Centro Servizi di Prototipazione del Politecnico di Torino. Open Automation Project Overview
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1 Open Automation Project Overview This This work work isis licensed licensedunder under thethe Creative Creative Commons Commons Attribution-Share Attribution-Share Alike Alike 3.0 License. 3.0 License. To view Toa view copy a copy of thisvisit license, visit send acommons, letter to of this license, or send a letter toorcreative Creative Commons, Howard Street, 5th Floor, San Francisco, 543 Howard Street, 5th543 Floor, San Francisco, California, 94105, USA. California, 94105, USA.
2 Open Automation: Project Overview Mechatronic Framework OpenECU Open Motion Control OpenPLC OpenVision Demonstrators 2
3 Open Automation: Project Overview Mechatronic Framework Industrial Machinery Mobile Robotics Light Vehicles Avionics OpenECU Open Motion Control OpenPLC OpenVision Demonstrators 3
4 Industrial Machinery Numerical Controller User Panel 4
5 Industrial Machinery PLANT CONTROLLER USER PANEL (HMI) 5
6 Industrial Machinery PLANT Hard Real Time Loop CONTROLLER USER PANEL (HMI) 6
7 Industrial Machinery PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop USER PANEL (HMI) 7
8 Industrial Machinery PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop USER PANEL (HMI) Human-in-the-Loop 8
9 Industrial Machinery PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine USER PANEL (HMI) Human-in-the-Loop 9
10 Mobile Robotics ECU (Electronic Control Unit) Jog Box 10
11 Mobile Robotics PLANT CONTROLLER JOG BOX (HMI) 11
12 Mobile Robotics PLANT Hard Real Time Loop CONTROLLER JOG BOX (HMI) 12
13 Mobile Robotics PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop JOG BOX (HMI) 13
14 Mobile Robotics PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop JOG BOX (HMI) Human-in-the-Loop 14
15 Mobile Robotics PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine JOG BOX (HMI) Human-in-the-Loop 15
16 Light Vehicles ECU (Electronic Control Unit) Handlebar and throttle 16
17 Light Vehicles PLANT CONTROLLER HANDLEBAR, THROTTLE (HMI) 17
18 Light Vehicles PLANT Hard Real Time Loop CONTROLLER HANDLEBAR, THROTTLE (HMI) 18
19 Light Vehicles PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop HANDLEBAR, THROTTLE (HMI) Human-in-the-Loop 19
20 Light Vehicles PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine HANDLEBAR, THROTTLE (HMI) Human-in-the-Loop 20
21 Avionics Vibration Reduction ECU (Electronic Control Unit) Host PC Monitoring 21
22 Avionics Vibration Reduction PLANT Hard Real Time Loop CONTROLLER Host PC 22
23 Avionics Vibration Reduction PLANT Hard Real Time Loop CONTROLLER Fast Enough Loop Host PC Human-in-the-Loop 23
24 Avionics Vibration Reduction PLANT Field Hard Real Time Loop Machine to Machine CONTROLLER Fast Enough Loop Man to Machine Host PC Human-in-the-Loop 24
25 Mechatronic 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-in-the-Loop 25
26 Open Automation: Project Overview Mechatronic Framework OpenECU Industry Analisys OpenHRTOS OpenACU Plus Concept Open Motion Control OpenPLC OpenVision Demonstrators 26
27 μprocessor for control analisys and Field Modules data logging for I/O connections FPGA for control (analog/digital) and I/O management Proprietary Comm. Modules Standard Industrial/Auto motive Network Modules. SOFTWARE Field Modules Operating System: LabVIEW Run-Time Engine + Linux/Windows/OS LabVIEW O.S. (PXI Architecture) FPGA: LabView DSP: LabView Proprietary Dev. Tools Controller SCENARIO HARDWARE Rugged Rack Controller: NI Compact RIO Applications: motorcycle control prototyping, (i.e Yamaha YZF-R6) 27
28 μprocessor MPC565 Field Modules Signal Conditioning and Pwer Stage Unit add-on modules Comm. Modules Standard Industrial/Auto motive Network protocol integrated in Control Unit. proprietary Applications: Rapid Prototyping SCENARIO HARDWARE Controller Operating System: Dev. Tools SW Rapid Prototyping Automotive Controller: dspace AutoBox 28
29 μprocessor MPC656 (56MHz) Field Modules Comm. Modules Fixed number CAN of I/O integrated in analog/digital controller unit SCENARIO HARDWARE Controller Dev. Tools SW Semi Open Automotive Controller: G850 OpenECU Operating System:OpenECU Development Software:OpenECU Developer Software (as Matlab Simulink library), Enginuity tuning tool Supported Vehicles: Subaru from 2001 and some Mitsubishi 29
30 HARDWARE Controller 2 x 32bit Nec µp 2x 16bit Mitsubishi µp 1 ESPC Denso Field Comm. Modules Modules Fixed number of I/O analog/digital Standard Automotive Network protocol integrated in Control Unit. Operating System: Proprietary Development Software: C/Assembler SCENARIO Dev. Tools SW Automotive Controller: Toyota Prius Solution 30
31 OpenECU HARDWARE Controller DSP + FPGA Field Modules Custom Field Modules for I/O connections (analog/digital) SW Comm Module Comm. Modules Dev. Tools Field Module Standard Industrial/Automot ive Network Modules. Custom HRTGrid Operating System:OpenHRTOS Development Software:TI Code Composer Studio (DSP) + Altera QuartusII (FPGA) VHDL Rapid Prototyping SCENARIO Open ECU 31
32 OpenECU: Embedded Control Board ISA Connector TOP CycloneII FPGA Communication Connector Digital FB Connector 64/256/512kword Memory Debug Connector TMS320F2812 DSP Analog FB Connector 32
33 OpenECU: Kernel Programmable Logic Devices OpenECU is a Programmable Digital Platform DSP/µC EKU 2.1 FPGA 33
34 Open Programmable Digital Platform: OpenHRTOS Platform OpenHRTOS Elements OpenECU IC IC EKU Layer EKU Layer SR SR Blocks Blocks Blocks CW Layer FW Layer SW Layer Abstraction Layer EKU Field Bus CW OS EKU System Bus FW OS Cables Connectors Lines CW Components SW OS Cables Connectors Lines FW Components SW Components 34
35 OpenHRTOS: Hard Real Time OS EKU Kernel is based on two complementary digital programmable devices: DSP - Digital Signal Processor Executes SoftWare (SW) Service Routines (Srs) FPGA - Field Programmable Gate Array Implements FirmWare (FW) Intellectual Properties (s) System Bus FirmWare and SoftWare Templates are user friendly bridges between user code and HRTOS FW Template System Bus HRTOS allows the user to write his own application, in the form of FirmWare Intellectual Properties (FW) for FPGA or SoftWare Service Routines (SW-SR) for DSP, disregarding the HardWare devices FW HRTOS System Part User Part SR SR SW HRTOS SW Template HRTOS 35
36 SW SR SW Layer HRTOS Altera USBBlaster QuartusII DSP Emulator Developer FW Layer System Bus FW Development s Open Digital Platform Programmability: Manual Code Generation SR Code Composer Studio 36
37 Open Digital Platform Programmability: Authomatic Code Generation SW SR SW Layer HRTOS Altera USBBlaster QuartusII DSP Emulator Developer FW Layer System Bus FW Development s Graphical Templates & Block Diagrams SR Code Composer Studio 37
38 OpenECU: s From/To PC: Target to Target / Host to Target connection Used to interconnect a Floating Point micro processor with one or more EKUs for Hard Real Time Target to Target co-processing designs Used to communicate with a Host PC for Data logging, Monitoring and Tuning ISA bus Communications: Custom & Standard Networks Used to create a Hard Real Time Grid between EKUs through custom protocols Used to interconnect EKUs with the external world through standard automotive or industrial protocols From/To FIELD: Field Bus Used to interconnect the EKU with digital and analog sensors and digital peripherals Used to interconnect the EKU with one or more field modules for HardWare Programmability Used to interconnect the EKU with analog and digital signal power supplies 38
39 OpenECU: s From/to FIELD HardWare HRTOS consists in definitions and specifications that allow the user to design his own application, in the form of Integrated Circuits (IC) disregarding the EKU realization Hardware Template is a simple schematic template containing connectors and components present on Development Field Modules Implementation example of a field module containing General signal conditioning Signal Filtering Isolation LM741 LM741 IC HW HW HRTOS Template System Part IC Integrated Circuit User Part HRTOS Conditioning LM741 LM741 Filtering Components Schematic Isolation 39
40 Open Digital Platform Programmability IC IC Schematic SR Developer Development Sys. Bus OpenHRTOS FB QuartusII SR Code Composer Studio 40
41 OpenECU: s From/to Field - Power Open Source Motor Control (OSMC) H-Bridge PC Project WebSite: IC FB PowM 4L Sys. Bus PowerBus OpenHRTOS Schematic available for User 4 legs FieldBus PowerBus #1 SR PowerBus is a subset of FieldBus PowerBus #n 41
42 Open Programmable Digital Platform: OpenHRTOS with OpenACU Platform OpenHRTOS Elements OpenACU OpenECU EKU Layer PC IC IC IC EKU Layer EKU Layer SR SR Blocks Blocks Blocks Blocks PW Layer CW Layer FW Layer SW Layer Abstraction Layer AKU Power Bus PW OS EKU Field Bus CW OS Cables Connectors Lines PW Components EKU System Bus FW OS Cables Connectors Lines CW Components SW OS Cables Connectors Lines FW Components SW Components 42
43 OpenACU in Mechatronic Framework Field Machine to Machine OpenACU Power Supply Structure Sensors PLANT Hard Real Time Loop TARGET (CONTROLLER) Fast Enough Loop PC Man to Machine HOST (HMI) Human-in-the-Loop 43
44 Standard Network Custom Network OpenECU: s Communications HRT Grid Protocol is intended to interconnect DSPs of the EKUs in the Grid. HRT Grid is based on memory share and distributed scheduling. HRT Grid Protocol is entirely managed by FPGA. HRT Grid FlexRay CAN ControlNet Implemented with External Communication Module Boards DeviceNet... Comm. Module 44
45 OpenECU: s Communications Mechatronic Framework Plant #1 Plant #2 Plant #n Power Supply Plant 1 Structure Actuators Field [Target 1] Sensors [Target 1] Controller #2 Target to Target Controller #1 Hard Real Time Protocol Hard Real Time Protocols: Deterministic, Fault Tolerant, Robust Hard Real time Protocols Standard: [Target 1] Controller #n Hard Real Time Communication Protocol CAN Machine to Machine Automotive environment Industrial environme nt HOST (HMI) Man to Machine Human-in-the-Loop 45
46 Target-to-Target Communication Protocol Industrial FlexRay Ethernet/DeviceNet ControlNet CANOpen Profibus Mod F LIN Over network CAN TCP Field BUS Very Good No Possible Good No Possib. F Possib. Very Possible Good Good Medium Control & Automation Good Possible Good Information No Good Possible - Bad Determinism Limitations No SercosRS232 /48 5 Possible Good Possible F Possib. Possible Possible Possible F No Good Possible No Not Proibus Not Low deterministic Bad deterministic DP F Rate Determinism if if Hz multimaster multimaster No <0.5 Mb/s Kb/s Low Rate Low Rate 46
47 OpenECU s: From/To PC Embedded PC ISA Bus FPGA DSP/ µc HRTTandem Tandem ISA Bus OpenECU + Embedded PC = OpenECU Plus µp Embedded PC Open Programmable Digital Platform Standard PC/PC104 CPU Module Features: x86, PowerPC, Xscale CPU interfaces: Video USB LAN Floating Point Computational Power LAN/WLAN Operating System: or 47
48 OpenECU s: From/To PC SR SR SR Target FP FP FP Target HRTTandem: Hard Real Time Tandem Hard Real Time Co-Processing between fixed point Service Routines on DSP and Floating Point Service Routines on PC passing through FPGA as ISA-EKU SystemBus bridge HT Layer: Hardware Translation Layer EKU device driver which allows the communication between PC and EKU Port I/O for EKU configuration Memory I/O for data exchange Dedicated Interrupt from EKU to PC Dedicated DMA (Direct Access Memory) channel for data acquisition FP-SW Template System Part Service Routine Floating Point User Part Linux Real Time or Windows CE API C HT Layer API C HT Layer System Part Application Programming User Part MS Windows or Linux Target Host 48
49 API SR FP Development Tools IC Schematic SR IC Eclipse Sys. Bus SR Development FB QuartusII Developer API Tandem Real Time Tandem OpenHRTOS RTAI Win / Linux Open Digital Platform Programmability Code Composer Studio SR 49
50 OpenECU Plus in Mechatronic Framework Structure Power Supply Power Module Field Sensors Complex Plant PLANT Hard Real Time Loop OpenECU Plus Machine to Machine TARGET (CONTROLLER) Fast Enough Loop Man to Machine HOST (HMI) Human-in-the-Loop 50
51 Controller: HW Platform Embedded Controllers: ECU Hardware Summary National Instruments Programmabl e Automation Controller dspace RapidPro OpenECU G850 (ref. Toyota Prius ECU µprocessor DSP FPGA/ TDU Yes(PC) No Yes No Yes No Yes No Yes Yes (FPU) No Yes No Yes Optional Embedded PC Yes Field Modules Yes I/O Expansion Module Yes I/O Expansion Module No Integrated (FPU) Yes (ASIC) OpenEcu Comm. Module Yes Yes No Yes Yes Integrated Hardware Programmability 51
52 Industrial Controllers: ECU Software Summary National Instruments Programmabl e Automation Controller Operating System Proprietary close dspace AutoBox Proprietary close OpenECU G850 (ref. AdHoc Toyota Prius ECU AdHoc OpenEcu OpenHRTOS Communication Standards System Programmability CAN,PXI CAN, FlexRay, Ethernet/, Dlink grid Proprietary,CAN Proprietary,CAN Assembler (Dual)CAN, FlexRay, Ethernet/, HRTGrid, HRT Tandem on ISA 52
53 Index Mechatronic Framework OpenECU OpenHRTOS OpenACU Plus Concept Open Motion Control OpenPLC OpenVision Demonstrators 53
54 Open Motion Control in Mechatronic Framework Power Supply Sensors Structure Current Sensor Field PLANT Hard Real Time Loop HRT Tandem Machine to Machine OpenECU Plus TARGET (CONTROLLER) Fast Enough Loop Man to Machine HOST (HMI) Human-in-the-Loop 54
55 Open Motion Control: Parameters Tuning Target Host API SR FP Open Motion Control SR FB IC SR From/To PC Development Schematic Open Motion Control SR Open Motion Control User IC Sys. Bus Tandem Hard Real Time Tandem OpenHRTOS RTAI Win / Linux Open Motion Control Parameters Tuning 55
56 Index Mechatronic Framework OpenECU Open Motion Control OpenPLC Industry Analisys Software Architecture OpenVision Demonstrators 56
57 Controller Field Comm. Modules Modules Motion Control Module Proprietary DSP Dedicated FPGA Not Present I/O Modules: Digital Analog Industrial Network Module Operating System: proprietary Development Software: 907 AC 1131 Dev. Tools HARDWARE SOFTWARE Industrial Controller: PLC Allen-Bradley IEC (IL) Instruction List (ST) Structured Text (LD) Ladder Diagrams Closed (FD) Function Block Diagram (SFC) Sequential Function Chart Proprietary 57
58 Controller Motion Control Module Proprietary DSP + FPGA based Operating System: LabVIEW Run-Time Engine + Linux/Windows/OS LabVIEW O.S. (PXI Architecture) Closed Field Comm. Modules Modules I/O Modules: Digital Analog Standard Industrial Network Modules Dev. Tools HARDWARE SOFTWARE Industrial Controller: National Instruments PAC Development Software: G Dataflow Language Graphical Programming (VI) Closed Proprietary... Proprietary Proprietary 58
59 Controller Field Comm. Modules Modules Motion Control Module Proprietary μprocessor Based I/O Modules: Digital Analog Standard Industrial Network Modules Proprietary Dev. Tools HARDWARE SOFTWARE Industrial Controller: SoftPLC KONTRON Operating System: Windows/Linux/QNX Development Software: CoDeSys SP IEC (IL) Instruction List (ST) Structured Text (LD) Ladder Diagrams Closed (FD) Function Block Diagram (SFC) Sequential Function Chart Proprietary 59
60 Industrial Controllers: OpenPLC (Open ECU based) μprocessor Based (Embedded PC) DSP + FPGA Field Modules Custom Field Modules for I/O connections (analog/digital) Field Module Comm Module SOFTWARE Controller Open ECU Operating System: Linux/RTAI (Embedded PC) OpenHRTOS (OpenECU) O.S. Library: Orocos Framework Dev. Tools HARDWARE Embedded PC Development Software: C/C++ Hard Coding Graphical Programming (VI) Eclipse Open Comm. Modules Standard Industrial/Automot ive Network Modules. Custom HRTGrid 60
61 FPGA DSP/ µc Open Programmable Digital Platform HRTTandem OpenHRTOS PC-104 x86 CPU based Floating Point ISA BUS SR FP Orocos Service Routine Floating Point User Part Integrated Development Environment + OROCOS Framework IC FB µp SR FP Sys. Bus ISA BUS Linux RTAI OpenPLC: Software Architecture OpenPLC Applications: kinematic inverse/direct; robotic control SR 61
62 OpenPLC in Mechatronic Framework Structure Power Supply Power Module Field Sensors Complex Plant PLANT Hard Real Time Loop HRT Tandem Machine to Machine OpenPLC TARGET (CONTROLLER) Fast Enough Loop Man to Machine HOST (HMI) Human-in-the-Loop 62
63 HARDWARE Industrial Controllers: OpenPLC Stack System Field PC/104 CPU Open ECU Comm. Module Module Module Platform: Industrial Rack Passive Backplane Platform: PC/104 Stack Communication buses: standard (ISA) Communication buses: standard (ISA) 63
64 Embedded DSP + FPGA board up Board Comm Module Field Modules Yes Yes Comm Bus Industrial Controllers: PLC Hardware Summary Programmable Logic Controller Yes Yes AllenBradley, Siemens, Telemecanique, GE, Omnron Programmable Automation Controller Yes Proprietary PXI (NI) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes National Instruments SoftPLC Kontron OpenPLC Yes Yes 64
65 Industrial Controllers: PLC Software Summary Programmable Logic Controller AllenBradley, Siemens, Telemecanique, GE, Omnron Programmable Automation Controller National Instruments Operating System Proprietary close Proprietary close Kontron Open (Linux RTAI) Proprietary (WinCE) OpenPLC Open SoftPLC Communication Networks System Programmability IEC CVI / IEC
66 Index Mechatronic Framework OpenECU Open Motion Control OpenPLC OpenVision Demonstrators 66
67 Vision System: Mechatronic Framework Field Open Vision PLANT Hard Real Time Loop Embedded PC: Machine to Machine image elaboration; image transmission on Wi-Fi Wi-Fi Router CONTROLLER Fast Enough Loop Man to Machine JOG BOX (HMI) Human-the-Loop 67
68 ISA BUS Linux S.O. Vision System: Software Architecture Linux Tool for Video streaming Web Server µp Linux/Win Embedded PC Wi-Fi Router Web Browser Host PC 68
69 Index Mechatronic Framework OpenECU Open Motion Control OpenPLC OpenVision Demonstrators Fasti Chain-Machine RobMob Project TTW Vehicle RTR Avionic 69
70 Industrial Machinery chain-making machine 70
71 Industrial Machinery: FASTI Electric Camshaft OpenECU manages: hold new chainmail with clutch; chain putting on; chainmail closedown. Field PLANT Open HRTOS Machine to Machine Man to Machine OpenECU VIRTUAL USER PANEL (HMI) chain-making machine 71
72 Industrial Machinery: FASTI Vision System Field Machine to Machine PLANT OpenPLC FASTI Vision System: Man to Machine image capturing triggered by camshaft angle; image vision rallentee respect to working-cycle. USER PANEL (HMI) 72
73 Mobile Robotics RobMob Project 73
74 Mobile Robotics: RobMob - Traction CARRIER PLANT Field Hard Real Time Loop Machine to Machine OpenECU Fast Enough Loop Wi-Fi Router RF Man to Machine JOG BOX (HMI) Human-the-Loop 74
75 Mobile Robotics: RobMob - Arm Samples joint position and Jog deflection from EKU Board Inverse/direct kinematic: when cartesian trajectory is required, speed in cartesian reference system is converted into speed in joint reference system Computes trajectory and sends required joint speed to EKU Board PLANT Field OpenECU Machine to Machine HRT Tandem Embedded PC OROCOS Framework OpenECU Plus RTAI Real Time Linux Extension RF Man to Machine Arm Trajectory Generator JOG BOX (HMI) PC 75
76 Light Vehicles TTW 76
77 Light Vehicles: TTW - Traction Electric Traction Field Fuel Engine PLANT #1 Brushless Motor PLANT #2 OpenECU #2 Target to Target CONTROLLER #1 CONTROLLER #2 FlexRay Machine to Machine Man to Machine HANDLEBAR, THROTTLE (HMI) Red Baron 77
78 Light Vehicles: TTW - Telemetry Telemetry Sensors Field PLANT HRT Tandem Machine to Machine Man to Machine OpenECU Plus Parameters Tuning Telemetry 78
79 Avionics ic m a n y d re r o tu t Ro gna si A engine-like Test Rig 79
80 Avionics: RTR Rotordynamic signature: dynamic behavior of a real aeroengine Vibration damping: test of active vibration dampers (AMD) semiactive magnetic dampers (SAMD) Monitoring: vibration analysis for data logging and maintenance Field Open Motion Control Machine to Machine fft over angular sampling OpenECU Tuning Monitoring Rotordynamic for embedded systems Man to Machine Host PC 80
81 Thank You 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.
Open Automation Project Overview
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 http://creativecommons.org/licenses/by-sa/3.0/
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