Isolated Safety Controller Architecture Without Redundant Sensing
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Solution Overview
Problem
Existing machinery control systems require redundant sensing and signal conditioning, which increases complexity and cost, and can be time-consuming and expensive to modify or certify safety systems.
Innovation Solution
A system that uses a safety boundary with a separate processor for one-way communication from a certified safety system to a control system, allowing the control system to utilize signal conditioning from the safety system without redundant components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant sensing and signal conditioning are used in control systems, then safety and reliability are improved, but system complexity and cost increase
Solution Approach 1:
The patent merges the sensing and signal conditioning functions into a single integrated sensor module that serves both safety control and machine control purposes. The sensor performs signal conditioning internally and outputs a single conditioned signal that can be used by both the safety controller and the control processor, eliminating the need for separate redundant sensing and signal conditioning circuits for each control system.
2Reliability
If redundant sensing and signal conditioning are used in control systems, then safety and reliability are improved, but cost increases
Solution Approach 1:
The patent merges the sensing and signal conditioning functions into a single integrated sensor module that serves both safety control and machine control purposes. The sensor performs signal conditioning internally and outputs a single conditioned signal that can be used by both the safety controller and the control processor, eliminating the need for separate redundant sensing and signal conditioning circuits for each control system.
3Reliability
If isolated boundary processor is used to separate safety controller from control processor, then safety integrity is improved, but communication complexity increases
Solution Approach 1:
The patent introduces a boundary processor as an intermediary component that sits between the safety controller and the control processor. The boundary processor receives the conditioned signal from the sensor, performs isolation to prevent safety violations from propagating to the control system, and then communicates with both the safety controller and control processor using a proprietary protocol. This mediator approach maintains safety integrity while managing communication complexity through a standardized interface.
Data Source
AI summary
The present disclosure involves systems, software, and computer implemented methods for controlling machinery. The system can include a sensor configured to measure an operating characteristic of a machine, and a safety controller in communication with the sensor. The safety controller can include a dedicated boundary processor and be in communication with a control processor through the boundary processor that isolates operations of the control processor form the safety controller. The safety controller can be configured to receive measurement data from the sensor, perform signal conditioning on the measurement data to generate a conditioned sample, analyze the conditioned sample to determine whether to take a safety action, and send the conditioned sample to the boundary processor for transmission to the control processor. The control processor can be configured to perform operations including receiving the conditioned sample and controlling one or more operations of the machine based on the conditioned sample.