Integrated Safety and PLC Modules With Fixed Safety Function Mapping
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Solution Overview
Problem
Existing modular control devices require two separate devices for safety and programmable logic controllers, leading to increased space, installation, and wiring efforts, as well as a high number of relay contacts.
Innovation Solution
A modular control device with a central control module and two groups of electronic modules, where the first group provides fixed safety functions and the second group offers programmable standard functions, allowing for combined safety and logic control in a single device with a bidirectional communication interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate devices (safety controller and programmable logic controller) are used, then safety functions and standard functions can be provided, but space requirement, installation effort, and wiring effort increase
Solution Approach 1:
The patent combines a safety controller and a programmable logic controller into a single integrated control device. This merging eliminates the need for two separate devices, reducing space requirements, installation effort, and wiring complexity while maintaining both safety functions and standard control functions within one unified system.
Solution Approach 2:
The control device is designed with multi-functionality, where a single device can perform both safety-critical functions and standard programmable logic functions. The device includes safety inputs/outputs for safety functions and standard inputs/outputs for general control, allowing one device to replace multiple specialized devices.
2Adaptability or versatility
If two separate devices are used, then safety and logic control functions are provided, but wiring effort and relay contacts increase
Solution Approach 1:
By merging safety controller and PLC functions into one device, the patent reduces the number of external connections and relay contacts needed. The integrated design allows internal signal routing between safety and standard functions, eliminating the need for extensive external wiring that would be required if two separate devices were used.
3Adaptability or versatility
If safety functions are made programmable, then flexibility increases, but safety integrity may be compromised
Solution Approach 1:
The control device is segmented into distinct functional areas: safety inputs that are exclusively dedicated to safety functions and cannot be reprogrammed, and standard inputs/outputs that are fully programmable. This segmentation ensures that safety-critical signal paths remain fixed and integrity-preserving, while allowing flexibility in non-safety areas.
Solution Approach 2:
Different parts of the control device have different programmability characteristics. The safety input module has fixed, non-programmable safety functions to ensure integrity, while the standard input/output modules have full programmability for flexible control applications. This local differentiation of quality allows the system to simultaneously achieve safety integrity and operational flexibility.
Data Source
Figure 1
AI summary
The invention relates to a modular control device (1) comprising: - a central control module (2) with a first logic unit (20) and a second logic unit (21); - a first group (3) of electronic modules (3.1, 3.2, 3.3) connected to the first logic unit (20) and comprising a number of safety inputs and safety outputs, wherein the electronic modules (3.1, 3.2, 3.3) of the first group (3) are configured to provide safety functions of a safety controller; - a second group (4) of electronic modules (4.1, 4.2, 4.3, 4.4) connected to the second logic unit (21) and comprising a number of inputs and outputs, wherein the electronic modules (4.1, 4.2, 4.3, 4.4) of the second group (4) are configured to provide standard functions of a programmable logic controller; wherein - the central control module (2) and the two Groups (3, 4) of electronic modules (3.1, 3.2, 3.3, 4.1, 4.2, 4.3, 4.4) are arranged in at least one module row, - the safety functions of the electronic modules (3.1, 3.2, 3.3) of the first group (3) are defined by their positions in the module row and/or by fixed hardware settings, and - the standard functions of the electronic modules (4.1, 4.2, 4.3, 4.4) of the second group (4) are programmable.