Safety Network Wiring Reduction via Dual Data Bus Architecture
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Solution Overview
Problem
Existing safety networks for industrial machines require complex and costly wiring due to the need for separate data lines for each safety sensor, increasing circuitry and wiring complexity, which complicates the transmission of safety-relevant data.
Innovation Solution
A safety network design utilizing two data buses, one for safety-related data and another for non-safety-related data, with a third bus ensuring fail-safe transmission, compliant with the IO-Link Safety Standard, reduces wiring complexity while maintaining high safety standards by using a single transmission path and redundant data verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate data lines are used for each safety sensor to ensure reliable data transmission, then data transmission reliability is improved, but wiring complexity and circuitry increase significantly
Solution Approach 1:
Multiple safety sensors are connected to a single evaluation unit through one shared data bus instead of requiring separate data lines for each sensor. The data bus time-division multiplexes data from multiple sensors, reducing wiring complexity while maintaining reliable data transmission through protocol-level error checking and acknowledgment mechanisms.
Solution Approach 2:
The data bus serves as a universal communication medium that can carry data from multiple different safety sensors to the evaluation unit. A single data bus infrastructure replaces multiple dedicated data lines, providing multi-functional capability while simplifying the overall system wiring.
2Reliability
If redundant data processing units are implemented to ensure dual safety, then safety reliability is improved, but device complexity and cost increase
Solution Approach 1:
The evaluation unit implements feedback mechanisms where data from multiple safety sensors is continuously monitored and verified. The system uses acknowledgment signals and error checking protocols to ensure data integrity, providing redundant verification through software and protocol layers rather than requiring duplicate hardware processing units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design minimizes circuitry and wiring complexity while ensuring fail-safe communication of safety-relevant data, maintaining high safety standards without the need for redundant transmission paths or duplicate circuit configurations.
Implementation Method 1
it is activated and energized by an alternating electromagnetic field emitted by the RFID reader
Data Source
Figure 1~2
AI summary
A safety network with multiple safety sensors is depicted and described. These sensors are interconnected via a first and a second data bus. The first data bus is configured for transmitting non-safety-related data, while the second data bus is configured for transmitting safety-related data. Furthermore, at least one of the safety sensors has an interface to and is connected to a third data bus. This third data bus is configured to ensure fail-safe data transmission from the safety sensor to a control unit.