Segmented industrial control system architecture and related methods

A machine segment in an industrial control system, the machine segment comprising:

• a segment control system comprising at least a logic controller and an independent safety controller;
• one or more safety components;
• one or more motors;
• and
• one or more input/output devices, wherein:
• the segment control system is in direct network communication with a neighboring machine segment control system via a first network connection;
• the independent safety controller is in direct network communication with a neighboring machine segment independent safety controller via a second network connection;
• the logic controller is configured to receive input/output data from the one or more input/output devices and transmit the input/output data directly to the neighboring machine segment control system via the first network connection;
• the logic controller is configured to receive second input/output data from the neighboring machine segment via the first network connection;
• the logic controller is configured to receive identifying data for the neighboring machine segment from the neighboring machine segment via the first network connection;
• and
• the logic controller is configured to control operation of each of the one or more motors based on one or more of the input/output data, the second input/output data, or the identifying data for the neighboring machine segment.

An industrial control system machine segment comprising:

• a segment control system comprising a safety controller, one or more power components, and a programmable logic controller;
• one or more safety components in communication with the safety controller;
• one or more motors in communication with the programmable logic controller, the one or more motors comprising one or more motor controllers;
• and
• one or more input/output devices in communication with the programmable logic controller, the one or more input/output devices comprising one or more sensors and at least one input/output coupler providing a link between the one or more sensors and the programmable logic controller, wherein:
• the programmable logic controller is in direct network communication with a corresponding programmable logic controller for a second machine segment in the industrial control system;
• the one or more power components are configured to receive power directly from at least one of the second machine segment or an industrial control facility power source;
• the safety controller is configured to receive safety event data from the one or more safety components or an adjacent machine segment in the industrial control system and, in response, initiate a safety response based on the safety event data;
• the programmable logic controller is configured to control operation of the one or more motors via the one or more motor controllers both independent of the industrial control system and based on handling data received from the industrial control system;
• and
• the programmable logic controller is configured to receive input/output data from the one or more input/output devices and transmit at least a portion of the input/output data to at least one of the second machine segment in the industrial control system or a gateway computing system for the industrial control system.