Modular Safety Module for Multi-BUS Automation Integration
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Solution Overview
Problem
Conventional safety modules for automation system assemblies require elaborate configuration and certification for each communication system, leading to high costs and labor-intensive processes, especially when connecting to new or unknown systems.
Innovation Solution
A modular safety module design separates safety and adaptation components, with the safety component performing critical safety functions and the adaptation component mediating communication, allowing flexible connection to various systems without additional certification requirements, using separate circuit carriers and conventional connectors for data and energy transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional safety module is designed as a plug-in card solution for a specific communication system, then it can be integrated into that system, but it requires separate variants for different slot or BUS standards (PCI, PCIe, etc.), increasing device complexity and certification requirements
Solution Approach 1:
The safety module is divided into two separate components: a safety component containing only safety-relevant functions and an adaptation component containing communication-specific functions. This segmentation allows the safety component to remain unchanged across different communication systems, while only the adaptation component needs to vary. Consequently, a single certified safety component can be paired with multiple adaptation components for different BUS standards (PCI, PCIe, etc.), eliminating the need for separate certified variants for each communication system.
2Adaptability or versatility
If a safety module is customized for a new or unknown communication system, then it can communicate with that system, but it requires elaborate configuration and individual certification, increasing time and costs
Solution Approach 1:
The communication-specific adaptation functions are extracted from the safety component and placed into a separate adaptation component. This extraction allows the safety component to maintain its certification without being affected by changes in communication systems. When a new communication system is introduced, only the adaptation component needs to be configured and developed, while the already-certified safety component can be reused, significantly reducing certification time and costs.
Solution Approach 2:
The safety component is pre-certified for safety functions in advance, independent of any specific communication system. This preliminary certification action ensures that when the safety module needs to be integrated into a new communication system, the time-consuming certification process is avoided for the safety component, as it has already been certified. Only the non-safety adaptation component requires configuration.
3Ease of manufacture
If safety functions and communication functions are integrated in a single safety module, then the module can operate independently, but it requires re-certification for each communication system integration, increasing costs
Solution Approach 1:
The module is segmented into a safety component and an adaptation component that are physically separate and can be independently manufactured. The safety component can be produced once and certified, while the adaptation component can be manufactured in variants for different communication systems. This segmentation maintains production simplicity for the safety component while enabling flexibility through multiple adaptation component variants.
Solution Approach 2:
The safety component is designed as a universal module that can interface with multiple different communication systems through different adaptation components. This universality allows a single safety component design to serve multiple purposes across different communication standards (PCI, PCIe, and future standards), reducing the need for re-certification while maintaining ease of manufacture for the core safety functions.
Data Source
AI summary
The disclosure relates to a safety module for an automation system assembly, having a safety component which is configured to implement a safe operation of the automation system assembly, and an adaptation component which is configured to mediate between the safety component and a communication system of the automation system assembly in order to incorporate the safety module into the automation system assembly, wherein the safety component and the adaptation component are constructed on separate circuit carriers and are connected in such a way that they are mechanically detachable and reconnectable.