SAFETY in Automation
Transcript of SAFETY in Automation
Company Logo1KW-SoftwareGary Liang
TÜV Rheinland International Symposium in ChinaFunctional Safety in Industrial ApplicationsOctober 18 – 19, 2011 in Shanghai – China
SAFETY in Automation
IEC 61508 Compliant Software Solutions
Company Logo2KW-SoftwareGary Liang
KW-Software: Company Information
� Foundation: 1982� Employees: 65� A Phoenix Contact Company � Headquarter: Lemgo Germany,
active in Japan, China, USA
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The scalable Software Platform
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Safety related Standards
� Machinery Directive 2006/42/EC
� Risk analysis and risk assessment� EN ISO 12100-1 Basic concepts, general principles for design� ISO 14121/EN 1050 Principles of risk assessment
� Safety-related electrical control systems� EN ISO 13849-1 (old EN 954-1) Performance levels (PL) or� IEC/EN 62061 (sector-specific of IEC 61508) Safety Integrity
Level (SIL)
� PLCopen Safety TC5� Specification for safety related FBs
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Functional safety management
� Can be done on company level or on project level� QA-Manual (process, documents, ...)� Coding guidelines� Safety plan� Safety Requirement Specification� Requirement tracking� Validation & Verification� …
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Certificated Development Process
� Certification of the IEC 61508 development process by TÜV
� Validation of KW-Software development process already done by TÜV, no need for extra validation by customer
� KW-Software supports partners in building up their own functional safety management
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KW-Software offers a wide variety of Safety Softwar e
ProgrammingProgrammable IEC 61131safety logic with integration
of non-safe areas
SAFEPROG / SafeOS SAFECONF / SafeOS SAFEGRID
Parameterization of safety devices
(drives, sensors, etc)
ConfigurationBased on PLCopen
safety function blocksfor simple safety logic
� Safety software components are certified according to IEC 61508 SIL3
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Diversified Software Structure
� Diversified Software enables to develop a Safety system on base of the same CPU Type!
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Safety Communication (PC)Safety Communication (PC)
PLC program 1PLC program 1
SAFEPROG / SAFECONFSAFEPROG / SAFECONF
Compiler 1Compiler 1 Compiler 2Compiler 2
PLC program 2PLC program 2
Communication InterfaceCommunication Interface
CPU 1CPU 1 CPU 2CPU 2
Firmware 1Firmware 1
SafeOS 1SafeOS 1
Firmware 2Firmware 2
SafeOS 2SafeOS 2
PC
Saf
ety
PLC
KW-SoftwareKW-Software
Manufacturer of Safe PLC
Manufacturer of Safe PLC
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SAFEPROG / SAFECONF / SafeOS: Scalable solutions
� SafeOS supports diversified software structure for safety solutions up to SIL3.
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SAFEPROG: User Interface
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Programming (FBD/LD) Variable Declaration
Connection of I/Os with PLC Variables Cross References Simulation
Validation Check List Debug
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SAFEPROG: Fulfills PLCopen Safety Requirements
� Support of PLCopen Safety Guide Lines� Different colors for safe and standard function blocks
� Using of safe and standard data types
� Different user levels
� Graphical programming languages (FBD, LD)
� Plausibility checks
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Easy Programming with SAFEFBs
� 20 certified PLCopen safety function blocks as an independent library
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� SF_EnableSwitch � SF_SafeRequest� SF_TwoHandControlTypeII� SF_TwoHandControlTypeIII� SF_MutingSeq� SF_MutingPar� SF_MutingPar_2Sensor� SF_SafeStop1� SF_SafeStop2� SF_SafelyLimitedSpeed
� SF_Equivalent� SF_Antivalent� SF_EmergencyStop� SF_OutControl� SF_EDM� SF_GuardMonitoring� SF_GuardLocking� SF_ESPE� SF_TestableSafetySensor� SF_ModeSelector
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SAFECONF: Easy to use User Interface
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Toolbox with safety functions Connection editor Project information
Hardware Manager Simulation
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SAFECONF: Easy Drag & Drop Programming
� Input and output signals can be inserted into the connectioneditor from the hardware manager using drag & drop.
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Safety function blocks and functions can be inserted into the connection editor from the toolbox using drag & drop.
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Multicore and Safety
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� Multicore approaches� Consolidation:
Several applications that had been executed on standalone Hardware before can be run on one CPU now
� Virtualization: Control applications run on different virtualized systems using the Hypervisor that is protecting each application
� Separation: Of safe and non-safe applications by Hypervisor
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Conclusion: Safety with KW-Software