IO-Link Fail-Safe Control Using Unified Actuator Data Sets
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Solution Overview
Problem
Existing IO-link systems require time-consuming and device-specific configuration for fail-safe mechanisms, leading to increased programming efforts and potential hardware costs, as well as risks of communication loss between devices and actuators, which can result in damage during failures.
Innovation Solution
A unified fail-safe IO-link system with a storage device containing pre-defined process data codes for both normal and fail-safe operations, allowing the fail-safe control device to take over and manage communication with actuators using index parameters, reducing the need for additional hardware and programming efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate parameters for each output are used for fail-safe configuration, then device-specific fail-safe handling is achieved, but programming time and complexity increase significantly
Solution Approach 1:
The patent implements a universal fail-safe configuration approach where a single fail-safe parameter setting can be applied across multiple outputs simultaneously. Instead of requiring separate acyclic commands for each output, the system allows one configuration to serve multiple functions, reducing programming time while maintaining device-specific fail-safe handling through the use of output masks and parameter inheritance.
2Reliability
If additional hardware is installed for parallel communication routes, then communication reliability improves, but system complexity and cost increase
Solution Approach 1:
The patent uses software-based redundancy where fail-safe data sets are copied and stored in the IO-Link device's memory. Instead of requiring physical parallel communication hardware, the system creates software copies of control data that can be activated when primary communication fails, achieving communication reliability without additional hardware complexity.
3Reliability
If device-specific acyclic commands are programmed for each output, then precise fail-safe control is achieved, but implementation effort and potential for errors increase
Solution Approach 1:
The patent implements preliminary action by pre-configuring fail-safe data sets and output masks in the IO-Link device memory before runtime. The system prepares multiple predefined data sets with different fail-safe behaviors, and the controller can activate appropriate pre-configured sets based on failure conditions, eliminating the need for complex real-time decision logic and reducing implementation effort.
Data Source
Figure 1~2
AI summary
A controlled IO-link (IOL) system (S) for unified implementation and for running an plant with at least one actuator (4) is proposed, comprising a process controller (1), an IOL device (3), at least one actuator (4), wherein said IOL device (3) communicates with the at least one actuator (4) and with said process controller (1) to transfer codes, in particular data and/or commands, between the process controller (1) and the at least one actuator (4), a fail-safe control device (3A) comprising a storage device that contains at least one set of process data codes for running the at least one actuator (4), where said storage device contains at least one fail-safe data set for handling a fail-safe situation, and that the fail-safe control device (3A) comprises a communication system which provides codes that contain additional index parameter assigned to fail-safe data set for running the at least one actuator (4).