Modular Safety PLC Layout With Fixed Safety Functions
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Solution Overview
Problem
Existing modular control systems require separate devices for safety controllers and programmable logic controllers, leading to increased space, installation complexity, and the need for numerous relay contacts.
Innovation Solution
A modular control apparatus with a central control module and two groups of electronic modules, where the first group provides fixed safety functions and the second group offers programmable standard functions, allowing for a single device to combine safety and programmable logic controller capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate devices are used for safety controllers and programmable logic controllers, then safety functions and standard functions can be provided independently, but space requirements increase and installation complexity increases
Solution Approach 1:
The patent combines safety controller functions and programmable logic controller functions into a single modular control device. The first group of electronic modules provides safety functions while the second group provides standard programmable functions, both integrated within the same device architecture, thereby reducing space requirements while maintaining functional independence
Solution Approach 2:
The control device is designed with multi-functionality to serve both safety-critical operations and standard programmable logic control tasks. The device can perform multiple roles simultaneously through its modular architecture, eliminating the need for separate dedicated devices for each function type
2Reliability
If separate devices are used for safety controllers and programmable logic controllers, then safety functions and standard functions can be provided independently, but installation and wiring complexity increases
Solution Approach 1:
By merging safety controller and PLC functions into one device, the patent reduces the number of separate installations required. The integrated architecture allows for unified wiring and configuration processes, thereby reducing installation and wiring complexity while maintaining independent safety function delivery
3Reliability
If separate devices are used for safety controllers and programmable logic controllers, then safety functions and standard functions can be provided independently, but the number of relay contacts increases
Solution Approach 1:
The integration of safety controller and PLC functions into a single device allows for shared relay contact resources. The modular architecture enables both safety functions and standard programmable functions to utilize the same physical relay contacts, thereby reducing the total quantity of relay contacts required compared to separate devices
4Adaptability or versatility
If safety functions are made software-modifiable, then flexibility and programmability increase, but safety and reliability may be compromised
Solution Approach 1:
The patent segments the control device into distinct functional groups: the first group of electronic modules provides safety functions with fixed, non-modifiable settings, while the second group provides programmable standard functions. This segmentation allows safety-critical operations to remain protected from software modifications while enabling flexibility in non-safety functions
5Area of stationary object
If a single device combines safety and programmable functions, then space and cost advantages are achieved, but functional separation and safety assurance become more difficult
Solution Approach 1:
The patent divides the integrated device into clearly separated functional modules: safety function modules with fixed settings and programmable function modules. This internal segmentation maintains functional separation and safety assurance while achieving external integration benefits of reduced space and cost
Solution Approach 2:
Different parts of the device have different qualities: the safety function group has fixed, non-modifiable characteristics for reliability, while the programmable function group has flexible, user-configurable characteristics. This local differentiation of properties allows both safety assurance and functional integration within a single device
Data Source
AI summary
A modular control apparatus comprises a central control module with a first logic unit and a second logic unit, first electronic modules connected to the first logic unit and having safety inputs and safety outputs, wherein the first electronic modules are designed to provide safety functions of a safety controller, and second electronic modules connected to the second logic unit and having inputs and outputs, wherein the second electronic modules are designed to provide standard functions of a programmable logic controller. The central control module and the first and second electronic modules are arranged in a row of modules. The safety functions of the first electronic modules are defined by positions of the first electronic modules in the row of modules and/or by fixed hardware settings, and the standard functions of the second electronic modules are programmable.