Modular Safety Switching System Parallel Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional modular safety switching systems are limited in handling complex scenarios, requiring high technical complexity, costly microcontrollers, and extended response times, making them unsuitable for time-critical applications and difficult to expand.
Innovation Solution
An expandable modular safety switching system with output modules controlling actuators, allowing for flexible logic evaluations and parallel processing, enabling the addition of units without extra cost, and using a central control unit to distribute evaluations for efficient response times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modules are connected to a control module with an association table and data bus, then logic links for deciding actuator switching can be implemented, but the running time for data communications increases and response time deteriorates
Solution Approach 1:
The patent divides the control functionality into distributed output module control units, each capable of independent logic evaluation. This segmentation eliminates the single-point bottleneck of a central control module, allowing parallel processing of multiple sensor inputs and actuator decisions simultaneously, thereby reducing overall response time while maintaining complex logic capabilities.
Solution Approach 2:
The patent introduces a hierarchical control architecture where output module control units operate at a lower level (local dimension) for time-critical decisions, while a central control unit operates at a higher level (system dimension) for overall coordination. This multi-dimensional approach allows simultaneous local responsiveness and global system management.
2Loss of time
If powerful microcontrollers are used to solve time critical applications, then response time can be improved, but system cost and technical complexity increase
Solution Approach 1:
Instead of using a single powerful microcontroller, the patent segments the control functionality across multiple simpler output module control units. Each unit handles specific local control tasks with minimal processing requirements, eliminating the need for expensive high-performance processors while achieving comparable or better response times through parallel operation.
Solution Approach 2:
Each output module control unit is designed to be self-sufficient, containing its own processor, memory, and logic evaluation capabilities. This self-service architecture allows each module to independently make control decisions without requiring complex inter-module communication or centralized processing, simplifying the overall system design.
3Adaptability or versatility
If additional output modules are added to the series, then system capacity increases, but the solution becomes impossible or requires additional expense
Solution Approach 1:
The patent employs a modular architecture where each output module is an independent, self-contained unit with identical interface standards. This segmentation allows systems to be expanded by simply adding more modules to the series without requiring changes to existing modules or infrastructure, enabling cost-effective scalability.
Solution Approach 2:
Each output module control unit is designed with universal functionality to handle multiple sensor types and actuator configurations. This universality means that the same module design can be used throughout the system regardless of specific application requirements, simplifying expansion and reducing the need for specialized components.
4Loss of information
If gateway is used to communicate status information externally, then monitoring capability is improved, but the gateway accesses process mapping information of a control module which fails when capacity is insufficient
Solution Approach 1:
The patent extracts the communication and information management functions from the control module and places them in dedicated gateway units. Each output module control unit directly communicates with the gateway, eliminating the need for the control module to handle communication overhead and process mapping, thereby freeing up its capacity for time-critical control operations.
Solution Approach 2:
The gateway acts as an intermediary between the distributed output module control units and external monitoring systems. It collects status information directly from the output modules without requiring the central control module to process or format the data, reducing the computational burden on the control module while maintaining comprehensive system monitoring.
Data Source
AI summary
A modular safety switching system (10) with at least one output module (14) and a central control unit (28), which is connected to all output modules (14) via a bus (22). The output module (14) receives input data of at least one sensor (16) or switch (16a) and has at least one output (14b) for an actuator. The central control unit (28) is designed to receive at least a portion of the input data which is evaluated for the transferring of the output data to the output (14b). The output module (14) has its own, dedicated output module control unit (20), which evaluates the input data in collaboration with the central control unit for the purpose of transferring the output data to the output (14b). A suitable method is also disclosed.