Rockwell Automation Technologies Incorporated

Timothy P Wolfe

Yongyao Cai

Burt Sacherski

Suresh Ramanujan Nair

Wayne R Foster

Brian J Taylor

Lee A Lane

Rebecca R Jaeger

Michelle L Poublon

Ashley M Killian

Linxi Gao

Kevin M Zomchek

Girish S Mali

Roberto S Santos

James Edward Dogul

Thomas Lloyd Botker

Steven Robert Tambeau

Todd Bubar

Arvind Ananthanarayanan

Andrew L Tsang

Kevin Zomchek

Mali S Girish

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.

Monitoring machine operation for various speed and loading conditions

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.

Radio frequency identifier apparatus for access control and user identification

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.

Predicting end of life for industrial automation components

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.

Monitoring machine operation with different sensor types to identify typical operation for derivation of a signature

An industrial locking switch comprises multiple locking tongue entry slots formed on adjacent sides of the locking switch housing, thereby supporting receipt of the corresponding locking tongue from multiple directions of approach without the need to mechanically modify the switch's head or to reorient the switch itself. The locking switch houses locking bolt detection circuity comprising multiple series connected RFID coils configured to detect an RFID tag mounted on the locking tongue when the locking tongue is inserted into any of the entry slots.

Guard locking switch with three concurrent directions of approach

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.

For locking industrial safety guarding, a sensor includes an inductive coil that generates a second sensing field about a second sensing field axis at a second frequency that detects advancement of a locking bolt. The sensor further includes at least two radio frequency identifier (RFID) coils that generate a first sensing field at a first frequency that detects an RFID tag. A second RFID coil of the at least two RFID coils has a second polarity reversed from a first polarity a first RFID coil of the at least two RFID coils and reduces the first sensing field at the second sensing field axis.

Sensor with three concurrent directions of approach

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.

Light curtain alignment using beam intensities

A system for sensing a position of a locking bolt of an industrial locking switch includes an inductive circuit, a converter, and a master controller. The inductive circuit includes an inductive coil and a capacitor electrically connected in parallel. The inductive coil is positioned to receive a locking bolt of an industrial locking switch when the locking bolt is transitioned to a lock position. The converter is configured to convert a frequency of a current signal on the inductive circuit to a digital frequency value. The master controller is configured to generate a bolt detection signal in response to determining that the digital frequency value changes by an amount equal to or substantially equal to a defined frequency shift corresponding to a frequency shift induced by the inductive coil in response to presence of the locking bolt within the inductive coil's magnetic field.

Diagnostic element for validation of bolt detection of a guard locking switch in a static state

An industrial locking switch includes an inductive sensing circuit that uses a non-contact technique to detect when the switch's locking bolt has transitioned to the lock position. The inductive sensing circuit can comprise an inductive coil, a capacitor, and a converter that converts a frequency of a current signal through the inductive coil to a digital frequency value. A controller detects when the locking bolt has advanced to the lock position by monitoring the digital frequency value for frequency shifts indicative of a disturbance of the induction coil's magnetic field by the locking bolt. To validate operation of the inductive sensing system without requiring actuation of the locking bolt, a diagnostic switch connects a diagnostic capacitor to the inductive circuit to simulate the frequency shift caused by the locking bolt, and the inductive sensing system is validated if the expected frequency shift is detected.

An apparatus for an imbalance test includes a strain measurement module that measures a strain voltage across terminals of a strain gauge. The strain voltage is representative of an amount of force on the strain gauge. The apparatus includes a test measurement module that measures a test voltage across the terminals of the strain gauge while a test resistor is connected in parallel with a resistor of the strain gauge. The test resistor is connected while the test measurement module measures the test voltage and is disconnected while the strain module measures strain voltage. The apparatus includes an average module that calculates an average strain voltage from two strain voltage measurements. The strain voltages are measured preceding and after the test voltage measurement. The apparatus includes a difference module that determines a difference voltage. The difference voltage is a difference between the average strain voltage and the test voltage.

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Medford, MA, United States of America

Timothy P Wolfe