Functional Safety for Electronic Control
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1 HYDAC ELECTRONIC Functional Safety for Electronic Control April 20, 2016 Speaker Eric Ringholm HYDAC ELECTRONIC Division Manager
2
3 Component range for modern machines Software
4 Product Range
5 Agenda Functional safety, why? Relevant standards First steps to designing a machine System design Example system design Software design
6
7 Technological Progress Electronic/ hydraulic circuit diagram of a typical mechatronic system Software
8 Resulting requirements with regards to the components Complexity of a combine harvester 8 CAN buses and 1 LIN bus (max. 5 per vehicle) Up to 25 controllers per vehicle > 80 electrical and electronic major functions >1000 sub functions >3000m electrical wiring >350 plug connections Development and Automatisation Controllers, the innovative force The software content in a Wirtgen new generation large-size stone mill Application SW (without firmware) More than lines of software code More than 200 components, modules and functions More than 600 global variables More than 4000 local variables 4 CANbuses using different protocols Approx. 3 years of engineering time Visualisation SW Machines with an increasing number (withoutof CAN server and Kernel) functions and with a complex system design, require: Networking of the vehicle fleet Networking of the entire process More components with increased Functional Safety Automatisation of particular functions Networking inside the vehicle More components with self diagnostic functions More than lines of software codes More than 380 classes with 3400 characteristics More than 600 local variables More than 126 XML lines of configuration data Approx status and error messages Approx graphics Approx. 3 years of engineering time Quelle/Source:: H. Hieronymus, CLAAS SE GmbH, VDI-Tagung 2012 Quelle/Source: H. Einig, Wirtgen GmbH, VDI-Tagung 2012
9 Functional Safety Diagnosis
10 Safety standards, comparable across all industry sectors DO 178B / 254 ISO ISO EN ISO IEC The system requirements are highly diverse! Mainly Fail-Safe Fail-Operational
11 Legal provisions, situation of the standards CE Mark: Legal basis: Required: Self-declaration from the manufacturer, all the relevant EU regulations are met Machinery Guideline 2006/42/EG Work equipment use directive 89/655/EWG Risk analysis, risk evaluation Standard-compliant product design Technical documentation, operation manual Relevant standards: Type- A-Standards Basic safety standards: z.b. EN ISO Methodology, superordinate Type-B-Standards Group safety standards: z.b. EN ISO Safety of machines Type-C-Standards z.b. DIN EN Product safety standards: Drilling equipment
12 Legal provisions, situation of the standards Machinery guideline Product safety A standards: Basic safety standards B standards: Group safety standards C standards: Product safety standards DIN EN EN EN 474 EN 4254 EN EN i.v. Loader cranes Mobile cranes Earth moving machines Agricultural machines Material handling Drilling machines
13 Extract from the relevant standards ISO 25119:2010, Tractors and machinery for agriculture and forestry Safety related parts of control systems ISO 15998:2008, Earth-moving machinery Machine-control systems (MCS) using electronic components ISO :2006, Functional safety safety related parts of a control system
14 First steps to designing a machine DIN EN ISO 12100: Safety Analysis
15 Safety Functional Safety for Electronic Control Comparison between SIL and PL 10-7 SIL Safety Integrity Level EN (IEC 61508) PL Performance Level EN e x d c b a 10-4
16 The right choice SIL or PL?
17 Comparison EN with IEC 62061, SIL or PL?
18 DIN EN ISO design process - Safety related parts of control systems SRP/CS - For each relevant safety function (1) Identify safety functions (2) and properties of SF (3) Define required Performance level PL r / AgPL r / SIL r (4) Realisation of safety functions, Identification of SRP/CS (5) Calculation of achieved PL Software: exclude systematic failures (6) Verification (7) Validation
19 Hazard & Risk Analysis Participants in a risk analysis: Generally, a representative group of persons, who are familiar with the machine throughout its whole life cycle. Marketing / product management Design engineers Test engineers Production / commissioning Service / maintenance Machine operator / driver
20 Hazard & Risk Analysis List of machine functions Example:
21 Hazard & Risk Analysis Definition of malfunctions Example: Proportional machine control function Unintended start Unintended stop Moving in wrong direction Unintended reverse movement Unintended fast movement Unintended slow movement Unintended acceleration Unintended deceleration
22 Hazard & Risk Analysis Determination of required performance level for each specific safety function Risk analysis based on EN ISO H&R Analysis Assessment S: severity of injury: F: frequency and / or duration of exposure to danger: P: probability of avoiding the exposure Machine function
23 Hazard & Risk Analysis Determination of required performance level for each specific safety function Risk Graph: Required risk minimisation and Performance Level: Severity of injury: S1 slight (usually reversible injury) S2 serious (usually irreversible injury which may include death) F1 F2 Frequency and / or duration of exposure to danger: rarely up to infrequent and / or the time of exposure to danger is short frequently up to continuously and / or the time of exposure to danger is long Probability of avoiding the danger: P1 possible under certain conditions P2 rarely possible
24 Hazard & Risk Analysis Safety function Each function in a machine whose malfunction can lead directly to an increase of the risk is defined as a safety function. A safety function is thus a function that can minimise a risk to an acceptable level by taking adequate (e.g. control) design measures. Examples of safety functions: Safety function Description - safe standstill (no operation) avoiding an unintended start - safe moving direction avoiding movement in a wrong direction - safe lift function avoiding exceeding a load limit (LMI) - safe acceleration avoiding exceeding an acceleration limit - function for a safe stop in case of achieving a defined safe state emergency in case of a failure
25 Channel Functional Safety for Electronic Control System Design Safety related part of a control system SRP/CS
26 System Design PL column chart according to EN ISO Illustrates the relations between PL, MTTFd, category and DC PL column chart
27 System Design PL column chart according to EN ISO Illustrates the relations between PL, MTTFd, category and DC PL column chart Example 1: Performance Level PL d for a machine function is required
28 System Design PL column chart according to EN ISO Illustrates the relations between PL, MTTFd, category and DC PL column chart Example 1: Performance Level PL d for a machine function is required
29 System Design The achieved safety level results from (balance) the combination of the characteristics: Architecture Reliability of the used components Recognition of the safety-relevant failures
30 Category Architecture / Design
31 Overview of the Control Architectures (Categories) Costs Achievable safety level design for normal safety level design with increased safety level
32 Reliability of the applied components
33 MTTFd Mean time to dangerous failure Statistically expected value of the average time to dangerous failure Note: indicator of the quality of a component
34 Characteristics MTTF Meaning: Scope of the directive: MTBF Meaning: Scope of the directive: Average period until failure occurs Valid for units which are not intended for repair. Average period between failures Valid for units which are intended to be repaired. MTTFd Meaning: Scope of the directive: B10 Meaning: B10d Meaning: Average period until dangerous failure occurs. Valid for units (components, systems), used in safety-critical systems. Statistically expected value of the number of cycles, in which 10% of the components have exceeded the defined limits (switch delay, leakage, switch pressure, etc.) under the defined conditions. Expected number of cycles in which 10% of the components have had dangerous failures.
35 Sensors with increased safety and/or diagnostic functions Example: Pressure Transmitter HYDAC Category B/1 Category 3 Category 2
36 Sensors for pressure, position and distance Pressure transducer HDA 8000 Category 2 MTTFd high (190 years) DC: low (87%) safety level: PL d, SIL 2 Pressure transducer HDA 4000 Category 3 MTTFd high (976 years) DC: low (84%) Safety level: PL d Position switch HLS 100 Category 2 MTTFd high (419 years) DC: low (88%) Safety level: PL d, SIL 2 Linear position sensor HLT 1000 Category 2 MTTFd high (83 years) DC: low (91%) Safety level: PL d, SIL 2 Valve position switch HLS 200 Category 2 MTTFD high (110 years) DC: medium (91%) Safety level: PL d
37 Products with increased safety and/or diagnostic functions Example: Controller (ECU) Cat 2 Architecture, PL d Diagnostic supply Redundant switch-off for the outputs to activate the safe state 2 CPUs monitor one and another Supply Actuator for safety-critical applications Sensor PWM MainCPU Diagnosis Diagnosis Monitoring Watchdog CPU Current feedback Release FET monitoring Monitoring of the PWM outputs Diagnosis of safetyrelevant inputs Periodic tests of RAM, Flash, CPU- Registers, Stack storage
38 Challenges for complex electronic systems Multi-Controller-Systems Machine functions distributed over a number of controllers
39 Functional Safety of Electronic Controls Controller and I/O modules Example: Controller and I/O modules HYDAC Standard and with increased functional safety level Certified units; IEC SIL 2 and SIL 3; ISO PL d Safety Certified Controllers General Purpose Controllers HY-TTC 30SH 14 Inputs, 14 Outputs EN ISO HY-TTC Inputs, 26 Outputs EN ISO HY-TTC 90, HY-TTC Inputs, 20 Outputs IEC & EN ISO HY-TTC Inputs, 36 Outputs IEC HY-TTC 500 Family HY-TTC Inputs, 60 Outputs HY-TTC Inputs, 44 Outputs IEC & EN ISO HY-TTC 30H 14 Inputs, 16 Outputs HY-TTC 50 Family HY-TTC Inputs, 20 Outputs HY-TTC60 28 Inputs, 20 Outputs Safe I/O Modules I/O Slave Modules HY-TTC 30XSH 14 Inputs, 14 Outputs EN ISO HY-TTC 30XSI 26 Inputs, 4 Outputs EN ISO HY-TTC 48XS 28 Inputs, 20 Outputs EN ISO HY-TTC 30X Family HY-TTC 30XH 14 Inputs, 16 Outputs HY-TTC 30XO 16 Inputs, 14 Outputs HY-TTC 30XI 26 Inputs, 4 Outputs HY-TTC 36X 26 Inputs, 16 Outputs 26 Inputs, 16 Outputs HY-TTC 48X 28 Inputs, 20 Outputs
40 Challenges for complex electronic systems HMI (Human Machine Interface) Example: Combination between Display and manual buttons and switches Joystick with function keys Hardware switches and buttons for safety-relevant operating functions 10,4 Touch Display Machine configuration Monitoring of the functions Failure display and diagnosis Convenience functions Hydraulic main switch
41 System design - Example -
42 System design Example: Required: PL r c Sensor PL c PL c PL c
43 System design Example 1: The simple way to the system Pressure sensor PL = c Controller PL = c Valve PL = c PL low = c N low = 3 PL = b
44 System design Example 2: The simple way to the system Pressure sensor PL = d Controller PL = c Valve PL = c PL low = c N low = 2 PL = c
45 Example: System design for a function with an increased safety level Category 2 design
46 System design Manual verification through the design engineer, or with the help of software tools i.e. software assistant SISTEMA Software Assisant SISTEMA (Sicherheit von Steuerungen an Maschinen) (Safety of Controls in Machines) Offers support for the evaluation of control safety, based on DIN EN ISO
47 System design Software assistant SISTEMA
48 Software design Some requirements for the design of safe software Modular and structured design and coding Taking into account the safety-related provisions of the electronic controls manufacturer (safety manual) Structured specification with safety requirements Specification has to be checked by second person (Safety functions incl. PL, reaction times, hardware interfaces, recognition and the control of external failures) Checking of the software code by a second person
49 Software design Designing a safe software according to V-Model
50 Software design Designing a safe software with design tool MATCH
51 Products with increased functional safety Sensors, Controllers, Software Sensoren / Sensors Steuerungen / Controller IO-Module / IO-modules Funktionale Sicherheit Functional safety HDA 4700 HDA 8700 HLS 100 HLS 200 HLT 1000 HAT 1000 HIT 1000 HY-TTC 90 HY-TTC 94 HY-TTC 200 HY-TTC 540 HY-TTC 580 HY-TTC 30S-H HY-TTC 30XS-H HY-TTC 30XS-I HY-TTC 48XS PL d PL d PL c PL c Kategorie Category SIL 2 SIL 2 Diagnosable Diagnosefähig
52 Thank you for your attention! Please discuss your applications with us. Electronic Division Functional Safety and Diagnostics - Sensors, Controllers, Displays, Systems... "Successful selling by understanding the applications" INNOVATION, MULTIPLICATION and LOCAL COMPETENCE Thank you for your attention! Please discuss your opportunities with us!
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