Industrial Systems Design Projects

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Industrial Systems Design Projects Powered By Docstoc
					people   leveraging   technology




                               People
                             Leveraging
                             Technology
                 EMBEDDED SYSTEMS
             IN INDUSTRIAL AUTOMATION




    We are engineers!
    - We like to improve things
    - We make things work
    - We solve problems




?                                         People
                                        Leveraging
                                        Technology
                            EMBEDDED SYSTEMS
                        IN INDUSTRIAL AUTOMATION




Our Focus is Industrial Automation
- Electrical Engineering
- Systems design
- Product design
- Systems Integration
- Project Management




                                                     People
                                                   Leveraging
                                                   Technology
              EMBEDDED SYSTEMS
          IN INDUSTRIAL AUTOMATION



Applications Areas of Embedded Systems
  Generally highlighted and discussed




                                           People
                                         Leveraging
                                         Technology
                     EMBEDDED SYSTEMS
                 IN INDUSTRIAL AUTOMATION




          Industrial Requirements
depend on applications; special requirements typically include:

Availability and Reliability
(resistant to failure and easy to repair)
Safety & Survivability
(fault tolerant)
Security
(protection of data, tamper proof, hacker proof)

Dependability
(robustness - temperature, vibration, moisture, frequent use)

Lifecycle Issues
(projected length of service, typically 10-20 years)

Real-time Operation & Deterministic Response
(faster than the process it controls)
                                                                    People
Real-time operation                                               Leveraging
                                                                  Technology
(micro-seconds to milliseconds)
                     EMBEDDED SYSTEMS
                 IN INDUSTRIAL AUTOMATION




Two Project Examples


- Embedded Control System for a Printing Machine


- Embedded Control System for a Robotic Golf Buggy




                                               People
                                             Leveraging
                                             Technology
                          EMBEDDED SYSTEMS
                      IN INDUSTRIAL AUTOMATION

                   Examples of Projects

Printing Machine – Embedded Control System
 The Client: An entrepreneur who envisioned a Flexo-Gravure
 printing machine targetting small to medium printers who specialised
 in short run, high quality print jobs. They did the mechanical
 engineering and needed an electrical engineering partner to design
 the embedded intelligence to enable their concept functionality.

 The Brief: To design an embedded control system for the machine
 that could be commercialised and form an integral part of their
 product.




                                                                 People
                                                               Leveraging
                                                               Technology
                            EMBEDDED SYSTEMS
                        IN INDUSTRIAL AUTOMATION

                     Examples of Projects

Printing Machine – Embedded Control System
 The Specifications:

 • Replace the mechanical line shaft drive with an intelligent AC Vector
   Drive and motor for accuracy and repeatability of the web motion
 • Infeed and Outfeed nips and Rewind to be controlled by intelligent AC
   Open Loop Vector Drives
 • Each print station (typically 6 for a 6 colour machine) to be individually
   controlled by a Servo Motion Controller, a PLC and a Servo Motor for
   the print head
 • All of the Motion Controllers (via CAN Bus) and the print head PLC’s
   (via CC-Link) to be networked back to a Master PLC which also
   manages the overall machine operation
 • A SCADA system providing operator interface and set up facilities for
   the machine


                                                                      People
                                                                    Leveraging
                                                                    Technology
                         EMBEDDED SYSTEMS
                     IN INDUSTRIAL AUTOMATION

                  Examples of Projects
Printing Machine – Embedded Control System

                        In A Nutshell



 We designed a system that replaced a traditionally used
 electro-mechanical printing machine control method with an
 electronic solution that synchronised and controlled the elements
 of the machine via high speed data exchange and distributed
 embedded controllers and high speed precision motor controllers




                                                                 People
                                                               Leveraging
                                                               Technology
                    EMBEDDED SYSTEMS
                IN INDUSTRIAL AUTOMATION

              Examples of Projects
Printing Machine – Embedded Control System

           Automatic Colour Registration
        Controlled with Software and Servo’s
    No Mechanical Synchronisation of Print Heads




                                                     People
                                                   Leveraging
                                                   Technology
                                         EMBEDDED SYSTEMS
                                     IN INDUSTRIAL AUTOMATION

                                 Examples of Projects
   Printing Machine – Embedded Control System



                 All Speed and Print Synchronisation is done electronically
                                                       Main
       Infeed                                   Electronic Lineshaft                             Outfeed
        Drive                                         AC Drive                                    Drive


   CC-Link Network                                          milli-seconds
  milli-seconds       Print Station Print Station Print Station           Print Station
                          - PLC 1      - PLC 2       - PLC 3                 - PLC n
                      - Servo Drive - Servo Drive - Servo Drive           - Servo Drive
 micro-seconds         - Controller - Controller - Controller              - Controller



    Supervisory
   Control and                                                    CAN Network
  Data Acquisition                                                milli-seconds
      System                Master Servo
        and                                        Main PLC
                             Controller
                                                                                            People
        HMI
                                                                                          Leveraging
                                                                                          Technology
seconds
                     Ethernet Network
                           EMBEDDED SYSTEMS
                       IN INDUSTRIAL AUTOMATION

                    Examples of Projects

Printing Machine – Embedded Control System
 The Functionality:

 • Line Speed reference synchronisation of all of the Print Head Servo’s to
   the master line speed reference encoder
 • Automatic registration from start up and at job completion to minimise
   wastage of print web and ink
 • Closed loop control of each Print Head position relative to the other
   Print Heads and the overall machine line speed
 • Machine print performance statistics collection and reporting in real time
   via the SCADA system

 All of the above resulted in:
 • Lower costs of printing
 • Fast Set-up and Operation
 • Minimal Wastage of web and ink
 • Reduced maintenance over the machine lifecycle
                                                                    People
                                                                  Leveraging
                                                                  Technology
                           EMBEDDED SYSTEMS
                       IN INDUSTRIAL AUTOMATION

                   Examples of Projects

              Robotic Golf Buggy - XBug
The Client: An entrepreneur who came to Itech via a
recommendation and asked us if we could design and build him a
golf buggy that could follow him.

The Brief: To design an embedded control system with the
appropriate sensor technologies for the XBug that could be
commercialised and form an integral part of the ultimate product. The
final product needed to be costed and sized to be saleable to the
average golfing consumer:
      • $2K-$3K Retail Price
      • Light and easy to lift into a car for most people
      • Totally transparent technology for ease of maintenance for the
        average golf shop professional
      • One button operation in automatic mode
      • Suitable for all weather use, regardless of the clothing the user
        was wearing
                                                                    People
                                                                  Leveraging
                                                                  Technology
                         EMBEDDED SYSTEMS
                     IN INDUSTRIAL AUTOMATION

                  Examples of Projects

             Robotic Golf Buggy - XBug
The Challenges:
• The terrain on a golf course is variable and unpredictable (similar to
  the skills of most golfers)
• The need to be able to sense a signalling device worn by the golfer,
  even when it was covered by clothing, eliminated many sensing options
• The environment of sunlight, wind, rain, dust, heat cold etc. placed
  constraints on the sensing technology options
• The tracking distance between the golfer and the XBug needed to be a
  constant regardless of the slope and texture of the terrain
• The costs of the technology designed into the solution needed to be
  contained to meet the projected Retail Pricing




                                                                People
                                                              Leveraging
                                                              Technology
                           EMBEDDED SYSTEMS
                       IN INDUSTRIAL AUTOMATION

                    Examples of Projects

              Robotic Golf Buggy - XBug
The Solution:
• 4.5 years of Research and Development to complete a working
  prototype
• Understanding the physics associated with motion replication on
  variable terrain
• Collaboration with the ACFR and Design Resource
• Development of a small scale RADAR scanner for the primary
  tracking system, based on a microwave beacon worn by the golfer
  and a RADAR scanner mounted in the XBug
• Development of a method of golfer motion replication as an
  augmentation of the RADAR tracking system, (WSCT – Patent
  Pending)
• Development of a clever control algorithm for the main control, fed
  with data from a state machine designed to reflect the important
  characteristics of the variable operating terrain the golfers
  movements
• Development of low cost and repeatable inclinometers            People
• Development of a distance to the pin computation system       Leveraging
                                                                Technology
                                 EMBEDDED SYSTEMS
                             IN INDUSTRIAL AUTOMATION

                          Examples of Projects

                     Robotic Golf Buggy - XBug
                            Golfer Motion
            Left Motor
Sensors                      Replication
            Controller
                               System

                               RADAR                    Golfer Motion
                          Microwave Scanner              Replication
      Main Control                                         System
        System                  Human
                           Machine Interface            Microwave Tx
                            Display/Keypad
                               Manual
Power       Right Motor
                               Remote
System       Controller
                              Controller




                                                                          People
                                                                        Leveraging
                                                                        Technology

				
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Description: Industrial Systems Design Projects document sample