Abstract: System(s) and method(s) that facilitate utilizing biometric sensors (e.g., fingerprint, hand scan, voice recognition . . . ) in manufacturing systems in order to maintain accurate safety audit trails. A safety audit system, utilizing a biometric sensing device, facilitates determining if a user is allowed to access and change the configuration of the manufacturing system. Once a user is allowed to change the configuration (e.g., programmable electronics, tooling changes, software updates, etc.) the changes are automatically recorded in a safety audit database. Automatic storage of configuration changes mitigates manual recording of changes thereby enhancing the safety audit data often necessary to meet safety standards for manufacturing systems.

Abstract: A system serializes control signals within a safety control architecture wherein a safety serial interface at least one of receives and transmits signals from one or more processing components. A serialization component receives and serializes at least one data packet from the safety serial interface to control at least one of an input and an output associated with the safety control architecture. A safety related test circuit verifies input signals associated with the serialization component are not internally falsifying the state of the input signals. A heartbeat watchdog component verifies a true heartbeat bit in the at least one data packet is opposite a complement heartbeat bit in the at least one data packet within a predetermined time interval and shuts off power to at least one of an output and an input if such a condition is not met.

Abstract: A safety controller with redundant controllers, each executing safety tasks and comparing their results, provides an improved interface in which a user interacts with a single processor and the second processor is invisible. The interacting processor provides for the transmission of programs and variables to both processors when they are safety tasks and coordinates synchronization of the two programs and comparison of their operation all without additional user input.

Abstract: A safety controller having a total worst case propagation delay, exceeding the required propagation delay required by a safety process, may be used to control the safety process by monitoring actual delays in signal processing in the safety controller and moving to a safety state if a signal delay exceeds an amount less than the total worst case propagation delay.

Abstract: Messages in a high reliability industrial control system are associated with safety messages that enable reliable detection of data errors caused during transmission of the message over the network. In particular, error detection codes are generated and transmitted along with message data. At a receiving node, an expected EDC is generated and compared to the EDC transmitted over the network to determine whether any data was corrupted.

Abstract: A safety controller executes a control program in two processing units to detect processor failure by comparison of the execution in each unit. This comparison is made rapid by synchronizing the input variables at the beginning of the task and comparing output variables at a conclusion of the task, avoiding line-by-line comparison of input and output variables. Intermediate variables, that are neither input nor output values, are compared at a less frequent interval.