Inline Controller Monitoring for Cybersecure Network Connectivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Network connected controllers in industrial applications are prone to technical malfunctions leading to downtime and financial losses, and are vulnerable to unauthorized modifications and cybersecurity threats, especially as they become more connected to the internet, with existing diagnostic methods being subjective and potentially late in detection.
Innovation Solution
A data acquisition device is interposed between the controller and the network to monitor and secure data communication, enabling real-time, non-intrusive, and protocol-independent monitoring and protection, using techniques like data extraction, decryption, and AI for anomaly detection, and allowing for process control and integrity verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional diagnostic methods are used by trained personnel, then errors can be localized, but the diagnosis is subjective and may be too late for timely restoration
Solution Approach 1:
The monitoring system enables the controller to monitor itself automatically without requiring human intervention. The data acquisition device continuously extracts and analyzes controller data, detecting errors and generating alerts autonomously, thus eliminating the subjectivity and time delays associated with manual diagnostics by trained personnel.
Solution Approach 2:
The system implements continuous feedback by constantly monitoring controller data and comparing it against expected parameters. When deviations are detected, the system immediately generates alerts, creating a closed-loop feedback mechanism that enables timely detection and response to errors, preventing the delays inherent in periodic manual checks.
2Adaptability or versatility
If the controller is connected to the network for data sharing, then operational flexibility is improved, but vulnerability to cyber attacks and unauthorized modifications increases
Solution Approach 1:
The data acquisition device serves as an intermediary between the controller and the network. It monitors all data communications passing through it, detecting and alerting on potential cyber threats, unauthorized modifications, or malicious activities. This intermediary position enables the system to maintain network connectivity while providing a protective layer that can identify and respond to security threats before they compromise the controller.
3Reliability
If firewalls and antivirus software are deployed, then cybersecurity protection is improved, but system complexity and vulnerability to advanced attacks remain
Solution Approach 1:
The monitoring function is extracted from the controller itself and placed in a separate data acquisition device. This separation allows the controller to remain simple and unchanged while the monitoring system provides comprehensive security and diagnostic capabilities independently. The extraction of monitoring functions reduces the complexity burden on the controller and creates a specialized monitoring infrastructure.
4Reliability
If software modifications are made to enhance security, then protection capabilities are improved, but the risk of introducing new vulnerabilities and operational disruptions increases
Solution Approach 1:
The data acquisition device acts as an intermediary monitoring layer that provides security and diagnostic capabilities without requiring any software modifications to the controller. By positioning the monitoring function externally, the system gains enhanced protection and detection capabilities while avoiding the risk of introducing new vulnerabilities through controller software changes.
Data Source
AI summary
The invention relates to a method for monitoring and securing a network connected controller. The method includes a step of providing a data acquisition device interconnected between the controller and the network. Further, the method includes a step of extracting data from the controller, using the data acquisition device. The invention also relates to a data acquisition device.