Distributed Control Modules with Safety Voting Over Ethernet

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Solution Overview

Problem

Industrial control systems face challenges with high costs due to the need for centralized PLCs, expensive cabling, susceptibility to noise interference, and inflexible expansion capabilities, particularly in coordinating multiple components and ensuring safety protocols like Modbus, which lack modern security and data handling capabilities.

Innovation Solution

A modular distributed networking system with a proprietary protocol that uses Ethernet for communication, incorporating safety cores with voting logic to manage a safety state environment, and power over Ethernet (PoE) to simplify wiring and reduce noise susceptibility, allowing for scalable and secure data transmission between modules without the need for separate PLCs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If centralized PLCs are used to control and monitor multiple components, then system coordination and safety are improved, but system cost and complexity increase significantly

Engineering Contradiction:

Improvesystem coordination and safetyVSAvoidsystem cost and complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the centralized control system into distributed control modules, each capable of independent operation. Each module has its own processor and memory, eliminating the need for a single complex centralized PLC. This segmentation reduces system cost and complexity while maintaining coordination through inter-module communication via the communication bus.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control modules are designed with universal functionality to perform multiple tasks including sensing, actuation, control logic, and communication. This multi-functionality eliminates the need for specialized components for each function, reducing overall system complexity and cost while maintaining reliable coordination through integrated module operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If analog signaling is used for component communication, then installation flexibility is improved, but susceptibility to noise interference and cost increase

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidnoise interference susceptibility

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces analog electrical signaling with digital communication over a standardized communication bus. This substitution eliminates susceptibility to noise interference that plagues analog systems while maintaining installation flexibility through the use of standard connectors and protocols. The digital signals are immune to the electrical noise that affects analog communications.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If separate cabling for power and data is used, then communication reliability is improved, but installation cost and complexity increase

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidinstallation cost and complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines power and data communication into a single communication bus infrastructure. The control modules draw power through the same bus used for data communication, eliminating the need for separate power cabling. This merging reduces installation cost and complexity while maintaining communication reliability through the use of shielded, twisted-pair wiring and differential signaling.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If traditional control protocols like Modbus are used, then compatibility with existing systems is improved, but data handling capabilities and security are insufficient

Engineering Contradiction:

Improvecompatibility with existing systemsVSAvoiddata handling capabilities and security

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs modern communication protocols with enhanced parameters for data integrity, security, and handling capabilities. The system uses protocols that support authentication, encryption, and advanced error detection while maintaining compatibility through standardized interfaces and communication methods. This allows the system to leverage modern security and data handling features without sacrificing compatibility with existing industrial communication standards.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11314235B2Systems to implement a safety state environment among control modules

Publication Date: 2022.04.26 PROFIRE ENERGY INC

AI summary

A distributed networking system and protocol is provided to a networking system with a modular design. The distributed networking system may include a networking system, modules, control module, user interface module, input/output module, network module, data transmission network, hybrid modules and composite modules. A method to interface with accessories of a system with a modular design using the distributed networking system and protocol is also provided.