Architectures and design patterns for functional design of logic control and diagnostics in industrial automation

Recently in most of the industrial automation process an ever increasing degree of automation has been observed. This increasing is motivated by the higher requirement of systems with great performance in terms of quality of products/services generated, productivity, efficiency and low costs in the design, realization and maintenance. This trend in the growth of complex automation systems is rapidly spreading over automated manufacturing systems (AMS), where the integration of the mechanical and electronic technology, typical of the Mechatronics, is merging with other technologies such as Informatics and the communication networks. An AMS is a very complex system that can be thought constituted by a set of flexible working stations, one or more transportation systems. To understand how this machine are important in our society let considerate that every day most of us use bottles of water or soda, buy product in box like food or cigarets and so on. Another important consideration from its complexity derive from the fact that the the consortium of machine producers has estimated around 350 types of manufacturing machine. A large number of manufacturing machine industry are presented in Italy and notably packaging machine industry,in particular a great concentration of this kind of industry is located in Bologna area; for this reason the Bologna area is called “packaging valley”. Usually, the various parts of the AMS interact among them in a concurrent and asynchronous way, and coordinate the parts of the machine to obtain a desiderated overall behaviour is an hard task. Often, this is the case in large scale systems, organized in a modular and distributed manner. Even if the success of a modern AMS from a functional and behavioural point of view is still to attribute to the design choices operated in the definition of the mechanical structure and electrical electronic architecture, the system that governs the control of the plant is becoming crucial, because of the large number of duties associated to it. Apart from the activity inherent to the automation of themachine cycles, the supervisory system is called to perform other main functions such as: emulating the behaviour of traditional mechanical members thus allowing a drastic constructive simplification of the machine and a crucial functional flexibility; dynamically adapting the control strategies according to the different productive needs and to the different operational scenarios; obtaining a high quality of the final product through the verification of the correctness of the processing; addressing the operator devoted to themachine to promptly and carefully take the actions devoted to establish or restore the optimal operating conditions; managing in real time information on diagnostics, as a support of the maintenance operations of the machine. The kind of facilities that designers can directly find on themarket, in terms of software component libraries provides in fact an adequate support as regard the implementation of either top-level or bottom-level functionalities, typically pertaining to the domains of user-friendly HMIs, closed-loop regulation and motion control, fieldbus-based interconnection of remote smart devices. What is still lacking is a reference framework comprising a comprehensive set of highly reusable logic control components that, focussing on the cross-cutting functionalities characterizing the automation domain, may help the designers in the process of modelling and structuring their applications according to the specific needs. Historically, the design and verification process for complex automated industrial systems is performed in empirical way, without a clear distinction between functional and technological-implementation concepts and without a systematic method to organically deal with the complete system. Traditionally, in the field of analog and digital control design and verification through formal and simulation tools have been adopted since a long time ago, at least for multivariable and/or nonlinear controllers for complex time-driven dynamics as in the fields of vehicles, aircrafts, robots, electric drives and complex power electronics equipments. Moving to the field of logic control, typical for industrial manufacturing automation, the design and verification process is approached in a completely different way, usually very “unstructured”. No clear distinction between functions and implementations, between functional architectures and technological architectures and platforms is considered. Probably this difference is due to the different “dynamical framework”of logic control with respect to analog/digital control. As a matter of facts, in logic control discrete-events dynamics replace time-driven dynamics; hence most of the formal and mathematical tools of analog/digital control cannot be directly migrated to logic control to enlighten the distinction between functions and implementations. In addition, in the common view of application technicians, logic control design is strictly connected to the adopted implementation technology (relays in the past, software nowadays), leading again to a deep confusion among functional view and technological view. In Industrial automation software engineering, concepts as modularity, encapsulation, composability and reusability are strongly emphasized and profitably realized in the so-calledobject-oriented methodologies. Industrial automation is receiving lately this approach, as testified by some IEC standards IEC 611313, IEC 61499 which have been considered in commercial products only recently. On the other hand, in the scientific and technical literature many contributions have been already proposed to establish a suitable modelling framework for industrial automation. During last years it was possible to note a considerable growth in the exploitation of innovative concepts and technologies from ICT world in industrial automation systems. For what concerns the logic control design, Model Based Design (MBD) is being imported in industrial automation from software engineering field. Another key-point in industrial automated systems is the growth of requirements in terms of availability, reliability and safety for technological systems. In other words, the control system should not only deal with the nominal behaviour, but should also deal with other important duties, such as diagnosis and faults isolations, recovery and safety management. Indeed, together with high performance, in complex systems fault occurrences increase. This is a consequence of the fact that, as it typically occurs in reliable mechatronic systems, in complex systems such as AMS, together with reliable mechanical elements, an increasing number of electronic devices are also present, that are more vulnerable by their own nature. The diagnosis problem and the faults isolation in a generic dynamical system consists in the design of an elaboration unit that, appropriately processing the inputs and outputs of the dynamical system, is also capable of detecting incipient faults on the plant devices, reconfiguring the control system so as to guarantee satisfactory performance. The designer should be able to formally verify the product, certifying that, in its final implementation, it will perform itsrequired function guarantying the desired level of reliability and safety; the next step is that of preventing faults and eventually reconfiguring the control system so that faults are tolerated. On this topic an important improvement to formal verification of logic control, fault diagnosis and fault tolerant control results derive from Discrete Event Systems theory. The aimof this work is to define a design pattern and a control architecture to help the designer of control logic in industrial automated systems. The work starts with a brief discussion on main characteristics and description of industrial automated systems on Chapter 1. In Chapter 2 a survey on the state of the software engineering paradigm applied to industrial automation is discussed. Chapter 3 presentes a architecture for industrial automated systems based on the new concept of Generalized Actuator showing its benefits, while in Chapter 4 this architecture is refined using a novel entity, the Generalized Device in order to have a better reusability and modularity of the control logic. In Chapter 5 a new approach will be present based on Discrete Event Systems for the problemof software formal verification and an active fault tolerant control architecture using online diagnostic. Finally conclusive remarks and some ideas on new directions to explore are given. In Appendix A are briefly reported some concepts and results about Discrete Event Systems which should help the reader in understanding some crucial points in chapter 5; while in Appendix B an overview on the experimental testbed of the Laboratory of Automation of University of Bologna, is reported to validated the approach presented in chapter 3, chapter 4 and chapter 5. In Appendix C some components model used in chapter 5 for formal verification are reported.

A framework for distributed intelligent automation systems developments

This paper proposes a pragmatic framework that has been developed for classifying and analyzing developments in distributed automation and information systems - especially those that have been labeled intelligent systems for different reasons. The framework dissects the different stages in the standard feedback process and assesses distribution in terms of the level of granularity of the organization that is being considered. The framework has been found to be useful in comparing and assessing different distributed industrial control paradigms and also for examining common features of different development projects - especially those that might be sourced from different sectors or domains. © 2012 IFAC.

A framework for distributed intelligent automation systems developments

This chapter proposes a simple and pragmatic framework that has been developed for classifying and analyzing developments in distributed automation and information systems - especially those that have been labelled intelligent systems for different reasons. The framework dissects the different stages in the standard feedback process and assesses distribution in terms of the level of granularity of the organization that is being considered. The framework has been found to be useful in comparing and assessing different distributed industrial control paradigms and also for examining common features of different development projects - especially those that might be sourced from different sectors or domains. © Springer-Verlag Berlin Heidelberg 2013.

An investigation approach to test protection intelligent electronic devices (IEDs) in IEC 61850 based substation automation systems (SAS) at station level

This thesis has developed a new approach to trace virtual protection signals in Electrical substation networks. The main goal of the research was to analyse the contents of the virtual signals transferred, using third party software. In doing so, a comprehensive test was done on a distance protection relay, using non-conventional test equipment.

Substation Automation Systems – Future possibilities for commissioning

Substation Automation Systems have undergone many transformational changes triggered by improvements in technologies. Prior to the digital era, it made sense to confirm that the physical wiring matched the schematic design by meticulous and laborious point to point testing. In this way, human errors in either the design or the construction could be identified and fixed prior to entry into service. However, even though modern secondary systems today are largely computerised, we are still undertaking commissioning testing using the same philosophy as if each signal were hard wired. This is slow and tedious and doesn’t do justice to modern computer systems and software automation. One of the major architectural advantages of the IEC 61850 standard is that it “abstracts” the definition of data and services independently of any protocol allowing the mapping of them to any protocol that can meet the modelling and performance requirements. On this basis, any substation element can be defined using these common building blocks and are made available at the design, configuration and operational stages of the system. The primary advantage of accessing data using this methodology rather than the traditional position method (such as DNP 3.0) is that generic tools can be created to manipulate data. Self-describing data contains the information that these tools need to manipulate different data types correctly. More importantly, self-describing data makes the interface between programs robust and flexible. This paper proposes that the improved data definitions and methods for dealing with this data within a tightly bound and compliant IEC 61850 Substation Automation System could completely revolutionise the need to test systems when compared to traditional point to point methods. Using the outcomes of an undergraduate thesis project, we can demonstrate with some certainty that it is possible to automatically test the configuration of a protection relay by comparing the IEC 61850 configuration extracted from the relay against its SCL file for multiple relay vendors. The software tool provides a quick and automatic check that the data sets on a particular relay are correct according to its CID file, thus ensuring that no unexpected modifications are made at any stage of the commissioning process. This tool has been implemented in a Java programming environment using an open source IEC 61850 library to facilitate the server-client association with the relay.

PRECYSE: Cyber-attack Detection and Response for Industrial Control Systems

In this short paper, we present an integrated approach to detecting and mitigating cyber-attacks to modern interconnected industrial control systems. One of the primary goals of this approach is that it is cost effective, and thus whenever possible it builds on open-source security technologies and open standards, which are complemented with novel security solutions that address the specific challenges of securing critical infrastructures.

Economic Citizenship and Workplace Conflict in Anglo-American Industrial Relations Systems

This article argues that the expansion of individual employment rights is presenting a series of challenges to the collective model of economic citizenship that prevailed in most of the Anglo-American world during the last century. We examine developments in the management of workplace conflict in Anglo-American countries to highlight the institutional manoeuvrings that have been taking place to mould the nature of national regimes of employment rights. We argue that Governments almost everywhere are actively seeking to create institutional regimes that weaken the impact of employment legislation and we find that statutory dispute resolution agencies are eagerly trying to develop organizational identities that are aligned with rights-based employment disputes.

An ontology-driven communication architecture for spontaneous interoperability in Home Automation systems

Current solutions to the interoperability problem in Home Automation systems are based on a priori agreements where protocols are standardized and later integrated through specific gateways. In this regards, spontaneous interoperability, or the ability to integrate new devices into the system with minimum planning in advance, is still considered a major challenge that requires new models of connectivity. In this paper we present an ontology-driven communication architecture whose main contribution is that it facilitates spontaneous interoperability at system model level by means of semantic integration. The architecture has been validated through a prototype and the main challenges for achieving complete spontaneous interoperability are also evaluated.

Recent international activity in cooperative vehicle-highway automation systems /

This report summarizes the current state of the art in cooperative vehicle-highway automation systems in Europe and Asia based on a series of meetings, demonstrations, and site visits, combined with the results of literature review. This review covers systems that provide drivers with a range of automation capabilities, from driver assistance to fully automated driving, with an emphasis on cooperative systems that involve active exchanges of information between the vehicles and the roadside and among separate vehicles. The trends in development and deployment of these systems are examined by country, and the similarities and differences relative to the U.S. situation are noted, leading toward recommendations for future U.S. action. The Literature Review on Recent International Activity in Cooperative Vehicle-Highway Automation Systems is published separately as FHWA-HRT-13-025.

Literature review on recent international activity in cooperative vehicle-highway automation systems /

This literature review supports the report, Recent International Activity in Cooperative Vehicle-Highway Automation Systems. It reviews the published literature in English dating from 2007 or later about non-U.S.-based work on cooperative vehicle-highway automation systems. This review covers work performed in Europe and Japan, with application to transit buses, heavy trucks, and passenger cars. In addition to fully automated driving of the vehicles (without human intervention), it also covers partial automation systems, which automate subsets of the total driving process. Recent International Activity in Cooperative Vehicle Highway Automation Systems is published separately as FHWA-HRT-12-033.

MIDAS: Motorist Information and Driver Automation Systems. Final report.

Arizona Department of Transportation, Phoenix

Power control in cognitive radios, Internet-of Things (IoT) for factories and industrial automation

Cognitive radio (CR) is fast emerging as a promising technology that can meet the machine-to machine (M2M) communication requirements for spectrum utilization and power control for large number of machines/devices expected to be connected to the Internet-of Things (IoT). Power control in CR as a secondary user can been modelled as a non-cooperative game cost function to quantify and reduce its effects of interference while occupying the same spectrum as primary user without adversely affecting the required quality of service (QoS) in the network. In this paper a power loss exponent that factors in diverse operating environments for IoT is employed in the non-cooperative game cost function to quantify the required power of transmission in the network. The approach would enable various CRs to transmit with lesser power thereby saving battery consumption or increasing the number of secondary users thereby optimizing the network resources efficiently.

Front end development for building automation systems using JavaScript Frameworks

Automation technologies are widely acclaimed to have the potential to significantly reduce energy consumption and energy-related costs in buildings. However, despite the abundance of commercially available technologies, automation in domestic environments keep on meeting commercial failures. The main reason for this is the development process that is used to build the automation applications, which tend to focus more on technical aspects rather than on the needs and limitations of the users. An instance of this problem is the complex and poorly designed home automation front-ends that deter customers from investing in a home automation product. On the other hand, developing a usable and interactive interface is a complicated task for developers due to the multidisciplinary challenges that need to be identified and solved. In this context, the current research work investigates the different design problems associated with developing a home automation interface as well as the existing design solutions that are applied to these problems. The Qualitative Data Analysis approach was used for collecting data from research papers and the open coding process was used to cluster the findings. From the analysis of the data collected, requirements for designing the interface were derived. A home energy management functionality for a Web-based home automation front-end was developed as a proof-of-concept and a user evaluation was used to assess the usability of the interface. The results of the evaluation showed that this holistic approach to designing interfaces improved its usability which increases the chances of its commercial success.