real-time ethernet protocol for connection of distributed...
TRANSCRIPT
1GDNET , Riccardo Ragnoli WFCS 2006
Torino, 27 June 2006 WFCS INDUSTRY DAY
Riccardo RagnoliSoftware Research Dept.
Real-time Ethernet Protocol
for connection of
distributed I/O
2GDNET , Riccardo Ragnoli WFCS 2006
COMPONENTS
Indication and control
of process variables
SENSORSMeasurement of
process variables
SYSTEMSHardware & Software for Automation
and Control of machines and industrial processes
MOTION CONTROL CC and AC motors
control
Gefran in the world
3GDNET , Riccardo Ragnoli WFCS 2006
Plastic machinery
•EXTRUSION
•BLOW MOULDING
•INJECTION MOULDING
•THERMOFORMING
4GDNET , Riccardo Ragnoli WFCS 2006
Plastic machinery: critical aspects
Number
of I/O
Timing performance
Numberof
Nodes
Jitter free
1 - 23 - 43 - 42 - 3
EXTRUSION BLOW MOULDING INJECTION MOULDINGTHERMOFORMING
= low critical = medium critical = high critical
5GDNET , Riccardo Ragnoli WFCS 2006
Plastic machinery: injection
• Main regulation
Cylinder temperature: typ . 8 thermocouples
Hot runner temperature: typ. 8 thermocouples
Position, Speed and Pressure of injection movements: analog input and output
Position Speed and Pressure of mould movements: analog input and output
• Type and number of I/O (typ.) = 48 DI, 48 DO, 8 AI, 8 AO, 16 Thermo Loop
6GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception during injection movement Threshold interception during injection movement Plastic machinery: injection
PressureSpeed Injectionposition
Out flow
Threshold
Out pressure
t
Analoginput/output
Td : must be known and repeteable(Td ~ 1 ms, σTd ~ 3 µs)
Td
Position
7GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception during injection movement Threshold interception during injection movement Plastic machinery: injection
PressureSpeed Injectionposition
Position
transducer
Td
Out flowOut pressure
Master
8GDNET , Riccardo Ragnoli WFCS 2006
Patent Pending
First RTE protocol in Italy
First plant running from 2004
Developed in collaboration with
University of Brescia
GDNET the solution of Gefran
State of the art (2003)
Fast I/O: local busDistributed I/O: CANopen
2003: no open RTE available
Technical requirements
I/O distribute High performance
Typ.Tc <= 1ms Jitter < 10µs
Few nodes (typ. 4)
Master requirements
PC-based R.T.O.S
No microprocessor for communicationVery light Software for
communication.
Industrial requirements
Std. Ethernet Hardware - RJ45, cat5, 100BaseT
- Different network cards- switch or hub
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GDNET: nodesGF-BOX: Network Master
• CPU Intel® Celeron® 400MHz, R.T.O.S • Etx technology (ethernet chip on board)• SoftPlc and HMI • GDNet interrupt handled every Tc ± 20 µs
• µP 32 bit, 200 MHz , 100Base-T, RJ45• Local timing (resolution ~150ns)• A/D: 16 bit (Tconv ~ 6µs)• D/A: 16 bit (Tconv ~ 10µs)• Thermal module = 8 thermocouples/RTD• ….
80Mbps
GILOGIK II: Slave R-ETH100
10GDNET , Riccardo Ragnoli WFCS 2006
• Each node Si: 1536 point of I/O ( 48 word Input / 48 word Output), 128 Thermo input
• Acyclic data A: up to 255 blocks of 64 word (16320 word)
• Network Tc min is a function of switch delay (configuration) and number of nodes (e.g. “store&forward” switch, 4 nodes, Tc=200 µs)
GDNET cycle
Logical Network1 Logical Network2 Logical Network3
S1
M A
S1 S2 SN NA
•M: cyclic output data A: acyclic data S: cyclic input data N: null slot
Up to 3 Logical networks
Cycle Tc Cycle Tc Cycle Tc
Up to 21 nodes
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GDNET Messages
HEADER
NetIDNcycle
MSGtype
Alias DataAlias Info
Alias Type
Alias DataWord 1-64
4 byte 2 byte 128 byte
Alias Message A
Master Message M
HEADER SLAVE 1 SLAVE N
NetID, Ncycle Msgtype , …
Aliasinfo
Event ack
Direct Acc.
DBout1 (word 1-48)
6 byte 114 byte 114 byte
Sincro DBout
Event ack
Direct Acc.
DBoutn(word 1-48)
Sincro DBout
4 byte 114 byte
Slave Message S
HEADER SLAVE N
NetIDNcycle
Alias info
Event
Direct Acc.
DBinput(word 1-48)
Sincro DBin
Each message takes a known time:
- M: < 66.4 µs - S: 11.52 µs -A: 12.8 µs
Tc is simple to design with constant bandwitdh occupancy
Direct Access:
writing or reading one word into I/O space or acyclic data
Event:
slave is programmable between always replay to Master message
or event depending
Sincro
- SincroDBin: timing input (e.g. Threshold)
- SincroDbout: programmable timing output
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GDNET performance
Minimum cycle time (NS < 8)
Tc = Tq ((NSW + 1) (NS + NA + NN ) + NS ))
Minimum cycle time (NS >= 8) Nln = number of logical network
Tc = Tq* Nln ((NSW + 1) (NS + NA + NN ) + NS ))
Maximum Band = (NS + NA ) / Tc
NS = number of nodes NA = number of slot for acyclic data NN number of null slot NSW = number of Switch
Maximum band
0,00%
12,00%
24,00%
36,00%
48,00%
60,00%
1 3 5 7 9 11 13 15 17 19 21
Number of nodes
Nsw=1Nsw=2Nsw=3Nsw=4Nsw=5
Cycle time
0,00
500,00
1000,00
1500,00
2000,00
2500,001 3 5 7 9 11 13 15 17 19 21
Number of nodes
Tc [u
s]
Nsw=1Nsw=2Nsw=3Nsw=4Nsw=5
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GDNET nodes synchronization
M M M
Syncout is programmable
Syncin synchronized to the average time distance between M messages (Delta RxM)
Tck = Tck-1 + α (TrxMk – TrxMk-1)
Synck = Synck-1 + Tck + β (TrxMk-1- Synck-1)
Tc
Syncin Syncout Syncin Syncin SyncinSyncout Syncout
TcTc
Delta RxM
14GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception during injection movement Threshold interception during injection movement Plastic machinery: injection
PressureSpeed Injectionposition
Out flow
Threshold
Out pressure
t
Analoginput/output
Td : must be known and repeteable(Td ~ 1 ms, σTd ~ 3 µs)
Td
Position
15GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception during injection movement Threshold interception during injection movement Plastic machinery: injection
PressureSpeed Injectionposition
Position
transducer
Td
Out flowOut pressure
Master
16GDNET , Riccardo Ragnoli WFCS 2006
MM M
t
New_Value
a
IN
Threshold
Syncin1
Crossin
Old_Value
b’
bc’
c
Crossin = (Syncin2-Syncin1)Threshold-Old_Value
New_Value- Old_ValueSyncin1 +
Crossin
SS S S SSyncout =
Crossin
Jitter 0
Analog input
Analog output
M M
1
1. Instant of threshold interception
2. Slave sends message to master
3. Master acquires information
4. Master sends message with action for ouput
5. Output action is performed
Syncin Syncout
TcSyncin Syncin Syncin Syncin SyncinSyncout Syncout Syncout Syncout
Syncin2 Syncin3
GDNET nodes synchronization
2
3 4
5
17GDNET , Riccardo Ragnoli WFCS 2006
GDNET: test measure
Outdig1
Indig1
Outdig2
Outdig3
Outdig6
Outdig5
Outdig4
Syncin
Analog input
OutdigA
OutdigA
Node 1
Node 2
Node 3
Node 4
Node 5
Node 6
Syncin
OutdigA
Syncin
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GDNET: measurement results
0%
1%
2%
3%
4%
5%
6%
7%
8%
375,991 375,995 375,999 376,003 376,007 376,011
Time (us)
Freq
uenc
y
0%1%2%3%4%5%6%7%8%9%
362,4 367,5 372,5 377,5 382,5 387,6
Time (us)
Freq
uenc
y
Tc = 375 µs Ns = 6 (imposed)
Node 1
Average value = 376.003 µs
Min Value = 363,443 µs
Max Value = 388,573 µs
σTrxM = 3.7 µs
Measure of Syncink –Syncink-1
(time distance between two Syncin signals)
Average value = 376.001 µs
σSincin << 100 ns
Measure of TrxMk – TrxMk-1
(time distance between two M message)
Tc = 375 µs Ns = 6 (imposed)
Node 5
25 µs
19GDNET , Riccardo Ragnoli WFCS 2006
GDNET: measurement resultsMeasure of Syncin1 – Syncin2
(time distance between two Syncin signals)
Average value = 1,27 µs
σ Syncin1 – Syncin2 = 0,14 µs
Average value = 1,83 µs
σ Syncin1 – Syncin6 = 0,23 µs
Node 1 – 2 (under the same switch) Node 1 – 6 (under different switch)
0%
2%
4%
6%
8%
10%
12%
0,584 0,808 1,032 1,256 1,480 1,704
Time (us)
Freq
uenc
y
0%
2%
4%
6%
8%
10%
12%
1,068 1,373 1,679 1,984 2,290 2,595
Time (us)
Freq
uenc
y
Tc = 375 µs Ns = 6 (imposed) Tc = 375 µs Ns = 6 (imposed)
Measure of Syncin1 – Syncin6
(time distance between two Syncin signals)
20GDNET , Riccardo Ragnoli WFCS 2006
GDNET: measurement results
Average value of TL= 1503,9 µs
σ TL = 0, 25 µs
TL= 4 * Tc = 1500 µs
0%
5%
10%
15%
20%
25%
1503,2 1504,0 1504,8
Time (us)
Freq
uenc
y
0%
2%
4%
6%
8%
10%
12%
14%
1,1 1,5 2,0 2,4 2,8
Time (us)Fr
eque
ncy
Average value of ∆TL= 2,04 µs
σ ∆TL = 0, 22 µs
Outdig1 =
not (Indig1)
Outdig1 =
not (Indig1)
Outdig6 =
not (Indig1)
TL
Tc = 375 µs , Ns = 6 (imposed)
Node 1
∆TL
Tc = 375 µs , Ns = 6 (imposed)
Node 1 - 6
21GDNET , Riccardo Ragnoli WFCS 2006
GDNET: test measure
Outdig1
Indig1
Outdig2
Outdig3
Outdig6
Outdig5
Outdig4
Syincin
Analog input
OutdigA
OutdigA
Node 1
Node 2
Node 3
Node 4
Node 5
Node 6
Syncin
OutdigA
Syncin
22GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception: Node 1Threshold interception: Node 1
OutdigA
Trigger Trigger Trigger
Delay in threshold interceptionDelay in threshold interception Delay in threshold interceptionDelay in threshold interception
0%
1%
2%
3%
4%
5%
6%
7%
8%
9303,4 9305,9 9308,3 9310,8 9313,3
Time (us)
Freq
uenc
y
Ns = 6, Tc = 375
Average ThreShInt = 9,309 ms
Delay = ThreShInt – Tr
Delay = (9,309 – 7,8) ms = 1509 µs
Delay ~ 4 * Tc
σ threshint = 1,84 µs
Tr Tr
ThreshInt ThreshInt
GDNET: measurement results
Threshold
Analog Input
23GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception: Node 2 (the same switch of Node 1)Threshold interception: Node 2 (the same switch of Node 1)
Trigger Trigger Trigger
Delay in threshold interceptionDelay in threshold interception Delay in threshold interceptionDelay in threshold interception
Tr Tr
ThreshInt ThreshInt
0%1%2%3%4%5%6%7%8%9%
10%
9304,1 9307,4 9310,6 9313,9 9317,2
Time (us)
Freq
uenc
y
Ns = 6, Tc = 375
Average ThreShInt = 9,310 ms
Delay = ThreShInt – Tr
Delay = (9,310 – 7,8) ms = 1510 µs
Delay ~ 4 * Tc
σ threshint = 2,33 µs
GDNET: measurement results
Analog Input
Threshold
OutdigA
24GDNET , Riccardo Ragnoli WFCS 2006
Threshold interception: Node 6 (not the same switch of Node 1)Threshold interception: Node 6 (not the same switch of Node 1)
Trigger Trigger Trigger
Delay in threshold interceptionDelay in threshold interception Delay in threshold interceptionDelay in threshold interception
Tr Tr
ThreshInt ThreshInt
0%1%2%3%4%5%6%7%8%9%
10%
9304,5 9307,4 9310,3 9313,1 9316,0
Time (us)
Freq
uenc
y
Ns = 6, Tc = 375
Average ThreShInt = 9,311 ms
Delay = ThreShInt – Tr
Delay = (9,311 – 7,8) ms = 1511 µs
Delay ~ 4 * Tc
σ threshint = 2,29 µs
GDNET: measurement results
Analog Input
Threshold
OutdigA
25GDNET , Riccardo Ragnoli WFCS 2006
Plastic machinery: gdnet applications
Numberof
Nodes
Number of
installations
3000200800600
100050200150
EXTRUSION BLOW MOULDING INJECTION MOULDINGTHERMOFORMING
Since2005 until today
• Test measurement results are very satisfying and design compliant
• Machine applications confirm test measure results