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Aig 2011 building intelligent control systems using graphical system design pdf

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Aig 2011 building intelligent control systems using graphical system design pdf

  1. 1. Building Intelligent Control Systems Using Graphical System Design Software And FPGA Based I/O Thorsten Mayerni.com
  2. 2. National Instruments What do we do: Leading provider of computer- based measurement and automation technology 2010 Revenue : $873 million Investment in R&D: 16% of annual revenue Net Revenue in Millions Customer base: 30,000 companies annually Network: More than 600 Alliance Partners Diversity: No industry makes up more than 15% of revenue Corporate headquarters: Austin, Texas Global operations: More than 5.000 employees in around 40 countries (more than 1000 in Central Eastern Europe)ni.com
  3. 3. Market-Driven Eras of Virtual Instrumentation Progression of Our Vision Graphical System Design Traditional PC-Based PXI Systems RIO Architecture Instrument Data Acquisition & RF Systems Control Real-Time Technology RF , MEMS, RF Design Medical, Audio Medical Laboratories Measurement Automated and Video Test Industrial & Research Automation Test Industrial Big Physics Measurement Embedded and Control DSP Design Robotics 1980 1990 2000 2010 2020ni.com
  4. 4. The National Instruments Vision Evolved “To do for embedded what the PC did for the desktop.” Graphical System Design Virtual Instrumentation Embedded Systems Instrumentation Real-Time Industrial Control RF Measurements RT/FPGA Systems Digital Embedded Monitoring Electronic Devices Distributed Hardware-in-the-Loop C Code Generation DESIGN PROTOTYPE DEPLOYni.com
  5. 5. Driving Forces in Industrial Control “…shift from quantity to quality manufacturing…” “…increase safety…” “…reduce energy consumption…” “…do more with less…”ni.com
  6. 6. Leveraging Latest Technology Optical Machine Vision Sensing Deterministic Networking High Speed Data Acquisition Embedded Technologies Multicore Wireless Technology Communicationni.com
  7. 7. Convergence of Technology PC PLC Custom Hardwareni.com
  8. 8. Convergence of Technology Programmable Automation Controllers PACsni.com
  9. 9. “The future.. is in the millions of niche markets at the shallow end of the bitstream” Chris Anderson Vendor Defined Solution “The Long Tail” i.e. plant automation system User defined Solutions i.e. advanced control, machine monitoring, vision inspection systemni.com
  10. 10. Making Steel Recycling Cheaper and Cleaner Application: Monitoring and advanced real- time control of steel recycling process. Challenge: Reduction of energy consumption to meet state compliancy regulations while increasing plant efficiency. Solution: Graphical System Design software (NI LabVIEW) and hardware (NI CompactRIO) as rapid prototyping and deployment platform for process optimization and real-time control of power consumption. "By programming with LabVIEW and PACs versus programming with PLCs and ladder logic, we have seen a ten-fold increase in efficiency and drastically reduced the costs of facility automation."ni.com
  11. 11. Enabling Technologies Measure It Control It Modular COTS HW Wireless FPGA Deterministic Architectures Systems Technology Communication Complete Data Intelligent Advanced embedded Distributed deterministic Acquisition, Distributed control systems communication Instrumentation and Systems Control Platformsni.com
  12. 12. FPGA Technology Programmable Interconnects Logic Blocks I/O Blocksni.com
  13. 13. FPGA Technology Highly Reliable Massively parallel Programmable Interconnects Reconfigurable Logic Digital-signal processing Blocks High-speed control Shorter time to market I/O Blocksni.com
  14. 14. An Ideal Embedded Architecture I/O Processor FPGA I/O I/O• Floating-point • High-speed control & • Low-level access to processing processing hardware• Communications • Reconfigurable • Custom timing &• Multicore technology hardware triggering • Reliability • Modular I/Oni.com
  15. 15. The Challenge I/O Processor FPGA I/O I/O • Multicore • Low-level tools • Custom drivers and programming Verilog & VHDL middleware challenge • Fixed-point algorithms • Custom digital • Custom timing for interface/buses different types of I/Oni.com
  16. 16. NI RIO Technology Platform Enet USB RTOS Analysis IP Control IP Analog I/O Digital I/O Analysis Multicore Timing IP Comm IP Comm I/O Motion I/O Logging Comm IPNet 3rd party IP 3rd party I/O Packaged Board-Levelni.com
  17. 17. NI CompactRIO Point-to-Point C Series FPGA FPGA Data Links Parallel I/O LabVIEW Real-Time Thread-Safe LibrariesMultithreaded RT OSLabVIEW FPGA Hardware and Rugged -40 to 70 deg C Up to 14 I/O Slots OEM Services Certifications/Ratingsni.com
  18. 18. Industrial Measurements  Accelerometer  Thermocouples  Strain Gauge  Current (5 Arms)  Load Cells  High Voltage (300 Vrms)  Digital I/O  RTD Motion Vision GPRS GPSni.com
  19. 19. Keeping Hydroelectric Power Plants Safe Industry: Energy, Power Challenge: Machine monitoring and control in Hydroelectric power plants. Solution: Graphical System Design software (NI LabVIEW) and hardware (NI CompactRIO) as rapid prototyping and deployment platform for process optimization and real-time control of power consumption. " The continuous monitoring of vibrations and other signals is critical to predicting mechanical behavior and efficiency and usually requires continuous data acquisition and in-line analysis. VESKI, a Croatian-based consulting firm that specializes in vibration analysis and diagnostics, relies on LabVIEW and CompactRIO as the core of its CoDiS monitoring software. "ni.com
  20. 20. Laboratory To Market Deployment Curve I/O I/O PXI RIOSystem Flexibility and Price I/O PCI RIO Processor FPGA Custom I/O CompactRIO Modular CompactRIO Integrated NI Single-Board RIO Number of Systems Deployed ni.com
  21. 21. Automation of Industrial Washing Machine Lines Industry: Consumer Goods, Industrial Controls/ Devices/ Systems Challenge: Developing a reliable, automated industrial washing machine line control system that offers easy supervision and alarm monitoring in real time. Solution: Using NI CompactRIO hardware and LabVIEW software to build an advanced real-time control and monitoring system that is fully automated, and highly reliable. " Using NI technologies, we developed an advanced, fully automated industrial washing machine line that is easy to use and maintain. The CompactRIO platform combined with the power of LabVIEW helped us rapidly solve complex challenges more easily than we could have using other products on the market.. "ni.com
  22. 22. Graphical System Design Software Data Flow C Code Textual Math Simulation Statechart Graphical System Design Platform Desktop Real-Time FPGA Microprocessorsni.com
  23. 23. Graphical System Design Software Data Flow C Code Textual Math Simulation Statechart Graphical System Design Platform Desktop Real-Time FPGA Microprocessorsni.com
  24. 24. LabVIEW FPGA Code Abstraction Counter Analog I/O I/O with DMA LabVIEW FPGA VHDLni.com
  25. 25. LabVIEW FPGA Code Abstraction Counter Analog I/O I/O with DMA LabVIEW FPGA VHDLni.com
  26. 26. LabVIEW FPGA Code Abstraction Counter Analog I/O I/O with DMA LabVIEW FPGA VHDLni.com
  27. 27. Solving Real-Time Control Challenges With Large Channel Counts Or Widespread Floor Space.ni.com
  28. 28. ESO - ELT – Primary Mirror (M1) Control A “Big” Distributed Control Challenge M1 984 MIRRORS 3,000 ACTUATORS 6,000 SENSORS 3k x 6k MATRIX 1 MILLISECONDvideoni.com
  29. 29. EtherCAT is a high-performance, deterministic, industrial network based on Ethernet.ni.com
  30. 30. EtherCAT Protocol Basics EtherCAT Telegram TCP/UDP TCP/UDP EtherCAT Header Data EtherCAT Data WC Header IP IP Data HeaderEthernet Ethernet Data (up to 1,498 bytes) CRCHeaderni.com
  31. 31. The “EtherCAT Train” • Ethernet frame is a moving train • EtherCAT telegrams are the train cars • Bits of data are people in the cars, extracted or inserted by appropriate slaves Master Slave Slave Slaveni.com
  32. 32. Timing and Synchronization • Each frame contains a special synchronization telegram • Timing Diagram Program I/O Program Master Scan Scan Scan Slave I/O Slave Slave Update Scan Update Source: http://www.ethercat.orgni.com
  33. 33. NI 9144 Expansion Chassis Programmable 2 Ports for FPGA Chip Daisy-Chaining Rugged Chassis • -40 to 70°C 8 Slots for C • 9-30V Input Series I/O • Hazloc Modules • Shock/Vibeni.com
  34. 34. NI RIO System with Deterministic Distributed I/O Host Computer Industrial CompactRIO PXI RT Desktop Controller(TCP/IP) Real-time Master Controller (EtherCAT) NI 9144 Expansion Chassis ni.com
  35. 35. Another “Big” Distributed Control Challenge Controlling The world’s most powerful particle accelerator, the Large Hadron Collider (LHC) at CERN: • More than 100 collimators: “…a device that narrows a beam of particles or waves” [3], to “protect the LHC from uncontrolled particle losses, and absorb energetic particles out of the nominal beam core and to reduce noise to the LHC experiments”. [4] • More than 600 stepper motors 27 km • Precise synchronization (ms) between collimators along the 27 km circle. • Motion control with accuracy of 20 µmni.com
  36. 36. “The future is already here, it is just unevenly distributed.” William Gibsonni.com

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