Automation Controller Register Verification for Safe Network Separation
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Solution Overview
Problem
Existing automation controllers fail to reliably protect safety-related register values from falsification, particularly in network interface assignments, especially when the automation controller is in a stopped state or without a safety program.
Innovation Solution
An automation controller is designed to generate a number cyclically and apply a logical function to register values, producing a return value that is compared with test values using code instructions, moving the controller to a safe state if variance is detected, and ensuring network separation by monitoring register values for hardware and software errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional protection methods using user programs are used, then the automation controller can protect register values during normal operation, but the controller cannot identify falsifications when in a stopped state or without a safety program
Solution Approach 1:
The patent implements preliminary protection by embedding verification logic directly in the operating system that operates continuously before and during normal operation. The system pre-establishes test value tables and combination tables that define valid register configurations, allowing it to detect falsifications in any state including stopped states without requiring a separate safety program to be active first.
2Reliability
If the automation controller monitors register values cyclically with logical functions, then it can detect falsifications of safety-related settings, but the complexity of the control system increases
Solution Approach 1:
The system performs self-verification by automatically comparing current register values against pre-stored test values and combination tables. The operating system itself provides the verification mechanism through built-in code instructions that cyclically check register assignments, eliminating the need for external safety programs or additional monitoring hardware, thus achieving high reliability without proportionally increasing system complexity.
3Reliability
If the automation controller switches to a safe state upon detecting variance, then it ensures network separation safety, but the availability of the network interface is reduced
Solution Approach 1:
The system pre-configures valid network interface assignments in combination tables before operation begins. By establishing the correct configuration state in advance and continuously verifying against it, the system maintains network availability during normal operation while ensuring that any deviation from the predetermined safe configuration immediately triggers a safe state transition, thus balancing availability with safety.
Data Source
AI summary
Automation controller and method for operating the automation controller, wherein the automation controller includes Ethernet channels to which network interfaces can be assigned via a first register with a first register value and a second register with a second register value, where the assignments are made and these are examined for variances via test values.