Safety Controller Rapid Backup via Removable Memory Module
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Solution Overview
Problem
Conventional methods for configuring and backing up industrial safety controllers are time-consuming and require connecting each controller to a programming device, making it difficult to track the distribution of safety control programs and limiting scalability and space in industrial settings.
Innovation Solution
A safety controller with non-volatile memory and removable slots that allow for configuration backup and loading using a memory module, eliminating the need for network connections and enabling rapid distribution without affecting safety operations, and allowing for the use of the same slot for other expansion modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to configure and backup safety controllers by connecting each controller to a programming device, then configuration can be performed, but the process is time-consuming and reduces productivity
Solution Approach 1:
The patent uses a memory card to create and distribute copies of the safety control program to multiple controllers simultaneously. Instead of connecting each controller individually to a programming device, the program is written once to a memory card and then rapidly distributed to numerous controllers, dramatically improving productivity and reducing configuration time
Solution Approach 2:
The memory card serves as an intermediary device between the programming device and multiple controllers. It acts as a temporary storage medium that receives the program once and then distributes it to multiple controllers through simple card insertion, eliminating the need for repeated connections to each controller
2Productivity
If a memory card is permanently slotted in an industrial controller, then configuration backup is enabled, but available space and expandability are reduced
Solution Approach 1:
The patent implements a dynamic slot system where the same physical slot can serve different functions at different times. The slot can host a memory card for configuration backup operations or be replaced with functional expansion modules during normal operation, providing adaptability and versatility while maintaining backup capability when needed
3Adaptability or versatility
If multiple functional modules are permanently installed in controller slots, then expandability is achieved, but the ability to perform rapid configuration backup is limited
Solution Approach 1:
The slot system is designed to be dynamic, allowing the same physical slot to be used for different purposes. When rapid configuration or backup is needed, a memory card can be inserted into the slot. During normal operational phases, functional expansion modules can occupy the same slot. This dynamic reuse of the slot provides both expandability and rapid configuration capability without requiring separate dedicated slots
Data Source
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AI summary
A safety controller and system of safety controllers and a removable memory module for rapid configuration and/or backup of safety controllers are provided. The safety controller comprises a non-volatile memory and one or more slots configured to host modules. A predetermined slot of the one or more slots is configured to communicatively couple the safety controller with a memory module. The safety controller is configured to transfer a backup of a configuration on the safety controller to a memory module hosted in the predetermined slot and configured to load a configuration from a memory module hosted in the predetermined slot. A method of distributing software to a plurality of industrial safety controller comprises utilizing a memory module.