Safety Module Integrating Secure I/O and Control Logic
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Solution Overview
Problem
Existing automation systems lack a standard interface for secure and non-secure input/output modules, making it difficult to separate safety critical functions from non-safety critical functions and requiring additional hardware and development expenditure for integration in modular control systems.
Innovation Solution
A safety module with a communication board connected to a central processing unit via an input/output bus, featuring secure processing units on circuit boards with safety-oriented input/output circuits, a serial communication master, and internal communication links for synchronized and secure message transmission, allowing for the separation of safety critical and non-safety critical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate safety oriented controllers and safe input/output modules are used, then safety critical functions are controlled reliably, but device complexity and development expenditure increase
Solution Approach 1:
The patent combines the safety oriented controller and safe input/output modules into a single integrated safety module. The controller unit with processing means and the input/output unit with field device access modules are merged into one device, reducing system complexity while maintaining safety functionality through internal separation of safety-critical and non-safety-critical components.
Solution Approach 2:
The safety module is designed to perform multiple functions: it can control safety-critical processes, handle non-safety-critical I/O operations, and provide monitoring functions all within a single device. The field device access modules can operate in both safety-oriented and standard modes, increasing versatility.
2Ease of manufacture
If standard modules for detecting process data are used, then ease of manufacture is improved, but the ability to separate safety critical functions from non-safety critical functions is reduced
Solution Approach 1:
The safety module internally segments functionality into distinct units: a controller unit for safety-critical control and an input/output unit for data acquisition. The field device access modules are further segmented into safety-oriented access modules and standard access modules, allowing clear functional separation while maintaining a unified manufacturable structure.
Solution Approach 2:
Different parts of the module have different functional qualities: the controller unit is designed with safety-critical processing capabilities, while the input/output unit handles standard process data. The field device access modules can be configured with appropriate safety levels based on their specific application requirements.
3Reliability
If existing safe input/output modules are integrated into modular control systems, then safety functions are achieved, but additional hardware and development expenditure are required
Solution Approach 1:
The patent merges the safety-oriented controller and safe input/output modules into a single integrated safety module that can be directly inserted into modular control system racks. This eliminates the need for additional separate hardware components and reduces integration complexity while maintaining safety functionality.
Solution Approach 2:
The safety module is designed as a universal component that can function both as a safety controller and as an input/output module within modular control systems. It interfaces with field devices through standard protocols while providing safety-critical monitoring and control, making it compatible with existing modular system architectures.
Data Source
AI summary
Exemplary embodiments are directed to a safety module for connection to an automation device or automation system which is provided for control of safety critical and non-safety critical processes and/or plant components. The module includes a communication board that includes a processing unit which is connected via an input/output bus slave and an external input/output bus connected to a central processing unit, and one or more secure processing units arranged on one or more circuit boards having safety oriented input/output circuits for safety oriented functions. A serial communication master is connected via communication links to at least one of the circuit boards so that the at least one circuit board receives messages sent by the communication board, transmits safety oriented messages from and/or to the processing unit of the communication board via one of the secure processing units.