Safety and Security in Robotic Systems

In the modern factory, human operators will still be required at many stages of the process. Therefore, it is essential that these AGVs are able to maneuver potentially heavy or dangerous items around in close proximity to humans without risk of causing harm. In order to achieve this, their computers need to use a range of sensors to detect what is around the AGV at all times in dynamically changing environments.

With the safety cages gone, sensing solutions, such as a safety light barriers and time-of-flight (ToF) cameras, will inform robotic systems about their environment. Speed and movement of a robotic arm could be reduced and restricted depending on the proximity of humans. By walking through a light barrier, a robot arm would limit its activity to an area away from where humans are standing. This would allow them to drop off a tray of work or pick up finished items without the robot having to stop completely.

However, seconds or minutes of motion without the attention of sensors could easily result in a fatality. Thus, for such machinery, a special type of computing machine is required.

TriCore computer processors, as found in the AURIX™ family of microcontrollers, are capable of executing each program instruction twice. The processor executes the instruction, undertaking whatever task the result determines. A moment later, the same instruction is executed again. If the results of both processing steps are the same, the processor simply continues its task. However, if the results are different, an emergency software routine can be executed to handle the issue. This ensures that an AGV can be stopped in a safe manner almost immediately – in case a failure occurs.

This is just one of many safety features and such capabilities should not be taken for granted. The AURIX™ microcontroller safety functions are the result of years of experience and research into potential sources of failure during operation. This results in a microcontroller, together with documentation, that makes a verifiably safe robot or AGV possible.

All of these robotics systems will need to be connected with one-another. As they roam the factory, they will wirelessly share their location with a fleet management system. Over time, a complete virtual map of the complex can be created. Temporary obstacles and new routes can also quickly be shared amongst the AGV fleet. This way, they know which paths around the factory are free and when and how to reach to the next island.

Just like our home computers and smartphones, such networked robots have to be protected from hackers, viruses and other malware. Additionally, in order to ensure their safety credentials have not been compromised, it will be necessary to warrant that only approved spare parts and consumables are used.

It is highly likely that the core components of AGVs and robots will need to register themselves with the main computer once any repairs have been made. This process will allow these parts to authorize themselves as parts or accessories – similar to how we look for a hologram sticker on software or high-value products to confirm their authenticity.

The basis for this authentication is the same as that used for today’s modern secure communication by email or encrypted messaging app. Each robot has a set of keys stored in a vault. Such vaults are emblematic of the chips embedded in its hardware. Parts and accessories fitted need to prove that they know this secret information in order to be allowed to be used.

It is critical that this type of security is central to the design of a robotics system and is not treated as a bolt-on extra. In fact, it should be considered as complimentary to the safety implementation. A functionally safe robot that can be hacked and remotely controlled is no longer safe. The same applies if sub-standard quality tooling or spare parts are fitted.

Products such as the Infineon OPTIGA™ family of security solutions support the electronics required for such functionality. Depending on what needs to be achieved, these devices can confirm that internet connections are secure or that only approved software updates are being uploaded. Some of the simpler products implement authentication, allowing consumables to prove that they come from an approved source. Among these consumables one can find oil or glue, for instance.