Safety Trip Configuration for Flexible I/O and Secure Setup
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Solution Overview
Problem
Current safety trip devices for process control systems face challenges in flexibility, complexity, and cybersecurity, with sophisticated devices being expensive and prone to errors, while simple devices lack redundancy and adaptability to different applications.
Innovation Solution
The development of safety trip devices with pre-programmed instructions for various safety applications, allowing users to select and configure settings easily, with built-in redundancy and enhanced cybersecurity features, including the ability to handle different types and numbers of I/O signals without extensive programming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sophisticated safety logic solvers are used to handle variable I/O points, then adaptability and functionality are improved, but device complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-programming multiple safety applications into the trip device before deployment. The configuration controller stores several different safety applications in memory, each with pre-defined logic and parameters. When deployed, the user simply selects from these pre-configured applications rather than programming from scratch, thus achieving high adaptability without requiring complex programming capabilities in the device itself.
2Device complexity
If simple trip amplifiers are used for basic safety functions, then device complexity is reduced, but adaptability and redundancy are limited
Solution Approach 1:
The patent implements universality by designing a trip device that can perform multiple safety applications through pre-programmed instructions stored in memory. The configuration controller can select from and execute different safety applications (e.g., vote logic, timing functions, mathematical operations) based on the specific application requirements. This allows a single device to replace multiple specialized devices, achieving versatility without proportionally increasing complexity.
3Adaptability or versatility
If fully configurable programmable safety solvers are used, then functionality is improved, but human error in programming and configuration increases
Solution Approach 1:
The patent reduces human error by performing the complex programming work in advance during manufacturing. Multiple safety applications are pre-programmed with correct logic, parameters, and interconnections. During deployment, the user only needs to select the appropriate pre-configured application and make minimal adjustments, eliminating the need for users to write complex safety logic and significantly reducing configuration errors.
4Reliability
If sophisticated safety logic solvers are used, then safety coverage is improved, but cybersecurity vulnerabilities increase
Solution Approach 1:
The patent extracts and separates the complex programming functionality from the runtime execution environment. The sophisticated safety logic is pre-programmed into fixed applications during manufacturing, and the configuration controller can only select from these predetermined options during operation. This extraction eliminates the need for users to access or modify the core safety logic through programming interfaces, thereby reducing cybersecurity attack surfaces while maintaining comprehensive safety coverage.
Data Source
AI summary
Methods and apparatus to implement safety applications associated with process control systems are disclosed. An apparatus includes a configuration controller to: provide a plurality of available safety applications for implementation by a safety trip device to a user for selection, a first one of the safety applications associated with a first set of I/O signals, a second one of the safety applications associated with a second set of I/O signals, the first safety application implemented based on first pre-programmed instructions stored in memory of the safety trip device, the second safety application implemented based on second pre-programmed instructions stored in the memory; and, in response to a user selection of the first safety application, prompt the user to specify values for configuration settings associated with the first safety application. The apparatus also includes an I/O analyzer to implement the first safety application.