Control and data-transfer system, gateway module, I/O module, and method for process control

Patent metadata

Field	Value
Publication number	US-11016463-B2
Application number	US-201515326478-A
Country	US
Kind code	B2
Filing date	Jul 15, 2015
Priority date	Jul 16, 2014
Publication date	May 25, 2021
Grant date	May 25, 2021

Abstract

Meeting the safety requirements of automation systems in a more flexible manner, the invention provides a control and data transmission system for controlling safety-critical processes comprising a plurality of I/O modules connected via a first communication network to a gateway module. The gateway module is connected to a second communication network hierarchically superior to the first communication network and acts as a gateway between the first and the second communication networks. At least one of the I/O modules comprises a diagnosis unit for generating status data relating to the functional state of an input and/or output and/or of a process device. The gateway module and the I/O modules communicate via the first communication network in a safe manner to transfer status data and input and/or output data. The gateway module performs safety processing of the status data and/or of the input and/or output data.

First claim

The invention claimed is:

1. A safety-related process control and data transmission system comprising:
a plurality of single-channel I/O modules, each of the single-channel I/O modules comprising a communication diagnosis unit connected to a bus interface via registers for an input and an output of each respective single-channel I/O module for standard data signals that are non-safety-related signals;
a gateway module, said gateway module and plurality of single-channel I/O modules communicable with each other through a local bus, said gateway module comprising a local bus master that generates a common data telegram, the common data telegram passing through each of the plurality of single-channel I/O modules in the manner of a shift register; and
a diagnosis unit active within each of the single-channel I/O modules for generating at least one status data relating to a functional state of the inputs or the outputs of the respective single-channel I/O modules, transferring the status data to the gateway module and evaluating the input and the output for generating the status data,
wherein a fault in communication between the gateway module and the single-channel I/O modules is detected in the gateway module by a checksum of a counter value using an individual counter that is provided in the common data telegram for each of the single-channel I/O modules, each respective individual counter having an initial value that is different for each of the respective single-channel I/O modules to provide an individual address for each of the respective single-channel I/O modules using the common data telegram, and
wherein values of each of the individual counters are incremented from their respective initial values after successful communication of the common data telegram between the gateway module and the respective single-channel I/O modules, and
wherein the status data generated at each single-channel I/O module is associated with a respective individual address.

2. The safety-related process control and data transmission system as claimed in claim 1 , wherein the gateway module comprises a safety logic which is in particular configured so as to be redundant, for executing the safety-related logic processing of the status data and/or of the input data and/or output data.

3. The safety-related process control and data transmission system as claimed in claim 1 , wherein the safety-related logic processing of the status data and/or the input data and/or output data comprises the execution of at least one safety function.

4. The safety-related process control and data transmission system as claimed in claim 1 , wherein each of the plurality of single-channel I/O modules is configured as a modular input and a modular output device.

5. The safety-related process control and data transmission system as claimed in claim 1 , wherein process control is performed by a control unit that is connected by a communication network to the gateway module or is performed by the gateway module.

6. The safety-related process control and data transmission system as claimed in claim 1 , wherein the diagnosis unit of at least one of the plurality of single-channel I/O modules exchanges data with an associated diagnosis unit which is arranged in a process device connected to an input or an output of said at least one of the plurality of single-channel I/O modules.

7. The safety-related process control and data transmission system as claimed in claim 1 , wherein the diagnosis unit of one of the plurality of the single-channel I/O modules and/or a diagnosis unit of a process device connected to one of the plurality of the single-channel I/O modules is controlled by a control data transmitted from the gateway module.

8. A gateway module for use in a safety-related process control and data transmission system as claimed in claim 1 , comprising:
a safety control unit in the form of a safety logic adapted for executing safety processing of the status data.

9. An I/O module for use in a safety-related process control and data transmission system as claimed in claim 1 , comprising:
at least one input and/or output for connecting a process device, the process device being in the form of a sensor or actuator;
a diagnosis unit for generating status data relating to the functional state of the input and/or output and/or of the process device connected to the input and/or output; and
an interface for connection to a communication network; wherein the I/O module is adapted to communicate with the gateway module via the communication network in a safe manner, said I/O module comprising a communication diagnosis unit, said communication diagnosis unit comprising a unit configured for performing the safe communication.

10. The safety-related process control and data transmission system of claim 1 , wherein the gateway module further comprises a safety control unit connected to the local bus master and the safety control unit comprising at least one redundant core capable of comparing results of a safety-related output data on the basis of a safety-related input data.

11. The safety-related process control and data transmission system of claim 1 , wherein the gateway module further comprises a network gateway for connection to a higher level network, the gateway module supporting a plurality of protocols, and the single-channel I/O modules operate independent of which one of the plurality of protocols is employed by the higher level network.

12. The safety-related process control and data transmission system of claim 1 , wherein when an individual counter reaches a maximum value, the counter is reset to an initial value.

13. The safety-related process control and data transmission system of claim 1 , wherein a diagnosis unit in a single-channel I/O module is remotely controlled by the gateway module by transmitting a control data from the gateway module to the diagnosis unit.

14. The safety-related process control and data transmission system of claim 1 , wherein each single-channel I/O module is configured to respond to receipt of the common data telegram by sending a mirrored counter value to the gateway module.

15. The safety-related process control and data transmission system of claim 14 , wherein each single-channel I/O module sends the generated status data to the gateway module and the gateway module uses the mirrored counter values from the single-channel I/O modules to detect faults in data transfer from the single-channel I/O modules to the gateway module.

Assignees

• Phoenix Contact Gmbh & Co

Inventors

• Hellmann Klas
• Oster Viktor

Classifications

• G05B9/03 Primary

  with multiple-channel loop, i.e. redundant control systems · CPC title

• H04L12/4625

  Single bridge functionality, e.g. connection of two networks over a single bridge · CPC title

• H04L12/40019

  Details regarding a bus master · CPC title

• G05B19/4185

  characterised by the network communication · CPC title

• G05B19/048 Primary

  Monitoring; Safety · CPC title