Designing Real-Time Control Applications Using LabVIEW and CompactRIO. Developer Days 2009

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2 Designing Real-Time Control Applications Using LabVIEW and CompactRIO Developer Days 2009

3 Agenda CompactRIO Overview Technology Applications Real-Time Control Software Architecture Basic Process Control State-based Architectures Managing Multiple Tasks Fault and Error Handling Programming with LabVIEW FPGA Conclusion and Next Steps 3

4 NI CompactRIO Embedded Architecture Real-Time Processor Reconfigurable FPGA Extreme Ruggedness -40 to 70 C temperature range 50g shock, 5g vibration I/O Modules Low Power Consumption 9 to 35 VDC power, 7-10 W typical Real-Time Processor for deterministic, stand-alone operation, logging and analysis Reconfigurable FPGA for high-speed and custom I/O timing, triggering, control I/O Modules with built-in signal conditioning for connection to sensors/actuators 4

5 Reconfigurable I/O (RIO) Using LabVIEW to design hardware Replace custom circuitry with software-programmable FPGA logic High speed control (1 MHz digital / counter-timer, 200 khz motion control / analog PID) Dedicated logic in silicon for highest reliability Intelligent DAQ (custom timing, triggering, synchronization, counter/timers, PWM) Digital signal processing (decoding and processing industrial sensor signals)

6 LabVIEW Development with CompactRIO 1. Develop on Host CompactRIO Real-Time, FPGA Target 2. Download to Target 3. Deploy to run stand-alone or communicate over Ethernet with host 6

7 CompactRIO Applications Machine Control Packaging/Processing High-speed motion control, batch control, discrete control Heavy Machinery Control Real-time signal processing and control of power electronics, hydraulic systems Semiconductor/Biomed Custom motion and vision inspection, material handling Machine Monitoring Machine Condition Monitoring Bearing order analysis, lubrication monitoring, cooling, combustion Mobile/portable DSA, NVH Noise, vibration, harshness, dynamic signal analysis, acoustics Distributed Acquisition Central controller with distributed I/O nodes over Ethernet/wireless In-Vehicle Data Acquisition In-Vehicle Data Acquisition Automobiles, motorcycles, recreational vehicles, research aircraft, trains Engine and ECU test cells HIL testing of engines and engine controllers, sensor simulation using FPGA Rapid Control Prototyping Automotive/aerospace control prototyping 7

8 DEMO 1 Basic LabVIEW Real-Time Application Demo Setup crio 9074 Real-Time Controller and Chassis NI 9211 Thermocouple

9 Distributed System Manager Monitor systems on the network Manage published data Adds test panels to CompactRIO 9

10 I/O Modules I/O Modules CompactRIO Programming Paradigms LabVIEW Real-Time NI CompactRIO FPGA LabVIEW Real-Time I/O Variables NI Scan Engine I/O memory table RIO Scan Interface FPGA Host Interface LabVIEW FPGA VI 10

11 Real-Time Control Architecture Components Housekeeping Initialization Shutdown Control /Meas Tasks Fault Engine Machine Control Motion Control Machine Vision Data Logging Process Control High Speed DAQ Memory Table I/O Variables Shared Variables I/O and Communications Drivers TCP/UDP Shared Variables Deterministic Ethernet Fieldbus Comm Scan Interface Custom FPGA Code

12 Section 1: Basic Process Control Housekeeping Initialization Shutdown Control /Meas Tasks Fault Engine Machine Control Motion Control Machine Vision Data Logging Process Control High Speed DAQ Memory Table I/O Variables Shared Variables I/O and Communications Drivers TCP/UDP Shared Variables Deterministic Ethernet Fieldbus Comm Scan Interface Custom FPGA Code

13 Section I: Basic Process Control Component Responsibilities Initialization Housekeeping Control and Measurement Tasks Control and Meas Tasks Memory Table Shutdown Housekeeping IO and Comm Drivers Initialize variables Create programming structures Prepare log files etc. Access I/O Execute application logic Stop all tasks Set outputs to safe states Housekeeping 13

14 Section I: Basic Process Control DEMO PID Control Demo Setup crio 9074 Real-Time Controller and Chassis NI 9474 Digital Output NI 9411 Digital Input DC servo motor with encoder Encoder feedback Pulse Width Modulation

15 Section 2: State-based Architectures Initialization Housekeeping Control and Measurement Tasks Control and Meas Tasks Memory Table Shutdown Housekeeping IO and Comm Drivers 15

16 State Machines in LabVIEW While Loop Type Def. Enum Case Structure Shift Register 16

17 Managing Data in State Machines Type Def. Cluster constant Unbundle by Name 17

18 State Machine Transitions Use an enum in each state Use additional logic to select the next case to execute 18

19 Section 2: State-based Architectures DEMO State-based Process Control Demo Setup crio 9074 Real-Time Controller and Chassis NI 9474 Digital Output NI 9411 Digital Input DC servo motor with encoder Encoder feedback Pulse Width Modulation

20 LabVIEW Statechart Module Statecharts and state machines both contain the same basic concepts: States Transitions Statechart adds additional concepts: Hierarchy Concurrency Event-based paradigm Pseudostates & Connectors Based on the UML statechart diagram specification 20

21 Section 3: Managing Multiple Tasks Housekeeping Initialization Shutdown Control /Meas Tasks Fault Engine Machine Control Motion Control Machine Vision Data Logging Process Control High Speed DAQ Memory Table I/O Variables Shared Variables I/O and Communications Drivers TCP/UDP Shared Variables Deterministic Ethernet Fieldbus Comm Scan Interface Custom FPGA Code

22 Why Divide Code into Separate Tasks? Determinism - the ability to complete a task within a fixed amount of time If not separated, non-deterministic operations will cause time critical control tasks to miss execution deadlines (be late). Deterministic Operations Non-Deterministic Operations PID control Motion control Safety logic etc. File I/O Network or serial communication Memory allocation etc. 22

23 Add Tasks with Additional Timed Loops Provide deterministic scheduling for real-time tasks Variety of sources for loop timing Assign unique priorities to a maximum of 128 tasks Obtain timing feedback from loop Dynamically change loop timing Assign to particular CPU core on multicore systems 23

24 Considerations When Adding Tasks Priority Timing Deterministic Control Task Sharing data RT FIFO Shared Variable Non-deterministic Task 24

25 Section 3: Managing Multiple Tasks DEMO Adding a Data Logging Task Demo Setup crio 9074 Real-Time Controller and Chassis NI 9474 Digital Output NI 9411 Digital Input DC servo motor with encoder Encoder feedback Pulse Width Modulation

26 Section 4: Fault and Error Handling Housekeeping Initialization Shutdown Control /Meas Tasks Fault Engine Machine Control Motion Control Machine Vision Data Logging Process Control High Speed DAQ Memory Table I/O Variables Shared Variables I/O and Communications Drivers TCP/UDP Shared Variables Deterministic Ethernet Fieldbus Comm Scan Interface Custom FPGA Code

27 What is a Fault? NI Scan Engine errors I/O scan running late Hardware failed to initialize etc. Users can set faults I/O value out of range Processor usage too high Task ran late etc. E-Stops should be hardware-based 27

28 LabVIEW Real-Time Fault Engine NI Scan Engine error reporting tool View and clear in system manager Access programmatically with Fault VIs Get fault list Set fault Clear fault Clear all faults 28

29 Basic Fault Handler Logic Get fault list Fault logic Shut down? Communicate to other tasks Add fault handler task with additional timed loop Timing: Faster than control loop Priority: Just below control task(s), above logging and processing 29

30 Hardware-based Watchdog To protect against application hangs, you can use the real-time watchdog to reboot the controller All outputs will be set to default power-up states since you reboot Keep him happy Configure the watchdog for reboot and enable him If you don t call the WHACK VI for the duration of timeout then the controller will reboot 30

31 Section 4: Fault and Error Handling DEMO Implementing a Fault Handler Demo Setup crio 9074 Real-Time Controller and Chassis NI 9211 Thermocouple input NI 9474 Digital Output NI 9411 Digital Input DC servo motor with encoder Encoder feedback Pulse Width Modulation

32 Section 5: Programming with LabVIEW FPGA Housekeeping Initialization Shutdown Control /Meas Tasks Fault Engine Machine Control Motion Control Machine Vision Data Logging Process Control High Speed DAQ Memory Table IO Variables Shared Variables I/O and Communications Drivers TCP/UDP Shared Variables Deterministic Ethernet Fieldbus Comm Scan Interface Custom FPGA Code

33 I/O Modules I/O Modules CompactRIO Programming Paradigms LabVIEW Real-Time NI CompactRIO FPGA LabVIEW Real-Time I/O Variables NI Scan Engine I/O memory table RIO Scan Interface FPGA Host Interface LabVIEW FPGA VI 33

34 When to Use LabVIEW FPGA Waveform acquisition > 1kHz Custom timing (25ns resolution) Custom triggering Hardware based signal processing and analysis Highest performance Support for additional C Series Modules 34

35 Using LabVIEW FPGA with Scan Mode 1. Add FPGA to project 2. Drag modules to FPGA 3. Requires compile Scan mode modules FPGA mode modules 35

36 Adding the LabVIEW FPGA I/O Task Read/Write Control Open FPGA VI Reference Close FPGA VI Reference Add LabVIEW FPGA I/O task with additional timed loop Timing: Application dependent Priority: If not control, below fault handler 36

37 Section 5: Programming with LabVIEW FPGA DEMO High-speed DAQ and Signal Processing Using LabVIEW FPGA Demo Setup crio 9074 Real-Time Controller and Chassis NI 9474 Digital Output NI 9411 Digital Input NI 9233 Accelerometer DC servo motor with encoder and accelerometer Encoder feedback Pulse Width Modulation

38 Next Step Search Control Primer on ni.com Learn more National Instruments Customer Education LabVIEW and crio Development Fundamentals National Instruments Customer Education LabVIEW Real-Time Application Development National Instruments Customer Education LabVIEW FPGA 38

39 LabVIEW Learning Paths Advanced LabVIEW Advanced I: Large Application Development LabVIEW Object-Oriented Programming System Design Intermediate LabVIEW Intermediate I and II Specialty LabVIEW Real-Time Application Development CompactRIO Fundamentals and LabVIEW FPGA LabVIEW Instrument Control RF Fundamentals and RF Application Development LabVIEW Machine Vision and Image Processing LabVIEW DAQ and Signal Conditioning Foundation LabVIEW Basics I and II

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