Industrial Control Input Module for Fixing Failure Detection
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Solution Overview
Problem
Industrial control apparatuses face challenges in detecting circuit failures within input modules, particularly fixing failures due to high fixing, which can lead to erroneous determinations in the operation state of emergency stop switches.
Innovation Solution
The input module includes an input circuit with an ORAND circuit and a photo coupler, which outputs a binary internal signal. A determination unit analyzes this internal signal to determine the level of the digital signal, identifying a fixing failure when the internal signal fails to switch from high to low after initially switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the input module uses a simple level detection method, then the device complexity is reduced, but the reliability of failure detection deteriorates
Solution Approach 1:
The system performs preliminary actions by monitoring the time sequence of signal level changes and detecting patterns that indicate potential failures before they cause erroneous determinations. The determination unit tracks the duration of high levels and anticipates potential fixing failures by analyzing the temporal pattern of signal transitions.
Solution Approach 2:
The determination unit uses feedback from the internal signal's temporal behavior to detect fixing failures. By monitoring whether the signal returns to low level within expected timeframes and comparing actual behavior against predicted behavior, the system can identify when a fixing failure has occurred and prevent erroneous emergency stop switch state determinations.
2Reliability
If the input module monitors signal transitions continuously, then the reliability of failure detection is improved, but the use of energy increases
Solution Approach 1:
The determination unit performs periodic monitoring of signal transitions rather than continuous monitoring. It checks for level changes at specific intervals and analyzes the timing of transitions, which reduces energy consumption while maintaining the ability to detect fixing failures through temporal pattern recognition.
Solution Approach 2:
The system applies partial monitoring by focusing only on critical transition points and time periods when failures are most likely to manifest. Rather than monitoring every aspect of the signal continuously, it concentrates detection efforts on the specific temporal patterns that indicate fixing failures, achieving reliable detection with reduced energy use.
3Reliability
If the input module implements comprehensive failure detection, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The determination unit serves multiple functions: it determines the level of digital signals, detects fixing failures in the input circuit, and prevents erroneous emergency stop switch state determinations. By making this single component multi-functional, the system achieves comprehensive failure detection without proportionally increasing device complexity.
Solution Approach 2:
The patent combines the failure detection functionality with the existing signal determination logic in the determination unit. Rather than adding a separate dedicated failure detection system, it merges the temporal analysis of signal levels with the level determination process, achieving comprehensive monitoring through integration and reducing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables accurate detection of fixing failures and prevents erroneous determinations of emergency stop switch states, thereby enhancing the safety and reliability of industrial control systems.
Implementation Method 1
an input circuit with an ORAND circuit and a photo coupler, which outputs a binary internal signal
Data Source
AI summary
An input module of an industrial control apparatus receives a digital signal from an external source, outputs a binary signal as an internal signal, and determines a level of the digital signal based on the internal signal. The input module determines that the digital signal has a low level when a low level of the internal signal continues for a certain time period, determines that the digital signal has a high level when the internal signal switches from the low level to a high level and then switches to the low level again, and determines an occurrence of a fixing failure when the internal signal switches from the low level to the high level and then fails to switch to the low level again.