Input Channel Diagnostics for Industrial Process Control Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial process control systems face challenges in providing flexible fault tolerance levels without excessive cost, particularly in containing faults within input channels to prevent disruption to other parallel modules and ensuring fail-safe operation in case of overload conditions.
Innovation Solution
An input module with a series resistor and operational amplifier configuration, along with a field conditioning circuit that includes a fuse and Zener diode for overvoltage protection, and a method for fault detection using high impedance input circuits and analogue to digital converters, allows for effective fault containment and reporting, enabling flexible fault tolerance and fail-safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Triple Modular Redundancy (TMR) is implemented to provide fault tolerance, then system reliability is improved, but system cost increases significantly
Solution Approach 1:
The patent applies local quality by implementing fault containment regions that isolate faults to specific input channels rather than requiring system-wide redundancy. Each input channel has its own isolation mechanism, allowing selective fault management rather than universal TMR implementation across all system components.
Solution Approach 2:
The system is segmented into independent fault containment regions for each input channel. This segmentation allows faults to be isolated to individual channels without affecting other channels, enabling more economical fault tolerance strategies compared to system-wide TMR while maintaining overall system reliability.
2Reliability
If dedicated hardware test and diagnostic regimes are implemented for fast fault recognition, then fault detection speed is improved, but device complexity increases
Solution Approach 1:
The input module performs self-diagnostics by monitoring its own operational parameters and detecting faults internally. The module can identify and report faults in its input channels without requiring external dedicated test equipment, reducing overall system complexity while maintaining fast fault detection capabilities.
Solution Approach 2:
The system implements feedback mechanisms where the input module continuously monitors its own status and provides diagnostic information about fault conditions. This internal feedback loop enables rapid fault recognition and reporting without adding complex external testing infrastructure.
3Reliability
If fault containment regions are implemented to prevent fault propagation, then system safety is improved, but device complexity increases
Solution Approach 1:
The input module is divided into separate fault containment regions for each input channel, with isolation mechanisms that prevent fault propagation between channels. This segmentation approach enhances system safety by containing faults locally while avoiding the need for complex system-wide fault isolation infrastructure.
Data Source
AI summary
This invention relates to input channel diagnostics for an industrial process control system. The invention provides improved apparatus and methods relating to fault containment, overload protection and input channel diagnostics.