Safety Controller Verification ID for Time-Limited Test Runs
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Solution Overview
Problem
There is a need for a method to validate and verify safety control programs in industrial controllers that ensures compliance with safety standards, preventing the risk of inappropriate configuration jeopardizing human life and machine integrity, while allowing flexible software configuration.
Innovation Solution
An industrial controller with an interface for uploading and verifying safety control programs, using a verification ID (VID) to limit execution of unverified programs and indicate unverified run mode, with a timer to stop unverified program execution and a process for assigning a VID through computer-readable media instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a safety control program is configured using software editor program, then flexibility in configuration is improved, but the risk of inappropriate configuration compromising safety requirements increases
Solution Approach 1:
The patent implements a test run mode that executes the safety control program before final deployment to identify configuration errors in advance. This preliminary execution allows validation of safety logic, detection of programming mistakes, and verification of safety requirements compliance before the program is activated in the actual safety-critical system, thus resolving the contradiction between configuration flexibility and safety reliability.
2Reliability
If a newly configured safety control program is allowed to operate for testing, then performance validation is improved, but the risk of unverified program execution increases
Solution Approach 1:
The patent implements a dynamic operational state system where the safety control program can transition between different modes: test run mode for validation and active mode for operational use. The controller dynamically adjusts its behavior based on the validation status, allowing controlled testing when unverified while preventing unauthorized execution of potentially harmful unvalidated programs, thus balancing performance validation needs with safety risk mitigation.
3Object-affected harmful factors
If operation is limited to predetermined period for unverified programs, then safety risk is reduced, but the ability to validate performance is constrained
Solution Approach 1:
The patent implements a periodic test run mechanism where unverified safety control programs are executed in controlled time-limited test cycles. The controller automatically manages test run durations, allowing sufficient time for comprehensive safety validation while enforcing periodic interruptions or termination to prevent excessive exposure to unverified code. This periodic action pattern ensures both adequate validation opportunity and safety risk containment.
Data Source
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Figure 3A
AI summary
An industrial safety controller (100) is disclosed. The controller (100) comprises an interface (110) for downloading of a safety control program into a memory (120) and at least one processing unit (130) for executing a safety control program (122). The at least one processing unit (130) is configured to determine whether a safety control program (122) is verified and to limit an execution of an unverified safety control program according to an unverified run mode. An indicator (140) is configured to indicate the execution of an unverified safety control program. A method (300) of assigning a verification ID to an industrial controller comprises steps of configuring (320) and downloading (340) a safety control program, validating (360) the configured safety control program for the target industrial controller, and assigning (380) a verification ID. Execution of the configured safety control program is limited before the verification ID is assigned.