Gateway I/O Architecture for Unified Safety Signal Processing
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Solution Overview
Problem
Current automation systems require multiple types of I/O modules for safety and non-safety signals, increasing development and operational complexity, and necessitate different secure protocols for safety-related data transmission, leading to inefficiencies and increased variance.
Innovation Solution
A control and data transmission system with a gateway module that processes safety-related data and executes safety functions, using a single communication network for both safety and non-safety signals, and incorporates a diagnostic unit for error detection, reducing the need for multiple I/O modules and simplifying data transmission protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate safe I/O modules with redundant cores are used for safety signals, then safety reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges safe and non-safe I/O functionality into a single module type. The gateway module consolidates multiple I/O modules, each containing a microprocessor that can handle both safety and non-safety signals, eliminating the need for separate redundant safe I/O modules while maintaining safety integrity through software-based safety functions.
Solution Approach 2:
The I/O modules are designed with universal functionality to handle both safety and non-safety signals through a single microprocessor. The same hardware platform performs multiple functions by executing different software routines, allowing a single module type to replace multiple specialized modules while maintaining safety requirements through standardized safety protocols.
2Reliability
If multiple types of I/O modules are used for safety and non-safety signals, then safety requirements are met, but ease of operation and training requirements worsen
Solution Approach 1:
The system employs a single universal I/O module design that handles both safety and non-safety signals, eliminating the need for operators to learn and manage multiple different module types. The unified interface and consistent communication protocols simplify operational procedures and reduce training requirements while maintaining full safety compliance through standardized safety function implementation.
3Measurement precision
If separate safe I/O modules are used for each safety signal, then measurement precision for safety detection is improved, but quantity of components and system complexity increase
Solution Approach 1:
The patent combines multiple I/O module functions into fewer modules by implementing safety functions at the gateway level rather than requiring redundant safety cores in each I/O module. This consolidation reduces the total number of modules while maintaining precise safety signal detection through centralized safety processing and validation in the gateway module.
4Reliability
If different secure protocols are implemented for safety signal transmission, then reliability of safety communication is improved, but device complexity and adaptability worsen
Solution Approach 1:
The system implements a universal communication protocol that handles both safety and non-safety data transmission through the same interface. The gateway module provides standardized safety protocol implementation that works across all I/O modules, eliminating the need for separate protocol implementations while maintaining communication integrity through unified error handling and validation mechanisms.
Data Source
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AI summary
In order to meet security requirements placed on an automation system, the invention provides a control and data-transfer system (10) for controlling security-critical processes, which comprises I/O modules (201, 202), which are connected to a gateway module (100) by means of a first communication network (510), wherein the gateway module (100) is connected to a second communication network (520) hierarchically superior to the first communication network and acts as a gateway between the first and the second communication network. The I/O modules (201, 202) comprise a diagnosis unit (400) for producing status data. Furthermore, the gateway module (100) and the I/O modules (201, 202) communicate by means of the first communication network (510) in an error-secured manner. The gateway module (100) is also designed to perform security processing of the data. The invention further relates to a gateway module (100) and an I/O module (201, 202) for use in such a control and data-transfer system (10) and to a method for secure process control.