Control system for controlling safety-critical processes

• US 8,509,927 B2
• Filed: 09/09/2010
• Issued: 08/13/2013
• Est. Priority Date: 09/23/2009
• Status: Active Grant

• Current Assignee: Phoenix Contact GmbH & Company KG
• Original Assignee: Phoenix Contact GmbH & Company KG
• Inventors: Schmidt, Joachim, Horn, Steffen
• Primary Examiner(s): Padmanabhan, Kavita
• Assistant Examiner(s): Everett, Christopher E
• Application Number:
  US12/878,442
• Publication Number:
  US 20110071654A1
• Time in Patent Office: 1,069 Days
• Field of Search: None
• US Class Current: 700/79
• CPC Class Codes: G05B 19/0428 Safety, monitoring G05B19/0423 takes precedence

Abstract

The invention relates to a control system for controlling safety-critical processes in an automated system by using a communications network with a communications master for controlling the communications on the network and a plurality of network subscribers. At least a few of the network subscribers are constructed as decentralized, secure network subscribers, and each has a separate, decentralized safety controller for controlling a safety-relevant application. Each of the decentralized, secure network subscribers has a unique safety address. The decentralized, secure network subscribers themselves execute the safety functions and/or safety logic operations relevant to them. The decentralized, secure network subscribers communicate with each other in a fail-safe way in which each executes automatic, fail-safe point-to-point communications with another of the decentralized, secure network subscribers, in order to be able to provide safety functions covering the decentralized, secure network subscribers.

Claims

1. A control system (10) for controlling safety-critical processes in an automated system by means of a communications network (20) with:

an unsecured communications master (22) for controlling the communications on the network (20); and

a plurality of network subscribers (12, 14, 16, 18), wherein at least three of the network subscribers are configured as decentralized, secure network subscribers (16) and each has a separate, decentralized safety controller (17) for controlling a safety-relevant application,

each of the decentralized, secure network subscribers (16) has a unique safety address,

each of the decentralized, secure network subscribers (16) executes safety functions or safety logic operations relevant for said subscriber (16),

the secure network subscribers (16) are grouped into at least three safety islands (1, 2, 3), and

a logical point-to-point communication (36) via a data line on the network (20) between the decentralized, secure network subscribers (16) is configured as a fail-safe point-to-point communication (36) based on a chain of point-to-point relationships (36) from one safety island to another safety island,

wherein a decentralized, secure network subscriber (16) of a first safety island (1) in a point-to-point relationship forms a master (32) and a decentralized, secure network subscriber (16) of a safety island (2) that follows the first safety island in the chain forms a slave (33),

the master-slave relationships between safety islands (1, 2, 3) forming the chain of point-to-point relationships, so that decentralized, secure network subscribers (16) are pairwise individually connected with each other, thus providing each other safety functions.

2. The control system (10) according to claim 1, wherein the decentralized, secure network subscribers (16) are interlinked with allocated safety data input objects or safety data output objects (12, 14), each of which lacks a separate, decentralized safety controller for controlling a safety-relevant application, so that the decentralized, secure network subscribers (16) are grouped with the allocated safety data input objects or the safety data output objects (12, 14) into the safety islands (1, 2, 3), wherein each safety island comprises at least one decentralized, secure network subscriber (16).

3. The control system (10) according to claim 2, wherein the decentralized, secure network subscribers (16) have means for fail-safe cross communications within the safety islands (1, 2, 3).

4. The control system (10) according to claim 2, wherein island-covering safety functions are provided in which the decentralized, secure network subscribers (16) of the safety islands (1, 2, 3) communicate with each other in an island-covering, fail-safe way by means of the fail-safe point-to-point communications (36).

5. The control system (10) according to claim 1, wherein system-wide, fail-safe communications are automatically established between the decentralized, secure network subscribers (16) by means of the fail-safe point-to-point communications (36).

6. The control system (10) according to claim 1, wherein, by means of a data flow automatically established by the fail-safe, point-to-point communications (36) between the decentralized, secure network subscribers, a software busbar (30) is formed as a replacement for a hardware connection.

7. The control system (10) according to claim 6, wherein each safety island (1, 2, 3) is fixed to exactly one data line (38) of the software busbar (30).

8. The control system (10) according to claim 1, wherein a secure communications protocol is used for the fail-safe point-to-point communications (36) between the decentralized, secure network subscribers (16).

9. The control system (10) according to claim 8, wherein

i) data contained in the secure communications protocol is evaluated by an application program or an underlying routing layer, and

ii) telegrams of the underlying routing layer are routed from a source to a corresponding target address.

10. The control system (10) according to claim 1, wherein the safety address can be fixed by means of a switch or by means of software in the decentralized, secure network subscriber (16).

11. The control system (10) according to claim 1, wherein standard telegrams between the decentralized secure network subscribers (16) are routed in the unsecured communications master (22).

12. The control system (10) according to claim 11, wherein an application program executes the routing of the standard telegrams by executing copy commands that are configured or parameterized as a function of the addressing of the decentralized, secure network subscribers (16).

13. The control system (10) according to claim 11, wherein the unsecured communications master (22) generates a routing table and automatically routes the telegrams from a source to a target address with reference to a routing table.

14. The control system (10) according to claim 1, wherein telegrams controlled by the unsecured communications master (22) between the network subscribers have an identical data width for all point-to-point connections between the decentralized, secure network subscribers (16).