Systems, methods, and articles of manufacture for operation of an industrial machine

An article of manufacture comprising a control system including a processor for monitoring operation of an industrial machine, the control system spliced into control circuitry of the industrial machine, the article further comprising a non-transitory, tangible, computer readable storage medium having instructions stored thereon that, in response to execution by the processor, cause the processor to perform operations comprising:

• dynamically configuring at least one of a shape and a size of an image zone around the industrial machine to which the control system is connected based upon one or more dimensions of the industrial machine;
• receiving image data from an imaging device that monitors the image zone around the industrial machine;
• analyzing the image data;
• determining, based upon the analyzing, whether to halt operation of the industrial machine;
• in response to determining to halt operation of the industrial machine, providing a proximity signal to a first redundant plurality of hardware relay modules coupled between the processor and the industrial machine, wherein at least one relay module of the first redundant plurality of relay modules is configured to be coupled to a machine stop wire of the industrial machine to enable the first redundant plurality of hardware relay modules to halt operation of the industrial machine;
• determining whether the control system is functional;
• in response to determining that the control system is functional, providing a no fault found signal to a second redundant plurality of hardware relay modules coupled between the processor and the industrial machine, wherein at least one relay module of the second redundant plurality of relay modules is configured to intercept a machine cycle permit wire of the industrial machine;
• generating, based upon the analyzing, operational data associated with the industrial machine;
• and
• transmitting, to a client device communicatively coupled to the processor, at least one of the image data and the operational data.

A method for monitoring operation of an industrial machine using a control system spliced into control circuitry of the industrial machine to connect the control system to the industrial machine, the control system comprising a processor, the method comprising:

• dynamically configuring, by the processor, at least one of a shape and a size of an image zone around the industrial machine to which the control system is connected based upon one or more dimensions of the industrial machine;
• receiving, by the processor, image data from an imaging device that monitors the image zone around the industrial machine;
• analyzing, by the processor, the image data;
• determining, by the processor and based upon the analyzing, whether to halt operation of the industrial machine;
• in response to determining to halt operation of the industrial machine, providing, by the processor, a proximity signal to a first redundant plurality of hardware relay modules coupled between the processor and the industrial machine, wherein at least one relay module of the first redundant plurality of relay modules is configured to be coupled to a machine stop wire of the industrial machine to enable the first redundant plurality of hardware relay modules to halt operation of the industrial machine;
• determining whether the control system is functional;
• in response to determining that the control system is functional, providing a no fault found signal to a second redundant plurality of hardware relay modules coupled between the processor and the industrial machine, wherein at least one relay module of the second redundant plurality of relay modules is configured to intercept a machine cycle permit wire of the industrial machine;
• generating, by the processor and based upon the analyzing, operational data associated with the industrial machine;
• and
• transmitting, by the processor and to a client device communicatively coupled to the processor, at least one of the image data and the operational data.