Safety Electrical Controller Software Protocol Switching
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Solution Overview
Problem
Existing electrical controllers require hardware adjustments to change safety communication paths, limiting flexibility and efficiency in data transfer between different safety communication protocols.
Innovation Solution
An electrical controller with multiple interfaces and a control unit that switches between safety-oriented operating modes using software settings, allowing for flexible data transfer via different protocols like FSoE and PROFIsafe without hardware changes, and includes a storage medium for parameter sets and CRC codes to validate safety parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hardware adjustments are made to change safety communication paths in existing electrical controllers, then the safety communication protocol can be changed, but the flexibility and efficiency of data transfer is limited due to required hardware modifications
Solution Approach 1:
The patent replaces the mechanical/hardware-based communication interface with a software-based communication module. The controller uses a programmable communication module that can be configured via software to support different safety communication protocols (FSoE, PROFIsafe) without any physical hardware changes. This substitution of hardware with software enables flexible switching between communication paths and protocols.
Solution Approach 2:
The communication module is designed with multi-functionality to handle multiple safety communication protocols through software configuration. A single hardware interface can be programmed to support FSoE, PROFIsafe, or other protocols, making the controller adaptable to different communication requirements without adding or modifying hardware components.
2Adaptability or versatility
If multiple safety communication protocols are supported through hardware adjustments, then protocol versatility is improved, but the device complexity and cost increase
Solution Approach 1:
The communication module employs dynamic reconfiguration through software, allowing the controller to adapt its communication protocol in real-time based on operational requirements. The system can switch between different safety protocols (FSoE, PROFIsafe) and communication paths (controller-based, drive-based) dynamically without hardware changes, enhancing versatility while maintaining simplicity.
Solution Approach 2:
The patent utilizes parameter changes in the software configuration of the communication module to switch between different safety communication protocols. By modifying software parameters and communication settings rather than hardware characteristics, the system achieves protocol versatility without increasing hardware complexity or cost.
3Reliability
If a single interface is used for safety data transfer, then device simplicity is maintained, but the reliability and error processing capability is reduced
Solution Approach 1:
The patent introduces a safety communication module as an intermediary layer between the controller and external safety systems. This module provides standardized interfaces with built-in error processing and validation mechanisms, ensuring reliable safety data transfer. The intermediary handles protocol-specific error checking, CRC validation, and fault management, improving reliability without requiring complex interface configurations from the user.
Solution Approach 2:
The communication module implements feedback mechanisms for error detection and handling in safety data transfer. Through CRC checks, acknowledgment signals, and error logging, the system continuously monitors communication integrity and can trigger appropriate error processing routines, enhancing reliability while maintaining interface simplicity.
Data Source
AI summary
An electrical controller includes a first interface via which data are able to be transferred, a second interface, separate from the first interface, via which data are able to be transferred, a control unit, and an operating mode memory for storing operating mode information. The control unit is configured to operate the controller in a first safety-oriented operating mode or in a second safety-oriented operating mode depending on the stored operating mode information.