25 to 36 - University of Khartoum
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1. Relay16 h contains the object definition of an ST RELAY1I6 Arcom STE pc interface card and the object definition of a relay channel Resource hMicrosoft Embedded Visual C 3 0 file It should not be edited Stdafx h Microsoft Embedded Visual C 3 0 file It should not be edited Timer h contains the object definition of a Windows CE 3 0 software timer 7 SYSTEM OPERATION The application is initialized by the InitInstance function Fig 7 It registers and creates the main window for the application In the creation of this main window Windows CE sends a WM_CREATE message to its controlling function WndProc found in the file papp cpp The response to this message initializes the entire Numerota numbering printing press application The following list describes the initialization in order 1 Create a status bar window at the bottom oof the main window CreateStatusWindow 2 Create the dialog control window used for the Graphical User Interface GUI CreateDialog 3 Initialize the motor object named MainDrive InitMotor 4 Initialize the invisible Arcom Control window which is the personality of the printer itself inittArcom WWE Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 35 5 Initialize the Input Manager thread InitInputManager 8 CONCLUSION Generally the implemented system has the following advantages e The complication of wiring and sequential relays fo2. 21 647 The design and implementation of the controlled system is based on embedded system The embedded system may be defined as a hardware and software which forms a component of some larger system and which is expected to function without human intervention 10 A typical embedded system may consists of a single board microcomputer and software in ROM which starts running some special K KK Chief Engineer Sudan Currency Printing Press SCPP WE Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 25 purpose application program as soon as it 1s turned on and will not stop until it is turned off Gf ever Generally they are used in automobiles planes trains space vehicles machine tools cameras consumer and office appliances and other handheld as well as robots and toys In embedded systems traditionally the software was permanently set into a read only memory such as a ROM or flash memory chip in contrast to a general purpose computer that loads its programs into RAM each time However nowadays modern embedded systems which are usually implemented with a single board multi purpose PC operate under an embedded operating system e g Windows CE Embedded Windows XP Embedded Linux etc and thus functioning the same as a general purpose computer but used for a specific application such as the control of an industrial plant Sometimes single board and rack mounted general purpose compute
3. Card Address RELAY 16 0x150 0 NO RELAY 16 0x150 1 NO RELAY 16 0x150 2 NO RELAY 16 0x150 3 NO RELAY 16 0x150 4 NO RELAY 16 0x150 5 NO RELAY 16 0x150 6 NO RELAY 16 0x150 7 NO RELAY 16 0x150 8 NO RELAY16 0x150 9 NO RELAY 16 0x150 11 NO ANALOG 0x160 Pin on Connector Channel on Card m m m VININILYIX X WM OQ e o ON MN GO _ NO The input and output wiring schemes are given in table 1 and 2 respectively These components were installed and wired according to a wiring diagram Figure 5 is a photo for the complete wiring of the embedded control system and the other components hosted in a cabinet for the simulation process uy i abode i iad ad i iL i FS Figure 5 Simulation process for the embedded system 5 SOFTWARE DESIGN ENVIRONMENT The embedded controller selected for this electronic based system is operated under Microsoft Windows CE 3 0 The software is coded with Microsoft visual C 3 0 The software development was done in four stages of development before being integrated to control the Numerato printing press The software was developed using Object Oriented approach The stages were as follows Stage One Understanding the original operation of the Numerota printing press Stage Two Connecting to the embedded controller and communicating with the embedded input and output interface cards Stage Three Initial software implementation and the simu
4. 104NC The SC400 processor is packaged in a 256 pin Ball Grid Array The SC400 processor is a low power device and no heat sink is required for this device on the ELAN 1O4NC Without a heat sink the processor can operate at ambient temperatures up to 70 C when run at 66MHz or 50 C when running at LOOMHz The ELAN 104NC board supports up to SMB flash memory This memory is configured as a read write silicon disk drive The flash drive uses a 32KB memory window to access the device and two I O address locations are used to select the appropriate flash area The FLASH status MI Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 29 ml LED will illuminate whenever the Flash drive is accessed The ELAN 104NC uses the Real Time Clock internal to the Elan SC400 The date and time functions are stored in the real time clock when the main power is removed and the battery backup supply is enabled The battery backup circuit maintains the Real Time Clock and CMOS settings when the main power input is disconnected A lithium cell provides the battery backup supply and has a capacity of 170 MAH This battery will provide sufficient support for at least 3 years continuous backup If the main supply is present on the board the battery 1s automatically disconnected from the Real Time Clock circuitry The ELAN 104NC contains two independent watchdog timers which can be used to protect against application software condition
5. A BANKNOTE NUMBERING MACHINE EMBEDDED COMPUTER CONTROL SYSTEM Sami M Sharif and Sayed Harron AbdelKarim ABSTRACT This paper is discussing the design and implementation of embedded computer based control system for a banknote numbering machine Numerota The design is based on the embedded system ELAN 10O4NC with windows CE preinstalled in it ELAN is a single board PC with inputs outputs cards it is a rack mounted system The application software is designed by using the data and signal flow diagrams and coded with Microsoft Visual C 3 0 1 INTRODUCTION Sudan Currency Printing Press SCPP has many printing machines some of them are old but mechanically they are functioning well Their relay based control systems beside its disadvantages are very old many of the electrical components are no longer produced or have been superseded by newer designs Therefore these machines are constantly stopping due to electrical faults which render low production SCPP decided to upgrade the control systems of those machines by contracting companies who work in this field One company proposed an upgrade cost for one machine at a minimum cost of 130 000 EURO The grade included the installation of Programmable Logic Controller PLC It has been noticed that 75 of this cost was just labor Thus it is decided to do the work locally design and implementation and the total cost for this upgrade was estimated to be about
6. an W Kernighan Dennis M Ritchie The C Programmable Language Proposed ANSI Draft Edition E A Parr Bsc MIEE Programmable Controllers and Engineers Guide SCPP Electrical Section 1996 Siemens Programmable Data Sheet Simatic S5 100 U PLC SCPP Electrical Section 1995 E A Parr Bsc MIEE Programmable User Manual 890 William Stallings Computer Orgnization And Architecture Fourth Edition SCPP Electrical Section 1996 Michael Barr Programming Embedded System In C And C SCPP Electrical Section 1996 hyperdictionary online http www hyperdictionary com nren ma 36 Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 itim
7. and Cooling Fans The embedded computer is a rack mounted STEbus chassis fitted with an Elanl04 NC single board PC attached to serial interface card which provides a PC 104 to STEbus interface bus connector The following I O cards also attached to the system e One digital input card providing 32 digital input channels e One relay output card providing 16 changeover relays e An analog I O card providing an analog output channel for controlling the run operation of the power converter to the main drive and an input channel providing analog input channel for sensing the rate of the main drive via its tachometer e In addition another analog I O card providing an analog output channel for controlling the inch operation of the power converter to the main drive Four connectors have been installed for each of the input and output cards fitted in the embedded controller These connectors link the embedded computer s input and output channels with the printing press s electrical system A series of various rated interface relays have been installed in order to protect the relay channels that control high current components on the printing press These components include 1 The main drive brake contactor 2 The power converter enable switch 3 The impression solenoids 4 The delivery solenoid 5 The feeder enable switch The original motor is an AC motor and controlled by resistance or potentiometer This kind of mo
8. contactors have been used to control the above motors Three measuring devices have been installed for monitoring 1 the mains AC voltage 2 the DC voltage of the main drive and 3 the current of the main drive An emergency stop button cuts power from the entire cabinet when it is pushedt A selector switch used for checking the voltages in different phases in the mains AC voltmeter Three 50 amp ultra rapid fusses are installed for the protection of the main drive and its electronic controller Two 63 amp ultra rapid fusses are used to protect the motor and the circuit of the field inside the electronic controller Two 40 watt cooling fans are fixed high on the left and right sides of the cabinet for ventilating generated heat from the electronic components Table 1 Input Wiring Assignments Channel Name Card Address Channel on Card IN32 0x120 Main Controller Over Temperature IN32 0x120 Main Drive Brake Sensor Pin on Connector N NO NO Air Pump Over Load IN32 0x120 I 23 Air Pump 2 Over Load IN32 0x120 8 5 Front Table Out Sensor IN32 0x120 9 24 Back Table Out Sensor IN32 0x120 10 6 1 Lower Numbering CAM Control IN32 0x120 15 Switch Upper Numbering CAM Control IN32 0x120 16 Switch ANALOG 0x160 AININ NO ON m KO NO O W VOo Table 2 Output Wiring Assignments Channel Name WWE Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43
9. e Cylinder system and the Inking system The cylinder system is made up of three cylinders Upper Numbering Cylinder the Impression Cylinder and the Lower Numbering Cylinder The numbering units are fixed in the numbering cylinders The function of the numbering cylinder is to hold the numbering units and revolve them in contact with the impression cylinder during the printing process The ink from rollers contacts the numbering units in the numbering cylinders Consequently the numbers in the numbering units are inked Then a sheet is fed between the numbering cylinder and the impression cylinder and then the images of Wt Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 27 the numbers are transferred to the paper The grippers in their way to the delivery unit receive the paper The function of the inking unit is to transfer a uniform thin layer of ink to the numbering units The ink stored in a reservoir and then fed in small quantities through different types of rollers During this process the ink worked into the type of the delivery system used in this press is the chain gripper system it is made up of two closed loops of chains There are bars fixed across the two chains the grippers are fixed on the bar When the sheet leaves the printing unit its front edge is grabbed by the grippers pulled out of the printing unit and dropped on one of the two delivery tables of the press then the grippers mov
10. e back to receive another paper At the end a neat stack of paper is formed on the two delivery tables The chain of the gripper system moves at the same rate of the printing unit registration unit and the feeder unit That means the three units move in synchronization TAF S gt Display Error Erroi gt STOP Inch Pr OO END NO Print Inchin A Run Pr a Print Runnit Figure 3 Flowchart for the operation of Numbering Machine NO Pape Aligne Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 Jill Turn on Im 3 HARDWARE DESCRIPTION For upgrading the control of the banknote numbering machine an embedded system called Standard Europe PC STEpc using ELAN IO4NC single board PC was used This system consists of the following Microprocessor Memory Inputs and outputs cards Peripheral components and Software It 1s a rack mounted system Figure 4 shows the STEpc from inside L Lo CO i N N nl hin i L Figure 4 STEpc with single board computer and I O cards The AMD Elan SC400 processor is an Am486 class processor without a floating point unit It is a fully integrated PC AT Personal Computer Advanced Technology IBM compatible architecture The SC400 is a 32 bit x86 compatible device A 1OOMHz processing unit is used on the ELAN
11. e is generating by Microsoft Embedded Visual C 3 0 It describes the Graphical User Interface components e g buttons edit controls progress bars etc It is processed and compiled by Microsoft Embedded Visual C Relay 16 cppContains software for controlling the ST RELAY16 Arcom STE pc bus interface card Stdafx cpp This file is generated by Microsoft Embedded Visual C 3 0 file Timers cpp Contains the software code for handling software timers in Windows CE 3 0 Definition Header Files Analog h contains the object definition of the ST Analogue I O Arcom STE pc interface card and the object definition of an in out analogue channel Arcom h contains the interface functions for the software contained in the arcom cpp source code file Common hcontains the definition of the global configurations data Structure and the application specific event identifiers for the Numerota Software application Halio h contains the definitions of the I O bus interface functions used by the Arcom STE pc interface card control objects x nan 34 Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 Jit va In32 h contains the object definition of an ST INPUT32 Arcom STE pc interface card and the object definition of an input channel Inmgr h contains the interface functions for the input manager software code contained in the inmgr cpp source code file Motor h contains the object definition of the main motor
12. ent message that is sent to it by effecting 1 Internal variables like the paper counter or the Impression on button status for example 2 Relay channels connected to the ST RELAY16 interface card used for controlling the main drive brake and main controller or indicator lamps like the stop and ready lamps 3 Analog Output channels used for inching and running the printing press note 32 gt Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 putnim Nurerota Murbenng Piring Press Q Arcoms TE pe Enb elded Controller FlanlO4NC Embedded PC fa Furr Window CE 3 0 Figure 6 Complete Data Path Diagram Figure 6 shows the software to hardware access path diagram Generally The Arcom STE pc Embedded Controller contains four interface cards 1 ST IN32 receives all printer input signals including buttons sensors and limit switches 2 ST RELAY16 controls all output printers signals including indicator lamps solenoids contactors and switches 3 ST ANALOGIO one to control the running operation 4 ST ANALOGIO one to control the inching operation In reference to Figure 7 these physical hardware interfaces are accessed via C object interfaces which internally utilize the Elanl04 NC board support package which is represented by the rectangle labeled Hardware Abstraction Layer Halio cpp in Figure 7 It is specifically designed for the Elan 104 NC microprocess
13. four printing units as shown in Figure and 2 namely these units are 1 the feeding unit 2 The registration unit 3 The printing unit and 4 The delivery unit feeder then it goes through registration unit to the printing unit and finally the sheets are collected in two piles in the delivery unit Figure 3 shows a flowchart the sequence of operation of the machine The feeder is an air vacuum device it has two motors limit switches and mechanical latches Registration is the process of controlling a sheet before it enters the printing unit to get image position consistency in every printed sheet In our machine the goal of registration is to print the two serial numbers in the exact position in every printed banknote As the sheet enters the registration unit it is halted by the head stop then the rotary motion of the pull guide for proper positioning pulls it then the head stop moves out of the way so that the sheet can enter the printing unit In this press a two point pull rotary system is used for registration Figure 1 Numbering Machine Components m 26 X Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 putnim 4 sw Figure 2 Numerota Machine manufactured in 1963 The goal of the printing unit is to place ink on the numbering unit and then to transfer image to the paper and finally to deliver the paper to the delivery unit The printing unit for this press 1s made up of two parts th
14. lation environment Stage __ Four The final implementation design a Windows CE 3 0 application The Numerota printing press application software consists of two windows one visible and the other invisible a motor object that contains two threads for controlling acceleration and deceleration and a third thread to monitor the input signals coming in via the ST INPUT32 Arcom STE pc interface card and generating corresponding event messages This type of design was selected in order to catch or to trap error events as soon as they occur irrespective of other events that are simultaneously occurring By scanning the input interface card and controlling the acceleration and deceleration in separate threads the application is able to detect 1f another event perhaps an error event occurs while another task is in progress and respond immediately appropriately responsively In case of error events the printing press can be stopped immediately while accelerating or decelerating or while any of the control buttons are being pressed or released 6 DATA AND SIGNAL PATH DIAGRAM Figure 6 shows the complete data and signal flow diagram The flow of the data or signals originates at the buttons limit switches sensors or contactors or from Graphical User Interface on the monitor Every input signal is processed and an event message is sent to the Arcom Control window described later This particular window reacts to each ev
15. or in order to read from and write to the physical interface cards on the STEbus The Numerota printing press application consist of four components as mentioned before 1 The GUI Control window 2 The Arcom Control window 3 The Motor MainDrive object contains two threads for controlling acceleration and deceleration 4 The Input Manager thread MI Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 33 jn Arcom Input Cantril Motor ib ject Manager Wind Brake Rumning hod Charel i Arabe bowed 3 Tred Chanel 31 Anibe Chanel 0 j ic Oo Hardware Abstraction Layer Elan INC VO TEF Bus a 5 E Bo eo z E Figure 7 Software to Hardware Access Path Diagram Figure 8 shows the Event Messages Paths via Windows CE 3 0 The beginning of a Windows application is in a function called WinMain which is found in the papp cpp source file It first begins by instantiating windows and objects initializing them and initiating the necessary threads and synchronization utilities namely two signaled events and a mutex Once the initialization has completed the Win Main enters the controlled message loop waiting for message sent by the Windows Operating and from within the application itself The message loop receives messages and dispatches them to either the GUI Control window or the Arcom Control window or any of the GUI components within the GUI Control window depending on the destina
16. r implementing control logic is eliminated it is provided by modern operating system i e Windows CE 3 0 This makes the design of the control system have elegance simplicity and functionality e Embedded systems are growing in popularity their phenomenal growth is closely linked to the increasing availability of more powerful and less expensive processors as well as to the decreasing price points of low cost high density memory and the development in their operating systems e Many programming languages can program it some of them are known and easy like Java and C e They are accessible and controllable through LANs WANs and the Internet which makes it easier for the suppliers to monitor performance update configuration information and give technical support to customers e The system provides a very powerful tool for the diagnosis of faults that occur during operation of the machine for this project a diagnostic feature was added by showing errors on the screen Figure 8 showing the new control cabinet with the embedded system while the machine is running Figure 8 The new control cabinet REFERENCES 1 Kurtis Johnson Process Control Instrumentation Gazera University Library 1999 2 Groupe Schneider Modicon Modsoft SCPP Electrical Section 1997 10 E A Parr Bsc MIFE USE 11500 Version 2 0 Upgrading and Repairing PCs 12th Edition SCPP Electrical Section 1996 Bri
17. rs are called embedded computers if they are integrated in systems to operate in this way An embedded system is a real time system it has the ability to make certain decisions in a timely manner These decisions have a deadline for completion The issue of what happens if a deadline is missed is a crucial one For example if the real time system is part of an airplane s flight control system it is possible for the life of the Associate Professor Department of Electrical and Electronic Engineering University of Khartoum The type of the feeder for this press is a sheet fed type The trip of the sheet in the press starts from the in feed pile in the passengers and crew to be endangered by a single missed dead line However if the system is evolved in a satellite communication the damage could be limited to a single corrupt data packet Embedded software unlike software of general purpose computers cannot be run on other embedded systems it needs significant modifications This is due to the variety in the underlying hardware The hardware in each embedded system is tailored specifically to the application in order to keep system costs low 2 OPERATION OF THE BANKNOTE NUMBERING MACHINE NUMEROTA The Numerota is a sheet fed letter press numbering machine specially made for the requirements of manufacturing securities and used for printing numbers signatures and text parts This press is made up of
18. s that may cause the ELAN 1O4NC to hang The watchdog timers once started will trigger a CPU reset if they are not re triggered within a set timeout period The watchdog timers can be disabled permanently by removing jumpers on the board one corresponding to each timer The PC 104 interface supports 8 16 bit ISA Industry Standard Architecture style PC 104 signals Add on boards can be used to enhance the functionality of the main board A large number of companies have adopted the PC 104 standard and boards are available which support a wide range of interfaces This bus can be used to add digital I O analogue I O serial ports video capture devices PC CARD interfaces motion control devices etc Any board plugged into this interface will be accessed as if it were part of the main board Therefore it may conflict with I O and memory devices onboard if it has not been configured Before using an expansion board it should be checked that it could be configured to work alongside the peripherals already incorporated onboard The PC 104 bus signals are fully compatible with the ISA bus electrical timing definitions 4 SYSTEM HARDWARE DESIGN The control cabinet included the following hardware components An embedded computer Interface Connectors Interface Relays Power Converter Main Isolating Switch Transformers Rectifiers Overload Switches Main Contactors Measuring Devices User Control Panel Fusses
19. tion of the message The following are two lists naming and describing the source code and definition files used in the Numerota numbering printing press application Source Code Files Analog cpp contains software code for controlling the ST Analogue I O Arcom STE pc bus interface card Arcom cpp contains software code for controlling the operations of the Numerota numbering printing press Figure 8 Event Messages Paths via Windows CE 3 0 Halio cpp contains software code for interfacing with microprocessors I O bus interface in order to communicate with the Arcom interface cards on the STE pc bus In32 cpp contains software code for controlling the ST INPUT32 Arcom STE pc_ bus interface card Inmgr cpp contains software code for managing the various input signals coming from the Numerota numbering printing press and firing appropriate events to the control software contained in the Arcom cpp software code file Motor cpp contains software code for managing the operational features of the main motor i e stopping applying and releasing the brake accelerating decelerating and inching the main drive Papp cpp contains software code initializing the main window and child windows for the Windows CE 3 0 printer application papp cpp In addition it contains the control function for controlling the entire Graphical User Interface feature displayed on the computer terminal Papp rc This fil
20. tor with its traditional control has many disadvantages It cannot be controlled smoothly and there is much energy loss due to use of resistance in motor s speed controller and more importantly it cannot be controlled by an embedded system Thus the main drive was replaced by a Baumiller DC motor with the corresponding 520VDC_ power converter which has an electronic based control system The converter is very efficient reliable heavy duty economical in the consumption of the energy and easily controllable by a computer based controlled system Three line reactors have been installed before the main input voltage enters the controller to protect from surge voltages Additionally two reactors have been fitted before the field input voltage enters the controller for the same purpose The main switch provides isolation and protection of the cabinet Two transformers have been fitted One transformer rated at 650 VA 220 60VAC is connected to a 20 amps rectifier producing 60VDC used for supplying the solenoids Another transformer rated at 450 VA 220 24 VAC used for supplying the control of the entire cabinet Six overload switches have been used to protect the six motor in the system as follows Main drive motor Main drive cooling fan motor Feeder compressor motor Main feeder drive Delivery compressor motor and Hydraulic pump x nan 30 Sudan Engineering Society JOURNAL January 2005 Volume 51 No 43 Jil va motor Six
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