Safety Control Data Relay Logging Without Program Interference
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Solution Overview
Problem
Existing control systems face challenges in implementing data logging processes for safety control devices without interfering with the execution of safety programs, especially in environments with resource constraints and the need to maintain safety standards.
Innovation Solution
A control system comprising a standard control unit and a safety control unit, where the standard control unit executes data logging processes without involving the safety control unit, using a data transfer relay unit, storage unit, and monitoring processing unit to determine trigger conditions and output data, allowing for data logging without disrupting safety program execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If a data logging process is implemented in a safety control device, then the ability to analyze abnormal events is improved, but the execution of the safety program may be influenced or disrupted
Solution Approach 1:
The control system is divided into two independent control units: a safety control unit that executes the safety program and a standard control unit that performs data logging. This segmentation allows the data logging process to be separated from the safety control function, enabling status recording without influencing the execution of the safety program.
Solution Approach 2:
A data transfer relay unit acts as an intermediary between the safety control unit and the standard control unit. The safety control unit sends status data to the standard control unit through this relay mechanism, allowing the safety control unit to offload data logging tasks while maintaining its primary safety function without direct involvement in the logging process.
2Loss of information
If a data logging process is implemented in each control unit, then comprehensive status recording is achieved, but resource constraints prevent implementation in resource-constrained environments
Solution Approach 1:
The data logging function is merged into the standard control unit, which has sufficient resources to handle the logging process. The safety control unit, which may be resource-constrained, focuses solely on executing the safety program. This combination allows comprehensive status recording to be achieved without requiring each control unit to have full logging capabilities.
Solution Approach 2:
The standard control unit serves multiple functions: it controls the control target according to a standard control program and simultaneously performs data logging for the safety control unit. This multi-functionality allows the system to achieve comprehensive status recording while avoiding the need for additional dedicated logging hardware in resource-constrained environments.
Data Source
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AI summary
A first control unit (100) includes a data transfer relay unit (20; 120) that executes a process of transferring input data corresponding to a signal input to an input and output unit (10, 250) to a second control unit (200) according to a request from the second control unit (200), and/or a process of transferring output data that defines a signal to be output from the input and output unit (10, 250) from the second control unit (200) to the input and output unit, a storage unit (124) that holds the data transferred by the data transfer relay unit (20; 120), and a monitoring processing unit (160) that determines whether or not a predetermined trigger condition (1622) has been satisfied on the basis of the data held in the storage unit (124), and outputs a value of any data held in the storage unit (124) according to a predetermined output configuration (1624) when it is determined that the trigger condition (1622) has been satisfied.