Abstract: A method includes sending a first safety instruction to a machine in response to, within an entry window of time, receiving an open alert that a movable barrier is in an open state, where the movable barrier is at an entry point of an enclosure protecting personnel from the machine, receiving tag information of a person from a reader at the movable barrier, and confirming that the tag information belongs to a person authorized to enter the enclosure. The method includes sending a second safety instruction to the machine in response to, within the entry window of time, receiving the open alert, and without receiving tag information or confirming that the tag information belongs to a person authorized to enter the enclosure. The first and second safety instructions are different and the first safety instruction is less restrictive than the second safety instruction in terms of actions to prevent injury.

Abstract: A method for predicting end-of-life for a component includes determining a baseline lifetime model for a component connected to a machine functional safety system. The component is part of a system with physical devices. The method includes monitoring environmental conditions and usage conditions of the component and modifying the baseline lifetime model based on the monitored environmental and usage conditions to produce a modified lifetime model for the component. The method includes tracking a lifetime progress of the component with respect to the modified lifetime model and sending an alert in response to lifetime progress of the component reaching a lifetime threshold associated with the modified lifetime model.

Abstract: A method for derivation of a machine signature includes receiving sensor information from a primary sensor, where the primary sensor is positioned to receive information from a portion of an industrial operation, and receiving sensor information from one or more secondary sensors. The secondary sensors are arranged to provide additional information about the industrial operation indicative of current operating conditions of the industrial operation. The method includes using the sensor information from the secondary sensors and machine learning to determine if the portion of the industrial operation is operating in a normal condition and, in response to determining that the portion of the industrial operation is operating normally, using sensor information from the primary sensor during the normal operating condition to derive a primary sensor signature for the sensor information from the primary sensor.

Abstract: A method includes sending a first safety instruction to a machine in response to, within an entry window of time, receiving an open alert that a movable barrier is in an open state, where the movable barrier is at an entry point of an enclosure protecting personnel from the machine, receiving tag information of a person from a reader at the movable barrier, and confirming that the tag information belongs to a person authorized to enter the enclosure. The method includes sending a second safety instruction to the machine in response to, within the entry window of time, receiving the open alert, and without receiving tag information or confirming that the tag information belongs to a person authorized to enter the enclosure. The first and second safety instructions are different and the first safety instruction is less restrictive than the second safety instruction in terms of actions to prevent injury.

Abstract: A component includes a housing mounted at an entry point of an enclosure protecting a machine. The component includes a first RFID sensor, in the housing, that reads a first RFID tag in close proximity to the first RFID sensor indicating a closed status of a movable barrier of the enclosure at the entry point. Opening of the movable barrier allows entry to the enclosure. The component includes a second RFID sensor, in the housing, that reads a second RFID tag of an authorized person. The component includes a barrier access module that sends an open alert that the movable barrier is in an open state in response to the first RFID sensor not being close enough to read the first RFID tag, and an identification module that sends tag information unique to a person from the second RFID tag.

Abstract: An expansion module for an industrial controller is configured to perform independent local processing of its input signals and to independently generate control outputs in parallel with the primary control program executed by the industrial controller. This can reduce or eliminate response latency for time-critical processes that would otherwise be present if all monitoring and control were performed by the industrial controller alone. This approach can be beneficial for configurations in which the industrial devices that are monitored and controlled via the expansion module require fast response times, as in the case of industrial safety applications.

Abstract: A component includes a housing mounted at an entry point of an enclosure protecting a machine. The component includes a first RFID sensor, in the housing, that reads a first RFID tag in close proximity to the first RFID sensor indicating a closed status of a movable barrier of the enclosure at the entry point. Opening of the movable barrier allows entry to the enclosure. The component includes a second RFID sensor, in the housing, that reads a second RFID tag of an authorized person. The component includes a barrier access module that sends an open alert that the movable barrier is in an open state in response to the first RFID sensor not being close enough to read the first RFID tag, and an identification module that sends tag information unique to a person from the second RFID tag.

Abstract: A method for derivation of a machine signature includes receiving sensor information from a primary sensor, where the primary sensor is positioned to receive information from a portion of an industrial operation, and receiving sensor information from one or more secondary sensors. The secondary sensors are arranged to provide additional information about the industrial operation indicative of current operating conditions of the industrial operation. The method includes using the sensor information from the secondary sensors and machine learning to determine if the portion of the industrial operation is operating in a normal condition and, in response to determining that the portion of the industrial operation is operating normally, using sensor information from the primary sensor during the normal operating condition to derive a primary sensor signature for the sensor information from the primary sensor.

Abstract: A method for using sensor data and operational data of an industrial process to identify problems includes gathering sensor data from one or more sensors sensing conditions on equipment of an industrial process, receiving command information about operational commands issued to the equipment of the industrial process, and for each sensor of the one or more sensors, comparing the sensor data with signature information for the sensor. The signature information for the sensor is relevant for operational commands issued to the equipment. The method includes determining if the sensor data of a sensor of the one or more sensors exceeds the signature information corresponding to the sensor, locating a problem with a piece of equipment of the industrial process monitored by the sensor of the one or more sensors based on the sensor data exceeding the signature information for the sensor and issuing an alert reporting the problem.

Abstract: A method for risk assessment violation monitoring during a functional safety process includes receiving parameters from a risk assessment of a portion of a system with physical devices. The parameters of the risk assessment are applicable to a safety device of a machine safety system. The safety device is configured to prevent a hazardous condition in the system. The method includes detecting a change of a condition of the safety device. The condition is indicative of a potential safety issue affecting operation of the machine safety system. The method includes comparing parameters related to the change of the condition of the safety device with the parameters from the risk assessment and sending an alert in response to determining that the change of the condition of the safety device results in a violation of the risk assessment.

Abstract: A method for predicting end-of-life for a component includes determining a baseline lifetime model for a component connected to a machine functional safety system. The component is part of a system with physical devices. The method includes monitoring environmental conditions and usage conditions of the component and modifying the baseline lifetime model based on the monitored environmental and usage conditions to produce a modified lifetime model for the component. The method includes tracking a lifetime progress of the component with respect to the modified lifetime model and sending an alert in response to lifetime progress of the component reaching a lifetime threshold associated with the modified lifetime model.

Abstract: A method for monitoring machine operation for various machine speed and loads includes measuring vibration information at a sensor associated with a machine and an associated machine speed. The machine is a rotating machine. The method includes performing an operational frequency analysis of the vibration information and comparing results from the operational frequency analysis with a vibration signature for the machine. The vibration signature is for a machine speed that matches the machine speed of the measured vibration information. The vibration signature is one of several vibration signatures for the machine where each is for a different machine speed. The method includes identifying a potential failure mode based on a frequency range where the frequency analysis of the measured vibration information exceeds, by a threshold amount, the vibration signature of the plurality of vibration signatures that matches the machine speed, and transmitting an alert comprising the identified potential failure mode.

Abstract: A component for light curtain alignment includes a light intensity receiver that receives a plurality of light intensity signals from beam receivers of a receiver unit of a light curtain. The light curtain includes a transmitter unit with beam transmitters arranged linearly on the transmitter unit. The light curtain includes the receiver unit with the plurality of beam receivers arranged linearly. Each beam receiver is configured to receive light from a corresponding beam transmitter. The component includes a light intensity transmitter configured to transmit, from the light curtain, the plurality of light intensity signals received by the light intensity receiver, where each light intensity signal is from one or more beam receivers, and a trip transmitter that transmits a trip signal in response to determining that a light intensity signal from a beam receiver of the plurality of beam receivers is below a trip threshold.

Abstract: A single-wire safety system architecture yields reliable safety device monitoring without the need for dual redundant signal channels. The safety system comprises a safety relay and one or more compatible safety input devices connected in series with the safety relay via a single-wire communication circuit. A safety signal with a recognizable pulse pattern traverses the single-wire safety circuit to the safety relay via the safety devices. The safety relay opens its contactors and deenergizes its associated industrial equipment if the pulse pattern is not received and recognized. The safety relay can also be configured to initiate a global emergency stop in response to a loss of a safety function by one of its safety input devices, the global emergency stop instructing other safety relays of other safety circuits to open their contactors and enter safe mode.

Abstract: The present invention relates to an optoelectronic sensor used with light curtains for monitoring a sensing field. The optoelectronic sensor includes at least one optical unit having at least one radiation emitting element and at least one radiation receiving element and a control unit for processing an output signal generated by said radiation receiving element and for generating a defined sensor signal based on the output signal. The optical unit has a diagnostic unit including a monitoring unit operable to monitor at least one parameter indicative of an operational status of the optical unit. The diagnostic unit includes a processing unit operable to generate a communication signal indicative of said operational status, and the diagnostic unit is arranged in a separately housed, detachable plug-in module. The processing unit comprises a wireless communication interface for wirelessly receiving and transmitting communication signals.

Abstract: A safety input device for use in a single-wire safety system comprises a fast-switching architecture that allows a safety signal to propagate through the safety device to downstream devices with negligible delay. Rather than placing the signal processor in-line between the signal input and output terminals of the safety device, an electronic switch is placed between the input and output terminals. A signal processor in parallel with the switch monitors the incoming signal and closes the switch if the safety signal is absent, effectively shorting the input and output terminals and allowing the incoming safety signal to pass substantially instantaneously. Loss of the safety signal at the input terminal is immediately reflected by the loss of safety signal output at the output terminal, eliminating processing delay between loss of the safety signal at the input terminal and cessation of the output signal at the output terminal.

Abstract: A single-wire safety system architecture yields reliable safety device monitoring without the need for dual redundant signal channels. The safety system comprises a safety relay and one or more compatible safety input devices connected in series with the safety relay via a single-wire communication circuit. A safety signal with a recognizable pulse pattern traverses the single-wire safety circuit to the safety relay via the safety devices. The safety relay opens its contactors and deenergizes its associated industrial equipment if the pulse pattern is not received and recognized. The safety relay can also be configured to initiate a global emergency stop in response to a loss of a safety function by one of its safety input devices, the global emergency stop instructing other safety relays of other safety circuits to open their contactors and enter safe mode.

Abstract: An expansion module for an industrial controller is configured to perform independent local processing of its input signals and to independently generate control outputs in parallel with the primary control program executed by the industrial controller. This can reduce or eliminate response latency for time-critical processes that would otherwise be present if all monitoring and control were performed by the industrial controller alone. This approach can be beneficial for configurations in which the industrial devices that are monitored and controlled via the expansion module require fast response times, as in the case of industrial safety applications.

Abstract: The present invention relates to an optoelectronic sensor used with light curtains for monitoring a sensing field. The optoelectronic sensor includes at least one optical unit having at least one radiation emitting element and at least one radiation receiving element and a control unit for processing an output signal generated by said radiation receiving element and for generating a defined sensor signal based on the output signal. The optical unit has a diagnostic unit including a monitoring unit operable to monitor at least one parameter indicative of an operational status of the optical unit. The diagnostic unit includes a processing unit operable to generate a communication signal indicative of said operational status, and the diagnostic unit is arranged in a separately housed, detachable plug-in module. The processing unit comprises a wireless communication interface for wirelessly receiving and transmitting communication signals.