Extending CompactRIO connectivity through Anybus CompactCom
Contents
1. Anybus protocol On Name amp link to target M Master S Slave Price market SEK Fieldbus versions BACNet MS TP CANopen Yes NI 9881 http sine ni com nips cds view p lang sv nid 209998 6 090 CC Link CompoNet ControlNet DeviceNet Yes NI 9882 http sine ni com nips cds view p lang sv nid 2 11943 6 090 Modbus RTU Profibus Yes http sine ni com nips cds view p lang sv nid 208386 M S 17 230 http sine ni com nips cds view p lang sv nid 208387 S 10 090 Ethernet versions BACNet IP EtherCAT EtherNet IP Yes http www sea gmbh com en products compactrio 869 products wireless technology wlan Modbus TCP Powerlink Yes 28 Profinet Yes http sine ni com nips cds view p lang sv nid 211935 S 12 760 Sercos III Other versions Bluetooth RS 232 Yes NI 9870 http sine ni com nips cds view p lang sv nid 204262 5 235 38 Anybus CompactCom module for cRIO systems RS 485 Yes NI 9871 http sine ni com nips cds view p lang sv nid 204263 6 280 USB 4 4 1 Conclusion As the table above describes there are certainly a market for WireFlow to expand into if they decide to start developing these new types of modules Although many of the leading networking standards are available for CompactRIO standards as CC Link one of the largest open networking standard and Sercos III are still not available for CompactRIO users 4 5 Expanding the LabVIE2. Application Data Application Parameter Application Parameter Application Parameter Acyclic Request These buffers holds data from ADI s that are mapped to process data Figure 11 Layout of parameters handling in ABCC module 15 p 8 As the picture above explains the ABCC module holds a process data buffer readable and writeable that is accessed through a dedicated channel The dedicated channel is a part of the telegram sent to and from the module the process subfield which was explained before It can also handle acyclic request by sending them straight through the module and to the host application All of the parameters that are being accessible either through the process data buffer or application data object need to be setup in the host application before the program starts If they are to be used in the process data buffer they also need to be mapped in it as well ADIs are objects holding several parameters all having the same layout with fields as name data type number of elements and value etc 2 3 7 1 ADI s in process data buffer The ADI s that are mapped in the process data buffer need to be accessible to both the module and the host application This is done by the process data subfield that is used in the telegrams that are exchanged between the ABCC module and the host application If an ADI is mapped to be read process data the value of that ADI is present in the process data subfield o
3. 3E07h 3FFEh 3FFFh 38FFh 39FFh 3AFFh 3C06h 3CFFh 3E06h 3FFDh Area Access reserved Process Data Write Area Write Only Process Data Read Area Read Only BEEN Message Write Area Write Only Message Read Area Read Only NEL RN Control Register Read Write Status Register Read Only Figure 9 Memory map for parallel interface 15 p 21 b Telegram handling When the module exchanges a new telegram this is signaled by the STAT T bit in the status register To read this bit the host application can either poll the status registers cyclically or rely on interrupt operation which is highly recommended by HMS 15 p 22 2 3 5 The Anybus state machine The active modules in the ABCC series are configured to use the Anybus state machine This means that at any given time the state machine reflects the status of the module and the network 15 p 23 17 Power up EXEPTION 07h From all states WAIT PROCESS 02h PROCESS ACTIVE 04h Figure 10 Anybus state machine 15 p 23 2 3 5 1 States In each state the host application is expected to perform certain tasks i e in NW INIT the module preforms network related initialization tasks When the module is configured and connected to the network it will be in the PROCESS ACTIVE state which means it is able to fully communicate with the network Depending on the user action the module can transitio
4. gt 8 co u 9 Vs salar 15pt Application Font is 69 ES l Search A 9 vem Program output Refnum Temperature Refnum Actual speed Refnum Ref speed Refnum Direction Refnum Poles Refnum No Error vj 1 New temperature Value Cha NewVal Program output Strin Temperature 2 Digital Temp input queue Stop notifier Actual speed Digital Ref speed amp Digital Direction Digital Poles Digital stop FET fies Network type babe Firmware versic VISA resource name CZ Serial number Network type Strin Program outpu Firmware version Strin Temperature Serial number Strin Actual speed New temperature CI Ref speed Node adress Laat Direction Baudrate Lus PM ales Figure 19 Main application code block diagram 26 Anybus CompactCom module for cRIO systems File Edit View Project Operate Tools TO 9 Window Help VISA resource name Network type kowmi CANopen New temperature a e MMC TL C e rg y 120 build 7 A0 1D 40 DD sl Node adress J Actual speed Temperature Ref speed Direction Poles jo fo f fa ABCC_SDK Ivproj My Computer Figure 20 Main ap
5. please refer to its WWW home page http www ep liu se Emil Martinsson
6. 4 2 3 CompactElashi Connector onn Pee BEP PP ep PED RPG 35 4 2 4 Front panel of cRIO module sse nennen ementi 35 4 25 Alignment of ABCC module on cRIO module PCB see 35 42 6 Creating a prototype PCB re ed e et etre ede gerer e RR eee ns or 36 ADT CcGonclusion rio ph n UR CERTI GR Dn Ao 36 4 3 cRIO interface together with the ABCC module esee 36 4 34 Object hierarchy ecrire ih irm en eir i eee dede eri 37 4 3 2 rt ree en He B e Pe RP ep PP 37 4 4 Market research n n AA A cr e ere eer eer ud 37 FAT Conclusion uino Eee ente de tede tede ete dee 38 4 5 Expanding the LabVIEW SDK ninaosa mnia E AESA nn non nonnonn oracion AE iSi 38 AL Object Suppott i teet o et Co etes AA e 38 452 S lltobeumplemented AAA Ree ete get etii reete gt 39 45 3 Reallfescenaro g nine ee ne een aede ete redo et rette ende 39 Referentes NO 41 Abstract This thesis report describes an exploratory work for a network communication modules to be used together with the CompactRIO system a system used to control or monitor industrial machinery This thesis was carried out by integrating the existing ABCC module series which is a communication solution that can be used to control or observe industrial machinery into a CompactRIO module The report describes how the implementation has been carried out and describes the parts that were implemented and give the company WireFlow
7. ODV A 2006 The Common Industrial Protocol CIP and the family of CIP Networks http www odva org Portals O Library Publications Numbered PUB00123R0 Co mmon 4o20Industrial Protocol and Family of CIP Netw pdf 2014 02 12 PROFIBUS amp PROFINET International PI 2012 Profibus http www profibus com technology profibus overview 2014 02 12 Step Automation amp Test StepAT no date Ethernet POWERLINK on CompactRIO http www stepat com index php content download 3260 29835 version 1 file Eth ernet POWERLINK on CompactRIO pdf 2014 01 02 Universal Serial Bus USB 2014 http www usb org 2014 02 12 43 30 WireFlow AB WireFlow About http www wireflow se about 1 2013 12 12 P svenska Detta dokument halls tillg ngligt pa Internet eller dess framtida ers ttare under en l ngre tid fran publiceringsdatum under f ruts ttning att inga extra ordin ra omst ndigheter uppst r Tillg ng till dokumentet inneb r tillst nd f r var och en att l sa ladda ner skriva ut enstaka kopior f r enskilt bruk och att anv nda det of r ndrat f r ickekommersiell forskning och f r undervisning verf ring av upphovsr tten vid en senare tidpunkt kan inte upph va detta tillst nd All annan anv ndning av dokumentet kr ver upphovsmannens medgivande F r att garantera ktheten s kerheten och tillg ngligheten finns det l sningar av teknisk och administrativ art Upphovsmanne
8. BNC 2 Port 11 x 28 2 mm e CompoNet 10 x 33 3 mm Figure 25 Measurements of ABCC module with housing 10 p 6 4 1 2 2 Current consumption In every network appendix for the ABCC modules HMS has written the current consumption for that type of module Table 5 The supported networking systems and their actual power consumption 13 Network Consump Power Connector type tion mA W P V I 1 BACnet IP 2 Port 380 1 254 RJ45 2 port 2 BACnet MSTP 317 1 0461 Pluggable Screw Terminal 3 Bluetooth Passive 50 0 165 None 4 CANopen 185 0 6105 D SUB 9pin 5 CC Link 280 0 924 Pluggable Screw Terminal 6 ControlNet 660 2 178 BNC 7 CompoNet 188 0 6204 CompoNet 8 DeviceNet 65 0 2145 Pluggable Screw Terminal 9 EtherCAT 370 1 221 RJ45 2 port 10 Ethernet IP 1 2 Port 200 380 0 66 1 254 RJA5 1 2 port 11 Modbus RTU 210 0 693 D SUB 9pin 12 Modbus TCP 400 1 32 RJ45 2 port 13 Profibus DP V1 230 0 759 D SUB 9pin 14 Profinet 1 2 Port 200 380 0 66 1 254 RJ45 1 2 port 15 RS232 Passive 22 5 0 07425 D SUB 9pin 16 RS422 485 Passive 170 0 561 D SUB 9pin 17 Sercos III 400 1 32 RJ45 2 port 18 USB Passive 50 0 165 USB 4 1 2 3 Thermal requirements The ABCC modules are fully operational between 40 to 85 C 10 Appendix A these can also withstand the same temperatures when being sto
9. for five Application Data Objects ADI s Support for CANopen network specific object During the developing process the ABCC software design guide has been used as a basis The developing only extends to the objects that are marked mandatory in the guide 4 5 2 X Still to be implemented Make SDK independent regarding what data format that each module has LSB or MSB Take necessary action towards PDS parameter data support in case a module doesn t have it If that is the case what should happen Add support for passive modules not supported at all in today s SDK All network specific objects for the supported standards available in the ABCC series Expanding the support for the Application Data Objects making it fully automatic Implementing the Application Object Implementing support for the Diagnostics Object 4 5 3 Real life scenario In this part we will try to give the reader an understanding on how this future product can be used in a real life scenario An industry develops some sort of electronics In their industry they are about to invest in two valves for controlling the flow of some kind of liquid these valves have a cRIO chassis integrated in them with IO s for controlling the valves The main network standard in the industry is CANopen to which several machines and resources are connected to today and now they want to be able to observe and control the valves using the same network By
10. the driver software in LabVIEW was the object hierarchy that exists on the ABCC C driver This causes problems since there are a lot of objects needed to be implemented in order for the driver to support them all When developing the LabVIEW SDK driver this became known However since time was limited the decision was made to only implement the support needed for just the module was going to be used When designing a driver to support all the available modules it is best to base that the code on parameters that are gettable from the module at startup such as Module type Network type etc 4 3 2 Conclusion The working LabVIEW SDK driver will hopefully give WireFlow a good sense of what they need to expand and implement and that this code can be a guide for them to follow in order to implement the needed functionality 4 4 Market research In order to develop a successful product the company has to know what is available on in today s market WireFlow s main concern was not to reinvent the wheel and develop a product that already exists WireFlow want to be able to give NI s users an extra dimension by being able to give the users possibility to connect to any type of network standard available today During this thesis we found that from what networking standards HMS will provide via the Anybus system these are available and not Table 6 Market analysis 18
11. the practical part of the thesis was carried out and the steps that where taken during the thesis 3 1 Starter kit In order to be able to communicate with the ABCC module a computer had to be connected to the module therefor WireFlow purchased a starter kit from HMS which is intended to help developers learn the basics of ABCC and speed up the implementation of ABCC module in host applications The starter kit consists of a PCB with a CompactFlash connector A for connecting the ABCC module and a serial COM port D for communicating with the ABCC module The board also holds a power socket E a reset switch C and a baud rate switch B With the starter kit HMS there was also a full driver provided to be used in the host application and also a demo application called Anybus SDK with some settings already in place to be able to set up a small industrial network environment This SDK is written in C and is run by using the command prompt on a PC Figure 12 Starter kit board 11 3 2 LabVIEW communication The main thing for this thesis was to get the ABCC module communicating via NI LabVIEW towards the CompactRIO This was done by creating a demo application or SDK similar to the Anybus SDK and test the communication A LabVIEW environment was set up with a serial COM connector and an input text field for sending telegrams to the ABCC module A VI was also created for adding the CRC field automatically to th
12. using a cRIO CANopen module from WireFlow the company can extend their current network and be able to control or observe the new valves all from one monitoring station 40 Anybus CompactCom module for cRIO systems Monitoring workstation industrial WireFlow CC module I I I I I I I I i I I cRIO il chassis Oth RIO erc I components i i I I I I I I I This is an easy way of explaining how this new product can be implemented in expanding industries Making sure that new equipment stays fully operational in the current networking standard instead of having to expand the network with another standard just to make sure an investment can be fully operational It will be a lot easier to implement and also help the company save money 41 References 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Bluetooth 2013 Fast Facts http www bluetooth com Pages Fast Facts aspx 2014 02 12 CAN in Automation CiA 2006 CANopen http www can cia org index php id canopen 2014 02 12 CAN in Automation CiA 2006 Controller Area Network CAN http www can cia org index php id systemdesign can 2014 02 12 CC Link Partner Association CLPA 2013 Welcome http www clpa europe com 2014 02 12 EtherCAT Technology Group 2012 EtherCAT http www ethercat org en ethercat html 2014 02 12 IEBEXplore IB
13. using a drill for the fieldbus connector in the front panel of the cRIO module 4 2 5 Alignment of ABCC module on cRIO module PCB The ABCC module was measured and aligned on the PCB and drilled holes for the mounting kit of the ABCC module and then cut out a horizontal hole for the slim connector to the CompactFlash connector By doing this and creating the holes in the front panel it was proven that the ABCC module would fit inside the cRIO module 36 Anybus CompactCom module for cRIO systems Figure 32 Pictures showing the ABCC module inside the cRIO module In this mockup the RS232 module from the ABCC collection was used this was used because it has the same connector as the CANopen module D SUB 9pin When the mockup was made the requirements of cRIO modules had not been examined and it was not known that the connector was too high although we manage to fit it inside 4 2 6 Creating a prototype PCB As discussed before in LabVIEW SDK and ABCC module in cRIO chassis the decision was made since all the components were available to build a real prototype It was also decided that a PCB would be created holding all the needed components to test the ABCC CANopen module 4 2 7 Conclusion The conclusion of the question on how to fit the ABCC module inside the cRIO module is that it is possible Although a normal CompactFlash connector cannot be used since that requires too much space on the PCB Since the mockup was made u
14. 0 15 11 19 193 Y 100000 2013 10 18 node ID a gi M SDO read d stop J Temperature I J fo STOP m c 9 ro m aam Figure 17 CANopen interface in LabVIEW In this application there are interface controllers on the left and controllers to access the writeable parameters in the process data buffer called PDO s There is also a control for changing the parameter Poles that is accessible through acyclic data write request SDO Furthermore there is one indicator for the readable parameter in the process data buffer Actual speed and an indicator for the parameter accessible through acyclic data read request Temperature The CANopen fieldbus is structured like the ABCC modules with object orientation and in order to set up these parameters to access the right objects studying of the CANopen protocol was needed 6 3 5 3 Conclusion of tests towards Anybus SDK By studying the telegrams exchanged between the ABCC module and the host application it was established how the messaging between the two works It was also demonstrated that the module handle both read and write requests through the process data buffer and the acyclic requests It was established that HMS has setup their ADI s and how they are mapped in the process data buffer Although all of this could have been learned by reading and studying the C code for the Anybus SDK this saved a lot of time and also gave a good understanding
15. 2 1 byte 16 bytes Up to 256 bytes 2 bytes Handshake register Message subfield Process data subfield CRC16 field 1 byte last byte The CRC16 is a 16 bit Cyclic Redundancy Check which covers the whole telegram except the CRC itself 15 p 12 As described before the message subfield when using the serial interface is always limited to 16 bytes if the module or the host application has longer messages than that to send these are sent as multiple small fragments It is up to the receiving end to bundle these small fragments and interpret the whole data as one message 2 3 4 3 Parallel In this thesis the parallel communication was never used when communicating with the ABCC module and therefore this is just a short explanation of parallel communication towards the ABCC When using the parallel interface to communicate with the module telegrams are read or written to a shared memory area 15 p 21 When the host application sends a new message the application updates the Control register in the memory map The same concept is used for the module which updates the status register to indicate that a new message is available Because of this system the process data and message subfield needs to be written to before accessing the control register 16 Anybus CompactCom module for cRIO systems a Memory map Address Offset 0000h 37FFh 3800h 3900h 3A00h 3B00h 3C07h 3D00h
16. AB a good basis for future development The result shows that it is possible to integrate the ABCC modules in cRIO both in terms of hardware and software integrating The thesis delivered a working cRIO prototype to the company together with a driver developed in LabVIEW Gothenburg Sweden March 2014 Emil Martinsson 6 Anybus CompactCom module for cRIO systems Preface This thesis report is an exploratory work for an IT company to be used as a basis for a new product development I would like to thank all the personnel at WireFlow AB for making this thesis possible and I would also like to thank my supervisor Bogdan Tanasa and examiner Unmesh Bordoloi at Link ping University Gothenburg Sweden March 2014 Emil Martinsson Chapter 1 Introduction This thesis was carried out as a final project at candidate level for a three year degree in Computer science at Link ping University 1 1 Background As technology moves forward and changes from day to day the need for adoption in industry networks is essential Being able to adapt or expand systems is vital for companies to keep their system up to date In today s market there are a lot of different types of fieldbuses e g CC Link and Ethernet standards e g EtherCAT available for companies to use when expanding or renewing their current system layout Making industrial control and monitoring systems such as CompactRIO or cRIO able to communicate with many different network
17. CC series is developed by the Swedish company HMS and is meant to be used to connect any type of industrial controller to any of the available networks included in the ABCC series 13 This chapter will describe more in detail how the components of the ABCC module connects and communicate with the host application 2 3 1 Fieldbuses and Ethernets Today HMS offers 20 different types of fieldbuses 13 Ethernet standards and other versions in their ABCC series e g CANopen EtherCAT Bluetooth and USB The main objective for the ABCC is to integrate them in machines or productions and make them available for a wide number of networking standards The ABCC modules are run by a C driver within the host application Anybus Module Host Application Main Application Software Host Interface i o gt a UO i po o Figure 7 Layout of the ABCC the driver and the host application e g an industrial machine 16 p 10 2 3 2 Active and passive modules The ABCC modules are divided into active and passive formats 14 p 8 Depending on which type of format they have they interact differently with the responding network The passive module works as a bridge between the host application and the network whereas the active module have the Anybus chip built in and translates the messages from the network to the host application and vice versa Since the passive modules only pass on the information from
18. CompactCom Software Design Guide pdf 2014 01 02 HMS 2010 Anybus CompactCom Standard Driver http anybus com upload Anybus CompactCom 3403 Anybus CompactCom 3295 Anybus 20CompactCom 20Driver 20Package 202 11 zip 2014 02 12 National Instruments NI 4 slot cRIO chassis NI 9075 Picture http sine ni com images products us 02221111_m jpg 2014 01 02 National Instruments NI 2013 CompactRIO Third Party Products http www ni com white paper 2726 en 2014 01 02 National Instruments NI cRIO module Picture http sine ni com images products us 041119_crio9954_1 jpg 2014 01 02 National Instruments NI 2011 NI cRIO 9951 CompactRIO Module Development Kit User Manual Hardware User Manual Provided by WireFlow AB National Instruments NI NI PXI 1031 Chassis Picture http sine ni com images products us 01051217_m jpg 2012 12 12 National Instruments NI 2012 What is LabVIEW http www ni com labview 2013 12 01 National Instruments NI 2010 What is NI CompactRIO http www ni com compactrio whatis 2014 01 02 Open DeviceNet Vendors Association ODVA 2014 ControlNet http odva org default aspx tabid 244 2014 02 04 Open DeviceNet Vendors Association ODV A 2014 DeviceNet Technology Overview http www odva org Home ODV ATECHNOLOGIES DeviceNet DeviceNetTechn ologyOverview aspx 2014 02 12 Open DeviceNet Vendors Association
19. Current When using 5 volt 5V 200mA 1 W When using 3 3 volt with 8596 efficiency 1W 0 85 3 3V 257 mA This means that in order to be able to use the ABCC modules together with the cRIO module the ABCC module cannot draw more than 257mA of current This implies that 11 of the 20 available ABCC modules will work within the cRIO module However the rule in the MDK can be taken out of consideration if an external power supply is used to power the electronics inside the module This is something that has been discussed with WireFlow So in the case of power consumption there is not really an issue for the modules to be integrated in the cRIO modules 4 1 3 3 Thermal Since the ABCC module will be installed inside the cRIO module it is important to make sure that the inside of the cRIO module meets the requirements of the ABCC modules temperature range 40 85 C With the rule stated in the cRIO MDK 20 that modules cannot exceed the power limit of 0 625 W for modules with 85 C rated components it is important for WireFlow to make sure that the power doesn t exceed this limit otherwise the inside of the cRIO module may be too hot for the ABCC module to be fully functional Since the current drawn of each module is known as well as the voltage level required to power them a column with the power is shown in Table 5 This shows that 7 of the 20 ABCC modules will meet the thermal requirements stated in the cRIO MDK 20 In order to supp
20. EE An introduction to CANopen http ieeexplore ieee org lt Itag bibl liu se xpl articleDetails jsp tp2 amp arnumber 79 6056 amp queryText 3Dcanopen 2014 03 07 IXXAT 2008 CANopen Basics Introduction http www canopensolutions com english about_canopen about_canopen shtml 2014 01 02 IXXAT 2008 CANopen Basics Device Configuration http www canopensolutions com english about_canopen device_configuration_ca nopen shtml 2014 02 12 IXXAT 2008 CANopen Basics Process Data Exchange http www canopensolutions com english about_canopen pdo shtml 2014 02 12 HMS 2011 Anybus CompactCom Mounting Kit Appendix Provided by HMS on CD HMS no date Anybus CompactCom Starter Kit Installation Guide Provided by HMS on CD HMS 2012 CANopen module Picture http anybus com upload 334 Default ABCC 20COP 2 20Ima jpg 2013 12 12 HMS 2012 Introducing Anybus CompactCom 30 series http anybus com products abcc30 shtml 2013 12 01 HMS 2013 Anybus CompactCom Hardware Design Guide http anybus com upload Anybus CompactCom 63 1 8 Anybus CompactCom Hardware design guide pdf 2014 01 02 42 Anybus CompactCom module for cRIO systems 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 HMS 2012 Anybus CompactCom Software Design Guide http anybus com upload Anybus CompactCom 9379 Anybus
21. Institutionen f r datavetenskap Department of Computer and Information Science Final thesis Extending CompactRIO connectivity through Anybus CompactCom by Emil Martinsson LIU IDA LITH EX G 14 005 SE 2014 03 19 Me universitet Link pings universitet Link pings universitet SE 581 83 Link ping Sweden 581 83 Link ping Link pings universitet Institutionen f r datavetenskap Examensarbete Anybus CompactCom modul f r CompactRIO System av Emil Martinsson LIU IDA LITH EX G 14 005 SE 2014 03 19 Handledare Bogdan Tanasa Examinator Unmesh D Bordoloi Glossary Term Description ABCC Anybus CompactCom a product concept developed by HMS which are communication solutions for fieldbus and industrial Ethernet 13 Bluetooth A wireless communication standard used to exchange data over short distances 1 CAN The serial bus CAN Controller Area Network developed for automotive applications allow nodes to send messages fast and secure 3 CANopen Communication protocol used in embedded control system 2 CC Link Open network standard mainly used in industrial networks 4 CIP Common Industrial Protocol CIP is an upper layer used in e g DeviceNet network protocol It standardizes the objects that can be specified inside the network so that the user knows what to access where 26 ControlNet Fieldbus used in industries where t
22. W SDK During the development of the SDK for LabVIEW we made some decisions in order to limit the time spent on the development process Meaning that for other modules than the CANopen from the ABCC series the SDK would not work properly To fix this and to give WireFlow a good estimation of how much there is left to do before the SDK is fully developed I decided to pinpoint the needed expansions 4 5 1 Object support The ABCC is as explained before built based on object orientation Network Configuration Object e A Diagnostic Network Specific 1 Object Objects E Application Data KN gr rt TT Object E ADI A i Network Specific 1 V Objects Application Object Figure 33 ABCC object orientation 15 p 7 39 Every object in the Anybus side of the picture is implemented in the ABCC module and is if supported by the host application usable by the same The router part is as explained in the software guide 15 p 7 The router part in the figure above symbolizes a software component which interprets the header information in an object message and routes its data to the appropriate software function The router part has been embedded into the driver and it is based on the same functionality as described above E During this thesis the following implementation has been made Basic driver with functionality for supporting the ABCC CANopen module Support
23. ation of how to implement the SLEEP pin which all modules use to save power in the cRIO module was done and found that the ABCC module draws approx 50 96 less power when the signal to the Reset pin is active It s active when low The consideration was also made that WireFlow will need to add more power externally to the ABCC module if required Adding such a connector at the front of the module would require space on the PCB which was left out Since this was just a prototype a DIP switch was added to be able to control the baud rate of the serial port interface This should be done automatically instead in future work Another part to take into consideration when designing the PCB for this module is the LED diodes that the ABCC module uses When the ABCC module sits in the plastic cover these are directed through the front of the module using plastic bracket WireFlow could reuse this feature or come up with a simpler connection for these The GND on the prototype is shared between the cRIO module and the ABCC module this is something that should be avoided and WireFlow should use another power regulator with different ground pins for each in output The other IO pins Rx Tx and Reset should also be included in this electrical isolation Figure 21 3D view of the PCB for the module 28 Anybus CompactCom module for cRIO systems Figure 22 Complete PCB layout 3 7 2 Fully functional prototype With all the needed
24. ay s market which was done by integrating the existing ABCC module in the CompactRIO 1 5 Thesis limitations This thesis has been limited in certain aspects since it was clear that covering every potential angle would be far too great for the duration of this thesis Therefor the thesis has been focus on a specific 8 Anybus CompactCom module for cRIO systems communication solution CANopen with mostly the software part of the solution although some hardware solutions are covered as well 1 6 Thesis structure The report is structured as e Chapter two gives the reader a background into WireFlow cRIO systems and the structure of the Anybus CompactCom e Chapter three explains the approach of the thesis e Chapter four evaluates the result of the thesis Chapter 2 WireFlow cRIO systems and ABCC This chapter will give a background to the company and to the two systems that is being used in this thesis 2 1 WireFlow AB WireFlow is an engineering company that works closely with National Instrument NI WireFlow develops both hardware and software products for NI s systems such as CompactRIO The company was founded three years ago and has today four employees located in Gothenburg Since the start they have developed three modules for the CompactRIO series and also USB dongles for securing LabVIEW code 30 2 2 CompactRIO systems This part explains the main concept behind the CompactRIO systems developed by National Instrum
25. components ordered and delivered the assembly of the prototype began There were some minor changes made some things got mirrored on the PCB during development to be done to the PCB In the end everything fit well and the whole prototype looked good na i Figure 23 Complete assembled prototype without the back panel 29 After assembling the prototype some measurements were made to check that all power levels were within the limits and also made sure that all pins were connected to the tight paths Everything looked good and the next step was to test the module in a cRIO chassis It worked as good as it had done before in the starter kit environment and in the end fully functional prototype was complete 30 Anybus CompactCom module for cRIO systems Chapter 4 Evaluation The goal with this thesis was to answer four questions e Will there be enough space in the cRIO module for the ABCC module including extra needed electronics e Will the ABCC module meet the power requirements for cRIO modules e How will the software interfaces between ABCC module and cRIO work together e Are there any similar products available in the market today What fieldbuses doesn t exist for cRIO modules today In this chapter we will give answers to these questions 4 1 Requirements When developing a module for the cRIO standard certain requirements are set on the module and the components within the module Additionally the ABCC modules requ
26. e telegram that was sent to the module 22 Anybus CompactCom module for cRIO systems r T3 Basic Serial Write and Read vi Front Panel on serialwithcrc lvproj My Computer s led e File Edit View Project Operate Tools Window Help Basic 15pt Application Font Pox tox 2 E 0000 0000 0000 0000 0000 0000 0000 0000 00 serialwithcrc lvproj My Computer Figure 13 LabVIEW serial interface 3 3 Modules The ABCC module that was used during this thesis was an ABCC module with the fieldbus CANopen With the CANopen module a network was set up consisting of Starter kit connected to the computer via a serial COM port and the module connected to a NI PXI chassis with a CAN port Figure 15 NI PXI 1031 Chassis 21 Figure 14 CC Link and RS 232 module without housing 3 4 CANopen CANopen is a network standard most commonly used in industrial networks The protocol for CANopen is based on the CAN protocol but is on a higher level making it easier to work with 7 LabVIEW also holds several example libraries for communicating over CANopen that where really helpful during the thesis 23 3 5 Full testing of Anybus SDK With the different components in place and a complete environment for communication from the PC to the CANopen network and vice versa a test was run in order to get a wider kno
27. ents NI and also gives a brief background to the programming language LabVIEW 2 2 1 Background CompactRIO or cRIO is a control system developed by National Instruments The system consists of three main parts a reconfigurable FPGA chassis I O modules and an embedded controller The language for programming cRIO is National Instruments own LabVIEW 23 cRIO systems are used to control or observe industrial applications all from machinery to fire alarms They can also be used to simulate systems when testing products 2 2 2 Example applications The CompactRIO systems are used widely around the world e g mounted on an oil well pump to monitoring the system under harsh environments or to control hydraulic valves with great accuracy while lifting heavy concrete trays Figure 2 CompactRIO system used to Figure 1 CompactRIO system mounted lift and control a concrete tray with high on an oil well pump accuracy 10 Anybus CompactCom module for cRIO systems 2 2 3 cRIO modules cRIO modules are used together with cRIO chassis in industries for controlling or observing real time or simulated environments Figure 3 cRIO module 19 Figure 4 4 slot cRIO chassis NI 9075 17 NI who developed the cRIO system have developed some modules for their cRIO chassis available today however they allow third party developers such as WireFlow to develop modules for their cRIO chassis The third party developer can then send t
28. ests Acyclic data write requests EN Administrat r C Windows system32 cmd exe main 13 iC Users Emil Desktop fAnybus CC SDK U2 82 61 Main Debug gt main 1 3 DIP switch settings SW1i 1 SW2 3 Serial port opened Starting driver Network type CANopen Firmware version 2 66 build 7 Serial number AB 1D 46B DD ABCC state NW_INIT ate WAIT_PROCESS ate PROCESS fiCTIUE Speed 188 rpm Poles 6 Temperature 40 New Temperature Figure 16 Command prompt of Anybus SDK 3 5 2 CANopen communication to Anybus SDK To be able to fully understand the Anybus SDK a small industrial network was set up as explained before The network communication towards the Anybus SDK would have to be CANopen and the programing environment used was LabVIEW since that is the only way of 24 Anybus CompactCom module for cRIO systems communicating through the PXI chassis In LabVIEW there are libraries available for easy usage and setup of external controllers CAN controllers or serial controllers etc The CANopen library and the examples that came with it were used to setup an easy environment for communicating with the ABCC module EEE E TH ABCC App withSDO vi on CANopen PXLivproj Battuta mn ER File Edit View Project Operate Tools Window Help een 9 L3 interface PDO write SDO write PDO read CANO El Ref end Poles Actual speed timestamp baudrate nm J6 10
29. f the telegram that is sent from the module If the ADI is mapped to be write process data the value of that ADI is present in the process data of the telegram sent from the host application The process data buffer is represented in different ways on the network depending on which type of network that is used For instance on CANopen it is represented as PDO s and on DeviceNet they are represented as dedicated CIP objects It is up to the user to make sure that the handling of these objects on the network side is handled in the right manner 15 p 14 2 3 7 2 Acyclic requested ADI ADIs that are to be exchanged in acyclic requests on the network are stored in the host application When a network acyclic request of a certain acyclic ADI s value is sent that 20 Anybus CompactCom module for cRIO systems message is sent through the module to the host application as seen in Figure 8 It is then up to the host application to provide a correct response to that request For the host application to be able to know which ADI s that is requested the module translates the request into the corresponding instance in the Application data object FEh 15 p 55 As with the representation of the ADI s in the process data buffer acyclic ADI s are also represented in different ways depending on which network that is used On CANopen for example acyclic ADI s are represented as SDO objects 21 Chapter 3 Approach This chapter explains how
30. h since the host application is ready to receive a command The response from the module will also have set the STAT T bit low but keeping the STAT R bit high In case of the status register in telegrams received from the module all of the eight bits are used to indicate the status of the module Table 2 Explanation of the status register 15 p 12 b7 MSB b6 b5 b4 b3 b2 bl bO LSB STAT T STATM STAT_R STAT AUX SUP S2 S1 SO e STAT_T will be set to the same value as the value of CTRL_T had in the last telegram received e STAT M is set to 1 if the message subfield in the current telegram is valid e STAT Ris set to 1 if the module is ready to receive new commands e STAT AUX is by default not used same functionality as CTRL AUX e SUP is used to indicate if the module is supervised by another network device e S 2 0 is used to indicate in which Anybus state the module is in S2 S1 S0 Anybus state 0 0 0 SETUP 0 0 1 NW_INIT 0 1 0 WAIT_PROCESS 0 1 1 IDLE 1 0 0 PROCESS_ACTIVE 1 0 1 ERROR 1 1 0 reserved b Message subfield Next part of a message sent to or from the ABCC module is the Message Subfield This field holds all the information regarding the object that is being addressed in the module or host application as well as the message that is being sent The message subfield is at least 16 bytes 1t can be more when using the para
31. he design to NI for inspection and feedback 2 2 4 NI LabVIEW LabVIEW is a graphical orientated programming language that is used for developing NI related products 22 LabVIEW is developed by National Instrument and is used in businesses around the world In LabVIEW the user creates functions in VI s A VI or Virtual Instrument is a part of a code that the user creates Since LabVIEW is a graphical programming language no rows of code are written instead code is created by placing functions inside of a VI Each VI can be connected to other VI s making them sub functions to a bigger system as explained in the picture below Each VI holds both a block diagram and a front panel During runtime the user can interact with controllers on the front panel whereas the block diagram holds the code T3 Mainvi File Edit View Project Operate Tools Wind GM 2 3 CREATE ADD SEND R TELEG CRC TELEG Telegram to send Telegram sent with CRC 15 14000 0000 00 4000 0000 0052 08 zl Figure 5 Simple block diagram a VI holding three subVI s Figure 6 Simple LabVIEW front panel In LabVIEW the user make use of the sequence flow structure of the program meaning that each function is sequentially run from left to right This makes it relatively easy for the user to control what should execute and in which order things should execute 11 2 3 Anybus CompactCom The AB
32. ing standards is of high importance for the cRIO users 1 2 Problem description For a company that wants to expand their current product portfolio is it possible to integrate an already made communications solutions in a cRIO module taking full use of the ready made product The problem concerns both the physical and software layout of this potential new product 1 3 Goal The goal of the thesis is to deliver a thorough pre study to WireFlow in order to help them evaluate the potential of their new product We have divided the thesis goal into four main objects e Will there physically be enough space in the cRIO module for the ABCC module including extra needed electronics e Will the ABCC module meet the power requirements for cRIO modules e Are there any similar products available in the market today e How will the software interfaces between ABCC and cRIO work together o In order to achieve this the driver running the Anybus CompactCom must be translated into the programming language that the CompactRIO uses LabVIEW 1 4 Approach This thesis has been carried out at WireFlow AB located in Gothenburg WireFlow is an expanding engineering company that develops both software and hardware for National Instruments CompactRIO systems During this thesis the focus has been on both the software and hardware development of a new module for the CompactRIO system making it available to communicate with almost any type of fieldbus on tod
33. ire certain power and voltage to be able to run as intended In this part the requirements will be explained and will be evaluated whether or not the ABCC module will fit inside of the cRIO module both in terms of physical size and in terms of requirements 4 1 1 cRIO modules For cRIO modules certain recommendation and rules are available for developers These are thoroughly described in the CompactRIO Module Developer Kit User Manual MDK and here these are summarized 4 1 1 1 Dimension The PCB that is fitted inside the cRIO module must have an outer dimension of 73 38 x 66 04 x 1 57 mm 20 p 13 The components fitted inside the module cannot be higher than 13 46 mm if fitted in the main area of the PCB The I O connector fitted to the front panel cannot be wider than 73 38 mm and cannot be higher than 13 46 mm on the primary side top and 2 64 mm high on the secondary side bottom Same dimensions as for the components 20 p 20 31 3 05 mm Max component height in this 0 120 in oa 4 44 mm area is 4 44 mm 0 175 in to 0 175 in 0 080 in 13 46 mm 0 530 in 2 64 mm 49 78 mm 0 104 in e 1 960 in g 2 64 mm 4 0 104 in Max component height in this 3 05 mm area is 2 64 mm 0 104 in 0 120 in Figure 24 cRIO height restrictions 20 p 19 4 1 1 2 Current consumption It is stated in the CompactRIO MDK p 124 20 that the peak of the current draw from the power line
34. is object It handles both the request to the process data buffer as well as the acyclic request from the network 15 p 55 b Application object FFh Optional Within this object there are general settings for the host application For example if implemented it is able to support multiple languages and reset request made from the network 15 p 64 This object was not implemented during this thesis C Network specific object Optional This object holds the network specific settings in the host application The module will attempt to acquire the values within this object during startup and if none are implemented the module will use the default value for these parameters Although an error responses is needed to be sent to the module even if not implemented For example on CANopen this object refers to the CANopen object FBh and on CC Link this object refers to the CC Link host object F7h 2 3 7 Application Data Instances Application Data Instances or ADI s are parameters that are accessible by the network There are two different ways of creating ADI s It can either be implemented in the modules process 19 data buffer as PDS or accessible by acyclic data requests Depending on what type that is created different approaches are used 101010101010101010101 Host Application z ocess Data Buffer oi Cyclic Data Rea 0101010 Process Data handling 0101010 ocess Data Write 0101010 Cyclic Data
35. llel interface but on serial it is always 16 bytes 14 Anybus CompactCom module for cRIO systems Table 3 Description of the message subfield 15 p 26 Contents Offset b7 b b5 b4 b3 b2 b1 bO Description 0 Source ID ID used for keeping track of messages 1 Object These three fields are used for specifying 2 Instance Isb the destination for the message 3 Instance msb 4 E Value Meaning 0 Message is either a command or successful response C 1 Message is an error response Value Meaning 0 Message is a response Command code 1 Message is a command Command e g get or set 5 Message data size Specifies the size of the message max 255 bytes 6 CmdExt 0 Specifies the attribute that is being addressed y CmdExt 1 8 n MsgData 0 n Message data field Example Host application Response from module A000 0000 0000 0000 0000 0000 0000 0000 00 A000 0000 0000 0000 0000 0000 0000 0000 00 4001 0101 0041 0001 0000 0000 0000 0000 00 2000 0000 0000 0000 0000 0000 0000 0000 00 A000 0000 0000 0000 0000 0000 0000 0000 00 E001 0101 0001 0201 0002 0400 0000 0000 00 In this example the host application first initiates the communication by sending a telegram with the CTRL_T bit set to high then it is requesting the attribute one from the object one Module type The greyed number 41
36. n between different states e g if the network connection to the ABCC module is taken down when the module is in PROCESS ACTIVE state the module will switch into IDLE state ready to be activated again as soon as the network connection is reestablished 2 3 6 The object model The ABCC modules are structured in an object oriented manner which means that in order to update or request an attribute e g node address the host application has to specify the instance and attribute that it want to update or request within a specific object It is important to note that both the host application and the module can and will issue both request and commands towards each other and they must both be able to respond to each request in a correct way This is taken care of the Anybus driver easily since it is also structured in an object orientated manner Each message is tagged with an object number instance and attribute specifying the location of the data or setting associated with the message There are several different objects within the ABCC module as well as there are several objects needed to be implemented in the host application which is described in the two coming sections 2 3 6 1 ABCC module objects These are objects that are implemented in the module and holds information that can be accessed or updated by the host application 15 p 38 18 Anybus CompactCom module for cRIO systems a Anybus object 01h This object holds data abo
37. ns ideella r tt innefattar r tt att bli n mnd som upphovsman i den omfattning som god sed kr ver vid anv ndning av dokumentet p ovan beskrivna s tt samt skydd mot att dokumentet ndras eller presenteras i s dan form eller i s dant sammanhang som r kr nkande f r upphovsmannens litter ra eller konstn rliga anseende eller egenart F r ytterligare information om Link ping University Electronic Press se f rlagets hemsida http www ep liu se In English The publishers will keep this document online on the Internet or its possible replacement for a considerable time from the date of publication barring exceptional circumstances The online availability of the document implies a permanent permission for anyone to read to download to print out single copies for your own use and to use it unchanged for any non commercial research and educational purpose Subsequent transfers of copyright cannot revoke this permission All other uses of the document are conditional on the consent of the copyright owner The publisher has taken technical and administrative measures to assure authenticity security and accessibility According to intellectual property law the author has the right to be mentioned when his her work is accessed as described above and to be protected against infringement For additional information about the Link ping University Electronic Press and its procedures for publication and for assurance of document integrity
38. o orare os rre C o Cr pap eod oa 17 2 3 1 Application Data Inst nices tice ebenso edes 18 Chapter a AAA 21 3 1 SEALEI NOTO 21 3 2 LabVIEW communication iii a 21 3 3 Modules in EE e NIE AAE ESE EASA E AE A AENA EA SNES 22 3 4 CANOPEN v anrora gando e EE EEE G GEE EE N 22 35 Full testing of Anybus SDR idad it no n o is 23 35 JAnybus SDR rn beret tr Rer ete ete t dite e EET RES 23 3 5 2 CANopen communication to Anybus SDK sss 23 3 5 3 Conclusion of tests towards Anybus SDK mssssressssssrsrssrsrsresrsresrsresrsrersesrsresrrrenrrrerrr renen rn rst 24 3 6 Lab VIEW SDR nit AA A a 24 3 6 1 Conclusion of the LabVIEW SDK eese eerte ener 26 3 7 LabVIEW SDK and ABCC module in cRIO chassis eene 26 S l y design notesa en n entere tree ted eee tr rre eee easet erede 27 3752 Bully functional prototype rte A 28 Chapter 4 7 rri uuu 30 4 1 Requirements iii ebd eb deuote ee dete de edes 30 AAT CRIO modules ERE E e ORI E ee HERI RES EORR SUE EUN 30 42 JABCGCmodules icit ie nte it eee Saber ese SNR eee ain ea eg ene an Lee Cup eoe 31 4 1 3 Conclusion of requirement cece cece cece eerte nennen ener enne nne 33 4 2 How to fit a ABCC module inside a CRIO module eerte 34 42 L cRIO module components eite te dete nr een been 34 4 Anybus CompactCom module for cRIO systems 4 2 2 ABCC mod le Components nasio rsisi snr e tte e ne ere ce ced ete 34
39. of the Anybus driver But this was just the start since the goal for WireFlow is to implement the ABCC module in their cRIO module it needed to be communicating through another programming language LabVIEW 3 6 LabVIEW SDK The next goal after testing the Anybus SDK against the CANopen interface was to develop the Anybus SDK in LabVIEW translating both the driver of the Anybus and the host application The host application in this case is the part of the application that handles the user input and updates the needed parameters according to what the user inputs Since the LabVIEW SDK would only be able to be tested towards the CANopen module from Anybus a decision was made to hardcode some of the functionality that is specific to just that module Even though it is expected to be working with several different modules since most of the commands are common among all of the ABCC series modules The developing process was started by testing some simple transmit and receive commands to the ABCC module through a pre defined program in LabVIEW that uses a 25 serial port for communication In the beginning the commands sent was just the exact ones that was sniffed earlier in testing and all the commands gave valid responses Then step by step the building of the SDK started in LabVIEW making it more and more automatic To control what message where sent to the module the serial sniffer was used again to verify that all commands where gi
40. ort the remaining 13 WireFlow would have to work around this issue by e g implementing a cooling or ventilation system It should also be noted that for 100 C rated components the maximum power limit is 1 5 W which covers all but the ControlNet ABCC module 34 Anybus CompactCom module for cRIO systems 4 2 How to fit a ABCC module inside a cRIO module One of the most interesting parts of this thesis was for WireFlow to get an understanding of how to fit the ABCC module inside the cRIO module and in order to test this properly the decision was made to build a mockup a hardware design of the needed components This part will give an understanding of how this was done and what an end designer needs to think of when making this complete module 4 2 1 cRIO module components The cRIO module consists of two major components Outer shell divided in a front panel aluminum silver and a back panel metal blue PCB with dimensions of 73 38 x 66 04 mm Figure 26 Empty cRIO module Figure 27 PCB for cRIO module with DSUB As visible at the PCB a D SUB connector has to be fitted at the back of the PCB this is used when plugging the module into a cRIO chassis 4 2 2 ABCC module components All ABCC modules have an outer casing which is same for all of them the only difference between different modules are the connector and the LED at the front 4 2 2 1 Removing outer shell When the ABCC modules are delivered they were enclo
41. plication SDK GUI in LabVIEW 3 6 1 Conclusion of the LabVIEW SDK In developing the LabVIEW SDK the recorded telegrams from the serial sniffer was a great help With the telegrams from the Anybus SDK to compare and work against the needed functionality and implementations became clear Although the SDK only supports the CANopen interface it is hopefully something that WireFlow can use as a guide in future work with his product 3 7 LabVIEW SDK and ABCC module in cRIO chassis The finished LabVIEW SDK meant that a fully functional program is able to run together with a cRIO chassis The next step of the developing process was to make a prototype of a cRIO module that would integrate the ABCC module The first intent was to use a ready module for a cRIO chassis called Tangent Blue The Tangent Blue module has all the pins that were needed to connect it to the ABCC module In order to be able to run the Tangent Blue module in the cRIO chassis with the module an FPGA driver was needed to control it Since the developing of such a driver requires quite a lot of experience WireFlow helped with that driver While WireFlow worked on the driver the decision was made to make a mockup and try to answer the question on whether all the components would fit inside a cRIO module With the finished mockup it was clear that the ABCC module would fit inside the cRIO module The next step then was decided to be to design a PCB just for the module that would pro
42. ransmission of time critical I O data and messaging data are transmitted at high speed 24 CompactRIO CompactRIO or cRIO is a system developed by National Instrument for controlling or observing industries applications DeviceNet A network designed for industrial automation 25 EtherCAT Ethernet for Control Automation Technology extends the Ethernet technology by reducing the processing time of the Ethernet frames making it ideal for automation applications 5 NI National Instruments company that develops cRIO systems and LabVIEW NI LabVIEW LabVIEW is a graphical programming platform for engineers It is used for measurements and control system PCB Printed Circuit Board PDO Process Data Object is used for delivering real time data between nodes in the CANopen protocol 9 PROFIBUS An application independent communication protocol that is used in both process automation as motion control and safety related tasks 27 RS232 Serial interface SDO Service Data Object is used in CANopen as a direct access between two nodes to read or write to a certain object within the requested device 8 USB Universal Serial Bus an interface mainly used to connect peripherals to computers as well as connecting devices together 29 VI Virtual Instruments a program or subroutine in a LabVIEW environment XXh Hexadecimal number where XX refers to the specific number Table of Contents GlOSSaPy 1 dab teet D Re e int s bed d dt eb a
43. red 33 4 1 3 Conclusion of requirements The next part will summarize all the above mentioned requirements and give a good evaluation to what needs to be considered when designing the real product 4 1 3 1 Dimension At first glance of the requirements for the cRIO module it is clear to see that the ABCC module is to high at least with the D SUB connector 16 8 mm in contrast to the height requirements for the cRIO which is 13 46 mm The gap means that the ABCC modules with Pluggable Screw Terminal only will meet the rules in the cRIO MDK This was also discovered when building the mockup since a cutout had to be made in the cRIO module outer case in order to fit it completely In other areas there is no problem in fitting the module since the connector is the highest component on the module For a more detailed description see section 5 2 When choosing components to be used in the cRIO module it is also important to take into considerations the dimensions of these such as voltage regulator etc 4 1 3 2 Current consumptions As stated in the CompactRIO Module Development Kit user manual MDK the maximum current peak that is allowed is 200mA This however is meant as a rule when using 5 Volt for the components within the module In this case a DC DC converter is used to limit the voltage to 3 3 volt to power the ABCC module This means that the current peak from the DC DC converter is a bit higher P U I P Power U Voltage and I
44. sed in a plastic housing and enclosed in this plastic housing the ABCC module were too high to fit inside the cRIO module The modules were therefore taken apart something that is possible since HMS delivers modules without the casing as well Figure 29 CC Link module without e housing Figure 28 CC Link module with housing 35 As visible in the pictures above the height of the module without the plastic housing is far less The dimensions of the width are also less which gives more space on the PCB to fit other components 4 23 CompactFlash connector As mentioned previously the PCB for the cRIO module holds a DSUB connector at the back of it This causes problems since the CompactFlash connector used for connecting to the ABCC module requires quite a lot of space This is mainly because the connector was design to be mounted on the surface of the PCB Because of this a decision was made to try to use a smaller connector and a connector with through hole pins was found which requires less space Figure 30 PCB with CC Link module Figure 31 PCB with CC Link module and CompactFlash connector and through hole connector 4 2 4 Front panel of cRIO module The front panel of the cRIO module is where the connection to the fieldbus will be accessible At first the plan was to reuse the front panel of the ABCC module but after discussion with WireFlow it was obvious that it didn t look good enough So instead a cutout would be made
45. shall remain within 0 mA and 200mA when developing a cRIO module 4 1 1 3 Thermal requirements The thermal requirement for modules is that they shall be able to operate within 40 70 C NI has also listed that modules should be able to be stored at temperatures between 40 85 C 20 p 131 Another rule that is detailed in the cRIO MDK 20 is that the modules have certain power limits depending on the type of components that are used in them this power limit is constant through the temperature range described before 40 to 70 C 0 625 W for modules with 85 C rated components 1 5 W for modules with 100 C rated components This means for example that if a component that is used in the cRIO is rated at 85 C then the module cannot draw more than 0 625 W at any time 4 1 2 ABCC modules The ABCC modules have certain requirements that need to be fulfilled in order for them to work 4 1 2 1 Dimensions When removing the housing from the ABCC module it is quite small in fact the module then contains of a PCB board with outer dimensions of 50 5 x 36 6 x 1 6 mm and the fieldbus connector at the front The fieldbus connectors vary in size from fieldbus to fieldbus Height from ABCC PCB to top of connector width is also included 10 p 9 12 D SUB 12 6 x 30 8 mm RJ45 9 5 x 15 5 mm RJ45 2 Port 12 3 x 33 6 mm USB 10 9 x 12 mm 32 Anybus CompactCom module for cRIO systems e Pluggable Screw Terminal 8 6 x 27 4 mm e
46. sing a ABCC module with a D SUB connector at the front figure 29 it is known that no matter which ABCC module that will be used in future work it will physically fit inside the module since the D SUB connector is the highest one Dimensions Although weighing in the height restrictions rules for the cRIO module it is not possible to use such a PCB layout as was created Since some of the ABCC modules requires more current than it is possible to get from the cRIO chassis an external power source need to be used We had this in mind when designing the PCB for our prototype although such a connector was not placed during this thesis However there is enough space for such a connector to be placed beside the ABCC module on the PCB with the connector having its own hole cut out in the front panel of the cRIO module Another important detail to take into account when and if WireFlow decide to take this product into production is the placement of the ABCC module on the PCB Since the initial point was not to make a functioning prototype the placement of the module on the PCB is not the most optimal There is a possibility of moving the module closer to the side of the PCB making room for more components alongside it 4 3 cRIO interface together with the ABCC module This part will discuss the challenges on how to integrate the communications towards the ABCC module in LabVIEW 37 4 3 1 Object hierarchy One of the challenges with integrating
47. states that this is a get request As visible in the response from the module the module type is 0402h MSB first which means it is an ABCC Drive Profile module c Process Data Subfield The Process Data Subfield or PDS is used when the user wants to exchange data cyclically on the network as shown in Figure 8 The exchange of cyclic data can be done either by read process data received from the network or write process data sent to the network 15 p 14 Depending on the network that is used the representation of process data varies It is up to the user to define the size and structure of the PDS in the host application to control the process data mapping If the user chooses not to exchange any data cyclically the PDS will not exist in the telegrams It is also possible to set up either read or write process data both doesn t have to exist 15 2 3 4 2 Serial When the host application uses the serial interface to communicate with the module the telegrams are a two way communication meaning that they can both be received by the module and be sent to the host application 15 p 17 The settings for the serial interface are e Data bits 8 e Parity None e Stop bits 1 Each telegram is divided into fields as explained before and also a CRC checksum is added to each telegram The layout of a telegram when sent over serial interface will therefore be Table 4 Layout of telegrams when sent over serial interface 15 p 1
48. the Handshake register field which is always one byte Depending on whether the host application or the module sends the telegram the field has different functionality If the host application sends a telegram to the ABCC module this field controls the communication and is called Control Register When a telegram is received from the module this field holds the current status and is called Status Register A more detailed insight into the control register reveals that only the four most significant bits are used Table 1 Explanation of the control register 15 p 12 b7 MSB b6 b5 b4 b3 b2 bl bO LSB CTRL T CTRL M CTRL R CTRL_AUX e CTRL T is toggled between 1 and 0 in every message that the host application sends e CTRL M is 1 if the message subfield in the current telegram is valid e CTRL R is if the host application is ready to receive a new command e CTRL AUX is by default not used however it can be used to indicate if the process data in the current telegram has changed from the previous telegram sent Example The host application is to send the first start telegram The Control register should look like A0h CTRL T and CTRL R bit set to 1 The response from the module will then also have a high bit at STAT T indicating that the module is in the right phase Next message after the response has been given should look like 13 20h CTRL T set to low and CTRL R still hig
49. the application through the module these are not covered in this thesis 2 3 8 Hardware design The hardware part of the ABCC modules are not especially complicated each has a 50 pin CompactFlash connector at the back and a network interface specific interface at the front The network interface varies depending on which network the user wants to be able to use Some modules also have LED indicators in the front indicating the current operations of the module 12 Anybus CompactCom module for cRIO systems Figure 8 ABCC module with CANopen interface 12 2 3 4 Communication The communication between the host application e g industrial machine and the ABCC modules can be set up as either serial or parallel however the passive modules only supports serial communication Depending on what the user decides the handling of the communication differs Both share the same basic protocol telegram exchange 14 p 8 2 3 4 1 Telegram The communication between the host application and the ABCC module is based on continuous telegram exchanging between the two It is important to note that it is up to the host application to keep the communication running 15 p 11 It is always the host application that initiates the communication and no telegram is sent from the module unless a start telegram is sent to the module Each telegram contains of three subfields a b and c a Handshake register field The first part of a telegram is
50. ti dit attt egt RR eet 1 Table of Contents aida 3 ADAC eet SUR RR S S S t 5 Preface ues ite e o HH HII I HERE EA E HR Pe E P ERN 6 Chapter 1 Introduction ccscscssrsersessecsccsrserscscsscsersecsccscssesessacscssessesesscssessesensecsessssessessessessnsesees 7 1 1 Background arte yess ee eI pe i e epe cud che e 7 1 2 Problem description c eee ue eee eet b repe epe 7 1 3 30al sco eoa edt eie tette e een tet ie ree i ee AAA ru ei TA 7 1 4 Approach a it etti defe idee eio een etui cdeabus ds 7 1 5 Thesis imitations cu sep et e D RR RE RR RR RE RR RR RE RE 7 1 6 THESIS Str COU secs ERAN ERNA 8 Chapter 2 WireFlow cRIO systems and ABCC ooccnccccconnononocconecoonononnoncnnnncnonocoonoconsononcanononocoonoconnonos 9 2 1 WireFlow AB ironico 9 2 2 ConipactRIO Systems 5 m PD AA PP 9 2 2 1 Backeground eth e fete ette eet e P dert 9 2 2 2 Example applications iia 9 2 2 3 CRIO modules oe RE et ais 10 UA NEAD VIEW E EE sen rr seb cane beaut noe 10 2 3 Anybus CompactCOom iii a EEEE dne diio pee 11 2 3 1 Fieldbuses and Ethernets eese AI E 11 2 3 2 Active and passive modules ree a tee bete eerte 11 2 3 3 Hardware design oro eate en eee tena eet ee ie e RE eis 11 2 3 4 COMMUNICAUON s e eU aia RR DR RR RR RR RE GR ER QN 12 2 3 9 The Anybus st te machine nee e SEU a E ares 16 23 03 The Object MOE isc essa onto et
51. ut the module that is being used The data can be used in the host application and is i e firmware version and serial number Most of the attributes within this object is of get type accessible from the host application but this objects also holds set parameters e g setup complete which is set by the host application when the initiation of the application is complete 15 p 39 b Diagnostic object 02h The ABCC holds a feature for host related diagnostics If such an event occurs the host application can create an instance within the Diagnostic object and when the event has been solved the instance is simply removed by the host 15 p 44 This object was not covered in this thesis c Network object 03h The network object holds information about the network Furthermore it is used when the user wants to set up Application Data Instances ADI s to cyclic exchange parameters 15 p 47 d Network configuration object 04h Within the network configuration object the parameters such as baud rate and node address are stored 15 p 51 2 3 6 2 Host application object These are object that the host application has to or in some cases should implement to be able to communicate with the module a Application data object FEh Mandatory Within this object all of the ADI s that the user has mapped are stored This means that when the user module are accessing any of these ADI s the module translate such request to th
52. ven valid responses The Anybus state machine that the ABCC modules use was replicated and was the basis for the LabVIEW SDK See picture below A SETUP Default 5 gt NW INIT WAIT PROCESS Start case for the driver sets the baudrate and the device address in the module Then sets PROCESS ACTIVE 2 i i IDLE SETUP v STOP aul UPDATE oureut VALUES Node adress v amp i 310000 0000 0000 0000 0000 0000 0000 0000 00 Baudrate eH e GE oo y Set baudrate and node adress for the network No error check on the setup complete telegram Figure 18 Picture over state machine in LabVIEW SDK The next step was to create functions for handling the commands that the module sends during NW_INIT phase containing some of the hardcoded data as explained before After implementing all the needed parts of the driver and testing it the SDK was up and running The SDK was then tested towards the CANopen interface using the same network setup as earlier This proved to be working very well although some minor modifications were needed since the mistake of not separating the driver of the SDK and the application was made this was fixed in an updated version of the SDK Once the SDK was completed it was able to run all commands as it was with the ABCC SDK Bc e X ompactCom Main vi Block Diagram Computer File Edit View Project Operate Tools Window Help E oe
53. vide a complete prototype The Tangent Blue integration was therefore scrapped When the designing of a PCB started helpful guides and tips was provided by WireFlow The layout of the PCB was created by reusing a layout of an old module that WireFlow have developed before The process started with the creating of a schematic with all the components that were needed The PCB design software that was used was DesignSpark which is a free software that WireFlow have used before DesignSpark is an easy software to start working with but when creating a pin connector for the CompactFlash connector it became quite challenging When the schematic was finished it was translated in to a PCB using a built in function Then the components were placed on the PCB and connected with wires In the design a two layer PCB was used with components on both sides in order to fit them all 27 3 7 1 PCB design notes In order to be able to acquire a copy of the finished PCB in time only the vital components to get the module to work was considered Some shortcuts were taken The possible reuse of the MOSI Master data Output Slave data Input and MSIO Master data Input Slave data output pins on the DSUB connector was not implemented Instead two other DIO Digital IO pins were used to set up the serial connection In the future WireFlow would want to reuse the MOSI and MISO pins since that would work as well although more components need to be added An investig
54. wledge of how the Anybus SDK works In order to solve this a serial sniffer was created which was able to log all the communication be sent and received to and from the PC and the starter kit To record the serial communication a LabVIEW VI was created that saved all the data to a file and stored it on the PC The LabVIEW code for communication through CANopen is quite simple to setup although to be able to access the right parameters that are set up in the ABCC module by the host application the Anybus SDK i e some extensive studying of the CANopen protocol had to be made 3 5 1 Anybus SDK In the Anybus SDK that comes with the starter kit the host application is set up to be a fictional motor with five accessible parameters available from the network ADI s Three of these are set up as PDO and two as acyclic data requests The five parameters are 1 Actual speed a parameter mapped as input process data readable from network Read PDO 2 Temperature a parameter that lets the user to set this value from within the application and can be read from network using acyclic data read requests Acyclic data read requests 3 Ref speed a parameter that is mapped as output process data and can be written by the fieldbus master Write PDO 4 Direction a parameter mapped as output process data and can be written by the fieldbus master Write PDO 5 Poles a parameter that the user can set from the network using acyclic data write requ
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