Modular Safety Control Architecture with Master-Slave Fieldbus Coupling
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Solution Overview
Problem
Existing safety-critical control systems are not easily integratable into modular control systems, requiring significant adjustments and replacements of communication modules, interfaces, and power supplies, leading to high costs and complexity.
Innovation Solution
A modular control system design featuring a first control unit for non-safety-critical processes and a second safety control unit with dual-port RAM for simultaneous read/write access, enabling master and slave communication functionalities, and the use of the 'black channel communication principle for safety-related telegram transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing safety-critical control systems are integrated into modular control systems, then safety functionality is achieved, but significant adjustments and replacements of communication modules, interfaces, and power supplies are required, leading to high costs and complexity
Solution Approach 1:
The control system is divided into distinct modules: a first control unit for non-safety-critical processes and a second control unit for safety-critical processes. Each module can be independently configured and integrated, allowing safety functionality to be added without redesigning the entire system. The communication coupler is also segmented into separate interfaces for each control unit, enabling independent adaptation to fieldbus standards.
Solution Approach 2:
The communication coupler is designed with universal functionality to support both safety-critical and non-safety-critical communication protocols simultaneously. It can interface with different fieldbus standards (PROFIBUS, PROFINET, EtherCAT) and provides standardized communication interfaces that work with various control units, eliminating the need for multiple specialized communication modules.
2Reliability
If existing safety-critical control systems are integrated into modular control systems, then safety functionality is achieved, but communication modules, interfaces, and power supplies must be replaced, leading to high costs
Solution Approach 1:
The communication coupler merges multiple communication interfaces and protocols into a single unified component that can handle both safety-critical and non-safety-critical communications. This consolidation eliminates the need for separate communication modules for each control unit, reducing component count and integration costs while maintaining safety functionality.
Solution Approach 2:
The communication coupler acts as an intermediary between the first and second control units and the fieldbus network. It provides standardized interfaces that mediate between different communication protocols and the control units, allowing existing control units to be integrated without replacing their native communication interfaces, thereby reducing costs.
3Reliability
If separate control units are used for safety-critical and non-safety-critical processes, then functional separation is achieved, but the number of communication interfaces increases
Solution Approach 1:
The communication coupler is designed with universal multi-functionality to handle multiple communication protocols and interfaces simultaneously through a single unified component. It can interface with both the first control unit (non-safety-critical) and the second control unit (safety-critical) using standardized protocols, thereby reducing the total number of communication interfaces required while maintaining functional separation.
Data Source
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AI summary
The invention relates to a control system (100, 101) for controlling safety-critical and non-safety-critical processes and/or system components. The system comprises at least one control unit (1) which is designed to control non-safety-critical processes and/or non-safety-critical system components, at least one safety control unit (2) for controlling safety-critical processes and/or safety-critical system components, and at least one input/output unit (11, 21) which is connected to the first control unit (1) via an internal input/output bus (B2), wherein the control system (100, 101) is designed to operate as the communications master or as the communications slave, or as both, in combination with other devices connected via a fieldbus (FB), and wherein the control system also comprises a master communications coupler (5) and a slave communications coupler (6).