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

A control system for operation of an industrial machine, the control system configured to be connected to control circuitry of the industrial machine to connect the control system to the control circuitry of the industrial machine, the control system comprising:

• a processor;
• and
• a tangible, non-transitory, computer-readable memory communicating with the processor, the memory having instructions stored thereon that, in response to execution by the processor, cause the processor to perform operations comprising:
• receiving fault detection data indicating whether at least one of the processor and an imaging device that monitors an image zone around the industrial machine is functioning properly;
• analyzing the fault detection data;
• determining, based upon the analyzing, that the control system is functional;
• transmitting, in response to determining that the control system is functional, a no fault found signal to at least one relay module of a plurality of relay modules to permit operation of the industrial machine, wherein the at least one relay module is coupled between the processor and the industrial machine and configured to intercept a machine cycle permit wire of the industrial machine;
• dynamically configuring at least one of a shape and a size of the image zone around the industrial machine to which the control system is connected based upon one or more dimensions of the industrial machine, the image zone being sized to include a portion of the industrial machine within the image zone;
• receiving image data from the imaging device;
• and
• controlling, based upon the image data, the industrial machine, wherein said controlling comprises transmitting a proximity signal to at least one additional relay module of the plurality of relay modules coupled to a machine stop wire of the industrial machine to halt operation of the industrial machine.

A control system for operation of an industrial machine, the control system configured to be spliced into control circuitry of the industrial machine to connect the control system to the control circuitry of the industrial machine, the control system comprising:

• a processor;
• and
• a tangible, non-transitory, computer-readable memory communicating with the processor, the memory having instructions stored thereon that, in response to execution by the processor, cause the processor to perform operations comprising:
• receiving fault detection data indicating whether at least one of the processor and an imaging device that monitors an image zone around the industrial machine is functioning properly;
• analyzing the fault detection data;
• determining, based upon the analyzing, that the control system is functional;
• transmitting, in response to determining that the control system is functional, a no fault found signal to at least one first relay module coupled between the processor and the industrial machine, wherein the at least one first relay module is configured to intercept a machine cycle permit wire of the industrial machine;
• receiving image data from the imaging device;
• analyzing the image data;
• determining, based upon the analyzing, whether the image data includes at least one of a predefined color and a predefined shape;
• and
• transmitting, in response to determining that the image data includes at least one of the predefined color and the predefined shape, a proximity signal to at least one second relay module coupled between the processor and the industrial machine, wherein the at least one second relay module is configured to be coupled to a machine stop wire of the industrial machine to enable the at least one second relay module to halt operation of the industrial machine.