The diploma thesis devotes to the process of ensuring functional safety of products in Bosch Rexroth Brno, which deals with industrial hydraulic systems. The first part introduces the basic legislative regulations concerning product safety and describes selected standards relevant to this thesis. The second part focuses on Bosch Rexroth and the current state in the field of ensuring functional safety of their products. It also includes a description of the functional safety solution of a specific project – a hydraulic try-out press. At the end of the thesis, improvements to the process of ensuring functional safety in response to the identified shortcomings are proposed.

Due to higher requirements of computational power and safety, or functional safety ofequipments intended for the use in the industrial domain, embedded systems containing areal-time operating system are still the active area of research. This thesis addresses thehardware-assisted control module that is based on the runtime model-based verificationof a target application. This subsystem is intended to increase the diagnostic coverage,particularly, the detection of the execution errors. After the specification of the architecture,the formal model is defined and implemented into hardware using FPGA technology.This thesis also discuss some other aspects and embodies new approaches in the area ofembedded flow control, e.g. the integration of the design patterns. Using the simulation,the created module was tested using the created scenarios, which follow the real programexecution record. The results suggest that the error detection time is lower than usingstandard techniques, such a watchdog.

The article identifies the challenges during the system and specifically the software development process for safety critical electro-hydraulic control systems by using the example of the hydrostatic driveline with a four speed transmission of a feeder mixer. An optimized development approach for mobile machinery has to fulfill all the requirements according to the Machinery Directive 2006/42/EC, considering functional safety, documentation and testing requirements from the beginning and throughout the entire machine life cycle. The functionality of the drive line control could be verified in advance of the availability of a prototype by using a “software-in-the-loop” development approach, based on a MATLAB/SIMULINK model of the drive line in connection with the embedded software.

Eaton created a new safety controller architecture to allow our customers to design implement, verify and maintain a SIL-2 safety certified application for compliance with IEC 61508:2010 and ISO 13849 Functional Safety Standards. The new architecture has been implemented in a line of safety controllers SFX12 and SFX20 that extend the line of existing mobile controllers HFX12 to HFX48. The new controllers are targeted for controlling mobile and stationary machine applications with focus on steer by wire and propel by wire.

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The main aim of using radars in industrial safety system is to detect the presence of target accurately. The conventional methods of radar target detection algorithm such as the Cell averaging constant false alarm rate method (CA-CFAR), Greatest of constant false alarm method (GO-CFAR) and the Smallest of constant false alarm rate method (SO-CFAR) has their own disadvantage when it comes to precise target detection which is a key factor for a safety system. This thesis investigates the above mentioned conventional CFAR algorithms for its pros and cons in target detection and proposes a new and improved method called Cell Evaluation target detection method. The proposed method is shown to mitigate the limitations present and the assumptions made in the conventional target detection method. Further more angular estimation is performed to determine the precise location of the target and the artifacts due to the angular estimation is eliminated by aggregating the detected points from multiple radar modules by linear translation. This gives a better visualization of the target. / Radarteknik kan användas inom maskinsäkerhet (MS) för att detektera skyddsvärda objekt, typiskt människor i arbete nära maskiner. Konventionella metoder för detektering med given frekvens falsk alarm (eng. Constant False Alarm Rate (CFAR)) som baseras på medelvärden, har dock betydande brister. Främst beträffande precision och tillförlitlighet, vilket är centralt för MS. Exempel som studerats i detta examensarbete är “Cell-averaging CFAR” (CA-CFAR), “Greatest of CFAR” (GO-CFAR) samt “Smallest of CFAR” (SO-CFAR). Med målet att förbättra detektionen föreslås även en ny CFAR-metod, vilken benämns ”Cell Evaluation target detection”. I detta arbete visas denna metod undertrycka begränsningar med konventionella tekniker. Den undviker även en del antaganden som inte alltid stämmer i praktiken. Studien inkluderar även skattning av riktning. Det visas hur visualisering av skyddsobjekt kan förbättras, genom att felaktigheter elimineras efter sammanläggning av detektioner från flera radarmoduler efter koordinattransformation.

Modulare Prozessanlagen bestehen aus einfach austauschbaren Prozess- und Funktionseinheiten, deren Konfiguration (Aufbau) und Rekonfiguration (Umbau) neue Möglichkeiten der flexiblen Prozessrealisierung eröffnen. Die Wandelbarkeit der Anlagen stellt aus Perspektive der funktionalen Sicherheit eine Herausforderung dar, da bestehende Methoden und Vorgehensweisen auf den verhältnismäßig statischen Betrieb von konventionellen Anlagen optimiert sind. Um den Zielkonflikt zwischen Flexibilität und Sicherheit abzumildern wurde ein Konzept zur Orchestrierung von verteilten Sicherheitssystemen entwickelt und in einer Demonstrationsanlage erfolgreich erprobt. Der Konzeptentwurf integriert sowohl technische als auch menschliche Anforderungen, mit dem Ziel, Operateure durch eine geschickte Systemgestaltung zur Beherrschung der Re-Konfiguration zu befähigen. / Modular process plants consist of easily exchangeable process and functional units whose configuration (assembly) and reconfiguration (modification) open up new possibilities for flexible process implementation. The changeability of the plants poses a challenge from the perspective of functional safety, since existing methods and procedures are optimized for the relatively static operation of conventional plants. To mitigate the trade-off between flexibility and safety, a concept for orchestrating distributed safety systems was developed and successfully tested in a demonstration plant. The concept design integrates both technical and human requirements, with the goal of enabling operators to master reconfiguration through smart system design.

Optimised allocation of system architectures is a well researched area as it can greatly reduce the developmental cost of systems and increase performance and reliability in their respective applications.In conjunction with the recent shift from federated to integrated architectures in automotive, and the increasing complexity of computer systems, both in terms of software and hardware, the applications of design space exploration and optimised allocation of system architectures are of great interest.This thesis proposes a method to derive architectures and their allocations for systems with real-time constraints.The method implements integer linear programming to solve for an optimised allocation of system architectures according to a set of linear constraints while taking resource requirements, communication dependencies, and manual design choices into account.Additionally, this thesis describes and evaluates an industrial use case using the method wherein the timing characteristics of a system were evaluated, and, the method applied to simultaneously derive a system architecture, and, an optimised allocation of the system architecture.This thesis presents evidence and validations that suggest the viability of the method and its use case in an industrial setting.The work in this thesis sets precedence for future research and development, as well as future applications of the method in both industry and academia.

The rapidly evolving technologies in the automotive industry have been defining new challenges, setting new goals and consenting to more complex systems. This steered the AUTOSAR community toward the independent development of the AUTOSAR Adaptive Platform with the intention of addressing and serving the demands defined by the new technology drivers. The use of an already existing software based on an open-source development - specifically GNU/Linux - was recognized as a matching candidate fulfilling the requirements defined by AUTOSAR Adaptive Platform as its operating system. However, this raises new challenges in addressing the safety aspect and the suitability of its implementation in safety-critical environments. As safety standards do not explicitly handle the use of open-source software development, this thesis proposes a tailoring procedure that aims to match the requirements defined by ISO 26262 for a possible qualification of GNU/Linux. And while very little is known about the behavior specification of GNU/Linux to appropriate its use in safety-critical environments, the outlined methodology seeks to verify the specification requirements of GNU/Linux leveraging its claimed compliance to the POSIX standard. In order to further use GNU/Linux with high pedigree of certainty in safety-critical applications, a software partitioning mechanism is implemented to provide control over the resource consumption of the operating system –specifically computation time and memory usage- between different criticality applications in order to achieve Freedom from Interference. The implementation demonstrates the ability to avoid interference concerning required resources of safety-critical applications.

This master thesis examines the functional safety of the pressure sensor XMP i which is produced by BD SENSORS Company. The aim of this thesis is the demonstration of compliance of the pressure sensor XMP I with functional safety integrity level SIL3 requirements. The thesis is divided into three parts. The first part deals with the concept of functional safety, defines the basic concepts of functional safety, compares the approaches of functional safety according to selected standards and provides a general procedure for the functional safety determination. The second part deal with technical systems reliability defines reliability indicators and describes selected types of reliability analysis used in practice, especially the FMEA/FMECA analysis. Third part deals with the reliability analysis of the sensor XMP i and with evaluation of results.