Modern Industrial Automation Sofhvare Design

Transcription

1 Modern Industrial Automation Sofhvare Design Principles and Real- World Applications Lingfeng Wang Kay Chen Tan IEEE IEEE PRESS A JOHN WILEY & SONS, INC., PUBLICATION

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3 Modern Industrial Automation Sofiare Design

4 IEEE Press 445 Hoes Lane Piscataway, NJ IEEE Press Editorial Board Mohamed E. El-Hawary, Editor in Chief M. Akay T. G. Croda M. S. Newman J. B. Anderson R.J. Herrick F. M. B. Pereira R. J. Baker S. V. Kartalopoulos C. Singh J. E. Brewer M. Montrose G. Zobrist Kenneth Moore, Director of IEEE Book and Information Services (BIS) Catherine Faduska, Acquisitions Editor, IEEE Press Jeanne Audino, Project Editor, IEEE Press

5 Modern Industrial Automation Sofhvare Design Principles and Real- World Applications Lingfeng Wang Kay Chen Tan IEEE IEEE PRESS A JOHN WILEY & SONS, INC., PUBLICATION

6 Copyright by The Institute of Electrical and Electronics Engineers, Inc. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) , fax (978) , or on the web at Requests to the Publisher for permission should he addressed to the Permissions Department, John Wiley & Sons, Inc., 1 11 River Street, Hoboken, NJ 07030, (201) I, fax (201) , or online at Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) , outside the United States at (317) or fax (317) Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic format. For information about Wiley products, visit our web site at Library of Congress Catuloging-in-Publication Data is avuilable. ISBN-I ISBN Printed in the United States of America

7 Contents Preface Aclcnow ledgments Acronyms xxi xxiii xxv Part I Design Principles of Modern Industrial Automation Systems 1 Introduction Developmental Trends Classifications and Existing Products Functionality of Industrial Automation Systems About the Book 7 2 Virtual Instrumentation Introduction Characteristics of VXI Instruments VXI Plug&Play (VPP) Specification Virtual Instrument Software Architecture (VISA) 16 V

8 v; CONTENTS VISA model structure VISA characteristics 2.5 Programming platforms Textual programming Visual programming Graphical programming 2.6 Liquefied Petroleum Gas Network (PLPGN) Monitoring Overall structure design 2.7 Hardware and Software Design Development requirements Development environment Configurations of system hardware and software 2.8 Summary 3 Component-Based Measurement Systems 3.1 Introduction 3.2 Component Technology 3.3 Component-Based Industrial Automation Software 3.4 Writing Component 3.5 Case Study Case Study Definition of base class of instruments UI base class of VIs 3.7 Summary 4 Object- Oriented Software Engineering 4.1 Software Development Models bject Orientation OOA/OOD Advantages 5 Graphical User Interface Design 6 Database Management 6.1 Database Systems 6.2 Relational Database

9 CONTENTS vii 6.3 Structured Query Language (SQL) 6.4 Open Database Connectivity (ODBC) 7 Software Testing 7.1 Software and Industrial Automation 7.2 Software Testing Strategies Black- box testing White-box testing Software Testing Processes and Steps Unit testing Integration testing Verification testing System testing Validation 7.4 Software Performance Testing Availability testing Reliability testing Survivability testing Flexibility testing Stress testing Security testing 74.7 Usability testing Maintainability testing 7.5 Software Maintenance 7.6 Summary Part 11 Real- World Applications 8 Overview 9 An Object-Oriented Reconfigurable Software 9.1 Introduction Evolution of reconfigurable software 9.2 Design Requirements, Development Environments, and Methodologies Design requirements Development environments Development methodologies

10 viii CON TENTS 9.3 IMC System Structure and Software Design Overall structure of IMC systems Configuration- based IMC software Reconfigurable IMC software design Development tool selection Object-oriented methodology Windows programming Database technologies Relational database model Database management system (DBMS) Database application Delphi database functionality 9.4 RSFIMC Architecture Data acquisition module Data processing module Data browsing module 9.5 RSFIMC Functions User configuration Running status indications Alarm management Data exchange Visual database query Remote communication 9.6 Summary 10 Flexible Measurement Point Management 10.1 Introduction 10.2 System Architecture Overall architecture Interfaces with other modules 10.3 Development Platform and Environment 10.4 Measurement Point Management MP configuration Task eonfiguration Dynamic configuration of MPs and tasks System running 10.5 An Illustrative Example on a Serial Port Driver Serial port hardware driver

11 CONTENTS ix Serial port system driver DIT maintenance for serial port system driver Hardware simulation terminal Summary A Blending System Using Multithreaded Programming 11.1 Introduction 11.2 Overall Blending System Configuration Hardware configuration Software configuration Multithread- based communication 11.3 The Overall Software Design Design requirements Software structure VxD Front-end software Device management module User management Database management 11.4 Field Experience and Summary Field experience Summary A Flexible Automatic Test System for Rotating Turbine Machinery Introduction Design Goals of FATSFTM Design Strategies of FATSFTM Hardware design strategy Software design strategy Test Software Development Process Requirements capture Analysis Design Programming Testing Function of FATSFTM Initialization and self-examination 221

12 x CONTENTS Data acquisition User configuration Running status indication and realtime/historical data analysis Alarm management and post-fault diagnosis Remote test Other system functions 12.6 Implementation and Field Experience On-site implementation and field experience System benefits 12.7 Summary An Internet-Based Online Real- Time Condition Monitoring System Introduction Problem Description Field data acquisition devices Field data acquisition workstation System servers Remote browsers Requirements Capture and Elicitation Data acquisition workstation software Analysis (diagnosis) and management workstation software 13.4 Analysis Data-flow model Entity-relationship model Event-response model 13.5 Transition to Design Choice of development strategies Choice of development environment and programming tool 13.6 Overall Design Database design Overall design of DAQ workstation software Overall design of the A&M workstation software

13 Design of Web server CGI application 13.7 Detailed System Design and Implementation Implementation of DAQ module Implementation of data management module Communication module Multitasking coordination Implementation of Web server 13.8 Field Experience 13.9 Summary 14 Epilog 14.1 Middlware 14.2 Unified Modeling Language (UML) 14.3 Agent- based software development 14.4 Agile methodologies 14.5 Summary CONTENTS xi Index 31 0

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15 List of Figures A typical industrial automation system. Basic framework of automated measurement system based on virtual instruments. The structure of PLPGN monitoring system. Hardware configuration of the PLPGN monitoring system. Software functions of the PLPGN monitoring system. Delphi s VCL object hierarchy. Virtual instrument object. Phase tasks in the software life cycle. Incremental software development model. The generic ODBC architecture. Software testing stages. Software testing steps. Test sequence in top-down integration testing xiii

16 xiv LIST OF FIGURES 7.4 Test sequence in bottom-up testing Real-tame monitoring and control system Software maintenance Reconfigurable software in IMC system Basic architecture of IMC system Database software system constitution Delphi database system structure Overall structure of the RSFIMC Data processing in RSFIMC MP configuration interface Task configuration interface Structure of the data processing module New variable calculation process New variable calculation data Bow Screenshot of new variable calculation interface Screenshot of status indication interface Message handling an Windows applications Information Bow of the real-time alarm system API interfaces in MS Excel Screenshot of OLE Automation interface Process of visual database query Screenshot of visual database query interface Overall structure of industrial reconfigurable supervision software The architecture of MP management module Running module architecture for MP management Driver loading process in the MP management module. 165

17 LIST OF FIGURES xv 10.5 Task scanning mechanism Task priority management mechanism Snapshot of the G UI- based operational panel Schematic diagram of the serial driver testing Communication mechanism in RS232Dru Communication mechanism in the hardware simulation terminal l Flowchart of the automated blending system The hardware setup The overall software structure Package formats for communication between ICPC and PLC PLC communication mechanism Data flowchart of the communication sub-thread The data flow between VxD and front-end software Snapshot of working status for the blending system The framework of FATSFTM Hardware architecture of FATSFTM OOA model structure OOD model structure Software structure of FATSFTM Data-flow diagram Entity-relationship diagram (ERD) State transition diagram (STD) Whole-part relationship based on physical containment Whole-part relationship based on physical association Generalization-specialization relationship. 21 3

18 xvi LIST OF FIGURES 12.12Subject layer in the OOA model Class structure in DAQ Directory structure of FATSFTM An overview of FATSFTM functions IMP for distributed data acquisition Screen capture of Bode chart in the running FATSFTM Mechanism of alarm management module Architecture of fault diagnosis module Plant layout Number of machine defects detected in test process at diflerent stages Average monthly test cost at diflerent project stages Configuration of the Internet-based online condition monitoring system Data-flow diagram of overall distributed condition monitoring software Data-flow diagram of data acquisition workstation module Data-flow diagram of data processing module Data-flow diagram of data acquisition module System entity-relationship diagram Module structure of the data acquisition workstation Module structure of the A&M workstation software Data flowchart of the in-house developed DAQ driver Basic ODBC architecture Datagram-socket- based communication Stream-socket- based communication CGI- based communication mechanism Screen capture of real-time waveforms in spectral analysis. 298

19 List of Tables 3.1 Main properties and methods in VI base class 9.1 Language evolution 9.2 Structure of the real-time database 9.3 Structure of the original historical database 9.4 Structure of the medium-term database 9.5 Structure of the processed database 9.6 Structure of the alarm configuration database 9.7 Structure of the alarm record database 9.8 Formula database structure 10.1 Performance comparison between the earlier manual system and the automatic supervision system 11.1 Event-response relationships for the automatic blending system 11.2 User management for the automatic blending system xvii

20 xviii LIST OF TABLES 11.3 Database management for the automatic blending system 12.1 System state list 12.2 Event-response model 12.3 Partial OOA/OOD working table 12.4 OOA Model 12.5 Databases in FATSFTM 13.1 System event-response model 13.2 System database 13.3 Workstation configuration table 13.4 Machine configuration table 13.5 MP configuration table 13.6 Historical data record strategy selection table 13.7 Vibration variable channel configuration table 13.8 Process variable channel configuration table 13.9 Report format selection table Record strategy definition table Server and A&M workstation properties table Vibration variable real-time data table Process variable real-time data table Switch variable real-time data table Medium-term historical database table for vibration variables Detailed composition of variables Record configuration (cluster) Report configuration Current machine alarm channel table Back-end processing software status

21 LISTOF TABLES Startup/shutdown status Server properties Server properties Workstation communication properties (array) Major modules of A&M workstation software Measurement range Frequency response A/D resolution Input impedance Measurement accuracy Priorities of some major system modules xix

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23 Preface This book contains significant results from our research on industrial automation software conducted in previous years. Industrial automation software can be used in a wide variety of industrial fields such as condition monitoring and fault diagnosis for rotating machinery, public utilities monitoring, plant process supervision, intelligent building management, and many others. With the fast development of computer technology in recent years, a number of emerging software technologies can be adopted to build more powerful industrial automation software. These innovative technologies include modern software engineering, object-oriented methodology, visual/graphical programming platform, graphical user interface, virtual instrumentation, componentbased system, systematic database management, dynamic data exchange, and so forth. All these technologies provide new opportunities to develop more comprehensive and reliable software artifacts than before. Thus the demand for new books in this field arises as the field continues to keep evolving, and both practicing engineers and academic people are simultaneously challenged by how to develop industrial automation software in a more effective and efficient manner. This book is intended to address how the industrial automation software can be developed in a purposeful and disciplined fashion. Broadly speaking, the whole book is divided into two parts. The first part provides the reader with an overview of this field and a variety of fundamental design principles. Chapter 1 introduces the modern industrial automation systems, virtual instrumentation technology is discussed in Chapter 2, and the development of

24 xxii PREFACE component-based measurement systems is addressed in Chapter 3. Chapter 4 introduces the object-oriented software engineering. User interface design is discussed in Chapter 5. Database management is presented in Chapter 6. Software testing is fleshed out in Chapter 7. In the second part of this book, first an overview on the five typical applications in real-world industrial automation software design is given in Chapter 8. All of these case studies are highly representative so that they can serve as useful references when the reader wants to construct their own software systems. Chapter 9 represents an ob ject-oriented reconfigurable software for industrial measurement and control. Because the reconfiguration concept is used throughout the software development process, the obtained software turns out to be highly flexible and able to accommodate different industrial application requirements. Chapter 10 focuses on the flexible measurement point management in the industrial measurement and control system. It provides the basis for building industrial automation systems with high configuration capability. A VxD-based automatic blending system is discussed in Chapter 11. To meet the communication speed in the presence of a large volume of data, multithreaded programming technique is used to avoid the data transmission bottleneck. Rotating turbine machinery is widely used in various industrial environments, and its design quality is of particular importance. Thus in Chapter 12, an automatic test system for turbine machinery is discussed, which is developed for ensuring the machine quality by automatic testing. Networked industrial systems are the development trend for different industry applications. In Chapter 13, an Internet-based online real-time condition monitoring system is discussed. It is developed based on the concept of modular design and functional decomposition. In the final chapter, the emerging technologies for building more powerful industrial automation software are introduced, which include middleware, Unified Modeling Language (UML), agent-based software development, and agile methodologies. The authors welcome all the comments and suggestions regarding this book. All the correspondence may be addressed to the first author at 1.f.wangQieee.org. Thank you for reading the book, and I look forward to hearing from you. College Station, Tezas L. F. WANG NUS, Singapore K. C. TAN

25 Acknowledgments We would like to thank the many wonderful people who helped us research and complete this book. First, our sincere thanks go to all at Wiley-IEEE Press who interacted with us during advance marketing for their time and effort. We are especially grateful to Anthony VenGraitis (Project Editor), Lisa Van Horn (Managing Editor), and Bob Golden (Copy Editor) for making amazing progress with the manuscript and for smoothing out the rough edges. Their effort and patience made possible an enjoyable and wonderful journey through various steps in production. Thanks are also due to the anonymous reviewers, whose constructive and useful comments have helped us greatly improve the quality of the book. We owe immense gratitude to Dr. L. Y. Wang, Dr. X. X. Chen, Dr. H. Zhou, Dr. C. G. Geng, Dr. Y. Z. Wang, Dr. L. Liu, Dr. X. L. Chen, Dr. Y. C. Ma, X. D. Jiang, Y. B. Chen, S. L. Liao, P. F. Yu, J. T. Huang, H. Chen, J. H. Chen, H. X. Wu, and Amy Ton for their useful help and beneficial discussions throughout this endeavor. In particular, some chapters included in this book are the joint work with many other excellent researchers: Chapter 3 (H. Chen), Chapter 4 (J. T. Huang), Chapter 11 (Y. B. Chen), Chapter 12 (Y. B. Chen and X. D. Jiang), Chapter 13 (X. D. Jiang), and Chapter 14 (S. L. Liao). Without their help, this study could not have occurred. We also would like to thank our families, who endured our extended time leave and gave us endless spiritual support. L. F. W. and K. C. T.

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27 Acronyms 3GL 3VM 4GL ADRE A&M AM API ASD ATS BDE BSD BU c/s C4ISR CAN CAS Third-Generation Language 3-View Modeling Fourth-Generation Language Automated Diagnostics for Rotating Equipment Analysis & Management Agile Modeling Application Programming Interface Adaptive Software Development Automatic Test System Borland Database Engine Berkeley Software Distribution Butt om- Up Client/Server Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance Controller Area Network Complex Adaptive System XXV

28 xxvi Acronyms CASE CBS CBSD CIMS CIN CM COM CORBA COTS CP CPU DAIU DAQ DBD DBMS DCB DCE DCL DCOM DCS DDE DDL DFA DFD DIT DLL DMC DML DNA DSDM DSS EAD EAI EIS Computer-Aided Software Engineering Component -B ased System Component-Based Software Development Computer Integrated Manufacturing System Code Interface Node Condition Monitoring Component Object Model Common Object Request Broker Architecture Commer cial-0 ff- t he-s helf Control Package Central Processing Unit Data Acquisition Interface Unit Data Acquisition Database Desktop Database Management System Device Control Block Distributed Computing Environment Data Control Language Distributed Component Object Model Distributed Control System Dynamic Data Exchange Data Definition Language Dat a-flow Analysis Data-Flow Diagram Driver Image Table Dynamic Link Library Database Management Component Data Manipulation Language Distributed Network Architecture Dynamic Systems Development Method Decision Support System Enterprise Application Development Enterprise Application Integration Enterprise Information Systems

29 Acronyms mi; ERD Entity-Relationship Diagram FATSFTM Flexible Automatic Test System for Turbine Machinery FDD Feature-Driven Development FFT Fast Fourier Transform GPIB General-Purpose Interface Bus GQS Generic Query System GUI Graphical User Interface HIC Human Interaction Component HMI Human-Machine Interaction HTML HyperText Markup Language I/O Input /Output ICPC Industrial Control Personal Computer IDE Integrated Development Environment IMC Industrial Measurement and Control IPC Inter-Process Communication ISDN Integrated Services Digital Network ITS Integrated Transaction Server JAD Joint Application Development LabVIEW Laboratory Virtual Instrument Engineering LAN LD LIA MDI MEMS MMI MP MS MTS NCS NDI OA ODBC Workbench Local Area Network Lean Development Linguistic-based Information Analysis Multiple Document Interface Microelectromechanical Systems Man-Machine Inter face Measurement/Measuring Point Microsoft Microsoft Transaction Server Networked Control System Non-Developmental Item Object Adapter Open DataBase Connectivity

30 miii Acronyms OLE OMG OMT 00 OOA OOD OOP OOSE OPC ORB 0s oss P2P PCI PCM PDC PFA PLPGN PLC PP PTP Pub/Sub PXI PZT QP RAD RDBMS RMI RPC RSFIMC RUP SAC SBC Object Linking and Embedding Object Management Group Object Modeling Technique Object- Orient at ion Object-Oriented Analysis Object-Orient ed Design Ob ject-oriented Programming Object-Oriented Software Engineering OLE for Process Control Object Request Broker Operating System Open Source Software Peer- t o-peer Peripheral Component Interconnection Pulse Code Modulation Problem Domain Component Phrase Frequency Analysis Pipeline Liquefied Petroleum Gas Network Programmable Logic Controller Pragmatic Programming Point-To-Point Publisher / Subscr i b er PCI extensions for Instrumentation Piezoelectric Query Package Rapid Application Development Relational Database Management System Remote Method Invocation Remote Procedure Call Reconfigurable Software for Industrial Measurement and Control Rational Unified Process Scan, Alarm, and Control Single-Board Controller

31 Acronyms XXiX SCADA SCMC SD SDI SICL SOC SP SPX/IPX SQA SQL STD TCP/IP TD TMC UDP UDT UML URL VBX VCL VI VISA VME VMS VPP VxD VXI WAN Supervisory Control And Data Acquisition Single-Chip Micro-Controller Structured Design Single Document Interface Standard Instrument Control Library S yst em-on-a- C hip Structured Programming Sequenced Packet Exchange/Internetwor Pac <et Exchange Software Quality Assurance Structured Query Language State Transition Diagram Transmission Control Protocol/Internet Protocol Top-Down Task Management Component User Datagram Protocol Uniform Data Transfer Unified Modeling Language Unified Resource Location Visual Basic extension Visual Component Library Virtual Instrument/Instrumentation Virtual Instrument Software Architecture VersaModul Eurocard Virtual Memory System VXI Plug&Play Virtual X Device Driver VME extensions for Instrumentation Wide Area Network WYWIWYT What You Write Is What You Think WinSock Windows Socket XML extensible Markup Language XP extreme Programming Y2K Year 2000

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33 Part I - Design Principles of Modern Industrial Automation Systems

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35 In t rod u c t i o n In the past years before the personal computer (PC) was widely incorporated into industrial automation systems, all the faults that occurred in industrial processes were checked and dealt with by trained or experienced operators. For example, in the condition monitoring systems for the natural gas pipeline network, all operations were handled in a manual or semiautomatic manner, which, however, had some major drawbacks. For instance, the operator had to do the majority of the work by hand, the abnormal conditions could not be monitored and handled in real time, the remote measurement parameters could not be effectively monitored, and operators were prone to make mistakes in recording and manipulating a large amount of data. Therefore, it is highly necessary to automate the measurement operations as well as to improve the operating efficiency. In recent decades, this picture has been dramatically changed due to the wide adoption of industrial PC in a wide range of industrial applications. A typical industrial automation system, as illustrated in Fig. 1.1, is usually made up of the physical system, transducers, device drivers and data I/O, host computer, network server, and remote computers. Information technologies have been rapidly developed in recent years, and they have provided sufficient technical support for building modern industrial automation systems with more open architecture with respect to the previous ones. It turns out that the computerized real-time monitoring analysis Modern Industrial Automation Software Design, By L. Wang and K. C. Tan Copyright 2006 the Institute of Electrical and Electronics Engineers, Inc. 1