Real Time Control Using an Isolated Controller

A method comprising:

• receiving, at a safety controller and from a sensor configured to measure an operating characteristic of a machine, measurement data;
• performing, by the safety controller, signal conditioning on the measurement data to generate a conditioned sample;
• analyzing, by the safety controller, the conditioned sample and determining whether to take a safety action;
• and
• sending the conditioned sample to a boundary processor that isolates operations of a control processor from the safety controller for transmission to the control processor;
• receiving, by the control processor and from the boundary processor, the conditioned sample;
• and
• controlling, by the control processor, one or more operations of the machine based on the conditioned sample.

A machinery control system comprising:

• a sensor configured to measure an operating characteristic of a machine;
• a safety controller in communication with the sensor, the safety controller comprising a dedicated boundary processor, wherein the safety controller is in communication with a control processor through the boundary processor which isolates operations of the control processor from the safety controller, and wherein the safety controller is configured to perform operations comprising:
• receiving, from the sensor, measurement data;
• performing signal conditioning on the measurement data to generate a conditioned sample;
• analyzing the conditioned sample and determining whether to take a safety action;
• and
• sending the conditioned sample to the boundary processor for transmission to the control processor, wherein the control processor controls one or more operations of the machine based on the conditioned sample.