Safety-Critical Medical Actuators - Socci

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    : 2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t 1

    Health-Tech SymposiumWelch Allyn Lodge, Skaneateles, NY April 23, 2009

    Vince Socci, Chief EngineerOn Target Technology [email protected] (607) 755-4980

    Actuator Control Designfor Safety-Critical

    Medical Applications

    Actuator Control Designfor Safety-Critical

    Medical Applications

    A b s t r a c t

    A b s t r a c t A b s t r a c t

    A b s t r a c t - D e s i g n e r s o f s a f e t y - c r i t i c a l m e d i c a l a c t u a t o r c o n t r o l a p p l i c a t i o n s f a c e r i g o r o u s

    r e q u i r e m e n t s a n d s t a n d a r d s t o a s s e s s s a f e t y r e q u i r e m e n t s , d e v e l o p s y s t e m a r c h i t e c t u r e s ,

    a n d d e s i g n c o m p o n e n t h a r d w a r e a n d s o f t w a r e . T h i s p a p e r d e m o n s t r a t e s i n t e g r a t e d

    t e c h n i q u e s o f s a f e t y - c r i t i c a l d e v e l o p m e n t w i t h e x a m p l e s f r o m v a r i o u s a c t u a t o r a p p l i c a t i o n s .

    S t r a t e g i e s f o r s a f e t y a n a l y s i s , e n g i n e e r i n g d e s i g n a n d a p p l i c a t i o n o f l i f e c y c l e g u i d e l i n e s a r e

    d i s c u s s e d . M e t h o d s o f d e v e l o p i n g a c t u a t o r c o n t r o l s w i t h r o b u s t f a u l t t o l e r a n c e a n d

    t e s t a b i l i t y a r e h i g h l i g h t e d . T h e s e c r e t s o f e f f e c t i v e s a f e t y - c r i t i c a l d e v e l o p m e n t a r e r e v e a l e d .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 2

    Stupid is as stupid does. -- Forrest Gump

    E v e n t u a l l y , e v e r y o n e s c r e w s u p a n d e v e r y t h i n g b r e a k s .

    I f y o u r w o r l d i s v o i d o f f a i l u r e s , y o u d o n I f y o u r w o r l d i s v o i d o f f a i l u r e s , y o u d o n I f y o u r w o r l d i s v o i d o f f a i l u r e s , y o u d o n I f y o u r w o r l d i s v o i d o f f a i l u r e s , y o u d o n t n e e d t o b e h e r e . t n e e d t o b e h e r e . t n e e d t o b e h e r e . t n e e d t o b e h e r e .

    B u t i f s a f e t y

    B u t i f s a f e t y B u t i f s a f e t y

    B u t i f s a f e t y -

    --

    - r e l a t e d f a i l u r e s w o r r y y o u , s t i c k a r o u n d .

    r e l a t e d f a i l u r e s w o r r y y o u , s t i c k a r o u n d . r e l a t e d f a i l u r e s w o r r y y o u , s t i c k a r o u n d .

    r e l a t e d f a i l u r e s w o r r y y o u , s t i c k a r o u n d .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3

    Ready for the Ride?

    Roadmap

    Problem: Rigorous industry standards to assesssafety requirements, develop system architectures,and design component hardware and software.

    Integrated techniques of safety-critical development Strategies for engineering design and application Methods of robust fault tolerance and testability Effective safety-critical development tips

    Your Guide

    Vince Socci BS EE, MS EE, MBA TM Principal, On Target Technology Cross-disciplined systems, hardware, software

    engineering Electronics design and embedded controls

    S p e a k e r B a c k g r o u n d V P S , O T T D , w e d o P D & M , R & D T S ,

    V i n c e n t S o c c i i s a c r o s s - d i s c i p l i n e d s y s t e m s , h a r d w a r e a n d s o f t w a r e e n g i n e e r . H i s

    t e c h n o l o g y e x p e r t i s e i n c l u d e s e m b e d d e d s y s t e m s , s e n s o r s a n d s i g n a l p r o c e s s i n g , p o w e r

    c o n t r o l s y s t e m s , a n d d i a g n o s t i c s . S o c c i h a s 2 0 y e a r s o f e x p e r i e n c e i n s a f e t y - c r i t i c a l

    s y s t e m s d e v e l o p m e n t . H e h o l d s a n M B A i n t e c h n o l o g y m a n a g e m e n t , a n d M S a n d B S

    d e g r e e s i n e l e c t r i c a l e n g i n e e r i n g . A s P r i n c i p a l o f O n T a r g e t T e c h n o l o g y D e v e l o p m e n t ,

    S o c c i s u p p o r t s c l i e n t s w i t h e l e c t r o n i c s d e s i g n a n d e m b e d d e d c o n t r o l s d e v e l o p m e n t . H e h a s

    a p p l i e d t h e s a f e t y - c r i t i c a l d e s i g n c o n c e p t s p r e s e n t e d i n t h i s p a p e r i n m e d i c a l , a e r o s p a c e ,

    a u t o m o t i v e , l o c o m o t i v e , a n d i n d u s t r i a l a p p l i c a t i o n s .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4

    Agenda

    Fundamentals of Safety-Critical Systems

    Actuator Control Design from a Systems Perspective

    Industry Specifications and Standards

    Development Strategies

    Example Cases

    Conclusions

    Questions and Answers

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5

    Industrial Trends in Safety-Critical Systems

    Medical

    Growing focus on safety development standards Sensitive to failure, development cost/time,

    marketability, global competition

    Aerospace Long history of fly-by-wire and other x-by-wire

    actuator control systems Long development, low volume, expensive safety-

    critical applications.

    Automotive Emerging x-by-wire needs Short development, high volume, cost-efficient safety-

    critical applications. Demand for fault tolerance, speed-to-market & low cost.

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 6

    Fundamental Concepts ofSafety-Critical Systems

    Fundamental Concepts ofSafety-Critical Systems

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    Fundamental Concepts of Safety-CriticalSystems

    Scenario:

    Imagine sitting comfortably on an airplane, enjoying a newissue of your favorite magazine. All of a sudden, as youfly over the Equator, the plane does a fast 180-degreeroll, and you find yourself in an inverted flight. The pilotannounces over the loudspeaker Hmmm that doesntseem right. Are there any systems engineers onboard?

    T h e s o f t w a r e d e v e l o p m e n t f o r t h e F - 1 6 f i g h t e r p l a n e

    e x p e r i e n c e d t h i s e x a c t f a i l u r e m o d e d u r i n g s i m u l a t i o n

    f l i g h t t e s t i n g . I t w a s r e s o l v e d i n t h e f i e l d e d d e s i g n .

    I f t h i s f a i l u r e o c c u r r e d i n r e a l

    I f t h i s f a i l u r e o c c u r r e d i n r e a lI f t h i s f a i l u r e o c c u r r e d i n r e a l

    I f t h i s f a i l u r e o c c u r r e d i n r e a l -

    --

    - l i f e ,

    l i f e , l i f e ,

    l i f e ,

    t h e a i r c r a f t a n d p i l o t w o u l d b e l o s t .

    t h e a i r c r a f t a n d p i l o t w o u l d b e l o s t . t h e a i r c r a f t a n d p i l o t w o u l d b e l o s t .

    t h e a i r c r a f t a n d p i l o t w o u l d b e l o s t .

    S o u n d f a r f e t c h e d ?

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    Other F-16 Simulation Failures

    When the computer was commanded to raise the

    landing gear while the aircraft was standing still on therunway, the computer complied and turfed the aircraft.

    The aircraft system also complied with commands tojettison missiles, bombs, fuel tanks, etc. while the planewas upside-down, resulting in them falling on anddamaging the wings.

    When the F-16 went into a spin, the software did notgive the pilot enough control authority to recover. Thepilot had to eject.

    F a i l u r e s l i k e t h i s p u t l i v e s a n d p r o p e r t y a t r i s k .

    W e c a n W e c a n W e c a n W e c a n

    t l e t t h e m h a p p e n

    t l e t t h e m h a p p e n t l e t t h e m h a p p e n t l e t t h e m h a p p e n

    p e r i o d .

    p e r i o d . p e r i o d . p e r i o d .

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    Safety-related vs. Safety-Critical

    Safety-related systems those in which a failure during operation

    can have serious or irreversible effects such as loss of life or limb,severe property damage or financial losses. (e.g. insulin pump)

    Safety-critical systems safety-related systems that present a

    direct threat to human life. They can include aircraft controlsystems, medical instrumentation, railway signaling, nuclear reactor

    control systems and many other applications.

    Safety-critical systems include all of the components that worktogether to achieve the safety-critical mission.

    These may include input sensors, digital data devices, hardware,peripherals, drivers, actuators, the controlling software, and

    other interfaces. Their development requires rigorous analysis and

    comprehensive design and test.

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    Managing Design / Controlling Operation

    Failures occur in development and operation.

    Failures in development can be mitigated, but failures inoperation are unavoidable. Stuff breaks!

    Effects of these hardware failures must be predictable(i.e. deterministic) and not catastrophic.

    Design to consistently maintain and control the safety ofthe system when failures occur.

    Robust Design + Controlled Operation = Safe Mission

    Safe actuator control is guaranteed only through robustdesign (error-free) and robust operation (fault-tolerant).

    S a f e t y - r e l a t e d f a i l u r e s c a n o c c u r i n d e v e l o p m e n t o r i n o p e r a t i o n . T h e d e s i g n m a y b e w e a k

    o r n o t r o b u s t e n o u g h f o r t h e o p e r a t i n g e n v i r o n m e n t . D e s i g n s t a n d a r d s a n d p r a c t i c e s ,

    i n c l u d i n g r i g o r o u s r e q u i r e m e n t s m a n a g e m e n t , e n g i n e e r i n g a n a l y s e s , d e s i g n r e v i e w s a n d

    t e s t i n g c a n s u p p o r t v a l i d a t i o n o f t h e d e s i g n .

    F a i l u r e s i n o p e r a t i o n a r e u n a v o i d a b l e . S t u f f b r e a k s ! W h e t h e r i t s a w i r e i n a h a r n e s s o r a

    w o r n - o u t r e l a y h a r d w a r e w i l l e v e n t u a l l y f a i l . S a f e t y - c r i t i c a l s y s t e m s a r e d e s i g n e d s u c h

    t h a t t h e e f f e c t s o f t h e s e h a r d w a r e f a i l u r e s a r e p r e d i c t a b l e ( i . e . d e t e r m i n i s t i c ) a n d n o t

    c a t a s t r o p h i c . A r c h i t e c t u r e s a r e d e s i g n e d t o c o n s i s t e n t l y m a i n t a i n a n d c o n t r o l t h e s a f e t y o f

    t h e s y s t e m w h e n f a i l u r e s o c c u r .

    R o b u s t D e s i g n + C o n t r o l l e d O p e r a t i o n = S a f e M i s s i o n

    R o b u s t D e s i g n + C o n t r o l l e d O p e r a t i o n = S a f e M i s s i o n R o b u s t D e s i g n + C o n t r o l l e d O p e r a t i o n = S a f e M i s s i o n

    R o b u s t D e s i g n + C o n t r o l l e d O p e r a t i o n = S a f e M i s s i o n

    R e m e m b e r t h a t s a f e a c t u a t o r c o n t r o l i s g u a r a n t e e d o n l y t h r o u g h r o b u s t d e s i g n a n d r o b u s t

    o p e r a t i o n . D e s i g n r o b u s t n e s s i s a c h i e v e d t h r o u g h r o b u s t p r o c e s s e s a n d e n g i n e e r i n g

    d e s i g n p r a c t i c e s . C o n t r o l l e d o p e r a t i o n i s a c h i e v e d b y t h o r o u g h m o n i t o r i n g , f a u l t d e t e c t i o n

    a n d m i t i g a t i o n s t r a t e g i e s .

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    Safety-Critical Medical Actuator Examples

    Hospital beds

    Ambulatory scooters

    Patient lifts

    Pumps and valves for drug delivery

    X-ray controllers

    Massage therapy

    Prosthetics

    Laparoscopic tools

    Etc.

    M o n i t o r s a r e p a s s i v e ,

    M o n i t o r s a r e p a s s i v e , M o n i t o r s a r e p a s s i v e ,

    M o n i t o r s a r e p a s s i v e ,

    b u t a c t u a t o r s a r e a c t i v e .

    b u t a c t u a t o r s a r e a c t i v e . b u t a c t u a t o r s a r e a c t i v e .

    b u t a c t u a t o r s a r e a c t i v e .

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    Actuator Control Designfrom a Systems Perspective

    Actuator Control Designfrom a Systems Perspective

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    Actuator Control System Block Diagram

    An operator uses the control interface to stimulate the control system.

    Control algorithms drive an output to the actuator, which moves the mechanical interface.

    A feedback response of the mechanical interface is collected through feedback sensors.

    Signal conditioning is applied to inputs and outputs to convert raw signals to usable forms.

    Power

    Source

    Sensor

    Outputs

    Input

    Signal

    Conditioning

    Control

    Algorithms

    Output

    Signal

    ConditioningActuator

    Mechanical

    Interface

    Control

    Interface

    Control

    Stimulus

    Controller

    Command

    Output

    Command

    Driver

    Output

    Control

    Feedback

    Mechanical

    Response

    Actuation

    Force

    Actuation

    Energy

    T h i s p a p e r f o c u s e s o n a c t u a t o r c o n t r o l s y s t e m s b e c a u s e t h e s e a p p l i c a t i o n s p r o v i d e a

    r e l e v a n t m i x t u r e o f h a r d w a r e a n d s o f t w a r e f u n c t i o n s t h a t i n t e g r a t e t h e b r o a d r e q u i r e m e n t s

    o f s a f e t y - c r i t i c a l s y s t e m s . C o n s i d e r t h e f o l l o w i n g s y s t e m b l o c k d i a g r a m o f a n a c t u a t o r

    c o n t r o l s y s t e m .

    M o s t o f t h e s e c o n t r o l s y s t e m f u n c t i o n a l b l o c k s a r e h a r d w a r e f u n c t i o n s , i m p l e m e n t e d b y

    s o m e m e c h a n i c a l o r e l e c t r i c a l c o m p o n e n t s . T h e c o n t r o l a l g o r i t h m s a r e t y p i c a l l y s o f t w a r e

    f u n c t i o n s , i m p l e m e n t e d b y a c o m p u t i n g p r o g r a m i n s t a l l e d t o a n d o p e r a t i n g o n a p r o c e s s i n g

    d e v i c e . S i g n a l c o n d i t i o n i n g c a n o c c u r i n b o t h h a r d w a r e a n d s o f t w a r e .

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    Built-In-Test (BIT)

    Built-in-test (BIT) validates interfaces and control

    variables.

    Verify integrity of system before, during and after use.

    BIT analysis is part of the design process of a safety-critical system. Considers potential failures throughout the systems Verifies that these failures will be detected and

    mitigated by the BIT functions. Ex. If a power source is lost, BIT should detect the

    failure and respond by ensuring that the systemresponds in a safe manner.

    C o n t r o l l e r s g e n e r a l l y u s e s o m e f o r m o f b u i l t - i n - t e s t ( B I T ) t o v a l i d a t e i n t e r f a c e s a n d c o n t r o l

    v a r i a b l e s . B I T i s d e s i g n e d t o d e t e c t f a i l u r e s i n a n y o f t h e s y s t e m e l e m e n t s . B I T i s t h e

    p r i m a r y m e a n s t o v e r i f y t h e i n t e g r i t y a n d o p e r a t i o n o f s y s t e m a n d h a r d w a r e c o m p o n e n t s

    b e f o r e , d u r i n g a n d a f t e r t h e m i s s i o n .

    S y s t e m s e n g i n e e r s t y p i c a l l y p e r f o r m a B I T a n a l y s i s a s p a r t o f t h e d e s i g n p r o c e s s o f a

    s a f e t y - c r i t i c a l s y s t e m . T h i s B I T a n a l y s i s c o n s i d e r s p o t e n t i a l f a i l u r e s t h r o u g h o u t t h e s y s t e m s

    a n d v e r i f i e s t h a t t h e s e f a i l u r e s w i l l b e d e t e c t e d a n d m i t i g a t e d b y t h e B I T f u n c t i o n s . F o r

    i n s t a n c e , i f t h e p o w e r s o u r c e o f F i g u r e 2 f a i l s ( e . g . l o s s o f p o w e r ) , B I T s h o u l d d e t e c t t h e

    f a i l u r e a n d r e s p o n d b y e n s u r i n g t h a t t h e s y s t e m r e s p o n d s i n a s a f e m a n n e r .

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    BIT Software vs. Hardware

    Safety-critical systems are becoming more complex.

    Role of software is becoming more dominant for bothcontrol and monitoring.

    BIT can be implemented in hardware or software form.

    Software implementation of BIT functionality is preferred.

    Hardware is subject to failure, resulting in false positiveor false negative failure detection.

    Hardware that implements BIT functions should notreduce reliability or system safety.

    A s s a f e t y - c r i t i c a l s y s t e m s a r e b e c o m i n g m o r e c o m p l e x a n d c o m p u t e r - c o n t r o l l e d , t h e r o l e o f

    s o f t w a r e i s b e c o m i n g m o r e d o m i n a n t f o r b o t h c o n t r o l a n d m o n i t o r i n g . B I T f u n c t i o n a l i t y c a n

    b e i m p l e m e n t e d i n h a r d w a r e o r s o f t w a r e f o r m . S o f t w a r e i m p l e m e n t a t i o n o f B I T f u n c t i o n a l i t y

    i s p r e f e r r e d . H a r d w a r e t h a t i m p l e m e n t s B I T f u n c t i o n a l i t y c a n i t s e l f b e s u b j e c t t o f a i l u r e ,

    r e s u l t i n g i n f a l s e p o s i t i v e o r f a l s e n e g a t i v e f a i l u r e d e t e c t i o n . E n g i n e e r i n g d e s i g n p r a c t i c e s

    s u g g e s t t h a t h a r d w a r e t h a t i m p l e m e n t s B I T f u n c t i o n s s h o u l d n o t r e d u c e r e l i a b i l i t y o r s y s t e m

    s a f e t y .

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    Controller Implementation of a SimpleActuator Control System

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    N o w l e t s c o n s i d e r a s i m p l e a c t u a t o r s y s t e m f r o m t h e p e r s p e c t i v e o f c o n t r o l l e r

    i m p l e m e n t a t i o n . T h i s f i g u r e p r o v i d e s a g e n e r a l b l o c k d i a g r a m o f c o n t r o l l e r i m p l e m e n t a t i o n .

    T h e a r r o w s r e p r e s e n t a s i m p l i f i e d f u n c t i o n a l f l o w f o r t h e a c t u a t o r . A c t u a l d a t a f l o w c a n b e

    m u c h m o r e c o m p l e x . R e f e r t o t h e f i g u r e f o r t h e f o l l o w i n g d i s c u s s i o n .

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    External Interfaces

    The following interfaces are

    external to the controllerhardware: Actuator

    Input interfaces Feedback interfaces.

    Near controller or far away

    Connected through wireharnesses, or wireless

    Susceptible to hardware failures

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

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    Controller Hardware

    Includes: I/O signal conditioning peripheral interfaces core processing platform.

    Signal conditioning: Converts the input signals for

    the core processor Translates processor outputs

    into driver signals for theactuator.

    Peripheral hardware may includewatchdog monitors, protectivedevices etc.

    Processing platform includes theprocessor, memory, and any

    other devices needed to supportprocessing operation.

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    T h e c o n t r o l l e r h a r d w a r e p r o v i d e s I / O s i g n a l c o n d i t i o n i n g , p e r i p h e r a l i n t e r f a c e s a n d a c o r e

    p r o c e s s i n g p l a t f o r m . S i g n a l c o n d i t i o n i n g c o n v e r t s t h e i n p u t s i g n a l s i n t o f o r m s t h a t c a n b e

    i n t e r p r e t e d b y t h e c o r e p r o c e s s o r , a n d t r a n s l a t e s p r o c e s s o r o u t p u t s i n t o d r i v e r s i g n a l s f o r

    t h e a c t u a t o r . T h e s e d r i v e r s i g n a l s m a y b e h i g h c u r r e n t s i g n a l s t h a t d i r e c t l y d r i v e t h e

    a c t u a t o r o r t h e y c a n p r o v i d e i n d i r e c t c o n t r o l o f a n e x t e r n a l p o w e r s o u r c e , a s s h o w n i n

    F i g u r e 2 . P e r i p h e r a l h a r d w a r e m a y i n c l u d e w a t c h d o g m o n i t o r s , d a t a c o m m u n i c a t i o n

    d e v i c e s , p o w e r c o n v e r t e r s , p r o t e c t i v e d e v i c e s a n d f i l t e r s , c o n f i g u r a t i o n h a r d w a r e a n d o t h e r

    p e r i p h e r a l h a r d w a r e . T h e c o r e p r o c e s s i n g p l a t f o r m i n c l u d e s t h e p r o c e s s o r , m e m o r y , a n d

    a n y o t h e r d e v i c e s n e e d e d t o s u p p o r t p r o c e s s i n g o p e r a t i o n .

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    Controller RTOS

    Real-time Operating Systems

    perform: executive management task scheduling

    other operating utilities

    Examples:

    Ad-hoc operating system Commercial off-the-shelf

    RTOS:

    Integrity, VxWorks, LynxOS Must be certifiable to the

    safety criticality level of theapplication.

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    C o n t r o l l e r s o f t w a r e , w h i c h r e s i d e s a n d o p e r a t e s o n t h e c o r e h a r d w a r e , h a s a r e a l - t i m e

    o p e r a t i n g s y s t e m ( R T O S ) t h a t p e r f o r m s a l l e x e c u t i v e m a n a g e m e n t a n d t a s k s c h e d u l i n g , a s

    w e l l a s o t h e r o p e r a t i n g u t i l i t i e s . T h i s m a y b e a n a d - h o c o p e r a t i n g s y s t e m , o r i t c a n b e a

    c o m m e r c i a l o f f - t h e - s h e l f R T O S , s u c h a s V x W o r k s , C s L E O S o r I n t e g r i t y , t h a t i s c e r t i f i a b l e t o

    t h e s a f e t y c r i t i c a l i t y l e v e l o f t h e a p p l i c a t i o n .

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    Input/Output Signal Processing

    Input signal processing

    Read raw data from inputhardware

    Massage into usable form

    Software filters Discrete debouncing Range detection.

    Output signal processing

    Create physical signals to

    drive to hardware. Timing or filtering of output

    drivers

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    I n p u t s i g n a l p r o c e s s i n g s o f t w a r e r e a d s r a w d a t a i n p u t s f r o m t h e h a r d w a r e a n d m a s s a g e s

    t h e m i n t o u s a b l e f o r m f o r t h e s o f t w a r e a l g o r i t h m s . T h i s m a s s a g i n g i n c l u d e s s o f t w a r e f i l t e r s

    ( e . g . l a g a n d l e a d f i l t e r s ) , d i s c r e t e d e b o u n c i n g , a n d r a n g e d e t e c t i o n . O u t p u t s i g n a l

    p r o c e s s i n g c o n v e r t s t h e r e s u l t s o f t h e c o n t r o l a l g o r i t h m s i n t o p h y s i c a l s i g n a l s t o d r i v e t o

    h a r d w a r e .

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    Control Algorithm Processing

    Provides the heart of the actuator

    control functionality.

    Control data and variables areread and processed todeterministicallydrive the real-time response of the actuator.

    Critical real-time and frequency-

    dependent algorithms

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    C o n t r o l a l g o r i t h m s p r o v i d e t h e h e a r t o f t h e a c t u a t o r c o n t r o l f u n c t i o n a l i t y . T h i s i s w h e r e t h e

    p l a n t m o d e l s , c o n t r o l l o o p s a n d d e c i s i o n s a r e p r o c e s s e d . C o n t r o l d a t a a n d v a r i a b l e s a r e

    r e a d a n d r e a l - t i m e a l g o r i t h m s a r e p r o c e s s e d t o d e t e r m i n i s t i c a l l y d r i v e t h e a p p r o p r i a t e r e a l -

    t i m e r e s p o n s e o f t h e a c t u a t o r .

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    Data Communications and Management

    Manipulate the data associated

    with the inputs and outputs

    Provides any processingassociated with redundancy orcross-channel communication.

    Multichannel Datasets

    (copies) Data synchronization

    Self and cross-channel BIT.

    Amount of data that must bemanaged can become huge andcoordination can becomecomplex.

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    T h e d a t a c o m m u n i c a t i o n a n d m a n a g e m e n t f u n c t i o n s m a n i p u l a t e t h e d a t a a s s o c i a t e d w i t h

    t h e i n p u t s a n d o u t p u t s , i n c l u d i n g d i g i t a l c o m m u n i c a t i o n t o e x t e r n a l c o m p o n e n t s . T h e s e

    f u n c t i o n s a l s o p r o v i d e a n y p r o c e s s i n g a s s o c i a t e d w i t h r e d u n d a n c y o r c r o s s - c h a n n e l

    c o m m u n i c a t i o n . F o r e x a m p l e , a q u a d - r e d u n d a n t a c t u a t o r s y s t e m w o u l d h a v e a c o m p l e t e

    s e t o f d a t a f o r e a c h o f t h e f o u r c h a n n e l s . S o m e l e v e l o f d a t a s y n c h r o n i z a t i o n i s n e e d e d t o

    m a i n t a i n c o o r d i n a t e d c o n t r o l o f t h e f o u r c h a n n e l s . E a c h c h a n n e l m a y p e r f o r m B I T o n i t s e l f

    a n d o n e o r m o r e o f t h e o t h e r c h a n n e l s . D e p e n d i n g o n t h e i n t r i c a c y o f d a t a c o m m u n i c a t i o n ,

    t h e a m o u n t o f d a t a t h a t m u s t b e m a n a g e d c a n b e c o m e h u g e a n d c o o r d i n a t i o n c a n b e c o m e

    c o m p l e x .

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    Built-In-Test

    BIT functions detect faults and

    isolate them to individualcomponents or small groups.

    Detection Test during operationand compare results to expectedvalues.

    Isolation Determine if the fault

    occurred inside the controller orexternal interfaces.

    Test all faults that have an effecton the safe operation of themission.

    Controller Software (and Core Hardware)

    Input

    Interfaces

    Input

    Signal

    Conditioning

    Input

    Signal

    Processing

    Output

    Signal

    Processing

    Output

    Signal

    Conditioning

    Feedback

    Interfaces

    Control

    Algorithm

    Processing

    Built-In

    Test

    Data Communication and Management

    Real-Time Operating System

    Actuator

    Controller Hardware

    Peripheral

    Hardware

    A c t u a t o r c o n t r o l s i n c l u d e B I T f u n c t i o n s t o d e t e c t f a u l t s a n d i s o l a t e t h e m t o i n d i v i d u a l

    c o m p o n e n t s o r s m a l l g r o u p s o f t h e m . F a i l u r e d e t e c t i o n i s u s u a l l y a c c o m p l i s h e d b y

    c o n d u c t i n g a s e r i e s o f t e s t s d u r i n g o p e r a t i o n a n d c o m p a r i n g r e s u l t s t o e x p e c t e d v a l u e s .

    I s o l a t i o n l o g i c d e t e r m i n e s i f t h e f a u l t o c c u r r e d i n s i d e t h e c o n t r o l l e r o r w a s t h e r e s u l t o f

    e x t e r n a l i n t e r f a c e s . T h e d e s i g n e r s g o a l i s t o t e s t a n y p o t e n t i a l f a u l t t h a t h a s a n e f f e c t o n

    t h e s a f e o p e r a t i o n o f t h e m i s s i o n i n t h e a p p r o p r i a t e m o d e o f B I T .

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    BIT Modes

    BIT can be categorizedinto the following modes: Power-up BIT (PBIT) Continuous BIT (CBIT) Initiated BIT (IBIT)

    Each safety-critical fault istested in one or more ofthese BIT modes

    Each BIT mode mayperform a subset (orsuperset) of another BITmode

    Fault thresholds,persistence limits andscheduling of individualBIT are coordinated to

    reject false failureindications.

    CBIT

    PBIT IBIT

    CommonBIT

    N e s t e d a c r o n y m s

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    Power-up BIT (PBIT)

    Also known as Start-up BIT

    Executes on application of power Rapid check of ability to operate

    Examples Core processing failure the

    mission can be halted beforeoperator safety is jeopardized

    Actuator feedback interfacefailure the actuator may notbe controllable, and themission would be aborted

    Scope of PBIT testing dependson application power uprequirements.

    Designers must trade-off PBITtest coverage with PBIT timingconstraints.

    CBIT

    PBIT IBIT

    Sample PBIT Tests: Processor diagnostics Memory Configuration Watchdog timeout Power supply voltage Interrupts Critical I/O

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    Continuous BIT (CBIT)

    Also known as Periodic BIT

    Provides continuous monitoringof all system components.

    Minimizes failure exposure time.

    Example: Current feedback on a

    drug pump actuator detects if theflow is obstructed duringoperation.

    CBIT completion time must beconsidered when the maximumfailure exposure time (themaximum time between when afault occurs and when the fault is

    detected and mitigated) iscritical.

    CBIT

    PBIT IBIT

    Sample CBIT Tests: Subset of PBIT tests Control Sensors Control Discretes Feedback Sensors Feedback Discretes Dynamic responsiveness Data communication validation

    Actuator current monitors

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    Initiated BIT (IBIT)

    Also known as Maintenance BIT,

    or other alternative names.

    Extensive set of tests, initiated bythe operator, which occurs whenthe system is in a stable, knownenvironment.

    The environment must be

    controlled because control of theactuator is given to the BITfunctions rather than the normalcontrol algorithms.

    Example: range test on anactuator

    IBIT completion time is typicallylong because it performscomprehensive, full-range tests

    CBIT

    PBIT IBIT

    Sample IBIT Tests: Superset of PBIT and CBIT tests Power system tests Dynamic actuator tests Mechanical range tests Initiated failure tests

    S u p p o s e a n a c t u a t o r m o v e s a s w i n g - a r m f r o m 0 t o 1 8 0 . T h e s y s t e m c a n n o t t e s t t h e f u l l

    r a n g e o f m o t i o n d u r i n g o p e r a t i o n , u n l e s s t h e a p p l i c a t i o n g u a r a n t e e s t o m o v e t h e s w i n g - a r m

    o v e r i t s f u l l r a n g e o f m o t i o n d u r i n g t h e m i s s i o n . T h e o p e r a t o r c a n u s e a s p e c i a l c o n t r o l l e d

    t e s t i n I B I T t o v e r i f y t h a t t h e s w i n g - a r m c a n o p e r a t e o v e r i t s f u l l r a n g e o f m o t i o n .

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    BIT Analysis

    Leverages results of other system safety analyses,

    including: Preliminary System Safety Assessment

    Fault Tree Analysis Failure Modes and Effects Analysis

    Consider failure mode, probability of failure, cause andeffect, recognition/detection scheme, isolation, systemcompensation

    Will typically yield action items for design improvements.

    Not a do it once checkbox Analysis is incrementaluntil requirements are satisfied.

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    Redundancy

    Failures are mitigated by the

    other operating channels,perhaps with a degraded levelof performance.

    The effects of failures in non-redundant components, such

    as the control interface andpower source, cannot bealleviated.

    Power

    Source

    Sensor

    Monitors

    ActuatorController

    ActuatorController

    ActuatorController

    Actuator

    Control

    InterfaceController

    Mechanical

    Interface

    Sensor

    MonitorsSensor

    MonitorsSensor

    Monitors

    R e d u n d a n c y i s a c o m m o n d e s i g n p r a c t i c e t h a t i s o f t e n u s e d t o m a i n t a i n f u n c t i o n a l i t y a f t e r a

    f a i l u r e o c c u r s .

    I n t h i s c a s e , f u n c t i o n a l i t y i s m a i n t a i n e d b y f o u r r e d u n d a n t o p e r a t i n g c h a n n e l s . F a i l u r e s t h a t

    o c c u r i n a c o n t r o l l e r , a c t u a t o r o r m e c h a n i c a l m o n i t o r c a n b e m i t i g a t e d b y t h e o t h e r

    o p e r a t i n g c h a n n e l s , p e r h a p s w i t h a d e g r a d e d l e v e l o f p e r f o r m a n c e . T h e e f f e c t s o f f a i l u r e s

    i n n o n - r e d u n d a n t c o m p o n e n t s , s u c h a s t h e c o n t r o l i n t e r f a c e a n d p o w e r s o u r c e i n t h i s c a s e ,

    c a n n o t b e a l l e v i a t e d .

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    Degradation Categories for Failure Response

    Fail-Operational From an

    operator perspective, the systembehaves normally. Failure is reported, but

    system operation isunaffected.

    System components thatremain functional typically

    take over the functions of thefailed components.

    Example: Dual-redundantsurgical blood flow systemstypically can meetperformance requirementswith only one channel. When

    one channel fails, the systemcontinues to perform usingthe remaining channel.

    Power

    Source

    Sensor

    Monitors

    ActuatorController

    ActuatorController

    ActuatorController

    Actuator

    Control

    InterfaceController

    Mechanical

    Interface

    Sensor

    MonitorsSensor

    MonitorsSensor

    Monitors

    T h e r e a r e m a n y f a i l u r e m o d e s , b u t s y s t e m d e s i g n e r s h a v e d e v e l o p e d a p p r o a c h e s t o m i t i g a t e t h e m .

    V a r i o u s r e s p o n s e c a t e g o r i e s h a v e b e e n d e v e l o p e d t o d e s c r i b e m i t i g a t i o n o f t h e s e s y s t e m f a i l u r e s :

    F a i l - O p e r a t i o n a l F r o m a n o p e r a t o r p e r s p e c t i v e , t h e s y s t e m b e h a v e s n o r m a l l y . T h e f a i l u r e i s

    r e p o r t e d , b u t s y s t e m o p e r a t i o n i s u n a f f e c t e d . T h e s y s t e m c o m p o n e n t s t h a t r e m a i n f u n c t i o n a l

    t y p i c a l l y t a k e o v e r t h e f u n c t i o n s o f t h e f a i l e d c o m p o n e n t s . E x a m p l e : Q u a d - r e d u n d a n t f l i g h t c o n t r o l

    s u r f a c e a c t u a t o r s y s t e m s t y p i c a l l y c a n m e e t p e r f o r m a n c e r e q u i r e m e n t s w i t h o n l y t h r e e c h a n n e l s .

    W h e n o n e c h a n n e l f a i l s , t h e s y s t e m c o n t i n u e s t o p e r f o r m u s i n g t h e r e m a i n i n g t h r e e c h a n n e l s .

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    Degradation Categories for Failure Response

    Fail-Passive Outputs assume a

    predetermined desirable state,such as a power disconnect tothe actuators.

    Failure is reported, andoperation is reverted tobackup.

    Intervention may be required,

    but the system remains undercontrol in some degradedfashion.

    Example: Ambulatory scooterused reduced speed modewhen battery supply is low.The vehicle will not maintain

    desired performance, butrider can limp home.

    Power

    Source

    Sensor

    Monitors

    ActuatorController

    ActuatorController

    ActuatorController

    Actuator

    Control

    InterfaceController

    Mechanical

    Interface

    Sensor

    MonitorsSensor

    MonitorsSensor

    Monitors

    F a i l - P a s s i v e T h e s y s t e m o u t p u t s a p r e d e t e r m i n e d d e s i r a b l e s t a t e , s u c h a s a p o w e r d i s c o n n e c t t o t h e

    a c t u a t o r s . T h e f a i l u r e i s r e p o r t e d , a n d o p e r a t i o n i s t y p i c a l l y r e v e r t e d t o a b a c k u p m e c h a n i s m .

    I n t e r v e n t i o n m a y b e r e q u i r e d , b u t t h e s y s t e m g e n e r a l l y r e m a i n s u n d e r c o n t r o l , a l t h o u g h u s u a l l y i n

    s o m e d e g r a d e d f a s h i o n . E x a m p l e : M a n y m a r i n e a c t u a t o r c o n t r o l a p p l i c a t i o n s p r o v i d e a

    m e c h a n i c a l b a c k u p t h a t i s a u t o m a t i c a l l y e n g a g e d w h e n a u t o m a t e d s y s t e m s f a i l , t h e r e b y e n a b l i n g

    t h e p i l o t t o l i m p h o m e . T h e v e h i c l e m a y n o t m e e t p e r f o r m a n c e r e q u i r e m e n t s , b u t i t w i l l b e a b l e t o

    t r a v e l t o a s a f e e n v i r o n m e n t .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 2

    Degradation Categories for Failure Response

    Fail-Safe Provides a saferesponse when normal,predictable control is notpossible. Subcategory of fail-passive Actuators are not controllable

    in a manner to meet theperformance specification.

    System employs mechanismsto force the actuator in aknown state that maintains asafe operational state.

    Example: Patient lift backupis engaged when automatedsystems fail, holding patientsafely. The lift will not meetperformance requirements,

    but it will maintain a safeenvironment.

    Power

    Source

    Sensor

    Monitors

    ActuatorController

    ActuatorController

    ActuatorController

    Actuator

    Control

    InterfaceController

    Mechanical

    Interface

    Sensor

    MonitorsSensor

    MonitorsSensor

    Monitors

    F a i l - S a f e T h i s a p p r o a c h i s u s e d t o p r o v i d e a s a f e r e s p o n s e w h e n n o r m a l , p r e d i c t a b l e c o n t r o l i s n o t

    p o s s i b l e . I n t h i s c a t e g o r y , w h i c h i s s o m e t i m e s c o n s i d e r e d a s u b c a t e g o r y o f f a i l - p a s s i v e , t h e

    a c t u a t o r s a r e n o t c o n t r o l l a b l e i n a m a n n e r t o m e e t t h e p e r f o r m a n c e s p e c i f i c a t i o n . H o w e v e r , t h e

    s y s t e m e m p l o y s m e c h a n i s m s t o f o r c e t h e a c t u a t o r i n a k n o w n s t a t e t h a t m a i n t a i n s a s a f e

    o p e r a t i o n a l s t a t e . E x a m p l e : H y b r i d - e l e c t r i c v e h i c l e s ( H E V ) h a v e e x p e r i e n c e d f a i l u r e s t h a t c a u s e

    r u n a w a y m o t o r s w h e r e m o t o r s s p e e d u p o u t o f c o n t r o l a n d t r a n s f e r u n c o m m a n d e d p o w e r t o t h e

    d r i v e a x l e s . A f a i l - s a f e m i t i g a t i o n w o u l d d i s c o n n e c t p o w e r f r o m t h e m o t o r , u s u a l l y t h r o u g h h i g h -

    c u r r e n t r e l a y s , w h e n a f a i l u r e o c c u r s . T h e v e h i c l e m a y n o t b e d r i v a b l e , b u t t h e p a s s e n g e r s a n d

    c a r g o r e m a i n s a f e .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 3

    Degradation Categories for Failure Response

    Fail-Active Highly undesirable

    state occurring when mitigationinto one of the other categories isnot possible.

    Applications allow a smallprobability, such as 10-9.

    Actuators respond in anuncontrollable/unpredictable

    (nondeterministic) manner. Safety-critical systems are

    designed to minimize fail-active scenarios.

    Example: Automotive steer-by-wire applications havesteering wheel interfaces with

    common mode failures thatcould inhibit steering control.

    Power

    Source

    Sensor

    Monitors

    ActuatorController

    ActuatorController

    ActuatorController

    Actuator

    Control

    InterfaceController

    Mechanical

    Interface

    Sensor

    MonitorsSensor

    MonitorsSensor

    Monitors

    F a i l - A c t i v e T h i s c a t e g o r y i s h i g h l y u n d e s i r a b l e a n d s t r i k e s f e a r i n t o t h e h e a r t s o f s a f e t y - c r i t i c a l

    s y s t e m s d e s i g n e r s . I t o c c u r s w h e n m i t i g a t i o n i n t o o n e o f t h e o t h e r c a t e g o r i e s i s n o t p o s s i b l e . I t

    c a n n o t b e p r e v e n t e d c o m p l e t e l y , s o a p p l i c a t i o n s t y p i c a l l y a l l o w a s m a l l p r o b a b i l i t y , s u c h a s 1 0 - 9 .

    I n a f a i l - a c t i v e s t a t e , a c t u a t o r s d r i v e t h e s y s t e m i n a n u n c o n t r o l l a b l e a n d u n p r e d i c t a b l e

    ( n o n d e t e r m i n i s t i c ) m a n n e r . S a f e t y - c r i t i c a l s y s t e m s a r e d e s i g n e d t o m i n i m i z e f a i l - a c t i v e s c e n a r i o s .

    E x a m p l e : A u t o m o t i v e s t e e r - b y - w i r e a p p l i c a t i o n s h a v e a u n i q u e c h a l l e n g e i n t h a t t y p i c a l s t e e r i n g

    w h e e l i n t e r f a c e s h a v e c o m m o n m o d e f a i l u r e s t h a t c o u l d i n h i b i t s t e e r i n g c o n t r o l .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 4

    Degradation Requirements

    Performance specs apply degradation categories

    through multiple failure modes.

    Example for a tri-redundant artificial heart: After the first failure, the system shall remain fail-

    operational. After the second failure, the operation shall be fail-

    passive. After the third failure, the operation shall be fail-safe.

    Select architectures and components to meet theserequirements. In this example, the heart must be able topump with only two operating channels. The actuators

    must be sized to enable operation with only twofunctioning actuators.

    A p p l i c a t i o n p e r f o r m a n c e s p e c i f i c a t i o n s m a y r e q u i r e s y s t e m a r c h i t e c t u r e s t o a p p l y t h e s e

    d e g r a d a t i o n c a t e g o r i e s t h r o u g h m u l t i p l e f a i l u r e m o d e s . F o r i n s t a n c e , a f t e r t h e f i r s t f a i l u r e i n

    a q u a d - r e d u n d a n t f l i g h t a c t u a t o r s y s t e m , t h e s y s t e m m a y b e r e q u i r e d t o r e m a i n f a i l -

    o p e r a t i o n a l . A f t e r t h e s e c o n d f a i l u r e i n t h e s y s t e m , t h e a p p l i c a t i o n m a y r e q u i r e f a i l - p a s s i v e

    o p e r a t i o n . A f t e r t h r e e f a i l u r e s , t h e a p p l i c a t i o n m a y r e q u i r e f a i l - s a f e o p e r a t i o n . S y s t e m

    d e s i g n e r s m u s t b e a w a r e o f f a i l u r e r e s p o n s e r e q u i r e m e n t s a n d s e l e c t a r c h i t e c t u r e s a n d

    c o m p o n e n t s a c c o r d i n g l y . I n t h i s a p p l i c a t i o n , t h e a c t u a t o r s y s t e m m u s t b e a b l e t o

    a d e q u a t e l y m o v e t h e a i r c r a f t s u r f a c e s w i t h o n l y t w o o p e r a t i n g c h a n n e l s . T h e r e f o r e , t h e

    a c t u a t o r s m u s t b e s i z e d t o e n a b l e o p e r a t i o n w i t h o n l y t w o f u n c t i o n i n g a c t u a t o r s .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 5

    Industry Specifications andStandards

    Industry Specifications andStandards

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 6

    Role of Industry Standards

    Safety-critical applications are guaranteed only through

    robust designs and controlled operation.

    Industry specs and standards provide guidelines to: Support safety-critical application development

    Generally accepted engineering practices for robustdesign

    Definitions and expectations for controlled operation

    Compliance to these standards significantly influencedevelopment cost and schedule.

    Standards can contain requirements, guidelines or both. Requirementsprocesses/practices that must be

    implemented. Guidelinesrecommended practices/methods.

    W e c l a i m e d e a r l i e r t h a t s a f e t y - c r i t i c a l a p p l i c a t i o n s a r e g u a r a n t e e d o n l y t h r o u g h r o b u s t

    d e s i g n s a n d c o n t r o l l e d o p e r a t i o n . I n d u s t r y s p e c i f i c a t i o n s a n d s t a n d a r d s p r o v i d e g e n e r a l l y

    a c c e p t e d e n g i n e e r i n g p r a c t i c e s a n d g u i d e l i n e s t o s u p p o r t s a f e t y - c r i t i c a l a p p l i c a t i o n

    d e v e l o p m e n t . D e v e l o p m e n t p r o g r a m s w i l l i d e n t i f y a p p l i c a b l e i n d u s t r y s p e c i f i c a t i o n s a n d

    s t a n d a r d s e a r l y i n t h e l i f e - c y c l e , a s c o m p l i a n c e t o t h e s e s t a n d a r d s c a n h a v e a s i g n i f i c a n t

    i n f l u e n c e o n d e v e l o p m e n t c o s t a n d s c h e d u l e .

    S t a n d a r d s c a n c o n t a i n r e q u i r e m e n t s , g u i d e l i n e s o r b o t h . R e q u i r e m e n t s a r e p r o c e s s e s o r

    d e s i g n p r a c t i c e s t h a t m u s t b e i m p l e m e n t e d . G u i d e l i n e s p r o v i d e r e c o m m e n d e d p r a c t i c e s

    a n d m e t h o d s f o r s a t i s f y i n g r e q u i r e m e n t s .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 7

    Safety Standards Categories

    Safety

    Standards

    Development

    Processes

    Design

    Practices

    Management EngineeringAnalysis SystemArchitecture ComponentPractices

    S t a n d a r d s c a n b e a p p l i e d t o d e v e l o p m e n t p r o c e s s e s a n d / o r d e s i g n i m p l e m e n t a t i o n

    E x a m p l e s o f d e v e l o p m e n t p r o c e s s e s a r e s o f t w a r e d e v e l o p m e n t p l a n s , q u a l i t y m a n a g e m e n t

    p r o c e s s e s a n d v e r i f i c a t i o n p l a n s . E n g i n e e r i n g a n a l y s i s s t a n d a r d s i n c l u d e r e l i a b i l i t y a n a l y s i s

    a n d o t h e r p e r f o r m a n c e a n a l y s e s . D e s i g n p r a c t i c e s a r e v e r y s p e c i f i c t o t h e a p p l i c a t i o n

    i n d u s t r y . F o r i n s t a n c e , t h e F e d e r a l M o t o r V e h i c l e S a f e t y S t a n d a r d s ( F M V S S ) p r o v i d e

    d e s i g n p r a c t i c e s f o r m o t o r v e h i c l e s .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 8

    Sample Safety Standards and Applicability

    Automotive Industry SoftwareMISRA / MISRA C

    Motor vehicle systems and components (CAN)CMVSS

    Motor vehicle systems and components (US)FMVSS

    Railway IndustryEN 50128

    Medical EquipmentIEC 60601

    Automotive FMEASAE J1739

    Vehicle Electronic SystemsSAE J1938

    Guidelines for Electric Vehicle SafetySAE J2344

    Nuclear IndustryIEC 880

    Software design requirements (non-process)UL-1998

    Automotive software safety processesMOD DEF STAN 00-55

    Automotive system safety processesMOD DEF STAN 00-56

    Generic 'Programmable Systems'IEC 61508

    Aerospace and Aviation SoftwareRTCA/DO-178B

    Aerospace and Aviation HardwareRTCA/DO-254

    Aircraft systems certification considerationsARP 4754Airborne systems safety assessmentARP 4761

    Safety systems for US DoDMIL-STD-882

    ApplicabilityStandard

    A l t h o u g h t h e s c o p e o f t h i s p a p e r i s n o t t o p r o v i d e a t u t o r i a l o f s a f e t y s t a n d a r d s , i t i s r e l e v a n t

    t o i d e n t i f y s o m e s t a n d a r d s a n d t h e i r a p p l i c a b l e i n d u s t r i e s a n d a p p l i c a t i o n s . T a b l e 1

    h i g h l i g h t s s o m e c o m m o n s t a n d a r d s .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 3 9

    Applicability of Standards

    There is some cross-breeding of standards.

    Ex. DO-178B is used in some automotive and medicalapplications.

    System Integrity Levels (SIL)

    Classified from 4 (highest safety) to 0 (not safety-related) [DO-178B uses A (high) to E (low)]

    SIL determines applicable development and testprocesses

    Not globally adopted Some countries take deviations

    M a n y o f t h e s t a n d a r d s l i s t e d a b o v e c l a s s i f y s y s t e m s i n t o f i v e S y s t e m I n t e g r i t y L e v e l s ( S I L s )

    f r o m 4 ( h i g h e s t s a f e t y ) t o 0 ( n o t s a f e t y r e l a t e d ) . D O - 1 7 8 B u s e s A ( h i g h e s t s a f e t y ) t o E

    ( l o w e s t s a f e t y ) . T h e S I L o f t h e d e v e l o p m e n t p r o j e c t d r i v e s t h e p r o c e s s e s f o r t h a t p r o j e c t .

    F o r i n s t a n c e , t o t e s t s o f t w a r e i n a D O - 1 7 8 B L e v e l A p r o j e c t , s u c h a s a f l i g h t c o n t r o l s y s t e m

    w i t h n o m e c h a n i c a l b a c k u p , a l l c o d e s t a t e m e n t s m u s t b e e x e c u t e d , a l l c o d e b r a n c h e s m u s t

    b e f o l l o w e d , a n d a c t u a l t a r g e t h a r d w a r e m u s t b e u s e d .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 0

    But do I HAVE to?

    Designers mission is to achieve safety certification

    Deviations can be taken, if they are coordinated with andapproved by the applications certification representative.

    The Code is more what you'd call

    "guidelines" than actual rules.

    B a r b o s s a , P i r a t e s o f t h e C a r i b b e a n

    T o s t e a l a q u o t e f r o m t h e m o v i e P i r a t e s o f t h e C a r i b b e a n , m a n y o f t h e s e s t a n d a r d s a r e

    m o r e w h a t y o u ' d c a l l g u i d e l i n e s t h a n a c t u a l r u l e s . T h e d e s i g n e r s r e a l m i s s i o n i s t o

    a c h i e v e s a f e t y c e r t i f i c a t i o n . D e v i a t i o n s c a n b e t a k e n , i f t h e y a r e c o o r d i n a t e d w i t h a n d

    a p p r o v e d b y t h e a p p l i c a t i o n s c e r t i f i c a t i o n r e p r e s e n t a t i v e .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 1

    Development StrategiesDevelopment Strategies

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 2

    So Tell Me, Do You Feel Lucky Punk?

    For a system to be trusted with human life, it must be:

    Well-planned, Well-designed, Well-tested Design Goal Eliminate catastrophic failure modes, or Minimize the risk to a very low probability

    Testing is necessary, but not sufficient Proves the presence of errors, not their absence No way to test safety into the system

    Safety is built-in throughout the development life-cycle Safety-critical development plans and test procedures Independent reviews

    S y s t e m s t h a t a r e w e l l - p l a n n e d , d e s i g n e d , t e s t e d a n d c e r t i f i e d c a n b e t r u s t e d w i t h h u m a n

    l i f e . T h e d e s i g n g o a l o f s a f e t y - c r i t i c a l s y s t e m d e v e l o p m e n t i s t o e l i m i n a t e f a i l u r e m o d e s

    t h a t c o u l d r e s u l t i n c a t a s t r o p h i c f a i l u r e s , o r i f t h a t i s n o t f e a s i b l e , m i n i m i z e t h e r i s k s u c h t h a t

    t h e r e i s a v e r y l o w p r o b a b i l i t y o f c a t a s t r o p h i c f a i l u r e .

    S a f e t y i s p r o v e n n o t o n l y t h r o u g h t e s t i n g , b u t a l s o t h r o u g h s a f e p l a n n i n g a n d d e v e l o p m e n t

    p r o c e s s e s . T e s t i n g i s a n e c e s s a r y , b u t n o t s u f f i c i e n t , e l e m e n t o f s a f e t y - c r i t i c a l d e v e l o p m e n t

    i t o n l y p r o v e s t h e p r e s e n c e o f e r r o r s , n o t t h e i r a b s e n c e . W e h a v e n t y e t f o u n d a w a y t o

    t e s t s a f e t y i n t o t h e s y s t e m .

    S a f e t y m u s t b e b u i l t - i n t h r o u g h o u t t h e d e v e l o p m e n t l i f e - c y c l e u s i n g s a f e t y - c r i t i c a l

    d e v e l o p m e n t p l a n s a n d p r o c e d u r e s , i n d e p e n d e n t r e v i e w s , a n d c o m p r e h e n s i v e t e s t c a s e s .

    T h i s s e c t i o n h i g h l i g h t s s o m e b a s i c d e v e l o p m e n t s t r a t e g i e s t h a t h a v e p r o v e n t o b e i m p o r t a n t

    i n m a n y o f t h e a u t h o r s d e s i g n s . I t i s b y n o m e a n s a c o m p r e h e n s i v e l i s t , b u t i t d o e s c a p t u r e

    s o m e t h o u g h t p r o c e s s e s t h a t m u s t b e e x e r c i s e d .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 3

    Improving Fault Tolerance

    Brick wall partitoning

    Redundancy no single-point failures

    Cross-channel data voting

    Isolation and independence (e.g. power sources) Both hardware and software

    BIT mode allocation

    Hardware independence of control and BIT HW

    Reliability, maintainability and safety analyses

    Deterministic performance

    Comprehensive validation and verification

    Requirements-based simulation and testing

    Certified development tools

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 4

    Example CasesExample Cases

    T h r o u g h o u t m y c a r e e r , I h a v e w o r k e d o n s a f e t y - c r i t i c a l a p p l i c a t i o n s o n a v a r i e t y o f

    p l a t f o r m s , i n c l u d i n g a i r p l a n e s , l o c o m o t i v e s , h e a v y - d u t y t r u c k s , p a s s e n g e r v e h i c l e s , p o w e r

    s y s t e m s , a n d m e d i c a l d i a g n o s t i c s . I n t e r e s t i n g l y , t h e c o n c e p t s n e e d e d t o m a k e t h e s e

    s y s t e m s f a u l t - t o l e r a n t , f a i l - o p e r a t i v e o r f a i l - s a f e a r e q u i t e c o m m o n .

    T h e f o l l o w i n g d e s c r i b e s s o m e e x a m p l e s o f s a f e t y - c r i t i c a l s y s t e m s .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 5

    Fly-by-wire Aircraft Control Systems

    In the past, many aircraft had mechanical backups for

    their electronic flight control systems.

    Fly-by-wire systems with no mechanical backups arebecoming more prevalent in both military andcommercial environments.

    Actuation systems, such as those that move flightsurfaces, have become safety-critical.

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 6

    Automotive Drive-by-wire System

    Now developing full authority drive-by-wire systems:

    Brake-by-wire Steer-by-wire

    Throttle-by-wire.

    Previously achieved fault tolerance through hardwareredundancy.

    Redundancy can be cost and space prohibitive in drive-by-wire applications.

    Software standards such as MISRA are being developedto facilitate fault tolerance with less hardwareredundancy.

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 7

    Railway Signaling System

    Railway signaling systems enable operators to direct

    trains while preventing trains from colliding

    Malfunction in these systems could cause death

    Safety-related hardware is used to provide redundancy

    Control independence is provided through coordinatedactions by the train operator and the dispatcher.

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 8

    Submarine Depth Control System

    Similar challenges as aircraft applications

    Preferred fail-safe response depends on the applicationand environment.

    In a battle environment, underwater concealment isimportant, so surfacing the submarine may not be thebest mitigation

    Submarine pilot must be able to eventually surface afailed vehicle to recover personnel

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 4 9

    Nuclear Power Station Shutdown

    Nuclear power stations require a protection system that

    closes the station down in the event of a malfunction.

    Protection system must mitigate the consequences ofthe situation.

    Both hardware and software protection systems areused, since the multiple redundancy increasesconfidence in safety.

    With great power comes

    great responsibility.

    U n c l e B e n , S p i d e r m a n

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 0

    Medical Systems

    Can be directly responsible for human life

    Examples: Hardware that controls laparoscopic surgery devices Software that monitors safe amounts of x-rays

    Information systems that doctors use to coordinatemedication

    Safety development standards have recently become astrong focus in the medical industry.

    Therac-25 radiation therapy machine has resulted in lostlives due to software-related radiation overdoses.

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 1

    Conclusions

    System safety requires robust design and controlled operation

    during failure modes. Designers for safety-critical applications utilize industry standards

    and development processes, as well as preferred engineering

    practices, to develop safe, validated and deterministic designs.

    Redundancy and comprehensive BIT mitigate system failures

    Learn to expect the unexpected.

    The response to an unexpected event must be known anddesigned into the system before that unexpected event occurs.

    Predictable and deterministic responses to all potential failuremodes are paramount in safety-critical design.

    Many of the issues, practices and strategies described in thispresentation are a result of previous or ongoing projects atOn Target Technology Development.

    I f w e a l l k e e p o u r w i t s a b o u t u s a s w e d e v e l o p t h e s e s a f e t y - c r i t i c a l s y s t e m s , w e c a n s i t b a c k

    a n d r e l a x i n o u r c o n f i n e d s p a c e o n b o a r d a n a i r c r a f t w i t h o u t w o r r y i n g t h a t a d e s i g n f a i l u r e

    w i l l s e n d o u r s t e e l h o r s e f o r a l o o p e v e n w h e n w e f l y o v e r t h e E q u a t o r .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 2

    On Target Medical Actuator Projects

    Products, research projects, partnerships

    Medical monitor

    Muscle diagnostic system

    Circulation Actuation through the Limb Footwear (CALF)

    Personal transporter

    Respiratory therapy stimulation vest

    X-ray controller

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 3

    Q&AQ&A

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 4

    If you have any further questions

    On Target TechnologyDevelopment

    1701 North Street, Bldg 40-1, Endicott, NY 13760

    P: (607) 755-4990 F: (607) 755-4981

    Contact: Vince Socci, Principal

    [email protected]

    www.ontargettechnology.com

    On Time, On Budget, On Top On Target

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 5

    Backup slidesBackup slides

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 6

    How do you meet that demand?

    Education and training in safety-critical application

    development Integrated system awareness and development

    Proven safety standards, development processes, anddesign practices

    Lessons learned and development strategies from theschool of hard knocks

    Education and training in safety-critical application

    development

    Integrated system awareness and development

    Proven safety standards, development processes, anddesign practices

    Lessons learned and development strategies from theschool of hard knocks

    You took the initiative to participate in this workshopYou took the initiative to participate in this workshopYou took the initiative to participate in this workshopYou took the initiative to participate in this workshop

    and learn the skills needed to meet that demand.and learn the skills needed to meet that demand.and learn the skills needed to meet that demand.and learn the skills needed to meet that demand.

    As a result, you will become more valuable toAs a result, you will become more valuable toAs a result, you will become more valuable toAs a result, you will become more valuable to

    your organization and your industry.your organization and your industry.your organization and your industry.your organization and your industry.

    Congratulations!Congratulations!Congratulations!Congratulations!

    T h e r e i s o n l y s o m u c h w e c a n l e a r n i n a 9 0 - m i n u t e c o u r s e . B u t w e w i l l c o v e r t h e h i g h l i g h t s ,

    a n d y o u w i l l t a k e t h a t o v e r v i e w a s a f o u n d a t i o n f o r y o u r f u t u r e l e a r n i n g .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 7

    F-16 Thunderbird Crashes

    See http://www.f-16.net/f-16_news_article968.html

    F - 1 6 C p e r f o r m e d a b e l l y l a n d i n g o n t h e L u k e

    A F B r u n w a y o n J u n e 1 7 , 2 0 0 4 a t

    a p p r o x i m a t e l y 1 4 1 6 .

    T h e p i l o t o f t h e F - 1 6 d e c l a r e d a n i n - f l i g h t

    e m e r g e n c y w h e n h e c o u l d n o t e x t e n d t h e

    l a n d i n g g e a r . A f t e r n u m e r o u s a t t e m p t s t o

    e x t e n d i t , t h e a i r c r a f t r a n o u t o f f u e l a n d t h e

    p i l o t w a s f o r c e d t o p u t t h e j e t d o w n o n i t s b e l l y .

    A f t e r s l i d i n g t o a f i e r y s t o p , t h e c a n o p y w a s

    s e e n t o g o u p a n d t h e p i l o t s p r i n t e d a w a y f r o m

    t h e b u r n i n g a i r c r a f t . T h e p i l o t i s t h o u g h t t o b e

    o k , b u t t h e a i r c r a f t i s m o s t l i k e l y t o t a l e d .

    E v e n t # 1 E v e n t # 1 E v e n t # 1 E v e n t # 1

    P i l o t E r r o r

    P i l o t E r r o r P i l o t E r r o r P i l o t E r r o r E v e n t # 2

    E v e n t # 2 E v e n t # 2 E v e n t # 2

    S y s t e m F a i l u r e

    S y s t e m F a i l u r e S y s t e m F a i l u r e S y s t e m F a i l u r e

    See http://www.f-16.net/f-16_news_article1100.html

    A p i l o t ' s e r r o r c a u s e d a T h u n d e r b i r d s F - 1 6 C t o c r a s h s h o r t l y a f t e r t a k e o f f d u r i n g a S e p t e m b e r a i r s h o w a t M o u n t a i n

    H o m e A i r F o r c e B a s e , I d a h o . T h e p i l o t e j e c t e d j u s t b e f o r e t h e a i r c r a f t i m p a c t e d t h e g r o u n d .

    O n W e d n e s d a y t h e 2 1 s t , t h e A i r F o r c e A c c i d e n t I n v e s t i g a t i o n B o a r d h e l d a n e w s c o n f e r e n c e a t t h e h o m e o f t h e

    T h u n d e r b i r d s - N e l l i s A i r F o r c e B a s e - t o a n n o u n c e w h a t c a u s e d a n F 1 6 t o c r a s h l a s t S e p t e m b e r .

    A c c o r d i n g t o t h e a c c i d e n t i n v e s t i g a t i o n b o a r d r e p o r t t h e p i l o t , 3 1 - y e a r - o l d C a p t a i n C h r i s S t r i c k l i n , m i s i n t e r p r e t e d

    t h e a l t i t u d e r e q u i r e d t o c o m p l e t e t h e " S p l i t S " m a n e u v e r . H e m a d e h i s c a l c u l a t i o n b a s e d o n a n i n c o r r e c t m e a n -

    s e a - l e v e l a l t i t u d e o f t h e a i r f i e l d . T h e p i l o t i n c o r r e c t l y c l i m b e d t o 1 , 6 7 0 f e e t a b o v e g r o u n d l e v e l i n s t e a d o f 2 , 5 0 0 f e e t

    b e f o r e i n i t i a t i n g t h e p u l l d o w n t o t h e S p l i t S m a n e u v e r .

    W h e n h e r e a l i z e d s o m e t h i n g w a s w r o n g , t h e p i l o t p u t m a x i m u m b a c k s t i c k p r e s s u r e a n d r o l l e d s l i g h t l y l e f t t o

    e n s u r e t h e a i r c r a f t w o u l d i m p a c t a w a y f r o m t h e c r o w d s h o u l d h e h a v e t o e j e c t . H e e j e c t e d w h e n t h e a i r c r a f t w a s

    1 4 0 f e e t a b o v e g r o u n d - j u s t 0 . 8 s e c o n d s p r i o r t o i m p a c t . H e s u s t a i n e d o n l y m i n o r i n j u r i e s f r o m t h e e j e c t i o n . T h e r e

    w a s n o o t h e r d a m a g e t o m i l i t a r y o r c i v i l i a n p r o p e r t y .

    T h e a i r c r a f t , v a l u e d a t a b o u t $ 2 0 . 4 m i l l i o n , w a s d e s t r o y e d .

    T h e d i f f e r e n c e i n a l t i t u d e s a t N e l l i s a n d M o u n t a i n H o m e m a y h a v e c o n t r i b u t e d t o t h e p i l o t ' s e r r o r . T h e a i r f i e l d a t

    N e l l i s i s a t 2 , 0 0 0 f e e t w h e r e a s t h e o n e a t M o u n t a i n H o m e i s a t 3 , 0 0 0 f e e t . I t a p p e a r s t h a t t h e p i l o t r e v e r t e d b a c k t o

    h i s N e l l i s h a b i t p a t t e r n f o r s a p l i t s e c o n d . T h u n d e r b i r d c o m m a n d e r L t . C o l . R i c h a r d M c S p a d d e n s a i d S t r i c k l i n h a d

    p e r f o r m e d t h e s t u n t a r o u n d 2 0 0 t i m e s , a t d i f f e r e n t a l t i t u d e s d u r i n g h i s y e a r a s a T h u n d e r b i r d p i l o t .

    M c S p a d d e n s a y s S t r i c k l i n i s a n e x c e p t i o n a l o f f i c e r . " H e i s a n e x t r e m e l y t a l e n t e d p i l o t . H e c a m e i n h e r e a n d m a d e

    a n h o n e s t m i s t a k e , " s a y s L t . C o l . M c S p a d d e n . B u t t h a t m i s t a k e h a s c o s t S t r i c k l i n h i s p r e s t i g i o u s s p o t o n t h e

    T h u n d e r b i r d t e a m . " H e ' s a s s i g n e d t o W a s h i n g t o n D . C . , " s a y s M c S p a d d e n . " H e ' s w o r k i n g i n t h e P e n t a g o n t h e r e i n

    o n e o f t h e a g e n c i e s . "

    T h e m a n e u v e r t h e p i l o t w a s t r y i n g t o c o m p l e t e i s c a l l e d t h e " S p l i t S M a n e u v e r . " T h e s t u n t r e q u i r e s t h a t t h e p i l o t

    c l i m b t o 2 , 5 0 0 f e e t . I n v e s t i g a t o r s s a y S t r i c k l i n o n l y c l i m b e d t o 1 , 6 7 0 f e e t b e f o r e h e w e n t i n t o t h e s p i n n i n g r o l l .

    T h e b o a r d d e t e r m i n e d o t h e r f a c t o r s s u b s t a n t i a l l y c o n t r i b u t e d t o c r e a t i n g t h e o p p o r t u n i t y f o r t h e e r r o r i n c l u d i n g t h e

    r e q u i r e m e n t t o c o n v e r t s e a l e v e l a l t i t u d e i n f o r m a t i o n f r o m t h e F - 1 6 i n s t r u m e n t s - t o t h e i r a l t i t u d e a b o v e g r o u n d a n d

    c a l l o u t t h a t i n f o r m a t i o n t o a s a f e t y o p e r a t o r b e l o w .

    B u t t h e A i r F o r c e h a s n o w c h a n g e d t h a t a s a r e s u l t o f t h e c r a s h . T h u n d e r b i r d p i l o t s w i l l n o w c a l l o u t t h e M S L

    ( m e a n - s e a - l e v e l ) a l t i t u d e s a s o p p o s e d t o t h e A G L ( a b o v e - g r o u n d - l e v e l ) a l t i t u d e s .

    T h u n d e r b i r d p i l o t s w i l l n o w a l s o c l i m b a n e x t r a 1 0 0 0 f e e t b e f o r e p e r f o r m i n g t h e S p l i t S M a n e u v e r t o p r e v e n t

    a n o t h e r m i s t a k e l i k e t h e o n e o n S e p . 1 4 , 2 0 0 3 f r o m h a p p e n i n g a g a i n .

    C a p t a i n C h r i s S t r i c k l i n h a s b e e n i n t h e A i r F o r c e s i n c e 1 9 9 4 a n d f l e w w i t h t h e T h u n d e r b i r d s f o r t h e f i r s t s e a s o n

    n o w . H e h a s l o g g e d a t o t a l o f 1 , 5 0 0 + f l i g h t h o u r s a n d h a s r e c e i v e d n u m e r o u s a w a r d s . H e s e r v e d a s a f l i g h t

    e x a m i n e r , f l i g h t i n s t r u c t o r a n d f l i g h t c o m m a n d e r .

    T h e T h u n d e r b i r d s w i l l a g a i n t a k e t o t h e s k i e s t h i s y e a r . T h e y h a v e 6 5 a i r s h o w s s c h e d u l e d .

    T h e S e p t e m b e r c r a s h w a s t h e s e c o n d i n v o l v i n g a T h u n d e r b i r d s j e t s i n c e t h e t e a m b e g a n u s i n g F - 1 6 s i n 1 9 8 3 .

    P i l o t e r r o r w a s b l a m e d f o r a F e b . 1 4 , 1 9 9 4 , t r a i n i n g c r a s h i n v o l v i n g i n a m a n e u v e r c a l l e d a s p i r a l d e s c e n t a t t h e

    I n d i a n S p r i n g s A u x i l i a r y A i r f i e l d , n o r t h w e s t o f L a s V e g a s . T h e p i l o t s u r v i v e d , b u t t h e m a n e u v e r w a s d i s c o n t i n u e d .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 8

    Automotive Brake-by-Wire System

    FL FR

    RL RR

    P

    A brake actuator interfaces with

    each wheel (FL, FR, RL, andRR).

    These actuators are controlledusing the brake pedal input (P).

    Dual-redundant signal paths areused to prevent single-point

    failures in the wiring.

    What happens when a brake fails?

    (active/inactive)

    A pedal?

    B r a k e - b y - w i r e s y s t e m s a r e s a f e t y c r i t i c a l s y s t e m s . I f t h e b r a k e s f a i l t o o p e r a t e c o r r e c t l y , t h e

    v e h i c l e w i l l n o t b e c o n t r o l l a b l e . I m a g i n e w h a t w o u l d h a p p e n i f y o u w e r e d r i v i n g 1 2 0 k p h

    a n d t h e b r a k e s w o u l d n o t a c t u a t e ? W h a t i f t h e f a i l u r e f o r c e d t h e b r a k e s t o a c t u a t e

    u n c o n t r o l l a b l y ?

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 5 9

    Partitioning and Modularity

    Allocate system requirements and distribute them to

    functional components. Different functional componentsmay have different safety integrity levels.

    Systems SIL is the minimum SIL for any functionalcomponent that performs safety-critical functions

    Functional blocks may be implemented with brick-walltime and space partitioning of separately loadablesoftware applications. These programs can havedifferent SILs, which may result in reduced test andcertification costs and increased portability/reuse.

    R e m e m b e r - S e l e c t i o n o f t h e s a f e t y i n t e g r i t y l e v e l i s i m p o r t a n t b e c a u s e i t d e t e r m i n e s w h i c h

    d e v e l o p m e n t g u i d e l i n e s , p r o c e s s e s a n d s t a n d a r d s w i l l b e r e q u i r e d i n d e v e l o p m e n t .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 6 0

    System Redundancy

    Primary means to develop fault tolerant systems of components

    Lets compare these two systems

    Power

    Source

    Sensor

    Monitors

    ActuatorController

    ActuatorController

    ActuatorController

    Actuator

    Control

    InterfaceController

    Mechanical

    Interface

    Sensor

    MonitorsSensor

    MonitorsSensor

    Monitors

    FL FR

    RL RR

    P

    T h e f i r s t e x a m p l e i s a b r a k e - b y - w i r e s y s t e m . I f o n e b r a k e a c t u a t o r f a i l s i n a n i n a c t i v e s t a t e

    ( i . e . t h e b r a k e c a n n o t b e a p p l i e d ) , t h e b r a k e a c t u a t o r s o n t h e o t h e r t h r e e w h e e l s w i l l l i k e l y

    s t o p t h e v e h i c l e . R e d u n d a n c y a l l o w s t h e s y s t e m t o p e r f o r m , a l b e i t i n a d e g r a d e d m o d e ,

    w h e n f a i l u r e s o c c u r . I f a b r a k e f a i l s i n a n a c t i v e s t a t e ( i . e . t h e b r a k e i s a p p l i e d w h e n n o t

    c o m m a n d e d ) , t h e s a f e t y o f t h e o p e r a t o r m a y b e j e o p a r d i z e d , e s p e c i a l l y i f i t o c c u r s w h i l e t h e

    v e h i c l e i s t r a v e l i n g a t h i g h s p e e d s w h e n t h e f a i l u r e o c c u r s . T h e F e d e r a l M o t o r V e h i c l e

    S a f e t y S t a n d a r d s ( F M V S S ) p r o v i d e g u i d e l i n e s t o c o n s i d e r w h e n d e v e l o p i n g t h i s t y p e o f

    s y s t e m . D e p e n d i n g o n y o u r a p p l i c a t i o n , t h e f a i l - s a f e p o s i t i o n o f b r a k e a c t u a t o r s m a y b e

    f u l l - a c t i v e , p a r t i a l l y a c t i v e , o r f u l l i n a c t i v e .

    T h e s e c o n d e x a m p l e s h o w s a q u a d a c t u a t o r s y s t e m w h e r e b y a l l a c t u a t o r s c o n t r o l t h e s a m e

    m e c h a n i c a l i n t e r f a c e . F a i l u r e s i n t h e c o n t r o l l e r s , a c t u a t o r s a n d f e e d b a c k s e n s o r s a r e

    m i t i g a t e d b y r e d u n d a n t c o m p o n e n t s . H o w e v e r , f a i l u r e s i n t h e c o n t r o l i n t e r f a c e , p o w e r

    s o u r c e a n d e v e n t h e m e c h a n i c a l i n t e r f a c e c a n n o t b e m i t i g a t e d . T h e s e a r e c a l l e d s i n g l e -

    p o i n t f a i l u r e m o d e s , i n w h i c h a f a i l u r e a t a s i n g l e p o i n t w i l l c a u s e t h e s y s t e m t o b e

    i n o p e r a b l e . G o o d s y s t e m a r c h i t e c t u r e s m i n i m i z e s i n g l e - p o i n t f a i l u r e m o d e s , a n d i d e a l l y

    h a v e n o n e .

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 6 1

    System Redundancy

    Brake-by-wire system

    FL FR

    RL RR

    P

    If one brake actuator fails in an inactivestate, the brake actuators on the other

    three wheels will likely stop the vehicle.Redundancy allows the system to perform(degraded) when failures occur.

    If a brake fails in an active state, the

    safety of the operator may be jeopardized.

    The Federal Motor Vehicle Safety

    Standards (FMVSS) provide guidelines toconsider when developing this type ofsystem.

    Depending on your application, the fail-safe position of brake actuators may befull-active, partially active, or full inactive.

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    2 0 0 9 O n T a r g e t T e c h n o l o g y D e v e l o p m e n t P a g e 6 2

    System Architecture Analyses and Processes

    Formal development processes for:

    System requirements management Design and analysis

    Comprehensive verification

    Quantifies safety performance and determines safety-critical design practices that should be implemented.

    Evaluate static failures and dynamic failures such as:

    A required event that does not occur An undesirable event that does occur Order of events sequence failures Timing failures in event sequences

    Consider all failure modes that affect performance

    T h e i n d u s t r y s t a n d a r d s d e s c r i b e d e a r l i e r s t r e s s f o r m a l p l a n n i n g , d e v e l o p m e n t a n d t e s t

    p r o c e s s e s . S y s t e m s e n g i n e e r i n g f o r s a f e t y - c r i t i c a l s y s t e m s e m p h a s i z e s f o r m a l

    d e v e l o p m e n t p r o c e s s e s f o r s y s t e m r e q u i r e m e n t s m a n a g e m e n t , i t e r a t i v e d e s i g n a n d

    a n a l y s i s , a n d c o m p r e h e n s i v e v e r i f i c a t i o n . T h e s e g u i d e l i n e s , c o u p l e d w i t h r o b u s t d e s i g n

    p r a c t i c e s , p r o v i d e s a f e s y s t e m a r c h i t e c t u r e s .

    A s a f e t y a n a l y s i s , s u c h a s t h e s y s t e m s a f e t y a s s e s s m e n t p r o c e s s d e s c r i b e d b y g u i d e l i n e s

    l i k e A R P 4 7 6 1 [ 5 ] , a r e p e r f o r m e d o n t h e s y s t e m a r c h i t e c t u r e t o q u a n t i f y s a f e t y p e r f o r m a n c e

    a n d a s c e r t a i n w h a t s a f e t y - c r i t i c a l d e s i g n p r a c t i c e s s h o u l d b e