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ScilabTEC 2015 - Bavarian Center for Agriculture

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"Development of a diagnostic tool for performance analysis during the testing of agricultural implements"
By Zoltan Gobor, Bavarian State Research Center for Agriculture for ScilabTEC 2015

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ScilabTEC 2015 - Bavarian Center for Agriculture

  1. 1. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 1 Bavarian State Research Center for Agriculture Dr.-Ing. Zoltan Gobor Institute for Agricultural Engineering and Animal Husbandry Development of a diagnostic tool for performance analysis during the testing of agricultural implements Data acquisition and automated data analysis illustrated by the example of the prototype for automated attachment of the supporting wires in hop gardens Institute for Agricultural Engineering and Animal Husbandry Hop production – state of the art ● Germany: aproximately 18 000 ha cultivated area under hop ● Predominantly 7 or 8 m high trellis systems ● Annual replacement of the supporting wires (1.2 – 1.4 mm thick iron wire) ● Manual fastening of the support wire: – 3 workers-platform 12 man-hours and 3 tractor-hours per ha – 2 workers-platform 15 man-hours and 5 tractor-hours per ha ● Problems during manual fastening: – Accident risk – Ergonomically very uncomfortable task – Dependent on the weather conditions 21.05.2015 Gobor-ILT 5-15002 2
  2. 2. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 2 Institute for Agricultural Engineering and Animal Husbandry Automated attachment of the supporting wires ● The private limited company Soller (Geisenfeld, Germany) protected the idea by a patent in 2002 ● A joint project (2008-2010) funded by the German Federal Agency for Food and Agriculture (BLE) was realised – Main task – optimisation of the system and development of a new prototype based on the gained insights ● A joint project (2014-2016) funded by the German Federal Agency for Food and Agriculture (BLE) and Rentenbank within the DIP (Agricultural Innovation Partnership) programme – Main task –improvement of the existing prototype and the necessary diagnostic tools in order to produce the zero series device 21.05.2015 Gobor-ILT 5-15002 3 Institute for Agricultural Engineering and Animal Husbandry Design of the device – optimisation and development 21.05.2015 Gobor-ILT 5-15002 4 Subsystem for positioning Subsystem for wire attaching Intermediate storage of the wire External hydraulic power supply unit
  3. 3. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 3 Institute for Agricultural Engineering and Animal Husbandry Design of the device – optimisation and development 21.05.2015 Gobor-ILT 5-15002 5 (1) Telescopic leader mast (2) Subsystem for wire attaching (3) Intermediate storage of the wire (4) Wire coil (5) External hydraulic power supply unit (6) Subsystem for positioning (7) Electrical cabinet with embedded programmable logic controller (PLC) Institute for Agricultural Engineering and Animal Husbandry Hydraulic parameters and PLC signals acquisition ● Phase 1 – Compact modular data logging system NI cDAQ-9172 – Pressure sensors MBS 3250 060 G1 869 (Danfoss) – Turbine flow sensor RE 4 (Hydrotechnik) – Software solution for data acquisition (LabVIEW) – 9 AI (pressure + flow rate) – up to 27 DI (PLC signals) – 2 counters ● Phase 2 – NI cRIO-9033 Controller With 1.33 GHz Dual-Core CPU, 160T FPGA with NI Linux RT – Up to: 18 AI (pressure, flow rate); 32 DI (PLC signals); 2 counters – Test bench; prototype; zero series machine – Software (LabVIEW Real Time and FPGA) 21.05.2015 Gobor-ILT 5-15002 6
  4. 4. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 4 Institute for Agricultural Engineering and Animal Husbandry Software phase 1 (concept) 21.05.2015 Gobor-ILT 5-15002 7 Core 1 Core 2 Producer - Consumer Data streaming NIUSB -> PC Data logging State machine Enqueue DequeueFIFO States: •Initialise •Configure •Load configuration •Save configuration •Measure •Stop Institute for Agricultural Engineering and Animal Husbandry Software for data acquisition - Front panel (HMI) 21.05.2015 Gobor-ILT 5-15002 8
  5. 5. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 5 Institute for Agricultural Engineering and Animal Husbandry Software - Front panel (measurement) 21.05.2015 Gobor-ILT 5-15002 9 Institute for Agricultural Engineering and Animal Husbandry TDMS file in Excel 21.05.2015 Gobor-ILT 5-15002 10 ● File format with similar footprint and precision as a binary file (combination of binary and XML data) ● Self descriptive structure with three-level hierarchy: file-specific information; meta-data; row-data ● Data streaming - segmented or writing at once into the TDMS file depending on the required speed and amount of data
  6. 6. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 6 Institute for Agricultural Engineering and Animal Husbandry Semi-automated off–line data analysis (Scilab) 21.05.2015 Gobor-ILT 5-15002 11 ● Scilab function for direct reading of the TDMS files not available ● Intermediate steps: open in MS Excell, save as XLS and read with xlsread or xls_open in Scilab ● Developed function allows automated analysis considering defined parameters and graphical and statistical analysis by simply entering the TDMS (XLS) file name into the function Institute for Agricultural Engineering and Animal Husbandry https://www.youtube.com/watch?v=q5MNtrRoVmo Twisting WireattachingSubsystemup Wire attaching cycle simulation 21.05.2015 Gobor-ILT 5-15002 12 Wirefeedingslow (wirepreparation) Cutting Wirefeedingmidd WireattachingSubsystemdown Benderup Benderdown Wirefeedingfast
  7. 7. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 7 Institute for Agricultural Engineering and Animal Husbandry Measurement results before optimisation– hydraulic parameters and PLC signals 21.05.2015 Gobor-ILT 5-15002 13 Institute for Agricultural Engineering and Animal Husbandry Optimisation - hydraulic power unit with 2 pumps 21.05.2015 Gobor-ILT 5-15002 14 Pump 1 − Vertical Positioning − Horizontal Positioning − Intermediate storage (recharging) Pump 2 − Cutter − Wire attaching − Positioning of the subsystem − Wire feeding − Twining − Cutting − Bending
  8. 8. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 8 Institute for Agricultural Engineering and Animal Husbandry Results – duration of selected wire attaching sequences 21.05.2015 Gobor-ILT 5-15002 15 2009 2011 Area capacity 0.21 – 0.23 ha/h Average operating speed 1.45 – 1.65 km/h Institute for Agricultural Engineering and Animal Husbandry Measurement results after optimisation– hydraulic parameters and PLC signals 21.05.2015 Gobor-ILT 5-15002 16
  9. 9. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 9 Institute for Agricultural Engineering and Animal Husbandry Hydraulic parameters and PLC signals acquisition ● Phase 1 – Compact modular data logging system NI cDAQ-9172 – Pressure sensors MBS 3250 060 G1 869 (Danfoss) – Turbine flow sensor RE 4 (Hydrotechnik) – Software solution for data acquisition (LabVIEW) – 9 AI (pressure + flow rate) – up to 27 DI (PLC signals) – 2 counters ● Phase 2 – NI cRIO-9033 Controller With 1.33 GHz Dual-Core CPU, 160T FPGA with NI Linux RT – Up to: 18 AI (pressure, flow rate); 32 DI (PLC signals); 2 counters – Test bench; prototype; zero series machine – Software (LabVIEW Real Time and FPGA) 21.05.2015 Gobor-ILT 5-15002 17 Institute for Agricultural Engineering and Animal Husbandry Software aproach 1: LabVIEW with embedded Scilab code 21.05.2015 Gobor-ILT 5-15002 18 Core 1 Core 2 Producer - Consumer Data streaming NIUSB -> PC Data logging State machine Enqueue Dequeue
  10. 10. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 10 Institute for Agricultural Engineering and Animal Husbandry Software approach 2: Multicore 21.05.2015 Gobor-ILT 5-15002 19 Core 1 Core 2 Producer - Consumer Data acqisition Data logging Core 3 Core 4 Online analyse Data streaming Institute for Agricultural Engineering and Animal Husbandry Software HMI (concept) 21.05.2015 Gobor-ILT 5-15002 20 System diagnosticsProcess simulation
  11. 11. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 11 Institute for Agricultural Engineering and Animal Husbandry Considerations 1: LabVIEW to Scilab Gateway 21.05.2015 Gobor-ILT 5-15002 21 Source: http://sine.ni.com/nips/cds/view/p/lang/de/nid/210055 (20.05.2015) Institute for Agricultural Engineering and Animal Husbandry Considerations 2: LabVIEW MathScript RT Module 21.05.2015 Gobor-ILT 5-15002 22 Source: http://www.ni.com/labview/mathscript/ (20.05.2015)
  12. 12. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 12 Institute for Agricultural Engineering and Animal Husbandry Software HMI (concept) 21.05.2015 Gobor-ILT 5-15002 23 Institute for Agricultural Engineering and Animal Husbandry Hardware: NI cRIO-9033 21.05.2015 Gobor-ILT 5-15002 24 Source: http://sine.ni.com/nips/cds/view/p/lang/en/nid/212720 (20.05.2015)
  13. 13. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 13 Institute for Agricultural Engineering and Animal Husbandry Software (LabVIEW FPGA+RT) 21.05.2015 Gobor-ILT 5-15002 25 Institute for Agricultural Engineering and Animal Husbandry Test bench (simulator) in order to allow development of the software without necessity to test it directly on the machine: – FPGA RT Controller: NI cRIO-9033 – Simulator of the manual HMI – Universal simulator of the main actuators and sensors Development of a test bench 21.05.2015 Gobor-ILT 5-15002 26
  14. 14. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 14 Institute for Agricultural Engineering and Animal Husbandry Development of a test bench 21.05.2015 Gobor-ILT 5-15002 27 Testing: Testing of the manual control (simulator of the manual HMI) Testing of the actuators and sensors considering vertical positioning 1 5 6 4 2 3 Institute for Agricultural Engineering and Animal Husbandry Conclusions ● Using contemporary design and analysis tools (acquisition of relevant parameters combined with automated analysis, digital prototyping and capturing of high-speed videos) allowed faster and more reliable development ● The analysis of the oil pressure, flow and PLC signals provided new insights in the dynamics of the system and a new prototype with external hydraulic power unit was developed ● Logging and analysis of the PLC and sensor signals provided information (start and end of single operation, required time for execution of single operation, duration of every wire attaching cycle, time required for headland turn and failure correction) for further improvement of the system ● Development of the test bench will allow more easier and faster development of the software for diagnostic inspection 21.05.2015 Gobor-ILT 5-15002 28
  15. 15. Presented on SCILABTEC2015 Paris (France) 02.06.2015 (c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 15 Institute for Agricultural Engineering and Animal Husbandry Improvement possibilities ● The developed data acquisition system can and will be used for performance analysis and diagnostic inspection in case of outage ● Communication between the cDAQ an PLC using OPC need to be tested (jitter) ● Possibility to integrate additional signals from the tractor using e.g. CAN bus need to be discussed Comprehensive testing and improvement of the system will be continued 21.05.2015 Gobor-ILT 5-15002 29 Institute for Agricultural Engineering and Animal Husbandry THANK YOU FOR YOUR ATTENTION Gobor-ILT 5-15002 30 21.05.2015 http://www.lfl.bayern.de/ilt/mechatronik/index.php

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