Wireless Process Control Safety Architecture for Edge and Cloud
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Solution Overview
Problem
The need for ensuring functional safety in process control systems that have been moved to the edge or cloud environments via wireless networks, which introduces higher uncertainties due to their open and shared nature.
Innovation Solution
Incorporating safety field devices such as safety sensors and actuators into the automation function environment and control signal path environment, with a safety control function that monitors and responds to safety data to maintain safety integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If process control is moved to edge or cloud environments via wireless networks, then deployment flexibility and capital expenditure are improved, but functional safety and system reliability deteriorate due to higher uncertainties in open and shared environments
Solution Approach 1:
The system separates process control functions into distinct virtualized environments (edge/cloud) while maintaining a dedicated safety control architecture. The safety control function operates independently from the process control function, allowing flexible deployment of control while preserving safety through segregation of critical safety operations.
Solution Approach 2:
A safety control function acts as an intermediary between the process control function and safety field devices. This intermediary monitors the safety status of the automation function environment and wireless control signal path, and only permits control actions when safety conditions are satisfied, thereby bridging the flexibility of cloud/edge control with the reliability requirements of safety-critical operations.
2Ease of manufacture
If process control is moved to edge or cloud environments via wireless networks, then capital expenditure is reduced, but safety control complexity increases due to need for continuous safety monitoring in distributed environments
Solution Approach 1:
The safety control function is designed as a universal component that can operate in various deployment scenarios (cloud, edge, or hybrid) with wireless networks. It provides multi-functional capabilities including environment safety monitoring, control signal path monitoring, and coordinated safety actuation, thereby managing complexity through a standardized universal safety architecture rather than multiple specialized systems.
3Reliability
If safety control function monitors automation function environment and control signal path environment, then functional safety is improved, but system resource consumption increases
Solution Approach 1:
The safety control function implements partial monitoring by focusing only on critical safety-relevant parameters in the automation function environment and control signal path environment, rather than comprehensive monitoring of all system aspects. This selective monitoring approach maintains functional safety while minimizing unnecessary resource consumption from excessive monitoring activities.
Data Source
AI summary
A process control system includes an automation device, an automation function environment including a process control function, a hardware assigning unit and hardware for functions of the automation function environment, the process control function controlling the automation device using control signals in a control signal path through a wireless network and employing hardware in the automation function environment assigned by the hardware assigning unit. At least one safety actuator and at least one safety sensor are placed together in the automation function environment and/or a control signal path environment and a primary hardware entity implementing a safety control function obtains safety data from the safety sensor about the safety of the corresponding environment, determines the safety of the corresponding environment based on the safety data and performs a safety activity using the safety actuator if safety is insufficient.