Distributed Safety Controller Project Data Layout for Faster Response
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Solution Overview
Problem
Existing safety controllers face high implementation costs and limited flexibility due to the need for extensive data exchange between distributed control hardware components, leading to increased response times and inefficient use of memory resources.
Innovation Solution
A safety controller with a distribution unit that allows project data to be stored in individual data memories within control hardware components, including intelligent input/output units, enabling targeted use of existing memory and reducing data exchange, thereby optimizing response time and availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If project data is stored centrally in control units, then data exchange between components is extensive, but this leads to increased response times and higher implementation costs
Solution Approach 1:
The patent distributes project data to local data memories in intelligent I/O units rather than storing everything centrally. Each control hardware component stores the specific project data it needs locally, eliminating the need for continuous data exchange over the data bus and reducing response times while maintaining data availability.
Solution Approach 2:
The patent segments the centralized data storage into distributed data memories across multiple intelligent I/O units. Project data is divided and stored in various control hardware components based on their functional requirements, allowing parallel access and eliminating bottlenecks associated with centralized storage.
2Adaptability or versatility
If distributed safety controllers use many control hardware components, then hardware flexibility is improved, but data exchange requirements increase response times
Solution Approach 1:
The patent enables each intelligent I/O unit to store project data locally in its own data memory, so that distributed control hardware components can operate independently without requiring extensive data exchange. This maintains hardware flexibility while eliminating response time delays caused by data transmission across the network.
3Reliability
If control units have larger data memories, then central data storage is sufficient, but this increases implementation costs and wastes memory resources
Solution Approach 1:
The patent assigns specific project data to specific intelligent I/O units based on their functional requirements. Each control hardware component is equipped with only the data it needs, eliminating the need for oversized central memory and reducing implementation costs while ensuring data availability where needed.
Solution Approach 2:
The patent extracts project data from centralized storage and places it directly into the data memories of intelligent I/O units that require it. This eliminates the need for large central memory capacity and reduces the overall implementation cost while maintaining sufficient data storage at each location.
4Device complexity
If extensive data exchange occurs between control hardware components, then centralized control is maintained, but this increases response times and data transmission requirements
Solution Approach 1:
The patent segments project data storage across multiple intelligent I/O units, allowing each component to access its required data locally without extensive data exchange. This maintains the distributed control architecture while eliminating response time delays associated with centralized data access.
Data Source
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AI summary
The present invention relates to a safety controller for controlling an automated system (10) depending on project data (130) representing an application running on the system (10), comprising a plurality of control hardware components (28, 28', 28", 28"'), each comprising a project data memory (52, 52', 52", 52"', 52"") and at least one data processing unit (152, 154, 156, 158), wherein the project data memories (52, 52', 52", 52"', 52"") are each configured to store project data supplied to them, comprising a connection unit (34) via which the control hardware components (28, 28', 28", 28"') are interconnected, and a distribution unit (52, 142) configured to distribute at least a portion of the to distribute project data (130, 132) via the connection unit (34) to at least some of the project data storage locations (52, 52', 52", 52'', 52""),wherein project data (132") for a first data processing unit (154) is stored in a first project data memory (52) contained in the control hardware component (28') in which the first data processing unit (154) is contained, and wherein the required project data (132") for a second data processing unit (156), which is also contained in the control hardware component (28'), is stored in a second project data memory (52"). According to one aspect of the invention, the second project data memory (52") is contained in a different control hardware component, and the second data processing unit (156) can access the project data (132") in the second project data memory (52") via the first project data memory (52). (Fig. 3)