Wireless Proximity Stop RF Diagnostics for Fewer Out-of-Range Stops
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Solution Overview
Problem
Existing wireless Emergency Stop systems are inadequate for larger installations and mobile machines, as they require continuous communication between personal safety devices (PSDs) and machine safety devices (MSDs), leading to unacceptably high machine stop rates when out of range.
Innovation Solution
The implementation of a wireless Proximity Stop system with diagnostic coverage for RF transmission and reception, allowing PSDs and MSDs to operate in a non-continuous communication mode while maintaining safety through RF verification and beacon functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous communication mode is used between PSDs and MSDs, then safety monitoring is maintained, but machine stop rates become unacceptably high when out of range
Solution Approach 1:
The patent implements periodic RF diagnostic coverage verification instead of continuous communication. The system periodically checks RF signal strength and diagnostic coverage to determine if the PSD is within the proximity detection zone. This periodic action maintains safety monitoring while allowing the machine to operate continuously without unnecessary stops, resolving the contradiction between reliability and productivity
2Reliability
If wireless Emergency Stop systems are used for mobile machines, then operator safety is enhanced, but communication range limitations cause excessive machine stops
Solution Approach 1:
The patent changes the parameter from binary communication presence/absence to continuous RF diagnostic coverage measurement. By measuring RF signal strength and diagnostic coverage parameters, the system can determine proximity more accurately. This allows the machine to operate smoothly when the operator is within the detection zone while maintaining safety, resolving the contradiction between operator safety and operation continuity
3Reliability
If hardwired Emergency stop stations are used, then safety stop function is reliable, but operator response time is delayed due to physical movement requirement
Solution Approach 1:
The patent replaces the mechanical hardwired stop station system with a wireless RF-based Proximity Stop system. The operator carries a PSD that wirelessly communicates with the MSD on the mobile machine. This substitution eliminates the need for physical movement to trigger the stop function, reducing operator response time while maintaining reliable safety stop functionality through RF diagnostic coverage verification
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
This solution enables safe and reliable operation of mobile machines by allowing PSDs to trigger a Proximity Stop without continuous communication, ensuring machines stop only when within the proximity detection zone and maintaining a suitable functional safety level.
Implementation Method 1
diagnostic coverage to radio frequency (RF) transmission and reception to verify that RF communications are possible
Data Source
AI summary
A wireless Proximity Stop system includes one or more Machine Safety Devices (MSDs) and one or more Personal Safety Devices (PSDs). Each MSD includes a wireless communication interface with Diagnostic Coverage (DC). Each PSD includes a wireless communication interface with Diagnostic Coverage (DC) for wireless communication with the one or more MSDs. Each PSD is configured to be operable for initiating and safely terminating a Proximity Stop signal to the one or more MSDs to trigger a Proximity Stop function of the one or more MSDs for stopping operation of a connected machine(s). Each PSD includes a transmitter and separate receiver operable for verifying that the transmitter is transmitting with the correct data and power level. Each MSD includes a receiver and a separate transmitter or local transmitting beacon usable by the receiver for verifying that the receiver is capable of receiving with the correct data and power level.