section while maintaining power to the monitoring and control sections, and an emergency stop button for immediate wireless power cutoff, ensuring rapid and safe emergency stops without relying on wireless communication permissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If wireless communication is used for safe signal transmission, then device complexity is reduced, but reliability deteriorates due to temporary power outages or noise causing false emergency stops
Solution Approach 1:
The power supply system is segmented into two independent channels: a wireless power supply channel for normal operation and a wired power supply channel for emergency stop function. This segmentation allows the wireless system to maintain simplicity while the wired channel ensures reliable emergency stop signal transmission不受无线通信干扰的影响
Solution Approach 2:
The patent introduces an intermediary wired power supply line that serves as a backup communication channel for emergency stop signals. This intermediary channel bypasses the wireless communication system, providing a reliable path for safety-critical signals when wireless communication fails or experiences interference
2Reliability
If emergency stop is determined after specified continuous failures to receive safe signal, then false emergency stops are prevented, but response time increases causing safety delays
Solution Approach 1:
The system performs preliminary action by immediately detecting emergency stop signals through the wired power supply channel without waiting for multiple safe signal failures. The wired channel provides immediate alert capability, eliminating the delay inherent in counting consecutive safe signal failures
Solution Approach 2:
Instead of using the wireless safe signal channel to trigger emergency stops (which causes delays), the system inverts the approach by using the wired power supply channel for emergency stop detection. This reversal allows immediate response while the wireless channel continues to provide stable power
3Reliability
If wireless communication permissions are obtained for each country, then communication reliability improves, but time and cost increase
Solution Approach 1:
The patent extracts the emergency stop signal transmission function from the wireless communication system and places it in the wired power supply channel. This extraction eliminates the need for wireless communication permissions while maintaining reliable emergency stop capability, as the wired channel does not require country-specific wireless licenses
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 system prevents collisions by immediately stopping the work device when objects are detected and allows for quick restarts, minimizing emergency stop time and eliminating delays associated with wireless communication issues, while avoiding the need for complex permissions.
Implementation Method 1
power is supplied to the automatic exchanging unit from the component mounter side via wireless power supply (contactless electric power transmission)
Data Source
AI summary
In a component-mounted-board production line in which an automatic exchanging device moves along a row of multiple component mounters, each component mounter is provided with a power supplying section that supplies power wirelessly. The automatic exchanging device is provided with a power receiving section that receives electric power supplied wirelessly from the power supplying section of the component mounter that the automatic exchanging device is facing, a monitoring section that monitors whether a person or object has entered a monitoring area around the automatic exchanging device, and a safety circuit section that turns off the power supply to a motor that is the driving source of the automatic exchanging device but continues supplying power to the monitoring section and the like when the monitoring section detects that a person or object has entered the monitoring area.