factory automation full overview
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Factory AutomationOverview
22
Objectives
• Understand National’s Factory Automation Campaign
• Review National products that are used in Factory Automation
• Gain better understanding of the solution needs in Factory Automation and how National’s solutions and products support those application needs
33
Overview
• Market
– Factory Automation Market > $1B total analog content. (IMS)
– 16 largest suppliers address < 50% of segment sales (IMS).
• Key trends:
– Drive to more energy efficient systems
– Expanding competitive situation world wide is driving need for increase productivity, quality and throughput (need better / finer control)
– Increased diagnostics to reduce maintenance and down time
– Increase adoption of wireless for non critical applications (802.15.4: Hart, Zigbee, WISA,)
44
Factory Automation Market
Major Industry Segments:
• Manufacturing
– Pharmaceutical Manufacturing
– Consumables Manufacturing
– Automotive Manufacturing
– Material Handling
• Process
– Refining
– Chemical
– Food & Beverage
– Pulp and Paper
Nationals Focus Areas
• DCS (Distributed Control Systems)
• PLCs (programmable controller and I/O modules)
• CNC (computer numerical control)
• Embedded computer board
• Sensors / Measurement Equipment
• Motor control
• Motion control
• Machine vision
55
IndustrialFactory Automation Overview
Module: I/O Module
8/20/09
Module:Control Networks
7/9/09Module: Motor Control
Sensing 7/23/09
Module: Machine Vision
TBD
Module: Sensing 6/25/09
Automation Control Networks in Factory Automation
77
Control NetworkTrends and Challenges
• What is the challenge?– More products at a faster rate and
with higher quality
• Trend to use Ethernet based control network – Replaces RS-485 or proprietary bus
• Trend to synchronize devices on a factory network
• Synchronization provides– High speed sort and diverter
– Motion position and velocity control for coordinated drives and robotics
88
Automation Control Network Example
• System sorts defective parts off of a conveyor belt
• Network uses fieldbus protocols on a 10/100 Ethernet network with IEEE 1588 time synchronization support
HMI
Distributed I/O
Ethernet Switch
Motion Controller
Drive Controller Motion Controller
Good product
Bad productIndustrial Camera
Pick and place
MS
S S S
GPS Time
99
PHYTER® Family of Industrial Ethernet Single / Dual Port 10/100 Ethernet PHY
Basic Application Requirements
Key Features Supported in the Product Family
Family Speed
interface
Temp Support IEEE1588
Single Port
10/100
MII/RMII
Commercial
Industrial
Extreme
NO
• Commercial, Industrial, and Extreme Temp Support
• Low Latency
• JTAG Support
•Auto-MDIX
Dual Port (2) 10/100
(2) MII/RMII
Commercial
Industrial
NO
• Flexible Port Management
•JTAG Support
•Cable Health Diagnostics
•Fiber Support
IEEE 1588 10/100
MII/RMII
Industrial YES
•Time Sync up to 3.5 ns on single link
• High Precision Packet Timestamping
•Cable Health Diagnostics
•Fiber Support
Sensing Solutions in
Factory Automation
1111
Trends
• Expanding competitive situation world wide is driving need for increase need for better / finer control– Increased measurement / sensing nodes
– Move to higher performance “Smarter” transducers
• Portable applications are growing, driving the need for lower power more energy efficient sensors and measurement systems
• Increased need in system diagnostics to reduce maintenance driving the need for more process measurement
1212
Challenges / Solutions
• Solutions must cover a wide range of sensing parameters– National’s Op Amp / ADC solutions address complete classes of
applications (e.g. virtually all pressure sensor MEMS applications)
– Pin and function compatible product families allow customers to standardize board layouts
• Growth in portable applications is driving the need for lower energy consumption solutions– National has some of the lowest power Op Amps and ADC in the
market. All ADCs have a very efficient power down feature.
• Customer has limited design resources to determine a solution and validate their design– Webench Sensor Designer® generates signal path solutions
based on a sensor’s specifications and parameters
1313
Focus Areas
• Sensors Interface Solutions– 4-20mA– Voltage output– Signal path (SPI, I2C)
• Key Sensing Areas– Pressure– Temperature (Thermocouple, RTD)– Optical– Chemical– pH
1414
Sensing Solutions in Factory Automation example:Pressure
Product Selection• LMP7715/7716 and ADC121S021
for the signal path is a good starting point . LMP7702 is good for the cc drive
– Supports most popular performance ranges
• Alternatives• ADC based choice based on signal
path performance– 8 bit ADC is ±0.4%
– 10 bit ADC is ±0.10%
– 12 bit ADC is ±0.024%
• Opamps can be chosen to optimize signal path for a variety of applications
– Higher Bandwidth
– Low Noise
– Low Input Offset Voltage
– Low Power
Voltage Drive Current Drive
or
1515
Recommended Products
Recommended Opamps
Recommended ADCs
Base PartResolution
(bits) ChannelsSample Rate Range (Ksps)
Signal Accuracy
INL (LSB) [MAX]
ENOB (bits) [Min] Interface
ADC121S021 12 1 50 to 200 ±0.024% ± 1.0 11.3 SPIADC101S021 10 1 50 to 200 ±0.1% ± 0.7 9.8 SPIADC081S021 8 1 50 to 200 ±0.4% ± 0.3 7.8 SPIADC121C021/27 12 1 5.5 to 189 ±0.024% ± 1.0 11.3 I2CADC101C021/27 10 1 5.5 to 189 ±0.1% ± 0.7 9.9 I2CADC081C021/27 8 1 5.5 to 189 ±0.4% ± 0.25 7.8 I2C
Base Part Channels
Gain Bandwidth (MHz)
Voltage Noise (nV/root(Hz))
Max Input Bias Current (nA) TcVos (uV/˚C)
CMRR (dB)
Supply Voltage
LMP7715/16 1/2 17 5.8 0.1 1 100 1.8 to 5VLMP2011/12 1/2 3 35 0.005 0.015 130 2.7 to 5VLMP2021/22 1/2 5 11 0.025 0.004 139 2.2 to 5.5VLMP7701/2/4 1/2/4 2.5 9 0.05 1 130 2.7 to 12V
LMP2231 1 0.13 60 0.001 0.3 97 1.6 to 5.5V
Machine Vision inFactory Automation
1717
Machine VisionTrends and Challenges
• What is the challenge?– Inspect products at higher speeds
and with more detail
• Trend to use high resolution and fine resolution image systems
• Trend to support high bandwidth cameras using SerDes devices
• SerDes devices provide– Support for higher bandwidth image
transfer without software support– Smaller cables for improved
robustness– Small form-factor to support nano-
head camera form factor
1818
Machine Vision Imaging Example
Sensing Unit
Display
Control
Processing Unit
Storage
Sensor
LNA AFE
Ser/Des
Control Path
Data Path
FPGASer/Des
Key Requirements : High resolution, Multi-lane, Longer reach
FPGA
Control Network
1919
Industrial Imaging Interface Portfolio : Plug-and-Go! Devices
Basic Application Requirement
Other System RequirementsFamily Data Throughput
Max Cable Reach*
Data Type
FPGA-Link
1.25 to 3.125 Gbps
40m of CAT-6 @ 1.25 Gbps
20m of CAT-6 @ 3.125 Gbps
ANY • Redundancy & Daisy chaining
• FPGA friendly, LVDS parallel interface
• Low system BOM, design time
FPD-Link 2
120 to 2700 Mbps
4m to 8m of CAT-6 @ 2 Gbps
ANY • 10/16/18/24/32 bit data interface
• Lock to random data, low EMI
• FPGA/ASIC as logic interconnect
Channel Link
(Camera-Link)
500 to 5000 Mbps
4m to 8m of MDR cable at 2.5 Gbps
ANY • 21/28/48 wide bus interface
* Cable length is for reference only, various system conditions impact the maximum reach
Data Data Data Data DataPlug and Go! = Seamless Video
Data Header Data Header Data8b/10b Headers =
Interruptions in Data
Motor Control Sensing in Factory Automation
2121
Trends, Challenges / Solutions
Trends• Increasing energy costs driving the need to reduce energy
consumption on the factory floor– Instrumentation of motors to improve energy efficiency (Motors
are one of the largest energy consumers on the factory floor)
• Drive to lower cost AC/Servo motor control sensing solutions – Hall effect + SAR ADC versus optically isolated ΣΔ ADCs
Challenges / Solutions• Need for high performance, high value AC/ Servo Motor solutions
– National’s Simul. Sampling ADCs + Hall Effect sensors address the most popular “High Side” AC Motor sensing applications
– National’s Simul. Sampling ADCs are in very small packages with sample rates up to 1Msps ideal for encoder applications
2222
Focus Areas
• Why is Motor Control Sensing Important
• AC Motors Sensing Interface
• Servo Motors Sensing Interface
• Low Side Sensing
• High Speed Motor Synchronization
2323
Motor Control Sensing Example:Servo Motor Control Sensing
Power
ACMotor
CurrentSense
ADC
ADC122SXXX
ADC
I nverter
Controller
Rectifier
HV isolation barrier
Ethernet
LM4132 / LM4128
Ref
DP83640/848I/849I
ADC122SXXX
AD
C
AD
C
Encoder / Resolver
AMP AMPLMP7702
LM4132 / LM4128
Ref
ADCADC
ADC161S626
AMP
LM4132 / LM4128
Ref
LMP7731
LM73
Temp Sensor
Isolation barrier
LM4132 / LM4128
Ref
ADC121S021ADC121S625
AD
C
Power
ACMotor
CurrentSense
ADC
ADC122SXXX
ADC
I nverter
Controller
Rectifier
HV isolation barrier
Ethernet
LM4132 / LM4128
Ref
DP83640/848I/849I
ADC122SXXX
AD
C
AD
C
Encoder / Resolver
AMP AMPLMP7702
LM4132 / LM4128
Ref
ADCADC
ADC161S626
AMP
LM4132 / LM4128
Ref
LMP7731
LM73
Temp Sensor
Isolation barrier
LM4132 / LM4128
Ref
ADC121S021ADC121S625
AD
C
Power
ACMotor
CurrentSense
ADC
ADC122SXXX
ADC
I nverter
Controller
Rectifier
HV isolation barrier
Ethernet
LM4132 / LM4128
Ref
DP83640/848I/849I
ADC122SXXX
AD
C
AD
C
Encoder / Resolver
AMP AMPLMP7702
LM4132 / LM4128
Ref
ADCADC
ADC161S626
AMP
LM4132 / LM4128
Ref
LMP7731
LM73
Temp Sensor
Power
ACMotor
ACMotor
CurrentSense
ADC
ADC122SXXX
ADC
CurrentSense
ADCADC
ADC122SXXX
ADC
I nverter
Controller
Rectifier
HV isolation barrier
Ethernet
I nverterInverter
ControllerController
RectifierRectifier
HV isolation barrier
EthernetEthernet
LM4132 / LM4128
Ref
LM4132 / LM4128
Ref
DP83640/848I/849I
ADC122SXXX
AD
C
AD
C
Encoder / Resolver
AMP AMPLMP7702
LM4132 / LM4128
Ref
ADC122SXXX
AD
C
AD
C
AD
CA
DC
AD
CA
DC
Encoder / Resolver
AMP AMPLMP7702
Encoder / Resolver
AMP AMPLMP7702 AMP AMPLMP7702 AMP AMPLMP7702
LM4132 / LM4128
RefLM4132 / LM4128
Ref
ADCADC
ADC161S626
AMP
LM4132 / LM4128
Ref
LMP7731
ADCADC
ADC161S626
AMPADC
ADCADC
ADC161S626
AMP
LM4132 / LM4128
Ref
LM4132 / LM4128
Ref
LMP7731
LM73
Temp Sensor
LM73
Temp Sensor
Isolation barrier
LM4132 / LM4128
Ref
ADC121S021ADC121S625
AD
C
LM4132 / LM4128
RefLM4132 / LM4128
Ref
ADC121S021ADC121S625
AD
CA
DC
• Servo drives are AC drives with the addition of an encoder or resolver to provide finer control.
• Encoders provide better performance than resolvers, however a resolver can be used over a wider temperature range and can tolerate higher shock and vibration.
• The encoder may provide voltage output directly to an ADC or there may be an Op Amp in front of the ADC
2424
Product Initial AccuracyReference Voltage (V)
Tempco (ppm/°C)
Output Current (mA)
Input Voltage
LM4128 ±0.1, ±0.2, ±0.5 3, 3.3, 4.096 75, 100 20 2 to 5.5LM4132 ±0.1, ±0.2, ±0.4, ±0.5 2.048, 4.096 1, 10, 20, 30 20 2.2 to 5.5LM4140 ±0.1 1.25, 4.096 3, 6, 10 8 1.8 to 4.366
Recommended Products
References
Op AmpsProduct Channels Vs (V) Is (mA)
GBW (MHz)
Vos max (mV)
Output Drive (mA) RR Packaging
LMP2015/16 1/2 2.7 to 5 1.2 3 ±0.005 8 RRO SOT/SOIC/MSOPLMP7701/02/04 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOPLMP7707/08/09 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP
LMP8601 1/2/4 3 to 5.5 1.1 0.06 ±1 42 RRIO SOIC NARROWLMV841/2/4 1/2/4 2.7 to 12 1.02 4.5 ±0.5 30 RRIO SC70/SOIC
LMV712 2 2.7 to 5 1.22 5 ±3 35 RRIO LLP-10, MSOP-10
Simultaneous Sampling Differential ADCs
Product Resolution channelsSample Rate
(kSPS) INL ENOBTemperature
Range Packaging
ADC122S625 12 2 50 to 200 ±1.0 LSB 11.25 Bits -40 to 105°C MSOP-10ADC122S655 12 2 200 to 500 ±1.0 LSB 11.25 Bits -40 to 105°C MSOP-10ADC122S706 12 2 500 to 1000 ±1.0 LSB 11.25 Bits -40 to 105°C TSSOP-14
Data Acquisition in Factory Automation
2626
Trends, Challenges / Solutions
Trends• Expanding competitive situation world wide is driving need for
increase need for better / finer control
– Increase in distributed control
• Increased need in system diagnostics to reduce maintenance and production costs
Challenges / Solutions• Solutions need to cover a wide range of IO module parameters,
features and specifications
– National’s Op Amp / ADC solutions provide both integrated and discrete solutions to allow customers to develop a solution that meets their specific needs
2727
Focus Areas
• IO Module (Input)
• IO Module (Output)
• Data Acquisition - Single Channel
• Data Acquisition - Multi-Channel
2828
Data Acquisition in Factory Automation Example:Data Acquisition
• Single channel and multi-channel data acquisition
MicrocontrollerLM35
Thermocouple
+V
RG1 RF 1
-
+
Metal A
Metal B
CF2
CF1
RG2
RF2
A3
ReferenceJunction
ADC
BridgeSensor
VREF
DIFF _Av=(1+2RF/RG)
CM _Av =1
+
-
AMP
+
-A2
RF
RG
+V
+IN
-IN
R F
+VOUT
-VOUT
VREF
+V
SPI Port
VREF
16 bit Diff ADC
AMP
4-20mACurrent Loop 10
RR
470 pF
180
100nF
A2 = LMP8601
+V
AMP
LM34
AMP
2929
Recommended Products
Op AmpsProduct Channels Vs (V) Is (mA)
GBW (MHz)
Vos max (mV)
Output Drive (mA) RR Packaging
LMP2015/16 1/2 2.7 to 5 1.2 3 ±0.005 8 RRO SOT/SOIC/MSOPLMP7701/02/04 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOPLMP7707/08/09 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP
LMP8601 1/2/4 3 to 5.5 1.1 0.06 ±1 42 RRIO SOIC NARROWLMV841/2/4 1/2/4 2.7 to 12 1.02 4.5 ±0.5 30 RRIO SC70/SOIC
LMV712 2 2.7 to 5 1.22 5 ±3 35 RRIO LLP-10, MSOP-10
Single Ended Input ADCs
Product Vs (V) Res (bits/˚C)Conversion/Startu
pTime (ms) Interface Package
LM73 2.7 to 5.5 ±1.0˚C 10.1 to 80.8 SMBus/I2C TSOTLM94022 1.5 to 5.5 ±1.5˚C 0.8 Analog SC70
Temperature
Product Resolution Channels
Sample Rate
(kSPS) INL ENOBTemperature
Range Packaging
ADC121S021 12 1 50 to 200 ±1.0 LSB 11.7 Bits -40 to 85°C SOT23-6ADC124S051 12 4 200 to 500 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10ADC128S052 12 8 200 to 500 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10ADC128S102 12 8 500 to 1000 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10
3030
Product Resolution ChannelsSettling time
(µsec)Temperature
Range Packaging
DAC121C081/85 12 1 8.5 -40 to 125°C SOT, LLP, MSOPDAC121S101 12 1 10 -40 to 105°C SOT, MSOPDAC122S085 12 2 8.5 -40 to 105°C MSOP, LLPDAC124S085 12 4 8.5 -40 to 105°C MSOP, LLPDAC128S085 12 8 8.5 -40 to 125°C TSSOP, LLP
Product Initial AccuracyReference Voltage (V)
Tempco (ppm/°C)
Output Current (mA)
Input Voltage
LM4128 ±0.1, ±0.2, ±0.5 3, 3.3, 4.096 75, 100 20 2 to 5.5LM4132 ±0.1, ±0.2, ±0.4, ±0.5 2.048, 4.096 1, 10, 20, 30 20 2.2 to 5.5LM4140 ±0.1 1.25, 4.096 3, 6, 10 8 1.8 to 4.366
Recommended Products
References
Differential Input ADCs
DACS
Product Resolution Channels Sample Rate INL ENOBTemperature
Range Packaging
ADC121S625 12 1 50 to 200kSPS +0.6, -0.3 LSB 11.7 Bits -40 to 85°C MSOP-8ADC121S655 12 1 200 to 500kSPS ±0.95 LSB 11.25 Bits -40 to 85°C MSOP-8ADC121S705 12 1 500Ksps to 1Msps ±0.95 LSB 11.25 Bits -40 to 105°C MSOP-8ADC141S626 14 1 50 to 250kSPS ±0.95 LSB 13.7 Bits -40 to 105°C MSOP-10ADC161S626 16 1 50 to 250kSPS ±2.0 LSB 14.5 Bits -40 to 85°C MSOP-10
3131
Summary
• National’s product line supports a wide range of Factory Automation applications
• Webinars on Control Networks, Sensing, Motor Control, Machine Vision and I/O modules will be available as part of the Industrial Campaign
• Webinars provide solutions for sensing, I/O controls, motion controllers, automation control networks and machine vision applications.
• Does the material provided address your application concerns? If not let us know.
3232
Factory Automation Webinars
• Sensing Solutions in Factory Automation 6/24/09
• Control Networks 7/9/09
• Motor Control Sensing 7/23/09
• I/O Module 8/20/09
• Machine Vision TBD
3333
For Additional Information
• Released webinars in this series can be viewed at: • Powerwise® Design University
– http://www.national.com/analog/training
• Factory Automation signal path solutions can be found on Nationals technical and application support web sites
• SIGNAL PATH Solutions– http://www.national.com/signalpath
• SIGNAL PATH Designer– http://www.national.com/analog/signalpath/designer
• Technology Edge– http://www.national.com/analog/nationaledge
• Webench Sensor Designer® Tools– http://www.national.com/analog/webench/sensor