Safety Controller Parallelization for Mixed-Response Safety Functions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing safety-related engineering systems face challenges in efficiently processing multiple tasks with varying response times and reaction times due to limitations in parallelization and multitasking, leading to increased complexity, maintenance costs, and potential errors in task distribution.
Innovation Solution
A method for operating a safety controller that groups safety functions into classes based on pre-defined classification features, using a single compiler to generate separate executable codes for each processor, allowing efficient parallel execution without redundant processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If multiple parallel safety control units are installed to handle tasks with different response times, then the response time for critical safety functions is improved, but the system complexity and maintenance costs increase
Solution Approach 1:
The patent divides the safety controller into multiple independent tasks that can be executed in parallel on a single processor. Each task handles specific safety functions with different response time requirements, allowing critical functions to be processed faster without requiring multiple physical control units. This segmentation resolves the contradiction by achieving parallel processing capability while maintaining a single unified system architecture.
2Speed
If safety functions are distributed across multiple separate safety controllers, then the response time for specific safety functions is improved, but the ease of operation and task distribution flexibility deteriorate
Solution Approach 1:
The patent creates a universal safety controller architecture where a single controller can execute multiple different tasks in parallel, each optimized for specific response times. The controller universally handles various safety functions through a task management system that dynamically assigns and schedules tasks, eliminating the need for multiple specialized controllers while maintaining operational flexibility and ease of task distribution.
3Device complexity
If all safety functions are implemented in a single task with pre-described chronological order, then the device complexity is reduced, but the productivity and response time for critical functions deteriorate
Solution Approach 1:
The patent transforms the static single-task chronological execution model into a dynamic multi-task parallel execution model. Tasks can be dynamically created, scheduled, and executed in parallel based on real-time requirements, allowing critical safety functions to be processed concurrently with non-critical functions. This dynamic approach maintains relatively simple device structure while dramatically improving processing efficiency and response times.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In order to provide an efficient method for operating a safety controller (3) for a safety related engineering system (1), a set of safety functions (SF1, SF2) defining logical dependencies between sensor signals (32S) and actuator signals (33S) is provided and grouped into a first and a second class (C1, C2) of safety functions (SF1, SF2), the first class (C1) of safety functions (SF1) is compiled and linked to obtain a first executable program code, the second class (C2) of safety functions (SF2) is compiled and linked to obtain a second executable program code, the first and second executable program code are transferred to a memory (ROM) of the safety controller (3), the first executable program code is executed by a first processor (31a) and the second executable program code is executed by a second processor (31b) of the safety controller (3), generating actuator signals (33S) from sensor signals (32S).