Big Analog Data™, New Architectures to Realize New Insights€¦ · circuits per cRIO • Flexibility IO Sensors/Actuators Current Voltage Frequency Solution Advantage IT Infrastructure

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Jamie Smith

Director of Embedded Systems and IIoT Strategic Partnerships

National Instruments

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Topics

• Introduction to Big Analog Data

• Customer Case Studies (Firefly, London Underground, Innovari)

• IIoT Architecture & Edge System Architecture

• Systems & Data Management

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“

”

…it is the IoT’s industrial applications, or the Industrial Internet,

which may ultimately dwarf the consumer side in potential

business and socioeconomic impacts.

— World Economic Forum Report

Impact of the IIoT

Unstructured Data Structured Data

Explosion of Data to Drive Insights and Optimize

2011 2020201920182017201620152014201320102009200820072006 2012

Big Analog Data

Sample Rate

Vibration Signal Balance

Gear Mesh

Bearing

(fundamental + harmonics)

+

+

?

ComputationThe Physical

World

Infinite DataAny Bus

Open Data

Analog Input

Digital Output

Digital Input

Analog OutputFPGA CPU

Data Connectivity

I N T E R A C T C O M P U T E C O N N E C T

Smart Edge Device Architecture

Data Connectivity

The Physical World

I N T E R A C T C O M P U T E C O N N E C T

Smart PowerGeneration

Edg

e A

nalysis

Big

An

alog D

ata

Smart Measurements

Smart TestSystem

Smart Grid

Smart Machines

Smart PowerGeneration

The Industrial Internet of Things

½the Fuel

20%Faster

2XMore Productive

30 ParallelControl Loops

Analog/Digital I/O

CAN

Digital Outputs

HMI

EtherCAT

Ethernet

EncodersProx. SensorsPressure SensorsJ1939 KeypadPhoto Sensors

Sensors, Engine, User Controls

JoystickLoad CellSteer-by-wire DeviceOptical Level SensorJohn Deere Engine

ElectricActuators

HydrostaticTransmission

HydraulicValves

Harvester Control Systems

Servo Motion Cellular

Modem

Firefly ProSlab 155 System Diagram

Harvester

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100% productivity gains

Firefly Equipment - Intelligent Turf HarvesterEnd-to-End Industrial IoT Solution

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e

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ge

• >150 different I/O types… one CompactRIO

Sensors/Actuators

Pressure

Motor

Actuator

Encoder

Solution Advantage

IT Infrastructure

Network & Data Explorer

• Remote monitoring to improve reliability

• Remote software updates

Solution Advantage

Data Acquisition,Control Systems, and IoT Gateway

Wired or Wireless

• Design freedom for complex control• Brought domain experts closer to the

design

Solution Advantage

20% faster Half the fuel

ProcessorReal-Time or

PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

London Underground—Victoria Line

213 million passenger rides per year

33 trains per hour

45 km of deep tube railway

Track Section Track Section Track Section

Track Circuit

TX RX

Track Circuit

TX RX

Track Circuit

TX RX

• • •TC TC TC TC

Isolation•••

•••

•••

HMIServerDatabase

45 km of track divided into 385 circuits14 monitoring stations128 channels RMS voltage and frequency per station

~32 TB per day


Isolation


Isolation


39,000 customer hours regained

London Underground – Track Circuit Monitoring SystemsEnd-to-End Industrial IoT Solution

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e

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ge

• Integration of 30-32 track circuits per cRIO

• Flexibility IO

Sensors/Actuators

Current

Voltage

Frequency

Solution Advantage

IT Infrastructure


• Integration of track circuit health into control room visual data

• Historical logging of result

Solution Advantage

Data Acquisition,Control Systems, and IoT Gateway

Wired or Wireless

• Decimation of continuous data• Track circuit health determined near

the sensor• Rugged platform

Solution Advantage

Additional £350,000/year Improved Satisfaction


PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols


Innovari – Grid Load BalancingEnd-to-End Industrial IoT Solution

Th

e

Ed

ge

Sensors/Actuators

Voltage

Current Transformer

Relay Control

• High-quality measurements

• Custom I/O

Solution Advantage

Data Acquisition andControl Systems

Wired or Wireless

• Time to market• IP for power quality• Lower design risk

Solution Advantage

IT Infrastructure


• Grid wide load balancing• Capacity generation

reporting

Solution Advantage

Easier to integrate renewables

Utilities and customers both save money

Provide power tomore homes


PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

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Connect to the Enterprise, Internet, and CloudEnd-to-End Industrial IoT Solution

Sensors/Actuators

Pressure

Temperature

Temperature

Vibration

Voltage

Vibration

Voltage

RF Spectrum

Thermal Cameras

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e

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ge

IT Infrastructure


Platform Software

• Data Analytics• Systems Management• User Authentication• Data Management

CMMS Systems

Data Historian

Pumps

Transformers

Turbines

ThingsData Acquisition and

Control Systems

Wired or Wireless


PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols


PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols


PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols


PC-Based

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

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IIoT Three Tier Architecture (IIC IIRA)Edge Tier Platform Tier Enterprise Tier

Proximity Network

Access Network Service Network

Edge Gateway

Data Flow

Control Flow

Data Flow

Control Flow

Service Platform

DataTransform

Operations

Analytics Domain Applications

Edge Gateway

Device Management

Data Aggregation

...

Rules & Controls

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Sensors, Communications, Control and IIoT GatewaySmart Edge Device Architecture

Data Acquisition andControl Systems

Processor+ RTOS

FPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

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Advantages of Heterogeneous Processing Systems

“Maybe a PC can’t do the job”

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Processors are everywhere.

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Time and Reliability

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<1 microsecond <1 millisecond seconds dayshoursminutes

3 ms

100 us

2 s

300 ms ½ day

3-5 minutes

~ 1 hour 9 months

weeks

1us

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3 ms

100 us

2 s

300 ms ½ day

3-5 minutes

~ 1 hour 9 months

weeks

1us

Real-Time20 us - 1 msGuaranteed ~1msCrash - rare

FPGATypical – 25 nsGuaranteed 25 nsCrash – never

PC’s100ms – 2sGuaranteed - ?Crash - common

IT InfrastructureSensors / Actuators Processing

…

…

…

…

……

…


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CPU

Reliability with Real-Time OS

Hard

ware

Op

eratin

g S

ystem

IO D

rivers

Ap

plicatio

n S

oftw

are

Calcu

lation

Outputs

System or Device

Inputs

~25 usResponse

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CPU

Decision Making in Hardware - Reliability for safety control on FPGA.

FPGA

Op

eratin

g S

ystem

IO D

river

Ap

plicatio

n S

oftw

are

Calcu

lation

Outputs

System or Device

Inputs

~25 nsResponse

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Co-processing

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Easy to use tools for vision algorithms

Controller

Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

Wired or Wireless

Development Workstation – Vision Assistant

Plant

Tool LabVIEW

Vision on the Processor

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Perform high-speed vision algorithmsParallel processing for Vision

Controller

Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

Wired or Wireless

Development Workstation – Vision Assistant

Plant

Tool LabVIEW

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Host – 23.82 fpsFPGA – 98 fps

Original Convolution Threshold Morphology

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Host – 1.56 fpsFPGA – 98 fps

Original Convolution Threshold Morphology

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Advanced Diagnostics and Security


Developing a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater

Th

e

Ed

ge

IT Infrastructure


Systems Services


CMMS Systems

Data Historian

Things Data Acquisition andControl Systems

Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

MQTT


Start with a model of the chamber and develop ctrl codeDeveloping a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater

Th

e

Ed

ge

IT Infrastructure


Systems Services


CMMS Systems

Data Historian


Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

MQTT

Wired or Wireless

Development Workstation

Model Ctrl


Start with a model of the chamber and develop ctrl codeDeveloping a temp-chamber control system

Wired or Wireless


Model Ctrl


Perform HiL testing of control codeDeveloping a temp-chamber control system

Controller

Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

Wired or Wireless


Model Ctrl

Plant

Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

Model Ctrl


Implement control of actual temp chamberDeveloping a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater


Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

Ctrl


Implement control of actual temp chamberDeveloping a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater

Th

e

Ed

ge

IT Infrastructure


Systems Services


CMMS Systems

Data Historian


Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

MQTT

Ctrl


Common faultsDeveloping a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater

Th

e

Ed

ge

IT Infrastructure


Systems Services


CMMS Systems

Data Historian


Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

MQTT

Ctrl

1. Heater Breaks2. Heater Gets Stuck in “On Setting”3. Hacked – Spoofed Temp Reading


Leverage the model for diagnostics and securityDeveloping a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater

Th

e

Ed

ge

IT Infrastructure


Systems Services


CMMS Systems

Data Historian


Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

MQTT

CtrlModel

1. Heater Breaks2. Heater Gets Stuck in “On Setting”3. Hacked – Spoofed Temp Reading

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Demo


Implement model in FPGA higher reliabilityDeveloping a temp-chamber control system

Sensors/Actuators

Temperature

Fan

Heater

Th

e

Ed

ge

IT Infrastructure


Systems Services


CMMS Systems

Data Historian


Wired or Wireless

RTOSFPGA

Analog I/O

Digital I/O

Specialized I/O

Custom I/O

Bus Protocols

MQTT

CtrlModel

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Diagnostic Code

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Condition Monitoring

54

Acceptable Operating Zone

Operating Time

Machine Health FailurePredictive

MaintenancePreventative

Maintenance


Oak Ridge National Labs (ORNL): Software-defined Intelligent Grid Research Integration and Development platform (SI-GRID)

BATTERIES

RESIDENTIAL LOAD EMULATION

208V 3Phase

24V 3Phase

SOLAR GENERATION SOURCE

Disconnect Switch

Lead Acid MK 12VDC / 18Ah

42VDC

3ϕ 750W 24VAC

40VDC

24V 1ϕ 42VDC 0-42VDC

DC Servo

24V 3Phase

3ϕ 100W 24VAC

3ϕ 200W 24VAC

Li-Ion Fiat Battery 24VDC / 66Ah

60VDC

3ϕ 100W 24VAC

ASIG

MACHINE BASED (WIND) GENERATION SOURCE

MATLAB

Transformer (208V/24V)

DC Supply

42VDC

PHYSICAL MICROGRID:NI RIO FPGA BASED CONTROL SYSTEMS

WITH LOCAL DIGITAL TWINS

REAL-TIME GRID SIMULATION: FPGA BASED LOW-LATENCY

RECONFIGURABLE SUPERCOMPUTER

CONTROLVALUES

PREDICTED

VOLTAGE,CURRENT

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Automatic Model Conversion to Reconfigurable FPGA HardwareModels for power system including power electronics and electrodynamic models are automatically converted to ultra-high speed hardware accelerated implementation using graphical floating point high level synthesis.

HARD CORE DSPs (1520 PER FPGA)

FPGA PROGRAMMABLELOGIC FABRIC

PEER-TO-PEER COMMUNICATION

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ORNL Real-Time Power Grid Simulator – Benchmark Circuit

Power Grid Simulation System:• 80 FPGAs• 450 Peer-To-Peer Streams

Between FPGAs• 1 Microsecond Simulation

Timestep• 32 GB/s Data Computed

1 MHz Real-Time Grid Simulation:• 2 Main Power Grids• 80 Microgrids• 80 Distribution Lines• 160 3-Phase Inverters• 160 Energy Storage

Converters• 1280 IGBT/Diode Switches

SINGLE IGBT HALF-BRIDGE DATA(PHYSICAL MEASUREMENT vs. DIGITAL TWIN)

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Distributed Systems Management

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Host or Central Server

NI Devices

Web Dashboards

Systems Manager

NI Supplied

Partner or End User Supplied

3rd Party

Data Viewer

Custom Web App

Core Services

Tags and Health Monitoring

Data Management

Enterprise

CustomServices

MESSAGE

BUS

OSISoft Pi Historian

OPC Server

3rd Party

Web Server

Custom Gateway(s)

Applications

Customer APIs

User Application

Salt Minion

Salt Master

Systems Management Service

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Author

Description

MyFile.tdms

UUT Type

Test Fixture

Sensor Info

Units

Procedure

LCD Brightness

Cell Phone 1

TDMS File Format

• Single streaming binary file

• 3 levels of hierarchy for better organization

• File, groups, and channels

• Customizable, descriptive properties at each level

Property 1

Property n

Data Set (File)

Property 1

Property 2

Property 1

Property n

Property n

Channel(s)

Channel Group(s)

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Author

Description

MyFile.tdms

UUT Type

Test Fixture

Sensor Info

Units

Procedure

LCD Brightness

Cell Phone 1

TDMS File Format

• Single streaming binary file

• 3 levels of hierarchy for better organization

• File, groups, and channels

• Customizable, descriptive properties at each level

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Industrial Internet Consortium Testbeds

Time Sensitive Network Testbed

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August 1-4, 2016 | Austin, Texas

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Big Analog Data™, New Architectures to Realize New Insights€¦ · circuits per cRIO • Flexibility IO Sensors/Actuators Current Voltage Frequency Solution Advantage IT Infrastructure