Wiring Schema for Sharing Safety Controller Test Signals
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Solution Overview
Problem
Machine safeguarding systems face challenges in connecting multiple safety devices to a safety controller due to limited terminal availability, necessitating a solution to efficiently share test signals and expand the number of devices that can be connected.
Innovation Solution
The method involves determining the total number of terminals required by safety devices and generating a wiring schema that allows sharing of test signals through external terminal blocks, enabling multiple safety devices to connect to a safety evaluation device with fewer available terminals, using automatic terminal optimization to save terminals and provide a cost-effective, expandable, and configurable safety evaluation device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple safety devices are connected to a safety controller, then the monitoring coverage is improved, but the terminal availability of the safety controller is exceeded
Solution Approach 1:
The patent introduces external terminal blocks as intermediary components between safety devices and the safety controller. These terminal blocks serve as mediators that consolidate multiple device connections into fewer controller terminals, allowing multiple safety devices to be connected without exceeding the controller's terminal availability while maintaining full monitoring coverage.
Solution Approach 2:
The patent merges multiple safety device connections through shared terminals and external terminal blocks. By combining multiple input connections into shared terminals that can be externally expanded, the system accommodates more safety devices than the controller's native terminal count would allow, effectively merging connection paths to conserve controller terminals.
2Reliability
If the number of safety devices is increased, then the safety monitoring capability is improved, but the system cost increases
Solution Approach 1:
The patent makes terminal blocks universal components that can serve multiple safety devices simultaneously. A single terminal block can consolidate connections from multiple safety devices to fewer controller terminals, reducing the need for additional expensive controller modules or relay units while maintaining the ability to monitor all connected devices.
Solution Approach 2:
The patent uses external terminal blocks as cost-effective copies or substitutes for more expensive controller terminals. Instead of purchasing additional controller terminals or expensive relay modules for each safety device, the system uses simpler, cheaper external terminal blocks that provide the same connection and consolidation function.
3Adaptability or versatility
If a safety controller with more terminals is used, then the number of connectable devices is increased, but the system complexity and cost increase
Solution Approach 1:
The patent segments the terminal function between the safety controller and external terminal blocks. The controller maintains its original terminal count and complexity, while the expansion functionality is segmented into separate external terminal blocks. This segmentation allows the system to connect more devices without increasing the controller's complexity.
Solution Approach 2:
External terminal blocks serve as intermediary components that handle the complexity of multiple device connections without transferring that complexity to the safety controller. The terminal blocks mediate between multiple safety devices and the controller's limited terminals, keeping the controller simple while enabling expanded connectivity.
Data Source
AI summary
Apparatus and associated methods relate to generating a wiring schema with more than one safety device sharing at least one test signal through one or more external terminal blocks when the number of terminals required by safety devices exceeds the number of available terminals of a safety controller. In an illustrative example, the method may include determining a total number of terminals A of safety devices to be connected to a safety evaluation device having a number of terminals B. If A is greater than B, the method may then include generating a wiring schema that one or more external terminal blocks may show indicia of electrical connections between an identified set of safety devices and a shared terminal of the safety evaluation device associated with that set. By using the method, the number of devices that can be connected to the safety evaluation device may be expanded.