I/O Module Safety Loop Circuit for Low-Latency Fault Signaling
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Solution Overview
Problem
Industrial automation systems face delays in reacting to faults and safety signals due to network latency and communication delays, which can hinder timely safety operations.
Innovation Solution
A safety loop circuit with a direct path between input and output ports of an I/O module communicatively coupled to the local control system, allowing for direct communication of safety signals and reducing the safety distance between devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety signals are transmitted through the control system for processing, then the control system can determine and execute safety operations, but transmission delays and processing delays occur reducing safety reaction speed
Solution Approach 1:
The patent segments the safety signal transmission path into two independent channels: a direct path that bypasses the control system for immediate signal transmission, and an indirect path through the control system for processing and determination. This segmentation allows critical safety signals to be transmitted immediately while non-critical processing occurs separately, resolving the contradiction between reliability and reaction time.
Solution Approach 2:
The patent introduces an intermediary direct connection path between input and output ports that acts as a mediator for safety signals. This intermediary path allows signals to bypass the complex control system processing chain, providing a dedicated fast lane for safety-critical communications while maintaining the control system's processing capabilities through the indirect path.
2Loss of time
If a direct connection path is added for fast signal transmission, then safety reaction time is reduced, but device complexity increases
Solution Approach 1:
The patent merges the direct connection path with the existing control system architecture by integrating it into the I/O module structure. The direct path is combined with the indirect path through the control system at the input and output ports, creating a unified circuit that provides both fast transmission and processed control without requiring completely separate independent systems, thereby limiting the increase in device complexity.
Data Source
AI summary
A circuit may include one or more first ports that may receive one or more input signals from a first device, such that the one or more first ports may couple to a control system. The control system may generate one or more output signals based on the one or more input signals. The circuit may also include one or more second ports that may couple to a second device, such that the one or more second ports may couple to the one or more first ports via a direct connection. The control system may also couple the one or more output signals to the one or more second ports.