Safety Controller Toolchain with Fingerprint-Based Integrity Checks

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Solution Overview

Problem

Existing safety-related engineering systems with closed architectures and proprietary data formats face challenges in data management, flexibility, and integration of non-safety related software tools, leading to reduced efficiency and increased complexity in validation and maintenance processes.

Innovation Solution

A method for operating a safety controller that allows program files to be stored in open text formats like XML, JSON, or TXT, using fingerprint objects to ensure data integrity and detect inconsistencies, enabling the integration of external tools and flexible management of program files while maintaining safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If closed architecture with proprietary data formats is used, then safety and reliability are improved, but flexibility and ease of operation deteriorate

Engineering Contradiction:

ImprovesafetyVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system separates safety-critical functions from non-safety functions, allowing different data formats and toolchains to be used for different parts of the system. Safety-related program files can use proprietary formats while non-safety files use open formats like XML, JSON, or TXT.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The safety controller is designed to accept and process multiple data formats simultaneously. It can handle both proprietary safety-related formats and open standard formats, enabling flexibility in tool selection while maintaining safety integrity through format-appropriate processing paths.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If manual compilation processes are required, then safety validation is improved, but productivity and time efficiency deteriorate

Engineering Contradiction:

Improvesafety validationVSAvoidcompilation efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs preliminary consistency checks and validations on program files before compilation. Fingerprint objects are generated and stored in advance, enabling automated detection of inconsistencies without requiring manual intervention during the compilation process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The safety controller automatically performs consistency checks using fingerprint objects and metadata without requiring manual validation. The system self-verify program file integrity through automated comparisons, reducing the need for manual safety validation while maintaining rigor.

Inventive Principle:

Principle #25Self-service

3Reliability

If proprietary data formats are used, then data protection is improved, but ease of manufacture and adaptability deteriorate

Engineering Contradiction:

Improvedata protectionVSAvoidtool integration

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system changes the format parameter based on the type of program file being processed. Safety-critical files use proprietary formats with enhanced protection, while non-safety files use open formats that are compatible with external tools. The fingerprint object structure adapts to accommodate different format requirements.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Fingerprint objects serve as intermediaries between proprietary and open data formats. They contain essential metadata and consistency information that can be generated from proprietary formats and used by external tools working with open formats, enabling tool integration without compromising data protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If comprehensive validation measures are implemented, then systematic integrity is improved, but loss of time and complexity increase

Engineering Contradiction:

Improvesystematic integrityVSAvoidvalidation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Essential consistency checks are performed in advance using fingerprint objects and metadata before full compilation. This preliminary validation catches obvious errors early without requiring time-consuming manual reviews, reducing overall validation time while maintaining systematic integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system applies different levels of validation intensity based on the program file type and risk level. Critical safety functions receive comprehensive validation, while less critical functions undergo streamlined checking using fingerprint comparisons, reducing total validation time without compromising essential safety.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentEP4685588A1Method for operating a safety controller - toolchain

Publication Date: 2026.01.28 ABB (SCHWEIZ) AG

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AI summary

To provide a safety-related engineering system (1) that allows for the integration of non-safety-related software tools, a program file (PF) and a fingerprint object (FP) associated with the program file (PF) are provided at an update time point (tu), a consistency check between the program file (PF) and the fingerprint object (FP) is performed at a checking time point (tc) after the update time point (tu), and, at a transfer time point (tt) after the checking time point (tc), in case the consistency check confirmed a consistency between the program file (PF) and the fingerprint object (FP), said program file (PF) is compiled and linked to obtain an executable program code, which executable program code is transferred to a memory (ROM) of a safety controller (3) and executed by means of at least one processor (31) of said safety controller (3).