The Central Advanced Research and Engineering Institute at Hyundai Motor Company develops future mobility technologies. Rather than provide conventional vehicle products to customers, this research center creates new mobility devices with a wide range of speeds for a variety of people, including the elderly and the disabled. As our society ages, there is a greater need for systems that can aid mobility. Thus, we are developing wearable exoskeleton robots with NI embedded controllers for the elderly and patients with spinal cord injuries to use.
Developing a system that can handle complex control algorithms to capture data remotely from various sensors simultaneously and perform real-time control of multiple actuators for a wearable robotics device for walking assistance.
While on-site in Pavlodar, Kazakhstan, the DAQRI team of Business Development and Solutions Architecture personnel worked closely with KSP Steel’s production leadership to understand the steel production process, operational challenges, and worker pain points.
Widely used across many industries, Automated Guided Vehicles (AGV) have been scooting around factory floors for decades. Thanks to evolving technologies like sensors, wireless networks and automatic control technologies, their guidance methods and physical dimensions continue to evolve and now small lightweight trackless AGV are being rolled out.
An American AGV System Integrator (SI) was designing a Laser Guided Vehicle (LGV) for a material handling system in an automotive assembly plant. Since the plant’s existing AGV system used an expensive PLC-based control system there weren’t enough functions to meet the new control requirements, the company decided to upgrade and shift to a compact PC-based PAC control system ideal for the new compact vehicle design, capable of integrating with upper management systems using a single software application to replace the original two software applications.
A medical product company needed to install 230 thin client PCs across four manufacturing plants. Thin clients have been used in offices for many years, but their introduction onto the factory floor has been slow. A thin client network consists of a management computer in a secure, air-conditioned room with back up UPS, whilst on the factory floor there are a number of simple computers which are used to connect to the management computer, thereby removing the need to install individual operating systems and applications on each of the clients whilst also ensuing that there is only one point of failure.
The company was looking for a network architecture that would have the lowest maintenance costs and the quickest deployment time. To meet all these needs, each of these sites would have approximately 50 thin clients installed on the factory floor and these would then be connected to a central server located elsewhere on the site. This leaves only one point of maintenance for software updates, security patches and rules for what applications are allowed to run on the thin clients.
Water pumping, treatment and conveyance are among the largest energy and cost outlays for many local and regional municipalities. Electricity time-of-use rates and peak pricing tariffs are driving those costs even higher. This case study describes how Monterey Regional Water Pollution Control Agency (MRWPCA) implemented a process data monitoring and control solution in order to analyze and optimize energy use, reduce deployment costs and save operational expenses.
Naftamatika was looking to develop an oil well pump control system which could optimize oil well operation using only sensors installed on surface equipment.
As energy and operational efficiencies became critical to business operations, the telecom giant could no longer rely on its existing system to draw opportunities for energy savings and operational efficiency. The old system was limited to time-clock control, and had no intelligence on occupancy or building behavior. It was time to change the defunct lighting contactor based control system in both facilities
Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.
• Enhance safety for trams and passengers
• Deliver an innovative passenger experience
• Improve operational efficiency with better insight
Using the LabVIEW RIO platform, including a CompactRIO embedded system and a real-time controller with an FPGA control architecture provided by Single-Board RIO, to acquire data from various sensors and control peripheral units, high-speed communication devices, and actuators; and using LabVIEW software to acquire reliable data by conducting real-time analysis and applying various robot control algorithms to dramatically reduce development time.
Employing DAQRI SMART HELMET™ and visual markers at process-observation points, KSP Steel engineers could access two new capabilities.
1. Just-in-place AR data visualization: Workers could safely access necessary information at the point of need, without wasted travel time or an interruption of situational awareness.
2. Portable Process Data: Workers can select an AR data visualization for a given observation point and pin it to their AR display, independent of the unique marker. This decouples the dependence on installed physical infrastructure and allows the user to safely take information with them, providing exponential improvements in process flexibility.
The client had several requirements for this project. Not only did the new hardware have to be small enough and robust enough to survive in the harsh factory conditions, it was also essential that there wouldn’t be any breakdown in communication between the LGV and the control room.
To ensure this stability, the SI used industrial grade wireless devices with wider network coverage and higher power output. It was also required that any system provided to the SI would be able to support their bespoke version of Linux (Debian Wheezy X64).
Inside the LGV, an APAX-5580Control IPC with three modules (APAX-5490, APAX-5046, APAX-5040) was connected to the motion controller and safety relay. To wirelessly communicate to the control site and EKI-5525 and EKI-6331AN were connected to the APAX-5580. An IDS-3110 touchscreen monitor was attached to the exterior of the LGV.
The APAX-5580 combines the capabilities of PLC and PC but also is a PC-based open control platform to provide industrial computing performance and integrate a variety of I/O modules with ease. Featuring a fanless, low power, ultra-compact and cable-free connection makes it be particularly suitable for the AGV automation control applications which require high stability in limited space. To protect the operating system and its data, the APAX-5580 also includes an industrial-grade mSATA SSD with excellent anti-shock and anti-vibration properties. In the event of system problem the PAC also includes a SD card one key recovery function which lets users quickly return the system to the default factory settings. It’s also an application ready platform for embedded applications. Regardless of what the customers’ applications require, users can fully utilize itsrich I/O interfaces to connect a wide range of peripheral devices such as digital/analog signals, Ethernet network, computer monitor, memory card, etc. Plus, it can support multiple operating systems and drivers to shorten the development time of System Integrators.
To communicate with the control station the LGV also includes a small EKI-5525 5-port Fast Ethernet ProView Switch and an EKI-6331AN IEEE 802.11 a/n Wi-Fi AP/CPE wireless module. For users to help communicate directly with the LGV an IDS-3110 10.4” industrial-grade TFT LCD touch screen. By adopting ultra-thin and non-frame design, the monitor perfectly fits with the compact AGV embedded applications.
In the Control Site, an EKI-7710E Managed switch is responsible for sending signals to EKI-6311’s spread throughout the site. The EKI-7710 is an All-in-One managed redundant switch not only provides network redundancy in the car assembly factory but also has high output power for the reliable coverage and data throughput and 2x2 MIMO (Multiple Input Multiple Output) to optimize data transmission, as well as supporting wide temperature range (-20~70°C) with IP55 protection.
o meet the customer's requirements, Advantech's ThinManager ready hardware, consisting of the UNO-2053GL, ACP firmware and ThinManager software was presented. This deployment required the installation of ThinManager and HMI software on the server only, and the UNO-2053GL acted as a thin Client on the plant floor. 230 UNO-2053GL with AMD Geode™ LX800 processors, were installed across the four sites. The UNO-2053GL has no operating system or storage installed; each time the server boots, ThinManager sends the control software to the UNO-2053GL over the network and it then runs the small Linux operating system in RAM. The UNO-2053GL with an operating temperature range of -10 ~ 55°C (14 ~ 131°F) has been designed specifically for harsh industrial environments, and its rugged aluminum chassis protects the fanless and cableless design from the rigors of the factory floor. To guard against network failure, each UNO-2053GL has dual LAN ports that will automatically switch should one go down; thus, data will be protected and successfully transferred and stored on the management server. The management server is stored in a separate air conditioned room with UPS systems and a back-up server. On the factory floor, each UNO-2053GL is connected to a flat panel such as the IP65 compliant 15” FPM-3151G for onsite management.
Engineers determined that MRWPCA has the potential for additional peak power reductions by monitoring and controlling “time of use” (TOU) power requirements at the plant. Savings would come in part from qualifying for alternative PG&E rate structures, leveraging the use of the solar installation and carefully controlling monthly peak power demand. The plant set a goal to maintain peak loads below 500 kW to qualify for a lower electricity tariff that would minimize monthly costs.
These energy management goals required the ability to closely monitor and analyze a massive amount of new real-time data from twenty individual pumps and plant processes, with the ability to control discretionary lighting loads. In order to facilitate these goals, MRWPCA chose and installed a new energy and demand monitoring system.
The MRWPCA energy monitoring and demand management system was developed through a cooperative effort with MC Engineering, Inc., a California-based engineering consulting firm, and Candi Controls, which provides a cloud-based platform for machine-to-machine (M2M) data monitoring and control. MC Engineering specializes in identifying efficiency gains for water and wastewater utilities by leveraging technology and real-time data to develop projects that are funded from resulting efficiency gains and related savings. Candi Controls specializes in cross-platform, device- and protocol-agnostic communications. The company also has a suite of “PowerTools” user-interface templates which leverage its M2M platform, one of which was used to cost-effectively create a unique MRWPCA mobile and browser app.
Water treatment systems analysts began the project by obtaining in-depth knowledge of plant operations, conducting a facility audit and targeting strategic loads for monitoring. Low-cost energy monitors were then installed at strategic locations throughout the plant to meter instantaneous power usage. The data is encrypted and streamed via a local network to a hosted cloud service for archiving and processing. Additional network-based control switches were installed to manage industrial lighting during high-use periods if required to help keep peak load below the threshold goal.
By monitoring large loads that have some degree of operator discretionary control, an optimal time-of-use strategy and target usage peak was to be maintained. The data and controls are managed through a software Application Programmer Interface (API) and presented to operators through a secure web-based graphical interface on laptops, computer screens and portable Apple iPad tablets. The app includes a Facility Overview page to provide staff with at-a-glance real time power data.
The Naftamatika WellSim rod pump controller is highly effective, with hardware specifications far exceeding all modern analogue pump controllers.
Ovak Technologies developed the software upon technical specification of Naftamatika company. The Naftamatika WellSim controller, based on the NI SingleBoard RIO platform, was programmed using the LabVIEW Real-Time Module and LabVIEW FPGA Module. LabVIEW was chosen because it is easy to use and significantly faster to develop a complicated application with a user-friendly GUI. LabVIEW provides a platform to easily develop and change algorithms.
In addition to rod pump control functions, the Naftamatika WellSim controls and monitors the whole system. It provides a complete well simulation based on data obtained from the single universal integrated load and position sensors. This approach is very useful in monitoring well parameters and provides ample opportunities for real-time downhole equipment diagnostics. Such a system is necessary due to oil reserve exhaustion, high cost electric power, and the desire for oil companies to lower the cost of well maintenance and increase labor efficiency.
Using the controller, the user can manage the well in manual or automatic mode. Automatic control uses an improved algorithm based on this well model, which is how we achieve the highest accuracy, parameter calculation stability, and maximum pumping unit operating reliability. The controller supports the Modbus Remote Terminal Unit protocol and interacts with XSPOC and other supervisory control and data acquisition (SCADA) systems.
An accelerometer in a weatherproof enclosure takes accurate position measurements on the polished rod (not the modeled position). Internal electronics provide signal conditioning necessary for accurate data acquisition. The load cell sensor is mounted on polished rod. The sensor works on Wheatstone bridge principle with a temperature compensation. Load measurement accuracy is 0.25 percent, and load measurements range from 0 to 22,500 kg/50,000 lb.
- NI Single-Board RIO
- LabVIEW Developer Suite
- LabVIEW Real-Time Module
- LabVIEW FPGA Module
- Modbus Library for LabVIEW
Empowered by ControlScope’s open standards-based wireless mesh network, the lighting fixtures, occupancy sensors, and wireless switches have the ability to communicate wirelessly with each other and the ControlScope system. The ControlScope network provides the platform for JLL to centrally configure and manage lighting zones throughout the buildings, and specify lighting profiles to meet each floor tenants’ lighting needs and to maximize energy and operational savings. The different lighting zones are correlated to the occupancy sensors for occupancy sensing control is the most effective strategy.
From a standard Web browser, JLL can log into the ControlScope Manager console to:
• Dynamically tailor lighting profiles for each lighting zone
• Monitor and report energy usage in real time
• Discover opportunities to deepen energy and operational savings
Protocol Conversion and Front-end Data Processing
The data collected by a typical unmanned weather station includes temperature, rainfall and snow accumulation, air pressure, humidity, and ultraviolet intensity. One of the tasks that the UC-7420 unit must handle is protocol conversion, since there is no guarantee that the devices collecting the weather data all use the same protocol. In addition, the UC-7420 can be used to do preliminary data processing before downloading data to the central computer. MOXA's UC-7420 is ideally suited for these tasks, since the user can easily embed a C program that is custom written for the devices used at the station. If future changes involve adding or removing devices, the programmer simply needs to modify the C code, recompile it, and then download the executable program over the network to the UC-7420 unit.
Connecting to the Network and the Internet
In addition to being programmable, the UC-7420 also offers users an array of connection options. To begin with, data entering the serial ports from attached sensors can be processed and then forwarded through one or both of the dual Ethernet ports to the LAN. One of the serial ports can also be connected to a V.90 or GPRS modem for PPP connections, and a PCMCIA port is available for installing a wireless LAN card for 802.11b/g networks. By including multiple connection options in the UC-7420's design, user's gain the flexibility needed to connect from virtually anywhere. Combinations of connection types can also be used to provide redundancy. For example, if unavoidable network problems cause an interruption in service, the user can connect by modem.
CompactFlash Storage Space
One of the dilemmas faced when creating a "small" computer is how to provide users with adequate storage space. For unmanned applications, it is best if the storage device does not contain moving parts. Although hard drives may seem to last forever for day-to-day use, we cannot make this assumption for continuous use at remote locations. The UC-7420 overcomes this problem by providing a CompactFlash slot. If needed, flash memory cards with storage capacity of up to several gigabytes can be used to store data until it is convenient to transfer the data to a central computer.
• Built on the existing Cisco network as its high-availability platform
• Deployed Wi-Fi and sensors on city trams connected to the network
• Used Cisco Industrial Ethernet to connect stations, ticketing machines, and digital displays
Hyundai Motor Company
KSP Steel, the first Kazakhstan Company producing steel seamless pipes for oil and gas sector, was founded in early 2007. Republic of Kazakhstan President Nursultan Nazarbayev attended the official opening of KSP Steel’s plant in the city of Pavlodar in December 2007. The total area of the company production facilities amounts to approximately 133 ha. Over 7,500 well-trained specialists work there. The company’s head office in Almaty coordinates the operation of the plant.
An American AGV System Integrator (SI)
A medical product company
The Monterey Regional Water Pollution Control Agency (MRWPCA) operates a regional wastewater treatment plant that is the world’s largest water recycling facility designed for raw food crop irrigation. MRWPCA operates 25 pumping stations and a main plant that together treat 20 million gallons of wastewater per day.
Naftamatika offers modern, efficient, proven solutions for producing oil wells.
Jones Lang LaSalle (JLL), large, publicly traded telecom company
Increased Worker Productivity - 40% Increase
Advantech's PAC open control platform provides many advanced features for System Integrators to quickly and conveniently develop their applications.
The enterprise-wide solution allows energy managers to collect data from a number of facilities through one centralized interface. Various reports can be generated at the click of a mouse, including instantaneous, fifteen minute, and hourly average demands for a selected interval, and for one or more monitored processes.
Increased Well Production Efficiency - By maintaining optimal formation pressure and continuous operation at minimal speeds (for wells that should not be shut down)
Cost Reduction - Less energy wasted results in lower costs
Multiple connection options for greater networking versatility. Maintenance personnel can monitor from a remote location
Simplified maintenance on ticketing machines