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Industrial Safety: Embedded World 2010

Altera Corporation
Altera Corporation

Learn about using FPGAs and embedded processors to enhance industrial safety applications. For more information, visit www.altera.com/industrial

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Industrial Safety with FPGA Devices Learning Zone @ Embedded World 2010 息 2010 Altera Corporation - Public
What Are Safety Systems? The function of a safety system is to monitor and control conditions on a machine or process that are hazardous Potential risks for machine operators Potential damage to machines/goods Potential damage to environment Systems and components must be designed such that they are safe under normal conditions Faults, failures and external influences must not result in an undetected loss of safety 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 2
Traditional Safety System Mains Power Safety Switch or Sensor Safety Relay Analog Input/ Fieldbus Drive Motor Controller PLC (optional) 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
Automation Trends A A B B + + + + + + + + + + + Input + + Output Input + + + Output Conv. + + + Conv. Conv. + + + Conv. 22 kW 1 1 1 1 5.5 kW kW kW kW KW 4.5 1 1 1 kW kW kW kW kW Drive/Controller Drives/Controllers Field-bus/ Network Inflexible Extremely Flexible Energy inefficient Energy Efficient Maintenance difficult Fast & easy maintenance Discrete operation Integrated Factory (networked) Difficult to stop quickly Fast shut down Safer! 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
Safety System With Integrated Functional Safety Mains Power Safety Switch or Sensor Safety Field-bus/Network Module Safety Packets Drive Motor Controller Safety Module PLC 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
Safety Standards - IEC 61508 IEC 61800-5-2 Electr. Drives IEC 61513 Nuclear Sector EN 50495 IEC 61508 Ex-Hazards EN 50128 Railway Applications IEC 60601 IEC 62061 Medical Machinery Devices IEC 61511 IEC 50156 Process Industry Furnaces 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
Designing a Safe Machine Historically safety in industrial automation only required simple mechanical appliances or electrical switches to turn off power Todays safety systems and new legislation require that products must be designed to ensure safety under both Normal and Fault/Failure conditions Developers must design in software safety features All potential failures must be assessed and safeguards designed into the product Developers must prove that their product is safe and submit the proof for certification e.g. TV Rheinland 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 7
TV Safety Certification All relevant aspects of the product are reviewed: Safety calculations Development flow (hardware and software) Component devices and IP Tools used Product design and construction Complex safety functionality increases development time, e.g. 2 to 4 years longer 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 8
Altera TV-Qualified Safety Data Package TV-qualified silicon, tools, and standard IP according to IEC 61508 safety standards Device Safety manuals for Altera FPGAs and CPLDs Quartus II design software version 9.0 SP2 Safe diagnostic IP Diagnostic IP blocks in accordance with IEC 61508 SIL3 Reduces development time Reduces development cost 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 9
FPGA Applications in Industrial Industrial Networking support Any industrial Ethernet standard from one platform Field buses Custom or proprietary standards Servos/Drives High performance Multiple Axis Integrated support for sigma delta A/D converters Multi standard support for encoders (EnDat, BiSS, etc.) Embedded processing /DSP functionality Nios II 32-bit processor DSP hardware, IP and development tools 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 10
Benefits of FPGA For Industrial Programmable Logic adds flexibility Support multiple interface standards Track changes in standards Add new features Increase performance Scalable and flexible integration of safe and standard IP Reduce total system cost System integration of multiple functions into 1 FPGA Smaller less complex boards Replace ASSPs and microcontrollers Build multiple products from one platform Protect against obsolescence 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 11
System Integration Encoder I/F Safe I/O Safe I/O FPGA Custom Motor Safety Safety Logic Controller Controller 1 Controller 2 Application Fieldbus / IE Custom PWM Processor Controller Drive Power Fieldbus/ Circuit Industrial Ethernet 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
Summary Altera is the first FPGA vendor to offer a TV-qualified (IEC 61508) safety data package FPGAs provide flexible, scalable, and obsolescence-proof solutions in the industrial space Reduce system complexity and increase flexibility Integrate multiple industrial fieldbuses for networking, application, and safety in one FPGA Simplification of development and certification processes Simplify certification process Reduce development time by as much as 2 years and reduce time to market www.altera.com/industrial 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 13
Thank You www.altera.com 息 2010 Altera Corporation - Public

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Industrial Safety: Embedded World 2010

  • 1. Industrial Safety with FPGA Devices Learning Zone @ Embedded World 2010 息 2010 Altera Corporation - Public
  • 2. What Are Safety Systems? The function of a safety system is to monitor and control conditions on a machine or process that are hazardous Potential risks for machine operators Potential damage to machines/goods Potential damage to environment Systems and components must be designed such that they are safe under normal conditions Faults, failures and external influences must not result in an undetected loss of safety 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 2
  • 3. Traditional Safety System Mains Power Safety Switch or Sensor Safety Relay Analog Input/ Fieldbus Drive Motor Controller PLC (optional) 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
  • 4. Automation Trends A A B B + + + + + + + + + + + Input + + Output Input + + + Output Conv. + + + Conv. Conv. + + + Conv. 22 kW 1 1 1 1 5.5 kW kW kW kW KW 4.5 1 1 1 kW kW kW kW kW Drive/Controller Drives/Controllers Field-bus/ Network Inflexible Extremely Flexible Energy inefficient Energy Efficient Maintenance difficult Fast & easy maintenance Discrete operation Integrated Factory (networked) Difficult to stop quickly Fast shut down Safer! 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
  • 5. Safety System With Integrated Functional Safety Mains Power Safety Switch or Sensor Safety Field-bus/Network Module Safety Packets Drive Motor Controller Safety Module PLC 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
  • 6. Safety Standards - IEC 61508 IEC 61800-5-2 Electr. Drives IEC 61513 Nuclear Sector EN 50495 IEC 61508 Ex-Hazards EN 50128 Railway Applications IEC 60601 IEC 62061 Medical Machinery Devices IEC 61511 IEC 50156 Process Industry Furnaces 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
  • 7. Designing a Safe Machine Historically safety in industrial automation only required simple mechanical appliances or electrical switches to turn off power Todays safety systems and new legislation require that products must be designed to ensure safety under both Normal and Fault/Failure conditions Developers must design in software safety features All potential failures must be assessed and safeguards designed into the product Developers must prove that their product is safe and submit the proof for certification e.g. TV Rheinland 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 7
  • 8. TV Safety Certification All relevant aspects of the product are reviewed: Safety calculations Development flow (hardware and software) Component devices and IP Tools used Product design and construction Complex safety functionality increases development time, e.g. 2 to 4 years longer 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 8
  • 9. Altera TV-Qualified Safety Data Package TV-qualified silicon, tools, and standard IP according to IEC 61508 safety standards Device Safety manuals for Altera FPGAs and CPLDs Quartus II design software version 9.0 SP2 Safe diagnostic IP Diagnostic IP blocks in accordance with IEC 61508 SIL3 Reduces development time Reduces development cost 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 9
  • 10. FPGA Applications in Industrial Industrial Networking support Any industrial Ethernet standard from one platform Field buses Custom or proprietary standards Servos/Drives High performance Multiple Axis Integrated support for sigma delta A/D converters Multi standard support for encoders (EnDat, BiSS, etc.) Embedded processing /DSP functionality Nios II 32-bit processor DSP hardware, IP and development tools 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 10
  • 11. Benefits of FPGA For Industrial Programmable Logic adds flexibility Support multiple interface standards Track changes in standards Add new features Increase performance Scalable and flexible integration of safe and standard IP Reduce total system cost System integration of multiple functions into 1 FPGA Smaller less complex boards Replace ASSPs and microcontrollers Build multiple products from one platform Protect against obsolescence 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 11
  • 12. System Integration Encoder I/F Safe I/O Safe I/O FPGA Custom Motor Safety Safety Logic Controller Controller 1 Controller 2 Application Fieldbus / IE Custom PWM Processor Controller Drive Power Fieldbus/ Circuit Industrial Ethernet 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S.
  • 13. Summary Altera is the first FPGA vendor to offer a TV-qualified (IEC 61508) safety data package FPGAs provide flexible, scalable, and obsolescence-proof solutions in the industrial space Reduce system complexity and increase flexibility Integrate multiple industrial fieldbuses for networking, application, and safety in one FPGA Simplification of development and certification processes Simplify certification process Reduce development time by as much as 2 years and reduce time to market www.altera.com/industrial 息 2010 Altera Corporation - Public ALTERA, ARRIA, CYCLONE, HARDCOPY, MAX, MEGACORE, NIOS, QUARTUS & STRATIX are Reg. U.S. Pat. & Tm. Off. and Altera marks in and outside the U.S. 13
  • 14. Thank You www.altera.com 息 2010 Altera Corporation - Public