Integrated Safety Control Module With One-Way Sensor Sharing
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Solution Overview
Problem
Existing machinery control systems require redundant sensing and signal conditioning, leading to increased complexity and cost, and modifying safety systems for integration is time-consuming and expensive due to third-party certification requirements.
Innovation Solution
A system that integrates a safety-certified sensor and signal conditioner with a control system using a one-way communication pathway, allowing the control system to utilize the safety system's sensors and signal conditioning circuits, thereby reducing redundancy and system complexity while maintaining safety compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant sensing and signal conditioning systems are implemented in machinery control, then safety reliability is improved, but system complexity and cost increase
Solution Approach 1:
The patent merges the safety system and control system into a single integrated module. The safety circuit and primary control module share common sensors, signal conditioning circuits, and processing resources within the same physical housing. This consolidation eliminates redundant sensing and signal conditioning components while maintaining independent safety functionality through separate processing paths for safety-critical signals.
2Device complexity
If safety systems are modified for integration with control systems, then system complexity is reduced, but certification time and cost increase
Solution Approach 1:
The integrated module employs functional segmentation where the safety circuit and primary control module are distinct functional units within the same physical housing. Each module has dedicated processing paths and can be independently certified to IEC 61508 safety standards. This segmentation allows the safety-critical functions to be validated separately while sharing common infrastructure, reducing overall certification complexity and time.
3Reliability
If independent safety monitoring system is used, then safety response reliability is improved, but system cost and complexity increase
Solution Approach 1:
The patent introduces an intermediary architecture where a boundary processor facilitates controlled communication between the safety circuit and primary control module. The communications bus provides a standardized interface that allows the control module to access sensor data and actuator commands while the safety circuit maintains independent monitoring capabilities. This intermediary structure enables resource sharing without compromising safety independence.
Data Source
AI summary
The present disclosure involves systems, software, and computer implemented methods for controlling machinery. The system can include a chassis, a backplane with a communications bus installed within the chassis and configured to provide electrical power to a plurality of modules, a safety circuit installed on the backplane, and a primary control module installed on the backplane. The safety circuit can be configured to monitor one or more sensed parameters of a machine and determine whether to actuate a safety mechanism, the safety circuit does not receive signals from the communications bus of the backplane. The primary control module can be configured to receive one or more sensed parameters of a machine and generate a command signal to send to an actuator of the machine, the one or more sensed parameters can be received via the communications bus, from one or more additional modules of the plurality of modules.