Process Mining of Programmable Logic Controllers: Input/Output Event Logs

This paper presents an approach to model an unknown Ladder Logic based Programmable Logic Controller (PLC) program consisting of Boolean logic and counters using Process Mining techniques. First, we tap the inputs and outputs of a PLC to create a data flow log. Second, we propose a method to translate the obtained data flow log to an event log suitable for Process Mining. In a third step, we propose a hybrid Petri net (PN) and neural network approach to approximate the logic of the actual underlying PLC program. We demonstrate the applicability of our proposed approach on a case study with three simulated scenarios

Relay ladder logic and petri nets for discrete event control design : a comparative study

In the 1960\u27s and earlier discrete event systems (DES) were controlled by hardwired electromechanical relay systems. In 1969 an electronic programmable logic controller (PLC) was introduced. PLC\u27s have been programmed utilizing relay ladder logic (RLL). RLL is a graphical programming language with software devices used to emulate electromechanical devices. RLL programs, however, often become large and difficult to understand because its graphical representation of physical switching devices obscures the discrete event dynamics inherent in the process to be controlled. Petri nets are a methodology for modeling discrete event systems (DES). Using a Petri net based controller, a control strategy could be developed that captures the discrete event dynamics of the process. This should result in a control strategy that is much easier to understand, troubleshoot, modify and evaluate

Towards Quantifying Programmable Logic Controller Resilience Against Intentional Exploits

Supervisory Control and Data Acquisition (SCADA) systems control and monitor services for the nation\u27s critical infrastructure. Recent cyber induced events (e.g., Stuxnet) provide an example of a targeted, covert cyber attack against a SCADA system that resulted in physical effects. Of particular note is how Stuxnet exploited the trust relationship between the human machine interface (HMI) and programmable logic controllers (PLCs). Current methods for validating system operating parameters rely on message exchange and network communications protocols, generally observed at the HMI. Although sufficient at the macro level, this method does not provide detection of malware that exhibits physical effects via covert manipulation of the PLC, as demonstrated by Stuxnet. In this research, an alternative method that leverages direct analysis of PLC input and output to derive the true state of SCADA end-devices is introduced. The behavioral input-output characteristics are modeled using Petri nets to derive metrics for quantifying resilient properties of systems against malicious exploits. The results yield metrics that are applicable towards quantifying resilience in PLCs and implementing real-time security solutions. These findings enable detecting programming changes that affect input and output relationships, identifying the degree of deviation from a baseline program, and minimizing performance losses against disruptive events

Performance evaluation and sequence control of an automatedmanufacturing system

In an automated sequential manufacturing system Programmable Logic Controllers (PLC) are widely used. As the control specification varies, the control software needs to be rewritten to accommodate the new specification. Since PLC has high flexibility, one can update the current system while it is running thereby making easier implementation. In order to design flexible, reusable and maintainable control software, a good modeling tool is required. Petri nets are such a tool. Which facilitates analysis of behavioral properties, performance evaluation, and systematic construction of discrete event simulators and controllers. In this thesis a system with one robot and five sequential work stations is used as an example of an automated system. To illustrate the Petri net method, performance and other properties of this system are evaluated. The PLC program is also developed for sequence control of the system

MECHATRONICS DESIGN FROM ZERO TO ONE (STRUCTURED LOGIC DESIGN TO PROGRAM LOGIC OF LADDER DIAGRAM FOR PLC)

The purpose of this work is to study and analyze the methods use to design logic of ladder diagram for PLC-based controller in automated manufacturing systems. Previous method employed to design the logic of ladder diagram does not show clearly on how it is done step by step, widely based on the programmer's experience and their intuition. The methods proposed namely method A and method G hopefully can help the programmer especially the new programmer to design the ladder logic systematically and efficiently while at the same time reduce the time consume to program it. This systematic logic design can help the programmer to trace back their program for debug purpose. A step by step instruction is provided in this paper for both method A and method G. Few basic sequence are tested Finally, a case study on packaging process is provided to illustrate the design procedure of the proposed methods. In the same time, author will also explore the capability of the Automation Studio software

Specifications of a device interface for service-oriented automation control components

Service-oriented paradigm is being used to develop distributed and reconfigurable control solutions for factory automation environments. Since service-oriented automation control components are logical entities that provide and consume services, they may have an interface that maps the logical processes into the actions of the representative physical mechatronics. The inter-connection with the physical hardware devices, namely accessing I/Os, is a crucial issue to achieve the vertical IT-enterprise integration in these service-oriented systems, covering the shop floor device control level. This paper describes a device interface approach, in the context of a service-oriented control architecture, in which High-level Petri nets are used as the control description to access to the physical device. The outgoing features of the solution allow integrating the physical behavior into the control of automation components and consequently thereby incorporate it in the modular service-oriented control architecture