Dual-Controller Safety Module Using Analog Signal Cross-Checks
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Solution Overview
Problem
Existing functional safety modules for industrial devices face challenges in promptly determining the normalcy of dual-system controllers while minimizing erroneous determinations, especially when noise is present in the operation sequences.
Innovation Solution
A functional safety module with a first controller that outputs digital signals converted into analog voltages and a second controller that receives and re-converts these analog voltages multiple times to determine the normalcy of the first controller, using a comparison of digital signals to assess continuity and accuracy of operation commands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If digital signals are directly compared between dual controllers, then determination speed is fast, but measurement precision deteriorates due to noise interference
Solution Approach 1:
The patent introduces an analog voltage signal as an intermediary between the first controller's digital output and the second controller's digital input. The first controller outputs digital signals that are converted to analog voltages, which are then converted back to digital signals by the second controller for comparison. This intermediary analog representation allows for multiple sampling assessments within a single command cycle, improving both determination speed and accuracy by enabling noise filtering through multiple measurements.
2Measurement precision
If multiple assessments are performed within a single command cycle, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent changes the signal parameter from direct digital comparison to analog voltage representation. By converting digital signals to analog voltages and back, the system enables multiple sampling points within a single command cycle. This parameter transformation allows the second controller to perform multiple assessments of the same command sequence without requiring multiple separate command cycles, thereby improving measurement precision while maintaining relatively simple device architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for rapid determination of the first controller's normalcy, reduces erroneous determinations, and improves accuracy by representing operation commands through analog voltages, enabling multiple assessments within a shorter time frame.
Implementation Method 1
The first controller is configured to output digital signals, and sequentially convert the digital signals into analog voltages
Implementation Method 2
The second controller is configured to receive the analog voltages, sequentially converts the analog voltages, and outputs the digital signals
Data Source
AI summary
The present disclosure provides a functional safety module for industrial devices, the functional safety module being connected between the industrial devices to manage safety according to a state of the industrial devices. The functional safety module may include a first controller and a second controller each configured to execute a common predetermined operation command including operation commands. The first controller is configured to output digital signals, and sequentially convert the digital signals into analog voltages. The second controller is configured to receive the analog voltages, sequentially converts the analog voltages, and outputs the digital signals, and determine whether the first controller is normal.