PLC Security Failover for Malicious Function Block Revisions
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Solution Overview
Problem
Conventional security solutions for industrial control systems are inadequate in addressing cyberattacks, particularly in open and dynamic production environments with increased connectivity from mobile devices and IoT paradigms, as they rely on perimeter protection mechanisms that fail to mitigate risks within the control systems themselves.
Innovation Solution
Implementing security failover procedures within Programmable Logic Controllers (PLCs) that detect malicious revisions by using digital signatures and failover computing devices, allowing for the execution of revised replicas of function blocks or data blocks to maintain control system resilience and minimize adverse impacts from cyberattacks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If perimeter protection mechanisms (firewalls, VPN concentrators) are used to protect control systems, then security against external attacks is improved, but security against internal attacks in open production environments deteriorates
Solution Approach 1:
The patent divides the control system into multiple independent segments: primary control system, backup control system, and failover management system. Each segment operates independently with its own control programs and data, allowing the system to isolate and contain cyberattacks within specific segments while maintaining overall system security and functionality in open production environments
Solution Approach 2:
The patent changes the security parameter from perimeter-based protection to internal redundancy-based protection. By implementing hot-standby failover mechanisms with real-time monitoring and automatic switching capabilities, the system adapts to open production environments while maintaining security through architectural redundancy rather than perimeter defenses
2Ease of operation
If control systems and security systems run independently with separate design and operation teams, then operational simplicity is improved, but integrated security response to cyberattacks deteriorates
Solution Approach 1:
The patent merges control system operations with security system operations by implementing a unified failover management mechanism. The failover management system monitors both control functionality and security status simultaneously, enabling coordinated response to cyberattacks that integrates operational simplicity with effective security response through a single management framework
3Adaptability or versatility
If production cell networks become open and dynamic with mobile devices and wireless sensors, then data collection and diagnostics capabilities are improved, but security risks to automation devices increase
Solution Approach 1:
The patent implements prior cushioning by pre-configuring backup control systems with identical control programs and data before cyberattacks occur. The failover management system continuously monitors for security threats and maintains readiness to switch to the pre-prepared backup system, providing a safety buffer that protects automation devices from open network risks while maintaining enhanced connectivity capabilities
Data Source
AI summary
A method for performing security failover in an industrial production environment includes a programmable logic controller (PLC) receiving notification that a function block (FB) or a function (FC) on the programmable logic controller has been maliciously revised. The PLC next determines whether the function block or the function is also maliciously revised on a failover computing device. If the failover computing device is not maliciously revised, a failover operation is performed by the PLC. This operation includes sending a data block comprising one or more input parameters to the function block or the function and receiving an output data resulting from executing the function block or the function with the data block on the failover computing device.