ni.

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 Industrial Automation and
Communications using cRIO
Avichal Kulshrestha
Technical Marketing Engineer
National Instruments

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 Industrial Automation:
Machine Vision and Automated Inspection

In-process and end-of-line quality control

Vision increases flexibility, quality, productivity resulting in

better products at reduced costs
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 Vision Inspection

VISION

Velocity
of the web

MOTION
The vision system generates the pulse train to trigger the
camera(s). The motion system moves the web, usually at
a constant velocity.

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 Automated Smart Industries:
The NI Way

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 NI Motion Platform
Integrate motion with I/O and Vision through Graphical Programming
Customize what you need to, abstract the rest

Controllers Advanced motion control software and algorithms

CompactRIO

PXI
Drive Interfaces Drives Motors
Stepper Stepper Stepper
Single Board RIO NI 9512 NI 9501
P7000

Servo Servo Servo

NI 9514 NI 9505
NI 9516 NI 9502
PCI/PXI AKD

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 NI cRIO Motion System

Stepper Motor Stepper

Drive Motor
DC
Motor

BLDC
Motor

9505 9512 9502

cRIO Controller

FPGA

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 NI 951x Drive Interface Modules
NI 9512 Stepper
NI 9514 Servo
NI 9516 Servo (Dual encoder
feedback)
Connectivity to 100s of drives
Full set of motion I/O for home and limit switches, encoder,
and DIO.
RIO Scan Interface support, so you can use these modules
directly from the NI LabVIEW Real-Time Module

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 NI 950x Drive Modules
NI 9501 Stepper
NI 9502 Brushless Servo

NI 9505 Brushed Servo

Directly power and control motors from cRIO

Customize power electronics control with LabVIEW FPGA motor
control IP blocks
Hardware defined synchronization with other C series I/O

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 NI Motion Control Over EtherCAT
AKD Brushless Servo Drives
NI 9144 C Series EtherCAT Chassis

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 Drives and Motors

P7000 Stepper Drives CT Stepper Motors

AKD Brushless Servo Drives AKM Brushless Servo Motors

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 Stepper Stepper
Touch Panel

Brushed Servo Brushless Servo

Ethernet

cRIO
NI 9505
NI 9512
NI 9501

EtherCAT Stepper DriveBrushless Servo Drive

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 Semiconductor Medical Research
& Solar & Devices
Industrial Pharmaceuticals
Monitoring & Cosmetics

Industrial
Robotics
NI Vision Food Production

Consumer Goods
Autonomous
Robotics

Textile &
Military &
Paper
Aerospace
Automotive Electronics &
Components

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 NI Vision Capabilities

Enhance Check Locate Identify Measure

Calibrate Measure Match Read text Detect
image intensity patterns (OCR) edges
Filter noise Count Match Read 1D Measure
particles geometry barcodes distance
Remove Match colors Detect Read 2D Calculate
distortion edges codes geometry
Classify
shapes

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 Vision in Manufacturing Environments

Defect Detection
High-speed sorting
Packaging inspection
Traceability & identification
Bar code reading
OCR, Data matrix grading
Web inspection
Industrial robot guidance
Pick & Place
Etc.

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 NI Machine Vision Algorithms
Match Pattern OCR (Read and Grade) Frequency
Match Geometric Pattern Classification Measurements
Detect Shapes Color Segmentation Operators (Add, Subtract,
Edge Detector Detect Texture Defect Multiple, Divide, AND,
OR, XOR, Compare, etc.
Peak Valley Detector Contour Analysis
Geometry Measurements
Caliper Tool Golden Template
Comaprison Object Tracking
Line Gauge Tool
7 Segment LCD Reader Magic Wand
Rake
Barcode Readers (1D, Auto Threshold
Concentric Rake
QR, DataMatrix, PDF417) Circle Fit
Spoke
DataMatrix Barcode Coordinate Systems
Straight Edge
Grading Nonlinear Calibration
Clamp
Read Dial Meter Light Meter
Measure Intensity
Stereovision Convex Hull
Detect Objects
3D Image Analysis And many more
Motion Estimation
Optical Flow

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 NI Vision Software - Features
Communicate inspection results to PLCs, HMIs, and
other automation devices with digital I/O, serial, and
Ethernet protocols.
Enterprise
Network Control Network

EtherNet
Servers and workstations Serial Digital I/O Other
PAC HMI PLC
TTL Robotics System
Vision Network
Opto-isolated
Smart Cameras Vision System
RS232 Serial

Operator Interface
GigE Vision Camera Network IEEE 1588
Network-Shared
TCP/IP
Real-Time variables
Vision System

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 NI Vision Platform - Hardware

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 Smart Cameras
11 models
Rugged and small
Integrated camera and processor
CCD sensors (VGA to 5 MP resolution)
Monochrome or Color
Up to 1.6 GHz processor
Isolated digital I/O
Direct drive lighting
Wide range of connectivity options
EtherNet/IP, Modbus TCP/Serial , RS232, TCP/IP

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 Camera Sensor & Camera Bus Support

Buses Sensors
Line-scan
Area scan
Thermal/infrared
Near infrared (NIR)
Lasers
Proximity sensors
3D laser triangulation
sensors
Contact Image Sensors (CIS)
Parallel digital Etc.

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 Integration with CompactRIO

IP Security Cameras Machine Vision, Scientific, Specialty Cameras

Supported brands: GigE Vision on high-end cRIO and cDAQ
Basler Vision Technologies Full-frame rate, uncompressed images
Axis Communications GigE Vision, EtherNet, USB options
Compressed images
1-5 frames per second
(depending on resolution)
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 USB3 Vision on CompactRIO
Support on cRIO-9068
Support for all CompactRIO and Single-Board RIO targets
with a USB port
Supports cameras that are USB3 Vision compliant and
have USB 2.0 backwards compatibility
Support enabled for Basler USB3 cameras

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 Compact Vision System
Rugged, passively cooled
Small form factor
1.66 GHz Atom processor
2 independent GigE Vision ports
Power over Ethernet (PoE) compliant
1 GigE port for network connectivity
2 USB ports for external data storage
Built-in VGA port for display
Selectable RS232/RS485 serial port
FPGA-based industrial I/O
8 Bidirectional TTL (2 MHz)
8 Opto-Isolated Inputs (~200 kHz)
8 Opto-Isolated Outputs (~2 kHz)
1 Quadrature Encoder Input (5 MHz)

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 Embedded Vision Systems
Stand-alone real-time machine vision
Multi-camera support
(GigE Vision, IEEE 1394, Camera Link)
Industrial, fanless design
Solid-state drive
Dual-core processor
Reconfigurable digital I/O (TTL, isolated)
Industrial communications options
Built-in video output

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 Communication with Automation Devices
Motion Network
Enterprise Network Industrial Communication Network

PAC HMI PLC

Servers and workstations

Operator Interface
Robotics System

Ethernet Vision Camera Network

Vision Network

Real-Time
GigE Cameras Smart Cameras Vision System
Vision System

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 What Devices can you Connect to?

Actuators

PLCs

Motors & Drives Valves

Sensors
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 3 Methods to Connect LabVIEW to Other Devices

Analog & Digital I/O -- Industrial Communications -- OPC

3rd Party Devices

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 Method 1: Basic Analog and Digital I/O

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 3 Methods to Connect LabVIEW to Other Devices

Analog & Digital I/O -- Industrial Communications -- OPC

3rd Party Devices

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 Method 2: What are Industrial Networks
- Ethernet connects PCs, Printers, & Servers in office settings
- Similarly, Industrial Commutations connects Industrial
Devices, such as PLCs, Sensors, Motors, & Actuators

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 Physical Layer Implementation

TCP

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 Device Specific Protocol Selection

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 Communications Protocols Cheat Sheet
Protocol cRIO PXI PCI Protocol cRIO PXI PCI
CAN SPI/I2C
LIN DNP3
FlexRay IEC 60870-5
CANopen IEC 61850
DeviceNet MIL-STD-1553
EtherCAT ARINC429
AFDX/ARINC
EtherNet/IP
664p7

FOUNDATION Serial: RS-232, RS-

Fieldbus 422, RS-485
PROFIBUS OPC DA
PROFINET OPC UA
TCP/IP HART
UDP AS-Interface
Modbus Serial/TCP Sercos

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 3 Methods to Connect LabVIEW to Other Devices

Analog & Digital I/O -- Industrial Communications -- OPC

3rd Party Devices

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 NI OPC Servers
OPC Protocol
Multiple Protocols

NI OPC
Servers

No Direct Support

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1. Advanced Simulator 46. Mitsubishi CNC Ethernet 92. User Configurable Driver
2. Allen-Bradley Bulletin 1609 47. Mitsubishi Ethernet 93. WAGO Ethernet
3. Allen-Bradley Bulletin 900 48. Mitsubishi FX 94. Yaskawa Memobus Plus
4. Allen-Bradley DH+ 49. Mitsubishi FX Net 95. Yaskawa MP Series Ethernet
5. Allen-Bradley Ethernet 50. Mitsubishi Serial 96. Yaskawa MP Series Serial
6. Allen-Bradley Unsolicited Ethernet 51. Modbus Ascii Serial 97. Yokogawa Controller Serial
7. Allen-Bradley DF1 52. Modbus Ethernet 98. Yokogawa CX
53. Modbus Plus 99. Yokogawa Darwin
8. Allen-Bradley ControlLogix 54. Modbus Serial 100. Yokogawa Darwin Serial
55. Modbus Unsolicited Serial
Ethernet 56. ODBC Client Driver 101.Yokogawa DX
9. Analog Devices 57. Omron FINS Ethernet 102. Yokogawa DX Serial
10. Aromat 58. Omron FINS Serial 103. Yokogawa DXP
11. Aromat Ethernet 59. Omron Host Link 104. Yokogawa HR
12. AutomationDirect EBC 60. Omron Process Suite 105. Yokogawa MW
13. AutomationDirect DIRECT-NET 61. Omron Toolbus 106. Yokogawa MX
14. AutomationDirect K Sequence 62. OPC DA Client Driver 107. Yokogawa YS100 Serial
15. AutomationDirect ECOM 63. OPC UA Client Driver
16. AutomationDirect Productivity 3000 64. Optimation OptiLogic
17. Beckhoff TwinCAT 65. Opto 22 Ethernet
18. BUSWARE Ethernet 66. Partlow ASCII
19. Contrex 67. Philips P8/PC20
20. Contrex M-Series 68. SattBus Serial
21. Custom Interface Driver (CID) 69. SattBus Ethernet
22. Cutler-Hammer D50 70. Scanivalve Ethernet
23. Cutler-Hammer ELC Ethernet 71. Siemens S5
24. Cutler-Hammer ELC Serial 72. Siemens S5 (3964R)
25. Dataforth isoLynx 73. Siemens S7 MPI
26. DDE Client Driver
27. EtherTRAK 74. Siemens S7-200
28. Fuji Flex 75. Siemens TCP/IP Ethernet
29. GE CCM 76. Siemens TCP/IP Unsolicited Ethernet
30. GE Ethernet 77. Simatic 505
31. GE Ethernet Global Data 78. Simatic 505 Ethernet
32. GE Focas 1 Ethernet 79. Simulator
33. GE SNP 80. SIXNET UDR
34. GE SNPX 81. SquareD
35. Honeywell HC900 Ethernet 82. System Monitor
36. Honeywell UDC 83. Thermo Westronics Ethernet
37. Honeywell UDC Ethernet 84. Thermo Westronics Serial
38. IA Super SEL 85. TIWAY Host Adapter
39. Idec 86. Torque Tool Ethernet
40. InTouch Client Driver 87. Toshiba
41. IOtech PointScan 100 88. Toshiba Ethernet
42.
43.
44.
KraussMaffei MC4 Ethernet
Memory Based
Mettler Toledo Continuous Mode
89.
90.
91.
Toyopuc Ethernet PC3/PC2
Toyopuc Serial
Uni-Telway
ni.com/opc
45. Micro-DCI

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 NI OPC Servers
UA
OPC Protocol
Multiple Protocols

OPC UA

- Removes DCOM Dependencies

- Support RTOS Platforms

NI OPC
Servers

No Direct Support

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 Connectivity Approach Comparison

Attribute Analog & Digital Industrial OPC

I/O Communications
Primary Use Simple Native Bus Openness &
Applications Protocol Aggregation
Devices To Few Protocol Specific Many
Connect (10-1000s)
Data Points Few Multi Multi
Support for Yes No Yes
Different Vendor
Devices
Response Time s ms s

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 Supervisory Control and Data Acquisition

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 What is DSC module

Extension to the LabVIEW ADE

for SCADA and Industrial
Automation applications
All features accessible in
LabVIEW through APIs
Most features can be configured
interactively

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 DSC module - Features

Alarming
Level
Rate of Change
Acknowledgement

Data logging
Citadel database
Log value changes of shared variables automatically
Query historical data from LabVIEW or through an SQL-
compatible ODBC interface
Interactive and Programmatic tools for Database Management

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 DSC module - Features

Industrial Graphics
Library of more than 4,000 graphics
Additional indicators for pipes, tanks, and pumps
Historical and real-time trending of data

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 DSC module - Features

Security
Create groups and users
Set read/write/visibility access to each control and indicator for
each user or group

Development Tools
Multiple Variable Editorcreate large numbers of shared
variables at one time
Distributed System Managerview the connection status and
value of shared variables
Front Panel Bindingbind any control or indicator to a shared
variable

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 I2S Uses CompactRIO to Optimize PLC Automation in
Steel Rolling Mills
Case study on ni.com

The Challenge: Updating a PLC architecture from

the ground up using off-the-shelf, programmable
automation controller (PAC) hardware.

The Solution: Increasing production and quality of

steel rolling mills using the NI CompactRIO
programmable automation controller (PAC) for
improved efficiency and accuracy.

"With the performance of CompactRIO, we were able to add this custom measurement and analysis for
our gamma-based sensors without compromising our control rate speed. - Clark Hummel, I2S

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 Stay Connected
NI MOTION: www.ni.com/motion/

NI VISION: www.ni.com/vision/

NI Communication Buses and Protocols: www.ni.com/comm/

ni.com