Modern human machine interface in industrial wireless networks

This paper presents several existing experimental setups on latest industrial systems and provide comparison of advantages and disadvantages of different HMI implementation. It proposes a simple and low cost HMI system for automation by using remote software application. The method does not required specific software package from vendors, hence provide a low cost and easily available solutions for control. We have examined their switching on various wireless technologies including Bluetooth, Infrared, Wi-Fi and Cellular Mobile Systems. The presented HMI provide effective and inexpensive control of automation systems by using remote software packages on the mobile phone, tablet and laptop. This paper presents several experiments on HMIs. The first set of experiments are related existing HMI systems on latest Siemens TIA Portal software and hardware. The second set of experiments presents the developed method of HMI switching and control by using remote communication software; Vectir and Teamviewer over different industrial wireless technologies

Safety and security profiles of industry networks used in safety- critical applications

The author describes the mechanisms of safety and security profiles of industry and communication networks used within safety – related applications in technological and information levels of process control recommended according to standards IEC 61784-3,4. Nowadays the number of vendors of the safety – related communication technologies who guarantees besides the standard communication, the communication amongst the safety – related equipment according to IEC 61508 is increasing. Also the number of safety – related products is increasing, e. g. safety Fieldbus, safety PLC, safety curtains, safety laser scanners, safety buttons, safety relays and other. According to world survey the safety Fieldbus denoted the highest growth from all manufactured safety products.The main part of this paper is the description of the safety-related Fieldbus communication system, which has to guaranty Safety Integrity Level

An Experimental Framework for 5G Wireless System Integration into Industry 4.0 Applications

The fourth industrial revolution, or Industry 4.0 (I4.0), makes use of wireless technologies together with other industrial Internet-of-Things (IIoT) technologies, cyber–physical systems (CPS), and edge computing to enable the optimization and the faster re-configuration of industrial production processes. As I4.0 deployments are ramping up, the practical integration of 5G wireless systems with existing industrial applications is being explored in both Industry and Academia, in order to find optimized strategies and to develop guidelines oriented towards ensuring the success of the industrial wireless digitalization process. This paper explores the challenges arisen from such integration between industrial systems and 5G wireless, and presents a framework applicable to achieve a structured and successful integration. The paper aims at describing the different aspects of the framework such as the application operational flow and its associated tools, developed based on analytical and experimental applied research methodologies. The applicability of the framework is illustrated by addressing the integration of 5G technology into a specific industrial use case: the control of autonomous mobile robots. The results indicate that 5G technology can be used for reliable fleet management control of autonomous mobile robots in industrial scenarios, and that 5G can support the migration of the on-board path planning intelligence to the edge-cloud

Exploring security controls for ICS/SCADA environments

Trabalho de projeto de mestrado, Segurança Informática, Universidade de Lisboa, Faculdade de Ciências, 2020Os Sistemas de Controlo Industriais (ICS) estão a começar a fundir-se com as soluções de IT, por forma a promover a interconectividade. Embora isto traga inúmeros benefícios de uma perspetiva de controlo, os ICS apresentam uma falta de mecanismos de segurança que consigam evitar possíveis ameaças informáticas, quando comparados aos comuns sistemas de informação [29], [64]. Dada a natureza crítica destes sistemas, e a ocorrências recentes de ciberataques desastrosos, a segurança ´e um tópico que deve ser incentivado. À luz deste problema, na presente dissertação apresentamos uma avaliação de possíveis aplicações e controlos de segurança a serem implantados nestes ambientes críticos e a implementação de uma solução de segurança extensível que dá resposta a certos ataques focados em sistemas industriais, capaz de ser implantada em qualquer rede industrial que permita a sua ligação. Com o auxilio de uma framework extensivel e portátil para testes de ICS, e outros ambientes industriais de testes, foi possível analisar diferentes cenários de ameaças, implantar mecanismos de segurança para os detetar e avaliar os resultados, com o intuito de fornecer uma ideia de como empregar estes mecanismos da melhor maneira possível num ambiente real de controlo industrial.Industrial Control Systems (ICS) are beginning to merge with IT solutions, in order to promote inter-connectivity. Although this brings countless benefits from a control perspective, ICS have been lacking in security mechanisms to ward off potential cyber threats, when compared to common information systems [29], [64]. Given the critical nature of these systems, and the recent occurrences of disastrous cyber-attacks, security is a topic that should be encouraged. In light of this problem, in this dissertation we present an assessment of possible security applications and controls that can be deployed in these critical environments and the implementation of an extensible security solution that responds to certain attacks focused on industrial systems, capable of being deployed in any industrial network that allows its connection. With the help of an extensible and portable framework for ICS testing, and other industrial testing environments, it was possible to analyze different threat scenarios, implement security mechanisms to detect them and evaluate the results in order to provide an idea on how to employ these mechanisms as best as possible in a real industrial control environment, without compromising it’s process

Smart Reactor Production Monitoring System-an Industry 4.0 Application in the Chemical Industry

Decrease in costs. More production flexibility. More efficient processes. These are one of the common demands of manufacturing enterprises in almost every sector. In this marketplace where there is very serious competition, the most important factor in the chemical industry is competitiveness as in every sector. The best way to take advantage of competitive advantages can be with integrated and innovative electrification, automation and digitalization solutions. Completing the digital transformation includes many disciplines, from engineering and design to automation, information technology and lifecycle management. Adopting digitalization lies in the merging of different expert knowledge, working in many different disciplines that are complex, able to offer the best solution. This strategy is also the motivation behind the strategic cooperation initiated by the German government in 2011 to promote Industry 4.0. In this article, in a chemical factory that produces paint, the project implementation of industrial automation and control systems and the details of the collection, recording, monitoring and reporting of the requested information in accordance with the Industry 4.0 concept of this application are explained. The article explains in detail how a real Industry 4.0 software application is applied in the chemical industry producing paint and reveals the benefits of Industry 4.0 in process automation. At the same time, this project, which is described in this article and implemented in a real paint production factory, will give new ideas to the industrial enterprises that are trying to realize the fourth industrial revolution and digitalization which has been on the agenda recently

Wireless industrial intelligent controller for a non-linear system

Modern neural network (NN) based control schemes have surmounted many of the limitations found in the traditional control approaches. Nevertheless, these modern control techniques have only recently been introduced for use on high-specification Programmable Logic Controllers (PLCs) and usually at a very high cost in terms of the required software and hardware. This ‗intelligent‘ control in the sector of industrial automation, specifically on standard PLCs thus remains an area of study that is open to further research and development. The research documented in this thesis examined the effectiveness of linear traditional control schemes such as Proportional Integral Derivative (PID), Lead and Lead-Lag control, in comparison to non-linear NN based control schemes when applied on a strongly non-linear platform. To this end, a mechatronic-type balancing system, namely, the Ball-on-Wheel (BOW) system was designed, constructed and modelled. Thereafter various traditional and intelligent controllers were implemented in order to control the system. The BOW platform may be taken to represent any single-input, single-output (SISO) non-linear system in use in the real world. The system makes use of current industrial technology including a standard PLC as the digital computational platform, a servo drive and wireless access for remote control. The results gathered from the research revealed that NN based control schemes (i.e. Pure NN and NN-PID), although comparatively slower in response, have greater advantages over traditional controllers in that they are able to adapt to external system changes as well as system non-linearity through a process of learning. These controllers also reduce the guess work that is usually involved with the traditional control approaches where cumbersome modelling, linearization or manual tuning is required. Furthermore, the research showed that online-learning adaptive traditional controllers such as the NN-PID controller which maintains the best of both the intelligent and traditional controllers may be implemented easily and with minimum expense on standard PLCs

Modelling of Hazards Effect on Safety Integrity of Open Transmission Systems

The paper is concerned with safety appraisal of safety-related communication systems (SRComSs) with open transmission system, where except in addition to message transmission integrity also confidentiality is recommended to be provided. The authors focused on safety analysis of safety-related messages transmission secured using cryptographic and safety code mechanisms and on the possibilities of modelling safety-related industrial communication system, where a high safety integrity level SIL3 is required to be guaranteed. The paper features mathematical procedures to calculate the rate of hazardous transmission failure of safety-related messages in the result of electromagnetic interference (EMI) effects in the communication channel and by the presence of random hardware failures of SRComS. The theoretical techniques and safety analyses emerge from risk analysis and are compared with the knowledge gained by the authors during safety verifications of such systems for transportation applications. It is a little explored area, because the standards concerning safety-related control systems (SRCSs) did not support any cryptography-based methods. A quantitative safety integrity analysis of SRComS is based on utilisation of Markov's processes. The proposed Markov's model is applied on an open transmission system built on the IEEE 802.11g standard, which is complemented by cryptographic and safety code. The calculations are performed using Mathematica software tool. The proposed base model is universal and can be modified (simplified) in dependence on the parameters of a specific SRComS