CONTROL SYSTEM FOR CONTROLLING SAFETY-CRITICAL AND NON-SAFETY-CRITICAL PROCESSES

• US 20200133243A1
• Filed: 10/24/2019
• Published: 04/30/2020
• Est. Priority Date: 10/25/2018
• Status: Active Grant

• Current Assignee: ABB Schweiz AG (ABB Limited)
• Original Assignee: ABB Schweiz AG (ABB Limited)
• Inventors: Scheible, Guntram, Veryha, Yauheni
• Granted Patent: US 11,662,714 B2
• Time in Patent Office: Days
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence
• CPC Class Codes: G05B 19/4184 characterised by fault tolerance, reliability of production system
• CPC Class Codes: G05B 2219/24008 Safety integrity level, safety integrated systems SIL SIS
• CPC Class Codes: G05B 2219/33156 Communication between two processors over shared, dualport ram
• CPC Class Codes: G05B 2219/50193 Safety in general
• CPC Class Codes: G05B 9/02 electric

Abstract

A control system configured to control safety-critical and non-safety-critical processes and/or plant components includes: a non-safety controller module, at least one safety controller module, and at least one condition monitoring module. The non-safety controller module is configured to control the non-safety-critical processes and/or the non-safety-critical plant components. The at least one safety controller module is configured to control the safety-critical processes and/or the safety-critical plant components. The at least one condition monitoring module is configured to perform fail-safe condition monitoring and to collect monitoring data. The non-safety controller module is configured to receive the collected monitoring data from the condition monitoring module and to pass the collected monitoring data to the safety controller module. The safety-controller module is configured to evaluate the monitoring data based on safety conditions.

Claims

1. A control system configured to control safety-critical and non-safety-critical processes and/or plant components comprising:

a non-safety controller module, configured to control the non-safety-critical processes and/or the non-safety-critical plant components;

at least one safety controller module, configured to control the safety-critical processes and/or the safety-critical plant components;

at least one condition monitoring module, configured to perform fail-safe condition monitoring and to collect monitoring data;

wherein the non-safety controller module is configured to receive the collected monitoring data from the condition monitoring module and to pass the collected monitoring data to the safety controller module; and

wherein the safety-controller module is configured to evaluate the monitoring data based on safety conditions.

2. The control system according to claim 1, wherein the condition monitoring module is a non-safety condition monitoring module which is configured to additionally perform safety condition monitoring.

3. The control system according to claim 1, wherein the safety controller module is configured to provide diagnostic measures to the at least one condition monitoring module.

4. The control system according to claim 1, wherein the non-safety controller module and the condition monitoring module are configured to perform the safe communication via a non-safe interface.

5. The control system according to claim 1, wherein the control system further comprises an internal coupler bus connected to the safety controller module and the non-safety controller module;

and

wherein the internal coupler bus is configured to provide safe communication between the safety controller module and the non-safety controller module.

6. The control system according to claim 5, wherein the control system further comprises:

a field bus,

a communication coupler connected to the internal coupler bus and the field bus; and

at least one communication module connected to the field bus;

wherein the communication coupler is configured to communicate with the communication module via the field bus and to communicate with the safety controller module and the non-safety controller module via the internal coupler bus.

7. The control system according to claim 6, further comprising at least one safety I/O module connected to an associated communication module;

wherein the system is configured to transfer safety data between the at least one safety controller module and the at least one safety I/O module.

8. The control system according to claim 7, wherein the at least one safety I/O module is an in/out module which is configured to receive safety data and to output safety control signals.

9. The control system according to claim 1, further comprising:

at least one non-safety I/O module connected to an associated communication module;

wherein the system is configured to transfer non-safety data between the non-safety controller module and the at least one non-safety I/O module.

10. A condition monitoring module of a control system according to claim 1, wherein the condition monitoring module is a non-safety condition monitoring module connected to a non-safety controller module, configured to perform fail-safe condition monitoring and to communicate safety monitoring data over a non-safety interface to the non-safety controller module.

11. A non-safety controller module of a control system according to claim 1,

wherein the non-safety controller module is connected to a condition monitoring module and a safety controller module;

and

wherein the non-safety controller module is configured to receive safety monitoring data from the condition monitoring module over a non-safety interface and to pass the safety monitoring data to the safety controller module.

12. A safety controller module of a control system according to claim 1, configured to receive safety monitoring data collected by a condition monitoring module from a non-safety controller module over a non-safety interface.

13. A method comprising:

using the control system according to one of claim 1 as;

a control system for a relatively large automation system, as a decentralized processing facility in such a decentralized relatively large automation system, as a stand-alone automation device in conjunction with the input/output devices which are coupleable in a decentralized manner, or as a central automation device.