Aspect Block Programming for Safety Controller Complexity
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Solution Overview
Problem
Existing methods for programming safety controllers become overly complex for large machine systems with numerous safety devices, leading to increased risk of faults and uncontrolled hazardous situations, and lack flexibility to handle complex applications effectively.
Innovation Solution
A method and device utilizing aspect blocks to structure user programs, allowing for the creation of component subprograms and aspect subprograms that can be combined to form a user program, enabling independent programming of control aspects and reducing complexity through hierarchical organization and the use of predefined software components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the user program is created using predefined certified program modules only, then the reliability is improved, but the adaptability deteriorates
Solution Approach 1:
The user program is segmented into multiple independent aspect subprograms, each handling a specific control aspect (safety control, standard control, diagnostics, visualization). This segmentation allows each aspect to be developed, certified, and maintained independently while maintaining overall system reliability and enabling flexible combination for different applications.
Solution Approach 2:
The invention introduces a new organizational dimension by separating the user program into aspect-specific subprograms rather than a single monolithic program. This dimensional change enables independent programming and certification of safety-critical aspects while allowing flexibility in non-safety aspects, resolving the contradiction between reliability and adaptability.
2Productivity
If the user program monitors a large machine system with high number of safety devices, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The monitoring system is segmented into aspect-specific subprograms that can independently handle different control aspects. This segmentation reduces the perceived complexity by organizing numerous safety devices and control logic into manageable, aspect-based modules that can be developed and maintained separately.
Solution Approach 2:
The invention introduces an aspect-based organizational dimension that structures the complex user program into independent aspect subprograms. This dimensional organization allows the system to monitor large machine systems with many safety devices while maintaining manageable complexity through aspect-specific modularization.
3Adaptability or versatility
If the user program is made more flexible for very large systems, then the adaptability is improved, but the reliability deteriorates
Solution Approach 1:
The user program is segmented into aspect-specific subprograms, allowing flexibility to be introduced in non-safety aspects (standard control, diagnostics, visualization) without compromising the reliability of safety-critical aspects. Each aspect can be independently developed and certified according to its specific requirements.
Solution Approach 2:
Different quality requirements are applied to different aspects: safety control aspects maintain strict reliability through certification, while standard control and other aspects can be more flexible. This local differentiation of quality attributes allows adaptability where needed while preserving reliability where critical.
Data Source
AI summary
A new method and to a new programming tool for creating a user program for a safety controller is disclosed. The new method and programming tool exploit a matrix-type organization of occurring programming tasks. Itemized software components allocated to specific hardware components are combined with aspect blocks that enable programming grouped according to functional control aspects of the system to be controlled.