Technical Report - La Taverne des 3i
Contents
1. time_ramp_tgt 25 3 2 10 STRING TEST Create a complete test string ready to be sent using data string seq number CRC16 etc STRING TES 26 3 3 PARSING Every program which deal with conversion from one character of the HAL Test code to one test parameter 3 3 1 HI HO LIMITS CHAR TO TIME HAL 103 HI LO LIMITS vi Front Panel 27 3 3 2 PARSE RESPONSE HAL 103 PARSE 5 Front Pane HAL 103 PA RSE RESPO gt zu 1 ock Jia ra File Edit View Project Operate Tools Window Help 2181 ale or 15 heic Fon Se 28 3 3 3 PARSERSA B C SE 2 34 HAL 103 PARSER Front Panel 2 uM pnt ag Ele Edit View Project Operate Tools Window Help File Edit View Project Operate Tools Window Help 18 HAL 103 PARSER Cvi Front File Edit View Project Operate Tools Window Help 29 3 4 READING Programs used to read responses and sequences 3 4 1 READ RESPONSE HAL 103 READ RESPONSE vi Block Diagr File Edit View Project Operate Tools Window 30 3 4 2 READ SEQUENCES HAL 103 READ SEQUENCE vi Front Panel File Edit View Project Operate Tools Window Help 31 13 4 3 STATUS DATA To get the test status T2 HAL 103 STATUS Front Panel HAL 103 STATUS DATA vi Block Diagram 1 Test aborted arc detected Test a2. The Main Menu 38 How to use the instrument driver 1 Download test sequence information is really easy once the tests were configured manually in advance on the HAL 103 you must first download the first test sequence do this launch the application and select the cursor mode Download Sequences Do not forget to specify the COMM port on the PC where the RS232 cable is connected Finally click on the button located just below the label START During the download indicator Downloading Sequences becomes highlighted When it is no longer highlighted that means the download is complete and then you can see the names of the test sequences Clare HAL 103 Tester Pump ID 1648913 Test Name Test Code 71234567890 Current Status WAITING FOR START CONDITIONS Test time s 0 TEST SEQUENCE RESULT Test applied V or mA lo Test reading 0 Remote Mode MOhms or mOhms Tests Pass Fail Downloading Sequences pcd 5end to the Reworking Station Performing sequence pem Waiting for start conditions P Figure 6 The Driver Instrument Interface If a problem occurs please check the connections of the device and restart the application if the problem persists please contact support 39 2 Perform the wanted sequence Once you have the names of test sequences make sure that sequence you want to use is well within the downloaded list Then type the n
3. 2 HEX ASCII characters u16 15 4 HEX ASCII characters and here float type is representation by 8 ASCII HEX characters The analysis of construction for string commands at a start session will also allow us to understand how they are built for the requests strings for the HAL 103 Thus it is sufficient to concatenate the following pieces of ASCII HEX string 01 the cmdseq it is logical cause it is the first command sent to the device before to perform any operation 10 the cmd code to indicate that is a start session command e 0000 the item id and the instance in the case of a start command both are to set to 0 e the datasz simply calculated by LabVIEW after parsing the string 000000000000000000000000000 According to the definition we gave before for data and as the client did not want management password it is simple sequence of 0 e 0278 This is the CRC16 calculated by the standard method for Telecommunications CCIT it is used to verify data integrity Therefore to start a session it is enough to send the HAL 103 the following string 01100000000E0000000000000000000000000000278 AND to read the appropriate answer sent by the HAL103 to the PC To be correct the string must verify the following conditions in this start session case e cmdseg 0x01 must be the same sequence number than the request response code 0 01 matching to SSSRSP FINAL means that the command is successfully received
4. and completely processed by the tester datasize must fit to data field received the CRC16 must match to the rest of the string So if the start session is successfully processed we should read the following string 01010000C544 Of course we must pay attention to the presence of carriage return at the end of the string using parsing to only compare the true strings themselves 2 3 HHP 38000 Honeywell HHP 3800g produces the barcode scanner used and it connects to a PC via a USB cable As this device has been used by ELCOM to use for the platform leak test the driver to control it has already been created and it reads the bar code present on the pumps to see what tests are applicable If the serial number does not exist or the previous test was faulty the driver returns an error message that says to send the pump to the reworking station and testing cannot be performed If all conditions are satisfied the appropriate tests will be performed on the HAL 103 using the driver developed during this internship So the driver for this device has already been achieved and the integration within the project has been very quick at SORS 4 ney HN M Y aH M es 3 W 4 Figure 7 The HHP 3800g Barcode Scanner Figure 8 A pump Bar Code 2 4 XMLAND WEBSERVICES XML stands for Extensible Markup Language Extensible Markup Lang
5. POLYTECH GRENOBLE dm Technical Report Designing and Coding of the HAL 103 Driver Intern Ehouarn Perret Engineering School Polytech Grenoble Department Industrial Computing and Instrumentation Company Supervisor Michal Harhaj School Supervisor Irfan Ahmad Internship Period 16 05 2011 05 08 2011 This technical report deals with the implementation of the necessary driver for the HAL 103 used electrical testing station This work was carried out at ELCOM in Czech Republic in the Virtual Instrumentation division located in Ostrava My work has been guided by the following persons e Michal Harhaj responsible for Service of Automated Test Systems e Petr Bilovsky Instrumentation Engineer in the service of Automated Test Systems e Kominek responsible for Service of Software Components e Anton Timofieiev network administrator working in the Software Components Service Actually Edwards a British pump manufacturer is setting up a new fab in Czech Republic located in Lutin In this report expose the source code that resulted in the driver being used First will explain the principle of drivers and the context in which it was built and then show the various programs and subroutines that were used in its construction TABLE CONTENTS 1 Context and DRIVER PRINCIPLE nun ana 1 1 1 Soil ee ee ee 1 E ee ee ee en ee 4 2 1 PAB WE WY ee ee ee e
6. Read TE 31 3019 S ec o pcm nU mA CUL UE 32 28001 UU MTM 33 3 5 Herode M 34 3 6 35 3 7 WI THC AY mE 36 4 User nee ee een 37 AND DRIVER PRINCIPLE 11 CONTEXT Today the quality of a product is largely determined during its manufacture Thus it is not uncommon that following the assembly phase there are several tests to verify the validity and conformity of the product This permits the following To avoid inconvenience to the customer To have a guarantee of the quality of the product If the product does not meet the requirements requested by the service quality then quality controls service can possibly repair the product for re taking the tests and save time and money on possible returns to technical support In terms of context of quality had the opportunity to interact with one of ELCOM customers A few months before the beginning of my internship a contract was signed with Edwards Edwards is a British company specializing in the manufacture of pumps From the perspective of an expansion strategy the company decided to install a new factory in the Czech Republic to produce products at lower costs The production line i
7. ame of the desired sequence in the appropriate field located below the label Test sequence to perform Once everything is ready you just press again the button START For each test however please be aware that seeing Waiting for start conditions is highlighted before you start to trigger the test in the manner that has been configured If the name does not exist in the machine then there will be an error At the end of the test sequence you can see the various lights indicating which tests were PASS or FAIL Note that the result of the sequence will be PASS only if all tests PASS as well General remarks on error operating HAL 103 e Please note that if the device does not respond you must restart by pressing two times the orange SUPPLY ON OFF e You should know that the red button RESET can also be used to exit the Remote mode must be used intelligently eg its use is discouraged during the download phase sequences 40
8. borted no data from Measurement Test aborted no data from GUI inter packet gap pper limi est aborted no result reading was available est abortec reserved cause est aborted reserved cause THE ZE 5 x91 A2 AS A Zu AG A9 32 3 4 4 STATUS TELLER Show the test status HAL 103 STATUS TELLER vi Front Panel et serico Font 5 8 5 1 103 1 STATUS TELLER in 33 3 5 TYPEDEFS Typedefs used in this project HAL 103 SSSCMDDATA_HALTEST ct Type De EXE EJ Laie 14 1 4 34 3 6 MAIN Clare HAL 103 Tester Pump 10 1648913 Test Test Code 71234567890 Current Status WAITING FOR START CONDITIONS Test time s Test applied V or mA Test reading 0 MOhms mOhms Test names Downloading Sequences Performing sequence EEE Waiting for start conditions TEST SEQUENCE RESULT pom Tests Pass Fail 5end to the Reworking 5tation 35 3 7 VI HIERARCHY HAL 10 STATUE TELLER HAL 102 WRITE HAL 102 STRING HAL 102 SENT DATATO STRING HAL 102 CODE lt HAL 102 HAL 102 REAL FEHU ETOP HAL 103 HAL 103 READ OHSE IHITIALIZE HAL 103 HI p LO LIMITS 36 4 USER MANUAL Purpose of t
9. e re 4 2 2 6281 81 21 ee UL E 5 2 2 1 OENELAN ES T Umm 5 2 2 2 Formatting Requests and 6 2 2 3 Basic Communication Example Start 5 7 2 3 zzi 8 2 4 8081 61 27 ee ee ee 9 S o COE rer 10 3 1 ooo 10 ON NONU 10 22122214 121 85 user 11 SOPE SION 12 SLA 6058 COMMUNICATION a t mmm 13 33 0818 Command nern mercem 14 6 TREO ea ne 15 3 2 nee 16 E e ere E T 16 S Ri ee eer le 17 213 MU EE 18 SP EE 19 20 20 ee 21 327 ae een 22 520 40008 10 1 23 3 29 Sent Data TO SEFIDIB nennen anne ansehen 25 3 2 10 STEINE METUIT 26 3 3 TENEO 27 33 1 ALAO Lmt char TOT ee Oe Cei nove oe Dept Er ibus 27 3 34 Parse Response iius Deo ee 28 3 3 3 Cc 29 3 4 tem ET 30 9 41 Read RESPONSE 30 34 2
10. error in no error E wei CE i wies R out 11 3 1 3 STOP SESSION HAL 103 STOP vi Front Panel _ 13 HAL 103 5 Block Diagram File Edit Project Operate Tools Window Help 12 3 1 4 CLOSE COMMUNICATION T3 HAL 103 CLOSEvi Diagram Eile Edit View Project Operate Tools Window Help AL 103 13 3 1 5 WRITE TEST COMMAND 1 103 WRITE AL 103 nz WRITE EMO 14 3 1 6 GET SEQUENCES 3 HAL 103 GET 5 5 Block Diagram 15 3 2 TOOLS 3 2 1 CRC16 Calculate the CRC16 CCIT an HEX String HAL 103 CRC16 vi Front Panel T3 HAL 103 CRC16 vi Block Diagram File Edit View Project Operate Tools Window Help gt gt 8 data 8 Oxff 16 3 2 2 ADD 16 Concatenate the CRC16 calculated previously to the string used HAL 103 ADD CRC16 vi Block Diagram ADD 17 3 2 3 DATA SIZE Calculate the data size of a string DATA SIZE JE E epe e w V sd flet 18 13 2 4 ADD DATA SIZE Concatenate the Data size calculated previously to the string used 13 HAL 103 ADD DATA SIZE vi Block Diagram Eile Edit View 9 HAL 103 ADD DATA SIZE vi Front Panel File Edit View Project 77777 Tools Window 19 3 2 5 ASCII TO CODE Convert an ASCII string to ap
11. his manual Provide the information necessary to perform measurements using the remote mode Hardware requirements An HAL 103 properly connected to a PC using an RS232 cable to the COM port e Apreconfigured tests in manual mode Connection to PC For information remember that the RS232 cable should be connected to COMMS 1 on the rear panel of the device in order to work using a PC The position of the COMMS port is shown below in Figure 1 COMMS 1 COMMS 2 comms 3 i 4 COOLING FAN MAINS IN MFAD04 GUARD SWITCH COH 966 Figure 1 The Rear Panel HAL 103 37 How to start the device Once the machine is plugged in you can start the apparatus just in pressing the orange button SUPPLY ON OFF on the front panel Its location is indicated in Figure 2 below SUL PASS AND FAIL INDICATORS SUPPLY OGN OFF FUNCTION KEYS a ROTARY 227 FULSING INDICATION OF VOLTAGE PRESENT HIGH TENSION Figure 4 The Front Panel Choose the Remote Mode To choose the remote mode simply turn the rotatory encoder to highlight the remote mode on the visual display and then press the green button START TES VIEW TEST RESULTS DOWMLOAD RESULTS SETUP MEMORY OPTIONS DEHO ADV SITE CLARE INST LOCATION Uk Hed nesdau 11 April 288202 16 54 MANUAL CHANGE USER Figure 5
12. ings values or structures e lt 16 gt Four ASCII HEX digits representing the 16 bit CRC of all encoded bytes up to but not including the CRC value itself lt cmdseq gt Two ASCII HEX digits representing the command sequence number received from the host in the command to which this response relates response Two ASCII HEX digits representing the response code interim datasz Four ASCII HEX digits indicating number of encoded data bytes in the response e data ASCII HEX representation of the reason code for response code contents or the requested data for ACK or interim ACK response codes Some ACKs and interim ACKs do not return any data in which case lt datasz gt will be zeros e lt 16 gt Four ASCII HEX digits representing the 16 bit CRC of all encoded bytes up to but not including the CRC Note that if the host includes the CRC value within the CRC calculation then the result will always be zero for uncorrupted data 2 2 3 BASIC COMMUNICATION EXAMPLE START SESSION Then in order to send the desired commands open a session through the session start the data required which can be basically translated into the following C code typedef struct ssscmddata session start protocol ver baud code password seed 18 password ARRAYSZ 555 PASSWORD Ssscmddata Session Start Reminder stands for unsigned integer 8 is
13. is a powerful tool to assist in the analysis of the safety of electrical and electronic equipment Many tests are provided with a wide range of innovative features to aid difficult test situations which allow the testing of a wide variety of equipment Figure 5 the Clare HAL 103 Tester The Tester is designed to be easy to use and also includes the following innovative features non exhaustive list e Universal Supply Input e Highly accurate Ground Bond Hipot leakage and DC IR measurements e Large Full graphics display Real time clock e Remote mode connecting to PC port serial COMM RS232 e Auto test code generation e Fully isolated test outputs to comply with EN50191 a new European standard provides guidance on how to carry out safety testing in a variety of environments Connection settings are the following e Baud rate 9600 e Data Bits 8 e Parity None e Stop Bits 1 0 e Flow Control XON XOFF e Timeout ms 1000 e Termination Character Carriage Return OxOD in HEX Figure 6 Edwards Pump The Remote Command Protocol is an RS232 protocol that allows Clare Tests to be done reliably and quickly configured from a remote host and also allows the remote host to send commands to the instrument in order for the system to automatically perform electrical tests The protocol is based on an ASCII HEX notation That is every byte of data is coded using two hex digits in the range 0 through 9 A thro
14. propriate ASCII code string HAL 103 ASCI TO Front Panel 2 SS 4 HA HAL 103 ASCI TO CODE vi Block Diagram 20 13 2 6 ASCII TO HEX Convert a string to a byte array T3 HAL 103 Front P Panel ves 21 3 2 7 CODE TO STRING Convert ASCII code string to the appropriate ASCII string SS T8 HAL 103 CODE STRING vi 13 HAL 103 CODE TO STRING vi Block Diagram A i File Edit View Project Operate Tools Window Help 22 3 2 8 CODE STRUCT Convert aHAL Test code to a HAL Test structure T3 HAL 103 CODE TO STRUCT vi File Edit View Project Operate Tools Window Help DIE bala 15pt Application Font 205 23 103 CODE TO File Edit View Project Operate Tools Window Help m 15 Appication Font 8 1 Se SSSCMD target output 550 TEST test start EXE SSSCMD time ramp tgt PSSSCMD time_ramp_zero SSSCMD lo_limit SSSCMD hi_limit SSSCMD SSSCMD arc detect detect SSSCMD test start phj SSSCMD time hold 24 13 2 9 SENT DATA TO STRING Convert structure parameters into a data string File Edit View Project Operate Tools Window Help testflags
15. s on one hand a set of units of manufacturing and assembly as Building Stations On the other hand there are also test units also referred as Testing Stations Note that a pump can only move to the next step if it passes the tests applied If the tests fail then the pump is sent to the Reworking Station to be repaired After being repaired the pump is returned to take the tests If no repair is possible the pump will be sent to the Recycling Station To verify the test results and validate the various stages of testing all test stations are connected by Ethernet cable using the TCP IP protocol to a PC server running Windows Server 2008 This server uses Microsoft SQL Server to manage a database containing all information about the tests results units time and date they were performed tolerance compared with the standard provided in specific cases etc Note that the data sent by the various stations to the server should be in XML to be able to interact with the database TCP IP Ethernet MS 501 SERVER gt Figure 1 System Architecture Sub routine for Test Stations Con Sub poe Station receives pump Send pump to Test Station Reworking Station Electrical Test Station Functionalities Test Station Send pump to Send pump to Recycling Station Next Station Packaging Figure 2 Production Line Flow Chart HAL Test Proce
16. ss in normal operation in abnormal operation Conditions to start the test are Bar code exists Previous Test is Pass Get Information from Server Devices connected Measurement within limits Send Results to Server Figure 3 The HAL Test Process 2 TOOLS 2 1 LABVIEW The choice for using LabVIEW was natural choice because as stated in the opening of the report the fact that National Instruments is a privileged partner of ELCOM indicates that most of their system software developments about 99 are using LabVIEW or using other related products from National Instruments For the developer a program in G language is a diagram chart linked together using different icons connected by colored wires Each wire symbolizes the passage of data from the source it leaves as a result to a target when it arrives as a parameter Therefore diagrams of the G language have a meaning quite different in comparison to electronic schematics In a LabVIEW block diagram the data is transmitted in the wire ONLY when it is generated by the icon source The target icon will start its execution when all its input data becomes available This model for scheduling data flow determines the execution order of the treatment program An important consequence of this rule is that treatments that do NOT exchange data are free to run in parallel This property of language G facilitates the development of multi
17. threaded applications particularly useful in the control of reactive systems embedded or not Program design language G retains an essential procedure Combined with the performance of data flow this approach gives good results in the field of instrumentation It is also the most intuitive for engineers and researchers often more familiar with experimental protocols than with computer concepts This dual front panel block diagram allows the programmer to easily and distinctly separate between the graphical user interface and measurements process and more generally the information processing calculations etc It is therefore a very powerful ool programming language to quickly create GUI programs and computers even for people who have no computer background File Edit View Project Operate Tools Window Help E fe Application For E I U I U I U ER ER ER ER ER I _ xl 1 File Edit View Project Operate Tools Window Help 1 Spt Figure 4 A LabVIEW sample As can be seen from the Figure 2 3 above the front panel allows a user to design GUI here we simply display the inputs x and y and the output x y Concerning the Block Diagram is used to do calculation programming here a simple addition x like signal processing communication with the hardware etc 2 2 THE CLARE HAL 103 TESTER 2 2 1 GENERALITIES The Clare Hal 103 Safety Electrical Tester
18. uage is markup language from the SGML generic which is another well known very traditional markup language This syntax is called extensible because it allows the definition of different name paces languages with their own vocabulary and grammar such as XHTML XSLT RSS etc With tools and languages associated an XML application is generally consistent with certain principles the structure of an XML document is defined and validated by a schema an XML document is completely transformed into another XML document Below a XML sample lt Test Name ID UltimateTest lt TestStartTime gt 2011 07 13 22 05 35 TestStartTime lt ExecutionTime gt 93 87 lt ExecutionTime gt lt Count gt 2 lt Count gt lt Status gt Failed lt Status gt lt Results gt lt Result Name Test nol gt lt Status gt Passed lt Status gt lt Measurement gt 45 043945 lt Measurement gt lt Units gt mOhms lt Units gt lt Test Type gt DC Hipot lt Test_Type gt Limit Low gt 1 000000 lt Limit Low Limit High 70 000000 Limit High Result Result Name Test no2 lt Status gt Failed lt Status gt lt Measurement gt 50 4654 lt Measurement gt lt Units gt mOhms lt Units gt lt Test Type gt DC Hipot Test Type lt Limit_Low gt 0 000000 lt Limit Low Limit High gt 40 000000 lt Limit High Result Results Test As shown above in the example XML that process is
19. ugh Upper case ASCII hex must be used throughout the process This is common notation that allows easy detection of corrupted characters and avoids the need for special encoding of control characters etc 2 2 2 FORMATTING REQUESTS AND RESPONSES 2 2 2 1 REQUESTS Requests from the host are formatted as follows lt cmdseq gt Two ASCII HEX digits for an ever incrementing command sequence number A host should increment its command sequence number before transmitting command but not when transmitting retries of the same command The sequence number is copied to all responses generated If the tester receives a command with a command sequence number the same as that for the previously correctly decoded command then the tester simply re sends its last response without performing any action this deals with the situation where an ACK NAK InterimACK is corrupted before being received by the host e cmd Two ASCII HEX digits representing the required command code e instance Two ASCII HEX digits indicating the particular item instance 0 through N For many protocol commands the item instance number is not relevant and must be set to zero e datasz Four ASCII HEX digits indicating number of encoded data bytes in the request Many protocol commands to not require any data to be supplied from the host in which case the data size must be zero e data ASCII HEX representation of the data for commands that required str
20. used to send different information resulting from electrical testing web services and to save them in the database A web service or service toile1 is a computer program that allows communication and exchange of data between heterogeneous systems and applications in distributed environments It is therefore a set of functionalities exposed on the Internet or an Intranet by and for applications or machines without human intervention and stays synchronous A Web service is also a software component identified by a URI whose public interfaces are defined and called XML Its definition can be discovered by other software systems Web services can interact with each other in a manner prescribed by its definition using XML messages carried by the Internet protocols As part of my project using XML and web services were relatively transparent In fact LabVIEW had a module to automatically create all the necessary functions to send and receive data via the web service 3 SOURCE CODE MODULES 3 1 COMMANDS 3 1 1 INITIALIZATION i pen i nt E31 Baud gt Data Bits Parity Stop Bits Timeout XON Char TermChar End Out Endin 10 3 1 2 START SESSION e NOP command 5 Start session ASCI End session HEX 1111 0102 0301 0203 i H VISA Resource 170 ASATI i E 17545 visa 70 VISA Resource Name out
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