1 / 34

Process Control Using Compact Field Point/Labview Real-time

Process Control Using Compact Field Point/Labview Real-time. Michael Tockstein Microelectronics Technology Department Electronics Photonics Laboratory June 20 th , 2006. LabView Users Group Meeting June 20 th , 2006. Outline. Furnace Bank Control Application Overview

taya
Download Presentation

Process Control Using Compact Field Point/Labview Real-time

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Process Control Using Compact Field Point/Labview Real-time Michael Tockstein Microelectronics Technology Department Electronics Photonics Laboratory June 20th, 2006 LabView Users Group Meeting June 20th, 2006

  2. Outline • Furnace Bank Control Application Overview • Requirements of our System • Compact Fieldpoint (cFP) Overview • Connecting to cFP • Labview Real-Time code structure • Remote Panels • Shared Variables • Things to Remember about Real-Time Software LabView Users Group Meeting June 20th, 2006

  3. Our Control Project • Wafer Processing Gas Flow 1 2 3 LabView Users Group Meeting June 20th, 2006

  4. Furnace Bank

  5. Requirements • Adaptable to Existing System • Single cFP Control Unit Covers: • Process Sequence Controller • Gas Flow Controllers • Boat Loaders • Four Three-Zone Furnace Tubes • Programmable for new Process • Graphical User Interface • Remote Access from Office • Technician Friendly LabView Users Group Meeting June 20th, 2006

  6. What is Real-Time? • Independently Run Controllers • Real-Time = Real Reliable

  7. Why cFP/LV Real-Time For Our System? • Eliminates need for separate controllers for each aspect of the process (i.e. gas flow, temp control, etc…) • Very customizable through both hardware and software • Best interface for our “individual” channels • Very reliable since VI runs independently from PC • Network Ready

  8. Compact FieldPoint Assembly • Includes: • CPU and Process Control Module • Backplane • Digital and Analog I/O Modules • Connector Blocks LabView Users Group Meeting June 20th, 2006

  9. cFP Backplane • 4 or 8 channel backplanes available • I/O modules receive power directly from backplane • NI data bus protocol LabView Users Group Meeting June 20th, 2006

  10. cFP Control Module • Labview Real-Time code runs in on-board controller, not your PC • Ethernet port • Serial port • 11-30 VDC input. (20W power supply recommended) • Provides power to backplane • “cFP-2000” LabView Users Group Meeting June 20th, 2006

  11. Discrete Output Module • 16 Channels, 2A sinking per channel • Used for control of gas flow • “cFP-DO-403” LabView Users Group Meeting June 20th, 2006

  12. Pulse Width Modulator (PWM) Module • 8 channels of PWM • Used for control of Watlow 100A Solid State Relay Firing • Pulse period parameters set through “Measurement and Automation Explorer” (MAX) • “cFP-PWM-520” LabView Users Group Meeting June 20th, 2006

  13. Thermocouple Input Module • 8 channels of any type T/C • Used for temperature monitoring of the three zone heaters • Selection of T/C and Cal through MAX • Uses isothermal connector blocks • “cFP-TC-120” LabView Users Group Meeting June 20th, 2006

  14. Discrete Input Module • 32 digital input channels • Compatible with 24VDC sourcing-output devices • Used to read important indicators, (e.g. vacuum seal, etc…) • “cFP-DI-304” LabView Users Group Meeting June 20th, 2006

  15. Connector Blocks • Connected to corresponding module through backplane • Used to physically wire devices to cFP unit • Two types: • “cFP-CB-1” • “cFP-CB-3” LabView Users Group Meeting June 20th, 2006

  16. cFP Hardware Setup • NI Measurement and Automation Explorer • Will “see” any NI hardware on the network • Assign IP address • Set parameters • Ready to Go!

  17. User Specified Inputs For cFP System

  18. Components of the Real-Time Software • “Drivers” for each cFP module • PID control blocks • Needed to control temperature • Program “step” code • Needed to take program through the logical sequence of events required for a specific process • Safety shutdown code • Temperature Overshoot • Zone Differential Exceeded • Manual Shutdown LabView Users Group Meeting June 20th, 2006

  19. cFP Module “Drivers” in LV 7.1 LabView Users Group Meeting June 20th, 2006

  20. “Drivers” in Labview 8 • “Drivers” are much easier to implement in Labview 8. • Labview 8 has “drag and drop” features which allow you to drag a specific channel of a device (along with it’s “drivers”) over to your VI from the project window.

  21. Drag and Drop “Drivers” For Each Device Channel Source: [1]

  22. What is PID? • Proportional-Integral-Derivative + - Desired Setpoint PID Compensator SYSTEM

  23. PID Control Blocks • Necessary for each zone of our temperature controller LabView Users Group Meeting June 20th, 2006

  24. High Level Program Flow Chart False User Enters Table Values Compare Delay Counter to Zero Set Delay Counter True Start Program Increment Row Counter Increment Column Counter Read Inputs From cFP Reset Column Counter Set Center Zone Temperature Outer Zones Track Center Zone Temperature Compare Inputs To Table Increment Column Counter False True Increment Column Counter Activate Desired Outputs

  25. Program Step Code • Reads Table • Determines if input requirements are met • Activates desired outputs • Sets new temp • Waits a desired time before next step

  26. Program Table LabView Users Group Meeting June 20th, 2006

  27. Program Table Values • Decimal numbers correspond to a binary value which represents I/O ports. • Example for a particular output step: Actual = N2 NH3 H2SiCl2 GateValve A B C D Want = OnOFF OFFOn OnOffOn On Binary = 1 0 0 1 1 0 1 1 10011011b = 155d Tech enters 155 into table. • Independent number conversion needed to save memory space onboard real-time controller. LabView Users Group Meeting June 20th, 2006

  28. Control Panel • Available on host PC and remote window. LabView Users Group Meeting June 20th, 2006

  29. Remote Panel • Built in Web server. • Monitor/control your application from a Web browser • Advantage to user running a long duration process

  30. Shared Variables • Allows easy communication of data between Real-Time target VI and Host VI • Save program memory onboard Real-Time target by conducting most processing tasks on board PC using Host VI • Available only in Labview 8

  31. Things To Remember About The Real-Time Software • When you execute your program, it is downloaded and run on the Real-Time controller, not your PC! • This effects the size of your program and ultimately limits the number of “bells and whistles” you can have

  32. Summary • Advantages of using cFP w/ LV Real-Time: • Very Flexible • Expandable • Relatively Easy to Understand • Simple Network Interface • Disadvantages: • Limited Memory • Expensive LabView Users Group Meeting June 20th, 2006

  33. References [1] NI LabView Real-Time Hands-On Seminar Manual. February 2006 Edition. Part Number 351171C-01 Additional Resources • National Instruments: www.ni.com • Compact Field Point: http://www.ni.com/compactfieldpoint/ • Labview Tour: http://www.ni.com/swf/labview/us/tour

  34. Thank You! Questions, Comments, and Suggestions Welcome!

More Related