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LabVIEW for Real-Time Control in Measurement and Automation LabVIEW RT and the RT Series Hardware Agenda Definitions PID control Fuzzy Logic control control Issues control Overview Acquire Data from process Analyze Determine needs Output Data to process Closed-Loop Control Data acquired to determine current state control system determines output needs No Feeback.
LabVIEW for Real-Time Control in Measurement and Automation LabVIEW RT and the RT Series Hardware Agenda Definitions PID control Fuzzy Logic control control Issues control Overview Acquire Data from process Analyze Determine needs Output Data to process Closed-Loop Control Data acquired to determine current state control system determines output needs No Feeback.
LabVIEW for Real-Time Control in Measurement and Automation LabVIEW RT and the RT Series Hardware Agenda Definitions PID control Fuzzy Logic control control Issues control Overview Acquire Data from process Analyze Determine needs Output Data to process Closed-Loop Control Data acquired to determine current state control system determines output needs No Feeback.
National Instruments LabVIEW RT and the RT Series Hardware Agenda Definitions PID Control Fuzzy Logic Control Control Issues Real-Time Control Control Overview Analyze Determine needs Output Data to process Open-Loop Control System determines output needs No Feeback Control Overview Acquire Data from process Analyze Determine needs Output Data to process Closed-Loop Control Data acquired to determine current state Control system determines output needs Feedback provided Control Overview Acquire Thermometer Analyze Temperature Controller Output Heater / AC turned on, off Temperature Example Data acquired from thermometer Controller determines temperature status (too high? Low?) Heater or AC turned on / off Control Terminology Terms: Process variable Setpoint Controller output Plant Examples: Temperature Desired temperature Heater voltage Furnace Acquire Single-point acquisition Allows fast control loops Acquire Data from process Analysis Analyze acquired points Use full range of LabVIEW functions Mean, RMS, FFT, Single-point versions of multiple-point functions Analyze Determine needs Analysis Functionality Array-Based Analysis 1. Acquire all points of data stream 2. Filter and analyze 3. Make decision 4. Generate report Point-by-Point Analysis 1. Acquire one point of data stream 2. Filter and analyze 3. Make decision 4. Generate report Demo: Single-point analysis 1- PointByPoint.vi Software only Analysis Analyze acquired points Determine proper output signal Simple Control PID Fuzzy Logic Analyze Determine needs How do you implement Control? Evaluate Error Proportionally Evaluate History Integrate error over time Evaluate dynamics Rate of change of error- derivative Analyze Determine needs PID Control Analyze Determine needs PID Parameters Proportional gain K c Integral gain K c /T i T i is the integral time constant or reset time Derivative gain K c *T d T d is the derivative time constant or rate time Analyze Determine needs PID Gains P Proportional gain K c The Sledgehammer Immediate controller response to setpoint change PV may not settle exactly on SP Demo: P only 2- Simple PID.vi DAQ, Simple Circuit + - + - Excitation Analog In 1 MOhm .153uF .153uF 1 MOhm 1 MOhm PID Gains PI Integral gain K c / T i Fine tuning Integrates error over time Overcomes offset from Proportional May cause overshoot, oscillation, and instability problems Demo: PI 2- Simple PID.vi DAQ, Simple Circuit + - + - Excitation Analog In PID Gains PID Derivative gain K c * T d Whoa Puts the reigns on PI control Prevents overshoot and oscillation Adds stability Demo: PID 2- Simple PID.vi DAQ, Simple Circuit + - + - Excitation Analog In PID Considerations Tuning Integrator Windup Varying Behaviors Manual / Auto switch Hold Value Loop Speed Analyze Determine needs PID Toolkit Autotuning Integrator Anti-windup Gain scheduling Switch Hold mode Tuning Integrator Windup Varying Behaviors Manual / Auto switch Hold Value Loop Speed Analyze Determine needs Demo: PID Toolkit 3- Toolkit PID DAQ, Simple Circuit + - + - Excitation Analog In Fuzzy Logic Dataflow Fuzzy Logic Control for LabVIEW Why is fuzzy logic important? Easy to implement an intuitive control strategy Better control of non-linear systems PID control is linear Fuzzy control is non-linear Analyze Determine needs Fuzzy Logic: Rule-Based Control Example If temperature is high, then heater voltage output should be low. Membership sets What is meant by high? Analyze Determine needs Fuzzy Sets Boolean (or two-valued) sets: Members belong to a set non-members do not Traditional Boolean values (on/off, 1/0) Fuzzy Sets: Partial membership to set allowed Values along continuum of 0 to 1 Analyze Determine needs Boolean Set High Body Temperature Temperature M e m b e r s h i p Analyze Determine needs Fuzzy Set High Body Temperature Temperature M e m b e r s h i p Analyze Determine needs Fuzzy Logic Control Demo: Fuzzy Logic 4- Fuzzy.vi Simple Circuit + - + - Excitation Analog In Fuzzy Logic and PID Combined IF AND THEN IF AND THEN IF AND THEN Rule base
Fuzzificatio n Fuzzy Inference Defuzzification
Process Fuzzy Controller Set Point Values Measur ed Values PID Command Variable P I D Fuzzy Logic Design Software Analyze Determine needs Demo: Fuzzy Logic Design 5- Fuzzy.vi Simple Circuit + - + - Excitation Analog In Control Concerns Autotuning Integrator Anti-windup Gain scheduling Switch Hold mode Tuning Integrator Windup Varying Behaviors Manual / Auto switch Hold Value Loop Speed Real-Time Real-Time Definitions Real-time means same time Real-time does NOT mean real fast Hard real-time - deadlines can not be missed Flight control Engine testing Soft real-time - missed deadline acceptable Temperature logging Banking More soft real-time applications than hard Output Data to process Real-Time Applications Real-Time OS General-Purpose OS Type Example Event Response Control temperature and provide safe shutdown in an emergency Control Monitor temperature, compare to desired temperature, initiate appropriate heating or cooling Data Acquisition Monitor temperature Operating Systems General-purpose OS High-priority tasks can be preempted by lower-priority tasks Many extraneous programs run in the background Screen savers, disk utilities, virus software, etc. Must service interrupts from peripheral devices Mouse, keyboard, etc. No determinism guaranteed Real-Time OS Scheduling system ensures that high-priority tasks execute first Difficult software integration Can be very expensive Typical Real-Time Applications Hardware Real-Time OS General OS Milliseconds Microseconds Mechanical Test Telecom Test Motion Control Hydraulic Control Business/POS Medical Network Control H/W Loop Simulation Dynamic Signal Analysis Industrial Automation Engine Test Internet 1000 100 10 1 100 50 10 1 Windows LabVIEW-RT LabVIEW-FPGA LabVIEW Development System Rapid development with graphical programming Built-in functionality for measurement and control applications Tight software and hardware integration LabVIEW Real-Time System Develop on Host Computer Download Processor I/O modules Execute on RT Target Target PXI - Compact PCI for Control Compact and modular form Ethernet connectivity Excellent networking protocols DataSocket VI Server TCP/IP RT Series PXI Embedded Controllers Up to 40 kHz PID loop rate I/O integration Headless operation Hard drive or CompactFlash Watchdog timer Processor PXI Backplane Memory DAQ Boards SCXI Modules Demo: PXI-RT 6- Audio.vi PXI Sound Demo LabVIEW RT Low cost RT controller Easy to configure Easy to program Reliable Full access to hard drive, cards, and some peripherals High loop speeds ~50 microseconds 132 Mb/s, 33 MHz, 32-bit Computer Bus PXI Trigger Bus P e r i p h e r a l 10 MHz CLK Star Trigger R e a l - T i m e
O S Local Bus PXI Timing and Triggering P e r i p h e r a l P e r i p h e r a l S t a r
T r i g g e r C o n t r o l l e r S y s t e m C o n t r o l l e r RT PXI Modular Components I/O connectivity Data acquisition Signal conditioning Dynamic signal acquisition Motion control Image acquisition Third party connectivity with NI-VISA Communication protocols Ethernet Serial GPIB CAN Chassis expansion through MXI-3 LabVIEW Real-Time Module Delivers reliable, deterministic performance Creates embedded, stand-alone applications Features built-in tools for control RT Series DAQ Board I/O options 16-bit multifunction 12-bit multifunction High-speed digital DAQ Daughter Board Local PCI Bus Memory Processor Processor Board Features Shared memory User-defined LEDs RT DAQ for Safety Shutdown Windows Computer R T
S e r i e s D A Q E
S e r i e s D A Q D S A B o a r d Turbo Charger Unit Under Test Safety Shutdown Signal Conditioning Signal Monitor Oil Pressure Oil Temperature Air Pressure Turbo Speed Vibration LV-FPGA More information - 2003 Distributed I/O with FieldPoint Rugged, reliable I/O Built-in isolation and signal conditioning Communication interfaces for Ethernet, serial, Foundation Fieldbus, and wireless networks Distributed monitoring, control, and datalogging applications FieldPoint for Industrial Control Embedded processor Watchdog timers Sensor and device diagnostics Isolation Programmable power-up output Hot swappable modules Demo: FP-RT 7- PID- Cycle Time.vi FP - Temperature RT Targets RT Series DAQ RT PXI RT FieldPoint Performance (PID loop rate) 1 kHz 40 kHz (max) < 1kHz Small Size Good Better Best I/O Variety Good Best Better I/O Count Low High High Rugged Better Best Distributed Better Best Remote System Explorer Configures system Installs or upgrades software Creates utility disks Lists installed software or hardware Develop Host Computer Download RT Target Host Computer Execute Default Communication Front Panel displays on Host Code executes on RT Engine RT Target Host Computer Demo: Default Communication 7- PID-Cycle Time.vi FP - Temperature Default Communication No additional programming Quick for debugging Insufficient for some cases Uses more network bandwidth than necessary Unable to save data for further analysis Need LabVIEW Real-Time development system on host LabVIEW Web Server FP-2000 Runs Web Server Clients view VI Front Panel in Internet Explorer Clients need run-time installed (free) Clients can request control of VI Deploy Custom Communication RT Target Host Computer Demo: DataSocket Communication 8- FP - Temperature Round Robin Scheduling Shop Manager (Scheduler) Mechanic (CPU) Normal Normal Normal Preemptive Scheduling Mechanic (CPU) Time Critical Normal Normal Normal Shop Manager (Scheduler) LabVIEW Real-Time Scheduler Combination of Round Robin and Preemptive Normal priority shares the CPU Time-critical priority releases CPU when finished or sleeping Assign priority to each VI Timing for Real-Time Applications Real-Time Terminology Determinismhow consistently a system is able to perform operations within a fixed time Jitteramount of time the actual loop cycle time varies from the desired cycle time Sleepperiod of time when the thread programmatically relinquishes control of the processor Objectives Maximize performance Maximize determinism Minimize jitter Jitter Diagram L o o p
I t e r a t i o n Loop Time Desired Loop Time 1 2 3 4 5 Jitter Software Wait until next millisecond multiple VI Millisecond loop rates (microsecond jitter) Hardware Sample or update clock of I/O board Microsecond loop rates (nanosecond jitter) Timing Strategies HW Clock AI Scan Software Timing Diagram L o o p
I t e r a t i o n Time PID AO 1 s jitter AI SW Sleep 2 3 4 5 Desired Loop Time (ms) AI sampled AO written AI Hardware Timing Diagram PID AO 1 AI HW Sleep 2 3 4 5 L o o p
I t e r a t i o n Time ns jitter Desired Loop Time ( s) AI sampled AO written Synchronized I/O Timing Diagram PID AO 1 AI HW Sleep 2 3 4 5 L o o p
I t e r a t i o n Time ns jitter Desired Loop Time ( s) AI sampled AO written Demo: Jitter 9- Jitter Test.vi NI-Scope PXI - Scope Networked Real-Time Application FieldPoint Development Machine GPIB Web Viewers PC-Based Instrument Serial PXI PLC Internet Conclusion More Information: 2002 National Instruments Catalog www.ni.com zone.ni.com www.daqman.com Steve.summers@ni.com Steve.aposhian@ni.com