Modular Safety Modules for Automation Systems
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Solution Overview
Problem
Current automation systems require time-consuming and costly processes for validating and implementing safety functions, especially during commissioning and modifications, due to the need for specialized fail-safe programming tools and personnel, which limits flexibility and efficiency.
Innovation Solution
The method involves creating modular safety modules with address-independent logic and address-dependent parameter modules, using a fail-safe programming tool, allowing for computer-aided design, storage, and decentralized loading of safety functions, enabling flexible and efficient validation and integration of safety functions into automation systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If decentralized modular safety functions are implemented in automation systems, then system flexibility and ease of reconfiguration are improved, but the complexity of validating safety functions increases
Solution Approach 1:
The patent divides the automation system into decentralized safety islands, each with its own safety functions implemented in separate safe participants (safe PLCs, safe I/O devices). This segmentation allows independent validation of each safety island without requiring system-wide validation, thereby maintaining flexibility while managing validation complexity through modular verification.
2Adaptability or versatility
If safety functions are implemented in decentralized safe participants connected via fieldbus, then system reconfigurability is improved, but the time and cost for commissioning and validation increase
Solution Approach 1:
The patent implements pre-validation of safety functions during the programming and configuration phase using specialized fail-safe programming tools. Safety programs and parameters are validated before being downloaded to safe participants, and restoration information is prepared in advance. This preliminary validation eliminates the need for time-consuming on-site commissioning and re-validation when reconfiguring the system.
Solution Approach 2:
The patent uses restoration information that captures the validated safety configuration and allows it to be copied or reloaded onto safe participants during reconfiguration. This copying mechanism preserves the pre-validated safety functions without requiring re-validation, significantly reducing commissioning time for reconfigured systems.
3Reliability
If specialized fail-safe programming tools are used for validation and programming, then safety function correctness is improved, but the cost and resource requirements increase
Solution Approach 1:
The patent designs the fail-safe programming tool to serve multiple functions: programming safety logic, validating safety functions, generating restoration information, and supporting system reconfiguration. This multi-functional approach consolidates what could be multiple separate tools into one universal platform, maintaining safety correctness while reducing overall system complexity and cost.
4Ease of operation
If safety modules are created with address-independent logic and address-dependent parameters, then ease of loading and reusability are improved, but the complexity of module creation increases
Solution Approach 1:
The patent segments safety modules into address-independent logic components and address-dependent parameter components. The logic modules contain the actual safety functions that can be reused across different devices, while parameter modules contain device-specific addressing information. This segmentation allows logic modules to be created once and reused multiple times, simplifying loading while the modular structure manages creation complexity through systematic organization.
Solution Approach 2:
The patent applies local quality by making different parts of the safety module have different characteristics: logic modules are universal and address-independent for broad reusability, while parameter modules are localized and address-dependent for device-specific correctness. This differentiation enables automatic loading and reusability without requiring complex creation processes for each individual module.
Data Source
AI summary
The present invention relates to a method for safely providing safety functions for safety devices (10, 11, 12, 20, 21, 30, 31, 32) of an automation system. For this purpose, modular safety components are introduced, comprising a logic module (A, B,..., X), an address-dependent parameter module (1, 2, ..., n), and failsafe information. The modules are stored separately with recovery information. After turning on a safety device in an automation system, a safety component created for a specific device can be restored and transmitted to the safety device, wherein the accuracy of the safety component is checked in the safety device.