Modern Industrial Automation Sofhvare Design

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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Modern Industrial Automation Sofiare Design

IEEE Press 445 Hoes Lane Piscataway, NJ 08854 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

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

Copyright 0 2006 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) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. 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) 748-601 I, fax (201) 748-6008, or online at http://www.wiley.com/go/permission. 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) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. 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 www.wiley.com. Library of Congress Catuloging-in-Publication Data is avuilable. ISBN-I3 978-0-471-68373-5 ISBN- 10 0-47 1-68373-6 Printed in the United States of America. 10987654321

Contents Preface Aclcnow ledgments Acronyms xxi xxiii xxv Part I Design Principles of Modern Industrial Automation Systems 1 Introduction 1 1.1 Developmental Trends 2 1.2 Classifications and Existing Products 3 1.3 Functionality of Industrial Automation Systems 5 1.4 About the Book 7 2 Virtual Instrumentation 9 2.1 Introduction 9 2.2 Characteristics of VXI Instruments 13 2.3 VXI Plug&Play (VPP) Specification 14 2.4 Virtual Instrument Software Architecture (VISA) 16 V

v; CONTENTS 2.4.1 VISA model structure 2.4.2 VISA characteristics 2.5 Programming platforms 2.5.1 Textual programming 2.5.2 Visual programming 2.5.3 Graphical programming 2.6 Liquefied Petroleum Gas Network (PLPGN) Monitoring 2.6.1 Overall structure design 2.7 Hardware and Software Design 2.7.1 Development requirements 2.7.2 Development environment 2.7.3 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 1 3.6 Case Study 2 3.6.1 3.6.2 Definition of base class of instruments UI base class of VIs 3.7 Summary 4 Object- Oriented Software Engineering 4.1 Software Development Models 4.2 0 bject Orientation 4.2.1 OOA/OOD 4.2.2 Advantages 5 Graphical User Interface Design 6 Database Management 6.1 Database Systems 6.2 Relational Database 17 18 19 20 20 21 23 24 26 26 27 27 29 31 31 32 35 36 36 38 39 40 41 43 44 48 48 51 53 59 60 61

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 7.2.1 Black- box testing 7.3 7.2.2 White-box testing Software Testing Processes and Steps 7.3.1 Unit testing 7.3.2 Integration testing 7.3.3 Verification testing 7.3.4 System testing 7.3.5 Validation 7.4 Software Performance Testing 7.4.1 Availability testing 7.4.2 Reliability testing 7.4.3 Survivability testing 7.4.4 Flexibility testing 7.4.5 Stress testing 7.4.6 Security testing 74.7 Usability testing 7.4.8 Maintainability testing 7.5 Software Maintenance 7.6 Summary 64 66 69 69 71 72 73 73 75 76 78 78 79 79 80 81 81 81 82 82 82 83 84 85 Part 11 Real- World Applications 8 Overview 9 An Object-Oriented Reconfigurable Software 9.1 Introduction 9.1.1 Evolution of reconfigurable software 9.2 Design Requirements, Development Environments, and Methodologies 9.2.1 Design requirements 9.2.2 Development environments 9.2.3 Development methodologies 91 93 94 94 105 105 106 107

viii CON TENTS 9.3 IMC System Structure and Software Design 9.3.1 Overall structure of IMC systems 9.3.2 Configuration- based IMC software 9.3.3 Reconfigurable IMC software design 9.3.4 Development tool selection 9.3.5 Object-oriented methodology 9.3.6 Windows programming 9.3.7 Database technologies 9.3.8 Relational database model 9.3.9 Database management system (DBMS) 9.3.10 Database application 9.3.1 1 Delphi database functionality 9.4 RSFIMC Architecture 9.4.1 Data acquisition module 9.4.2 Data processing module 9.4.3 Data browsing module 9.5 RSFIMC Functions 9.5.1 User configuration 9.5.2 Running status indications 9.5.3 Alarm management 9.5.4 Data exchange 9.5.5 Visual database query 9.5.6 Remote communication 9.6 Summary 10 Flexible Measurement Point Management 10.1 Introduction 10.2 System Architecture 10.2.1 Overall architecture 10.2.2 Interfaces with other modules 10.3 Development Platform and Environment 10.4 Measurement Point Management 10.4.1 MP configuration 10.4.2 Task eonfiguration 10.4.3 Dynamic configuration of MPs and tasks 10.4.4 System running 10.5 An Illustrative Example on a Serial Port Driver 10.5.1 Serial port hardware driver 108 108 111 112 113 115 118 118 119 119 120 122 122 124 124 125 126 126 133 134 135 140 142 144 151 152 153 154 157 157 158 158 159 160 161 167 168

CONTENTS ix 10.5.2 Serial port system driver 170 10.5.3 DIT maintenance for serial port system driver 171 10.5.4 Hardware simulation terminal 172 10.6 Summary 172 11 A Blending System Using Multithreaded Programming 11.1 Introduction 11.2 Overall Blending System Configuration 11.2.1 Hardware configuration 11.2.2 Software configuration 11.2.3 Multithread- based communication 11.3 The Overall Software Design 11.3.1 Design requirements 11.3.2 Software structure 11.3.3 VxD 11.3.4 Front-end software 11.3.5 Device management module 11.3.6 User management 11.3. 7 Database management 11.4 Field Experience and Summary 11.4.1 Field experience 11.4.2 Summary 179 179 181 181 183 183 185 186 188 189 189 190 190 190 190 191 191 12 A Flexible Automatic Test System for Rotating Turbine Machinery 197 12.1 Introduction 198 12.2 Design Goals of FATSFTM 199 12.3 Design Strategies of FATSFTM 201 12.3.1 Hardware design strategy 201 12.3.2 Software design strategy 202 12.4 Test Software Development Process 206 12.4.1 Requirements capture 207 12.4.2 Analysis 207 12.4.3 Design 212 12.4.4 Programming 219 12.4.5 Testing 220 12.5 Function of FATSFTM 221 12.5.1 Initialization and self-examination 221

x CONTENTS 12.5.2 Data acquisition 12.5.3 User configuration 12.5.4 Running status indication and realtime/historical data analysis 12.5.5 Alarm management and post-fault diagnosis 12.5.6 Remote test 12.5.7 Other system functions 12.6 Implementation and Field Experience 12.6.1 On-site implementation and field experience 12.6.2 System benefits 12.7 Summary 222 222 223 224 227 228 229 229 230 232 13 An Internet-Based Online Real- Time Condition Monitoring System 239 13.1 Introduction 239 13.2 Problem Description 241 13.2.1 Field data acquisition devices 241 13.2.2 Field data acquisition workstation 242 13.2.3 System servers 243 13.2.4 Remote browsers 243 13.3 Requirements Capture and Elicitation 244 13.3.1 Data acquisition workstation software 245 13.3.2 Analysis (diagnosis) and management workstation software 13.4 Analysis 13.4.1 Data-flow model 13.4.2 Entity-relationship model 13.4.3 Event-response model 13.5 Transition to Design 13.5.1 Choice of development strategies 13.5.2 Choice of development environment and programming tool 13.6 Overall Design 13.6.1 Database design 13.6.2 Overall design of DAQ workstation software 13.6.3 Overall design of the A&M workstation software 24 5 246 246 24 9 250 251 252 254 259 260 263 2 79

13.6.4 Design of Web server CGI application 13.7 Detailed System Design and Implementation 13.7.1 Implementation of DAQ module 13.7.2 Implementation of data management module 13.7.3 Communication module 13.7.4 Multitasking coordination 13.7.5 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 282 282 282 285 287 291 293 295 298 303 303 304 305 308 309 Index 31 0

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List of Figures 1.1 2.1 2.2 2.3 2.4 3.1 3.2 4.1 4.2 6.1 7.1 7.2 7.3 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. 2 24 25 28 29 36 38 45 47 67 74 75 77 xiii

xiv LIST OF FIGURES 7.4 Test sequence in bottom-up testing. 78 7.5 Real-tame monitoring and control system. 80 7.6 Software maintenance. 84 9.1 Reconfigurable software in IMC system. 103 9.2 Basic architecture of IMC system. 109 9.3 Database software system constitution. 120 9.4 Delphi database system structure. 123 9.5 Overall structure of the RSFIMC. 123 9.6 Data processing in RSFIMC. 1 24 9.7 MP configuration interface. 127 9.8 Task configuration interface. 127 9.9 Structure of the data processing module. 128 9.10 New variable calculation process. 131 9.11 New variable calculation data Bow. 132 9.12 Screenshot of new variable calculation interface. 133 9.13 Screenshot of status indication interface. 1 34 9.14 Message handling an Windows applications. 135 9.15 Information Bow of the real-time alarm system. 136 9.16 API interfaces in MS Excel. 137 9.1 7 Screenshot of OLE Automation interface. 1-41 9.18 Process of visual database query. 143 9.19 Screenshot of visual database query interface. 143 10.1 Overall structure of industrial reconfigurable supervision software. 154 10.2 The architecture of MP management module. 156 10.3 Running module architecture for MP management. 163 10.4 Driver loading process in the MP management module. 165

LIST OF FIGURES xv 10.5 Task scanning mechanism. 166 10.6 Task priority management mechanism. 166 10.7 Snapshot of the G UI- based operational panel. 168 10.8 Schematic diagram of the serial driver testing. 172 10.9 Communication mechanism in RS232Dru. 173 10.10 Communication mechanism in the hardware simulation terminal. 174 11.l Flowchart of the automated blending system. 182 11.2 The hardware setup. 182 11.3 The overall software structure. 183 11.4 Package formats for communication between ICPC and PLC. 184 11.5 PLC communication mechanism. 186 11.6 Data flowchart of the communication sub-thread. 187 11.7 The data flow between VxD and front-end software. 188 11.8 Snapshot of working status for the blending system.188 12.1 The framework of FATSFTM. 199 12.2 Hardware architecture of FATSFTM. 201 12.3 OOA model structure. 204 12.4 OOD model structure. 205 12.5 Software structure of FATSFTM. 206 12.6 Data-flow diagram. 208 12.7 Entity-relationship diagram (ERD). 209 12.8 State transition diagram (STD). 209 12.9 Whole-part relationship based on physical containment. 21 3 12.10 Whole-part relationship based on physical association. 21 3 12.11 Generalization-specialization relationship. 21 3

xvi LIST OF FIGURES 12.12Subject layer in the OOA model. 12.13 Class structure in DAQ. 12.14 Directory structure of FATSFTM. 12.15 An overview of FATSFTM functions. 12.16 IMP for distributed data acquisition. 12.17Screen capture of Bode chart in the running FATSFTM. 12.18 Mechanism of alarm management module. 12.19 Architecture of fault diagnosis module. 12.20 Plant layout. 12.21 Number of machine defects detected in test process at diflerent stages. 12.22 Average monthly test cost at diflerent project stages. 13.1 Configuration of the Internet-based online condition monitoring system. 13.2 Data-flow diagram of overall distributed condition monitoring software. 214 216 218 221 222 225 226 228 229 231 232 241 24 7 13.3 Data-flow diagram of data acquisition workstation module 1. 248 13.4 Data-flow diagram of data processing module 1.1. 248 13.5 Data-flow diagram of data acquisition module 1.2. 249 13.6 System entity-relationship diagram. 250 13.7 Module structure of the data acquisition workstation. 270 13.8 Module structure of the A&M workstation software.280 13.9 Data flowchart of the in-house developed DAQ driver. 285 13.10 Basic ODBC architecture. 286 13.11 Datagram-socket- based communication. 290 13.12 Stream-socket- based communication. 290 13.13 CGI- based communication mechanism. 294 13.14 Screen capture of real-time waveforms in spectral analysis. 298

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 39 121 128 129 129 130 130 130 133 175 194 195 xvii

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 13.10 Record strategy definition table 13.11 Server and A&M workstation properties table 13.12 Vibration variable real-time data table 13.13 Process variable real-time data table 13.14 Switch variable real-time data table 13.15 Medium-term historical database table for vibration variables 13.16 Detailed composition of variables 13.17 Record configuration (cluster) 13.18 Report configuration 13.19 Current machine alarm channel table 13.20 Back-end processing software status 195 210 211 212 236 237 251 261 262 263 264 264 265 265 266 266 267 267 268 268 269 270 271 271 272 272

LISTOF TABLES 13.21 Startup/shutdown status 13.22 Server properties 13.23 Server properties 13.24 Workstation communication properties (array) 13.25 Major modules of A&M workstation software 13.26 Measurement range 13.27 Frequency response 13.28 A/D resolution 13.29 Input impedance 13.30 Measurement accuracy 13.31 Priorities of some major system modules xix 272 272 280 281 281 283 283 284 284 284 298

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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

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

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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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

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

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

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

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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Part I - Design Principles of Modern Industrial Automation Systems

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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