SAFETY CONTROLLER AND METHOD FOR CONTROLLING AN AUTOMATED INSTALLATION

• US 20110301720A1
• Filed: 05/24/2011
• Published: 12/08/2011
• Est. Priority Date: 11/25/2008
• Status: Active Grant

• Current Assignee: PILZ GmbH & Company KG
• Original Assignee: PILZ GmbH & Company KG
• Inventors: Reusch, Matthias, EHRHART, Helmut
• Granted Patent: US 8,560,094 B2
• Time in Patent Office: Days
• US Class Current: 700/12
• CPC Class Codes: G05B 19/0425 Safety, monitoring
• CPC Class Codes: G05B 2219/31437 Monitoring, global and local alarms
• CPC Class Codes: G05B 2219/32414 Workstation has two displays, for process control and for general applications
• CPC Class Codes: G05B 23/0251 Abstraction hierarchy, e.g. "complex systems", i.e. system is divided in subsystems, subsystems are monitored and results are combined to decide on status of whole system

Abstract

A safety controller for controlling an automated installation which has a plurality of sensors and a plurality of actuators, comprises a control unit to which a plurality of control input signals are supplied by the sensors. The control unit produces a plurality of control output signals in an automatic mode on the basis of the control input signals in accordance with a user program running in said control unit. The plurality of control output signals is used to actuate the plurality of actuators. The safety controller also has a diagnosis evaluation unit to which a number of diagnoses input signals are supplied. The diagnosis evaluation unit takes the diagnosis input signals as a basis for ascertaining which of a plurality of operating states is present at a defined instant of time. The diagnosis evaluation unit produces an operating state data record which represents an ascertained operating state. The safety controller also has an interface for a display unit in order to display diagnosis reports. The operating state data record includes a plurality of diagnosis data and a Boolean status indicator. The control unit actuates at least one actuator on the basis of the Boolean status indicator contained in the operating state data record.

Claims

1. A safety controller for controlling an automated installation which has a plurality of sensors and a plurality of actuators, said safety controller comprising:

a control unit to which a plurality of control input signals from the sensors are supplied, said control unit being designed to produce a plurality of control output signals on the basis of the control input signals and in accordance with a user program running in an automatic mode in said control unit, wherein the plurality of control output signals are configured to actuate the plurality of actuators,

a diagnosis evaluation unit to which a number of diagnosis input signals are supplied, wherein the diagnosis evaluation unit is designed to take the diagnosis input signals as a basis for ascertaining which one of a plurality of operating states is present at a defined instant of time, and

an interface for a display unit designed to display diagnosis reports from the diagnosis evaluation unit,

wherein the diagnosis evaluation unit produces an operating state data record representing an ascertained operating state of a plurality of operating states,

wherein the operating state data record has a plurality of diagnosis data and a Boolean status indicator, and

wherein the control unit is designed to actuate at least one of the plurality of actuators as a function of said Boolean status indicator.

2. The safety controller of claim 1, wherein the plurality of operating states comprise at least one process state that the installation adopts in response to the control output signals, and at least one system state of the safety controller, wherein the operating state data record represents both the process state and the system state.

3. The safety controller of claim 1, wherein the operating state data record comprises a plurality of diagnosis reports that are different from one another, with each of said different diagnosis reports representing said ascertained operating state, wherein the control unit is configured to receive a user access authorization signal representing a user access authorization, and wherein the diagnosis evaluation unit selects one of the plurality of diagnosis reports as function of the user access authorization.

4. The safety controller of claim 1, wherein the operating state data record comprises a plurality of diagnosis reports that are different from one another, with each of said different diagnosis reports representing said ascertained operating state, wherein the control unit is configured to run in one of several different operating modes, and wherein the diagnosis evaluation unit selects one of the plurality of diagnosis reports as function of said one of said several operating modes.

5. The safety controller of claim 1, wherein the operating state data record comprises a plurality of diagnosis reports that are different from one another, with each of said different diagnosis reports representing said ascertained operating state, wherein the diagnosis evaluation unit is designed to select a diagnosis report on the basis of a location statement representing a location of a faulty actuator or a faulty sensor within the installation.

6. The safety controller of claim 1, wherein the user program has at least one safety control module, in which safety-related control input signals are processed in failsafe fashion, and at least one standard control module, in which process-related control input signals are processed in a non-failsafe fashion.

7. A method for controlling an automated installation which comprises a plurality of sensors and a plurality of actuators, the method comprising the steps of:

supplying a plurality of control input signals from the sensors to a control unit, wherein the control unit produces a plurality of control output signals on the basis of the control input signals and in accordance with a user program running in an automatic mode in said control unit,

actuating the plurality of actuators using the plurality of control output signals,

ascertaining which one of a plurality of operating states is present at a defined instant of time and producing an operating state data record which represents an ascertained operating state, said operating state data record comprising a plurality of diagnosis data representing the ascertained operating state and a Boolean status indicator,

displaying the diagnosis data on a display unit in response to said operating state data record, and

actuating at least one of the actuators as a function of the Boolean status indicator.

8. A computer program product comprising a data storage medium having program code stored which is designed to be loaded into the memory of a safety controller for controlling an automated installation having a plurality of sensors and a plurality of actuators, with said program code being designed to carry out a method comprising the following steps when executed on the safety controller:

receiving a plurality of control input signals from the sensors and producing a plurality of control output signals on the basis of the control input signals,

providing the plurality of control output signals for actuating the plurality of actuators,

ascertaining which one of a plurality of operating states is present at a defined instant of time and producing an operating state data record which represents an ascertained operating state, said operating state data record comprising a plurality of diagnosis data representing the ascertained operating state and a Boolean status indicator,

displaying the diagnosis data on a display unit in response to said operating state data record, and

actuating at least one of the actuators as a function of the Boolean status indicator.