Open Automation Project Overview
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1 Open Automation Project Overview This work is licensed under the Creative Commons Attribution-Share Alike 3.0 License. To view a copy of this license, visit or send a letter to Creative Commons, 543 Howard Street, 5th Floor, San Francisco, California, 94105, USA.
2 Context 2
3 Industrial Machinery Numerical Controller User Panel 3
4 Industrial Machinery PLANT CONTROLLER USER PANEL (HMI) 4
5 Industrial Machinery PLANT Hard Real Time Loop CONTROLLER USER PANEL (HMI) 5
6 Industrial Machinery PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop USER PANEL (HMI) 6
7 Industrial Machinery PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop USER PANEL (HMI) Human-the-Loop 7
8 Industrial Machinery PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine USER PANEL (HMI) Human-the-Loop 8
9 Mobile Robotics ECU (Electronic Control Unit) Jog Box 9
10 Mobile Robotics PLANT CONTROLLER JOG BOX (HMI) 10
11 Mobile Robotics PLANT Hard Real Time Loop CONTROLLER JOG BOX (HMI) 11
12 Mobile Robotics PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop JOG BOX (HMI) 12
13 Mobile Robotics PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop JOG BOX (HMI) Human-the-Loop 13
14 Mobile Robotics PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine JOG BOX (HMI) Human-the-Loop 14
15 Electric Wheelchair ECU (Electronic Control Unit) Armrest Joystick 15
16 Electric Wheelchair External PLANT (environment) PLANT CONTROLLER ARMREST JOYSTICK (HMI) 16
17 Electric Wheelchair External PLANT (environment) PLANT Hard Real Time Loop CONTROLLER ARMREST JOYSTICK (HMI) 17
18 Electric Wheelchair External PLANT (environment) PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop ARMREST JOYSTICK (HMI) 18
19 Electric Wheelchair External PLANT (environment) PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop ARMREST JOYSTICK (HMI) Human-the-Loop 19
20 Electric Wheelchair External PLANT (environment) PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine ARMREST JOYSTICK (HMI) Human-the-Loop 20
21 Light Vehicles ECU (Electronic Control Unit) Handlebar and throttle 21
22 Light Vehicles PLANT CONTROLLER HANDLEBAR, THROTTLE (HMI) 22
23 Light Vehicles PLANT Hard Real Time Loop CONTROLLER HANDLEBAR, THROTTLE (HMI) 23
24 Light Vehicles PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop HANDLEBAR, THROTTLE (HMI) 24
25 Light Vehicles PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop HANDLEBAR, THROTTLE (HMI) Human-the-Loop 25
26 Light Vehicles PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine HANDLEBAR, THROTTLE (HMI) Human-the-Loop 26
27 Mechatronics Framework Power Supply Actuators Structure Sensors PLANT Field Hard Real Time Loop Machine to Machine TARGET (CONTROLLER) Fast Enough Loop Man to Machine HOST (HMI) Human-the-Loop 27
28 Open Automation Controllers 28
29 Industrial Controller: PLC Allen-Bradley Development Software: 907 AC 1131 Field Module 2 Field Module 1 Communication Module DSP Board Embedded uprocessor Board HARDWARE SOFTWARE Hardware Component Modules IEC (IL) Instruction List (ST) Structured Text (LD) Ladder Diagrams (FD) Function Block Diagram (SFC) Sequential Function Chart Operating System: Unknown/Custom DSP: Dedicated Development System FPGA: Not Present 29
30 Industrial Controller: SoftPLC KONTRON Embedded uprocessor Board Field Module 3 Field Module 2 Field Module 1 Communication Module HARDWARE Hardware Component Modules SOFTWARE Development Software: CoDeSys SP IEC (IL) Instruction List (ST) Structured Text (LD) Ladder Diagrams (FD) Function Block Diagram (SFC) Sequential Function Chart Operating System: Windows/Linux/QNX DSP: Not Present FPGA: Not Present 30
31 Industrial Controller: National Instruments Compact RIO Field Module 3 Field Module 2 Communication Module Field Module 1 Embedded uprocessor Board HARDWARE SOFTWARE Hardware Component Modules Development Software: G Dataflow Language Graphical Programming (VI) Operating System: LabVIEW Run-Time Engine + Linux/Windows/OS LabVIEW O.S. (PXI Architecture) DSP: LabView FPGA: LabView 31
32 Industrial Controller: OpenPLC Field Module(s) Field Module(s) Communication Module DSP and/or FPGA Board Embedded uprocessor Board HARDWARE SOFTWARE Hardware Component Modules Development Software: Scilab/Scicos Scilab Dataflow Language C/C++ Hard Coding Graphical Programming (VI) Operating System: OpenHRTOS + Linux/RTAI DSP: Open Development Environment FPGA: Free Editor 32
33 Field Module(s) Communication Module DSP and/or FPGA Board Embedded uprocessor Board HARDWARE Hardware Component Modules SOFTWARE Industrial Controller: OpenECU Development Software: Scilab/Scicos Scilab Dataflow Language C/C++ Hard Coding Graphical Programming (VI) Operating System: OpenHRTOS + Linux/RTAI DSP: Open Development Environment FPGA: Free Editor 33
34 OpenECU: Open Hardware Digital Platform ISA Connector TOP DSP Motor Manager Connector CycloneII FPGA Communication Connector Digital FB Connector 64/256/512kword Memory 3.3V Regulator Power Supply Connector Debug Connector TMS320F2812 DSP Analog FB Connector User Oscillator 34
35 OpenECU: OpenHRTOS Platform OpenHRTOS Elements ACU ECU ECU Layer PC IC IC IC ECU Layer ECU Layer SR SR Blocks Blocks Blocks Blocks PW Layer CW Layer FW Layer SW Layer Abstraction Layer ACU Power Bus PW OS ECU Field Bus CW OS Cables Connectors Lines PW Components ECU System Bus FW OS Cables Connectors Lines CW Components SW OS Cables Connectors Lines FW Components SW Components 35
36 OpenECU Development: Manual Code Generation SW SR SW Layer HRTOS Altera USBBlaster DSP Emulator User (Developer) FW Layer System Bus FW Development s Textual Templates (Hard Coding) SR UltraEdit32 Anjuta 36
37 OpenECU Development: Authomatic Code Generation SW SR SW Layer HRTOS Altera USBBlaster DSP Emulator User (Developer) FW Layer System Bus FW Development s Graphical Templates & Block Diagrams SR Scilab/Scicos 37
38 SR Development Tools IC IC Schematic FP SR Host QuartusII Service Routine Fixed Point User (Developer) SR FB Real Time Tandem Service Routine Floating Point Sys. Bus OpenHRTOS Linux/RTAI OpenECU: Real Time Tandem (I) Code Composer Studio SR 38
39 API SR FP Development Tools IC Schematic SR IC Eclipse Sys. Bus SR Host FB QuartusII User (Developer) API Tandem Real Time Tandem OpenHRTOS RTAI Win / Linux OpenECU: Real Time Tandem (II) Code Composer Studio SR 39
40 Field Field Module1 Module2 Embedded PC104 DSP + FPGA board Comm Module Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes Yes Yes Yes Yes Yes Yes Industrial Controllers: Hardware Summary Programmable Logic Controller AllenBradley, Siemens, Telemecanique, GE, Omnron Programmable Automation Controller National Instruments SoftPLC Kontron OpenPLC OpenECU 40
41 Industrial Controllers: Software Summary Programmable Logic Controller AllenBradley, Siemens, Telemecanique, GE, Omnron Programmable Automation Controller National Instruments SoftPLC Kontron OpenPLC OpenECU Operating System Communication Networks IEC Proprietary close Proprietary close CVI Open / Proprietary Open System Programmability / IEC Scilab + Custom 41
42 Open Automation s 42
43 6 5 presentation session 4 transport 3 network 2 data link 1 physical Plastic Fiber Optical Fiber Wireless data link 2 network 3 transport 4 presentation session 5 Physical Link ISO-OSI Model application 7 6 Twisted Pair application physical Coaxial 7 1 Logical Link s: Open Hardware Communication Modules 43
44 Mechatronics Framework: Wireless s PLANT Field Hard Real Time Loop Machine to Machine TARGET (CONTROLLER) Fast Enough Loop Man to Machine HOST (HMI) Fast Loop 44
45 Wireless: Standard Protocols WPAN IEEE Protocol Frequency (Hz) WLAN a b g 868M, 915M(US), 2.4G 2.4G 5G 2.4 Ghz 2.4Ghz Network initialization 30ms 10s 3s 3s 3s Modulation DSSS FHSS OFDM DSSS/CCK OFDM/PBCC Mac CSMA/CA TDMA CSMA/CA CSMA/CA CSMA/CA Througput (bps) 250K,40K,20K 1M, 723K 54M 11M 54M Distance 10m~75m 10m~100m 15m~30m 60m~90m 45m~75m Network size Channel band(hz) 600K, 2M, 5M 1M 16.6M 22M 22M Tarnsmission power (dbm) -4~20 0~ Target unit price ($) 1.5~ Consortium Logo: ZigBee Bluetooth WPAN: Wireless Personal Area Network; WLAN: Wireless Local Area Network; 45
46 Mechatronics Framework: Deterministic Networks Plant 1 FieldBus (Hard Real Time) Field Plant 2 FieldBus (Hard Real Time) Controller [Target 1] FieldBus (Hard Real Time) Controller [Target 2] Control and Automation (Real Time) Machine to Machine Real Time Protocols: Deterministic, Fault Tolerant, Robust 46
47 Mechatronics framework: OPC Plant Plant Field Fieldbus-([H]RealTime) Controller [Target] Machine to Machine Control and Automation (Real Time) Information (Fast Enough) PMI (i.e.scada) Information HMI: Maintenance Tuning HMI: Development HMI: Common User Man to Machine Management Computer 47
48 Industrial communications Industrial network Field BUS Control & Automation Information Limitations OPC No No Very Good - FlexRay Very Good Good No Ethernet/ No Possible ControNet Possible Good Possible CANopen No Possible Possible Profibus PA Good Good Possible No determinism if MultiMaster ProfibusDP Modbus (TCP) No Possible Possible Bad Determinism F F F LIN Possible Possible No Low Rate CAN Possible Medium No No determinism if MultiMaster Sercos Very Good Good No DeviceNet Possible Possible.. 0.5Mb/s RS232/485 Good Kb throughp ut Bad Determinism Good Hz high Medium F to high F Low Rate Low Rate 48
49 Open Automation Demonstrators 49
50 Industrial Machinery Field Machine to Machine Man to Machine PLANT OpenPLC USER PANEL (HMI) 50
51 Mobile Robotics Field Machine to Machine PLANT OpenECU SMAC Man to Machine JOG BOX (HMI) 51
52 Electric Wheelchair External PLANT (Environment) Field Machine to Machine Man to Machine PLANT OpenECU ARMREST JOYSTICK (HMI) 52
53 Light Vehicles Field PLANT FlexRay Machine to Machine Man to Machine OpenECUs HANDLEBAR, THROTTLE (HMI) Red Baron 53
54 Light Vehicles Field Machine to Machine Man to Machine PLANT OpenECU PDA, SMARTPHONE (HMI) Maintenance/Remote Control 54
55 Thank You
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