Verification and Optimization of a PLC Control Schedule

We report on the use of the SPIN model checker for both the verification of a process control program and the derivation of optimal control schedules. This work was carried out as part of a case study for the EC VHS project (Verification of Hybrid Systems), in which the program for a Programmable Logic Controller (PLC) of an experimental chemical plant had to be designed and verified. The intention of our approach was to see how much could be achieved here using the standard model checking environment of SPIN/Promela. As the symbolic calculations of real-time model checkers can be quite expensive it is interesting to try and exploit the efficiency of established non-real-time model checkers like SPIN in those cases where promising work-arounds seem to exist. In our case we handled the relevant real-time properties of the PLC controller using a time-abstraction technique; for the scheduling we implemented in Promela a so-called variable time advance procedure. For this case study these techniques proved sufficient to verify the design of the controller and derive (time-)optimal schedules with reasonable time and space requirements

Model checking embedded system designs

We survey the basic principles behind the application of model checking to controller verification and synthesis. A promising development is the area of guided model checking, in which the state space search strategy of the model checking algorithm can be influenced to visit more interesting sets of states first. In particular, we discuss how model checking can be combined with heuristic cost functions to guide search strategies. Finally, we list a number of current research developments, especially in the area of reachability analysis for optimal control and related issues

Automated Verification and Generation of Flexible Automation Control

Consumer product life-cycles are constantly shortening; the automotive industry is an illustrative example. As a consequence, the introduction of new products into the manufacturing system necessarily becomes more frequent. Inherently, this brings a performance reduction for the manufacturing system. The reduced performance is caused by a down-time and a ramp-up-time. During the down-time the mechanical equipment is rebuilt and the new control programs are debugged. During ramp-up there are a large number of errors mainly caused by mechanical devices not being properly adjusted, bugs in the control programs and operators not used to new procedures. Thus, in order to maintain the productivity level and to achieve full cost-efficiency both the down-time and the ramp-up time must be reduced. One way to reduce these lead times is to verify the control programs in offline mode. However, efficient and reliable offline verification requires some major improvements of the current development process of manufacturing systems. Information handling and development of control programs based on information reuse are the two most important improvement areas.The work presented here addresses four industrial problems related to this, lack of tools for offline verification of control programs, lack of information reuse in the development process of a manufacturing system, lack of operator support in error situations, and lack of tools for analyzing the control of complex manufacturing cells.We propose a development method where information from different tools in the development process of a manufacturing system is reused and processed by tools for verification and optimization. Then the control programs are generated by combining the processed information with a library of standardized software components. The proposed method solves the above-mentioned industrial problems without adding work to the development process. On the contrary, the amount of work will be reduced since the control program development will be automated and the time for debugging the control programs on the shop floor will be drastically reduced, due to the new mathematically based verification process

Formal Verification of Real-Time Function Blocks Using PVS

A critical step towards certifying safety-critical systems is to check their conformance to hard real-time requirements. A promising way to achieve this is by building the systems from pre-verified components and verifying their correctness in a compositional manner. We previously reported a formal approach to verifying function blocks (FBs) using tabular expressions and the PVS proof assistant. By applying our approach to the IEC 61131-3 standard of Programmable Logic Controllers (PLCs), we constructed a repository of precise specification and reusable (proven) theorems of feasibility and correctness for FBs. However, we previously did not apply our approach to verify FBs against timing requirements, since IEC 61131-3 does not define composite FBs built from timers. In this paper, based on our experience in the nuclear domain, we conduct two realistic case studies, consisting of the software requirements and the proposed FB implementations for two subsystems of an industrial control system. The implementations are built from IEC 61131-3 FBs, including the on-delay timer. We find issues during the verification process and suggest solutions.Comment: In Proceedings ESSS 2015, arXiv:1506.0325

Optimal Scheduling Using Branch and Bound with SPIN 4.0

The use of model checkers to solve discrete optimisation problems is appealing. A model checker can first be used to verify that the model of the problem is correct. Subsequently, the same model can be used to find an optimal solution for the problem. This paper describes how to apply the new PROMELA primitives of SPIN 4.0 to search effectively for the optimal solution. We show how Branch-and-Bound techniques can be added to the LTL property that is used to find the solution. The LTL property is dynamically changed during the verification. We also show how the syntactical reordering of statements and/or processes in the PROMELA model can improve the search even further. The techniques are illustrated using two running examples: the Travelling Salesman Problem and a job-shop scheduling problem

Modelling flexible manufacturing systems through discrete event simulation

As customisation and product diversification are becoming standard, industry is looking for strategies to become more adaptable in responding to customer’s needs. Flexible manufacturing systems (FMS) provide a unique capability where there is a need to provide efficiency through production flexibility. Full potential of FMS development is difficult to achieve due to the variability of components within this complex manufacturing system. It has been recognised that there is a requirement for decision support tools to address different aspects of FMS development. Discrete event simulation (DES) is the most common tool used in manufacturing sector for solving complex problems. Through systematic literature review, the need for a conceptual framework for decision support in FMS using DES has been identified. Within this thesis, the conceptual framework (CF) for decision support for FMS using DES has been proposed. The CF is designed based on decision-making areas identified for FMS development in literature and through industry stakeholder feedback: set-up, flexibility and schedule configuration. The CF has been validated through four industrial simulation case studies developed as a part of implementation of a new FMS plant in automotive sector. The research focuses on: (1) a method for primary data collection for simulation validated through a case study of material handling robot behaviour in FMS; (2) an approach for evaluation of optimal production set-up for industrial FMS with DES; (3) a DES based approach for testing FMS flexibility levels; (4) an approach for testing scheduling in FMS with the use of DES. The study has supported the development of systematic approach for decision making in FMS development using DES. The approach provided tools for evidence based decision making in FMS

Recent Developments at the NASA Langley Research Center National Transonic Facility

Several upgrade projects have been completed or are just getting started at the NASA Langley Research Center National Transonic Facility. These projects include a new high capacity semi-span balance, model dynamics damping system, semi-span model check load stand, data acquisition system upgrade, facility automation system upgrade and a facility reliability assessment. This presentation will give a brief synopsis of each of these efforts

Smart Grid Communications: Overview of Research Challenges, Solutions, and Standardization Activities

Optimization of energy consumption in future intelligent energy networks (or Smart Grids) will be based on grid-integrated near-real-time communications between various grid elements in generation, transmission, distribution and loads. This paper discusses some of the challenges and opportunities of communications research in the areas of smart grid and smart metering. In particular, we focus on some of the key communications challenges for realizing interoperable and future-proof smart grid/metering networks, smart grid security and privacy, and how some of the existing networking technologies can be applied to energy management. Finally, we also discuss the coordinated standardization efforts in Europe to harmonize communications standards and protocols.Comment: To be published in IEEE Communications Surveys and Tutorial