Modular Duplex Robot Safety Architecture for Sensor Reconfiguration
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Solution Overview
Problem
Existing robot systems require architectural changes when sensors are added or removed to meet performance level d (pl-d) for functional safety, leading to inefficiencies.
Innovation Solution
A modular duplex system architecture for mobile robots that includes an input unit, logic unit, output unit, and controller, allowing sensors to be dynamically allocated and processed without altering the entire system architecture, using duplexing parameters and OR gates to manage sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the system architecture is changed to add or remove sensors to meet performance level d requirements, then functional safety is improved, but system complexity and reconfiguration effort increase
Solution Approach 1:
The system is divided into multiple independent sensor groups, each capable of autonomous operation. Each sensor group contains sensors that can independently perform safety functions, allowing individual sensors to be added or removed without affecting the overall system architecture. This segmentation enables modular configuration where sensors are organized into independent units that can be dynamically adjusted while maintaining pl-d functional safety.
Solution Approach 2:
The sensor groups are designed with universal functionality where multiple sensors within a group can perform the same safety-critical functions. This allows any sensor within a group to replace another, enabling flexible addition or removal of sensors without requiring architectural changes. The universal design ensures that functional safety requirements are met regardless of which specific sensors are active, as long as the required number of redundant sensors are present.
2Reliability
If the entire system architecture is reconfigured to accommodate sensor changes, then performance level d compliance is improved, but manufacturing time and cost increase
Solution Approach 1:
By segmenting the system into independent sensor groups with standardized interfaces, each group can be manufactured, tested, and assembled separately. This modular approach allows parallel manufacturing of multiple sensor groups, significantly reducing overall assembly time compared to configuring the entire system as a single integrated unit. The standardized interfaces enable plug-and-play assembly without requiring complex system-wide reconfiguration.
Solution Approach 2:
Sensor groups are pre-configured and pre-tested as complete functional units before being integrated into the overall system. This preliminary action ensures that each sensor group already meets performance level d requirements independently, eliminating the need for time-consuming system-wide reconfiguration and testing when sensors are added or removed. The pre-validated modular units can be quickly assembled into the final system configuration.
3Adaptability or versatility
If sensors are dynamically added or removed, then system flexibility is improved, but maintaining performance level d without architectural changes becomes difficult
Solution Approach 1:
The system employs dynamic sensor group configuration where sensors can be added or removed during operation without shutting down the system. The controller dynamically reassigns sensors to different functional roles and automatically recalculates safety parameters to maintain performance level d compliance. This dynamic capability allows the system to adapt to changing operational requirements while continuously maintaining the required safety integrity through automated redundancy management and real-time safety parameter adjustment.
Data Source
AI summary
A functional safety system of a robot according to an exemplary embodiment of the present disclosure can duplicate modules so as to satisfy a performance level d (pl-d) required for the functional satisfy of a robot.