Model-based Safety Assessment of Industrial Automation Systems Using IEC 61499

Model-based Safety Assessment of Industrial Automation Systems Using IEC 61499
Author: Zeeshan Ejaz Bhatti
Publisher:
Total Pages: 219
Release: 2017
Genre: Model-driven software architecture
ISBN:

Industrial automation systems are complex control systems that perform control and automation of hazardous plants. Safety of such systems is of paramount importance and may even be mandated by law. Safety-related systems may be required to demonstrate conformance to an applicable functional safety standards to assure safety and demonstrate the that these systems mitigate the risk to human lives, as much as reasonably possible. IEC 61508 is a standard of functional safety for generic electric, electronic, and programmable electronic (E/E/PE) systems and is used as the principal guide in this thesis. IEC 61508 adopts a two-pronged approach for addressing random failures in the hardware and systematic errors in the software. Random failures are addressed using quantitative techniques for reliability analysis e.g., reliability block diagrams and Markov analysis, and by computing the safe failure fraction to establish a confidence level. Systematic errors, on the other hand, are avoided by following quality assurance recommendations and qualitative validation techniques. However, this segregated application of quantitative and qualitative approaches is inadequate for addressing complexities introduced by software-intensive control systems. Furthermore, the manual application of traditional safety analysis techniques is tedious, error-prone, and largely dependent on practitioners' skills. In order to ameliorate these problems, a model-driven approach towards safety analysis named, model-based safety assessment (MBSA) was proposed, which has gained significant interest in academia and industry in the recent years. MBSA approaches use system models for the purpose of safety analysis such as extracting fault trees, performing quantitative analysis, or discovering a critical sequence of errors that may cause system failures. MBSA can be performed on either by using dedicated safety models or by using system development models. The latter approach allows seamless integration with model-driven development (MDD), which is the state-of-the-art for design, implementation and validation of control and automation systems. In MDD, high-level system models are constructed that are iteratively refined by adding details until an implementation of the system software can be automatically extracted from the development models using automatic code generation. One such approach for implementing industrial control systems uses IEC 61499, which is an open standard for implementing industrial process controller and measurement systems. It proposes various design artefacts e.g., basic and composite function blocks and enables a component-oriented design approach for implementing complex behaviours i.e., by connecting function blocks to form function block networks. A popular design pattern for the development of IEC 61499 based systems suggests the implementation of two separate tiers called plant-model and controller. The plantmodel mimics the expected behaviour of the plant and the controller implements the automation logic. When connected in a closed-loop, the overall system model is formed that is used for various verification and validation activities such as formal verification, testing, simulation. Such analyses are well-suited for safety-critical systems and help to avoid systematic errors. However, plant-models are also susceptible to random errors, which cannot be analysed by using qualitative techniques alone. Unfortunately, all existing validation and verification techniques available for IEC 61499 based systems are qualitative in nature, which cannot be used for the purpose of quantitative risk assessment. This calls for developing an approach for the quantitative safety assessment of IEC 61499 based systems. In this thesis, we present an MBSA approach for quantitative risk assessment of industrial automation systems using IEC 61499. The presented approach proposes a novel structure named stochastic function block for modelling stochastic aspects of random failures and environmental non-determinism in the plant-model. The controller, on the other hand, is developed using standard IEC 61499 function blocks. The overall system model is transformed into Markov decision processes in the Prism language for probabilistic verification using the Prism model checker. This enables quantitative analysis of the system behaviour presuming software behaviour under random errors of the plant. The controller is eventually used for automatic code generation and deployment onto the physical plant. Use of standard function blocks for the controller renders the proposed technique complaint to the IEC 61499 standard and permit seamless integration into the MDD activities. The key contributions of the presented work are as following. 1) A novel structure based on IEC 61499 basic function blocks named stochastic function block. This structure is used for representing the random errors in the plant model and environmental non-determinism. 2) A rule-based transformation from IEC 61499 function blocks to Prism model that preserves the adopted synchronous execution semantics. The generated Prism model is a Markov decision process that represents the probabilistic and non-deterministic aspects of the system due to its random errors. 3) A scalable MBSA approach for a unified qualitative and quantitative analysis, which is useful in the early design validation and managing modifications in system design. 4) An MDE tool-chain named BlokIDE, which provides support for the proposed stochastic function blocks and automatic translation to the Prism language. This enables stochastic error modelling and integration with the Prism model checker for the purpose of proposed MBSA approach. 5) A proposal for conforming to IEC 61508 requirements using IEC 61499 modelbased approach, showing various specification and design various stages of the V-Model. To the best of our knowledge, the proposed approach is the very first attempt for providing a model-based safety assessment approach for industrial automation systems using IEC 61499 along with a comprehensive tool-chain.

Modelling Control Systems Using IEC 61499

Modelling Control Systems Using IEC 61499
Author: Alois Zoitl
Publisher: IET
Total Pages: 246
Release: 2014-05-30
Genre: Technology & Engineering
ISBN: 1849197601

This book provides a concise introduction to the main concepts and models defined in the standard for modelling distributed control systems for use in factory automation.

Model-Driven Design Using IEC 61499

Model-Driven Design Using IEC 61499
Author: Li Hsien Yoong
Publisher: Springer
Total Pages: 209
Release: 2014-11-13
Genre: Technology & Engineering
ISBN: 3319105213

This book describes a novel approach for the design of embedded systems and industrial automation systems, using a unified model-driven approach that is applicable in both domains. The authors illustrate their methodology, using the IEC 61499 standard as the main vehicle for specification, verification, static timing analysis and automated code synthesis. The well-known synchronous approach is used as the main vehicle for defining an unambiguous semantics that ensures determinism and deadlock freedom. The proposed approach also ensures very efficient implementations either on small-scale embedded devices or on industry-scale programmable automation controllers (PACs). It can be used for both centralized and distributed implementations. Significantly, the proposed approach can be used without the need for any run-time support. This approach, for the first time, blurs the gap between embedded systems and automation systems and can be applied in wide-ranging applications in automotive, robotics, and industrial control systems. Several realistic examples are used to demonstrate for readers how the methodology can enable them to reduce the time-to-market, while improving the design quality and productivity.

Model-Based Safety and Assessment

Model-Based Safety and Assessment
Author: Yiannis Papadopoulos
Publisher: Springer Nature
Total Pages: 380
Release: 2019-10-11
Genre: Computers
ISBN: 3030328724

This book constitutes the proceedings of the 6th International Symposium on Model-Based Safety and Assessment, IMBSA 2019, held inThessaloniki, Greece, in October 2019. The 24 revised full papers presented were carefully reviewed and selected from 46 initial submissions. The papers are organized in topical sections on safety models and languages; dependability analysis process; safety assessment; safety assessment in automotive industry; AI in safety assessment.

Model-Based Safety and Assessment

Model-Based Safety and Assessment
Author: Marc Zeller
Publisher: Springer Nature
Total Pages: 255
Release: 2020-09-03
Genre: Computers
ISBN: 303058920X

This book constitutes the proceedings of the 7th International Symposium on Model-Based Safety and Assessment, IMBSA 2020, held in Lisbon, Portugal, in September 2020. The conference was held virtually due to the COVID-19 pandemic. The 15 revised full papers and 4 short papers presented were carefully reviewed and selected from 30 initial submissions. The papers are organized in topical sections on safety models and languages; state-space modeling; dependability analysis process; safety assessment in automotive domain; AI and safety assurance.

IoT Automation

IoT Automation
Author: Jerker Delsing
Publisher: CRC Press
Total Pages: 403
Release: 2017-02-17
Genre: Computers
ISBN: 149875676X

This book presents an in-depth description of the Arrowhead Framework and how it fosters interoperability between IoT devices at service level, specifically addressing application. The Arrowhead Framework utilizes SOA technology and the concepts of local clouds to provide required automation capabilities such as: real time control, security, scalability, and engineering simplicity. Arrowhead Framework supports the realization of collaborative automation; it is the only IoT Framework that addresses global interoperability across multiplet SOA technologies. With these features, the Arrowhead Framework enables the design, engineering, and operation of large automation systems for a wide range of applications utilizing IoT and CPS technologies. The book provides application examples from a wide number of industrial fields e.g. airline maintenance, mining maintenance, smart production, electro-mobility, automative test, smart cities—all in response to EU societal challenges. Features Covers the design and implementation of IoT based automation systems. Industrial usage of Internet of Things and Cyber Physical Systems made feasible through Arrowhead Framework. Functions as a design cookbook for building automation systems using IoT/CPS and Arrowhead Framework. Tools, templates, code etc. described in the book will be accessible through open sources project Arrowhead Framework Wiki at forge.soa4d.org/ Written by the leading experts in the European Union and around the globe.

IEC 61499 Function Blocks for Embedded and Distributed Control Systems Design

IEC 61499 Function Blocks for Embedded and Distributed Control Systems Design
Author: Valeriy Vyatkin
Publisher:
Total Pages: 0
Release: 2012
Genre: Automatic control
ISBN: 9781936007936

IEC 61499 is the standard for distributed control systems that follows on from the IEC 61131 standard for programmable logic controllers (PLC). This book is a practical guide for component-based development of distributed embedded and control systems as proposed by this international standard.

The Digital Shopfloor- Industrial Automation in the Industry 4.0 Era

The Digital Shopfloor- Industrial Automation in the Industry 4.0 Era
Author: John Soldatos
Publisher: CRC Press
Total Pages: 495
Release: 2022-09-01
Genre: Technology & Engineering
ISBN: 1000795047

In today’s competitive global environment, manufacturers are offered with unprecedented opportunities to build hyper-efficient and highly flexible plants, towards meeting variable market demand, while at the same time supporting new production models such as make-to-order (MTO), configure-to-order (CTO) and engineer-to-order (ETO). During the last couple of years, the digital transformation of industrial processes is propelled by the emergence and rise of the fourth industrial revolution (Industry4.0). The latter is based on the extensive deployment of Cyber-Physical Production Systems (CPPS) and Industrial Internet of Things (IIoT) technologies in the manufacturing shopfloor, as well as on the seamless and timely exchange of digital information across supply chain participants. The benefits of Industry 4.0 have been already proven in the scope of pilot and production deployments in a number of different use cases including flexibility in automation, predictive maintenance, zero defect manufacturing and more. Despite early implementations and proof-of-concepts, CPPS/IIoT deployments are still in their infancy for a number of reasons, including:• Manufacturers’ poor awareness about digital manufacturing solutions and their business value potential, as well as the lack of relevant internal CPPS/IIoT knowledge.• The high costs that are associated with the deployment, maintenance and operation of CPPS systems in the manufacturing shopfloors, which are particularly challenging in the case of SME (Small Medium Enterprises) manufacturers that lack the equity capital needed to invest in Industry 4.0.• The time needed to implement CPPS/IIoT and the lack of a smooth and proven migration path from existing OT solutions.• The uncertainty over the business benefits and impacts of IIoT and CPPS technologies, including the lack of proven methods for the techno-economic evaluation of Industry4.0 systems. • Manufacturers’ increased reliance on external integrators, consultants and vendors. • The absence of a well-developed value chain needed to sustain the acceptance of these new technologies for digital automation.In order to alleviate these challenges, three European Commission funded projects (namely H2020 FAR-EDGE (http://www.far-edge.eu/), H2020 DAEDALUS (http://daedalus.iec61499.eu) and H2020 AUTOWARE (http://www.autoware-eu.org/)) have recently joined forces towards a “Digital Shopfloor Alliance”. The Alliance aims at providing leading edge and standards based digital automation solutions, along with guidelines and blueprints for their effective deployment, validation and evaluation. The present book provides a comprehensive description of some of the most representative solutions that offered by these three projects, along with the ways these solutions can be combined in order to achieve multiplier effects and maximize the benefits of their use. The presented solutions include standards-based digital automation solutions, following different deployment paradigms, such as cloud and edge computing systems. Moreover, they also comprise a rich set of digital simulation solutions, which are explored in conjunction with the H2020 MAYA project (http://www.maya-euproject.com/). The latter facilitate the testing and evaluation of what-if scenarios at low risk and cost, but also without disrupting shopfloor operations. As already outlined, beyond leading edge scientific and technological development solutions, the book comprises a rich set of complementary assets that are indispensable to the successful adoption of IIoT/CPPS in the shopfloor. The book is structured in three parts as follows: • The first part of the book is devoted to digital automation platforms. Following an introduction to Industry 4.0 in general and digital automation platforms in particular, this part presents the digital automation platforms of the FAR-EDGE, AUTOWARE and DAEDALUS projects. • The second part of the book focuses on the presentation of digital simulation and digital twins’ functionalities. These include information about the models that underpin digital twins, as well as the simulators that enable experimentation with these processes over these digital models. • The third part of the book provides information about complementary assets and supporting services that boost the adoption of digital automation functionalities in the Industry4.0 era. Training services, migration services and ecosystem building services are discussed based on the results of the three projects of the Digital Shopfloor Alliance. The target audience of the book includes:• Researchers in the areas of Digital Manufacturing and more specifically in the areas of digital automation and simulation, who wish to be updated about latest Industry4.0 developments in these areas.• Manufacturers, with an interest in the next generation of digital automation solutions based on Cyber-Physical systems.• Practitioners and providers of Industrial IoT solutions, which are interested in the implementation of use cases in automation, simulation and supply chain management.• Managers wishing to understand technologies and solutions that underpin Industry4.0, along with representative applications in the shopfloor and across the supply chain.

A Model-driven Approach for Safety Critical Systems

A Model-driven Approach for Safety Critical Systems
Author: Zeeshan Ejaz Bhatti
Publisher:
Total Pages: 178
Release: 2011
Genre: Model-driven software architecture
ISBN:

Rapidly increasing dependence on computers for the purpose of monitoring, control and automation raise safety concerns. Some applications demand high availability and reliability of the system. Example of such systems are the y-by-wire, pace-maker (for heart patients) and stability control systems. Failure or unavailability of such systems usually have severe consequences. The complexity of system software has increased in recent years. While a remarkable amount of effort has gone into the standardization of PLC programming, control systems are still largely implemented in an ad hoc manner. Shorter time-to-market and higher expectations on reliability of embedded systems, demands improvements in the development practices. We suggest using model-driven development (MDD) paradigm for implementing safety critical systems using IEC 61499 standard. IEC 61499 is a recent standard for PLC programming using a block-diagram oriented visual language. The component-based approach of IEC 61499 supports a modular system design with a scope of re-usability of models. We have proposed a formal verification approach for IEC 61499 systems for the purpose of evaluating reliability. An observer based approach is proposed for capturing system properties in an intuitive manner. We employ model checking and reachability analysis algorithms that formally prove the absence of certain errors in the system, thus providing reliability guarantees. This formal verification approach in conjunction with synchronous execution semantics ensure that the system is deterministic, free from deadlocks and satisfies certain correctness criteria. We have implemented an integrated development environment (IDE) named TimeMe Studio, for safety critical systems. It implements IEC 61499 as a domain specific language that leverages the automatic code generation using synchronous compiler, observer-based formal verification and static timing analysis. This provides certain guarantees on the predictability, dependability and timeliness aspects of safety critical systems. Observability and executability features of MDD are provided by implementing a visual simulator.