Functional Safety Networks and Protocols in the Industrial Internet of Things Era PMC

A real-life example is – a production employee presses an emergency stop (estop) because a part was not loaded into a horizontal pneumatic press properly. The mindset of the employee would be to hit the estop when everything stops moving, then proceeding to reposition the part in the press window because it appears to be safe. Since it is a horizontal press, there is no gravity risk present such as a vertical press would have. However, if the lines are still under pressure then the risk of the press cycling could lead to a major injury or possible fatality. After hitting the estop the systems air should have been dumped from the supply lines and electrical power to components not involved in safety monitoring should be opened. All potential and stored energy must be released or opened so it cannot activate any non-safety components.

Automation of Safety-Related Protocols

Functional safety networks are expected to be increasingly used in IIoT ecosystems, particularly over wireless media. In this respect, in this paper, we addressed safety protocols, focusing on those described by the IEC 61784–3 International Standard, and investigated their suitability for IIoT applications. The provided analysis, as well as the results of an extensive experimental session carried out on a prototype implementation of FSoE over WiFi, allowed us to make some interesting considerations. First, the black channel principle can be successfully exploited to bring safety protocols over communication media different from those for which they were natively designed. Second, although the black channel approach in principle ensures feasibility, it is clear it might introduce limitations, particularly with respect to performance. This aspect derives from the undeniable fact that each protocol has been conceived for a specific network.

Functional Safety Networks and Protocols in the Industrial Internet of Things Era

In ProfiSAFE, SFRT is calculated under the hypothesis that during the transmission of a safety PDU there may be at most a single faulty device in the safety network. This means that the procedure of reaching the safe state by a system has to consider, in the worst case, also the possibility of a fault in one of the devices of the network. The detection of such fault is made possible by watchdog timers used by the safety devices. Thus, since ProfiSAFE is based on a master–slave protocol, if a slave does not respond to the query of the master within a timeout, then the master marks that slave as faulty and moves to the next one. Conversely, if a slave is not polled by the master within a timeout, then it enters the safe state. These new safety modules have redundancy designed into them to check for component failures, ensuring an unsafe condition is not introduced.

Automation of Safety-Related Protocols

Department of Labor, firms spend nearly $170 billion annually on injuries and illnesses. Additionally, according to the Occupational Safety and Health Administration of the U.S. Department of Labor, businesses can save these expenditures by 20% to 40% by merely enhancing safety protocols. The phrase “hierarchy of controls” does not refer to real-time controls; rather, it describes the actions users should take to reduce the risks that every piece of equipment or installation presents. There are frequently numerous possible actions that can be taken in some combination with one another. The use of robots can have a great effect on productivity and efficiency, however, the safeguarding of robotic cells is critical.

Although its specific formulation is related to ProfiSAFE, it has been subsequently characterized by [26,27] for other protocols. In this section, we present an example of implementation of the FSoE protocol on general purpose commercial devices, using WiFi as wireless network. In particular, we provide some details about the testbed and the obtainable performance. Notably, the proposed implementation does not make use of any industrial application layer, and relies only on the protocol stack of the adopted devices.

As a consequence, the implementation cannot take benefit of the techniques typically adopted by the application layer protocols to increase reliability. Thus, from this point of view, the achieved performance can be considered, roughly, as a lower bound for reliability. Conversely, the measurement of the polling time does not include the time necessary to execute the application layer protocol stack, possibly leading to slightly more optimistic results. Safety-relevant data are transported with Profisafe[8][9] as F-messages between an F-Host (safety controller) and its F-Device (safety device) as payload in a telegram of an industrial network. In the case of a modular F-Device with several F-modules, the payload consists of several F-messages.

TwinSAFE software

A certified application manual makes the engineering process even more straightforward from conceptual design through to realization. Companies must comply with Federal Motor Vehicle Safety Standards and certify that their vehicle is free of safety risks. There is no vehicle currently available for sale that is fully automated or “self-driving.” Every vehicle currently for sale in the United States requires the full attention of the driver at all times for safe operation. While an increasing number of vehicles now offer some automated features designed to assist the driver under specific conditions, these vehicles are not fully automated. Types of automated technologies, such as advanced driver assistance system technologies already in use on the roads and future automated driving systems at their mature state, have the potential to reduce crashes, prevent injuries, and save lives.

In order to assess the situation and choose the best design course, trained specialists should conduct a safety audit prior to planning for any safety-related systems because safety standards and laws change over time. Programmable logic controllers, or PLCs, are industrial computers designed to monitor, control, and execute a custom program. PLCs are specially designed to be rugged and durable, able to withstand the industrial environment. Their original design and release aimed to replace the old hard-wired, relay logic of the past.

Getting started with AI and robotics in safety

Having safety procedures in place would limit the liability as they serve as evidence that you have done your best to ensure a safe workplace. If it can be proven that you caused an injury to either workers or customers by neglecting workplace safety in any way, you may be liable for damages in a civil lawsuit. Depending on the extent of the issue, the settlement could be hefty and potentially damaging, especially to small businesses.

Review the procedures regularly, and revisit them especially if there is an incident or a change in operations such as a new piece of equipment or a new project. Temperature checks, social distancing, and mask mandates have become standard across many businesses. While necessary, enforcing these protocols can limit facilities’ productivity, as they rely on staff who could otherwise work on value-adding tasks. Since many companies had to reduce their active workforce by 39% on average, they need to improve productivity wherever possible. Elimination, or eradicating the potential hazard, is the best and most efficient risk mitigation approach. Unfortunately, most devices and processes cannot be designed in a way to completely eliminate all potential hazards, thus most of the time this is not an option.

Focusing on WiFi, performance might be further improved with respect to both reliability and reaction time. Indeed, rate adaptation algorithms specifically designed for industrial WiFi applications, as well as suitable network protocol tuning, may lead to significant benefits in terms of reliability and timeliness, as discussed in [36,37]. In addition, new forthcoming WiFi versions, such as those based on the IEEE 802.11ax standard, promise considerable performance improvements. Functional safety networks are becoming of paramount importance in industrial systems, due to the progressive innovation introduced by the Industry 4.0 paradigm, characterized by high production flexibility, reliability and scalability.

web application security practices

What kind of sequence is necessary, from initial start-up to programmed commands? These are just some of the questions that we should ask ourselves and answer thoroughly to ensure a proper initial safety assessment is conducted. There are a plethora of safety components available to help ensure a safe, automated machine is available to protect employees and improve efficiency. The international standard IEC Functional safety of electrical/electronic/programmable electronic safety-related systems. IEC Safety of machinery – Functional safety of safety-related electrical, electronic and programmable electronic control systems and ISO Safety of machinery — Safety-related parts of control systems are also the basis for Profisafe. Machine builders and users will benefit from the extensive and long-standing safety expertise provided by Beckhoff.

  • By instituting effective safety procedures and thus reducing such incidents, you are reducing all these costs as well.
  • Special knowledge for ensuring proper preprocessing is then no longer needed, reducing the complexity of the centralized safety application and in turn simplifying validation and verification of the centralized safety application.
  • Functional safety networks are expected to be increasingly used in IIoT ecosystems, particularly over wireless media.
  • Since some bus components, such as switches, have a buffer memory, a 32-bit monitoring number was selected for Profisafe.
  • Creating and implementing safety procedures, as well as reviewing and updating them regularly can become complex and time-consuming, especially if all of it is done manually.
  • Unfortunately, most devices and processes cannot be designed in a way to completely eliminate all potential hazards, thus most of the time this is not an option.

Also, vehicle electrification opens up possibilities to improve efficiency with less personal driving, resulting in further reductions of air pollutants from the transport sector. Although the robot itself may have excellent safety functions, the robot maker generally does not know how its robot is being used, or even what end effector it will have. (Most robots have safety functions that meet PLd with either a category 2 or 3 architecture, enabling integration with safety devices and other machines.) That’s why it’s advisable to use a good integrator. During the test, 10 packets were lost in total, resulting in a ratio of lost packets equal to 1.04×10−6.

Automation of Safety-Related Protocols

Just because a piece of equipment is in a resting, potential energy state does not mean it is safe to work in the environment or around it. While great advancements occur to push a company’s overall yield, safety risk should also be a major interest. The great thing about the innovations we have made in the technology is that it can help improve safety in our working environments so that productivity and quality do not deteriorate. While maintaining a safe work environment is necessary, it’s easy to see why so many employers failed safety testing and why so few employees knew their rights. As those rights continued to change, it became harder for staff to stay up-to-date with safety regulations. Over the years, its inclusion has made startups more competitive, productive and, importantly, more secure.

Automation of Safety-Related Protocols

In this case Profisafe has no further requirements for the transmission channel, this is considered as a black channel. Different transmission channels such as copper cable, fiber optic cable (FOC), backplane bus or wireless systems[10] such as WLAN can be used. Neither the transmission rates nor the respective error detection of the transport protocol play a role for safety. Profisafe (usually styled as PROFIsafe, as a portmanteau for Profinet or Profibus safety)

is a standard for a communication protocol for the transmission of safety-relevant data in automation applications with functional safety.