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

1. Industrial Safety with
FPGA Devices
Learning Zone @
Embedded World 2010
© 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
© 2010 Altera Corporation - Public
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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)
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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!
© 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
© 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
© 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
Today’s 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. TÜV Rheinland
© 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.
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8. TÜV 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
© 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 TÜV-Qualified Safety Data Package
TÜV-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
© 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
© 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.
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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
© 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
© 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 TÜV-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
© 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
© 2010 Altera Corporation - Public