new products increase their reliability by adding
redundant systems to help self-diagnose a
malfunction among others in a sensing device (e.g.,
a peripheral input device), an external safety
component (such as an emergency stop button), or
the CPU itself.
These technologies are still relatively new,
novel, and expensive. For this reason, they are only
adopted in newer, more expensive equipment. Older
industrial machinery could have possibly been built
with more relaxed safety standards. It is also a
possibility that current owners of older but still
expensive machinery are reluctant to upgrade their
equipment with newer hardware due to the
associated costs with the hardware, programming,
design, and installation.
The authors believe that current PLCs used in
older equipment (and do not currently conform to
newer safety standards) can support at least a subset
of the newer features such as diagnosing routines
with no hardware modifications. This research is
motivated by the fact that current owners of older
machinery would be willing to improve their safety
scores by only applying minor software updates.
As part of ongoing research in this area, the
authors have already proposed a method that allows
current non-fail-safe devices to detect external
sensor failure by employing techniques in software
and have shown that the advantages are comparable
to those of the newer fail-safe devices. Extending
this research, the paper proposes a software
algorithm that will allow current legacy software to
be able to detect hardware failure at the CPU level,
for the executing program to be able to shut down in
a safe manner, and to predict hardware faults of
PLC itself.
Researchers are actively figuring out techniques
that allow PLC-operated machinery to function in
more safe and reliable ways. The authors of a paper
have proposed a solution for formal verification that
uses mathematical models of the specific application
scenario to offer improvements in both fail and non-
fail-safe PLCs, [1], [2].
Another approach discussed by researchers aims
to detect safety violations (caused by faults or
attacks) by comparing data sets of event sequences
and the time of occurrence with data traces collected
beforehand in Industrial Control Systems (ICS).
Furthermore, researchers are studying the
advances of the new safety devices, in terms of the
diagnostic capabilities, implementation strategies,
and metrics such as response times of these routines,
[3], [4].
Although the motivation of the research
presented in this paper is in line with other work
presented above (i.e., to study and improve upon the
safety operation of devices), the approach discussed
here differs in the following ways:
a) The solution extends previous work to directly
port features of newer (fail-safe) PLCs to older
legacy hardware.
b) The algorithm does not depend on each specific
application scenario.
c) An application use case has been included to
present the function of the algorithm.
The rest of this paper is organized as follows:
Section (2) analyses current strategies for improving
safety and downtime records in terms of relevant
standards. Section 3 describes the approach that
current PLC manufacturers are using to detect
hardware failures in modern fail-safe equipment.
Section 4 proposes a solution in the form of an
algorithm that is able to run on legacy devices and
present similar advantages as the newer more
expensive products. The section also describes the
experimentation setup. Finally, Section 5
summarizes the results of the presented approach.
2 Redundant Systems
The redundant automation systems are commonly
used to offer greater availability. The objective of
these systems is to reduce the possibility of
production interruptions, the protection of
individuals, the protection of the surrounding
environment, and the safe termination of production.
In very critical applications such as refineries,
airports, and nuclear plants, such systems are
required not only to avoid the cost associated with
stopping production but also to prevent accidents.
Software Redundancy
In many applications, the requirements for fault-
tolerant cannot be justified. Simple software
mechanisms are sufficient to allow a failed process
to continue on a substitute system if an error occurs.
These mechanisms can be applied to control
processes that can tolerate larger transition delays to
a surrogate system, e.g., in waste-water plants, water
treatment plants, or traffic streams.
Hardware Redundancy
Hardware Redundancy consists of two subsystems
that are synchronized via fiber optic cables.
Both subsystems create a fault-tolerant automation
system that works with two channels and is based
on the principle of active redundancy. Active
redundancy means that all redundant resources are
continuously running and simultaneously
participating in the execution of the control task,
This means that the programs on both CPUs are
WSEAS TRANSACTIONS on SYSTEMS and CONTROL
DOI: 10.37394/23203.2023.18.28
Efstathios Theocharis, Michail Papoutsidakis,
Andrew Short, Konstantia Zisimou