Rockwell Automation Germany Gmbh & Co Kg

Rockwell Automation Technologies Incorporated

Oliver Heckel

Rudolf Papenbreer

Thomas Helpenstein

Norbert Machuletz

Bradley Alan Prosak

Mussa Tohidi Khaniki

Suresh Ramanujan Nair

Wayne R Foster

Dirk Lorenz

Alex Harris

Christopher Burke

Van Duros

Jan Anslinger

Todd Bubar

Carol A Knez

Nhat Nam Trinh

Pujianto Cemerlang

Sascha Wagner

Rudolph Papenbreer

Rudolf Laurenz Papenbreer

Bradley A Prosak

Carol Knez

Rudolf Lorenz Papenbreer

Bradley Prosak

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.

Input signal coordination and method for use with an expansion module

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.

Global e-stop in an industrial safety system with local and global safety input devices

A safety controller module for providing safety control comprises a non-volatile memory configured for storing a safety control program and one or more processing units configured to execute safety control functions associated with the safety control program to provide independent safety control. The safety controller module further comprises a connector configured to communicatively couple the safety controller module with a non-safety controller. The safety controller module is configured to communicate an input and/or an output signal of the safety controller module via the connector to the non-safety controller.

Safety controller module

An industrial safety controller comprises a non-volatile memory configured for storing an industrial control program and at least one processing unit. The industrial safety controller, which may be a safety relay, further comprises a connector configured to communicatively couple the safety controller with an expansion module. The safety controller is configured to receive an input and/or provide an output via an I/O expansion module that is coupled to the safety controller utilizing the connector. The industrial safety controller may comprise an expansion module bay and the connector may comprise a bay connector.

I/O expansion for safety controller

A configurable industrial safety relay device allows individual adjustment of rated input currents for each safety input. The safety relay device can support a number of programmable configuration settings or parameters, including parameters that allow a desired input current to be individually selected for each safety input. In this way, an input current can be selected for each safety input that is appropriate for the safety circuit being monitored by the safety input. In particular, an input current can be selected that ensures reliable detection of the safety signal by the safety input while substantially minimizing power consumption by the safety relay device.

Configurable safety input

A safety relay configuration system for configuring safety functions to be carried out by a safety relay is provided. The configuration system comprises a number of features that facilitate intuitive and simplified configuration of an industrial safety relay, including but not limited to features that guide the user through the configuration process using an intuitive sequential procedure that provides feedback and prompts based on user interaction, enforce design consistency throughout the configuration project by intelligently limiting user selections, and visually organize configuration and status information in a manner that efficiently utilizes display space and allows the user to quickly evaluate available configuration options.

Safety relay configuration system with safety monitoring and safety output function blocks

An industrial safety controller comprises a non-volatile memory configured for storing an industrial control program and at least one processing unit. The industrial safety controller, which may be a safety relay, further comprises connector means configured to communicatively couple the safety controller with an expansion module. The safety controller is configured to receive an input and/or provide an output via an I/O expansion module that is coupled to the safety controller utilizing the connector means. The industrial safety controller may comprise an expansion module bay and the connector means may comprise a bay connector.

An industrial controller for safety control is disclosed. The controller comprises an interface for receiving a download of a safety control program, a memory for storing at least one safety control program and at least one processing unit for executing a safety control program stored in the non-volatile memory. The at least one processing unit is configured to determine whether a safety control program is verified and to limit an execution of an unverified safety control program according to an unverified run mode. An indicator is configured to indicate the execution of an unverified safety control program. A method of assigning a verification ID to an industrial controller comprises steps of configuring and downloading a safety control program, validating the configured safety control program for the target industrial controller, and assigning a verification ID. Execution of the configured safety control program is limited before the verification ID is assigned.

Method for assignment of verification numbers

Safety relay configuration system with multiple test pulse schemes using graphical interface

A safety controller and system of safety controllers and a removable memory module for rapid configuration and/or backup of safety controllers are provided. The safety controller comprises a non-volatile memory and one or more slots configured to host modules. A predetermined slot of the one or more slots is configured to communicatively couple the safety controller with a memory module. The safety controller is configured to transfer a backup of a configuration on the safety controller to a memory module hosted in the predetermined slot and configured to load a configuration from a memory module hosted in the predetermined slot. A method of distributing software to a plurality of industrial safety controller comprises utilizing a memory module.

Safety controller with rapid backup and configuration

A single-wire safety system is provided that yields reliable safety device monitoring without the need for dual redundant signal channels. The safety system comprises a safety relay acting as a communications master device and one or more safety devices connected in series with the safety relay via a single-wire communication circuit. A smart tap device is used to interface safety devices that are not compliant with the single-wire protocol to the single-wire channel. The safety device or smart tap device farthest from the safety relay on the safety circuit modulates a safety signal with a recognizable pulse pattern that traverses the single-wire safety circuit to the safety relay via the intermediate safety devices or smart taps. The safety relay maintains safety mode as long as the pulse pattern is received and recognized. The architecture allows bi-directional communication of initialization, configuration, and diagnostic messages over the single-wire safety channel.

Smart taps for a single-wire industrial safety system

A single-wire safety system architecture is provided that yields reliable safety device monitoring without the need for dual redundant signal channels. The safety system comprises a safety relay acting as a communications master device and one or more compatible safety devices connected in series with the safety relay via a single-wire communication circuit. The safety device farthest from the safety relay on the safety circuit modulates a safety signal with a recognizable pulse pattern that traverses the single-wire safety circuit to the safety relay via the intermediate safety devices. The safety relay maintains safety mode as long as the pulse pattern is received and recognized. The architecture allows bi-directional communication of initialization, configuration, and diagnostic messages over the single-wire safety channel, and can also allow safety devices to insert prognostic data into the safety signal in order to convey health information while the system is in normal operation mode.

Single-wire industrial safety system with safety device diagnostic communication

A single-wire safety system architecture is provided that yields reliable safety device monitoring without the need for dual redundant signal channels. The safety system comprises a safety relay acting as a communications master device and one or more compatible safety input devices connected in series with the safety relay via a single-wire communication circuit. The safety input device farthest from the safety relay on the safety circuit modulates a safety signal with a recognizable pulse pattern that traverses the single-wire safety circuit to the safety relay via the intermediate safety devices. The safety relay maintains safety mode as long as the pulse pattern is received and recognized. In addition to conveying the safety signal, the architecture allows bi-directional communication of initialization, configuration, and diagnostic messages over the single-wire safety channel. The architecture also facilitates rapid initialization of the safety channel using asynchronous sub-link detection and device enumeration.

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Frechen, Germany

Oliver Heckel