A component-based virtual engineering approach to PLC code generation for automation systems

In recent years, the automotive industry has been significantly affected by a number of challenges driven by globalisation, economic fluctuations, environmental awareness and rapid technological developments. As a consequence, product lifecycles are shortening and customer demands are becoming more diverse. To survive in such a business environment, manufacturers are striving to find a costeffective solution for fast and efficient development and reconfiguration of manufacturing systems to satisfy the needs of changing markets without losses in production. Production systems within automotive industry are vastly automated and heavily rely on PLC-based control systems. It has been established that one of the major obstacles in realising reconfigurable manufacturing systems is the fragmented engineering approach to implement control systems. Control engineering starts at a very late stage in the overall system engineering process and remains highly isolated from the mechanical design and build of the system. During this stage, control code is typically written manually in vendor-specific tools in a combination of IEC 61131-3 languages. Writing control code is a complex, time consuming and error-prone process. [Continues.

Cyber-physical manufacturing systems: An architecture for sensor integration, production line simulation and cloud services

none9noThe pillars of Industry 4.0 require the integration of a modern smart factory, data storage in the Cloud, access to the Cloud for data analytics, and information sharing at the software level for simulation and hardware-in-the-loop (HIL) capabilities. The resulting cyber-physical system (CPS) is often termed the cyber-physical manufacturing system, and it has become crucial to cope with this increased system complexity and to attain the desired performances. However, since a great number of old production systems are based on monolithic architectures with limited external communication ports and reduced local computational capabilities, it is difficult to ensure such production lines are compliant with the Industry 4.0 pillars. A wireless sensor network is one solution for the smart connection of a production line to a CPS elaborating data through cloud computing. The scope of this research work lies in developing a modular software architecture based on the open service gateway initiative framework, which is able to seamlessly integrate both hardware and software wireless sensors, send data into the Cloud for further data analysis and enable both HIL and cloud computing capabilities. The CPS architecture was initially tested using HIL tools before it was deployed within a real manufacturing line for data collection and analysis over a period of two months.openPrist Mariorosario; Monteriu' Andrea; Pallotta Emanuele; Cicconi Paolo; Freddi Alessandro; Giuggioloni Federico; Caizer Eduard; Verdini Carlo; Longhi SauroPrist, Mariorosario; Monteriu', Andrea; Pallotta, Emanuele; Cicconi, Paolo; Freddi, Alessandro; Giuggioloni, Federico; Caizer, Eduard; Verdini, Carlo; Longhi, Saur

Agile manufacturing: General challenges and an IoT@Work perspective

This paper describes the potential impact of the Internet of Things (IoT) technologies and architecture on factory automation. Whereas, IoT use cases range from intelligent infrastructure and smart cities to health care and shopping assistants, it is important to note that factory automation could benefit as well from an IoT approach. In this paper, we argue that there will not be one IoT but many IoTs that could differ in the type of infrastructure they are running or applications they support. In IoT@Work we focus on the potential of making manufacturing environments more agile and flexible. We explain how the IoT-centric architecture for manufacturing also needs a deep understanding of the manufacturing system and its state today. We, therefore, do a reverse engineering based on the requirements and the description of the agility expected in the automation system itself

An efficient industry 4.0 architecture for energy conservation using an automatic machine monitor and control in the foundry

In this article, a machine monitor and control architecture (MMCA) satisfying the industry 4.0 standard is proposed for energy conservation by optimizing the core moulding machine in industrial automation. Since the foundry environment is a fine dust area and is maintained at very high temperatures (around 140°C), the manual operation of machines is more complex and demanding. Moreover, the monitoring and controlling of machines need highly reliable eco-friendly systems. With real-time data logging, the proposed MMCA prototype system has been installed to monitor and control the overall process in a single core shooter machine (CSM). The parameters controlled using MMCA in foundry machinery include pressure, temperature and power consumption. The complete system can be controlled using an intranet or Internet connection without any human intervention in the machinery environment, which operates at a very high temperature. After explaining the architecture and its features, the experimental results are presented on a real-time implementation of the framework to validate the optimal energy management by the proposed MMCA. The experiments were performed on a CSM, which is automated for practical industrial applications. Its real-time implementation ensures that MMCA-based monitoring and controlling is more effective and advantageous than the programmable logic controller-based machine monitoring

PLC Code Vulnerabilities Through SCADA Systems

Supervisory Control and Data Acquisition (SCADA) systems are widely used in automated manufacturing and in all areas of our nation\u27s infrastructure. Applications range from chemical processes and water treatment facilities to oil and gas production and electric power generation and distribution. Current research on SCADA system security focuses on the primary SCADA components and targets network centric attacks. Security risks via attacks against the peripheral devices such as the Programmable Logic Controllers (PLCs) have not been sufficiently addressed. Our research results address the need to develop PLC applications that are correct, safe and secure. This research provides an analysis of software safety and security threats. We develop countermeasures that are compatible with the existing PLC technologies. We study both intentional and unintentional software errors and propose methods to prevent them. The main contributions of this dissertation are: 1). Develop a taxonomy of software errors and attacks in ladder logic 2). Model ladder logic vulnerabilities 3). Develop security design patterns to avoid software vulnerabilities and incorrect practices 4). Implement a proof of concept static analysis tool which detects the vulnerabilities in the PLC code and recommend corresponding design patterns

Operator interfaces for the lifecycle support of component based automation systems

Current manufacturing automation systems (specifically the powertrain sector) have been facing challenges with constant pressures of globalisation, environmental concerns and ICT (Information and Communication Technology) innovations. These challenges instigate new demands for shorter product lifecycles and require customised products to be manufactured as efficiently as possible. Manufacturing systems must therefore be agile to remain competitive by supporting frequent reconfigurations involving distributed engineering activities. [Continues.

Implementation of functional safety in a robotic manufacturing cell using iec 61508 standard and siemens technology

The past 50 years have seen a staggering amount of change in the technology and the business of process automation. The programmable logic controller (PLC) based control and monitoring system is a proven technology used to not only control processes but also to perform safety functions for processes in many industrial applications. There are many opportunities for improvements in any process or manufacturing system. One of the opportunities is achieving accurate safety function for measurement and process control to prevent human injury or death. The programmable electronic systems (PES) such as PLC systems are increasingly being used to perform safety functions as an integral part of the process or plant control system. A Robotic Manufacturing Cell is an example of a PES system and is used as an experimental setup for this work. The IEC 61508 standard defines various phases involved in the overall safety lifecycle for the PES system. This thesis study concentrates on such phases that include safety analysis methods, selection of an appropriate safety control system, implementation of safety as per the standard and safety validation. In this study four test cases are selected to perform safety analysis and implementation. It is verified how the conventional safety analysis method (FMEA) can be used to estimate the risk associated with each test case. As recommended by IEC 61508, a Risk-Graph method is used to calculate the Safety Integrity Level (SIL) requirement for each test case. A number of factors are required to be considered for selecting the appropriate safety control system architecture. After studying these factors and the safety analysis results, the Siemens safety PLC-based control system with SIL 3 configuration is selected for this application. IEC 61508 also recommends implementation of independent control systems for normal operation and safety. This study demonstrates how two independent PLC based control systems, one for normal operations and other for safety-related functions, are implemented to offer the most effective solution for this application. This is achieved by using PLCs from two different manufacturers, a non-safety PLC for normal operations and a Siemens safety PLC for safety-related functions. This study focuses on Machine Safety, and it can be used as a guideline for implementation of functional safety in real-life manufacturing environment

Programmable Logic Controller Modification Attacks for Use in Detection Analysis

Unprotected Supervisory Control and Data Acquisition (SCADA) systems offer promising targets to potential attackers. Field devices, such as Programmable Logic Controllers (PLCs), are of particular concern as they directly control and monitor physical industrial processes. Although attacks targeting SCADA systems have increased, there has been little work exploring the vulnerabilities associated with exploitation of field devices. As attacks increase in sophistication, it is reasonable to expect targeted exploitation of field device firmware. This thesis examines the feasibility of modifying PLC firmware to execute a remotely triggered attack. Such a modification is referred to as a repackaging attack. A general method is used to reverse engineer the firmware to determine its structure. Once understood, the firmware is modified to add an exploitable feature that can remotely disable the PLC. The attacks utilize a variety of triggers and take advantage of already existing functions to exploit the PLC. Notable areas of the firmware are described to demonstrate how they can be used in attack development. The performance of the repackaged firmwares are compared to known unmodified firmwares to determine if the modifications negatively impact performance. Findings demonstrate that repackaging attacks targeting PLCs are feasible and that the repackaged firmware does not impact the PLC s ability to execute programmed tasks. Finally, design recommendations are suggested to help mitigate potential weaknesses in future firmware development