SAFETY in Automation

Company Logo1KW-SoftwareGary Liang

TÜV Rheinland International Symposium in ChinaFunctional Safety in Industrial ApplicationsOctober 18 – 19, 2011 in Shanghai – China

SAFETY in Automation

IEC 61508 Compliant Software Solutions

Company Logo2KW-SoftwareGary Liang

KW-Software: Company Information

� Foundation: 1982� Employees: 65� A Phoenix Contact Company � Headquarter: Lemgo Germany,

active in Japan, China, USA

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The scalable Software Platform

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Safety related Standards

� Machinery Directive 2006/42/EC

� Risk analysis and risk assessment� EN ISO 12100-1 Basic concepts, general principles for design� ISO 14121/EN 1050 Principles of risk assessment

� Safety-related electrical control systems� EN ISO 13849-1 (old EN 954-1) Performance levels (PL) or� IEC/EN 62061 (sector-specific of IEC 61508) Safety Integrity

Level (SIL)

� PLCopen Safety TC5� Specification for safety related FBs

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Functional safety management

� Can be done on company level or on project level� QA-Manual (process, documents, ...)� Coding guidelines� Safety plan� Safety Requirement Specification� Requirement tracking� Validation & Verification� …

5KW-SoftwareGary Liang

Company Logo6KW-SoftwareGary Liang

Certificated Development Process

� Certification of the IEC 61508 development process by TÜV

� Validation of KW-Software development process already done by TÜV, no need for extra validation by customer

� KW-Software supports partners in building up their own functional safety management

Company Logo7KW-SoftwareGary Liang

KW-Software offers a wide variety of Safety Softwar e

ProgrammingProgrammable IEC 61131safety logic with integration

of non-safe areas

SAFEPROG / SafeOS SAFECONF / SafeOS SAFEGRID

Parameterization of safety devices

(drives, sensors, etc)

ConfigurationBased on PLCopen

safety function blocksfor simple safety logic

� Safety software components are certified according to IEC 61508 SIL3

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Diversified Software Structure

� Diversified Software enables to develop a Safety system on base of the same CPU Type!

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Safety Communication (PC)Safety Communication (PC)

PLC program 1PLC program 1

SAFEPROG / SAFECONFSAFEPROG / SAFECONF

Compiler 1Compiler 1 Compiler 2Compiler 2

PLC program 2PLC program 2

Communication InterfaceCommunication Interface

CPU 1CPU 1 CPU 2CPU 2

Firmware 1Firmware 1

SafeOS 1SafeOS 1

Firmware 2Firmware 2

SafeOS 2SafeOS 2

PC

Saf

ety

PLC

KW-SoftwareKW-Software

Manufacturer of Safe PLC

Manufacturer of Safe PLC

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SAFEPROG / SAFECONF / SafeOS: Scalable solutions

� SafeOS supports diversified software structure for safety solutions up to SIL3.

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SAFEPROG: User Interface

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Programming (FBD/LD) Variable Declaration

Connection of I/Os with PLC Variables Cross References Simulation

Validation Check List Debug

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SAFEPROG: Fulfills PLCopen Safety Requirements

� Support of PLCopen Safety Guide Lines� Different colors for safe and standard function blocks

� Using of safe and standard data types

� Different user levels

� Graphical programming languages (FBD, LD)

� Plausibility checks

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Easy Programming with SAFEFBs

� 20 certified PLCopen safety function blocks as an independent library

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� SF_EnableSwitch � SF_SafeRequest� SF_TwoHandControlTypeII� SF_TwoHandControlTypeIII� SF_MutingSeq� SF_MutingPar� SF_MutingPar_2Sensor� SF_SafeStop1� SF_SafeStop2� SF_SafelyLimitedSpeed

� SF_Equivalent� SF_Antivalent� SF_EmergencyStop� SF_OutControl� SF_EDM� SF_GuardMonitoring� SF_GuardLocking� SF_ESPE� SF_TestableSafetySensor� SF_ModeSelector

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SAFECONF: Easy to use User Interface

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Toolbox with safety functions Connection editor Project information

Hardware Manager Simulation

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SAFECONF: Easy Drag & Drop Programming

� Input and output signals can be inserted into the connectioneditor from the hardware manager using drag & drop.

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Safety function blocks and functions can be inserted into the connection editor from the toolbox using drag & drop.

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Multicore and Safety

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� Multicore approaches� Consolidation:

Several applications that had been executed on standalone Hardware before can be run on one CPU now

� Virtualization: Control applications run on different virtualized systems using the Hypervisor that is protecting each application

� Separation: Of safe and non-safe applications by Hypervisor

Company Logo16KW-SoftwareGary Liang

Conclusion: Safety with KW-Software