Distributed implementation of Grafcets through IEC 61499

Comunicación presentada en 25th IEEE International Conference on Emerging Technologies and Factory Automation (ETFA), 2020A Grafcet is a standardized model for describing the behavior of systems which is popular among automation engineers. As the Grafcet standard excludes implementation details, the models are typically translated to automation software. Such software was traditionally programmed in one of the languages specified in IEC 61131-3. Nowadays, automation software is increasingly modelled in IEC 61499 which facilitates designing distributed control systems. In this paper, we define a standardized translation methodology, so that automation engineers can benefit from the advantages of IEC 61499 while continuing to use Grafcet. We discuss the differences between Grafcet and IEC 61499. We translated a Grafcet model into an IEC 61499 application to illustrate the process and derive guidelines for application designers. For the core concepts of Grafcet, we present the corresponding structure in IEC 61499

AUTOMATIC GENERATION OF THE PLC PROGRAMS FOR THE SEQUENTIAL CONTROL OF PNEUMATIC ACTUATORS

Nowadays, programmable logic controllers (PLC) are widely used in many automated systems, especially for the control of various actuators. The most common PLC programming is performed by either using a ladder diagram or a structured text. The paper presents the automatic generation of PLC programs for the purpose of sequentially controlling pneumatic actuators. In this paper, the pneumatic actuators are supplied and controlled by 5/2-way as well as 5/3-way bistable pneumatic valves with electric activation. The valve type depends on the number of positions in which the actuator should come, and the position sensors are used for detecting its movement. The characteristic encoding of the movement of actuators, position sensors and control commands is performed. The advantages of the automatic generation of the PLC commands and the entire program described in this paper are illustrated in a real example

Security Analysis for Distributed IoT-Based Industrial Automation

Internet of Things (IoT) technologies enable development of reconfigurable manufacturing systems--a new generation of modularized industrial equipment suitable for highly customized manufacturing. Sequential control in these systems is largely based on discrete events, whereas their formal execution semantics is specified as control interpreted Petri nets (CIPN). Despite industry-wide use of programming languages based on the CIPN formalism, formal verification of such control applications in the presence of adversarial activity is not supported. Consequently, in this article, we introduce security-aware modeling and verification techniques for CIPN-based sequential control applications. Specifically, we show how CIPN models of networked industrial IoT controllers can be transformed into time Petri net (TPN)-based models and composed with plant and security-aware channel models in order to enable system-level verification of safety properties in the presence of network-based attacks. Additionally, we introduce realistic channel-specific attack models that capture adversarial behavior using nondeterminism. Moreover, we show how verification results can be utilized to introduce security patches and facilitate design of attack detectors that improve system resiliency and enable satisfaction of critical safety properties. Finally, we evaluate our framework on an industrial case study

Contribution à la commande sûre des Systèmes à Événements Discrets

Les activités de recherche rentrent dans le spectre de la section 61 du CNU et ont pour domaine l’Automatique des Systèmes à Événements Discrets (SED). Elles sont conduites en vue d’accroître la sûreté de fonctionnement des systèmes automatisés comme ceux qu’il est possible de trouver dans le cadre de la production manufacturière, de la production d'énergie ou du transport. Une grande partie de ces recherches a concerné la conception sûre des systèmes de contrôle-commande à base d’Automates Programmables Industriels (API) et plus particulièrement les thématiques suivantes :- la vérification formelle de programmes de contrôle-commande,- la synthèse algébrique de programmes de contrôle-commande à partir de spécifications informelles,- le test de conformité d’un contrôleur logique vis-à-vis de sa spécification.D'autres recherches ont porté sur la formalisation des outils pour l’analyse de sûreté, utilisés dans le cadre de l’analyse prévisionnelle des risques d’un équipement ou d’une installation industrielle. Cette formalisation des outils utilisés en sûreté a été faite en examinant avec un point de vue SED une problématique qui ne l’était pas à son origine. Il a été étudié :- la modélisation algébrique des arbres de défaillances dynamiques,- l’analyse prévisionnelle des risques d’un point de vue qualitatif pour les systèmes réparables à partir de Boolean logic Driven Markov Processes (BDMPs),- l’analyse prévisionnelle des risques d’un point de vue quantitatif pour les systèmes réparables à l’aide de chaînes de Markov.D'une manière générale, ces activités de recherche ont pour objectif de proposer des apports formels ou méthodologiques à des outils de modélisation généralement issus de l’industrie tout en répondant à des besoins industriels déjà présents ou sur le point de le devenir

Model-Driven Development of Control Applications: On Modeling Tools, Simulations and Safety

Control systems are required in various industrial applications varying from individual machines to manufacturing plants and enterprises. Software applications have an important role as an implementation technology in such systems, which can be based on Distributed Control System (DCS) or Programmable Control System (PLC) platforms, for example. Control applications are computer programs that, with control system hardware, perform control tasks. Control applications are efficient and flexible by nature; however, their development is a complex task that requires the collaboration of experts and information from various domains of expertise.This thesis studies the use of Model-Driven Development (MDD) techniques in control application development. MDD is a software development methodology in which models are used as primary engineering artefacts and processed with both manual work and automated model transformations. The objective of the thesis is to explore whether or not control application development can benefit from MDD and selected technologies enabled by it. The research methodology followed in the thesis is the constructive approach of design science.To answer the research questions, tools are developed for modeling and developing control applications using UML Automation Profile (UML AP) in a model-driven development process. The modeling approach is developed based on open source tools on Eclipse platform. In the approach, modeling concepts are kept extendable. Models can be processed with model transformation techniques that plug in to the tool. The approach takes into account domain requirements related to, for example, re-use of design. According to assessment of industrial applicability of the approach and tools as part of it, they could be used for developing industrial DCS based control applications.Simulation approaches that can be used in conjunction to model-driven development of control applications are presented and compared. Development of a model-in-the-loop simulation support is rationalized to enable the use of simulations early while taking into account the special characteristics of the domain. A simulator integration is developed that transforms UML AP control application models to Modelica Modeling Language (ModelicaML) models, thus enabling closed-loop simulations with ModelicaML models of plants to be controlled. The simulation approach is applied successfully in simulations of machinery applications and process industry processes.Model-driven development of safety applications, which are parts of safety systems, would require taking into account safety standard requirements related to modeling techniques and documentation, for example. Related to this aspect, the thesis focuses on extending the information content of models with aspects that are required for safety applications. The modeling of hazards and their associated risks is supported with fault tree notation. The risk and hazard information is integrated into the development process in order to improve traceability. Automated functions enable generating documentation and performing consistency checks related to the use of standard solutions, for example. When applicable, techniques and notations, such as logic diagrams, have been chosen so that they are intuitive to developers but also comply with recommendations of safety standards

A Sequential Control Language for Industrial Automation

Current market trends for industrial automation are the need for customizable production, shorter time to market, and powerful global competitive pressure. Based on these trends two challenges have been identified: 1) flexible production systems and 2) integration and utilization of devices and software. Applications from both process automation, manufacturing, and robotics have been considered. More flexible languages and tools are needed to get a flexible production system. The graphical programming language Grafchart, based on the IEC 61131-3 standard language Sequential Function Charts (SFC), is considered with the aim to make both the language and its implementation more flexible. In particular, new constructs have been added to the Grafchart language and modern compiler techniques are evaluated for JGrafchart, a Grafchart implementation, with focus on an extensible language implementation. A first step toward real-time execution of Grafchart applications is also taken to make it possible to use Grafchart for hard real-time control. High execution rates often reveal concurrency issues and thus execution concurrency has also been investigated. Access to more data from industrial devices and software can be used to optimize production. Architectures for factory integration have been considered as this is the foundation to connect all devices and thus address the challenge of integrating and utilizing devices and software. Service Oriented Architecture (SOA) is a flexible software design methodology widely used in IT systems and for business processes. SOA service orchestration is brought to industrial automation by integrating support for both Devices Profile for Web Services (DPWS) and OPC Unified Architecture (OPC UA) in JGrafchart. Looking further, SOA 2.0 is event driven and features extremely loose coupling between components. An architecture based on SOA 2.0 where it is easy to integrate any device or software, in particular legacy devices with limited knowledge and capabilities, has been developed with focus on service choreography in industrial manufacturing. Another step toward real-time execution of Grafchart applications is integrated support for the high performance communication protocol LabComm. Additionally, it is investigated how Grafchart can be connected to Functional Mock-up Interface (FMI) for co-simulation to further address the shorter time to market trend by introducing simulation support. The PID controller is the most common controller for industrial automation. A PID implementation has been added to a Grafchart library and a flaw with the PID algorithm has been discovered. The problem occurs for PID controllers with a derivative part when the process value saturates. The derivative part then backs off which leads to undesired changes in the control signal. This issue has been analyzed and a solution to the problem is proposed