ni.com Jam amie ie Sm Smith th Director of Embedded Systems - - PowerPoint PPT Presentation

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Jam amie ie Sm Smith th

Director of Embedded Systems and IIoT Strategic Partnerships National Instruments

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Topics

• Introduction to Big Analog Data
• Customer Case Studies (Firefly, London Underground, Innovari)
• IIoT Architecture & Edge System Architecture
• Systems & Data Management

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“ ”

…it is the IoT’s industrial applications, or the Industrial Internet, which may ultimately dwarf the consumer side in potential business and socioeconomic impacts.

— World Economic Forum Report

Impact of the IIoT

Unstructured Data Structured Data

Explosion of Data to Drive Insights and Optimize

2011 2020 2019 2018 2017 2016 2015 2014 2013 2010 2009 2008 2007 2006 2012

Big Analog Data

Sample Rate Vibration Signal Balance Gear Mesh Bearing

(fundamental + harmonics)

+ +

?

Computation

The Physical World

Infinite Data Any Bus Open Data

Analog Input Digital Output Digital Input Analog Output

FPGA CPU

Data Connectivity

I N T E R A C T C O M P U T E C O N N E C T

Smart Edge Device Architecture

Data Connectivity The Physical World

I N T E R A C T C O M P U T E C O N N E C T

Smart Power Generation

Edge Analysis Big Analog Data Smart Measurements Smart Test System Smart Grid Smart Machines Smart Power Generation

The Industrial Internet of Things

½

the Fuel

20%

Faster

2X

More Productive

30 Parallel Control Loops Analog/Digital I/O CAN Digital Outputs

HMI

EtherCAT Ethernet Encoders

• Prox. Sensors

Pressure Sensors J1939 Keypad Photo Sensors

Sensors, Engine, User Controls

Joystick Load Cell Steer-by-wire Device Optical Level Sensor John Deere Engine Electric Actuators Hydrostatic Transmission Hydraulic Valves

Harvester Control Systems

Servo Motion

Cellular Modem

Firefly ProSlab 155 System Diagram

Harvester

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100% productivity gains

Fire refly ly Equipme ipment nt - Inte telligen igent t Turf rf Har arveste ester

End-to-End Industrial IoT Solution

T h e E d g e

• >150 different

I/O types… one CompactRIO

Sensors/Actuators

Pressure Motor Actuator Encoder

Solution Advantage IT Infrastructure

Network & Data Explorer

• Remote monitoring to

improve reliability

• Remote software updates

Solution Advantage Data Acquisition, Control Systems, and IoT Gateway

Wired or Wireless

• Design freedom for complex control
• Brought domain experts closer to the

design

Solution Advantage

20% faster Half the fuel

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

London Underground—Victoria Line

213 million passenger rides per year 33 trains per hour 45 km of deep tube railway

Track Section Track Section Track Section Track Circuit

TX RX

Track Circuit

TX RX

Track Circuit

TX RX

• • •

TC TC TC TC

Isolation

• HMI

Server Database

45 km of track divided into 385 circuits 14 monitoring stations 128 channels RMS voltage and frequency per station

~32 TB per day

• • •

TC TC TC TC

Isolation

• • •

TC TC TC TC

Isolation

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39,000 customer hours regained

Lond ndon

• n Undergr

dergrou

• und

nd – Tra rack ck Circu cuit it Monitoring nitoring System stems

End-to-End Industrial IoT Solution

T h e E d g e

• Integration of

30-32 track circuits per cRIO

• Flexibility IO

Sensors/Actuators

Current Voltage Frequency

Solution Advantage IT Infrastructure

Network & Data Explorer

• Integration of track circuit

health into control room visual data

• Historical logging of result

Solution Advantage Data Acquisition, Control Systems, and IoT Gateway

Wired or Wireless

• Decimation of continuous data
• Track circuit health determined near

the sensor

• Rugged platform

Solution Advantage

Additional £350,000/year Improved Satisfaction

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

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Innovari – Grid id Load

• ad Balancing

lancing

End-to-End Industrial IoT Solution

T h e E d g e

Sensors/Actuators

Voltage Current Transformer Relay Control

• High-quality

measurements

• Custom I/O

Solution Advantage Data Acquisition and Control Systems

Wired or Wireless

• Time to market
• IP for power quality
• Lower design risk

Solution Advantage IT Infrastructure

Network & Data Explorer

• Grid wide load balancing
• Capacity generation

reporting

Solution Advantage

Easier to integrate renewables Utilities and customers both save money Provide power to more homes

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

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Conne nect ct to the e Ente terpri prise se, , Interne ernet, t, and d Cloud ud

End-to-End Industrial IoT Solution

Sensors/Actuators

Pressure Temperature Temperature Vibration Voltage Vibration Voltage RF Spectrum Thermal Cameras T h e E d g e

IT Infrastructure

Network & Data Explorer

Platform Software

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian Pumps Transformers Turbines

Things

Data Acquisition and Control Systems

Wired or Wireless

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Processor Real-Time or PC-Based FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

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IIoT Three Tier Architecture (IIC IIRA)

Edge Tier Platf tform rm Tier Ente terp rprise Tier

Proximity Network Access Network Service Network Edge Gate teway Data ta Flow Contro trol Flow Data ta Flow Contro trol Flow Serv rvice Platfo tform rm Data ta Transfo form rm Opera rati tions Analyti tics Domain Applicati tions Edge ge Gatew teway Device Management Data ta Aggre regati tion ... ... Rules & Contro trols

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Sensors sors, Communi municati cation

• ns, Contr

trol

• l and IIoT Gate

teway

Smart Edge Device Architecture

Data Acquisition and Control Systems

Processor + RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

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Advantages of Heterogeneous Processing Systems “Maybe a PC can’t do the job”

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Processors are everywhere.

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Time and Reliability

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<1 microsecond <1 millisecond seconds days hours minutes

3 ms 100 us 2 s 300 ms

½ day

3-5 minutes ~ 1 hour 9 months

weeks

1us

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<1 microsecond <1 millisecond seconds days hours minutes

3 ms 100 us 2 s 300 ms

½ day

3-5 minutes ~ 1 hour 9 months

weeks

1us

Real-Time 20 us - 1 ms Guaranteed ~1ms Crash - rare

FPGA Typical – 25 ns Guaranteed 25 ns Crash – never

PC’s 100ms – 2s Guaranteed - ? Crash - common

IT Infrastructure Sensors / Actuators Processing

… … … … … … …

<1 microsecond <1 millisecond seconds days hours minutes

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CPU

Reliability with Real-Time OS

Hardw rdware are Operating System IO Drivers Application Software Calc lcul ulatio tion

Outp tputs ts Syste tem m

• r Devic

ice Inputs

~25 us Response ponse

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CPU

Decision Making in Hardware - Reliability for safety control on FPGA.

FPGA GA Operating System IO Driver Application Software Calc lcul ulatio tion

Outp tputs ts Syste tem m

• r Devic

ice Inputs

~25 ns Response ponse

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Co-processing

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Easy sy to use se tools

• ls for
• r vision

ion algori

• rithm

thms

Controller

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Wired or Wireless

Development Workstation – Vision Assistant Plant

Tool LabVIEW

Vision on the Processor

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Perf rform rm high-sp spee eed d visio sion n algorithms gorithms

Parallel processing for Vision

Controller

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Wired or Wireless

Development Workstation – Vision Assistant Plant

Tool LabVIEW

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Host – 23.82 82 fps FPG PGA – 98 98 fps Original Convolution Threshold Morphology

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Host – 1.56 56 fps FPG PGA – 98 98 fps Original Convolution Threshold Morphology

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Advanced Diagnostics and Security

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Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater T h e E d g e

IT Infrastructure

Network & Data Explorer

Systems Services

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

MQTT

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Start art with th a model del of f the e cha hamber mber and d develop lop ctr trl l code de

Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater T h e E d g e

IT Infrastructure

Network & Data Explorer

Systems Services

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

MQTT

Wired or Wireless

Development Workstation

Model Ctrl

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Start art with th a model del of f the e cha hamber mber and d develop lop ctr trl l code de

Developing a temp-chamber control system

Wired or Wireless

Development Workstation

Model Ctrl

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Perf rform rm HiL testing sting of cont

• ntrol code

de

Developing a temp-chamber control system

Controller

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Wired or Wireless

Development Workstation

Model Ctrl

Plant

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Model

Ctrl

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Impleme ement nt contr ntrol

• l of actual

ctual temp mp cha hamber mber

Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

Ctrl

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Impleme ement nt contr ntrol

• l of actual

ctual temp mp cha hamber mber

Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater T h e E d g e

IT Infrastructure

Network & Data Explorer

Systems Services

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

MQTT

Ctrl

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Common mon fau aults lts

Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater T h e E d g e

IT Infrastructure

Network & Data Explorer

Systems Services

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

MQTT

Ctrl

• 1. Heater Breaks
• 2. Heater Gets Stuck in “On Setting”
• 3. Hacked – Spoofed Temp Reading

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Leverage rage the e model del for

• r diag

agnostics nostics and nd securit curity

Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater T h e E d g e

IT Infrastructure

Network & Data Explorer

Systems Services

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

MQTT

Ctrl

Model

• 1. Heater Breaks
• 2. Heater Gets Stuck in “On Setting”
• 3. Hacked – Spoofed Temp Reading

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Demo

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Impleme ement nt model del in FPGA GA higher gher relia iabi bility lity

Developing a temp-chamber control system

Sensors/Actuators

Temperature Fan Heater T h e E d g e

IT Infrastructure

Network & Data Explorer

Systems Services

• Data Analytics
• Systems Management
• User Authentication
• Data Management

CMMS Systems Data Historian

Things

Data Acquisition and Control Systems

Wired or Wireless

RTOS FPGA

Analog I/O Digital I/O Specialized I/O Custom I/O Bus Protocols

MQTT

Ctrl

Model

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Diagnostic Code

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Condition Monitoring

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Acceptable Operating Zone

Operating Time Machine Health Failure Predictive Maintenance

Preventative Maintenance

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Oak Ridge National Labs (ORNL): Software-defined Intelligent Grid Research Integration and Development platform (SI-GRID)

BATTERIES RESIDENTIAL LOAD EMULATION

SOLAR GENERATION SOURCE Disconnect Switch

MACHINE BASED (WIND) GENERATION SOURCE

Transformer (208V/24V)

PHYSICA CAL L MICROGRI RID: NI RIO FPGA BASED CONTROL OL SYSTEMS WITH LOCAL DIGITAL L TWINS REAL

• TI

TIME GRID SIMULA LATI TION ON: FPGA BASED LOW OW-LA LATE TENCY RECONFI FIGURAB ABLE LE SUPERCOM OMPUTE TER

CONTRO ROL VALUES UES PREDICT DICTE D VOLTAGE, AGE, CURRENT RENT

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Automatic Model Conversion to Reconfigurable FPGA Hardware

Models for power system including power electronics and electrodynamic models are automatically converted to ultra-high speed hardware accelerated implementation using graphical floating point high level synthesis.

HARD D CORE E DSPs (1520 PER FPGA) GA) FPGA A PROGRAMM RAMMABL ABLE LOGIC IC FABRIC BRIC PEER ER-TO TO-PE PEER ER COMMUNICAT MUNICATION ION

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ORNL Real-Time Power Grid Simulator – Benchmark Circuit

Power Grid Simulation System:

• 80 FPGAs
• 450 Peer-To-Peer Streams

Between FPGAs

• 1 Microsecond Simulation

Timestep

• 32 GB/s Data Computed

1 MHz Real-Time Grid Simulation:

• 2 Main Power Grids
• 80 Microgrids
• 80 Distribution Lines
• 160 3-Phase Inverters
• 160 Energy Storage

Converters

• 1280 IGBT/Diode Switches

SINGLE IGBT HALF-BRIDGE DATA (PHYSICAL MEASUREMENT vs. DIGITAL TWIN)

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Distributed Systems Management

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ni.com Host or Cent ntra ral l Serv rver NI Device ices Web b Dash shboar boards Systems Manager

NI Supplied Partner or End User Supplied 3rd Party

Data Viewer Custom Web App Core Services Tags and Health Monitoring Data Management Enterpri terprise se Custom Services

M E S S A G E B U S

OSISoft Pi Historian OPC Server 3rd Party Web Server Custom Gateway(s) Applications Customer APIs User Application Salt Minion Salt Master Systems Management Service

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Author Description

MyFile.tdms

UUT Type Test Fixture Sensor Info Units Procedure

LCD Brightness Cell Phone 1

TDMS File Format

• Single streaming binary file
• 3 levels of hierarchy for better
• rganization
• File, groups, and channels
• Customizable, descriptive

properties at each level

Property 1 Property n

Data Set (File)

Property 1 Property 2 Property 1 Property n Property n

Channel(s) Channel Group(s)

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Author Description

MyFile.tdms

UUT Type Test Fixture Sensor Info Units Procedure

LCD Brightness Cell Phone 1

TDMS File Format

• Single streaming binary file
• 3 levels of hierarchy for better
• rganization
• File, groups, and channels
• Customizable, descriptive

properties at each level

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Industrial Internet Consortium T estbeds

Time me Sensi nsitive ve Network

• rk

Testbed bed

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