Report - La Taverne des 3i
Contents
1. m Writting User Manual L gt Writing the Report Figure 6 2 The Final Gantt Chart 6 2 Difficulties Encountered Finally it turned out that the low level design coding and unit testing were done at the same that s why I met with the same name as it often happened that the unit tests reveal low as I corrected direct encoding so I can only assume that the segregation of duties were a little too strong in the V model and this have made me lose a little time Indeed it was not best suited to the particular situation because the design time should have been longer He might have had to use another method such as AGILE method is more responsive and has to deliver more regular Another major difficulty in this course was the documentation of the device which contained many gaps I had to repeatedly contact support Seaward who sometimes struggle to answer Sometimes the information given in the manual were completely wrong In fact the support service does not really know the remote control part because it was created by another company that no longer exists so it was very difficult to find all the answers I was looking for I finally managed to get out in force to hack and I was able to help improve the user manual and documentation of the device 21 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 6 RESULTS Finally the entire measurement process can be summarized with the diagram below2. The HAL Test Process C Stat Download Tests Seguences Scan Bar Code Get Information from Server i Get Test Name Perform HAL Test Get Results From HAL 103 Send Results to Server End in normal operation in abnormal operation Conditions to start the test are OK Bar code exists Previous Test is Pass Devices connected Measurement within limits Handle and Display Error s Figure 6 3 The HAL Test Process 22 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 7 CONCLUSIONS 7 CONCLUSIONS 7 1 Professional Assessment This internship allowed me to improve myself in many areas such as practicing English in a professional environment such as in an international context where 1 had to plan meetings between two different nationalities In a technical point of view I also widened my knowledge about the use of LabVIEW the graphical development platform At first it seemed particularly stark because 1 was more used to developing programming with languages like C and Java using the instructions as texts However the methodology using LabVIEW also has its advantages such as a better readability of programs which increase the understanding of the programs and therefore induce better re usage with other projects In addition LabVIEW included many tools for programming both low and high levels much like the communication driver which allows minimal development time and pr
3. 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 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 tool programming language to quickly create GUI programs and computers even for people who have no computer background AddExample vi tP 10 x File Edit View Project Operate Tools Window Help H OO
4. 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 e To avoid inconvenience to the customer e To have a guarantee of the quality of the product e If the product does not meet the requirements requested by the service quality then quality control 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 I 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 is 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
5. EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT ACKNOWLEDGMENTS ACKNOWLEDGMENTS I would like to thank Dr Daniel Kaminsky director branch Elcom virtual instruments for giving me the opportunity to fulfill my internship in the branch instrument Virtual ELCOM and its positive attitude towards my work I would also like to send my heartfelt thanks to Pavla Zajicova assistant director for all the help she gave to me from purchasing the bus pass to finding an accomodation in Ostrava I want to thank Michal Harhaj my supervisor and Ji Kominek responsible respectively for Services Automated Test Systems and Software Components for their reception and the attention they have shown to me during all the internship as the autonomy and the confidence they gave me in achieving my project to uphold my practical as well as theoretical skills in engineering I would also like to thank Petr Bilovsky Instrumentation Engineer in the service of Auto mated Test Systems for the time he sacrificed and the advice given to me regarding the use of LabVIEW and his expertise in the field of instrumentation Thanks to him I gained knowledge about the engineering profession Finally my thanks go to all those whom I would like to write their names on this page and there are so many who have helped me in various ways during my training especially my school supervisor Irfan Ahmad who Helped me in so many ways I thank all ELCOM employees for giving such a warm welc
6. tester displays the resistance measured and allows the user to confirm sufficient insulation exists e Hipot Test this test is used to determine that the insulation is of sufficient strength to prevent breakdown particularly where high transient voltages are likely During this kind of test a voltage of 3kV AC RMS is applied between the Hipot probe tip and the live and neutral pins of the Product mains supply plug e Insulation Ground Earth Bond Test Insulation Ground Bond Test this test is to ensure that the connection between the earth pin in the mains plug of the appliance and the metal casing of the appliance is satisfactory and of sufficiently low resistance When the test is running an AC voltage and the test current is applied between the earth pin of the mains supply plug and the ground bond test lead clip probe 6 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 3 TOOLS 3 2 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
7. E amp AddExample vi Block Diagram loj xj z do File Edit View Project Operate Tools Window Help 1 DOME Figure 3 1 LabVIEW sample Program 7 24 O0 IO O BUN F NN NNNNR FE ps OU B D FE O D JO OU RB UN E EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 3 TOOLS 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 z y like signal processing communication with the hardware etc 3 3 XML Language and Webservices XML stands for Extensible Markup Language Extensible Markup Language is a markup language derived 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 LE 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 e the structure of an XML document is defined and validated by a schema e an XML document is completely transformed into another XML document XML code snippet lt Test Name ID UltimateTest gt lt TestStartTime gt 2011 07 13 22 05 35 lt TestStartTime gt lt ExecutionTime gt 93 87 lt ExecutionTim
8. POLYTECH GRENOBLE REPORT ATH YEAR ENGINEER INTERNSHIP DEPARTMENT INDUSTRIAL COMPUTING AND INSTRUMENTATION Designing and coding of the HAL 103 Driver Company Supervisor Michal HARHAJ School Supervisor Irfan AHMAD Student Ehouarn PERRET Internship period 16 05 2011 05 08 2011 Universitary Year 2010 2011 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT ABSTRACT ABSTRACT As part of my fourth year at Polytech Grenoble in the Department Industrial Computing and Instrumentation I did an internship abroad to learn to adapt to new situations and to use my English in a professional context The objective of this internship was to create an instrument driver in the development of a test platform based around an electric device the HAL 103 With Michal Harhaj my company supervisor and Irfan Ahmad my school supervisor I designed and built the driver for the HAL103 to interact with a database to store the measurement data The HAL103 is a device electrical testing manager of very high voltages it is used to detect such leakage currents Firstly this report describes briefly the conditions surrounding this placement and then the different stages of design using concept of Project Management and implementation mainly in LabVIEW that led to the success of this placement Finally I thank for giving me so much confidence and letting me carte blanche to carry out this project with full autonomy in customer relationships that implied
9. RAVA g ographigue et postale T l phone standard 420 558 279 902 T l copie 420 558 279 901 Responsable administratif nom et fonction Dr Daniel Kaminsky T l phone 420 558 279 902 T l copie 420 558 279 901 M l Daniel Kaminsky elcom cz Maitre de stage nom et fonction T l phone 420 558 279 902 T l copie 420 558 279 901 M l michal harhaj dvi elcom cz Tuteur enseignant nom et fonction Irfan Ahmad T l phone 33 0 4 76 82 63 28 T l copie 33 0 4 76 82 63 88 M l Irfan Ahmad gipsa lab grenoble inp fr Titre maximum 2 3 lignes Conception et R alisation d un driver pour le HAL 103 R sum minimum 15 lignes Dans le cadre de ma quatri me ann e Polytech Grenoble au sein du D partement Informatique Industrielle et Instrumentation j ai fait un stage l tranger pour apprendre m adapter de nouvelles situations et utiliser mon anglais dans un contexte professionnel L objectif de ce stage tait de cr er un driver d instrumentation autour du d veloppement d une plateforme de test bas sur appareil de tests lectriques les HAL 103 Ceci s est d roul au sein de l entreprise ELCOM Avec Michal Harhaj mon superviseur en entreprise et Irfan Ahmad mon superviseur cole j ai con u et construit le pilote de la HAL103 afin d interagir avec une base de donn es pour stocker les donn es de mesure Le HAL 103 est un appareil d
10. 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 3 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 2 OBJECTIVES The Production Line Start Sub process Station receives a pump Pump pass the test Building Station 1 Building Station 2 Building Station 3 Leak Test Station Electrical Test Station Functionalities Test Station Packaging Station Send pump to Recycling Station Sub routine for Test Stations Send pump to Next Station End Sub process Figure 2 1 Production Line Flow Chart 2 2 Purposes During my internship I worked on an electrical testing station consisting of an electrical testing device the ClareHAL103 manufactured by the British manufacturer Seaward The task entrusted to me was two separate jobs to design an instrument driver for controlling the apparatus and to also provide a graphical interface to control and use the driver effectively in order to communicate with the server 4 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 2 OBJECTIVES In fac
11. e development methodology is outlined for this specific project as well as the specifications and the steps for development But first and foremost the specific tools hardware software used during this placement will be explained 5 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 3 TOOLS 3 TOOLS 3 1 ClareHAL 103 The Clare Hal 103 Safety Electrical Tester 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 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 testcode 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 The device is designed to perform the 3 mains following tests e Insulation Test this test is used to verify that adequate insulation exists between the mains supply pins and ground During the insulation a HV DC voltage is applied between the earth pin and both the live and neutral pins of the Product mains supply plug The
12. e gt lt Count gt 2 lt Count gt lt Status gt Failed lt Status gt lt Results gt lt Result Name Test_no1 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 lt Limit Low gt 1 000000 lt Limit Low gt lt Limit High gt 70 000000 lt Limit High gt lt Result gt lt Result Name Test_no2 gt 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 lt Test_Type gt lt Limit_Low gt 0 000000 lt Limit_Low gt lt Limit_High gt 40 000000 lt Limit_High gt lt Result gt lt Results gt lt Test gt 8 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 3 TOOLS As shown above in the example XML that process is used to send different information resulting from electrical testing web services and to save them in the database A web service or service toilel 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 defin
13. e tests lectriques tr s haute tension il est utilis par exemple pour d tecter les fuites de courant Nous tudierons d abord dans ce rapport une br ve description des conditions entourant ce stage et ensuite les diff rentes tapes de la conception en utilisant le concept de gestion de projet et la mise en uvre principalement en LabVIEW qui a conduit la r ussite de ce projet Enfin je remercie toute l quipe d ELCOM de m avoir donner tant de confiance et de m avoir laiss carte blanche pour mener bien ce projet avec une enti re autonomie dans la relation client que cela supposait
14. ent password it is a 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 e response code 0x01 matching to SSSRSP ACK FINAL means that the command is successfully received and completely processed by the tester 16 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT e datasize must fit to data field received e the CRC16 must match to the rest of the string So if the start session is successfully processed we should read the following string 010100000544 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 Below a basic example of one possible implementation for the connection using LabVIEW Right answer expected ASCII HEX 01010000C544 Start session 01100000000E00000000000000000000000000000278 ASCII HEX 1 gt al KTFI Connected Byte count abeJ Indicator Read Buffer COMM Port error in a Figure 5 2 A basic start session im
15. er Quality Systems Dr Ji Hula Electronics and Electrical Design Miroslav Rumpel Administration HR Accounting Office Management Automated Test Systems Michal Harhaj Test Systems Vision Systems Assembly Lines Electrical Machines Software Components Ji Kom nek Instrument Drivers Applications Figure 7 1 DVI Internal Structure EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT PEOPLE IN PROJECT B People in Project People in Project Front End Department Concept Designer Domain Expert Project Manager Integration Team Power Up Team ELCOM DVI Customer FMEA Team Customer specialists Project Manager Senior Software Developer Senior Electrical Designer Senior Machinery Designer Manufacturing Software Department Software Architect Software Developers Electrical Department Electrical Designer Electronic Designer Assembly technicians Machinery Department Machine Designer Assembly technicians FMEA Failure Mode and Effects Analysis Figure 7 2 People in Projects EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT BUSINESS PROJECT C Business Project Business Project Technical Track Business Track Time Reguirements mining eae Offer Sub can include feasibility study N a cameo Design Order and Contract Design Validation Partial Payment typically 30 to 50 Implementation Manufacturing Oualifica
16. gt 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 lt datasz gt FourASCII 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 lt data gt ASCII HEX representation of the data for commands that required strings values or structures e lt crc16 gt Four ASCII HEX digits representing the 16 bit CRC of all encoded bytes up to but not including the CRC value itself Responses from the tester take the following form e lt cmdseq gt TwoASCII HEX digits representing the command sequence number received from the host in the command to which this response relates e lt response gt Two ASCII HEX digits representing the response code ACK NAK in terim ACK e lt datasz gt Four ASCII HEX digits indicating number of encoded data bytes in the response e lt data gt ASCII HEX representation of the NAK reason code for NAK 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 zero e lt crc16 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 calc
17. he instrument driver In fact if you want to manually add another test you must first exit the remote mode so every time driver is running the test seguences available are updated The Seaward Test codes are an 11 character string where each character is in the ASCII range 0 to 9 and A to Z The character count starts from left to right The example below shows Z as digit 1 or character no 1 and the integer 1 as digit 2 character no 2 and so on e g 21234567890 5 3 Perform the HAL Tests Characteristics of the command to perform HAL Test Command Code 0x80 Item id e SSSID HAL TEST TYPE HIPOT 50 0x01 SSSID HAL TEST TYPE HIPOT 60 0x02 e SSSID HAL TEST TYPE HIPOT DC 0x05 SSSID HAL TEST TYPE DCIR 0x04 SSSID HAL TEST TYPE EBOND 50 0x05 18 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT e SSSID HAL TEST TYPE EBOND 60 0x06 Instance 0x00 About data referring to the HAL103 Manual including tables I was able to create a converter following the different code received 5 4 Store Data in Database As I mentioned in Part 3 communicating with the database via webservice and xml is simply entering the IP address of ethernet server in LabVIEW It then automatically generates the necessary vi communication and data management 19 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 6 RESULTS 6 RESULTS 6 1 Achievement At the end of the internship I managed to carry out the program req
18. is V model is a well known method of organization that dates far back to the industry and has been adapted to computers in as early as the 80s This model is still relevant even if not necessarily suited to projects where developments and changes of direction are freguent because almost all the theory is set before starting the project See below for the structure of the simplified V Model The V Model Ongoing Support Review Test A o Operational Testing High Level Design Integration Testing Unit Testing Low Level Design sepa Figure 4 1 The V Model Structure We can distinguish three main parts the design phase implementation phase coding and the validation phase Phases of design and validation are cut into several parts Each step can only be achieved once the previous step is completed which reduces the risk of failure on the project 10 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 4 PROJECT Below are the definitions of different stages of the V Cycle Model e Specifications They have already more or less been explained in Part 2 To summarize this is the criterion that must be met for the software implementation when the project is completed to meet all customer reguirements e High Level Design The phase of design of computer architecture and software architec ture can also be referred to as high level design The baseline in selecting the architec
19. ition 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 4 HHP 38008 Figure 3 2 The HHP 3800g Barcode Scanner 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 9 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 4 PROJECT 4 PROJECT MANAGEMENT 4 1 Software Development Model To manage this project I relied on a well known design pattern in the software development world the famous V Model Th
20. n country as evidenced by the company where I did my internship ELCOM The Czech Republic in contrast to France because it is so committed on improving the level of English for its citizens it shows everywhere both in business and in everyday life I have met some great people both at work and in daily life The Czechs are very proud of their country and know how to show it They know to be very friendly and even if their English is sometimes rough they will do everything to help you even if they have to use sign language This enabled me to broaden my view with others and discover new horizons and new ways of thinking Finally this course has given me the desire to go abroad again to guide myself in my international career even if my English has not changed much it is more fluent than before I now have less fear and am more confident when I approach people abroad I think that any engineer should do an internship abroad because it is what being an engineer is about knowledge and understanding of new situations and being open to the world 24 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT DVI STRUCTURE A PPENDIXES A DVI Internal Structure ELCOM DVI Internal Structure Head of Cee Directors Board Vladimir Korenc Ji Holoubek ELCOM DVI Division Director Dr Daniel Kaminsky Business Development Jan ma Special Projects Marketing Sales Assembly Machinery Design Petr Kotek Pow
21. nents Testing is usually done with the black box as the code is not directly checked for errors e Operational Testing Compare the system specifications against the actual system After the integration test is completed the next test is the system test System testing checks if the integrated product meets the specified requirements Why is this still nec essary after the component and integration tests The reasons for this are as follows In the lower test levels the testing was done against technical specifications LE From the technical perspective of the software producer The systems test though looks at the system from the perspective of the customer and the future user The test validates whether the requirements are completely and appropriately met Example The customer who has ordered and paid for the system and the user who uses the system can be different groups of people or organizations with their own specific interests and requirements of the system Many function and system characteristics result from the interaction of all system components Consequently they are only visible on the level of the entire system and can only be observed and tested there e Ongoing Support This is the last phase which is to provide technical support once the product is finished and delivered to the customer depending on the contract duration is shorter or longer in some cases and may need an additional payment from the customer as in
22. ome in the structure and intro ducing me to Czech culture A paper might not be enough for me to express all the support and guidance I received from them almost for all the work I did there II TABLE OF CONTENTS Abstract Acknowledgments 1 Company Presentation O IIA 1 2 Division of Virtual Instrumentation DVI 13 Main Contacts 2 Objectives OL CODEX 2 5644 4 9 5 4 Reo 2 2 Purposes du Pda da dees 3 Tools 31 ClareHAl 108 2 24246 Di ee ee ee 3 3 XML Language and Webservices 3 4 HHP 38008 4 Project Management 4 1 Software Development Model 4 2 Provisional Chart 5 Development 5 1 Protocol Basics uo 4 40 ee ed bo eed autre ed te di de bave oL Degcription s ste Boa ek ROR EKER RELA CERES EH OES BGO 5 1 2 Initialization lt lt lt lt lt ee 5 1 3 Formatting Requests and Responses R R E O O ei de 5 2 Download Test Seguences 5 3 Perform the HAL Tests 5 4 Store Data in Database us k we ee u de k RR ok k l ie 6 Results 6 1 Achievement 4 6 2 Difficulties Encountered lt lt 22 a a 7_ Conclusions 7 1 Professional Assessment 7 2 Personal Assessment Appendixes A DVI Internal Structure B People in Project C B
23. ovide more interaction with the client in a project Furthermore it is possible to achieve large scale projects without requiring that the cus tomer have a license with LabVIEW Compiling just like the C language is an executable with the necessary runtimes and its proper functions but it is a free download for anyone The language G from National Instruments has become an industrial standard for mea surements and instrumentation Having been part of a major project within ELCOM s partner the creator of LabVIEW allowed me access to a great learning experience at the professional level and be of great benefit for my potential international career This internship also allowed me to have a first person inside view of what is used in large industrial projects and to learn XML Finally to get involved in a big project from scratch from the specifications to the end product through the design phase was very rewarding on every point including teamwork management and even just being in an international study 23 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 7 CONCLUSIONS 7 2 Personal Assessment This internship allowed me to discover a new culture of the Czech Republic I had a lot of prejudice going there initially but they all proved unfounded In fact most people who saw me from there saw an evil eye and I think it s a misunderstanding Indeed far from the clich s of the communist era the Czech Republic is a moder
24. part of an extended warranty 11 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 4 PROJECT Yee ot O Month Nay Week LabVIEW Training Iu Specifications m High Level Design Low Level Design Coding C Unit Tests Integration Tests Operational Tests isd Writting User Manual Pa AAA Writing the Report Figure 4 2 The provisional Gantt Chart 4 2 Provisional Chart Thus by the definition of the V Cycle I was able to draw a Gantt chart that shows the tasks performed during the weeks of the internship The differences between the Gantt chart diagram and the original tasks will be seen further in the report Otherwise this diagram allowed me to Otherwise this diagram allowed me to e determine the dates of a project e identify existing margins on certain tasks e view at a glance or delay progress 12 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT 5 DEVELOPMENT 5 1 Protocol Basics 5 1 1 Description The Remote Command Protocol is an RS232 protocol that allows Clare tests to be done reliably and guickly 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 and A through F Upper case ASCII hex must be used
25. plementation using LabVIEW This principle of sending and verifying is used each time you send commands to the same session stop command which allows you to properly close the open session if necessary To stop a session we need to send the following string for example cause it depends on the seguence number here it s for the 4 send command by the way the command code for the stop session is 11 and 0 for the others fields except for the CRC16 of course 041100000000A6BA and reads the following one 040100007901 17 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT 5 2 Download Test Sequences After starting session the driver must download the names of test seguences and the corre sponding code This is the code test that contains all the reguired information type of test limits etc to perform the test Characteristics of the command to download test seguences e cmd code 0x20 e item id 0x25 e instance from 0x00 to 0x14 20 in Decimal Reguests to download the HAL 103 send responses in the data field containing information regarding the name and ID code for testing The algorithm is not very complicated it consists in incrementing the instance as the same way as it increments the cmdseg so through the 20 tests available in the device then analyse the responses strings and parse them to store in a table including the names and the ID code tests This download is done once the launch of t
26. rse may also use other sub sub vi and so on By customizing the icons for each vi allows a better readability of the program File Edit View Project Operate Tools Window Help IMITIALIZE A Flush Receive Buffer No I O v VISA Resource Name I O error in no error E m Pp Baud Data Bits Parity top Bits Flow Cntrl Timeout v v v ik gt XOFF Char gt TermChar ASRL End Out gt ASRL End In on m gt x lt 3 o A yl a F m 5 VISA VISA Resource Name out 170 error out Figure 5 1 The Initialization subvi 14 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT 5 1 3 Formatting Requests and Responses Reguests from the host are formatted as follows e lt cmdseq gt Two ASCII HEX digits for an ever incrementing command sequence number A host should increment it s command sequence number before transmitting a 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 lt cmd gt Two ASCII HEX digits representing the required command code e lt instance
27. s dedicated to particular supply substations dealing with compensations for low and high voltage It also provides analysis of power network in terms of optimal operation and to ensure electromagnetic compatibility e Production located in the industrial area of the town Bystrice nad Pernstejnem serves as a manufacturing and supply chain logistic unit for all other divisions e Virtual Instrumentation located in Ostrava provides services in the system inte gration designing and delivering of measuring and testing workstations based on virtual instrumentation 1 2 Division of Virtual Instrumentation DVI I did my internship in the Division of Virtual Instrumentation which is the youngest division It was founded in the Science and Technological Park in Ostrava in 1997 near the Technical University of Ostrava This division is closely cooperating with the Department of Measure ments and Information Technologies of the university Currently this division has 55 employees and its annual revenue is about 5 billions of euros 1 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 1 THE COMPANY The DVI offers to its customers e Turn Key Solutions Production testers electrical and optical Assembly lines Labo ratory testers e Products Power quality analysers Distributed systems for power quality monitoring Vision components e Design and Development Services Instruments drivers firmware applications End User software for te
28. st and measurements automation SCADA supervisory control and data acguisition Furthermore this division of ELCOM is very involved as a member of the National Instru ments Alliance Program a network of more than 600 partner companies dealing with technical support system integration and sales of National Instruments products The aim of this mem bership is to provide to the customers the best services in the area of virtual instrumentation and elevate the standards to the highest level around the world and gain a high level of support under this program In other words this partnership is to give a quality guarantee for every ELCOM clients Praha O Ostrava Figure 1 1 ELCOM DVI in Czech Republic 13 Main Contacts As my internship dealing with industrial computer is that of both software and hardware aspects of a measuring machine thus I worked with people from different services see below my main contacts e Michal Harhaj responsible of the service Automated Test Systems he was my internship Supervisor e Petr Bilovsky Instrumentation Engineer working in the Automated Test Systems service Ji Kominek responsible of the service Software Components e Anton Petrovska Network Engineer working in the Software Components service 2 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 2 OBJECTIVES 2 OBJECTIVES 2 1 Context Today the quality of a product is largely determined during its manufacture Thus
29. t the pumps should be tested one by one by an operator assigned to this position regarding the following architecture Operator Client PC Server PC Ethernet cable TCP IP a Microsoft SQL Server Webservices Database Bar code Scanner Clare HAL 103 Electrical Test Station Figure 2 2 System Architecture Regarding the placement note that I did not have any explanation on the reasons for different types of tests applied to the pumps for reasons of confidentiality Therefore I will focus more on the driver to communicate with the device and on the treatment of related data in response to the report which was the heart of my subject for this course The various meetings and discussions held with the client resulted in the following specifi cations Easy to use intuitive interface Standalone installation without buying a license LabVIEW e Communication with the database pre test and post test e Management of communication errors eg device unresponsive To test the operation of the HAL 103 I had at my disposal a plate connected to ground so that all measurements were accurate using the above probe I could also simulate a bad test by exceeding the limits set in the sequence by removing the probe during the measurements which significantly increased the resistance measurement Several series of tests with pass or fail were conducted to test the reliability of my software In the next section th
30. throughout the process This is a common notation that allows easy detection of corrupted characters and avoids the need for special encoding of control characters etc 5 1 2 Initialization Connection settings are the following e Baudrate 9600 e Data Bits 8 e Parity None Stop Bits 1 0 Flow Control XON XOFF Timeout ms 1000 Termination Character Carriage Return 0x0D in HEX I have added a step for flushing clear the memory before it can communicate with a device and initialize properly between the PC and the HAL 103 The result of the initialization in LabVIEW is very fast and easy to implement as part of the serial link b simply using the tools provided by adapting the parameters of the communication data provided in the user manual It has also added a step to prevent the flush of the remnants from initializing the connec tion disrupts communication between the PC and the HAL 103 13 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT Note that in that case the inputs and outputs are e serial port COMM 1 or 2 which is connected to the RS232 cable e the error stream to see if there was a problem connection for example using the timeout if no value is read during the interval 1000 ms so an error is generated Note also the icon at the top right specific to the program vi is the file extension of LabVIEW so we will link it to other boxes to create the overall program the sub vi cou
31. tion Factory Acceptance Test Partial Payment up to 90 Project realization period Delivery Power Up Site Acceptance Training Partial Payment typically remaining 10 Technical Support and Warranty Figure 7 3 Business Project EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT Basic SADT D Basic SADT Perform HAL Test Read Test Result Write Test Command Init Close Communication Communication Set parameters Into HEX String Convert HEX string Into Measurements Figure 7 4 Basic Structured Analysis and Design Technique E Examples Character Equivalences Digit Character Test code Type Digit associates the test code with Seaward Group Ltd Equipment Dig 1 Test code Type 1 Test code Type e Seaward Group Ltd lest code Figure 7 5 Meaning of the 1st character Digit 2 Test Type 0 ws EEE 8 Wim o DC Insulation Resistance DIR E EEE i SS SP Figure 7 6 Meaning of the 2nd character Ramp to Target Time a PE OS PET O Oos m m m TY TO TO CT 6th and 7th characters 3 Figure 7 7 Meanings for the 5st DOS DU RAPPORT Etudiant nom et pr nom Ehouarn Perret Ann e d tude dans le d partement 4 Entreprise ELCOM a s Division of Virtual Instrumentation Adresse compl te Technologick 374 6 708 00 OST
32. ture is that it should recognize each item on the list consisting of modules brief functionality of each module their interface relationships dependencies database tables architecture diagrams technology details etc The integration testing design is carried out in this particular phase e Low Level Design Low Level Design The designed system is broken up into smaller units or modules and each of them is explained so that the programmer can start coding directly The low level design document or program specifications will contain a detailed functional logic of the module in pseudo code e Coding This is the implementation of the modules that have been previously defined e Unit Testing This is the method by which individual units of source code are tested to determine if they are fit for use A unit is the smallest testable part of an application In procedural programming a unit may be an individual function or procedure Unit tests are created by programmers or occasionally by white box testers The purpose is to verify the internal logic code by testing every possible branch within the function also known as test coverage Static analysis tools are used to facilitate in this process where variations of input data are passed to the function to test every possible case of execution e Integration Testing The separate modules will be tested together to expose faults in the interfaces and in the interaction between integrated compo
33. uested by the customer according to plan before with some differences The application has also been transformed into an executable that requires no license for the LabVIEW client but it can not see the source code It can be run on any machine with Windows if it has the appropriate runtimes that are provided free of charge at National Instruments We tested several scenarios such as the disconnection of some devices including the con nection to the server or tests that do not exist in order to ensure all possible cases of use The tests were passed and the client was satisfied with my achievement that met the specifications initially provided Clare HAL 103 Tester elm Pump ID 1648913 Test Name BETA Test Code 21234567890 Current Status WAITING FOR START CONDITIONS Test time s Test applied V or mA Test reading nan 4 Remote Mode MOhms or mOhms COM Port Zcom1 Test sequence to perform IDLE BETA Downloading Sequences Send to the Reworking Station Performing seguence Waiting for start conditions n Figure 6 1 The Driver GUI 20 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 6 RESULTS Yee ot O Month Nay Week LabVIEW Training Iu Specifications High Level Design Coding Integration Tests Operational Tests _
34. ulation then the result will always be zero for uncorrupted data 15 24 OR ND F EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 5 DEVELOPMENT 5 1 4 Start Session Then in order to send the desired commands open a session through the session start the data required which is able to be basically translated into the following C code Data for Session Start Command translated in C language typedef struct ssscmddata session start u8 protocol ver u8 baud code u8 password seed u8 password ARRAYSZ_SSS_PASSWORD ssscmddata session start Reminder u stands for unsigned integer u8 is 2 HEX ASCII characters u16 is 4 HEX ASCII characters and here a 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 e 01 the cmdseg it is logical cause it is the first command sent to the device before to perform any operation e 10 the cmd code to indicate that is a start session command e 00 00 the item id and the instance in the case of a start command both are to set to 0 e 000E the datasz simply calculated by LabVIEW after parsing the string e 000000000000000000000000000 According to the definition we gave before for the data and as the client did not want managem
35. usiness Project D Basic SADTI E Examples Character Equivalences 10 10 12 13 13 13 13 15 16 18 18 19 20 20 21 23 23 24 EHOUARN PERRET 4TH YEAR INTERNSHIP REPORT 1 THE COMPANY 1 COMPANY PRESENTATION 1 1 Overview My internship took place at ELCOM a Czech company created in 1990 by Mr Jiri Houbidek and Mr Vladimir Korenc The Headquarters are located in Prague and the company is also present in other places in Czech Republic Brno Ostrava and Ndvedice Currently the firm employs more than one hundred employees in 5 departments The original purpose of ELCOM was to create a high end Engineering and Consulting Center in the power electrical engineering field that specializes in reactive power compensation electromagnetics and optimization of electrical energy consumption After having enlarged its activities into the field of AC Alternating Current regulated drives electromotor and power related services ELCOM has now 5 divisions e Applied Electronics located in Prague and Brno is focused on research development and production of special power electronic eguipment particularly power supplies for Czech Railways and public transportation e Drives and Motors based in Prague is a workplace specialized on the delivery of electric motors mainly in explosion proof as for petrochemical industry e Implementation and Design situated in Brno and Ostrava this division i
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