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Connect LabVIEW to Any Industrial Network and PLC
National Instruments Technical National Instruments Technical Symposium
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Agendag
• Industrial Communications Overview• Why Connect NI LabVIEW to Industrial Networks and
PLCs?PLCs?• Basic Analog and Digital I/O
N ti I d t i l N t k C i ti• Native Industrial Network Communication• OPC with LabVIEW DSC
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What Are Industrial Networks?
• Similar to how Ethernet connects Common Industrial Networks
•DeviceNet
computers and printers• Industrial communications
•PROFIBUS
•Modbus TCP
•Modbus SerialIndustrial communications connect industrial devices such as PLCs, sensors, and actuators
•CANopen
•FOUNDATION fieldbus
•Interbusas PLCs, sensors, and actuators •Interbus
•CC-Link
•LonWorks
•HART
•PROFINET
•Ethernet/IP
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Why Connect NI LabVIEW to Industrial Networks and PLCs?Networks and PLCs?
High-speed analog measurementsHigh-resolution analog measurements Advanced analysis (digital filtering, frequency analysis) y ( g g y y )Custom hardware performance with FPGA technology
• High-speed closed-loop control• FPGA-based processing and analysis
Data loggingEnterprise connectivity (Web publishing, database)
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3 Methods to Connect LabVIEW to Any PLCyBasic I/O
Analog/Digital
Industrial
CommunicationsCommunications
OPC
PLCsNI PACs
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Basic I/O – Cheap, Easy, Fast, and Effectivep, y, ,
• Available on every platformy p• Analog and digital I/O options• PLC users can easily integrate analog and digital I/O • PLC users can easily integrate analog and digital I/O
into their ladder logic codeAll NI PAC t t i t lli t d i • Allows NI PACs to act as intelligent devices
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Basic I/O
• AdvantagesgFast, deterministic, little or no software overhead
• ConsiderationsConsiderationsDoesn’t scale wellPoint-to-point wiring (parallel) Point-to-point wiring (parallel) Can’t communicate lots of data
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Example – Automated Filling of Aerosol CansCans• Existing Allen-Bradley PLC system was being
f fused to automate the filling of aerosol cans• PLC did not have the capability to do high-
d l f tspeed analog for pressure measurements• CompactRIO was used for high-speed
pressure measurements on 8 channels (2 k per pressure measurements on 8 channels (2 k per channel)
• CompactRIO and Allen-Bradley PLC were CompactRIO and Allen Bradley PLC were integrated using digital I/O
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3 Methods to Connect LabVIEW to Any PLCyBasic I/O
Analog/Digital
OPC
Industrial PLCsNI PACs
Industrial
Communications
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What Is OPC?• Universal language for
reading and writing English
Speaker: “Hello!”
English Speaker: “Hello!”
reading and writing data
• OPC Client: Read
Windows PC
“Hello!” “Hello!” OPC Client: Read and write to OPC
• OPC Server: English
Spanish T l t
German T l t
French T l t
OPC Server:Translates between OPC and device-
TranslatorSpanish Speaker
TranslatorGerman Speaker
TranslatorFrench
Speaker
specific protocols
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p p p
NI LabVIEW DSC OPC Client
Windows PCAllen-BradleyOPC Server
Windows PC
Ethernet/IP
OPCClient
OPC Server
SiemensOPC Server
PROFINET LabVIEWDSCClient
MitsubishiOPC ServerCCLink
PLCs Device-Specific OPC Server OPC Client
OPC Driver
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OPC ServerDriver
What Is the LabVIEW DSC Module?• Makes LabVIEW an OPC client
Add f t t h d i bl• Adds features to shared variablesLoggingAlarmingAlarmingEvent monitoringScalingScaling
• Real-time and historicaldata trendingg
• System security• Extensive industrial graphics library
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g p y
NI OPC Servers for Third-Party PLCsy• New for LabVIEW 8.5
Add OPC f h 100 PLC• Adds OPC support for more than 100 PLCs• Connects with LabVIEW DSC OPC client
Evaluation version included with DSC
• Servers included for:•Allen-Bradley•AutomationDirect•Cutler-Hammer
•Modbus•Omron•Philips
•WAGO•Yaskawa•YokogawaCutler-Hammer
•GE•Hilscher
Philips•Siemens•Toshiba
Yokogawa•…and more!• ni.com/opc
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OPC
• AdvantagesgMost universalLeast device-dependentpIdeal for HMI and SCADA applications
• Considerations• ConsiderationsSlower, not deterministic, single-point onlyCan require PC based OPC serversCan require PC-based OPC serversNot for safety or critical communications
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Demo: Connecting LabVIEW to anDemo: Connecting LabVIEW to anAllen-Bradley MicroLogix PLC with OPC
Windows PC
Allen-Bradley DF1
OPC SDF1Allen-Bradley
MicroLogix PLCSerial
OPC Server
NI OPC ServerMicroLogix PLC LabVIEW DSCNI OPC Server
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ABCO Adds LabVIEW to PLC Systemy
• ABS brake testing system“The ease by which NI can speak to the Allen-Bradley hardware saved me g y
• PXI for high-speed encoder measurements
valuable time on this delivery-critical job.” -Arif Bustani, electrical engineer ABCOmeasurements
• Added to existing Allen-Bradley PLC assembly lineassembly line
• OPC used for communication bet een PXI and Allen Bradle PLCsbetween PXI and Allen-Bradley PLCs
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3 Methods to Connect LabVIEW to Any PLCyBasic I/O
Analog/Digital
OPC
I d t i l PLCsNI PACs
Industrial
Communications
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Methods for Industrial Communications
Modbus over Eth t/S i l
Plug-In Interfaces
Modbus Gateways over Ethernet/SerialInterfaces Gateways over Ethernet, Serial
VersatilityPerformance/Determinism
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Plug-In Communication Boards Plug-In Interfacesg
• CAN and CANopen
Interfaces
p• DeviceNet• FOUNDATION fieldbus• FOUNDATION fieldbus• Serial (RS232, RS422, RS485)• Third-party PROFIBUS (Comsoft)• Support for PXI, PCI, PCMCIA, and pp
CompactRIO (CAN)
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Plug-In Communication Boards Plug-In Interfacesg
• Advantages
Interfaces
gDirect, deterministic communication with the processorTiming and synchronization with other I/O (DAQ)g y ( Q)High-level API support for LabVIEW and other programming languagesp g g g g
• ConsiderationsMany smaller buses and protocols are not supportedMany smaller buses and protocols are not supportedOnly available on PC and PXI (real-time supported)
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CANopen LabVIEW Libraryp y
• Works with PCI, PXI, and PCMCIA high-speed NI g pCAN interfaces
• Turns them into CANopen master interfaces Turns them into CANopen master interfaces • Fully compliant with CiA DS301 standard
C l t th NI S ftM ti C t ll f C l • Complements the NI SoftMotion Controller for Copley CANopen distributed motion drives
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DeviceNet Master Interfaces
• Available in PCI, PXI, and PCMCIA• Deterministic control using LabVIEW Real-Time• Master (scanner) and slave protocols for complete • Master (scanner) and slave protocols for complete
access to DeviceNet networks500 V ti ll i l t d h i l l• 500 V optically isolated physical layer
• Onboard processor • NI-DNET driver software included
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PROFIBUS
• PROFIBUS master/slave for PXI and PCI
• SiemensSiemens• More than 2 million nodes
P l i E d A i• Popular in Europe and Asia• Recommended: Comsoft DF PROFI II
interfaces
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Modbus TCP and Serial Communication
Modbus over E h /S i lCommunication
• Modbus TCP is the most common industrial protocol Ethernet/Serial
pbased on Ethernet
• Simple protocol that reads and writes to registersSimple protocol that reads and writes to registers• Native support with LabVIEW 8.x (DSC and Real-
Time)Time)• LabVIEW 8.5 introduces 32-bit addressing• LabVIEW and PACs can function as slave and
master
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PEM2
Modbus Connectivity Options
Modbus over Eth t/S i lOptions
Slave Master
Ethernet/Serial
Slave(Connected to Sensors)
Master(HMI and Control)
Compact FieldPoint LabVIEW LabVIEW
RT (PACs) LabVIEWLabVIEW DSC & RT
(PACs)
cFP 1808 Modbus
( )
I/O Modbus
(PACs)
I/O cFP-1808, cFP-1804
Modbus Library
I/O Servers
Modbus Library
I/O Servers
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Modbus Connectivity Options
Modbus over Eth t/S i lOptions Ethernet/Serial
• AdvantagesgGood mix of performance and compatibilityCheap – works with standard Ethernet and SerialpStandardized – Not committed to a PLC brand
• Considerations• ConsiderationsNo determinismSlower than direct interfaces extra software layers Slower than direct interfaces – extra software layers
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Third-Party Gateways Modbus Gateways over y y
• Wide variety of communication buses and protocols
yEthernet, Serial
y psupported
• Ethernet or serial-basedEthernet or serial based• Perfect for non-PXI, PCI, and PCMCIA systems
PROFIBUSDeviceNet
Ethernet
DeviceNetEthernetIPControlNet
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Example: Adding Vision for Food Processing OptimizationProcessing Optimization• Needed NI Compact Vision System to calculate the
mass/volume of the food item coming through on the conveyor belt
• Cognex and DVT software too basic• Ethernet/IP connectivity was a requirement Ethernet/IP connectivity was a requirement
EthernetIPModbus TCP
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Summaryy
• Basic Analog and Digital I/Og g• OPC• Native Industrial Communications• Native Industrial Communications
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