Virtual and secure industrial controls

Although software is becoming increasingly important in control systems, its execution is still tied to physical hardware. Virtualization using container technology now makes it possible to abstract the hardware. This means that PLCs can be executed on different platforms such as industrial PCs, edge computing systems, or servers.

The necessary components of the PLC are “deployed” as an image in a container. This means that several PLC instances can be operated in parallel, allowing flexible and scalable utilization of memory and computing capacities. Physical or virtual network interfaces can be mapped to the PLC so that several fieldbus systems can be operated via a single port. The real-time capability of the controller is ensured by the operating system or real-time patch.

In safety-critical applications, e.g. in accordance with IEC 61508, compliance with safety requirements is crucial. A dual-channel control architecture is required for SIL3 at the latest. Virtual controllers enable software-based dual-channel capability without special hardware thanks to “Diversified Encoding”. The technology is based on “coded processing” and offers the possibility of detecting errors in the data and control flow of the PLC programs through redundant software channels. These channels execute the safety application one after the other on the same CPU core. In combination with other test mechanisms, this process achieves a level of safety comparable to that of dual-channel hardware - but without the need for special hardware.

As a control platform, CODESYS is device-independent per se. With CODESYS Virtual Control and CODESYS Virtual Safe Control, virtualization can be used directly in industrial automation. Your advantages:

• High cost and effort reduction for procurement, installation, and maintenance
• No need for special safety hardware
• Greater efficiency by freeing up control cabinet space and eliminating power supply units and cabling
• Optimized operating technology (OT) through central management of PLCs with modern IT methods
• Increased IT security through “Secure by Design”: Isolation of individual components in containers
• Simple generation of additional virtual controllers on existing resources instead of installing additional hardware

The CODESYS Visualization contains display variants (runtime clients) for the display of graphical visualization images that were created within the market-leading IEC 61131-3 programming system CODESYS Development System. These variants run as separate products on different platforms: CODESYS HMI is a variant for IPCs, the CODESYS WebVisu uses HTML5 to display the generated graphical visualization images within web browsers. With CODESYS TargetVisu, the generated images can be loaded directly onto suitable control systems with built-in or connectable displays to be used there. Using various communication options, control data can also be visualized on remote devices. Many available graphical operating elements and functions, such as language switching, integration of HTML pages, responsive design or integration of web applications, allow for simple development of intuitive user interfaces. In addition, all kinds of HTML5 canvas elements can be used for visualization and animation.

Product spezifications:

Overview of the Functionality

• Professional Controls
• Integration of HTML5 canvas elements
• Integrated development in the CODESYS Development System
• Integrated Alarm Management
• Comprehensive User Management
• User friendly Style Switch
• Smart Reusability
• Language Switch/Images/Unit Conversion
• Slim Modules for Data Recording
• Flexible Communication Concept
• Convenient support of client animations, gesture control, and multitouch functions

Available Clients

• Client in the development environment CODESYS Development System, e.g. for testing, service or diagnostic purposes while connected to the controller
• CODESYS Web Visualization
  The web browser communicates with the web server of the controller via Java script and displays the visualization with responsive design using HTML5 CanvasElement. This technology is supported by most browsers and is also available for iOS and Android.
• CODESYS TargetVisualization
  A driver for an internal or external display turns the controller itself into a client: Controller and visualization on one device
• CODESYS HMI
  A portable client makes it possible to display the visualization screens on remote displays for example under Windows or Linux.

CODESYS Safety offers DIN IEC 61508 / ISO 13849 certified safety software for various application areas. Device manufacturers use CODESYS Safety SIL2 or CODESYS Safety for SIL3 to create safety controllers with suitable device platforms, e.g. for use in production machines or mobile machines. Both products considerably facilitate or accelerate the certification of such intelligent safety systems. In addition, CODESYS Safety for EtherCAT Safety Modules is another product variant available. It provides simple integration and configuration of SIL3 safety applications in EtherCAT networks on the basis of already certified EtherCAT Safety Modules. New: Virtual PLCs secured through coded processing can be operated device-independently on virtualized platforms in a container. Engineering and programming of the safety functions is seamlessly integrated in the CODESYS Development System with suitable IEC 61131-3 editors and other specific additional functions for the respective SIL level.

Product specifications:

• CODESYS Safety - Develop your own SIL3 PLC with pre-certified IEC 61508 Safety software components programmable with CODESYS.
  
• CODESYS Safety for EtherCAT Safety Module - If you do not have your own Safety PLC, simply implement your SIL3 Safety solution in CODESYS with decentralized EtherCAT clamps.
  
• CODESYS Safety SIL2 - Develop your own SIL2 Safety PLCs for example for mobile applications with pre-certified Safety software components programmable with the standard IEC 61131-3 development system.
  
  
• CODESYS Virtual Safe Control SL - Virtual safety controller without hardware binding, certified for SIL3

The CODESYS Development System is the market-leading IEC 61131-3 programming system used to implement hundreds of thousands of applications in various areas of industrial automation worldwide. The software tool contains all editors of the standard and generates executable binary code for the most important CPU platforms used in industry from the code objects created using integrated native code generators. This is processed by the corresponding CODESYS Control runtime system. Many powerful functions support the task of creating, commissioning, and debugging control applications efficiently and conveniently - without the need for additional tools. A small selection:

• Assistance for input and configuration
• Sophisticated and field-proven library concept for easy reuse of application code
• Project comparison across all editors
• Extensive debugging and online features for troubleshooting, for optimizing application code, and for speeding up testing and commissioning

CODESYS supports genuine object-oriented programming (OOP) according to IEC 61131-3 3rd Edition in all languages of the standard. Its use is optional - if required, the use of OOP can be encapsulated in libraries that can be called according to the functionality required. Of course, CODESYS offers comprehensive security features to secure the source and binary code, communication, and operation of the controller via established standards such as X.509 certificates.

In addition to programming, the CODESYS Development System also covers other tasks that are required for the use of industrial controllers. For example, configuration tools for convenient connection to fieldbus systems such as CAN/CANopen, PROFIBUS/PROFINET or EtherCAT are fully integrated into the tool, and associated protocol stacks are available in the form of libraries. Within the tool, users can also generate graphical user interfaces for program testing, diagnostics, and operating the device, optionally with an integrated connection to Apache Subversion or Git for version management, as well as additional tools for static code analysis or runtime measurement of the application code.

Virtual and secure industrial controls

Although software is becoming increasingly important in control systems, its execution is still tied to physical hardware. Virtualization using container technology now makes it possible to abstract the hardware. This means that PLCs can be executed on different platforms such as industrial PCs, edge computing systems, or servers.

The necessary components of the PLC are “deployed” as an image in a container. This means that several PLC instances can be operated in parallel, allowing flexible and scalable utilization of memory and computing capacities. Physical or virtual network interfaces can be mapped to the PLC so that several fieldbus systems can be operated via a single port. The real-time capability of the controller is ensured by the operating system or real-time patch.

In safety-critical applications, e.g. in accordance with IEC 61508, compliance with safety requirements is crucial. A dual-channel control architecture is required for SIL3 at the latest. Virtual controllers enable software-based dual-channel capability without special hardware thanks to “Diversified Encoding”. The technology is based on “coded processing” and offers the possibility of detecting errors in the data and control flow of the PLC programs through redundant software channels. These channels execute the safety application one after the other on the same CPU core. In combination with other test mechanisms, this process achieves a level of safety comparable to that of dual-channel hardware - but without the need for special hardware.

As a control platform, CODESYS is device-independent per se. With CODESYS Virtual Control and CODESYS Virtual Safe Control, virtualization can be used directly in industrial automation. Your advantages:

• High cost and effort reduction for procurement, installation, and maintenance
• No need for special safety hardware
• Greater efficiency by freeing up control cabinet space and eliminating power supply units and cabling
• Optimized operating technology (OT) through central management of PLCs with modern IT methods
• Increased IT security through “Secure by Design”: Isolation of individual components in containers
• Simple generation of additional virtual controllers on existing resources instead of installing additional hardware

The CODESYS Visualization contains display variants (runtime clients) for the display of graphical visualization images that were created within the market-leading IEC 61131-3 programming system CODESYS Development System. These variants run as separate products on different platforms: CODESYS HMI is a variant for IPCs, the CODESYS WebVisu uses HTML5 to display the generated graphical visualization images within web browsers. With CODESYS TargetVisu, the generated images can be loaded directly onto suitable control systems with built-in or connectable displays to be used there. Using various communication options, control data can also be visualized on remote devices. Many available graphical operating elements and functions, such as language switching, integration of HTML pages, responsive design or integration of web applications, allow for simple development of intuitive user interfaces. In addition, all kinds of HTML5 canvas elements can be used for visualization and animation.

Product spezifications:

Overview of the Functionality

• Professional Controls
• Integration of HTML5 canvas elements
• Integrated development in the CODESYS Development System
• Integrated Alarm Management
• Comprehensive User Management
• User friendly Style Switch
• Smart Reusability
• Language Switch/Images/Unit Conversion
• Slim Modules for Data Recording
• Flexible Communication Concept
• Convenient support of client animations, gesture control, and multitouch functions

Available Clients

• Client in the development environment CODESYS Development System, e.g. for testing, service or diagnostic purposes while connected to the controller
• CODESYS Web Visualization
  The web browser communicates with the web server of the controller via Java script and displays the visualization with responsive design using HTML5 CanvasElement. This technology is supported by most browsers and is also available for iOS and Android.
• CODESYS TargetVisualization
  A driver for an internal or external display turns the controller itself into a client: Controller and visualization on one device
• CODESYS HMI
  A portable client makes it possible to display the visualization screens on remote displays for example under Windows or Linux.

CODESYS Safety offers DIN IEC 61508 / ISO 13849 certified safety software for various application areas. Device manufacturers use CODESYS Safety SIL2 or CODESYS Safety for SIL3 to create safety controllers with suitable device platforms, e.g. for use in production machines or mobile machines. Both products considerably facilitate or accelerate the certification of such intelligent safety systems. In addition, CODESYS Safety for EtherCAT Safety Modules is another product variant available. It provides simple integration and configuration of SIL3 safety applications in EtherCAT networks on the basis of already certified EtherCAT Safety Modules. New: Virtual PLCs secured through coded processing can be operated device-independently on virtualized platforms in a container. Engineering and programming of the safety functions is seamlessly integrated in the CODESYS Development System with suitable IEC 61131-3 editors and other specific additional functions for the respective SIL level.

Product specifications:

• CODESYS Safety - Develop your own SIL3 PLC with pre-certified IEC 61508 Safety software components programmable with CODESYS.
  
• CODESYS Safety for EtherCAT Safety Module - If you do not have your own Safety PLC, simply implement your SIL3 Safety solution in CODESYS with decentralized EtherCAT clamps.
  
• CODESYS Safety SIL2 - Develop your own SIL2 Safety PLCs for example for mobile applications with pre-certified Safety software components programmable with the standard IEC 61131-3 development system.
  
  
• CODESYS Virtual Safe Control SL - Virtual safety controller without hardware binding, certified for SIL3