Dual-Channel Wireless Safety Control for Remote Machines
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Solution Overview
Problem
Wired networks in automation control systems for remote machines are inflexible and expensive, and wireless local area network (WLAN) communications are unreliable, especially in multichannel control systems with interference from other radio technologies.
Innovation Solution
The automation control system employs mobile communication technology to transmit control signals using two or more safety channels, with a base station configured to transmit signals according to mobile communication standards, and a control receiver to extract and process these signals for reliable control of safety functions in remote machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired networks are used for transmitting control signals, then reliability is improved, but infrastructure costs and flexibility deteriorate
Solution Approach 1:
The patent replaces wired mechanical connections with wireless communication technology. The base station transmits control signals wirelessly to remote machines using established wireless communication protocols, eliminating the need for physical cable infrastructure while maintaining control signal transmission capability.
Solution Approach 2:
The wireless communication infrastructure serves multiple functions: it transmits control signals for safety functions, provides communication for machine operation, and can support multiple machines simultaneously. This multi-functionality reduces overall infrastructure requirements compared to dedicated wired connections for each function.
2Device complexity
If WLAN communication is used to reduce infrastructure costs, then device complexity is reduced, but reliability deteriorates due to interference and limited range
Solution Approach 1:
The patent introduces a base station as an intermediary device that manages wireless communication with multiple remote machines. The base station handles signal processing, error correction, and coordination of communication resources, thereby improving reliability while maintaining the benefits of wireless communication infrastructure.
Solution Approach 2:
The system implements feedback mechanisms where the base station and remote machines exchange acknowledgment signals to confirm successful reception of control signals. This feedback loop enables error detection and retransmission, ensuring reliable control signal transmission over wireless channels despite potential interference.
3Reliability
If multiple safety channels are used for control signals, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple safety channel functions into a unified wireless communication system. The base station manages multiple logical channels over the wireless medium, using protocol-level multiplexing to provide redundant safety communication paths without requiring separate physical infrastructure for each channel.
Solution Approach 2:
The system transitions from spatial diversity (multiple physical wired channels) to temporal and code diversity (multiple logical wireless channels using different time slots or coding schemes). This dimensional transformation maintains channel redundancy while reducing physical infrastructure complexity.
Data Source
AI summary
An automation control system wirelessly controls a safety function of a remote machine. The automation control system comprises a base station and a control receiver. The base station is configured to transmit a control signal for controlling the safety function using a first transmit signal of a first safety channel, and to transmit the control signal using a second transmit signal of a second safety channel. The control receiver comprises: a processor configured to extract a first received version of the control signal from the first received transmit signal, and to extract a second received version of the control signal from the second received transmit signal; and an electrical interface which is connectable with an electrical interface of the machine for controlling the safety function of the machine based on the first received version of the control signal and the second received version of the control signal.