Gateway I/O Architecture for Safe Process Control Networks
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Solution Overview
Problem
Current automation systems require multiple types of I/O modules for safety-relevant and non-safety-relevant signals, increasing development and operational complexity, and necessitating different safety protocols depending on the network used.
Innovation Solution
A control and data transmission system where safety logic is centralized in a gateway module, allowing single-channel I/O modules to handle both safety-relevant and non-safety-relevant signals, with the gateway module performing redundant processing and data transmission to ensure safe communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special safe input and output modules with multiple cores are used for safety-relevant signals, then safety requirements are met, but device complexity and development efforts increase
Solution Approach 1:
The patent merges the safety logic from distributed I/O modules into a centralized gateway module. Instead of each I/O module having its own safety processing cores, the gateway module consolidates the safety logic, allowing standard single-core I/O modules to be used while maintaining safety requirements through centralized redundant processing.
Solution Approach 2:
The gateway module serves multiple functions: it acts as a communication gateway between different bus systems, performs safety-related processing for all I/O modules, and provides diagnostic capabilities. This multi-functionality eliminates the need for separate safety modules and standard I/O modules, allowing a single unified architecture to handle both safety and non-safety functions.
2Reliability
If different I/O modules are employed for safety-relevant and non-safety-relevant signals, then safety functions are ensured, but manufacturing and logistics efforts increase
Solution Approach 1:
The invention enables a single type of I/O module to handle both safety-relevant and non-safety-relevant signals by centralizing safety processing in the gateway module. This universality means that the same I/O module design can be used throughout the system, eliminating the need for separate safety and standard I/O modules, thereby simplifying manufacturing and logistics.
Solution Approach 2:
The safety-critical processing functions are extracted from the I/O modules and placed in the gateway module. This extraction allows the I/O modules themselves to be simplified to standard single-channel designs, while the gateway module handles all safety-related processing, thus reducing manufacturing complexity without compromising safety functions.
3Reliability
If multiple cores are implemented in each I/O module for safety processing, then safety redundancy is achieved, but the station becomes technically and commercially more complex
Solution Approach 1:
The patent combines the redundant safety processing cores from multiple distributed I/O modules into a single centralized gateway module. Instead of having multiple cores in each I/O module, the gateway module implements the safety logic with redundancy, thereby achieving the same safety level while reducing overall station complexity by eliminating duplicate cores across multiple modules.
4Reliability
If different safety protocols are implemented for different networks, then network-specific safety requirements are met, but the variety of modules increases
Solution Approach 1:
The gateway module acts as an intermediary between different communication networks and the I/O modules. It implements the network-specific safety protocols at the gateway level rather than requiring each I/O module to support multiple protocols. This mediator approach allows standard I/O modules to communicate through the gateway, which handles protocol conversion and safety protocol implementation, thereby reducing module variety while maintaining protocol compliance.
Data Source
AI summary
Meeting the safety requirements of automation systems in a more flexible manner, the invention provides a control and data transmission system for controlling safety-critical processes comprising a plurality of I/O modules connected via a first communication network to a gateway module. The gateway module is connected to a second communication network hierarchically superior to the first communication network and acts as a gateway between the first and the second communication networks. At least one of the I/O modules comprises a diagnosis unit for generating status data relating to the functional state of an input and/or output and/or of a process device. The gateway module and the I/O modules communicate via the first communication network in a safe manner to transfer status data and input and/or output data. The gateway module performs safety processing of the status data and/or of the input and/or output data.