DW Tech Tip Smart Machine Design
DW Tech Tip Smart Machine Design
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Inside
Smart Machine Industry 2
Reconfigurable Motion Control 7
Application Examples 9
Trend Watch 2014 10
Case Study 11
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Key Technologies
known as graphical system design, is adopted by leading
machine builders and uses NI LabVIEW graphical programming
and the LabVIEW reconfigurable I/O (RIO) architecture.
LabVIEW graphical programming helps leading machine
builders master increasing system complexity. Machine builders
can use LabVIEW to consolidate their development toolchain
and further streamline the design process with add-on modules
for motion control, machine vision, and control design and
simulation; features for machine prognostics and condition
monitoring; and extensive support for I/O hardware and
communication protocols.
The LabVIEW RIO architecture offers a hybrid approach: a
fully customizable off-the-shelf platform, with programmable
FPGAs, that provides access to a wide range of existing I/O
modules from NI and third-party vendors. Using the features
and IP provided through the LabVIEW FPGA Module, machine
builders can focus on the design and optimization of their
custom algorithms rather than spend weeks or months on
hardware design or use a third-party company to design yet
another application-specific black box embedded solution.
Custom I/O front ends and board-only versions based on the
same architecture provide an additional level of flexibility.
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Key Technologies
attempting to adapt a single-element solution to a problem that
the element is not well suited for. For example, a single FPGA
might handle a parallel task requiring low latency equally as well
as a large number of CPUs.
Although embedded system designs that feature multiple
processing elements have many advantages, they raise some
challenges when it comes to software development. The
specialized architectures of individual processing elements
and the fragmented set of tools and expertise required to
program them means they often require large design teams. For
example, FPGA programming commonly requires knowledge
of VHDL programminga skill that can require a significant
training investment, larger staff, or costly outsourcing.
Additionally, developing the software stack to support a
heterogeneous architecture is a considerable undertaking
that involves driver integration, board support, middleware
for interelement communication, I/O interface logic, and
more. System designers can address these challenges with
an integrated hardware and software platform composed of
a standard heterogeneous architecture, interchangeable I/O,
and high-level system design software. Building on knowledge
of the underlying hardware, high-level design tools abstract
both the system architecture and I/O during the development
process, improving productivity and
reducing the need for system designers to
manage low-level implementation details.
When developing embedded systems
based on heterogeneous architectures,
system designers can use high-level
system design tools that can abstract
With NI Single-Board RIO, customers can
combine a custom I/O board with anoff- the architectures of individual computing
the-shelf embedded board hosting the
elements, such as FPGAs, and provide
real-time processor and FPGA.
a unified programming model that can
help designers take advantage of the capabilities of different
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NI CompactRIO combines a
heterogenous computing architecture
with a wide range of I/O modules in a
compact andrugged form factor.
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by the
user. These
controllers
and drives
could be
optimized for
a very specific
purpose such
as driving a
CNC endmill
spindle or designed with the intent to be as generic as possible
to cover a wide variety of applications within or even across
industries. As long as operated within the designed use case,
these fixed-function controllers and drives are usually effective
choices for implementing an application. Customers can take
advantage of all the design work and feature definition, such as
advanced filtering, autotuning, test panels, diagnostic tools, and
a host of other features baked into the firmware, that went into
that product.
The problem with fixed-function controllers arises when
machine builders need to step outside the capabilities defined
by motion controller and drive firmware. These scenarios
become common as machines become more specialized
and increasingly sophisticated. A common requirement
seen in manufacturing applications is the synchronization
of I/O with motion data (most often position and sometimes
velocity or acceleration). The I/O types involved can vary
widely from application to application, as can the precision
and measurement rate. Simple measurement types like
digital triggering are in many fixed-function devices, given the
application requirement doesnt exceed the number of built-in
I/O channels. More complex measurement devices necessitate
the addition of a dedicated data acquisition system to handle
the rates and I/O types. The higher the data rate, the more
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Motion Control
difficult it is to adequately synchronize this acquisition
to motion data. Above 2 to 3 kHz, deterministic buses
like EtherCAT necessitate a powerful master controller
or special acquisition and data decimation that causes
problems. Above 10 kHZ, digital buses generally
start to become impractical. Dedicated trigger lines can still
be used between systems, but can be difficult to configure.
Inline processing, custom triggering of data for storage, and
a host of other desirable features in these machines become
the bottlenecks to implementation because of high effort or
complexity of implementation.
The alternative solution machine builders often turn to is
custom design. With a custom-built motion controller or drive,
machine builders can define exactly the behavior they want to
see out of the system. However, custom design is costly, timeconsuming, and has its own set of limitations. Alternatively, the
design and manufacturing can be outsourced to a third-party
company, but this approach is expensive and might expose
core IP that differentiates a machine from the competition.
To combine the full feature sets and performance of
fixed-function devices with the ability to customize them as
necessary, machine builders need a persistent framework that
can be developed along the lines of a fixed-function device
with lots of testing and iterative feature improvements. It should
be modular such that the user can completely define the
components of the system to meet specific and demanding
application needs.
The LabVIEW RIO architecture and LabVIEW NI SoftMotion
Module give machine builders the best of both worlds by
allowing them to program motion profiles with a high-level
motion API and connect to fixed-function smart drives. By
moving the critical motor control IP to the FPGA and using
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LabVIEW NI SoftMotion and AKD EtherCAT drives offer an ideal solution for
multiaxis motion control based on CompactRIO or PXI.
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Application Examples
The Changing Landscape for Machine Designers
Demands to reduce the design cycle and design more
complex machines with increased functionality have profoundly
changed the design approach. Design tools can now offer an
unprecedented level of flexibility and speed. Algorithms and
tools that were available only for high-end research a few years
ago are now breaking into the industrial market along with the
increased capabilities to cycle in the design between hardware
and software.
National Instruments provides software tools that seamlessly
interact with other design tools and can be used to deploy
to heterogeneous hardware platforms to quickly generate
prototypes and evaluate and modify different controller
configurations. NI also delivers the necessary path to migrate
all the code written in the prototyping phase to a more custom,
flexible platform without the hassle and cost associated with
rewriting code.
If you are pushing the edge with a high-performance machine
that needs to be better, faster, and smarter than previous
designs, you are probably running into cases where you need
advanced I/O, custom motion control, machine vision, accurate
timing and synchronization, and specialized control algorithms.
You are stepping outside the boundaries defined by traditional
devices. When you do so, a reconfigurable architecture
becomes the most effective way to implement these systems.
Wafer Processing
In semiconductor manufacturing,
there is a never-ending push for greater
efficiency and semiconductor material
yield. As circuit features shrink in size and
global price competition intensifies, wafer
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Electronics Manufacturing
Automated Welding
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Applications
Metal Forming Machine
Medical Devices
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RF/Wireless
Cyber-Physical Systems
Incorporating a range
of technologies from
software-defined radio
to revolutionize RF test
equipment.
Connecting IT
infrastructures and
analytic tools, such as
the cloud, with data
acquisition systems to
make faster decisions
on test data.
Developing systems
that continuously and
dynamically interact with
their environment through
coupling of distributed
computational and
physical components.
Models of Computation
Mobile Communication
Future of STEM
Integrating multiple
development
approaches into a single
solution.
Combining fundamental
approaches to
engineering into more
complex, integrated
systems to meet
changing industry needs.
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The Solution
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Case Study
along with the flexibility of LabVIEW. Our system monitors the
temperature and controls the suppression system that deploys
foam into a container if a fire is detected.
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The
transition from
prototyping to
deployment
was seamless
due to the
common hardware architecture shared between CompactRIO
and NI Single-Board RIO. Creating our final deployed solution
was simple because we were able to reuse our LabVIEW
prototyping code without any major coding changes. The fact
that NI provides hardware and software to quickly prototype
and deploy embedded systems was crucial for us. We are quite
sure we would not have hit our aggressive deadlines without NI
tools.
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This case study (this case study) was developed by a National Instruments (NI)
customer. THIS CASE STUDY IS PROVIDED AS IS WITHOUT WARRANTY OF ANY
KIND AND SUBJECT TO CERTAIN RESTRICTIONS AS MORE SPECIFICALLY SET
FORTH IN NI.COMS TERMS OF USE (http://ni.com/legal/termsofuse/unitedstates/us/)
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