Integrated IS Barriers in Redundant Universal IO Modules
Solution Overview
Problem
Existing industrial process control and automation systems face challenges in providing cost-effective and simplified intrinsically safe barriers for universal IO channels in hazardous environments, as current solutions are complex and costly, often requiring additional cabinets.
Innovation Solution
An integrated energy limiting barrier with galvanic isolation is provided for redundant universal IO systems, which includes a back plane with primary and secondary modules, channel-to-channel isolation, and a programmable IS module that limits energy and provides current output regardless of the field device type, eliminating the need for external IS barriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external intrinsically safe barriers are used to limit energy in hazardous environments, then safety is improved, but system complexity and cost increase
Solution Approach 1:
The patent combines the intrinsically safe barrier functionality directly into the I/O module, merging previously separate components (barrier and I/O module) into a single integrated unit. This eliminates the need for external barriers while maintaining energy limiting capabilities, thus improving safety without increasing system complexity
Solution Approach 2:
The I/O module is designed to perform multiple functions: standard I/O operations and intrinsically safe energy limiting. By making the barrier functionality universal and integrated into the module, the system eliminates the need for separate dedicated barrier devices, reducing overall system complexity while maintaining safety
2Reliability
If external intrinsically safe barriers are used to limit energy, then intrinsic safety is improved, but installation space and cost increase
Solution Approach 1:
The barrier functionality is merged into the I/O module itself, eliminating the need for separate external barrier devices that would require additional cabinet space. The integrated design maintains intrinsic safety capabilities while reducing the physical footprint and installation space requirements
3Reliability
If redundant primary and secondary modules are implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The redundant system is segmented into modular primary and secondary I/O modules, each capable of independent operation. This segmentation allows for simplified redundancy implementation where each module is self-contained with integrated barrier functionality, reducing the complexity management compared to non-modular redundant systems
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 ensures intrinsic safety in hazardous zones while reducing costs and complexity by integrating the IS barrier within the IO system, allowing for safe operation without additional cabinets and supporting various I/O types without mechanical or software reconfiguration.
Implementation Method 1
The back plane is configured to limit energy from the at least one primary module and the at least one secondary module to a field device
Implementation Method 2
a first isolator of the first plurality of isolators coupled between a first channel of the first plurality of channels and a first channel of the second plurality of channels
Data Source
AI summary
A system includes a back plane having at least one primary module and at least one secondary module that is redundant to the at least one primary module. The back plane is configured to limit energy from the at least one primary module and the at least one secondary module to a field device. The at least one primary module includes a first plurality of channels and is configured to provide channel to channel isolation among the first plurality of channels. The at least one secondary module includes a second plurality of channels and is configured to provide channel to channel isolation among the second plurality of channels.