Automation Connection Verification via Point-to-Point Safety Links
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Solution Overview
Problem
Existing automation systems lack reliable methods to establish functionally safe connections between interchangeable automation devices, particularly in tool changers, due to the limitations of existing identification methods and communication protocols, leading to potential erroneous connections and safety risks.
Innovation Solution
Implementing point-to-point communication lines in addition to fieldbus communication, along with challenge-response procedures, to verify and ensure correct connections between automation devices, using functionally safe communication endpoints and protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fieldbus communication is used for connecting automation devices, then communication between devices is enabled, but reliable verification of correct connections cannot be ensured due to potential erroneous connections
Solution Approach 1:
A challenge-response mechanism is introduced as an intermediary verification layer between automation devices connected via fieldbus. The test device generates challenges and verifies responses to confirm correct pairing, acting as a mediator that ensures connection reliability without requiring changes to the underlying fieldbus communication infrastructure.
Solution Approach 2:
The communication verification process is segmented into distinct challenge and response phases. The test device separates the verification function from the main fieldbus communication, creating independent verification channels that can operate alongside normal data transmission without interfering with each other.
2Adaptability or versatility
If automation devices are made interchangeable and automatically connectable, then adaptability and ease of operation are improved, but the risk of erroneous connections and safety issues increases
Solution Approach 1:
The system performs preliminary verification through challenge-response procedures before allowing automated devices to be fully operational. The test device checks connection correctness in advance, ensuring that only properly paired devices can proceed with automated operations, thus preventing erroneous connections from causing safety issues.
Solution Approach 2:
The challenge-response mechanism provides immediate feedback about connection status. When an automation device connects, the test device sends challenges and verifies responses to confirm correct pairing, providing real-time feedback that prevents erroneous connections from being established.
3Reliability
If physical separation is used to ensure safety, then connection errors are prevented, but communication between robot controllers and tools becomes impossible
Solution Approach 1:
The challenge-response verification system acts as an intermediary safety layer that enables communication between previously separated systems. By verifying connections through challenges and responses, the system allows robot controllers and tools to communicate while maintaining safety guarantees, eliminating the need for physical separation.
Data Source
Figure 1~2
Figure 3~4
AI summary
In order to increase the functional safety of an automation system (1), it is proposed to install additional point-to-point communication lines (11, 12) in addition to the fieldbus (FB).