Wireless Handheld Emergency Stop Control With Safe Deregistration
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Solution Overview
Problem
Current machine control systems with wireless handheld devices have an unsatisfactory level of security, leading to potential operator misunderstandings and risks during machine operations, despite existing measures like registration procedures and multiple communication channels.
Innovation Solution
A method and device that utilize a handheld control device with a radio-technical data interface for establishing a control-technical active connection, featuring an emergency stop actuating element that can be manually activated and coupled into an emergency stop safety circuit, along with automated position detection and logout processes to ensure safe operation, minimizing risks and misunderstandings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wireless handheld operating device is used to control machine operations, then operator mobility and ease of operation are improved, but system security and reliability deteriorate due to potential operator misunderstandings and incorrect assignments
Solution Approach 1:
The system continuously monitors the operational status of the handheld device and provides feedback through status indicators (visual, acoustic, or haptic) to confirm active connections and emergency stop functionality. This real-time feedback ensures the operator is always aware of the system state, maintaining reliability while preserving mobility.
Solution Approach 2:
A control unit acts as an intermediary between the handheld operating device and the machine control system. This intermediary manages the wireless communication, ensures proper assignment, and maintains safety circuits, thereby preserving system security while enabling wireless operation.
2Reliability
If multiple communication channels or radio links are provided between handheld device and machine control, then communication reliability is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it manages wireless communication, maintains safety circuits, provides status monitoring, and handles emergency stop signals. By consolidating these functions into a single multi-functional control unit, the system achieves reliable communication without proportionally increasing overall device complexity.
3Reliability
If automatic position and zone detection is implemented with handheld device, then safety monitoring is improved, but system complexity and energy consumption increase
Solution Approach 1:
The system implements position and zone detection only when the handheld device is in active use or when approaching predefined zones. The control unit monitors basic position information continuously but triggers full safety monitoring and warnings only when necessary, thereby maintaining safety while reducing unnecessary energy consumption.
4Speed
If emergency stop actuation element is wirelessly integrated into machine control system, then response speed in emergencies is improved, but risk of unintended operation interruptions increases
Solution Approach 1:
The system performs preliminary checks before responding to emergency stop signals. The control unit verifies the authenticity and validity of emergency stop commands from the handheld device, ensuring they meet predefined criteria before executing shutdown sequences. This prevents unintended interruptions while maintaining rapid response capability.
Solution Approach 2:
The system provides immediate feedback confirmation when an emergency stop signal is received and processed. Status indicators notify the operator of the shutdown initiation, ensuring intentional operation and preventing unintended interruptions while maintaining the speed advantage of wireless emergency stop capability.
Data Source
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AI summary
The invention relates to a method for operating a machine control system (1) having at least one machine controller (3, 3') and at least one mobile handheld operating device (4) which can be carried by an operator. The handheld operating device (4) has at least one operating element (12) or at least one button (13) for an operator to manually influence machine operations. The handheld operating device (4) also comprises a first emergency stop actuation element (8) for terminating potentially dangerous machine operations. The actuation states of the first emergency stop actuation element (8) which are each present and can be manually activated and changed by an operator are transmitted in this case via at least one radio data interface (6, 6') of the handheld operating device (4) using signalling technology and are coupled into an emergency stop safety circuit (9, 9') of a selected or actively connected machine controller (3, 3'). On the basis of a deregistration process which can be manually initiated and carried out by an operator, the first emergency stop actuation element (8) can be decoupled and switched to be ineffective in terms of control with respect to the emergency stop safety circuit (9, 9') of the selected or actively connected machine controller (3, 3'), thus achieving increased system safety.