Integrated Safety Communication Module for Fieldbus Networks
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Solution Overview
Problem
Existing fieldbus systems face challenges in implementing functional safety without increasing system complexity or the number of network nodes, particularly for companies needing to integrate safety features into their industrial automation devices.
Innovation Solution
A communication system assembly comprising a communication module and a safety module, where the communication module connects to both the network and host system, separating safety data from process data and allowing the safety module to receive information directly, reducing the need for complex host systems and additional network nodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a black channel safety layer is implemented using PROFIsafe technology, then functional safety for SIL 3 continuous high-demand mode is achieved, but the number of network nodes increases and system complexity increases
Solution Approach 1:
The patent combines the safety module and communication module into a single integrated unit. The safety module receives process data directly from the fieldbus network through the communication module without requiring separate network nodes, thereby merging previously separate components (safety layer, communication layer, and network interface) into one unified device that achieves functional safety without increasing system complexity
Solution Approach 2:
The integrated safety and communication module performs multiple functions simultaneously: it communicates with the fieldbus network, processes control data, implements the black channel safety concept, and provides safety monitoring all within a single module. This multi-functional design eliminates the need for separate safety modules and reduces the overall number of network nodes
2Reliability
If separate PROFIsafe modules are introduced to provide functional safety, then safety requirements are met, but the number of network nodes increases
Solution Approach 1:
The patent merges the safety module with the communication module, allowing the safety function to be provided within the existing communication infrastructure. The safety module receives data directly from the fieldbus network through the communication module, eliminating the need for separate safety module instances on the network and thereby reducing the total number of network nodes
3Reliability
If new safety-aware controllers are provided to implement functional safety, then safety requirements are met, but substantial investment is required
Solution Approach 1:
The integrated module provides both standard communication functionality and safety functionality within a single device, allowing existing controllers to be used without requiring expensive safety-aware controller replacements. The module can operate in different modes (standard communication vs. safety mode) depending on configuration, providing cost-effective functional safety implementation
Solution Approach 2:
The module can switch between different operational modes by changing its configuration parameters. When operating in safety mode, it implements the black channel concept and receives safety-relevant data directly from the fieldbus network. This parameter-based flexibility allows the same hardware to serve both standard communication needs and safety requirements, avoiding the need for separate expensive safety controllers
Data Source
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AI summary
This invention relates to a communication system assembly comprising a communication module and a safety module, wherein the communication module is adapted to be connected to a network and to a host system, wherein the communication module is adapted to receive data from the network and provide a subset of said data as safety data to said safety module and provide a different subset of said data as process data to the host system.