Configurable modular safety system

• US 7,395,123 B2
• Filed: 10/07/2005
• Issued: 07/01/2008
• Est. Priority Date: 10/08/2004
• Status: Active Grant

• Current Assignee: Rockwell Automation Germany GmbH & Co. KG (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Germany GmbH & Co. KG (Rockwell Automation, Inc.)
• Inventors: Lorenz, Dirk, Papenbreer, Rudolf L., Machuletz, Norbert
• Primary Examiner(s): Pham; Thomas K
• Application Number:
  US11/245,929
• Publication Number:
  US 20060087773A1
• Time in Patent Office: 998 Days
• Field of Search: 700/79, 700/11, 700/21, 714/24, 714/2, 714/15, 714/8
• US Class Current: 700/21
• CPC Class Codes: G05B 19/0423 Input/output
• CPC Class Codes: G05B 19/054 Input/output
• CPC Class Codes: G05B 2219/21012 Configurable I-O
• CPC Class Codes: G05B 2219/21015 Easy expansion, extension of I-O
• CPC Class Codes: G05B 2219/24146 Configure actuators to be switched off in case of emergency stop
• CPC Class Codes: G05B 2219/25087 Selector switch to set function of each module
• CPC Class Codes: G05B 2219/25314 Modular structure, modules

Abstract

A modular safety system for controlling emergency stop applications includes a plurality of inputs, a plurality of output groups, and a plurality of safe relay outputs. The plurality of inputs is assigned to at least one of the output groups. Each output group is configured to control at least one of the plurality of safe relay outputs. The system also includes means for configuring the system and at least three freely programmable output groups.

Claims

1. A modular safety system for safety control in emergency stop applications, the modular safety system comprising:

a plurality of inputs, a plurality of output groups and a plurality of safe relay outputs, wherein each input is assigned to at least one of the output groups and each output group controls at least one of the safe relay outputs;

at least one rotary switch configured to select at least one of the output groups and input functions for the inputs; and

wherein the plurality of output groups includes at least three freely programmable output groups.

2. The system of claim 1 further comprising at least one input module corresponding to the plurality of inputs, a base module configured to control the system, and at least one output module configured to control the safe relay outputs.

3. The system of claim 2 wherein the at least one input module includes a corresponding configuration means.

4. The system of claim 3 wherein the configuration means is configured to select the input functions and output functions for the plurality of inputs of the at least one input module.

5. The system of claim 4 wherein the at least one input module is individually programmed to at least one of the plurality of output groups.

6. The system of claim 1 further comprising ten input modules and a maximum of twenty inputs.

7. The system of claim 6 further comprising six output modules and a maximum of 24 safe relay outputs.

8. The system of claim 1 further comprising means for controlling muting functionality for controlled access.

9. The system of claim 8 further comprising an individual module housing the means for controlling muting functionality.

10. The system of claim 1 wherein the output state of at least one of the output groups is a logical function of the output state of at least one of the other output groups.

11. The system of claim 1 further comprising at least one safe area functionality.

12. The system of claim 1 further comprising an interface for connecting the system to an external computer system.

13. The system of claim 1 further comprising a timer delay control for setting different switching times for each output group.

14. The system of claim 1 further comprising a memory device for saving the configuration settings of the system.

15. The system of claim 14 wherein the memory device is configured to save internal system errors.

16. The system of claim 15 wherein the internal system errors include an exceeded synchrony time limit, an unlocked safety input, and, if not all channels of an input circuit are interrupted and a reset button is pressed, a reset error.

17. The system of claim 1 further comprising a storage medium that stores settings of the at least one rotary switch and a comparator that compares the setting stored in the storage medium to the setting indicated by the at least one rotary switch.

18. The system of claim 17 wherein the system is configured to not start if the comparator indicates that the input modules have been changed without proper authorization.

19. The system of claim 1 further comprising a second rotary switch;

wherein the first, at least one, rotary switch is configured to select the input functions for the inputs and the second rotary switch is configured to select the output groups for the inputs.