Programmable Controller Integrating Safety and Application Processors

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Solution Overview

Problem

Existing programmable controllers for equipment like combustion systems often require separate safety and application functions, which can lead to limitations in user flexibility for application-specific programming without compromising safety protocols.

Innovation Solution

A programmable controller design that separates safety and application processing, allowing users to program application-specific functions without overriding safety functions, using a safety processor for pre-defined safety operations and an application processor for user-programmable functions, connected via a communication link to prevent interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a separate application controller is used for application-specific programming, then user flexibility for programming is improved, but device complexity increases

Engineering Contradiction:

Improveuser flexibility for programmingVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the safety controller and application controller into a single integrated controller unit. The safety processor and application processor are merged into one device, allowing both safety functions and application-specific programming to coexist in a single controller, thereby reducing overall system complexity while maintaining user flexibility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated controller is designed to perform multiple functions simultaneously - it acts as both a safety controller with pre-programmed safety protocols and an application controller with user-programmable functions. This multi-functional design eliminates the need for separate controllers while providing both safety assurance and programming flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If application-specific functions are freely programmable, then user flexibility is improved, but safety may be compromised due to potential overriding of safety functions

Engineering Contradiction:

Improveuser flexibilityVSAvoidsafety assurance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The controller is segmented into distinct functional modules: a safety processor dedicated to safety functions and an application processor for user-programmable functions. This segmentation ensures that application programming cannot interfere with or override safety functions, as each processor operates independently within its designated functional boundaries.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a communication link as an intermediary between the safety processor and application processor. This controlled communication interface allows the application processor to access certain safety-related data or status information when needed, while preventing the application code from directly modifying or overriding safety logic, thus maintaining safety assurance.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If safety and application functions are integrated in one controller, then device complexity is reduced, but programming flexibility may be limited due to safety constraints

Engineering Contradiction:

Improvedevice complexityVSAvoidprogramming flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The integrated controller employs dynamic function allocation where the application processor can be freely programmed for various application-specific tasks, while the safety processor dynamically monitors and manages safety functions. The system adaptively coordinates between the two processors, allowing full programming flexibility for application functions without being constrained by safety limitations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The communication link between the safety processor and application processor implements a feedback mechanism where the safety processor can monitor application program execution and provide feedback to ensure safety constraints are met. This allows the application processor to operate with full programming flexibility while the safety processor maintains oversight to prevent unsafe conditions.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS9678483B2Programmable controller with both safety and application functions

Publication Date: 2017.06.13 HONEYWELL INTERNATIONAL INC

AI summary

A controller that controls both safety and application functions of connected equipment is disclosed. The controller allows a user to freely program application specific functions while preventing the application functions from affecting the safety functions of the controller. This may give the user more flexibility and leeway when programming the application specific programming functions, without having to worry about affecting the safe operation of the connected equipment.