Power Module Safety Shutdown for Lost Controller Communication
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Solution Overview
Problem
Industrial automation devices, such as medium voltage drives, require complex and expensive circuit board designs for functional safety mechanisms like the Black Channel to comply with standards like IEC 61508, and the development of sophisticated safety messages is extensive, necessitating a simpler and cost-effective solution.
Innovation Solution
A functional safety mechanism that disables communication between the controller and power modules by disabling transmitters and driver circuitry, using multiple commands to prevent power from being provided to the motor, and includes diagnostic tests to verify the integrity of circuitry without disrupting operation, employing communication monitoring circuitry and periodic diagnostic tests to ensure safe states are maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a Black Channel functional safety mechanism is implemented using multiple intelligent devices like FPGAs, then functional safety compliance is achieved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the functional safety mechanism from the complex Black Channel communication protocol and implements it through a dedicated functional safety controller that separately manages safety functions. This separates the safety-critical operations from the complex communication infrastructure, reducing overall system complexity while maintaining safety compliance.
Solution Approach 2:
The functional safety controller is designed to perform multiple safety functions including monitoring communication integrity, detecting faults, and controlling safe states through a single integrated component rather than requiring multiple specialized intelligent devices. This multi-functional approach reduces device count and circuit board complexity.
2Reliability
If sophisticated safety messages are developed to meet functional safety standards, then safety compliance is achieved, but development time and effort increase extensively
Solution Approach 1:
The functional safety controller incorporates pre-configured safety monitoring logic and fault detection algorithms that are prepared in advance. The controller is designed with built-in capabilities to automatically generate and process safety-related communications, eliminating the need for extensive custom development of safety messages and reducing development time.
Solution Approach 2:
The functional safety controller autonomously monitors communication integrity and detects faults without requiring extensive external configuration or custom safety message development. The system self-manages safety functions through integrated monitoring and control capabilities, significantly reducing development effort.
Data Source
AI summary
A method may include receiving, by respective processing circuitry of one or more power modules of an industrial automation device, a control signal from a controller of the industrial automation device. The power modules may include driver circuitry and a power converter that may provide power to a motor based on the signal. The method may also include, detecting, by the respective processing circuitry, a lack of communication from the controller based on the signal, and, in response to detecting the lack of communication from the controller, transmitting, by the respective processing circuitry, a first command to gating signal enable circuitry to disable the driver circuitry, and transmitting, by the respective processing circuitry, a second command to driver power circuitry to prevent power from being provided to the driver circuitry.