Modular Safety Control Architecture with Master-Minion Fieldbus
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Solution Overview
Problem
Existing safety-critical control systems are not modularly designed and require significant additional effort and cost to integrate with non-safety-critical systems, as they need to replace communication modules, interfaces, and power supplies, and equip them with new software to meet safety criteria.
Innovation Solution
A modular control system with a safety control unit and a non-safety control unit, featuring dual port RAM for simultaneous read/write access, master and minion communication couplers, and a flexible architecture that allows the system to act as both communication master and minion, reducing the need for separate interfaces and simplifying design by reusing existing communication interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If safety-critical control systems are designed as separate dedicated systems, then safety reliability is improved, but device complexity and integration cost increase
Solution Approach 1:
The control system is segmented into distinct safety-critical control units and non-safety control units, each with dedicated safety functions. This segmentation allows safety-critical operations to be isolated and verified independently, improving reliability while maintaining clear system boundaries for integration
Solution Approach 2:
The control units are designed with universal communication capabilities that allow them to function both as safety-critical controllers and as integrated components in modular systems. The units can operate independently for safety functions while also participating in broader system communication through standardized interfaces, reducing integration complexity
2Reliability
If separate safety control systems are used, then safety function reliability is improved, but ease of manufacture and integration cost worsen
Solution Approach 1:
The control units incorporate universal communication interfaces and standardized connection protocols that enable them to be manufactured as modular components. These units can be integrated into existing systems without requiring custom communication modules, power supplies, or specialized software, thereby reducing manufacturing complexity and integration costs while maintaining safety certification
Solution Approach 2:
The patent combines safety-critical control functions with standardized communication capabilities in a single integrated unit. This merging eliminates the need for separate safety interfaces and communication modules, reducing the total number of components that need to be manufactured, tested, and integrated, thus lowering overall system cost
3Adaptability or versatility
If modular design is implemented, then adaptability and ease of integration are improved, but ensuring safety criteria compliance becomes more difficult
Solution Approach 1:
The modular control units are designed with clearly defined safety boundaries and isolated safety functions. Each module can be independently certified for safety compliance, allowing adaptability through module selection while maintaining verified safety characteristics. The segmented architecture enables compliance verification without requiring analysis of the entire integrated system
Data Source
AI summary
A control system is for controlling safety-critical processes, non-safety-critical processes, and/or installation components. The control system includes: at least one control unit configured to control non-safety-critical processes and/or non-safety-critical installation components, at least one safety control unit for controlling safety-critical processes and/or safety-critical installation components, and at least one input/output unit connected to the first control unit via an internal input/output bus. The control system is configured to act as communication master or as communication minion or as both in a pool having other devices that is connected via field bus, and to that end, the control system includes a master communication coupler and a minion communication coupler. The control system is modularly configurable. At least the safety control unit includes respective subunits with master functionality and subunits with minion functionalities.