Dual Interface Operator Panel for Secure Industrial Automation Data Transmission
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Solution Overview
Problem
Fail-safe industrial automation components face challenges in ensuring reliable transmission of parameter values due to potential errors in non-fail-safe operator panels and communication links, which can lead to incorrect parameter values.
Innovation Solution
An operating device with a dual user interface system is implemented, where user inputs are confirmed and converted into test values, ensuring that changes are only effective if matching test values are verified between the operator panel and the automation component, thereby ensuring secure and accurate data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a non-fail-safe operator panel is used to input parameter values, then the device complexity and cost are reduced, but the reliability of data transmission is compromised due to potential errors in the operating device or communication path
Solution Approach 1:
The patent introduces a dual user interface system as an intermediary between the operator and the fail-safe automation component. The first user interface accepts inputs, while the second user interface displays and requires confirmation of these inputs. This intermediary confirmation mechanism ensures data integrity without requiring the entire operator panel to be fail-safe certified, thus reducing device complexity while maintaining transmission reliability.
Solution Approach 2:
The system implements a feedback loop where inputs entered at the first user interface are displayed at the second user interface for confirmation. The automation component sends back the displayed values for verification, creating a feedback mechanism that allows the operator to verify data accuracy before final transmission. This feedback process ensures reliability while using a standard operator panel.
2Reliability
If a safety-certified operator station with redundant hardware is used, then the reliability of parameter transmission is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent segments the safety function into two separate parts: the standard operator panel for input operations and the fail-safe automation component for critical processing. By dividing the system this way, the safety certification burden is placed only on the automation component, while the operator panel can remain a standard, less complex device. The dual user interface acts as a bridge between these segmented parts.
Solution Approach 2:
The system creates a copy of the input data through the dual user interface mechanism. The first user interface captures the operator's input, and this information is copied to the second user interface for display and confirmation. This copying process allows verification of data integrity without requiring the entire operator station to be redundant and safety-certified.
3Reliability
If dual user interface confirmation is implemented, then the reliability of data transmission is improved, but the operating time and productivity are reduced due to additional confirmation steps
Solution Approach 1:
The system performs preliminary display of input values at the second user interface before final transmission to the automation component. By showing the values for confirmation in advance, the operator can verify correctness before the time-consuming finalization step. This preliminary action prevents errors that would require time-consuming corrections later.
Solution Approach 2:
The dual user interface system allows the operator to self-verify the displayed values against their intended input. The confirmation process is self-service in nature, where the operator independently checks the displayed values and confirms accuracy without requiring additional verification steps or external validation, thus minimizing time loss.
Data Source
Figure 1
AI summary
The method involves operating an input at an operating system (OS) by a user at a user surface and transmitting a result of the input by the operating system to an automation component (CPU). The result of the input is used in the automation component for the computation of a test value. An independent claim is also included for an operating system for safety-related industrial automation component.