A Smart Transducer Interface for Sensors and Actuators Tether-free Technologies and E-Manufacturing Workshop Milwaukee, WI October 1-2, 2001 Kang Lee Sensor Development and Application Group Manufacturing Engineering Laboratory National Institute of Standards and Technology United States Department of Commerce
Outline Introduction A smart sensor model Why networking smart sensors? What is IEEE 1451? Industry/government collaboration Relationship of IEEE 1451 with MIMOSA Relationship of IEEE 1451 with OSA- CBM Expected benefits of IEEE 1451 Wireless sensor interface standards activities
Introduction Smart features integrated into sensors and actuators. Increasing uses of digital communication and networked configurations for connecting sensors and actuators. The trend is moving toward distributed sensing and distributed control architecture. Networked sensor technology applied to commercial and consumer applications aerospace and automotive industrial automation process control smart buildings and homes
Example Needs in Government / Industry Networked sensors are needed Example 1: U.S. Navy needs tens of thousands of networked sensors per vessel to enhance automation because of the reducedmanning program. Example 2: Boeing needs to network hundreds of sensors to monitor and characterize airplane wing performance.
Barriers: For Sensor Manufacturers Large number of different networks to support. Lack of network software know-how and support. Significant sensor interface software development for each supported network. Lack of a standardized sensor interface.
A Smart Sensor Model Functional capability of a smart sensor: integrated intelligence closer to the point of measurement and control basic computation capability capability to communicate data and information in a standardized digital format Network Sensor Signal conditioning and analog-to-digital conversion Application algorithm Network communication
A Networked Sensor System - Functional partitioning into modules for implementation Network Sensor Signal conditioning and analog-to-digital conversion Application algorithm Network communication Smart Transducer Interface Module (STIM) Network Capable Application Processor (NCAP)
A Networked Sensor System - Ultimately all functions integrated into a single unit Network Sensor Signal conditioning and analog-to-digital conversion Application algorithm Network communication Integrated Networked Smart Sensor
Why Networking Smart Sensors? Networking smart sensors enable features not readily available with traditional sensors: significantly lowers the total system cost by simplified wiring time aware for time-stamping function local networking to share measurement and control provide Internet connectivity, thus global or anywhere, access of sensor information
What is IEEE 1451? A set of IEEE standards aimed to: simplify transducer (sensor or actuator) connectivity. For example: plug and play. It is developed as: an open, industry consensus interface standard. It s purposes are to: provide a general transducer data, control, timing, configuration and calibration model provide a set of common interfaces for connecting sensors and actuators to instruments, and control and field networks.
What Standards are being developed? IEEE Std 1451.1-1999, Network Capable Application Processor (NCAP) Information Model for smart transducers -- Published standard. IEEE Std 1451.2-1997, Transducer to Microprocessor Communication Protocols and Transducer Electronic Data Sheet (TEDS) Formats -- Published standard. IEEE P1451.3, Digital Communication and Transducer Electronic Data Sheet (TEDS) Formats for Distributed Multidrop Systems -- Being developed. IEEE P1451.4, Mixed-mode Communication Protocols and Transducer Electronic Data Sheet (TEDS) Formats -- Being developed.
A Networked Sensor System - Functional Partitioning Network Sensor Signal conditioning and analog-to-digital conversion Application algorithm Network communication Smart Transducer Interface Module (STIM) Network Capable Application Processor (NCAP)
IEEE 1451 Smart Transducer Interface System Block Diagram Smart Transducer Interface Module (STIM) 1451.2 Interface Transducer Independent Interface (TII) Any Arbitrary Network Physical world XDCR XDCR XDCR XDCR ADC DAC DI/O? Transducer Electronic Data Sheet Address Logic Network- Capable Application Processor (NCAP) with 1451.1 Object Model
Conceptual View of an IEEE 1451.1 NCAP IEEE 1451.1 NCAP uses a backplane or card cage concept Network communication viewed through the NCAP as port Function block application code is plugged in as needed Physical transducers are mapped into the NCAP using transducer block objects via the IEEE 1451.2 hardware interface NCAP centralizes all system and communications facilities Network Ports NCAP Block Transducer Block Function Block Physical Transducer Transducer Interface (for example: 1451.2) Communication Interface Client / Server and Publish / Subscribe Function Block Contains Other Software Objects (i.e., Parameters, Actions, and Files)
IEEE 1451.1 Networked Smart Transducer Model Any Arbitrary Network Network Hardware Network Protocol Transducer Software I/O Port Hardware Application Software (Function Blocks) Transducers NCAP Block Server Objects Dispatch, Ports Network Protocol Logical Interface Specification NCAP Transducer Blocks Transducer Logical Interface Specification Transducer Hardware Interface Specification ( e.g. IEEE 1451.2)
IEEE 1451.2 Transducer Independent Interface (TII) Line Driven Function by DIN NCAP Address and data transport from NCAP to STIM DOUT STIM Data transport from STIM to NCAP DCLK NCAP Positive-going edge latches data on both DIN and DOUT NIOE NCAP Signals that the data transport is active and delimits data transport framing. NTRIG NCAP Performs triggering function NACK STIM This signal serves two functions: 1. trigger acknowledge 2. data transport acknowledge NINT STIM Used by the STIM to request service from the NCAP NSDET STIM Used by the NCAP to detect the presence of a STIM POWER NCAP Nominal 5 V power supply COMMON NCAP Signal common or ground STIM with TEDS TII NCAP
IEEE 1451.2 Transducer Electronic Data Sheet (TEDS) Meta-TEDS Data structure related information version number number of implemented channels future extension key... Identification related information manufacturer s identification model number serial number revision number date code product description...
IEEE 1451.2 Transducer Electronic Data Sheet (TEDS) - cont d Channel TEDS Transducer related information lower range limit upper range limit physical unit unit warm-up time uncertainty self test key... Data Converter related information channel data model channel data repetitions channel update time channel read setup time channel write setup time data clock frequency channel sampling period trigger accuracy
IEEE 1451.2 Transducer Electronic Data Sheet (TEDS) - cont d Calibration TEDS Data structure related information Calibration TEDS length Calibration related information last calibration date-time calibration interval number of correction input channels multinomial coefficient. Data integrity information checksum for calibration TEDS
IEEE P1451.3 Distributed Multidrop System Synchronously reads large arrays of sensors at high speeds in a parallel transducer bus setting with multidrop connectivity for TBIM, in which sensors and/or actuators are connected. Supports sensors with bandwidth requirements to several hundred kilohertz and TEDS with XML format. Network Transducer Bus Controller (TBC) Signal & Power Return Network Capable Aplication Processor (NCAP) Transducer Bus Interface Module (TBIM) Transducer Bus Interface Module (TBIM) Transducer Bus Interface Module (TBIM)
IEEE P1451.4 Mixed-mode Transducer and Interface Simple, low-cost connectivity (2-4 wires) for analog sensors with very compact TEDS, as small as 64 bits. Mixed-mode interface supports a digital interface to read and write the TEDS, and an analog interface to make measurements with instruments. Network Capable Application Processor (NCAP) with IEEE 1451.4 Mixed-Mode Interface IEEE 1451.4 Mixed-Mode Interface(s) IEEE 1451.4 Mixed-Mode Transducer Network Node(s) Transducer Electronic Data Sheet (TEDS)..... Transducer(s) Energy Conversion
IEEE 1451 Family Member Independence Network X Library P1451.1 API Network Capable Application Processor (NCAP) 1451.2 P1451.3 Smart Transducer Interface Module 1451.x are designed to work with each other. However, they can also stand on their own. Network Smart Transducer Object Model P1451.4 T-Block, Transducer I/O API Transducer Bus Interface Module Mixed-Mode Transducer 1451.1 can work without any 1451.x hardware interface. 1451.x can be used without 1451.1, but software with similar functionality must provide sensor data / information to reach network.
Industry/Government Collaboration Control network providers participated in preliminary 1451.2 standards specification verification. DeviceNet by Allen-Bradley LonWorks by Echelon Smart Distributed System (SDS) by Honeywell Microswitch Ethernet by Hewlett-Packard
Interfacing IEEE 1451 to MIMOSA Architecture STEP Control Systems OPC MIMOSA OPC Gateway MIMOSA Equipment Operations and Maintenance Decision Support Enterprise Resource Planning -- ERP OAGI MIMOSA Condition Measuring Systems Digital Mixed Analog IEEE 1451 MIMOSA Firewire IEEE P1451.4 On-Line Transducers Off-Line Data Collectors Modem Disc MIMOSA MIMOSA - Machinery Information Management Open Systems Alliance CMMS - Computerized Maintenance Management System EAM - Enterprise Asset Management STEP - Standard for Exchange of Product Model Data OPC - OLE for Process Control OAG - Open Applications Group MIMOSA OAGI EAM / CMMS Systems
MIMOSA Tech-File Architecture for CBM Information Exchange MIMOSA Tech-File Architecture MED Files Vendor A MIMOSA Tech-File Export for Service Seg / Assets Application MIMOSA Tech-FILE Export for Service Segments / Assets Specification Vendor B MIMOSA Tech-File Import for Service Seg / Assets Application Tech-FILE Import for Service Segments / Assets Specification MIMOSA Export Data (MED) File Specification MIMOSA Site Zero Database Reference Entries MIMOSA Common Relational Information Schema (CRIS) Vendor A Supplied Vendor B Supplied MIMOSA Supplied Vendor A Database Vendor B Database Technologies VIB (Vibration/Sound) SAMPLE (Fluid/Gas/Solid Sampling) THERM (Thermography( Thermography) TREND (Trends/Alarms) DIAG (Diagnostics) REL (Reliability Data) ASSET (Asset Management) WORK (Work Management) Diagram courtesy of MIMOSA
Open System Architecture (OSA) for Condition Based Maintenance (CBM) Presentation Decision support Prognostics Health assessment Condition monitoring Signal processing Sensor module/ data acquisition
Major components of the OSA-CBM architecture and its links to MIMOSA and IEEE standards Diagram courtesy of OSA-CBM
IEEE 1451 Enables Plug and Play of Transducers to Networks Any Network 1451 NCAPs 1451-compatible transducer 1451-compatible transducer
IEEE 1451 Enables Plug and Play of Transducers to instruments 1451-compatible Instrument or Data Acquisition System Example: P1451.4 transducer demonstration (acceleration, load cell, position, and temperature sensors, etc) 1451-compatible Transducer... 1451-compatible Transducer
Web-based Distributed and Remote Monitoring and Control Monitoring Station Network NCAP #1 NCAP #2 NCAP #3 Actuator STIM Sensor STIM Sensor STIM Actuator STIM Distributed Control Remote Sensing Remote Actuating
Machine Condition Monitoring in the Shop Temperature sensors monitor spindle motors, bearings, axis drive motors. Allow monitoring of sensors over the Internet via any common web browser. NCAP & STIM in each box
NIST 1451.1 Platform-Independent Wireless Interface Demonstration Targets at the closed-loop control industrial automation area: Three hardware platforms representing various NCAPs: Windows NT Laptop Open-source Unix based Intel x86 embedded single board computer (SBC) Linux based Intel StrongARM SBC All connected via an IEEE 802.11b Wireless Access Point and an IEEE 802.3 Wired Ethernet Hub based subnetwork Each NCAP is executing a particular transducer application, i.e., temperature, pressure, and actuator applications Each transducer application is linked with the NIST-developed 1451.1 library and open-source Adaptive Communication Environment (ACE) Use a Java-based IEEE 1451.1 NCAP Configuration Tool to connect, configure, control and monitor the NCAPs in our demonstration control network
1451.1 Demonstration Setup IEEE 1451.1 Java NCAP 802.11 Wireless Access Point Linux Intel StrongARM Embedded System Activities 802.3 Ethernet Wired HUB 1. Discovery 2. Connection 3. Configuration 4. Execution Open-source Unix Intel x86 Embedded System Configuration Application IEEE 1451.1 Temperature Transducer Application
Benefits of 1451 A common transducer interface will Lower the cost to design sensors and actuators to a set of standardized digital interfaces. Lower overall cost to make networked sensors. Having TEDS with the sensors will Enable self-description of sensors and actuators. Eliminate error-prone, manual configuration Provide easy self-documentation. Simplify field installation, upgrade, and maintenance of sensors by simply plug and play devices to instruments and networks.
Benefits of 1451- Cont d System integrators Self-documenting of hardware and software Sensor systems - easier to install, maintain, modify and upgrade Easy and quick transducer replacement (plug and play) Mean to store installation details (in the TEDS) Choose sensors based on merit Application software developers Standard transducer model for control and data Facilitate distributed measurement and control applications Support for multiple languages - good for international developers
Benefits of 1451- Cont d Sensor Manufacturers Standard physical interfaces One set of standard interfaces to design and support Multi-level products developed based on TEDS. Standard calibration specification and data format End Users Sensors are simple to use basically just plug and play Based on the TEDS, software can automatically provide: physical units readings with significant digits as defined in the TEDS complete transducer specifications installation details such as instruction, ID, & location of the sensor
Wireless Sensor Interfaces Exploring a wireless interface for sensors and actuators within the framework of IEEE 1451 Conducted the first wireless sensing workshop June 4, 2001 Explored industry need and interest in wireless sensor interface standard Conduct a second wireless sensing workshop - October 4, 2001 Explore technologies for a wireless sensor interface and standardization approach Participating in the Bluetooth Industrial Automation (IA) Study Group To set up an IA Working Group To address the need for a wireless sensor interface for conditionbased monitoring and industrial automation To explore a wireless Bluetooth interface for sensors for industrial automation
For More Information Please contact: Kang Lee? by phone: (301) 975-6604,? by e-mail: kang.lee@nist.gov Visit IEEE 1451 web site: http://ieee1451.nist.gov