15.00 hr van Hilten
- 1. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded Besturen met FPGA‘s Erik van Hilten Technical Engineer National Instruments Agenda • Intro • What is an FPGA • Why are FPGAs important in automation • Engineering FPGAs (hardware) • Engineering FPGAs (software) What we do Low-Cost, Modular Productive Software Highly Integrated, Measurement and Development Tools Expandable Control Hardware Industrial Platforms Used by thousands of engineers and scientists for automated test, industrial control, and embedded design applications. www.ni.com 1
- 2. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded What is an FPGA? Programmable Interconnects Logic Blocks I/O Blocks Simplified FPGA Example Implementing Logic on FPGA: F = {(A+B)CD} ⊕ E E F LabVIEW FPGA Code A B C D FPGAs are truly parallel E F A B C D Z W X Y www.ni.com 2
- 3. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded Benefits FPGAs in Systems • Reliability – Designs become a custom circuit • Determinism – Runs algorithms at deterministic rates down to 25 ns (faster in many cases) • Parallelism – Enables parallel tasks and pipelining • Reconfigurable – Create new and alter existing task-specific personalities • Timing – Nanosecond precision for timing and synchronization Decision Making in Software Decision Making in Software Crash Possible Application Software Operating System Calculation Driver API Hardware ~25 ms PROCES Respons e Outputs Decision Making in Hardware Decision Making in Hardware Highest Application Software Determinism Operating System Calculation Driver API Hardware 25 ns* PROCES Respons e Outputs * Faster response for 80 and 120 MHz clocks Highest Reliability www.ni.com 3
- 4. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded Reliable: CERN Control World’s Largest Particle Accelerator • FPGA-based motion control system for intercepting misguided or unstable particle beams. • Measuring and controlling, in real time, the position of bulk components to absorb energetic particles out of the nominal beam core with high reliability and accuracy at the world’s most powerful particle accelerator, the Large Hadron Collider (LHC). • Custom motion control using small, rugged controllers for approximately 600 stepper motors with millisecond synchronization. Deterministic: VAPO - Controlling the Movement of 20 Tons of Concrete with 2 mm accuracy • Custom 4-axis hydraulic motion control system for unbalanced concrete trays • Advanced control, signal processing and high precision hydraulic motion Timing: Increased Production Throughput and Welding Quality • Welding of metal sheets used in cold rolling steel mils • In old factories strip breakage occurs around 2%, and in modernized European factories around 0.5%. • With a FPGA based control system we have achieved 0.05% • The result: a huge economic saving by having less downtime and higher production throughput. www.ni.com 4
- 5. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded Processing: Bearing Monitoring • Custom analysis algorithm on FPGA • Real-Time system for managing analysis and communication • Host application for control & asset management Digital Demodulation online 20KHz 20kHz / 50kS/s FPGA 20kHz / 50kS/s 20 Hz / 50 S/s ∆f = 0,0122 Hz A Z-n x 20Hz Sensor + √ FFT D +90 x ° 4k Samples http://www.fis-services.de/site/en/pst/1.Products/13.Condition_monitoring/29.Condition_Monitoring/103.FAG_ProCheck/FAG_ProCheck.html Developing the FPGA code FPGA (hardware) Processor (software) Time critical control Data analysis/conversion Acquisition Data Logging Timing in the FPGA User interface In line processing & data Communication (TCP/IP, reduction UDP/Modbus/…) Sensor processing Interface to FPGA code Custom triggering Supervise / control FPGA (setpoints…) Control Digital filtering Industrial Embedded Architecture I/O Processor FPGA I/O I/O • Floating-point • High-speed • Low-level access processing control & to hardware • Communications processing • Custom timing & • Multicore • Reconfigurable triggering technology hardware • Modular I/O • Reliability www.ni.com 5
- 6. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded The Challenge I/O Processor FPGA I/O I/O • Multicore • Low-level tools • Custom drivers programming Verilog & VHDL and middleware challenge • Fixed-point algorithms • Custom digital • Custom timing for interface/buses different types of I/O NI CompactRIO Architecture Real-Time FPGA Processor • Reconfigurable FPGA for high-speed and custom I/O timing, triggering, and control • I/O modules with built-in signal conditioning for connection to sensors/actuators • Real-time processor for reliable measurement, analysis, connectivity, and control NI RIO Deployment Curve I/O I/O System Flexibility and Price I/O PXI RIO Windows Real-time FPGA Processor Custom I/O PCI RIO CompactRIO CompactRIO Integrated LabVIEW Single-Board RIO Number of Systems Deployed www.ni.com 6
- 7. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded Handling Complexity through Abstraction System Design Tools IEC 1131 .NET Abstraction C, C++ VHDL Assembly Machine code System complexity LabVIEW Development Environment • Intuitive graphical programming for engineers and scientists • Tools to acquire, analyze, and present real-world data • LabVIEW programs are called virtual instruments, or VIs Ladder logic and LabVIEW www.ni.com 7
- 8. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded LabVIEW: Graphical System Design Timing Textual Math I/O integration Data Flow Parallel C and HDL Code Statecharts Simulation LabVIEW Graphical System Design Platform Dataflow C Code Textual Math Simulation Statechart LabVIEW Real-Time FPGA Microprocessors Desktop PC PXI Systems CompactRIO SB RIO HMI How Does LabVIEW FPGA Work? 1. Same graphical programming 2. Generate VHDL 3. Compile VHDL through Xilinx 4. Generate downloadable bit file www.ni.com 8
- 9. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded LabVIEW FPGA Code Abstraction Counter Analog I/O I/O with DMA LabVIEW FPGA VHDL Developing the FPGA code Interactive Front Panel Communication FPGA front panel FPGA block diagram Development PC FPGA hardware CompactRIO Software Architecture Host Program Real-Time Processor FPGA Network Inter -Thread FPGA Communication Communication Time Interface User Normal LabVIEW Interface Priority Critical FPGA VI Loop Loop Enterprise LabVIEW for LabVIEW LabVIEW Windows Real-Time FPGA • User interface • Time Critical Loop • I/O timing • Connect to enterprise – Interface to FPGA code • Custom triggering • Supervisory control • Normal Priority Loop • Control • Non real-time analysis – Data conversion • Digital filtering – Analysis and control • Sensor processing – Data logging – Networking (TCP/IP, UDP, Modbus/TCP) www.ni.com 9
- 10. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded LabVIEW IEC 1131 Function Blocks I/O Summary Processor FPGA I/O I/O FPGAs: • reliable, fast, reconfigurable hardware • applications: fast/tight/advanced control, data/sensor processing, triggering, acquisition • flexible hardware architecture with processor • VHDL or graphical software • Learn more: LabVIEW: ni.com/labview FPGA hardware ni.com/compactrio • Bonus: download the developers guide (200+ pages!) http://www.ni.com/compactriodevguide/ www.ni.com 10
- 11. Themadag PLC ofIPC - LabVIEW en FPGA's voor IPC/embedded www.ni.com 11