How do you design redundant sensor signal conditioning with voting logic for safety systems?
Answer
Redundant sensor voting design: implement 1oo2D (one-out-of-two with diagnostics), 2oo3 (two-out-of-three majority), or 2oo4D architecture based on SIL requirements, design independent signal conditioning channels (different power supplies, physical separation, diverse designs where feasible), implement comparison voting (difference threshold, rate-of-change limits, range checking), and define fault response (switch to single sensor, failsafe state, degraded operation mode). Each channel: complete signal conditioning with own ADC, isolation between channels, and diagnostic coverage (stuck-at, drift detection). Software voting algorithms must be deterministic with defined response time. Document systematic capability and verify PFDavg calculations including common-cause factors.
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