Customer Case Studies - National Instrumentsdownload.ni.com/.../asean/embedded_summit_09_case_study_bookle… · Customer Case Studies ... and planes safe from fires that may start

Customer Case Studies

This is the second collection of customer case studies featuring the graphical system design

platform in various industries. Learn how engineers and scientists are using National Instruments

computer-based measurement and automation products in their test, control and design

applications. NI technologies increase productivity and lower cost through virtual instrumentation

and graphical system design. This booklet focuses on application solutions using embedded

system design platforms, combining commercial, off-the-shelf (COTS) technologies with innovative

software and hardware.

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Contents Aerospace and Avionics

Embedded FedEx Fire Suppression System Using NI LabVIEW and NI Single-Board ............................ 1

Developing a Rugged, Embedded Solution for Extreme Altitudes with NI CompactRIO .......................... 5

Automotive and Transportation

Controlling the World’s Largest Fuel-Cell Hybrid Locomotive with NI LabVIEW and CompactRIO .......... 8

Team Victor Tango’s Odin: Autonomous Driving Using NI LabVIEW in the DARPA Urban Challenge .. 12

Harnessing the Power of Embedded Design to Develop an Innovative Measurement Sensor for Automotive Test Systems ........................................................................................................................ 16

Developing a Hardware-in-the-Loop, High-Speed Simulation and Data Acquisition System for ECU Testing with the NI PXI Platform and NI LabVIEW Software ................................................................... 20

Education and Research

Developing an Undergraduate Course in Robotics Using the NI LabVIEW Embedded Module for ADI Blackfin Processors .................................................................................................................................. 23

Real-Time Control of a Switched Reluctance Motor Using NI LabVIEW FPGA and CompactRIO ......... 26

Active Noise Control System Using National Instruments LabVIEW and CompactRIO .......................... 29

Gasoline Engine Management System Test Bench for Formula-SAE Race Car .................................... 34

A New Data Acquisition and Imaging System for Nuclear Microscopy Based on NI FPGA Technology 40

Environmental and Green Engineering

Researchers Use NI LabVIEW and NI CompactRIO to Perform Environmental Monitoring in the Costa Rican Rain Forest .................................................................................................................................... 46

National Instruments Aids CEMS Engineering in Lowering Energy Consumption of Centralized Air-Conditioning Systems by Thirty Percent .................................................................................................. 51

Controlling a Chemical-Free Water Treatment System with NI LabVIEW ............................................... 54

Using NI CompactRIO to Design a Maximum Power Point Tracking Controller for Solar Energy Applications .............................................................................................................................................. 57

Siliken Renewable Energy Optimizes Solar Panel Production by Standardizing on NI Hardware and Software ................................................................................................................................................... 60

High Dynamic Fuel Cell Testing with NI CompactRIO ............................................................................. 63


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Machines / Mechanics

Embedded Graphical System Design Empowers Life-Saving Spider Robots ......................................... 67

Using High-Level Prototyping Hardware and Software in Machine Control Applications ........................ 72

Earthquake Simulator System ................................................................................................................. 76

Medical Engineering

Using Graphical System Design to Rapidly Develop a Low-Cost Device for Helping Premature Infants Learn to Oral Feed ................................................................................................................................... 81

Using Graphical System Design for Tumor Treatment ............................................................................ 84

High Performance Configurable Umbilical Cord Blood (UCB) Collection System Based on CompactRIO ................................................................................................................................................................. 88

Structural Health Monitoring

Monitoring the Structural Health of the Rion-Antirion Bridge Using LabVIEW Real-Time ....................... 93

Performing Structural Health Monitoring of the 2008 Olympic Venues Using NI LabVIEW and CompactRIO ............................................................................................................................................ 96

Meazza Stadium Uses NI CompactRIO to Usher in a New Frontier in Structural Monitoring ............... 101

Oil and Gas

Deploying LabVIEW to Monitor Pipelines at the Ormen Lange in the North Sea .................................. 104

Oil Well Fracture Pump Monitoring and Analysis using LabVIEW and NI RIO Technology .................. 107

CompactRIO Helps Nexans Spider Dredging System Level Seabed for Oil and Gas Exploration ....... 111

Developing a Safety Monitoring System for Exposed Gas Pipelines .................................................... 113


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Embedded FedEx Fire Suppression System Using NI LabVIEW and NI Single-Board

Aerospace and Avionics

Author(s): Jeremy Snow - Ventura Aerospace Troy Ingram - Ventura Aerospace Industry: Aerospace/Avionics Products: CompactRIO, Real-Time Module, Touch Panel Module, LabVIEW, FPGA Module, Single-Board RIO, TPC-2106T The Challenge: Prototyping and deploying a cost-effective and reliable control solution for a fire suppression system for the main deck of FedEx Express freighter aircraft while meeting a very aggressive deployment schedule. The Solution: Developing an intelligent fire monitoring and suppression control system for FedEx Express using NI LabVIEW software and NI Single-Board RIO hardware to prevent catastrophic fires within freight aircraft and keep pilots, packages, and planes safe from fires that may start in the shipping containers.

"We were able to rapidly prototype our system for FedEx with LabVIEW and CompactRIO and create a final deployed solution with NI Single-Board RIO – all in under a year."

NI Single-Board RIO devices act as the primary control system in the fire suppression application we at Ventura Aerospace created for FedEx Express. Within each plane, we have two devices that use NI Single-Board RIO: the Fire Control Unit and the Fire Control Hub. Fire Suppression System Architecture The Fire Control Hub is the center of the system. It contains an NI Single-Board RIO device, a power supply, a signal conditioning daughterboard that we built, and an Ethernet switch. The Fire Control Hub is responsible for checking safety interlocks, power distribution, and communication.


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Figure 1: The Fire Control Hub is the center of the system. It contains an NI Single-Board RIO device, a power supply, a signal conditioning daughterboard, and an Ethernet switch.

Figure 2: The Fire Control Unit contains an NI Single-Board RIO device and our own daughterboard.

The Fire Control Unit contains an NI Single-Board RIO device and our own daughterboard. It reads temperatures from 16 infrared sensors, processes the data, and records it. Inside a cargo airplane sits an array of cargo containers. For example, in an MD-11 airplane, there are 14 rows of containers and each row of containers has its own Fire Control Unit. Thus, with the Fire Control Hub and the 14 Fire Control Units, we use a total of 15 NI Single-Board RIO devices for the MD-11.

Figure 3: System Architecture consists of the Fire Control Hub and several Fire Control Units, each with its own

NI Single-Board RIO.


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The Fire Control Unit and Fire Control Hub devices are designed to be aircraft- and location-independent. We have built them from the ground up to function in any type of aircraft. With LabVIEW, we have programmed intelligence into both the Fire Control Unit and the Fire Control Hub to be able to self-identify aircraft type and position based on the installation. This allows for greater interchangeability and the ability to work on any plane. The system runs with full autonomy and requires zero operator input; each unit continuously monitors its own health. In addition, the system is fault-tolerant – it continues to function to the best of its ability if a fire or fault should occur. The system also sends a notification and the location of the fault after every flight. All of this is possible because of the reliability of the real-time processor, field-programmable gate array (FPGA), and I/O featured on NI reconfigurable I/O (RIO) hardware products along with the flexibility of LabVIEW. Our system monitors the temperature and controls the suppression system that deploys foam into a container if a fire is detected. Rapid Prototyping with CompactRIO and LabVIEW Getting a reliable solution to market quickly was really important to us. Using the RIO deployment curve, we were able to rapidly prototype our system for FedEx with LabVIEW and CompactRIO and create a final deployed solution with NI Single-Board RIO – all in under a year. Because of the flexibility of the embedded CompactRIO system, we were able to quickly develop a working prototype of our suppression system using LabVIEW graphical tools along with CompactRIO and NI C Series analog and digital modules. While this was our first experience with CompactRIO and the LabVIEW FPGA Module, due to the quick learning curve of LabVIEW FPGA, we were able to complete a working prototype in three months. Fast Deployment with NI Single-Board RIO Because of the small size and low cost of NI Single-Board RIO, we decided to deploy with an NI sbRIO-9612 device for the final solution. The sbRIO-9612 contains an onboard real-time processor, reconfigurable FPGA, and analog and digital I/O. We implemented our control algorithms, along with the networking and data logging of the application, on the real-time processor. The sbRIO-9612 onboard analog inputs are connected to the infrared sensors via some custom signal conditioning.

Figure 4: Because of the small size and low cost of NI Single-Board RIO, we decided to deploy with an NI

sbRIO-9612 device for the final solution.


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The transition from prototyping to deployment was seamless due to the common hardware architecture shared between CompactRIO and NI Single-Board RIO. Creating our final deployed solution was simple because we were able to reuse our LabVIEW prototyping code without any major coding changes. The fact that NI provides hardware and software to quickly prototype and deploy embedded systems was crucial for us. We are quite sure we would not have hit our aggressive deadlines without NI tools. The Advantage of a Solution from National Instruments In addition to the technical advantages of using NI hardware and software, we received invaluable sales and technical support – including direct engineering support from Austin, Texas, as well as local technical support from sales and engineering – from NI during our development process. This support and the partnership from NI have exceeded our expectations. Author Information: For more information on this Case Study, contact: Jeremy Snow Ventura Aerospace [email protected]


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Developing a Rugged, Embedded Solution for Extreme Altitudes with NI CompactRIO

Aerospace and Avionics

Author(s): David S. Thomson - National Oceanic and Atmospheric Administration (NOAA) Industry: Aerospace/Avionics Products: CompactRIO, LabVIEW FPGA Module, LabVIEW The Challenge: Creating a custom airborne instrumentation solution with off-the-shelf hardware that can survive the harsh conditions of high-altitude operation. The Solution: Developing a compact, embedded, robust solution with National Instruments CompactRIO and reconfigurable I/O (RIO) technology and testing whether it can withstand extremes of high altitudes.

"Combined with the physical robustness of the system, these results give us great confidence that CompactRIO is ideal for airborne instrumentation and other harsh environments that require a rugged, embedded solution along with the ultimate in performance and flexibility."

Obstacles of High-Altitude Testing The harsh environmental conditions of high-altitude testing make it extremely difficult to create a solution for use in custom airborne instrumentation with off-the-shelf hardware. A variety of factors make it difficult for electronics to survive at extreme altitudes and low pressures. Instrumentation electronics must be able to withstand low temperatures and low air pressure. The low air density at high altitudes creates an environment that provides very little inductive cooling. Therefore, electrical components overheating are a big concern for airborne instrumentation. High-altitude testing also subjects electronics and instrumentation to extreme vibration. Thus, an ideal airborne instrumentation solution must be rugged to be able to withstand the physical shock of this type of testing. One specific problem the extreme vibration of airborne testing poses to instrumentation is in regards to mechanical hard disks. Although modern hard disks are designed to withstand significant shock and vibration, the extreme vibration present on some aircrafts can easily render a mechanical hard disk inoperative. In addition, hard disks require an air cushion to float the hard disk head above the disk surface. Although mechanical hard disks are sealed for protection against dust, they are not sealed to withstand extremely low pressure. Thus, mechanical hard disks generally fail at high altitude due to head crashes. Additionally, instrumentation must function in the


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presence of noisy electrical power often prevalent on airborne platforms. All of these physical and electrical obstacles of high-altitude operation create an extreme environment in which few instrumentation solutions can survive. Developing a High-Altitude Instrumentation Solution with CompactRIO The ruggedness of the CompactRIO embedded system, customization of RIO technology, and deterministic performance of NI LabVIEW Real-Time create an ideal solution that can withstand the environmental challenges of high-altitude testing while providing the ultimate in performance and flexibility. We found the CompactRIO embedded system to be the ultimate solution for the extreme environmental conditions of high-altitude testing. The system provides an extended operating temperature range of -40 ºC to 70 ºC, a dual-redundant power supply that can operate from DC power, isolated I/O signal conditioning modules, and is rated for 50 g of shock. The CompactRIO embedded system uses less than 20 W of electrical power, which proves very useful for low pressure environments. Normally, instrumentation used in high-altitude testing would require custom cooling that would be rather complicated for a system with multiple electronic components. You would need to enclose a system in a pressure vessel, which would add unwanted volume and weight. At extreme altitudes, we found that the CompactRIO embedded system survived without the use of custom cooling or a pressure vessel. This is largely a result of the low power consumption of CompactRIO. CompactRIO also contains Compact Flash solid-state disks that have no moving parts and therefore eliminate the hard disk failure dilemma of airborne testing. CompactRIO uses RIO technology, with which we can create custom hardware using the LabVIEW graphical programming environment. Using the LabVIEW FPGA module, we can develop high-speed analog and digital control algorithms and integrate custom timing and synchronization needed for airborne instrumentation. With numerous high-performance signal conditioning modules available, a CompactRIO system can easily be customized with the functionality required for a wide range of applications.

Figure 1: High-Altitude Test Aircraft The CompactRIO-based LabVIEW Real-Time controller has a powerful floating-point processor and contains a powerful LabVIEW Real-Time application. Besides its inherent determinism, LabVIEW Real-Time has the significant advantage of being built on a robust, compact real-time operating system. In particular, this operating system is, in our experience, immune to hard disk corruption upon unexpected power loss, which is a well-known problem for Windows operating systems and is a potential hazard that must be addressed for airborne instruments. In addition, using CompactRIO with LabVIEW Real-Time brings all the development power and ease of LabVIEW, including sophisticated GUIs; numerous acquisition, analysis, and control tools; and built-in support for networking.

Successful in Harsh Environments To simulate high altitudes, we placed an eight-slot reconfigurable embedded CompactRIO chassis inside a bell jar, with connections through the bell jar for power and network communication. We filled all eight module slots with digital and analog CompactRIO I/O modules. A LabVIEW program continuously tested the digital and analog CompactRIO I/O modules to ensure functionality at different altitudes.


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After starting the CompactRIO program with the embedded system inside the bell jar, we lowered the pressure to 300 mb (equivalent to 27,000 ft altitude) and observed the system for an hour. We then observed successful operation for one-hour periods at 150 mb (42,000 ft), 55 mb (65,000 ft), 17 mb (90,000 ft), and 0.53 mb (173,000 ft). We operated the system at 0.53 mb for over eight hours to verify that it could operate for extended times at high altitude. Although most research aircrafts have flight ceilings below 70,000 ft, for this test, we lowered the pressure to the lower limit of the bell jar operating range. CompactRIO performed flawlessly even at this extreme, and it is likely that removing the last 0.05 percent of atmospheric pressure would not have made any measurable difference. The operation of the CompactRIO system at extremely low pressure was quite impressive. Combined with the physical robustness of the system, these results give us great confidence that CompactRIO is ideal for airborne instrumentation and other harsh environments that require a rugged, embedded solution along with the ultimate in performance and flexibility. For more information, contact: David Thomson Research Scientist National Oceanic and Atmospheric Administration 325 Broadway Boulder, CO 80305 Tel: (303) 497-3470 Fax: (303) 497-5373 E-mail: [email protected]


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Controlling the World’s Largest Fuel-Cell Hybrid Locomotive with NI LabVIEW and CompactRIO

Automotive & Transport

Author(s): Tim Erickson - Vehicle Projects LLC Industry: Transportation, Energy/Power Products: CompactRIO, LabVIEW, FPGA Module, Real-Time Module The Challenge: Controlling the operation of a 250 kW fuel-cell hybrid locomotive The Solution: Using an NI CompactRIO controller to monitor and control the safety and operation of a fuel-cell locomotive and controller area network (CAN) bus to communicate the engine status to the operator via a touch panel programmed with NI LabVIEW software.

"We chose LabVIEW and CompactRIO because the NI C Series modules with integrated signal conditioning helped us implement fast monitoring of the various I/O points while connecting to a wide range of specialty sensors such as flowmeters and pressure sensors.”

The prime mover of a traditional switch locomotive is a diesel engine between 1 and 2 MW driving an alternator that supplies power to the traction motors and locomotive auxiliary systems. These traditional switch locomotives require a high-power diesel engine, which typically is not fuel-efficient and has limited emission control. Subsequent design iterations of switch locomotives have transitioned to a hybrid-electric design, which reduces the overall emissions and fuel consumption because the engine can be downsized while the battery stores energy for high-power transients. However, a large source of diesel particulate pollution in urban areas still comes from diesel-powered locomotives in rail yards. To help alleviate this pollution, a North American public-private partnership is prototyping a fuel-cell hybrid switch locomotive for urban rail applications and replacing the diesel engine with a 250 kW net fuel-cell power plant, creating the world’s largest fuel-cell hybrid locomotive.


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Figure 1: We removed the diesel fuel tank and generator set in preparation for retrofitting the fuel-cell power plant and hydrogen storage. Photo courtesy of Railpower Hybrid Technologies. Vehicle Projects LLC of Denver, Colorado, engineered the control system for the fuel cell using a CompactRIO embedded controller and LabVIEW graphical design software. Our goals are to reduce air pollution in urban rail applications, including yard switching associated with seaports, and to serve as a mobile backup power source for critical infrastructure during

military base grid failures or civilian disaster relief operations. Fuel Cells and Hybrid Power Trains Fuel cells are electrochemical power devices that directly convert the chemical energy of a fuel into electric power. The cells produce electricity and water from hydrogen fuel and oxygen, which is the reverse process of water electrolysis. While fuel cells share principles of operation with batteries, they differ in that the electrochemically active materials, hydrogen and oxygen, are stored or available externally and continuously supplied to the device rather than stored in the electrodes. They are periodically refueled, like an engine, rather than recharged electrically. Like batteries, individual cells are grouped together into “stacks” to provide the required voltage or power

Figure 2: The main components of a fuel-cell hybrid power train include the auxiliary storage battery or flywheel auxiliary energy/power device and the traction motors used as generators during breaking. A fuel-cell hybrid power train uses a fuel-cell prime mover plus an auxiliary power/energy-storage device to carry the vehicle over power peaks in its

duty cycle and recover kinetic or potential energy during braking. For steady-state operation, the continuous net power of the prime mover must equal or exceed the mean power of the duty cycle. Preliminary research has shown that a hybrid-switch locomotive can reduce capital and recurring operation costs. Designing a Control System Using CompactRIO We faced several design and integration challenges while developing the large hydrogen fuel-cell vehicle including weight, packaging, and safety considerations. Harsh operating conditions, especially


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the shock loads that occurred during coupling to railcars, required highly rugged component systems. Additionally, the fuel-cell control system needed to communicate with the existing commercial vehicle controller to interpret operator demand and adjust fuel-cell power plant parameters to meet the power requirement. The CompactRIO embedded controller provided an ideal form factor to meet these specifications with the right I/O combination for this application. This programmable automation controller (PAC) managed and executed all power plant functions and continuously monitored the performance and safety of the hydrogen storage and fuel-cell power systems.

Figure 3: The fuel-cell prime mover of the locomotive provides 250 kW of continuous power for traction or power

to grid, and the auxiliary traction battery permits transient power in excess of 1 MW. Software Architecture Based on LabVIEW A CompactRIO embedded controller running the LabVIEW Real-Time and LabVIEW FPGA modules controls the fuel-cell power plant operation. The user monitors the control system via a touch panel installed in the locomotive cab. The control application consists of modular control algorithm VIs that communicate with each other and the field-programmable gate array (FPGA) I/O system using a tag-based architecture so that we can refer to each I/O point by the assigned name within the LabVIEW application. Each tag has properties associated with it including alarm limits, scaling (converting from voltage to engineering units), and events such as when the user wants it to log to a disk. We implemented a programmable logic controller (PLC) mentality into our PAC-based system. Developing the Perfect Control Platform with LabVIEW and CompactRIO We chose LabVIEW and CompactRIO because the NI C Series modules with integrated signal conditioning helped us implement fast monitoring of the various I/O points while connecting to a wide range of specialty sensors such as flowmeters and pressure sensors. Additionally, we performed complex control algorithms beyond simple proportional integral derivative control at very fast loop rates. Some of our control algorithms included mathematical models that we implemented with LabVIEW, which we could not have developed using less flexible environments such as a PLC platform. Furthermore, we achieved the fast loop rates that we required because we had the ability to place some of the control algorithms on the FPGA


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Author Information: For more information on this Case Study, contact: Tim Erickson Vehicle Projects LLC 621 17th Street, Suite 2131 Denver, CO 80293 Tel: (303) 296-4218 [email protected]


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Team Victor Tango’s Odin: Autonomous Driving Using NI LabVIEW in the DARPA Urban Challenge


Author(s): Patrick Currier - Virginia Polytechnic Institute and State University, TORC Technologies LLC Jesse Hurdus - Virginia Polytechnic Institute and State University, TORC Technologies LLC Al Wicks - Virginia Polytechnic Institute and State University, TORC Technologies LLC Charles Reinholtz - Virginia Polytechnic Institute and State University, TORC Technologies LLC Industry: Automotive, Electromechanics/ Electrotechnics, Government/Defense, Education, Research, Transportation, RF/Communications Products: Touch Panel Module, LabVIEW, FPGA Module, Real-Time Module, Industrial PC Embedded OS, Vision Development Module, Control Design and Simulation Module, cRIO-9104, TPC-2006, cRIO-9012 The Challenge: Developing an autonomous vehicle to complete the Defense Advanced Research Projects Agency (DARPA) Urban Challenge, an autonomous ground vehicle race through an urban environment The Solution: Using the NI LabVIEW graphical programming environment and National Instruments hardware to enable rapid development, testing, and prototyping to successfully complete the challenge (placed third out of 89 competitors and won a $500,000 USD prize).

"Odin was the only vehicle to extensively use LabVIEW, and we placed third overall, just minutes behind the leaders."

Figure 1: Odin drives autonomously in the DARPA Urban Challenge under the control of the software developed using LabVIEW. The DARPA Urban Challenge required a ground vehicle to autonomously navigate through an urban environment. To complete the course, our fully autonomous vehicle had to traverse 60 miles in less than six hours, while navigating traffic through roads, intersections, and parking lots. At the start of the race, a mission file specified checkpoints

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LabVIEW Real-Time and LabVIEW FPGA modules, creating a stand-alone vehicle platform. We used the LabVIEW Touch Panel Module to create a user interface for the NI TPC-2006 touch panel computer, which we installed in the dashboard. Perception To fulfill the behavioral requirements of the Urban Challenge, Odin needed to be able to localize its position, detect the surrounding road coverage and legal travel lanes, perceive all obstacles in its path, and appropriately classify obstacles as vehicles. A number of sensors enabled Odin to meet these requirements, including three IBEO four-plane laser range finders (LRFs) at bumper level, four SICK LRFs and two computer vision cameras on the roof rack, and a high-accuracy Novatel GPS/IMU system. For each perception requirement, we used multiple sensors to achieve maximum fidelity and reliability. For flexible sensor fusion, the planning software neglects any raw sensor data and uses a set of sensor-independent perception messages generated by task-specific components. The localization component contains a LabVIEW Kalman filter that tracks vehicle position and orientation. The road detection component uses the NI Vision Development Module to combine camera and LRF data to determine a road coverage map and the position of each lane in nearby segments. The object classification component uses LabVIEW to process IBEO data to detect obstacles and classify them as either static or dynamic; the dynamic obstacle predictor then predicts the paths and actions of other vehicles. Planning The planning software on Odin uses a hybrid deliberative-reactive model dividing upper-level decisions and lower-level reactions into separate components. These components run concurrently at independent rates, making it possible for the vehicle to react to emergency situations without needing to re-plan an entire route. Splitting the decision making into separate components enables each system to be tested independently and fosters parallel development, which was necessary given the short timeline of the Urban Challenge. The route planner component uses an A* search algorithm to determine which road segments the vehicle should use to achieve all checkpoints. The driving behaviors component uses a behavior-based LabVIEW state machine architecture responsible for obeying the rules of the road and guiding the vehicle along the planned route. The motion-planning component performs an iterative trajectory search to avoid obstacles and guide the vehicle along the desired route. The system then passes motion profiles to the vehicle interface to be translated into actuator control signals. Communications We developed our entire communications framework using LabVIEW. We implemented the SAE AS-4 Joint Architecture for Unmanned Systems (JAUS) protocol, enabling automated, dynamic configuration and enhancing the future reusability and commercialization potential of Urban Challenge software. Our team also implemented each software module as a JAUS component with all interactions between modules occurring through this LabVIEW framework. Each software module operates as a stand-alone component that can run asynchronously on either the Windows OS or the Linux® OS. With this communications backbone, interfacing or reusing software modules written in LabVIEW with software modules written in other languages is trivial.


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Benefits of LabVIEW LabVIEW provided a successful programming environment for our team for several reasons. With a team composed mostly of mechanical engineers, LabVIEW enabled the development of advanced, high-level perception and planning algorithms by programmers without computer science backgrounds. Furthermore, easy interaction between LabVIEW and hardware enhanced the ability to implement the time-critical processing crucial for sensor processing and vehicle control. LabVIEW also provided an intuitive and easy-to-use debugging environment so we could run and monitor source code in real time for easy hardware-in-the-loop debugging. The LabVIEW environment enabled the team to maximize testing time and promoted rapid prototyping and a greater number of design cycles. Given the very short timeline for the Urban Challenge and the unique nature of the problem, these abilities played a critical role in the team’s overall success. We successfully used LabVIEW and NI hardware to develop an autonomous vehicle capable of completing the Urban Challenge, a never-before-attempted problem in robotics. Odin was the only vehicle to extensively use LabVIEW, and we placed third overall, just minutes behind the leaders. Linux® is the registered trademark of Linus Torvalds in the U.S. and other countries. Author Information: For more information on this Case Study, contact: Patrick Currier Virginia Polytechnic Institute and State University, TORC Technologies LLC Mechanical Engineering Department Virginia Tech M/C 0238 Blacksburg, VA 24061 United States Tel: (540) 231-6417 Fax: (540) 231-9100 [email protected]


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Harnessing the Power of Embedded Design to Develop an Innovative Measurement Sensor for Automotive Test Systems


Author(s): Alessandro De Grassi - Loccioni Group Luca Marassi - Loccioni Group Carmine Ungaro - Loccioni Group Francesco Siano - Loccioni Group Industry: Automotive Products: System Identification Toolkit, Real-Time Module, LabVIEW, FPGA Module, Control Design and Simulation Module, CompactRIO The Challenge: Designing a flexible and reliable automotive test system for measuring and charting the flow rate of diesel engine nozzles The Solution: Using the NI LabVIEW graphical programming environment to design a control program for data acquisition, management, processing, and reporting

"We were able to design an innovative automotive test system based on NI technologies characterized by their flexible, reliable, and easy-to-use framework."

Loccioni Group is considered a flag-bearer for Italian innovation because of its reputation for developing custom technical solutions to ensure quality, comfort, and safety in many areas. We work closely with universities and research centers to develop and implement turnkey systems using technology. We have applied our expertise in measurement and test for quality control, automation, ICT, energy, and service across a range of industries including automotive, electrical appliances, environmental, health, and manufacturing. In our labs, quality is emphasized as critical, because we strive to be the highly specialized experts in the design and deployment of automated test and quality control integrated systems. We focus primarily on two industries: automotive and electrical appliances. Currently, we implement custom lines and test workbenches for partners in the automotive component manufacturing industry.


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Researching, Developing, and Producing Our research and development lab is the “beating heart” of the group’s ideas. The lab is flexible and adapts quickly to tackle challenges in the automotive field. Moreover, it is used to test and verify new solutions and perform internal-use and end-user measurement campaigns. Areas of focus include pressure measurements, volumetric flow rate, mass flow rates, and operations of nozzle characterization. The latter gave birth to the Mexus project, an innovative, nozzle-specific measurement system development project based on National Instruments technology.

Figure 1: The injection chamber and its control system were modeled using the LabVIEW Control Design and Simulation Module. This project originated from the need to measure the flow rate of diesel engine nozzles with a detailed quantification of the fuel injected during a single injection. The final product is an instrument used worldwide by injector manufacturers for end-of-line production tests. Our goal was to provide a low-cost product with cutting-edge technology and better performance than other

available instrument. The solution is a reliable product capable of accurately determining the two fundamental parameters characterizing injectors: the flow rate injected for each shot and the chart of the instantaneous flow rate. The instrument provides the measurement of the fuel quantity injected in each single shot event up to a maximum of 10 events per revolution (also known as multi-injection). By simulating the engine operation at 3,000 rpm, the readout value injection for each revolution can be easily detected by the system, which provides the quantity of each fuel injection in real time. The innovative aspect of this project is the calculus algorithm used in the solution. The system acquires different analog signals and processes them in real time, providing the user with reliable test results up to the injector functioning rate of 50 instantaneous values per second. The system is also able to determine how much fuel is dispensed in each injection. This information is significant for injector characterization because emissions regulations are becoming more restrictive. Consequently, it is important to provide manufacturers with more detailed information to gain high-level combustion, reducing either fuel consumption or the quantity of pollutant gas within the environment.


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Technology Integration To ensure measurement reliability, we used National Instruments products to support the project. The design of the Mexus control program used LabVIEW to manage data acquisition, processing, and reporting.

Figure 2: The Mexus control program uses LabVIEW to manage data acquisition, processing, and reporting.

One critical element of the Mexus system is the injection chamber, the cylinder conveniently provided with control sensors and valves where the fuel is injected and the specific measurements are performed. The injection chamber and its control system were modelled with the LabVIEW Control Design and Simulation Module. In this stage, simulations were performed on a PC using the LabVIEW graphical programming environment. During prototyping, the same PC and Windows platform is maintained through an NI PC-based data acquisition board that performs functional characterization and validation. This important development stage of the project highlighted the need for a more refined chamber injection model. This was determined by using the LabVIEW System Identification Toolkit, which made it possible to obtain the transfer function of the injection chamber and consequently design a suitable control algorithm. To enable a large scale deployment, we needed a hardware device with failure-free technology that was capable of operating around the clock, offered a compact form factor, and suitable for an industrial environment. We chose the NI CompactRIO system to ensure maximum compatibility with the software. This hardware helped us make a quick shift from prototyping to deployment as well as ensured that we met the sampling rate requirements and the real-time, deterministic control of the process.


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In the solution, the user interface is controlled by a touch panel computer equipped with a Windows XPe OS programmed using LabVIEW and with an Ethernet connection to the CompactRIO. When developing our solution, the most important advantage was the use of a single development environment for the design, prototype, and deployment phases. This advantage reduced the need to interface with third-party programming languages. LabVIEW also provided great flexibility for development integration, ease of use, and hardware control. The Mexus final product guarantees the highest reliability in test operations. The accuracy of the measurements is due to the introduction of innovative working methodologies that ensure test compliance with the most restrictive regulations. We were able to design an innovative automotive test system based on NI technologies characterized by their flexible, reliable, and easy-to-use framework. Because of our know-how and technological partnership with National Instruments, Loccioni Group has provided the automotive world with an innovative product that delivers excellent test standards with no machine downtime and an easy-to use interface. Author Information: For more information on this Case Study, contact: Luca Marassi Loccioni Group Tel: +39.0731.8161 [email protected]


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Developing a Hardware-in-the-Loop, High-Speed Simulation and Data Acquisition System for ECU Testing with the NI PXI Platform and NI LabVIEW Software


Author(s): Thomas J.. Mangliers - DGE Inc. Edward Frank - DGE Inc. Industry: Automotive, ATE/Instrumentation, Electromechanics/ Electrotechnics Products: PXI-7831R, Real-Time Module, PXI-7833R, LabVIEW, PXI-8105, PXI CAN, FPGA Module The Challenge: Creating a hardware-in-the-loop (HIL) simulator capable of generating and monitoring multiple signals at extremely high acquisition rates with tight tolerances for an engine control unit (ECU) that requires the system to generate precision-timed Cam and crank waveforms as well as monitor spark, injector, and other timing signals. The Solution: Using the NI PXI platform and LabVIEW graphical programming software to develop a high-speed data acquisition system (DAS) that generates and monitors complex signals to accurately simulate a running engine/vehicle environment to enable ECU testing

Figure 1: DGE High-Speed DAS Connected to a DGE Load Box and Our Customer’s ECU Timing Signal Display Example

"We developed both the data acquisition system and logfile tool solely using LabVIEW, and our system relies entirely on the speed and accuracy of NI products."

The primary purpose of the DAS is to simulate a vehicle environment for an ECU to test under lab conditions where it is impractical or impossible to use the actual vehicle or engine. This requires the DAS to generate and monitor complex timed signals such as CAM and crank with nanosecond resolution.


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Typical ECU modules have a complex I/O layout. The ECU signals are defined in an Excel worksheet to identify any changes to existing signals. With this worksheet, users can outline the signal names, tolerances, and unit as well as signal conversion or scaling using the DAS multistage math functions. Users can easily add or remove typical signals without any system software changes. Due to tight tolerances, the ECU signals require the DAS to easily adapt to slight differences in production-built modules as well as variations in test setups. In response, DAS baselining records all ECU outputs over a specified time to dynamically adjust the user’s tolerances to match the current ECU outputs. With the baseline information, the user can now detect minute deviations during testing.

Figure 2: A large amount of data is produced at every reading recording due to a high monitoring rate.

Because the system monitors at such a high rate, recording every reading produces a large amount of data. To manage the data, the DAS produces a report that shows the nominal readings in the

recorded baseline and any reading that exceeds the user-defined tolerances. Now the DAS can spend more time monitoring the ECU for anomalies. Using our LabVIEW logfile tool, the user can quickly generate a detailed report that shows module performance broken down by individual tests. During the test procedure, the DAS can function as a master or slave for EMC testing, a benchtop HIL simulator, a functional tester, or with Ethernet control for simple integration with existing test control software. Features of the high-speed DAS include the following:

• 192 digital I/O lines

• 16 analog I/O lines

• Arbitrary waveform generator

• Two CAN ports

• Easily definable measurement criteria in an Excel spreadsheet (signal type, parameters, tolerance, and more)

• Remote command interface over Ethernet for test automation


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• Automatic module baselines for all signals for more accurate detection of system anomalies

• Data logfile creation

• Data reports, summaries, and graphs in Excel using a logfile tool developed with LabVIEW

• Timing signal display

High-Speed Data Acquisition Using the NI PXI Platform National Instruments products are the heart of our system. NI provides all of the I/O for our DAS system including complex signal generation, high-speed acquisition, and vehicle bus simulation and monitoring. We developed both the DAS and logfile tool solely using LabVIEW, and our system relies entirely on the speed and accuracy of NI products. We could not use our standard capture cards for our application due to the precision timing involved with the ECU signals. Instead, we chose to use NI R Series intelligent DAQ field-programmable gate array (FPGA) modules to provide the complex-timed waveforms and simulated-sensor outputs. The NI PXI-7831R and PXI-7833R R Series intelligent DAQ modules also gave us the ability to capture and properly time the ECU output signals at the higher acquisition rates. DAS data processing was another problem we faced. Our solution was to develop a logfile tool in LabVIEW using inherent parallel processing and generate a multicore application that processed our data using the host computer’s complete power. Benefits of Using the National Instruments Platform With the available tools to conduct testing in normal lab environments instead of special full-vehicle chambers, the DAS system greatly reduced our customer’s costs. Because the DAS could monitor and control all of the ECU signals, we completed the testing in a single pass instead of multiple passes, which was previously necessary due to the limited number of channels available on our customer’s old acquisition system. Now customers can complete test profiles in as little as three weeks rather than three months with older acquisition systems. Author Information: For more information on this Case Study, contact: Thomas Mangliers DGE Inc. 2870 Technology Drive Rochester Hills, MI Tel: (248) 293-1300 Fax: (248) 293-1309 [email protected]


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Developing an Undergraduate Course in Robotics Using the NI LabVIEW Embedded Module for ADI Blackfin Processors

Academic/ Research

Author(s): Fred Martin - University of Massachusetts Lowell Industry: Education, Research Products: LabVIEW The Challenge: Improving engineering curriculum to address the advancements in embedded control and signal processing design to better prepare engineering students. The Solution: Creating an undergraduate course in robotics and controls based on the NI LabVIEW Embedded Module for ADI Blackfin Processors.

"LabVIEW Embedded technology makes robotics programming accessible to people who would not otherwise be able to create embedded systems. It gives users an alternative to programming in C."

Robotics represents a radical departure from standard curricula because students can actually teach themselves while maintaining control over their designs. In 1995, in conjunction with the Massachusetts Institute of Technology (MIT) Media Laboratory, I published the design of the “Handy Board,” a hand-held, battery-powered microcontroller board optimized for classroom robotics applications. The board was developed for the MIT LEGO Robot Competition, an annual event in which 50 teams of undergraduates develop small robots to compete in an elimination tournament. The board was released with an open-source license, and was quickly adopted by a growing community of university educators. Today, more than 10,000 Handy Boards are in use worldwide. In 2001, we published Robotic Explorations: A Hands-On Introduction to Engineering, a textbook companion to the Handy Board for classroom and laboratory use. More than 50 universities and colleges have developed courses around the text. At the University of Massachusetts Lowell (UML), we are revamping the Handy Board, and we have created a new upper-level undergraduate course in robotics and controls to inspire the creativity of the next generation of engineers. We are using two new technologies to help us – the NI LabVIEW


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Embedded Module for ADI Blackfin Processors, a graphical programming environment based on a signal-flow metaphor, and the new Analog Devices, Inc. (ADI) Blackfin Handy Board. Beginning in the summer of 2005, ADI sponsored a collaboration with our UML research group to develop a next-generation Handy Board based on the ADI Blackfin embedded DSP microprocessor. The first prototypes of this new Blackfin Handy Board (BF-HB) became available in January 2006, with a stable design and debugged drivers expected to be ready in the fall of 2006.

Figure 1: Engineering students at the University of Massachusetts Lowell are using LabVIEW Embedded for

Blackfin Processors to learn about robotics. Course Description The new course extends our prior work, including the Robotic Explorations text. The course is based on the central task of designing a behavior-based mobile robot, and includes updated units on robot sensors (including electrical interfacing and applications), motor control (pulse-width modulation, DC motors, and servo motors), mechanical design with LEGO technical materials, and robot control. The course also features new units on classical control and robot vision, as well as a complete set of supporting course material, including lecture notes, laboratory projects, sample exams, and solutions. All programming ideas and concepts are developed using the LabVIEW Embedded Module for Blackfin Processors. Course laboratory assignments follow this sequence:


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Lab 1 – My First Robot Lab 2 – Basic Robot Behaviors Lab 3 – Introduction to Classical Control Lab 4 – Distance Sensors and Mapping Lab 5 – Behavior-Based Robot Control Lab 6 – Robot Vision Lab 7 – Robot Contest Lab 8 – Open Projects Developing the Blackfin/LabVIEW Robotics Toolkit The LabVIEW graphical programming model is especially powerful for signal flow and signal processing applications and is much better than textual languages, especially for embedded design. Coordinating multiple processes is a difficult challenge in robotics, and the LabVIEW Embedded Module for Blackfin Processors can address this issue. The module adds tremendous value in the debugging stages of development – you can easily see the state of variables while your code is running by creating visual displays such as indicators or graphs that represent key internal data. We are also developing LabVIEW VIs for use with the Blackfin Handy Board, which will be based on the Board Support Package that is being developed jointly by ADI and UML. These VIs will comprise a “Blackfin/LabVIEW Robotics Toolkit” that is closely tied to the Blackfin Handy Board. We will test the material in successive course offerings in the Department of Computer Science and disseminate it via a Web site developed specifically for this purpose. The Blackfin Handy Board is an extremely significant update of the original design, but it also preserves key design principles such as ease-of-use for classroom robotics and compatibility with existing Handy Board sensors and motors. With the power of the Blackfin processor, the new design has two important new features – it can run advanced software environments, and it can support camera subsystems and run robot vision applications. LabVIEW Embedded technology makes robotics programming accessible to people who would not otherwise be able to create embedded systems. It gives users an alternative to programming in C. For more information, contact: Fred Martin, Associate Professor Department of Computer Science University of Massachusetts Lowell 1 University Avenue Lowell, MA 01854 USA Email: [email protected]


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Real-Time Control of a Switched Reluctance Motor Using NI LabVIEW FPGA and CompactRIO

Academic/ Research

Author(s): Keunsoo Ha - Virginia Tech Industry: Industrial Controls/ Devices/ Systems, Education, Research Products: CompactRIO, LabVIEW Simulation Module, LabVIEW FPGA Module The Challenge: Developing a real-time speed control system for switched reluctance motor (SRM) drives The Solution: Using the National Instruments LabVIEW FPGA Module and CompactRIO embedded system to design, prototype, and deploy an experimental environment for developing new SRM simulation, control system, and drive technology. Because of its mechanical simplicity and inexpensiveness, the SRM has become the subject of great interest in the field of electrical motor drives. The Center for Rapid Transit Systems at Virginia Tech is an internationally recognized drive systems and motion control research group with expertise in the design, simulation, and control of SRMs and power converter topologies. Rapid Design and Simulation in LabVIEW We used NI LabVIEW to create a design and simulation platform for developing new control algorithms and power electronics. With the LabVIEW Simulation Module, we could simulate the closed-loop system dynamics of the SRM, and we used the LabVIEW Control Design Toolkit to design the motor current and speed control loops. We used lookup table (LUT) functions in LabVIEW to represent nonlinear relationships in the simulation model. SRMs have a nonlinear, three-dimensional relationship that relates inductance and torque to current and position. Then we added a model for the power electronics N+1 converter, which was invented by Virginia Tech professor Krishnan Ramu. After that, we added a LabVIEW block (for the commutation logic used to control the converter) to the model and validated the block using simulation. We conducted a simulation at 1,000 rpm to prove the validity of the commutation logic and closed-loop speed control system. The simulation included a precise model of the two-phase SRM, N+1 converter, commutation logic, two proportional integral derivative (PID) controllers, and two routines to find the inductance and the torque from the magnetization characteristic LUTs of the motor. For the continuous solver method, we used the Runge-Kutta 4 solver. After tuning, the control system performed well with a speed overshoot of less than 1 percent under no-load conditions and a settling time of about 50 ms.


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The control strategy development for SRM drive systems is more complicated than other types of motors because the machine inductance is a function of both the rotor and excitation current, even for small currents. With the LabVIEW environment, we could develop a complex dynamic simulation model in which we could include all of the programming structures of a complete programming language, such as case structures, for loops, and formula nodes. We used a formula node to easily make several control blocks, such as the model of the two-phase SRM, N+1 converter, and the commutation logic. The LabVIEW environment also made it easy to model special phenomena such as the reduction of the negative torque in the running the motor. In the LabVIEW simulation diagram, we could easily mix traditional LabVIEW code with model-based simulation objects such as the transfer function block. By using a true programming language, we were not limited to the single execution model and restricted functions palette of traditional dynamic simulation tools. Also, our LabVIEW code was very portable, and we could easily reuse the control algorithms and logic we developed later in the process for real-time control. With these simulations, we could validate the actual code used in the real-time target and take advantage of the full debugging and user interface visualization capabilities of LabVIEW.


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Using CompactRIO for Real-Time Speed Control of the Motor To demonstrate real-time speed control of the SRM, we connected our N+1 converter and two-phase SRM to the NI CompactRIO industrial control and acquisition platform. The CompactRIO I/O modules and user-programmable FPGA made it easy to connect our control algorithms to the actual motor hardware. The FPGA offered the ability to provide high-speed control of the power converter circuitry and motor current. The real-time control system software comprised five key modules – pulse-width modulation (PWM), commutation logic with programmable advance and commutation angles, high-speed inner current control loop, slower outer speed control loop, and self-starting logic. With the hierarchical nature of LabVIEW, we could capture the multirate cascaded control system logic in an intuitive graphical embedded software application. Because we could reuse the LabVIEW control algorithm code developed during the design and simulation phase, we were able to fine-tune the current control loops based on PI gains calculated during simulations. Consequently, we were able to quickly verify the simulation models using practical, measured data and create a reconfigurable platform to iteratively improve our simulation models, power electronics, and control system designs. For more information, contact: Keunsoo Ha Virginia Tech Electrical and Computer Engineering 340 Whittemore Blacksburg, VA 24061 Tel: (540) 231-6058 E-mail: [email protected]


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Active Noise Control System Using National Instruments LabVIEW and CompactRIO


Author(s): Wang Liang, Graduate Student (Phd Candidate) Gan Woon Seng,Senior Lecturer Chua Chong Hua Academic Institution: School of Electrical and Electronic Engineering, Nanyang Technological University, Singapore Products Used: NI LabVIEW Professional 8.0 NI PCI-4472 8-Channel Dynamic Signal Acquisition Board NI CompactDAQ Chassis NI 9263 CompactRIO 4-Channel Analog Output Module The Challenge: A flexible active noise control system requires accurate signal acquisition, generation, synchronization and powerful real-time signal processing capability. The Solution: Using National Instruments signal acquisition and output modules, chassis, and LabVIEW software to design a flexible test system based on desktop or notebook PC to perform various active noise control experiments. Abstract: The aim of this project is to implement active noise control (ANC) system on a real-time processing platform. PC based National Instruments LabVIEW environment is chosen due to its flexible, easy and fast to develop, which is especially preferable for research and prototyping. Under this setup, various experiments tested the behavior of the Filtered-x LMS (FXLMS) adaptive algorithm when applied to active noise control in an enclosed area. The quality attenuations of noises are acquired to verify the theoretical predictions and performances of FXLMS ANC. An Innovative Approach for ANC System Research Implementation ANC systems based on the principle of superposition have evolved and developed in many applications to cancel undesirable noise. ANC involves destructive interference between the primary (undesired) noise from the noise source and a generated anti-noise of equal amplitude and opposite phase to the primary noise. The efficiency of the ANC depends on the accuracy of the amplitude and phase of the anti-noise. To create a single ANC system with ability to test different ANC algorithms and setups is a challenging task. Generally, ANC systems require both high processing power and crucial delay and synchronization constrain. For our research work, there are many algorithms and setups to investigate. To cater all combinations with cost and time consuming limitations, National Instruments platform is the optimal solution for both software and hardware.


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Conventional Solution Limitations Before adopting PC based National Instruments setup, we build active noise control system based on DSP board. For different algorithms and audio peripherals setup we have to code different sets of programs. The coding part takes longer time compared to National Instruments’ LabVIEW approach. The setting for the peripheral synchronization and delay is another big challenge for ANC system. Furthermore, this setup has limited the number of audio channels and processing power. NI Solution Benefits Flexible For our research, various experiments based on different algorithms, variations and settings are to be conducted. To achieve this objective, the solution must be very flexible, and can be easily adapted to different hardware and software setups. The NI solution allows us to program and reuse our codes for different setups. The number of channels can be expanded using the same NI platform. The synchronization and timing on NI cards successfully meets the crucial time delay requirements for real-time ANC systems. Portable With NI CompactDAQ chassis, CompactRIO modules and laptop computer, the system can be a portable solution for testing and experiments in various situations, for example, in an automobile cabin. More importantly, with this platform, we are able to perform different tests and experiments based on different algorithms and modify them on the site. Low Cost For different setups, we can implement on the same NI PC-based platform. For different algorithms, many shared programming modular can be reused. The same platform can be used in future projects as well. This reusability cuts the costs in both short-term and long-term projects. Hardware System Architecture The experimental setup in Figure 1 exemplifies a small enclosed area, with approximation dimension of 2.80m x 0.95m x 1.18m. Sound absorbing foams are pasted around the walls and ceiling of the enclosed area. Inside the enclosed area is an upholstered seat occupied by a supported dummy head. Both the error and reference microphones are connected to a NI PCI-4472 signal acquisition board, which converts acoustic noises acquired from the microphones to digital signals. In addition, PCI-4472 analog input card supplies 4mV excitation voltage to power the PCB 130D20 microphone. After the processing done by LabVIEW, the control signal is generated and sent to NI CompactDAQ Chassis where a NI-9263 CompactRIO analog output module is mounted on it. NI-9263 module converts the control signal to anti-noise through digital-analog conversion and sends it to a loudspeaker


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Figure 1: Hardware Setup of the System

Software System Architecture The adoption of NI LabVIEW enabled us to easily reuse and adapt codes for different algorithms and different setups. All the programs are coded in LabVIEW. However, the flexibility of LabVIEW allows other programs as well, which gives other researchers the opportunity to port their codes from other programming languages. DAQassist in LabVIEW is particular useful for interfacing with hardware, which would be a challenging task with different setups. Modula programming makes the coding and later reuse easier. We programmed a few sub-VIs each handling certain processing task. Error signal and reference signal sensed by the error microphone and reference microphone respectively are fed into the FXLMS sub-VI. In the FXLMS sub-VI, the coefficients of the offline secondary path filter are also extracted from the filter coefficients data file. Based on the information provided by error and reference signals as well as the coefficients of the offline secondary path filter, the control signal is computed as an output of the FXLMS sub-VI. This control signal is then transmitted to the secondary loudspeaker as anti-noise. High-level and user-friendly graphical interface as shown in Figure 2 makes the control of system easy and interactive.


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Figure 2: Software Graphical Interface of the System Performing Experiments and Data Collection We performed various experiments using NI LabVIEW and hardware to simulate a flexible ANC system for the control of engine noise in automobile cabin. With this system, we are able to select different engine noise harmonics order to control based on different engine noise profiles. The adaptive system processes the signal real-time with updates from the NI I/O modules. The graphical interface on PC integrates the parameter selections and results display. All the parameters for the experiments can be easily modified to suit different setups. For instance, users can set the sampling frequency, step size, number of the adaptive filter weights. Furthermore, for different hardware setups, the hardware configurations including microphone excitation voltage and loudspeaker sensitivity can be set with no using the graphical interface. The waveform of the error signal collected by the error microphone can be displayed real-time. The data can be also saved to data files. Results from different experiments can be compared and used in analysis easily. Conclusion By adopting NI software and hardware solution, we were able to design and build a high-performance flexible active noise control system with low-cost. With this versatile system, we can conduct various experiments to test different algorithms without recoding or reconfiguration of the system. The portability of the system allows us to conduct these experiments in different locations. The flexibility of the solution also enables easy further development of multi-channel ANC system and active noise equalizer (ANE) system.


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Appendix: A video clip showing the setup and functioning of the system is available at: http://www.youtube.com/watch?v=5gYlrbyeVO4 For more information, contact: Wang Liang Nanyang Technological University 50 Nanyang Avenue, S2-B4-3 DSP Lab, Singapore 639798 Tel: +65-6790 6901 E-mail: [email protected]


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Gasoline Engine Management System Test Bench for Formula-SAE Race Car


Author(s): Wang Yang, Undergraduate Academic Institution: Department of Electrical and Computer Engineering National University of Singapore, Singapore Products Used: NI cRIO-9004 Real-Time Controller NI cRIO-9103 4-Slot, 3 M Gate CompactRIO Reconfigurable Embedded Chassis NI 9201 8-Ch, ±10 V, 500 kS/s, 12-Bit Analog Input Module, C Series NI 9263 4-Channel, 100 kS/s, 16-bit, ±10 V, Analog Output Module NI 9401 8 Ch, 5 V/TTL High-Speed Bidirectional Digital I/O Module NI LabVIEW 8.0 NI LabVIEW FPGA Module 8.0 The Challenge: In our race car, a modifiable Engine Control Unit (ECU) is required to operate the engine that is restricted by race regulations. Using an untested ECU puts the engine in high risk of damage, ushering the development of an effective test-bench to verify its capability to safely operate the engine. The Solution: A test-bench platform comprising of the NI cRIO-9004 controller, NI cRIO-9103 chassis, NI 9201, NI 9263, and NI 9401 modules replicate engine signals to the ECU, collecting time-precise data from it. A user interface is developed using LabVIEW 8.0 to control the replicated signals and validate the ECU outputs. Abstract This paper presents the development of a Field Programmable Gate Array (FPGA) and PC-based solution that is efficient and accurate for testing of custom ECUs. Integration of NI cRIo-9004 Real-Time Controller and software developed using LabVIEW FPGA module 8.0 creates a reliable platform for the simulation and collection of data. This is done to precision timing to meet our requirements. The developed user interface presents data collected in a meaningful way and automatically tabulates the collected information into a data file that can be accessed using Microsoft Excel. This greatly improved the efficiency during data-collection and testing. INTRODUCTION In the construction of a Formula-SAE (FSAE) race car, the power plant, a 600cc 4-cylinder 4-stroke gasoline engine, was obtained off-the-shelf and integrated with other in-house manufactured components. Being governed by the rules of the race, air-flow into the engine needs to be


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mechanically restricted, thereby reducing the power of the engine. The original ECU that controls it is unable to operate under such conditions. In order to operate the engine, the fuel supply has to be restricted as well, leading to the need for an “after-market” ECU that is able to vary these fuel injection rates. However, directly testing such a device on the engine itself can be dangerous and expensive. There is, therefore, a need for an effective test-bench to test ECU to make sure that they are able to operate the engine, with fuel restriction, without damaging the engine. SOLUTION DEVELOPMENT System Overview

Figure 1: Overview of system setup

The ECU illustrated above is the original ECU for the engine that we use in building our racecars. It consists of over 30 input/output ports that are connected to the test-bench. To better understand the workings of the ECU, the NI cRIO-9004 and its peripheral modules are used to simulate the signals coming out from the engine. Connecting these signals to the ECU allows it to run its normal programs. The output of the ECU is then fed into, and recorded by the same NI cRIO unit. Very precise signals have to be generated for the ECU for it to function correctly. These signals include:


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1. Crank and Cam signals. This gives the ECU the simulated engine speed and relating it to the position of the pistons in each cylinder. Monitoring the position of the pistons is vital to engine operation as it determines when to inject the fuel and spark the plugs. If the positions are miscalculated, firing the engine may damage it.

2. Throttle Position (TP) Sensor signal indicates to the ECU the driver’s demand for acceleration.

3. Manifold Absolute Pressure (MAP) Sensor signal indicates to the ECU how much air is going into the cylinders.

4. Intake Air Temperate (IAT) Sensor signal provides the ECU with the temperature of the air that is drawn from the atmosphere. Together with MAP, the ECU is able to calculate the amount of oxygen that is present for combustion in the cylinders.

5. Engine Coolant Temperature (ECT) Sensor signals provides the ECU with the temperature of the engine.

Hardware Implementation In order to achieve a sampling timing of 1 microsecond, high resolution samples, and simultaneous acquisition for correlation of data, we chose NI cRIO-9004 Real-Time Controller and NI cRIO-9103 CompactRIO Reconfigurable Embedded Chassis as the platform for our solution. It met our demand for high speed and high resolution data acquisition. Another key feature for selecting the NI cRIO is its expandability. By simply changing the chassis, more slots can be used to expand the number of modules and thereby increasing the number of functions that can be added to the system. The NI cRIO also features a real-time processor which can executed our LabVIEW Real-Time processes reliably and deterministically. The re-configurable multi-channel Analog and Digital Input/Output provided the suitable interface to communicate with the ECU and other components on the test bench as we need to access a combination of 8 digital and 7 analog ports. The three types of modules in use were: NI 9201 Analog Input Module -- used to monitor the simulated MAP, IAT and ECT sensor readings. It was chosen for its sampling rate of 500K S/s and measurement range of up to 10 Volts. It gave us the resolution and range that we needed for such signals. NI 9263 Analog Output Module -- used to generate the Crank and Cam signals. We chose it for its ability to generate simulated analog signals of up to 12kHz with high precision and consistent voltages. In addition, NI 9263 was also used to generate the TP signal. Since we needed to simulate many repetitions of TP value against Crank and Cam timings in order to attain a complete set of test results, the NI 9263 was relied upon to give us the consistency and stability that we demanded and the convenience of varying them from the PC. NI 9401 Digital Input/Output Module -- used to capture ECU ignition and injection outputs. NI 9401 was chosen for its 100ns input rate as we were monitoring high frequency ports. Also, the high precision of NI 9401 gave us the ability to record the exact timings of the signal edges accurately


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which was extremely critical in our data collection. In total we were monitoring and recording 4 ignition and 4 injection outputs from the ECU which utilized all 8 Input/Output ports of the module. Software Implementation LabVIEW with FPGA Module 8.0 was used to develop the software for FPGA. Timed-loop program structure was implemented for the FPGA target and could run precisely over a range of frequencies up to 10 KHz to simulate signals from the engine. Using LabVIEW, we were able to run parallel loops on the FPGA target, achieving acquisition of raw data and calculation of various pulse-widths, latency timings and frequencies of signals simultaneously. The result is a robust system that is able to generate stable high frequency outputs while capturing inputs at high resolutions with remarkable performance. A Graphical User Interface (GUI) for the PC was developed with LabVIEW 8.0. The GUI displays raw timing data collected from the NI cRIO FPGA and displays them in an easily interpreted format. Users are also able to vary the parameters through the GUI to control the ECU during a test procedure. User-defined variables such as RPM will be translated into a timing variable which governs the looping speed of the FPGA target, thereby generating the signal at the required frequency. The GUI was also designed to run the entire testing process across all RPM and TP values and save the results in specific data files. The integration of software and hardware platform enabled us to achieve high automation in data collection, processing and recording. The Data Processing Work Flow that allows us to integrate the NI cRIO hardware and LabVIEW software to achieve our desired system is shown below.


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Figure 2: Data Processing Work Flow

EXTENDING THE TESTING-PLATFORM Simulating ECUs in Real Time The test-bench that we have developed will aid us in collecting operation data from various ECUs. To test various ECUs that we selected for real engine performance, we can use our platform with LabVIEW 8.0 Real Time Module. This will allow us to test different ECUs efficiently without having to build separate wiring looms for each of them. The simulated ECU must run in deterministic time loops


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to meet timing and synchronization of outputs. The control algorithm must generate the I/O signals such as firing of a cylinder on time once an input such as a particular Cam signal is received. ADVANTAGES Testing made safer, easier and faster Compared with the traditional method of testing ECUs by connecting many wires to it while it is connected to a running engine, our design, utilizing the NI cRIO-based data-acquisition system and LabVIEW based PC interface, gave us the safety and comfort of conducting the test in lab and read off the data in numbers format. High accuracy in testing It is difficult to manually maintain sensors at a consistent reading and even a slight change can greatly vary the results of ECU outputs. Hence, using traditional testing methods, the ECU outputs are transient and most data collected would have to be an estimate. Our design, using the NI cRIO, is able to generate consistent values to simulate sensors which stabilize the ECU outputs. Data collected this way is therefore highly accurate. Tremendous amount of time saved Using the traditional method, it took us 2 man-hours to collect and record data for 10 settings of the experiment. To map out the behavior of one ECU, an estimate of 3360 permutations of settings has to be run, translating to a total of 672 man-hours. With the implementation of our design on automated settings and recordings, we took about 5 minutes to collect and record 168 settings of the experiment. This translates to a total of about 1.5 man-hours to complete the experiment. The use of NI cRIO and LabVIEW to implement our system saves us more than 670 hours for every ECU that we test! CONCLUSION The NI cRIO data-acquisition platform, coupled with LabVIEW 8.0 software interface, is an efficient and reliable platform for testing of our car’s ECU. The design is able to achieve precise and stable simulation results while realizing accurate high resolution data collection. The integration between software platform and hardware platform made it possible for automated data collection and recording which greatly reduced our testing time. For more information, contact: Wang Liang Design Lab, Block EA, #03-02, 9 Engineering Drive 1, Singapore 117576 E-mail: [email protected]


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A New Data Acquisition and Imaging System for Nuclear Microscopy Based on NI FPGA Technology


Author(s) C.N.B. Udalagama, Research Fellow A.A. Bettiol, Asst Professor F. Watt, Professor Academic Institution Centre for Ion Beam Applications Department of Physics National University of Singapore, Singapore Products Used LabVIEW 8.0 LabVIEW FPGA LabVIEW Application Builder Measurement Studio 8.0.20 IMAQ Vision 7.1 PCI-7833R The Challenge To produce an easily maintainable/upgradeable multiple dialog, control software to enable the scanning of a beam of MeV particles (H+, H2+, He4+2 or O+) over a sample and to collect, correlate, analyze, display & image the resulting stochastic data with minimal influence of software latencies on data collection. The Solution

1. Use a NI FPGA card for beam scanning, data collection & correlation independent of the CPU

2. Create a C++ based multiple dialog user interface for control and data representation in the .NET environment using Measurement Studio & IMAQ Vision

3. Communicate/transfer data between the FPGA and user interface through DLLs and DMA. Abstract The introduction of the FPGA cards by NI has made it possible for the first time to develop reconfigurable custom data acquisition hardware easily with LabVIEW. Data acquisition issues such as precise timing for scanning and operating system latencies can now be easily overcome using this new technology because the data acquisition software is embedded in the FPGA chip on the card. In this paper we present the first results of the new data acquisition system, IonDAQ, developed at the Centre for Ion Beam Applications, National University of Singapore using the new NI FPGA cards in conjunction with rack mountable Wilkinson type ADCs.


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Data Acquisition & Nuclear Microscopy The research programmes at the Centre for Ion Beam Applications (CIBA), Department of Physics, National University of Singapore (NUS), are based on the use of the available 3 MeV Singletron or 2.5 MeV van de Graff accelerators. These accelerators can provide continuous beams of ions (protons, alphas or oxygen) at MeV energies that can be focussed, with the aid magnetic quadrupole lenses, to a beamspot of micro/nanometre dimensions. The particle beam is normally scanned (using magnetic or electric fields) over a target sample, for material analysis or beam-induced modification. Ion beam analysis is carried out by collecting signals generated through the ion-atom interactions such as RBS, PIXE, ERDA, IL, IBIC, SE, STIM (see website for more details). The Data Acquisition System (DAS) realizes beam scanning is realized by digitising the target region into pixels and then stepping the beamspot from one pixel to another. The beamspot is allowed to dwell on any pixel for a fixed interval of time, during which the ions are allowed to interact with the sample producing the signals. The data generated through these ion-atom interactions ultimately need to be in the (Detector, Energy, Position) form. This allows the data to be used for generating (1) energy spectra and (2) images. The Detector identifies the detector the signal was generated from. The Energy refers to the actual energy of the detected signal (An example being, the energy of a detected ion that has traversed the bulk of a sample). This Energy is determined by processing the original signal by fast, dedicated electronics. The Position refers to the (x, y) coordinates of the location of the ion-beam on the sample, when the signal was generated. The establishment of the Energy – Position correlation is complicated by the fact that ion induced signals are stochastic. This means that an event (i.e. a instance where a signal induced response from a detector is registered) is not guaranteed at each pixel. When an event does occur, the DAS must be fast enough to detect it, correlate it to the present beamspot (x, y) position before the beamspot moves on or another event occurs. This correlation problem can be solved either in software or hardware. Although, a software solution is easier to implement and with the recent advances in CPU speeds, very feasible. A software solution, however well established, is always prone to loss of data in the event of a CPU latchup due to operating system latencies. Therefore, an ideal DAS should offer a hardware solution to the correlation problem where dedicated hardware establishes the correlation. This has by far been the most common solution opted for until present. Further, it is desirable that an ideal system sufficiently decouples the data collection (event detection, pulse height analysis, beam scanning, correlation) from the data analysis (data storage, displaying, image forming). It is also important that an ideal DAS be amenable to being upgraded, modified or repaired with the least investment of time and effort from the scientist. Any change of the system will take the form of a minor modification to the controlling core along with the replacement/addition of sub-units. IonDAQ is the new PC based DAS of Centre for Ion Beam Applications that addresses and solves all issues raised previously. IonDAQ At the heart of IonDAQ is the Xilinx Virtex-II 3 million gate field programmable gate array that resides on the PCI-7833R card. This FPGA constitutes the controlling core (CORE) that works together with rack mounted ADCs (from Fast ComTec) and a high-level host programme (HOST) that allows the


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user to interact with the CORE. The CORE software has been developed with LabVIEW 8.0. The HOST has been developed in-house using the .NET environment in C++. NI’s IMAQ Vision and Measurement Studio components are used by the HOST for it’s data presentation. The HOST instructs and monitors the CORE via dynamically linked libraries (DLL). These DLLs are produced using the LabVIEW Application Builder from our LabVIEW VIs written to communicate with the CORE. IonDAQ's design and implementation has been aimed at achieving the following key objectives:

The CORE is a compact hardware solution: Although the CORE is configured programmatically it is operationally indistinguishable from a wired hardware solution where individual electronic components are collected to form a specialized electronic circuit. The CORE contains all the connections necessary for the operation of IonDAQ that includes the outputs (X-scan,Y-scan, beam blanking), inputs (Fast pulse Imaging, Analogue Imaging, Pulse Height imaging, Charge). The scan and blanking outputs use the card’s DACs while communication with the rack mounted ADCs are via the DIO lines that handle all aspects of handshaking and data transfer. It must be noted that the present solution is more suitable than a wired hardware solution in that all the necessary features are located in a single PCI computer card, making it unnecessary to have additional, individual electronics. This has the virtue of making IonDAQ a highly compact system. De-coupling of data collection from data representation: Data collection is handled solely by the CORE while the HOST is only involved in data display and storage. The CORE requires no CPU overheads for its operation, which includes handling the correlation problem. The already correlated data is siphoned out of the CORE, without any CPU overhead, directly into the HOST's memory via DMA using the cards FIFOs. Maintainability: IonDAQ is easily maintained or upgraded. Any changes to the CORE are easily implemented by changing the LabVIEW diagram which can then be compiled within tens of minutes. Further, since the bulk of the basic functionality has already been incorporated any upgrades will only require a minor alteration in the diagrams. For instance, if another brand or model of rack mounted ADCs need to be supported the only modification required is to the digital handshaking and data transfer lines as per the new model. The HOST is completely oblivious to this modification. Similarly any changes to the HOST's data analysis or data handling are easily realized without affecting the data acquisition. Further, owing to LabVIEW’s compatibility any future upgrades in operating systems will at most require a recompilation of the relevant code. IonDAQ's CORE Figure 1 shows a schematic of IonDAQ and its CORE. Each of the loops shown in the image of the CORE represents a process that can run independently. Data is transferred to and from the CORE through the three available FIFOs. One of the FIFO's (FIFO - IN) is fed with the scan pattern from the HOST. The FIFO – OUT1 is dedicated to transferring pulse height data from the ADCs. The data arbitrator is necessary to manage the data flow from the separate ADC loops to avoid two or more loops from accessing the FIFO simultaneously. Since, our FPGA CORE is compiled to run at 40 MHz


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(equivalent to 25 ns ticks) it can easily handle the pulse height data input rates that IonDAQ (c.a. 100 KHz) is aimed at servicing. The third FIFO, FIFO – OUT2, is used solely for fast imaging using analogue signals, digital pulses and the ADC deadtime.

Figure 1: Schematic showing IonDAQ system. IonDAQ supports several imaging methods that can be used concurrently, depending on the data acquisition requirements and the beam current used in the experiment. Up to four NIM rack mounted ADCs can be used to simultaneously image signals and perform pulse height analysis from a variety of traditional ion beam analysis detectors. IonDAQ supports two additional imaging methods that allow the user the ability to image using either a TTL pulse input, or an analogue voltage input. Two Fast Pulse Imaging (FPI) inputs are provided on the IonDAQ interface box. These utilize DIO lines on the card and allow the user to spatially map using detectors that have a TTL pulse output. This imaging mode is useful for pulsed signals that do not carry any energy information such as signals from photomultiplier tubes and channel electron multipliers. Two further inputs are provided on the IonDAQ interface boxes that enable the user to perform analogue imaging (AI). This imaging method is useful for imaging detectors such as photomultiplier tubes configured in voltage output mode. Images pertaining to these modes are shown in figure 2. Shown in figure 3, is a screenshot of IonDAQ’s HOST.


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Figure 2: Images of a Ni grid acquired with IonDAQ system using (a) NIM ADC, (b) fast pulse imaging (FPI), (c) analogue imaging (AI). Experimental parameters were: Pixel dwell time 1 ms, image resolution 512 x 512, beam current 1pA, count rate 1.2 kHz, scan size 30 x 30 micrometers.

Figure 3: Screenshot of IonDAQ’s HOST portion. Conclusion NI FPGA technology has paved the way for an elegant, compact, readily maintainable data acquisition and imaging solution, IonDAQ, for nuclear microscopy. This is due to the ease of using LabVIEW for programming the FPGA chip (CORE) that controls all aspects of data collection,


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including the important, non-trivial problem of correlating a signal’s Energy and Position. Further, the ability to convert LabVIEW VIs into DLLs has made it possible to develop a C++ multiple dialogue HOST within the .NET environment that uses Measurement Studio and IMAQ Vision. Author Information For more information, please contact: Dr Chammika Udalagama, Research Fellow Centre for Ion Beam Applications National University of Singapore 2 Science Drive 3, Singapore 117542 Tel: +65-65164136 Email: [email protected]


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Researchers Use NI LabVIEW and NI CompactRIO to Perform Environmental Monitoring in the Costa Rican Rain Forest

Environmental and Green Engineering Author(s): Dr. William Kaiser - Department of Electrical Engineering, UCLA Dr. Philip Rundel - Department of Ecology and Evolutionary Biology, UCLA Industry: Biotechnology, Education, Research Products: CompactRIO, LabVIEW, Compact FieldPoint Controllers The Challenge: Supporting a wide range of wireless environmental measurements using a single device that provides robotic control, remote configuration, and data sharing over the Web for a measurement system that researchers use to characterize the forest understory microclimate and fluxes of carbon between the rain forest floor and the atmosphere The Solution: Using NI LabVIEW software and NI CompactRIO hardware, we developed a wireless sensor system that collects a variety of environmental measurements, offers remote configuration capabilities, permits future expansion, and gives researchers around the world access to the measurements over the Internet.

"Because of the flexibility of LabVIEW, we can configure measurement types, select channels, and even add scaling from a laptop connected to the system."

Approximately 70 percent of solar energy is absorbed by the Earth’s atmosphere. As the Earth’s surface emits this energy in the form of thermal radiation, the atmosphere naturally captures and recycles a large portion of it, keeping the planet warm. This process is known as the greenhouse effect. Recently, the greenhouse effect has been artificially enhanced by the increased emission of gases that absorb infrared radiation such as carbon dioxide (CO2), methane, and nitrous oxide. The increased absorption of thermal radiation may contribute to the Earth’s climate change known as global warming.

Figure 1: The NIMS measurement unit using CompactRIO and LabVIEW traverses on a cable between towers at the La Selva Biological Station.


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Conducting Carbon Flux Research in the Costa Rican rain forest To better understand the impact of the emission of greenhouse gases on the environment, researchers are conducting a study at La Selva Biological Station in the Costa Rican rain forest to measure the exchange of CO2 (also known as the carbon flux) and other materials between the forest floor and the atmosphere. The area under observation lies within a 3,900-acre tropical rain forest that averages 13 feet of rainfall per year and is located at the confluence of two major rivers in the Caribbean lowlands of northeastern Costa Rica.

Figure 2: Mist rising from gaps in the forest at the La Selva Biological Station in Costa Rica This area was chosen for observation because rain forests are naturally rich in biodiversity and are carbon sinks, meaning they function in a manner that is opposite of a human lung –absorbing CO2 and releasing oxygen into the environment. Tropical rain forests absorb more CO2 than any other terrestrial ecosystem and affect the climate locally and globally. However, in rain forests, carbon flux

is unusually complex because of the multilayered, diverse forest structure. The “Gap Theory” is a hypothetical explanation for the complexity of carbon fluxes. It hypothesizes that small, open areas in the forest canopy caused by natural processes such as tree falls, function as a chimneys, pulling out CO2 produced by soil respiration and leaking it into the atmosphere at local points. Due to the difficulty in making measurements from multiple points on the forest floor and corresponding points in the canopy, or in a 3D manner, a balanced budget for CO2 fluxes has been historically difficult to measure. Using Wireless Sensors Based on Systems Developed by CENS with NI Technology The wireless measurement technology deployed in Costa Rica is a networked infomechanical system (NIMS) based on LabVIEW software and CompactRIO hardware. The NIMS application was developed at the University of California Los Angeles (UCLA) by the Center for Embedded Networked Sensing (CENS). CENS develops embedded network sensing systems for critical scientific and social applications. It is a National Science Foundation (NSF) Science & Technology Center with an interdisciplinary and multi-institutional support structure that involves hundreds of faculty, engineers, graduate student researchers, and undergraduate students from partner institutions throughout California. CENS has received between $4 million and $6 million in NSF funding per year for the past six years and will continue to receive the organization’s financial support for the next four years.


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Figure 3: Using Wireless measurement systems based on LabVIEW and NI technology, researchers at La Selva hope to better understand how Carbon is absorbed and emitted in rain forests. To increase the accuracy of the measurements being taken and to determine the effects of uneven carbon flux, we developed a mobile, wireless, aerially suspended robotic sensor system capable of measuring the transfer of carbon and other materials between the atmosphere and the Earth. There are a wide range of measurements necessary to characterize the carbon flux including temperature, CO2, humidity, precise 3D wind movement, heat flux, solar radiation, and photosynthetic active radiation (PAR). In the past, acquiring this breadth of measurements required the use of multiple data loggers from different

vendors. CENS selected a modular approach using CompactRIO. The CompactRIO platform supports a wide range of measurements using C Series modules from National Instruments and third-party vendors. The flexibility of CompactRIO addresses our current measurement needs with a single platform while still leaving room to easily add new measurement modules in the future. Our system, called “SensorKit,” and is designed to provide flexibility, ruggedness, mobility, and ease of use, by utilizing LabVIEW and CompactRIO is technology.

Figure 4: The NIMS based on NI technology will help researchers take better measurements at the La Selva

Biological Station. Deploying the Wireless Sensors Three of the SensorKit systems have been deployed at La Selva Biological Station for the first phase of field trials. The SensorKits are equipped with a variety of instruments, including tools for conducting basic meteorological measurements, sonic anemometers, infrared sensors, and radiometers. All of the environmental data necessary to conduct the carbon flux study is acquired through a modular


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approach. The wireless sensor systems are arranged at points on the forest floor and on aerially suspended robotic shuttles creating the first environmental monitoring system capable of taking measurements three dimensionally.

Figure 5: This diagram shows how researchers can collect measurements using the wireless measurement

systems connected between towers in the forest canopy. In the initial test deployment, the wireless mobile sensing platforms traversed cables along three separate transects of the forest understory. During the deployment, the shuttle stopped at 1 m intervals along each transect for 30 s to allow sensors to equilibrate and take the required measurements. Each transect pass required 30 minutes and each transect ran for 24 hours.

Figure 6: Scientists are deploying new measurement technologies to better understand and calculate the transfer of carbon and other materials between the atmosphere and forests.


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Advantages of a System Based on LabVIEW By implementing the system using National Instruments modular hardware and software, we developed a flexible system with the additional communication and configuration advantages of LabVIEW software. CompactRIO was selected as the central measurement unit and the NI Compact FieldPoint network interface with cFP-180x controllers were selected for distributed wireless measurements. The NI Wireless Access Point (WAP-3701) was chosen to transfer data between the distributed sensors, the towers, and the canopy floor. We selected LabVIEW to connect to these distributed wireless measurement platforms and program the embedded CompactRIO processor. Using LabVIEW, we can supply measurements to local researchers in different data formats so that they can perform post-analysis. Because of the flexibility of LabVIEW, we can configure measurement types, select channels, and even add scaling from a laptop connected to the system. LabVIEW also provides advanced analysis tools for real-time embedded processing to perform local mass flux analysis and post-processing for remote researchers. In addition, LabVIEW is equipped with an HMI, so we can see real-time measurements. Prior to the development of this real-time analysis system, researchers typically spent a long time collecting large amounts of data on-site to bring the information back to their respective labs for further analysis. Future Expansion Plans In conjunction with the system designers at CENS, we plan to expand the system by adding high towers approximately 45 m above the forest floor with canopy walkways and increasing the total number of measurement systems in the upcoming months. Students from around the world can access the canopy walkways to experience the unique atmosphere and biodiversity of the rain forest canopy. Additionally, we plan to deliver remote data access through the Web to researchers and students who are not on-site. Using a Web browser and the Web capabilities of LabVIEW, researchers everywhere will be able to access and download live and archived data for their own analysis. Performing additional measurements using a 3D measurement system will provide the data needed to validate our “Gap Theory” hypothesis that carbon transfer occurs unevenly across the rain forest. Gaps in the forest canopy are sources of carbon loss while the canopy is a source of carbon absorption, which increases as the density of canopy vegetation increases. With this research, scientists will better understand the carbon absorption impact of rain forests and potentially calculate the carbon absorption value of an acre of forest ultimately providing a method of quantifying carbon credits. Author Information: For more information on this Case Study, contact: Dr. William Kaiser Department of Electrical Engineering, UCLA Los Angeles, CA 90095 United States [email protected]


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National Instruments Aids CEMS Engineering in Lowering Energy Consumption of Centralized Air-Conditioning Systems by Thirty Percent

Environmental and Green Engineering Author(s): Thirumalaichelvam Subramaniam - CEMS Engineering Sdn Bhd Industry: Energy/Power Products: LabVIEW, Compact FieldPoint The Challenge: Reducing energy consumption of large-scale air-conditioning systems in tropical climates The Solution: Using NI Compact FieldPoint and LabVIEW Real-Time to acquire and analyze real-time data for more efficient cooling.

"Operating instructions determined through a series of variance calculations of the real-time input data, PID control loops, principles of thermodynamics, heat transfer and advanced mathematical optimization and other proprietary equations in a LabVIEW Real-Time application, resulted in reduced electricity bills and energy consumption up to 30 percent.”

Chiller Energy Management System (CEMS Engineering) Engineering specializes in energy management of centralized air-conditioning systems. In the last three years, CEMS Engineering developed a breakthrough approach for improving the quality and energy efficiency of commercial air conditioning systems in the tropics including those located in office buildings, factories, and hospitals. To cool a large area, commercial and industrial centralized air-conditioning systems traditionally consist of multiple machines, commonly known as chillers that control air temperature by removing heat from a coolant liquid through vapor-compression or an absorption-refrigeration cycle. The typical approach to cooling a building is to determine how much energy is required to cool a particular building to a desired temperature and then set each chiller to produce chilled water at the same setpoint. The calculations are usually based on the worst-case condition – the one or two hottest days of the year – which leads to inefficient energy use and hard-to-control building temperatures.

Figure 1: The Chiller System


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CEMS Engineering pioneered technology to lower the energy usage of these chillers while still maintaining the same, cooled temperature of the building. CEMS Engineering uses the NI Compact FieldPoint programmable automation controller (PAC), and LabVIEW running on an industrial PC to acquire real-time input data directly from sensors on the chillers and then uses this data to determine and send new operating instructions to the chillers. These operating instructions are determined through a series of variance calculations of the real-time input data, PID control loops, principles of thermodynamics, heat transfer and advanced mathematical optimization and other proprietary equations in a LabVIEW Real-Time application. CEMS has saved clients up to 30 percent of their air conditioning energy costs in tropical countries where cooling costs typically consume 45 to 60 percent of building energy expenses. The CEMS Engineering systems use a novel approach in determining optimized operating parameters of chillers. Users acquire real-time input data directly from sensors outside, on the chillers, and in the buildings. CEMS Engineering conducts a series of variance calculations of the real-time input data with proportional-integral-derivative (PID) control loops, and then uses this data to determine and send new operating instructions to the chillers using small electrical signals. There are no moving parts and the operating instructions are determined using a series of genetic algorithms that combine heat transfer principles, thermodynamics and mathematical predication are used to operate the chillers in the most energy efficient manner, while maintaining industry standards and without compromising the comfort level of occupants in a commercial or industrial building. With the support of National Instruments LabVIEW and Compact FieldPoint hardware, implementation of the CEMS Engineering system was completed within six months of commencement and is now installed and running at customer sites. CEMS Engineering reduced time to market with the integration inherent between NI LabVIEW software and Compact FieldPoint hardware. With LabVIEW, CEMS Engineering could fully use the power of graphical system design, progressing from a design to a prototype, to working deployment in astounding speed. The system relied on Compact FieldPoint for data acquisition, analysis, decision making and solid state controls. With the graphical interface, users can literally see the heat flow coming into and out of each building. Another benefit of this graphical real-time monitoring approach is that his firm can cost-effectively handle its clients’ energy management remotely. After the systems are installed, CEMS engineers implement real-time monitoring from their offices to monitor and control systems anywhere in the world. CEMS modulates the chillers according to the change of internal and external load at 10-second intervals, automatically controlling the chiller loads. By benchmarking the average consumption of the chillers for each day, the plant managers can see drastic changes in consumption when CEMS is in savings mode. All necessary data is recorded and reported to plant managers to verify the amount of savings made in chiller consumption. In the event of a mechanical problem, CEMS engineers can alert the facilities manager or the plant manager to switch over to their standby system while they make arrangements to make on-site repairs. CEMS monitors the number of hours each chiller has been running, and schedules preventive maintenance based on the manufacturers’ specifications for each chiller type and condition.


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Author Information: For more information on this Case Study, contact: Thirumalaichelvam Subramaniam CEMS Engineering Sdn Bhd [email protected]


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Controlling a Chemical-Free Water Treatment System with NI LabVIEW

Environmental and Green Engineering Author(s): Scott Lindblad - WATERTECTONICS Industry: Water/Wastewater Products: LabVIEW, Compact FieldPoint Controllers The Challenge: Developing a flexible, automated control system for chemical-free storm and surface water treatment The Solution: Using NI hardware and software to create an environmentally friendly advanced contaminant and filtration treatment system while reducing our development time by half

"We believe that using NI tools gives us a competitive advantage over companies who are slower to adapt to new tools and technologies."

Today, one of the most significant developments in the commercial and industrial marketplace has been the implementation of Clean Water Act Phase II regulations. This second wave of legislation brings not only more stringent requirements but also more active enforcement at all levels of government to achieve compliance. As a result, businesses are heavily fined or closed for noncompliance with clean water standards and regulations. Increasing enforcement of federal and state water quality standards has created the need for more advanced contaminant and filtration treatment methods. We at WATERTECTONICS provide water treatment solutions that improve water quality to meet or exceed these regulations. Our WaveIonics product specifically uses electrocoagulation to reduce or remove contaminants such as turbidity and dissolved metals, so that water can be safely and legally discharged into waterways or storm sewers. Electrocoagulation and Wastewater Treatment Electrocoagulation (EC) is an environmentally friendly process that uses electrical current instead of chemicals to remove particles such as heavy metals and soluble pollutants. An EC system consists of pairs of conductive metal plates that apply an electric field on the contaminated water as it passes through the system. As a result, the primarily negatively charged contaminants combine with the positively charged metal plate, thus initiating the coagulation process. These particles agglomerate


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into larger clusters of particles, which may be filtered or removed without the use of chemicals. Industries such as mining, wood treatment, construction, and oil and gas have used EC wastewater treatment technology. To optimize and automate the EC reaction, the user must manage multiple variables including the cell reaction chamber, the voltage, the amperage, the flow rate, and the time within the cell chamber. WATERTECTONICS turned to National Instruments to resolve these control issues. Choosing the Right Tools – LabVIEW and Compact FieldPoint We standardized on NI LabVIEW software as our primary programming language because it offers more flexibility than ladder logic. We could easily program the open LabVIEW environment on both Windows computers and real-time controllers. With the tight integration between NI hardware and software, we were able to test the code extensively on a PC before deploying it to the embedded target. Plus, we could easily adapt the intuitive touch-panel GUI created in LabVIEW for multiple systems, providing operational control and vitals to our customers.

Figure 1: WaveIonics Interactive Touch Screen UI Created in NI LabVIEW For hardware, the system incorporates the NI Compact FieldPoint programmable automation controller (PAC). In the past, we had to use several devices from different vendors to acquire the breadth of measurements we achieve from Compact FieldPoint. This NI PAC integrates easily with different transducers as well as an external measurement system for

pH, conductivity, and turbidity. We also used the controller’s wide range of data communication capabilities, such as Modbus (RS232 and Ethernet), OPC, and Web communication, for remote access and control. Implementing the New System By using the NI platform, we are able to provide real-time pH and turbidity inline management. The system not only offers alarming and onboard data logging based on water quality but also monitors system components for predictive maintenance and recommends an exchange of consumables when needed. Because sites must report water quality and discharge data, clients can use the logged information for automating the filing process and can easily transfer the logged data into their supervisory control systems for further reporting.


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Figure 2: Environmentally Friendly Wavelonics Electrocoagulation System Treatment Process

LabVIEW and Compact FieldPoint provided the rich features and flexible function set to handle the challenges and changes that occurred throughout our design phase. We reduced our development time by half and customized multiple systems within strict timelines. Plus, we took advantage of additional resources such as other integrators and National Instruments Alliance Partners. We believe that using NI tools gives us a competitive advantage over companies who are slower to adapt to new tools and technologies. Author Information: For more information on this Case Study, contact: Scott Lindblad WATERTECTONICS 802 134th St. SW Ste. 110 Everett,, WA 98204 United States Tel: (866) 402-2298 [email protected]


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Using NI CompactRIO to Design a Maximum Power Point Tracking Controller for Solar Energy Applications


Author(s): Ru-Min Chao - Electromechanical Research Institute, National Cheng Kung University Industry: Energy/Power Products: Legacy Devices, Real-Time Module, LabVIEW, cRIO-9101, cRIO-9002, FPGA Module The Challenge: Identifying an efficiency point that achieves maximum solar cell power in varying environmental conditions The Solution: Developing a system for real-time solar cell calculation to ensure that the maximum power output is achieved in a variety of environmental conditions

"After we completed our application, we continued to receive service from NI applications engineers. We approached them with our maintenance and technical problems, and the annual forums and cost-free tuition were helpful."

Solar cells have an optimization point where we can achieve the maximum output power, but the most efficient working point usually varies with the environment. When fixing the output voltage of solar cells in a changing environment, it is difficult to continuously generate the maximum power output. Therefore, maximum power point tracking (MPPT) in existing solar cell application technologies increases the overall power generation efficiency. We wanted to improve the control design of solar cell MPPT and develop an MPPT system for the quadratic limit value of the power measuring type. High-speed pulse-width modulation (PWM) signal and acquisition capacity must support high-frequency PWM switching signals for the power tracking voltage converter. In addition, we wanted to develop a portable, embedded calculation system to ship for future applications. We used NI CompactRIO with the NI LabVIEW FPGA Module to develop a stable and efficient integral system. CompactRIO also contains a step-down circuit and a turn-on time power switch adjusted to control the output and achieve the maximum power requirement. These devices proved to be a feasible system for developing an MPPT controller according to the analog and actual test results.


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Application We designed a solar energy MPPT device using LabVIEW 8.2 software to generate algorithms for interface development, the LabVIEW FPGA Module to acquire signals in DMA mode, and the LabVIEW Real-Time Module to execute MPPT. We also used CompactRIO embedded hardware to obtain the solar cell current and voltage changes while the LabVIEW FPGA Module acquired data through I/O modules and transferred the data to the LabVIEW Real-Time Module for real-time calculations. Then, the PWM module delivered the duty cycle of the maximum power point application to a step-down circuit when we produced the output voltage at the maximum power point, making real-time calculations for other loads, such as battery power supply and motor supply, possible. System Architecture

Figure 1: Hardware System Architecture Diagram A 25 W solar battery and the step-down buck converter supplies electric energy, which is then stored in the chargeable cells and transferred to chargeable 6 V, 10 AH lead acid cells and the loaded motor, as shown

in the system architecture diagram in Figure 1. In the loaded motor, we used the PWM switch signals provided by the NI 9474 high-speed sourcing C Series digital output module for the voltage scaling of the converter input and output ends. After we measured the solar cell output power using the NI 9221 C Series module and acquired the data with the NI cRIO-9101 four-slot 1M gate reconfigurable embedded chassis, the NI cRIO-9002 embedded real-time controller provided the acquired power for MPPT calculation and PWM signal output. Then, the PWM signal of the converter operating on the duty point obtained the duty cycle corresponding to the maximum power point of the solar energy PD curve in a duty cycle, which was the converter output that obtained the maximum solar cell output power.

Figure 2: MPPT Test Process Flow


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As shown in Figure 2, MPPT test flow consists of the quadratic limit calculation and the recorded target end and local end for checking recorded data. We mapped the characteristic curve before each MPPT to check if the system duty cycle obtained from MPPT is the maximum power point of the characteristic curve at the solar illumination. Then we performed MPPT and compared the two duty cycles, identifying the power difference for MPPT efficiency. Using this system, we understood the actual MPPT performance as shown in the process flow diagram in Figure 3, which was similar to the process described in Figure 2 except that we cancelled the duty scanning step and added a charging process.

Figure 3: Charging Test Process Flow

Success with NI Products and Support Compared to other hardware platforms, developing with CompactRIO was much more time-efficient. The developed system is comparable with other systems created in VHSIC Hardware Description Language (VHDL), or with other LabVIEW FPGA tools, by simplifying many complicated steps. We used the internal 40 MHz operation frequency to provide the 20 kHz PWM output signals and voltage/current measurement required for MPPT calculation. Additionally, we synchronized functions such as display and recording for user reference, while the cRIO-9002 embedded real-time controller provided real-time calculation and further strengthened the stability of MPPT system operation. After we completed our application, we continued to receive service from NI applications engineers. We approached them with our maintenance and technical problems, and the annual forums and cost-free tuition were helpful. With NI products and assistance, we successfully developed our MPPT system for real-time solar cell calculation, ensuring that the maximum power output is achieved in variable air environments. We can apply this system calculation method for power tracking other solar power generation systems in the future. Author Information: For more information on this Case Study, contact: Ru-Min Chao Electromechanical Research Institute, National Cheng Kung University


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Siliken Renewable Energy Optimizes Solar Panel Production by Standardizing on NI Hardware and Software


Author(s): Alberto Cortes - Siliken Renewable Energy Ricardo Silla - Siliken Renewable Energy Industry: Energy/Power, Process Industries, Manufacturing, Machine Vision/Imaging Products: Touch Panel Module, LabVIEW, PXI-1422, Sound and Vibration Measurement Suite, PCI-6122, FPGA Module, NI CompactDAQ, PXI-4472, PCI-6220, CompactRIO The Challenge: Optimizing the production and installation of solar panels – from Silicon purification to end-of-line manufacturing verification to final installation and monitoring. The Solution: Using NI hardware and software to optimize the solar panel production process, from purifying silicon ore to manufacturing and testing the final product, to ensure that we consistently produce high-quality solar panels

"Using NI CompactRIO, LabVIEW FPGA, and an NI PCI-6122 S Series multifunction DAQ board, we performed these tests with greater accuracy and significantly increased our throughput."

Sunlight is the most plentiful natural resource. Because the sun is not subject to the same supply limitations as fossil fuels and it is available nearly everywhere, it is increasingly being used as a free, clean source of renewable energy. Our engineers at Siliken Renewable Energy work to help harness this abundant resource and address escalating environmental and energy concerns. As a company, we have grown to become one of Spain’s largest manufacturers of photovoltaic (PV) solar cells, which we use to convert sunlight into electricity. Siliken differs from other PV cell manufacturers because we handle all aspects of solar cell development including silicon purification, panel manufacturing, verification, and installation. NI

Figure 1: Siliken differs from other PV cell manufacturers because it handles all aspects of solar cell development.


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products play an important role in our research and development process to innovate and produce new technologies and to test every solar panel we produce. Optimizing the Silicon Purification Process with NI Products The typical silicon purification process consists of converting the chemical element to a silicon compound, which we can more easily purify by distillation than in its original state, and then converting that silicon compound back into pure silicon. At our facilities, we use a novel, patented silicon purification process that is approximately 40 percent cheaper than traditional methods such as the Siemens process. To further increase the efficiency of our new process, we began optimizing the standard control equipment already in place at the facility that we built using the NI PXI platform, LabVIEW FPGA Module, sound and vibration software, and vision software.

Figure 2: NI products play an important role in Siliken’s research and development process to innovate and produce new technologies and to test every solar panel we produce. Because we purify the silicon at temperatures hotter than 1,000 °C, we used an NI PXI-1422 digital image acquisition module to acquire images of the purified silicon particles as they are fed out of the purification reactor. Next, with NI vision software, we conduct a remote analysis of the images to measure the

size of large amounts of purified particles as they are produced. At the same time, we need faster control loop rates to measure the flow and pressure parameters of the purified silicon. Using the NI PXI-4472 dynamic signal acquisition module, we can monitor vibration levels to ensure that they never surpass predefined security levels, thus avoiding system instability that could cause the reactor to break. We chose to use the highly integrated LabVIEW and NI PXI platform and conducted two separate critical tasks using a unified solution. Solar Panel Manufacturing and Quality Testing Using NI Hardware and Software When we began manufacturing solar panels, our end-of-line test system consisted of a boxed scope that we used to perform manual testing. With our new PC-based system based on LabVIEW and an NI PCI-6220 multifunction M Series data acquisition (DAQ) board, we integrated the “closing” of the solar modules into a semiautomatic process. Using a LabVIEW front panel as the human machine interface (HMI) and the DAQ board to help perform the operation, this application essentially "closes" the module once the solar cells are inside.


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After we assemble the solar panels, we must perform I-V characterization tests to verify the power output of every module to ensure that each one produces the stated power. Performing these tests is rather complex because we have to administer a known quantity of light to each panel so we can simultaneously determine both the voltage and current draw of the panel. To accomplish this, we developed a method that only uses a single 10 ms pulse of light. When the light pulse is administered, we acquire the I-V of the panel to calculate its power in watts.

Figure 3: Siliken was recognized for providing the best advertised-to-actual performance ratio for its solar panels. Using NI CompactRIO, LabVIEW FPGA, and an NI PCI-6122 S Series multifunction DAQ board, we performed these tests with greater accuracy and significantly increased our throughput. In the past, we conducted this process using multiple sequential tests. In addition, while the previous I-V curve we used consisted of 30 points, we now use more than 2,000 points for I-V characterization testing, thus providing more precise calibration parameters. As a result, we received recognition for providing the best advertised-to-actual performance ratio for panel output. Beyond Solar Cell Manufacturing In addition to solar panel production, we are also manufacturing essential equipment such as solar panel inverters, which are used primarily to change direct current to alternating current via an electrical switching process. Before we began manufacturing our invertors, we developed a prototype using NI CompactRIO and an NI TPC-2006 touch panel computer. We are also using CompactRIO to conduct research in other renewable energy fields such as hydrogen fuel cells, and NI CompactDAQ for wind power research because these platforms offer compelling operational advantages and shorter development times than other traditional control and test tools. Author Information: For more information on this Case Study, contact: Alberto Cortes Siliken Renewable Energy 14. Parque Tecnológico E-46980 Paterna Valencia, Spain Tel: +34 902 41 22 33 [email protected]


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High Dynamic Fuel Cell Testing with NI CompactRIO Environmental and Green Engineering

Author(s): Dr. Guenter Randolf - GRandalytics Industry: Energy/Power, ATE/Instrumentation Products: Datalogging and Supervisory Control, CompactRIO, LabVIEW, FPGA Module, Real-Time Module The Challenge: Designing a fuel cell test system that is faster than any commercially available tester, inherently safe for 24/7 operation, not reliant on a Windows OS-based master PC, capable of receiving/transmitting data independently from/to multiple computers, and running multiple simulations and scripts in parallel, even from different machines. The Solution: Developing a control system based on NI CompactRIO hardware that can control the entire test station with the NI LabVIEW Real-Time Module, validate measurements and counteract alarms already on the FPGA level, communicate independently with GUIs and simulators via UDP, use plug-in modules to adapt on the fly, and operate easily with a powerful GUI.

"Unlike conventional, PC-controlled test stations, this system is entirely operated by the CompactRIO real-time controller, ensuring overall determinism; therefore, safety and reliability are inherently built in."

We are increasingly seeing fuel cells used as an environmentally friendly energy source that powers a wide range of applications, from stationary systems to automotive applications to even cell phones. Historically, engineers designed fuel cell test stations for long-term, steady-state testing and simple performance evaluations. However, transportation applications require fast responses from fuel cells and therefore require testing systems that are capable of drive cycle simulations and transient analysis. Hence, we designed a new system from scratch to enable high-dynamic testing, hardware-in-the-loop (HIL) simulation, platform-independent communication, and expandability. We designed and built an inherently safe and reliable system with unparalleled performance in a short time using cutting-edge technology including field-programmable gate arrays (FPGAs) and the LabVIEW Real-Time Module. System Overview


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Like the main graphical user interface (GUI) and simulation targets with different operating systems and software, the scalable, parallel presence of multiple data input/output (I/O) nodes is unique.

Figure 1: Block Diagram of the Entire Test Station with Optional (Dotted) Platform-Independent I/O Nodes The design required us to use multiple software models written in different tools such as The MathWorks, Inc. Simulink® software while processing multiple scripts in parallel (we used Simulink – see Figure 1). Hence, user datagram protocol (UDP) became our favorite communication strategy. It is native to many applications and does not require additional hardware. Multiple registered computers may send setpoints to the controller, and every value stays alive until it is overwritten by another sender. In return, the system transmits measurements and results from the controller to every computer registered in the configuration file.

CompactRIO – The Autonomous Brain Unlike conventional, PC-controlled test stations, this system is entirely operated by the CompactRIO real-time controller, ensuring overall determinism; therefore, safety and reliability are inherently built in. The FPGA, a key component of the system, represents the first layer of safety. All measurement data pass through the FPGA, where they are validated firsthand. Countermeasures to alarms may occur in just microseconds and are not compromised by a complex, high-level application. Our system transfers data to the controller using DMA and scales, and merges that information with virtual channels and setpoints received by UDP. A dynamically called, open-source plug-in VI serves as the functional kernel harboring all test stand-specific operations. Engineers embed it in the generic shell, which is responsible for data input/output, scaling, alarms, safety features, and much more. We check data against three static and two dynamic alarm levels; we cross-reference the latter to other channels. The system returns results to the FPGA and/or sends them to external nodes via UDP.


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Transmitting data requires considerable processor resources; therefore, we keep the number of channels to a minimum by deadband control and transmission management. Deadband and transmission priority are just two of 40 attributes that accompany each channel. Five-alarm levels, slew rate, and synchronization ID are further examples. The system imports all attributes from a protected file during startup but can change them on the fly via a second UDP port. We reserve a third UDP port for parameter exchange, such as limiting information, calibration data, or subsystem reinitialization. The design of the real-time code generously follows LabVIEW dataflow programming technique and parallelism because our system processes numerous loops in parallel. Due to this, we could achieve an architecture of timed loops of various cycle times and asynchronous event-triggered structures with elegance and compact code size. The Functional Face with XControl Power Experience in design and use of numerous test stations influenced the development of the GUI. Because the controller already masters safety and core functionality, we were able to turn our full attention to creating a user-friendly, intuitive, and expandable operator’s terminal. Separate loops handle peripheral tasks, such as data transmission or storage into the Citadel database, providing a transparent architecture. Experienced LabVIEW customers may access the source code to implement their own functionality as desired, without interfering with background processes. New LabVIEW XControls enabled us to pack a lot of functionality into the controls. In the interactive piping and instrumentation diagram (P&ID), we based all custom controls on one XControl. The controls follow DIN standards and change their appearances according to the physical property. We can inherently synchronize, ramp, and scale controls to different physical units. They also can display the alarm status.

Figure 2: Screen Capture of the GUI with XControls Ramping (Green) and in Alarm (Red)


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To provide an immediate status overview, the pipe color changes according to the transported media (for example, yellow for hydrogen or black for nitrogen). We dynamically call plug-in VIs via the run-time menu to add special features like counter/timer, scripting, or specialty measurements. Right-click menus show control properties and open tools for configuring tag attributes. Cutting-edge technology in the form of CompactRIO facilitated the development of a completely new breed of pure, real-time fuel cell test stations. We designed it around versatile, high-throughput data interfaces that interface with virtually every computer platform and all software. Reducing the response time of the electronic load from 800 ms of a state-of-the-art fuel cell tester to 50 ms is a quantum leap in dynamic fuel cell testing technique. Just as remarkable as the performance are the multiple layers of safety and the adaptive software. Our system grants the end user open-source code for the GUI and even the real-time plug-in VI because all safety-related subsystems are encapsulated and cannot be compromised. This option is valuable for the user and unique among competitors. Though the test station offers 176 analog and digital I/O channels along with RS232 and serial peripheral interface (SPI) communication to attached instruments, we achieved a very compact and well-structured setup. We based this revolutionary concept on scalable hardware architecture with FPGA and I/O modules along with ingenious software to ensure a high reuse value. Our configuration facilitates the efficient development of an entire family of test stations or the ability to economically retrofit existing systems. Author Information: For more information on this Case Study, contact: Dr. Guenter Randolf GRandalytics 500 University Ave 323 Honolulu, HI 96826 United States Tel: (808)-393-3356 Fax: (808)-942-8943 [email protected]


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Embedded Graphical System Design Empowers Life-Saving Spider Robots

Machine/Mechanics

Author(s): Pom Yuan Lam - Nanyang Polytechnic, Singapore Marco Schmid - Schmid Engineering Anders Frederiksen - Analog Devices Industry: Research, Machines/Mechanics Products: Embedded Module for Blackfin Processors, LabVIEW The Challenge: Designing a robot that operates with a high number of degree of freedom for good mobility in harsh environments to support critical, life-saving rescue missions The Solution: Combining graphical programming with high-processing performance and an ultra-low energy scheme to create a six-legged, highly functional robotic spider for use on rescue missions

"Building a powerful and superior robot has been successful, and the development time was greatly reduced by using the graphical programming environment offered by the LabVIEW Embedded Module for Blackfin Processors and the high-processor performance of the Blackfin Processor."

Designing for Missions in Rugged Environments The primary purpose of any life-saving equipment is to quickly prevent as many casualties as possible during rescue missions in the aftermath of catastrophes. With this objective in mind, we began development of a six-legged robotic spider to support rescue operations. It is a small, mobile, intelligent robot that can avoid obstacles and access hard-to-reach locations in search of trapped victims. Replacing humans in dangerous missions such as sweeping and neutralizing minefields is also another potential application area for the spider robot. We designed a highly mobile walking scheme consisting of six independent legs that move the robot omnidirectionally, even on terrain where robotic movement normally is not possible or too risky.

Figure 1: Using “creeping,” one of its many motion patterns, the robot spider squeezes through tight spaces.


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Walking and rotating are among the basic high-level motion patterns adopted from six-legged insects. With three legs moving and three lifted, the robot can reach the desired walking speed and provide the sufficient equilibrium required for harsh terrain. When creeping, the robot can squeeze through tight spaces and narrow slots. The low-level motion gaits of a single leg are geometrical primitives such as rectangular or circular trajectories in 3D space. Multifunctional Mechatronics System The leg mechanics and motion control are part of the key features of the spider robot. A total of 24 smart DC brush motors drive the legs and function as integral joints of the walking mechanics. This leads to a sturdy yet light weight construction, reducing power consumption and improving motion dynamics.

Figure 2: Under the hood the hexapod features machine vision, distance measurement, wireless communication, and is powered by two lithium polymer batteries. Apart from the legs, the spider features typical autonomous robotic subsystems including machine vision, distance measuring, and wireless communication. The embedded hardware, two 7.2 V lithium polymer batteries, and the fuel gauges reside in the robot’s rigid body. Mission parameters, I/O settings, and new motion gaits can be transferred wirelessly or by removable media.

Figure 3: The four smart motors with built-in programmable PD controllers addressed by a serial RS485 network are seamlessly integrated in the limbs. Smart Motion with 24 Degrees of Freedom The spider’s low-level movements rely on complex mathematical models calculated at run time. With the advanced embedded computing power of the Analog Devices Blackfin Processor and Schmid Engineering’s deterministic real-time services, the motion looks dynamic and smooth. High-level virtual instruments (VIs) from the NI LabVIEW Embedded Module for ADI Blackfin Processors continuously run an inverse kinematics algorithm. This algorithm, including trigonometric functions and matrix operations, finds suitable joint angles Θ1 and Θ2 to precisely move the end effecter along a desired trajectory in 3D. Depending on the high-level motion pattern, the trajectory vectors move along calculated lines, rectangles, or circles.


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The trajectories can be programmed in three different ways:

• Teach-in and playback to design and train new or special patterns • 3D CAD that software that allows visual checking of the simulated trajectories. The models

are exported as virtual reality files and imported into the LabVIEW picture controls. Movements are tuned by comparing the virtual and real models

• Continuously calculating trajectories at run time by the inverse kinematic algorithm This is done in parallel for the joint angles of all six legs resulting in 24 continuously calculated setpoints for all motors to ensure dynamic motion. These setpoints are transferred to each motor via a serial RS485 network and turned into physical actions by decentralized PD controllers. Position, feedback, and temperature readings of all 24 actuators are acquired over the same network. Smart Vision and Distance Sensing In addition to the smart motion and freedom of movement, the spider robot features an intelligent camera and a distance measurement sensor in its “eye." Objects and substances are localized and tracked by high-performance image processing algorithms. The “eye” can also be programmed to identify any color within its vicinity. Future versions will offer improved image processing, pattern matching, and edge detection, taking the Blackfin Processors' computation power and high-speed image acquisition to the next level. Wireless Communication with Bluetooth To communicate with the robot, a permanent Bluetooth communication interface is maintained for several functions, including:

• Debugging channels for ZMobile's Fast Debug Mode during development and test • Reading critical parameters such as motor status and battery level for system diagnostics • Acquiring vital algorithm variables online for tuning • Downloading new mission data prior to an operation • During development, two spider robots were linked through the wireless communication

channel to synchronize their movements. This was the prototype for a more serious scenario where several spider robots are given a task to complete using teamwork

Low-Power Embedded ZMobile Hardware The ultra low power mixed signal target, ZMobile, is the heart of the spider robot. ZMobile, supplied by the Swiss solution provider Schmid Engineering, integrates sensors, actuators, vision, batteries, and wireless communication in a single platform. Nanyang Polytechnic chose the ZMobile platform for three reasons. First, ZMobile is compatible with LabVIEW, and by programming the spider in LabVIEW, the robot designers could concentrate on the prime functions of this project. With the high productivity of graphical programming, the system engineers could add more functionality than originally specified during the development period.


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Figure 4: The ZMobile platform integrates and links to the whole Process I/O and provides high-level functions blocks Second, the ultra low energy scheme and dynamic power management of ZMobile was a vital feature for this autonomous robot because operation time can now be significantly lengthened. The same applies to the ZMobile’s power consumption, which is in the milliwatt range, meaning most of the remaining energy in the onboard batteries can be used by the motors.

Third, the scalable process I/O slot provides room to integrate more sensors and actuators in the future. Real-Time Graphical Embedded Software The spider robot application software was programmed using the LabVIEW Embedded Module for Blackfin Processors and extended by the ZBrain BSP for NI LabVIEW from Schmid Engineering. This provided the ideal embedded software platform for high-level programming, graphical debugging, graphical multitasking, and deterministic real-time behavior. Object-oriented design patterns helped further manage complexity on the graphical level. Main objects such as motors or sensors were abstracted by functional, global variables representing classes in LabVIEW. The main application framework consists of several tasks:

• Top level main loop plans for action represented by a classic state machine connecting to other loops by software queues and synchronization means such as semaphores.

• Communication task maintains a wireless data connection to the outside world. • Vision task is responsible for low-level image processing and distance reading. • Motion task manages high-level motion patterns and low-level limb control and monitors the

motor's position and state. • Housekeeping task acts as a common error handler. Events and errors are detected and

logged to removable media with timestamps for later retrieval. ZMobile functions as a watchdog, rebooting and shutting down with programmed wake-up and providing efficient means to restart from scratch if error self-correction did not succeed.

• These loops run simultaneously as threads in a cooperative multitasking environment. Context switching in the millisecond range and microsecond real-time determinism on the driver level ensure smooth and glitch-free movements. Finally, the heavy parallelism demands that the thread-safety of each software component and device driver are met by the board support package.

Building a powerful and superior robot has been successful, and the development time was greatly reduced by using the graphical programming environment offered by the LabVIEW Embedded


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Module for Blackfin Processors and the high-processor performance of the Blackfin Processor. Schmid Engineering’s ingenious graphical Fast Debug Mode was a great help during algorithm engineering and cut development time by a factor of five. ZMobile is a great product for user-friendly embedded system engineering, not only for robot designers but for anyone building a mechatronics system.

Figure 5: Smooth motion is achieved by inverse kinematics relying on trigonometry functions and matrix

operations. Advances in vision, a smarter power-management and energy-harvesting scheme, sensor fusion, fuzzy logic, and GPS data collection are promising components to be added to the common mechatronics platform. Further, we plan to reuse the modular hardware and software system in future mobile, autonomous robots. Author Information: For more information on this Case Study, contact: Pom Yuan Lam Nanyang Polytechnic, Singapore Singapore [email protected]


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Using High-Level Prototyping Hardware and Software in Machine Control Applications

Machine/Mechanics

Author(s): Erik Goethert - Boston Engineering Industry: Machines/Mechanics Products: CompactRIO, LabVIEW, LabVIEW FPGA Module, The Challenge: Developing embedded microprocessor systems that not only fulfill the mechanical controls function, but also take into account the entire manufacturing process. The Solution: Shifting to higher-level modeling tools that promote the generation of “correct by specification” code in an environment in which engineers with limited coding experience can evaluate the proposed software and make changes incrementally and interactively.

"Instead of many tools and environments for model, design, test, and target, LabVIEW Embedded, and now the NI LabVIEW Embedded Module for ADI Blackfin Processors, gives us one integrated tool chain so we spend time on the engineering, not on the syntax."

At Boston Engineering, we provide multidisciplinary engineering services to companies that need to design electrical and mechanical systems using microprocessor-based embedded systems to control mechanical movement. This requires moving beyond traditional programming languages, debuggers, linkers, and IDEs, as well as beyond simple board prototypes. To meet our customers’ needs, we need tools we can use to cost-effectively develop computer-based mechanical, electrical, and embedded software control simulations, graphical user interface (GUI) mock-ups, and functional system prototypes that we can then efficiently render into final solutions. Building a Tension-Control System We used a multifaceted approach to build a tension controller for film developing in a digital printing kiosk. In a film printer, the color media spools are fed through the printer head by a drive motor, with the take-up and feed motors controlling the tension. Vibrations from the cutter head, the varying


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number of photos printed at a time, and variances in the speed of either motor can affect the tension on the substrate. Developing a low-cost product was one of this project’s key objectives. We monitored the position of two dancers measured with analog Hall-effect sensors to indirectly control the substrate tension. The control system adjusts the position of both motors to keep the feed and take-up tensions within a commanded set point. If this tension is not precisely controlled, the registration error causes a photo to have offset colors. Simulating the System The mechanical modeling required several iterations as the customer better defined the subsystem mounting and volume allocation. We also further refined the mechanical model based on control system specifications such as motor size, maximum inertia of moving parts, and sensor selection. The simulation defined the open- and closed-loop characteristics of the system. We produced iterations of the 3-D model when we determined we had to reduce the dancer longitudinal dimension and some substrate travel distances. Through modeling and feedback, it became evident that a simple PID controller would not provide the closed-loop bandwidth with the required stability margins. To increase stability, we needed small PID gains, but we could not obtain the required closed-loop bandwidth of 20 Hz. Therefore, we needed a more sophisticated control algorithm. We used a fourth-order phase-lead controller with integration implemented in bi-quad form. We chose this implementation to reduce the errors coming from the fixed, 16-bit word lengths and their inherent arithmetic round-off errors, which can cause instability. When we create systems that have a user interface, we typically prototype the user interface in National Instruments LabVIEW, a graphical tool that we also use during the later prototyping and deployment stages of our design process. With NI LabVIEW, we can easily and quickly drag interface elements onto a panel so the customer can customize the placement, content, and operation of the interface. This reduces the number of interface adjustment cycles and the amount of churn in the final code. We have found that this practice also works well with embedded systems, which typically have no real user interface. We use the prototype interface to aid in system tuning for maximum stability. Prototyping the System The next step in the design phase was to make a physical prototype of the system. Prototyping serves several important functions. Most importantly, the prototype confirms that our designers completely understand the problem. By comparing the operation of the simulation to the operation of the prototype, we can observe any differences and figure out why they’re occurring. Occasionally, there are higher-order effects that we do not discover until the prototype is operational. We have traditionally used off-the-shelf development boards, usually with some sort of programmable DSP, FPGA, or microprocessor for reconfiguration during the prototyping stage. But these boards normally do not have I/O appropriate for critical timing control, or signal conditioning for that I/O. And even with the use of a reprogrammable element, such as an FPGA, we have encountered a number of issues that cause problems during our iterative design process, including use of proprietary language, lack of technical documentation and support, and minimum controller flexibility, including insufficient I/O or a canned controller algorithm that we cannot easily modify.


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For this project, we instead chose the LabVIEW FPGA rapid prototyping hardware platform with a controller, as well as a modular I/O system connected to the controller via an FPGA in the modular I/O backplane. We also used the National Instruments CompactRIO prototyping system, which has a backplane with four or eight slots that accept modules for digital I/O, analog I/O, or communication buses. The tension-control hardware in our design required two pulse-width modulator outputs to control the two motors; two encoders to provide velocity feedback for the two motors; two analog input channels for the Hall-effect sensor to detect the dancer position; two digital lines for signaling; and channels for thermal and air readings. We used custom signal conditioning circuitry to connect these modules to the hardware on the NI CompactRIO module, which incorporates two controllers. The first is an embedded microprocessor running at 266 MHz connected to the Ethernet controller and the solid-state disk drive. The second controller, a 1M gate FPGA located in the backplane of the chassis, connects the I/O modules and the embedded microprocessor. We took advantage of the LabVIEW graphical dataflow language not only to program the module’s embedded microcontroller but also to manage the FPGA in the backplane. Because the code is at a higher level than C, our control, mechanical, and electrical engineers could work directly on the code in the MCU. We chose to run the supervisory program on the embedded controller and the motor control algorithm on the FPGA to provide the greatest similarity in programming models between the prototype and the end system. To run the control algorithm on the FPGA, we converted the zero-pole-gain model into a filter similar to the one in the LabVIEW Digital Filter Design Toolkit. We easily converted the filter into code that would execute on the FPGA with the toolkit. Because floating-point arithmetic is very resource-intensive on an FPGA, we used the toolkit to automatically generate fixed-point code. We could then test quantization options so that the final filter was stable. We also took advantage of the fact that we used LabVIEW for both the system interface design and the underlying hardware. Each LabVIEW function contains both a block diagram representation of the code as well as a GUI with controls and indicators for that function. When cross-targeting, the GUI appears as a window on the system under design, which can be used to monitor the system’s internal state or to adjust the program’s parameters. We were able to use the front panel for the code running on the embedded microprocessor to tune the system while it was running, which was a great benefit. With the open, productive graphical system design platform of LabVIEW, we save a tremendous amount of time from design to prototype to deployment. In our industry, time savings means cost savings, and LabVIEW Embedded technology makes us much more valuable to our customers and competitive in the marketplace. To address a complicated, embedded motion control system, we used standard design tools and integrated those simulations with real-world data in LabVIEW to optimize the designs.


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Instead of many tools and environments for model, design, test, and target, LabVIEW Embedded, and now the NI LabVIEW Embedded Module for ADI Blackfin Processors, gives us one integrated tool chain so we spend time on the engineering, not on the syntax. For more information, contact: Erik Goethert, Program Manager Boston Engineering 411 Waverley Oaks Road, Suite 114 Waltham, MA 02452 Tel: (781) 466-8010 Fax: (781) 466-8020 E-mail: [email protected]


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Earthquake Simulator System Machine/Mechanics

Author(s) Aung Myo Tun, Senior Engineer Company Singapore Technologies Kinetics Limited Singapore Products Used: Hardware NI PCI-7352 2 Axis Stepper/Servo Motion Controller for PCI, NI UMI-7764 Universal Motion Interface, NI UMI-7774 2 and 4 Axis Universal Motion Interface, NI cRIO-9012, NI cRIO-9103, NI cRIO-9263, NI9401, NI9421, NI9472 Software LabVIEW 8.5 The Challenge: The occurrence of the recent tsunami and earthquake tremors around the neighboring countries of Singapore has brought close attention to the building structures developed on the island. The government and the residents are concerned with the ability of the buildings constructed to withstand the vibrations resulted from the earthquakes. The challenge is to develop an Earthquake Simulator that can generate single tone sine wave, sweep sine wave, random motion and real earthquake signal playback. The Solution: Using National Instruments (NI) FPGA technology, and the PCI motion controller module, together with LabVIEW 8.0, a large motion system is being developed using precision magnetic motion technology. This system is named as the earthquake simulator system.

"CompactRIO (cRIO) from NI enable us to deploy the entire control system in embedded form under harsh and rugged conditions."

Introduction The objective of the Earthquake Simulator System is to act as a test platform for the structural analysis of scaled down modeling of buildings under earthquake vibrations and also as a platform to train the public on the safety awareness to tackle the situation during an earthquake event. Small-scaled building models can be first built and fitted onto the earthquake simulator platform. Different types of motion profile can be selected to generate the earthquake motion. They are: Single Stroke, Cyclic, Sweep Sine or Random. The frequency of shake can be configured from 3 to 16Hz. The motion can be in single axes or two axes dependent on the desired test conditions.


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Measurement Specifications

• 1m x 1m and 2m x 2m Structures are simulated to ensure performance and durability extensible to larger sizes

• Precision Control using FPGA technology • Velocity profiles generation • Random motion profile generation • Multiple axis profile generation • Flexible profiles generation

o Inputs can be acceleration, velocity or displacement o Constant amplitude and frequency o Variable amplitude and frequency

• Frequency from 3 to 16 Hz • Maximum displacement of +/-20cm • Maximum acceleration of 1.5g at 50kg • Maximum acceleration of 0.4g at 300kg • Emergency Switch for safety

System Hardware

Figure 1: System Set-Up of the Earthquake Simulator System without loading


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Figure 2: System Set-Up of the Earthquake Simulator System with loading

With the system deployed on a truck to go round Singapore for public awareness to educate the skills required in avoiding harm during an earthquake event. CompactRIO (cRIO) from NI enable us to deploy the entire control system in embedded form under harsh and rugged conditions. System Block Diagram

Figure 3: Earthquake Simulator Block Diagram Conventional moving platform simulators are either driven by hydraulic system or rotational motors where hydraulic power are converted to linear motion or rotary motion are converted to linear motion respectively. In a typical hydraulic driven earthquake simulator system, the components include the hydraulic pump, accumulator, and actuator with a control system. For the rotary motor driven earthquake simulator system,

there are needs for servomotor, motor driver, and mechanism to convert rotational motion to linear motion with a control system.


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In our linear motor driven earthquake simulator system, the hardware needs only linear motor, motor driver with a control system. The above figure is a perspective view of the simulator designed and developed by the SI Team, with the driving mechanism using linear motor. The earthquake simulator comprises the platform (1), which is being interfaced to the linear motors (3) by an interface module (2). With high-resolution encoder up to nanometer resolution embedded in the motor, it makes precision shake profiles to be achieved easily. Since the motor only shakes to and fore in one direction, the design of the platform is as such that it is easily detached and rotated for another shaking orientation. In addition, linear motors can be easily replaced when the load or shake profile requirements changed. With load increases, motors can be sized up to a larger capacity module. If the load to be driven is over the maximum capacity of a single largest load motor, we can cascade multiples motors either in series or parallel to increase the overall driving capacity. In general, the design caters for easy detachable of parts for any replacement of parts and for maintenance. The key innovative features of this linear motor controlled earthquake simulator are the use of FPGA (Field Programmable Grid Array) and the magnetic technologies (like those applied in the bullet train) to be able to playback real earthquake signal. With this implementation of FPGA and magnetic technologies and the ability of the system to perform control immediately to the customer's desire, it basically enables the customer to build scaled down models of buildings or any other structures to be tested in the real situation. In the past, many of our competitors are unable to do such product that greatly enhances the customer test decisions abilities. System Software

Figure 4: System Application Software


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The Motion Controller card is designed with the unique National Instruments’ LabVIEW graphical development software. This graphical programming provides an interactive environment for rapid design iterations and makes interfacing with any measurement devices simple. The figure above shows the front panel of the earthquake simulator developed for the system. Some of the features of the software application include:

• Operator settings • Operator Name • Operator description • Shake profile definition • Frequency range setting • Displacement setting

Real-time profile control with FPGA technology

• PID tuning and control Development for the Future In the next 2 months, the 1-axes earthquake simulator will be upgraded to 2m by 2m in dimensions, and equipped with the ability to move into 2 axes. This will closer simulate the actual earthquake signals, and improve the structural analysis modeling. In terms of the hardware, the PCI motion controller card will be upgraded to the cRIO where the real-time code is embedded in FPGA. This will improve the precise control of the system. The software version will also be upgraded to LabVIEW 8.6. Conclusion With National Instruments motion controller platform, together with the availability of the FPGA technology; we are able to provide efficient virtual instrumentation solutions for our end users. The products have also enabled us to shorten our development period. For more information, please contact: Aung Myo Tun, Senior Engineer Singapore Technologies Kinetics Limited 249 Jalan Boon Lay Singapore 619523 Tel: +65-66607222 Fax: +65-62657003 Email: [email protected]


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Using Graphical System Design to Rapidly Develop a Low-Cost Device for Helping Premature Infants Learn to Oral Feed

Medcial Engineering

Author(s): Barry Price - KC BioMediX Inc. Daryl Farr - KC BioMediX Inc Industry: Biotechnology, Research, Medical Devices Products: CompactRIO, Real-Time Module, LabVIEW, FPGA Module, Single-Board RIO, Statechart Module The Challenge: Helping premature infants learn how to coordinate sucking, swallowing, and breathing for oral feeding to greatly increase their chances for survival The Solution: Creating a device that helps premature babies learn to oral feed, while providing doctors and nurses with the ability to accurately assess the baby’s feeding ability.

"With National Instruments LabVIEW and NI CompactRIO, we were able to reduce our development cost by $250,000. In addition, we were able to reduce our development time from four months to four weeks, and avoid the necessity of developing custom control software and drivers."

Up to one-third of the more than 600,000 premature infants born in the United States each year have feeding problems when their brains struggle to coordinate sucking, swallowing, and breathing. Infants born prematurely often spend weeks, and sometimes months, with tubes taped to their faces or wearing masks to help them breathe. This hinders them from learning how to eat at a critically important stage of brain development.

Figure 1: Research studies have demonstrated that the NTrainer System therapy actually trains the brains of premature infants, accelerating their ability to eat without feeding tubes.


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KC BioMediX, a start-up medical device company based in Shawnee, Kansas, is developing a product called the NTrainer System to help premature babies learn to oral feed and greatly increase their chances for survival. The device is essentially a computerized pacifier that makes the pacifier tip pulse with gentle bursts of air. Doctors or nurses can use the device to get a far more accurate assessment of a baby’s feeding ability, and then begin therapy to help the baby learn to suck. Research studies have demonstrated that the NTrainer System therapy actually trains the brains of premature infants, accelerating their ability to eat without feeding tubes and, thereby, boosting their chances to survive. The company’s leaders, and the scientist who invented the technology, contend this is a vast improvement over previous methods of placing a gloved finger in a baby’s mouth.

Figure 2: The NTrainer System Front Panel

Figure 3: The NTrainer System NTrainer System Design Initially, at KC BioMediX, we began our design process using a custom embedded solution and worked with a third-party company to commercialize the treatment. When it became clear that the cost was too high, we decided to bring the development in house. In only three weeks, our lead software engineer used LabVIEW graphical development software and CompactRIO hardware to create a proof of concept demonstrating the ability of CompactRIO to replace the custom embedded solution. We developed the software architecture using the LabVIEW Real-Time, LabVIEW FPGA, and LabVIEW Statechart modules. For the first round of commercial devices, we deployed the systems using CompactRIO. For high-volume deployment, we are using NI


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Single-Board RIO to create a more cost-effective device while fully maintaining our software development investment.

Figure 4: KC BioMediX is developing the NTrainer System to help premature babies learn to oral feed and

greatly increase their chances for survival. With LabVIEW and CompactRIO, we were able to reduce our development cost by $250,000. In addition, we were able to reduce our development time from four months to four weeks, and avoid the necessity of developing custom control software and drivers. Author Information: For more information on this Case Study, contact: Barry Price KC BioMediX Inc. 23733 West 83rd Terrace Shawnee, KS 66227 United States Tel: 913-742-4456 [email protected]


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Using Graphical System Design for Tumor Treatment Medical Engineering

Author(s): Jeff Stevens - Sanarus Industry: Medical Devices Products: CompactRIO, LabVIEW, FPGA Module, Real-Time Module The Challenge: Designing, prototyping, and deploying the user interface and control system for an FDA–approved, Class II medical device used to treat breast tumors in a less invasive and nearly painless procedure while maintaining the design process within strict regulatory guidelines. The Solution: Using the NI CompactRIO platform, NI LabVIEW Real-Time, and the LabVIEW FPGA Module to develop a flexible and reliable GUI and control system under extreme time-to-market pressure to deliver a device that would dramatically reduce the emotional and physical discomfort of patients undergoing tumor treatment.

"NI played a fundamental part in achieving our goals. Our product design, prototype, and eventual deployment timelines were met because of the graphical system design platform from NI."

At Sanarus, a medical device start-up company, we developed plans for a potentially revolutionary product that could change the way doctors treat benign tumors. With this device, doctors can eliminate tumors by freezing and killing them in an almost painless outpatient procedure, a dramatic change from the inpatient surgical solution or the “wait-and-see” approach used previously. With a well-executed design and development plan, we hoped to market a device that would have a huge impact on breast cancer treatment. The end result, the Visica2 Treatment System (V2), is an instrument intended for use in a doctor’s office or clinic. The procedure involves local anesthesia and a real-time, ultrasound-guided approach that is virtually painless. The treatment, which lasts 10 to 20 minutes, freezes and destroys targeted tissue through an incision so small that it does not require stitches. Time to Market Pressure We were tasked with developing a working prototype of the V2 system within four months to satisfy the product release schedule. In addition to fulfilling our commitment to our investors, we needed to meet marketplace demand and produce the V2 as soon as possible.


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Writing firmware and designing a custom circuit board for the device would have been time-consuming, and any error at the firmware or software level could have created delays that would have threatened the entire project. Because V2 is a medical device, it must not have any software or firmware errors that could compromise system performance. If the device had failed the exhaustive testing required for our 510(k) submission, our entire project would have failed and the V2 would not have made it to market. Based on these requirements, we needed an extremely reliable development option for V2. Speeding Development with Off-the-Shelf Hardware

Figure 1: Using the off-the-shelf CompactRIO platform, Sanarus was able to quickly develop a working prototype Sanarus invited a National Instruments field engineer to discuss possible solutions with us. We quickly realized that the CompactRIO was a viable solution for our needs because of its mix of programmability and integrated I/O development. We designed the prototype using CompactRIO to prove that the V2 would be developed reliably in a short period of time. A trade-off table illustrated the differences between using a CompactRIO system and our own custom hardware. The payoff from using CompactRIO was apparent; while a custom solution would have taken months to develop, the NI solution took only weeks.

In addition, with custom firmware, “late game” changes would have required new and difficult revisions, but with the CompactRIO platform, we could revise our code if needed with minimal effort. When we decided that the UI needed to be a touch panel PC instead of buttons and LEDs, we used the LabVIEW for Windows graphical programming environment to develop a UI for a PanelPC. We were able to simply manage communications between the GUI and the CompactRIO real-time controller using LabVIEW shared variables. We also met the new feature requests without causing delays in the development schedule because of the system flexibility. We knew CompactRIO would pass EMC certification, because NI precertified the modules. This guaranteed that our prototype would not have to be redesigned if it failed EMC certification.


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The final V2 system consists of a PanelPC that runs LabVIEW for Windows. This operates the user interface and sends commands to a CompactRIO system using LabVIEW Shared Variables. LabVIEW Real-Time was used to implement a state machine on the CompactRIO real-time controller, and on the PID, LabVIEW Real-Time regulated loops to control the temperature of the tip of the probe. This is done by providing control algorithms to a liquid nitrogen pump for cooling as well as a simple resistive heating element. The LabVIEW FPGA was used to manage the interfacing to the I/O signals necessary to control these devices.

Figure 2: LabVIEW FPGA was used to develop the control system and GUI for the Visica2 Treatment System.

In long-term studies, our technique is highly effective in destroying common tumors, and the V2 is now available at selected centers throughout the U.S. Thanks to NI, we quickly and efficiently developed an embedded control system with a user-friendly GUI for the V2 while maintaining the highest quality, and ultimately, ensuring the safety of our customers’ patients. NI played a fundamental part in achieving our goals. Our product design, prototype, and eventual deployment timelines were met because of the graphical system design platform from NI.


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With LabVIEW, we designed and coded our controller in house, then prototyped and deployed machines much quicker than we ever thought possible. In fact, our CEO called CompactRIO a key factor in the success of the Visica2 Treatment System project. Author Information: For more information on this Case Study, contact: Jeff Stevens Sanarus [email protected]


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High Performance Configurable Umbilical Cord Blood (UCB) Collection System Based on CompactRIO

Medical Engineering

Author(s): S.C. Ng, Obstetrics and Gynaecology, Gleneagles Hospital, Singapore K.K. Tan, Electrical & Computer Engineering Department, National University of Singapore K.Z. Tang, Electrical & Computer Engineering Department, National University of Singapore S. Huang, Electrical & Computer Engineering Department, National University of Singapore Industry: Life Science Product(s): NI CompactRIO NI LabVIEW 7.1 The Challenge: Umbilical Cord Blood is an increasingly important and rich source of stem cells. These cells can be used for the treatment of many deadly diseases, including cancers, immune and genetic disorders. It also provides a readily available source of stem cells for transplantation purposes. To-date, there has not been reported any well-developed method for automated UCB collection. Current methods of UCB collection relying on syringe or gravity-assisted approaches yield minute volumes of blood (dependent on skills of the clinician), is easily susceptible to contamination and are inefficient and unpredictable. The Solution: A novel UCB collection system, which ensures an automated and efficient collection of UCB from delivered placentas, is developed. This modular system, which is easy to operate and resistant to contamination, has been tested clinically and ever ready to be employed in delivery rooms. The automated approach outperforms the current means through a novel patented placenta manipulation system under the control of NI’s CompactRIO to meet the stringent requirements of compactness, robustness, ease in development, use and maintenance, as well as operability under diverse and tough ambient conditions. Abstract In this paper, the development of an automated and efficient UCB collection system is presented. The overall control system is comprehensive, comprising of various selected control and instrumentation components, integrated within a configuration of hardware architecture centered around a NI advanced embedded control and acquisition system, powered by NI RIO technology. It is easy to use, resistant to contamination, robust and designed with the constraints of the typical delivery room as well as possible sterilization and clinical processes in mind. The developed unit was put to the test on freshly delivered placentas and results show that the developed system performs significantly better than current methods of UCB collection.


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Introduction UCB is an increasingly important rich source of stem cells [1]. Stem cells are essential for basic human body functions. UCB can be used for the treatment of over 45 malignant and non-malignant diseases, including certain cancers such as leukemia, and immune and genetic disorders. UCB provides a readily available source of stem cells for transplantation in many situations where bone marrow is now used. There are many advantages to use UCB instead of other sources of stem cells such as bone marrow and peripheral blood. The importance of UCB is now widely recognized. Blood centers worldwide now collect and store UCB after the delivery of a baby upon the parents' request. However, one problem associated with UCB is that its collection is a one-time possibility and the amount of blood that can be collected is limited using current ways of blood collection, which include syringe-assisted and gravity-assisted methods ([2] and [3]). These methods are mainly manually carried out. Apart from being a tedious and difficult process, the current ways of extracting the blood also inherit a high risk of unnecessary contamination, are inefficient and the results are unpredictable depending on the skills and state of the clinician. In this paper, the development of an automated UCB collection system (patent pending) will be presented. The system is easy to use, can be readily sterilized and used in diverse temperature-controlled conditions during tests, and yields an improved collected UCB volume compared to prior art. It is also designed with the space constraints of a delivery room in mind. The paper will elaborate on the hardware and software aspects of the system and the operational function associated with each of the components. Results from laboratory experiments with placentas showed the relative advantage of the developed system over current methods. Development of the UCB Collection System The system comprises of mainly four modular components which can be modified or replaced, while the other components remain functional. Collectively, the four components form an electro-mechanical apparatus which is able to manipulate the placenta via a combination of high frequency vibration and controlled pneumatic pressure, to maximize the flow of blood from the placenta to a collection tube. In addition, all the key components which may be directly or indirectly in contact with the placenta can be readily sterilized and are also designed to filter contaminants from the collected blood. The hardware architecture and the pictorial diagram of the UCB collection system are shown in Figure 1 and 2, respectively.


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Figure 1: Schematic hardware setup of the UCB collection system

Figure 2: Pictorial diagram of the UCB collection system

The placenta tray serves as the support base for the placenta, with the maternal side facing upward, the fetal side facing downward, and the umbilical cord, originating from the fetal side, passing through the ventura of the funnel-shaped element which is formed by a plastic umbilical cord positioner. A


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variable thickness silicon pressure pad (i.e., which is inside the placenta tray) with an integral sealing ring can be snapped into position above the maternal side of the placenta in placenta tray. It serves to keep the slippery placenta in place within an air-sealed space. The pneumatic application system is employed to apply the massaging effect on the placenta. The pressure within the chamber is regulated via a pressure sensor. The stainless steel structure is integrated with a vibrator which generates high frequency vibration to the entire structure. Bottlenecks and clots impeding blood flow can be reduced. The amount of vibration is adjustable via the vibration controller. The various parts and functions of the UCB collection device requires a high performance and compact control system to fulfill, coordinate and synchronize. As the collection of UCB is a one-time possibility, there is no room for malfunction in control. UCB clogs after minutes unless the placentas are preserved under low temperature. Contamination is another critical issue here, as the tolerance for contamination is extremely low, as far as the possible applications of UCB are concerned. To this end, the control unit has to be compact, robust and lends itself to diverse conditions encountered during heated sterilization and clinical tests. Above all, due to the short time span permissible to complete the operation, it has to be easy to use, easy to test and easy to maintain. The controller finally selected and used for the UCB collection system is the NI CompactRIO embedded controller. Its compact structure, ruggedness, reliability and real-time deterministic capability are well-suited for this high precision and critical application. The core of this controller contains an industrial 200 MHz processor that is specifically designed for development of high-speed multivariable digital controllers and real-time simulations in various fields which is a characteristic of this application. The onboard FPGA boosts the performance of the controller. Besides these, the controller supports a total memory space of 64MB including program, data and I/O space. All off-chip memory and I/O can be accessed by the host even while the host is running thus allowing easy system setup and monitoring. The controller is fully supplemented by a set of on-board peripherals frequently used in digital control systems. Analog to digital and digital to analog converters, a DSP-microcontroller based digital-I/O subsystem and other sensor interfaces make the NI CompactRIO an ideal standalone solution for this very specialized application. Software Development Platform The NI CompactRIO is well supported in the highly productive NI LabVIEW program environment with its rich and growing array of modules. This software environment offer a rich set of standard and modular design functions for both classical and modern control algorithms. Of particular importance in this application is the LabVIEW FPGA module and LabVIEW Real-Time module which operate seamlessly together to fulfill the stringent requirements of this application. The developed unit was put to the test on freshly delivered placentas. Results show that the developed system performs significantly better than current methods of UCB collection. Conclusion A high performance configurable UCB collection system has been developed to enable an efficient and automated UCB collection process. The overall control system is comprehensive, and designed with the constraints of the typical delivery room in mind. The control and instrumentation components, integrated within a configuration of hardware architecture centered around NI CompactRIO, collectively achieves the objective function and yield an improved volume of UCB according to real tests carried out on freshly delivered placentas.


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References [1] Cairo, M.S., and Wagner, J.E., “Placental and/or umbilical cord blood: an alternative source of hematopoietic stem cells for transplantation”, Blood, 90, 4665-4678 (1997). [2] Bertolini, F., Lazzari, L., and Lauri, E., “Comparative study of different procedures for the collection and banking of umbilical cord blood”, J. Hematother Stem Cell Res., 4, 29-36 (1995). [3] McCullough, J., Herr, G., and Lennon, S., “Factors influencing the availability of umbilical cord blood for banking and transplantation”, Transfusion, 38, 508-510 (1998). For more information, contact: Tang Kok-Zuea, Professional Officer National University of Singapore Department of Electrical and Computer Engineering E4, Engineering Drive 3, SINGAPORE 119260 Tel: +65 68744460 Fax: +65 68744460 Email: [email protected]


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Monitoring the Structural Health of the Rion-Antirion Bridge Using LabVIEW Real-Time


Author(s): Bernard Basile - Advitam, Inc. Industry: Process Industries Products: PXI/CompactPCI, The Challenge: Developing a structural monitoring system to measure and define the behavior of the Rion-Antirion Bridge during normal operation, strong winds, and earthquakes. The Solution: Using a combination of four PXI/SCXI chassis linked with National Instruments LabVIEW Real-Time software to incorporate the conditioning, acquisition, processing, control, storage, and sharing of measurements

"This system is fully functional and the customer is extremely satisfied. It has already inspired a similar monitoring system for the Millau Viaduct in France. We will continue to optimize the system, and we intend to offer customized versions for other monitoring systems in the near future"

At Advitam, a subsidiary of Vinci Construction, we develop asset management, civil engineering, and structural monitoring services with a focus on occurrence detection and risk analysis methods. With this unique experience, Advitam was in charge of the design and implementation of a structural monitoring system for the Rion-Antirion Bridge, which spans the Corinth Strait and links Peloponnese in southern Greece to the Greek mainland. At 2,883 meters (9,458 feet) long, the bridge is frequently exposed to heavy lateral wind forces. It is also located in an area of high seismic activity, with each end on different tectonic plates, resulting in a relative movement of almost two centimeters per year.

Advitam uses the power of virtual instrumentation to monitor the integrity of the Rion-Antirion Bridge, which is nearly 10,000 feet long and subject to harsh environmental conditions.


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The challenge was to design a monitoring system that could operate in this harsh environment while providing a reliable, continuous data stream to record measurements and events that can affect the bridge’s structural integrity. Implementation The project started three years before the bridge opened and began with a risk analysis to define which elements of the bridge were critical and in need of monitoring. Advitam identified which sensors were required, as well as where they should be placed on the bridge. These included:

• 3D accelerometers on the deck, pylons, stay cables, and on the ground to characterize wind movements and seismic tremors

• Strain gages and load cells on the stay cables and their gussets • Displacement sensors on the expansion joints to measure the thermal expansion of the deck • Water-level sensors on the pylon bases to detect infiltration • Temperature sensors in the deck to detect freezing conditions • Linear variable differential transducer (LVDT) sensors on the stay cables to measure

movement • Load cells on the restrainers for recalibration in the event of an earthquake • Two weather stations to measure wind intensity, direction, air temperature, and relative

humidity With the addition of a power supply and a lightning conductor control, the required system needed a total of 372 measurement channels. It also had to be capable of acquisition and simultaneous, dynamic processing of multiple signals for the purpose of permanent monitoring, while presenting a user-friendly interface and well-designed output reports. Given the large number of input channels and the adverse operational environment, we chose the National Instruments PXI/SCXI chassis housing National Instruments LabVIEW Real-Time software to perform the task. The resulting system houses and performs the following tasks with a high degree of reliability:

• Signal conditioning • Data acquisition • Data processing • Program control • Data storage • Data transmission

Each of the bridge’s four pylons is equipped with an NI PXI-1010 chassis (with eight PXI slots and four SCXI slots) equipped with an NI PXI-8175 controller, SCXI signal conditioning modules linked to the sensors, an NI PXI-6040E module to acquire the data, and an NI PXI-8423/2 module to integrate (in RS485) the data from the weather station. NI LabVIEW Real-Time software runs on each PXI controller to ensure the acquisition and scaling of the measurements, comparing them to fixed or variable thresholds to trigger alarms if necessary. The four systems are linked through a fiber-optic Ethernet network to a control PC installed in the operations building.


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Each PXI device continuously acquires data and creates history files that are regularly sent to the control PC. When a threshold goes past its limit, a selective acquisition unit with real-time recording is started on each chassis. A pre-trigger mechanism is also incorporated to identify and record the events that occurred immediately before the alarm. The interface on the control PC offers different windows to the user, including a synoptic view of the bridge that shows measurement points. Those points are typically displayed in green, but change to red when a threshold goes past its particular limit. The interface also includes automatic and expert function analysis. We can remotely access the computer via a modem to access information or to redefine monitoring parameters. This system is fully functional and the customer is extremely satisfied. It has already inspired a similar monitoring system for the Millau Viaduct in France. We will continue to optimize the system, and we intend to offer customized versions for other monitoring systems in the near future. For more information, please contact: Bernard Basile Advitam 1 bis, rue du Petit Clamart BP 102 78143 Velizy Cedex France Tel: +33 1 01 46 01 85 00 E-mail: [email protected] Or, within the U.S., contact: John Stieb, P.E. Advitam, Inc. 44880 Falcon Place Sterling, VA, 20166 USA Tel: (703) 437 7177 E-mail: [email protected] www.advitam-group.com


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Performing Structural Health Monitoring of the 2008 Olympic Venues Using NI LabVIEW and CompactRIO

Structural Health Monitoring Author(s): Chris McDonald - CGM Engineering, Inc. Industry: Construction Products: LabVIEW, FPGA Module, CompactRIO, Real-Time Module The Challenge: Performing structural health monitoring (SHM) to determine the stability, reliability, and livability of multiple large structures throughout China, including the new Olympic venues in Beijing The Solution: Using the NI LabVIEW graphical programming environment and NI CompactRIO hardware platform to design a highly accurate SHM system with time-based GPS synchronization to monitor structures at critical points

"We deployed an embedded monitoring system with unmatched competitive accuracy, price, and flexibility by using LabVIEW and CompactRIO as the computing platform."

The loss of life and property in catastrophic events such as earthquakes, hurricanes, fires, or bomb blasts is mainly the result of damages to or the collapse of structures. Consequently, engineers worldwide are continually trying to validate structural models and iterate structural designs to reduce tragedies caused by these types of events. In 2004, the China Earthquake Administration (CEA), the governmental body managing the country’s earthquake preparedness and disaster mitigation, selected seven newly constructed megastructures as the test bed for structural health monitoring (SHM) technology. These landmark structures include the 2008 Summer Olympic venues in Beijing (including both the Beijing National Stadium and the Beijing National Aquatics Center), the 104-story World Trade Center in Shanghai, the 66-story Park Hyatt Hotel complex in Beijing, the 240 m concrete arch dam in Ertan, the 8266 m cable-stayed bridge in Shantou, and the base-isolated CEA data center in Beijing.

Figure 1: Structural health monitoring systems based on LabVIEW and CompactRIO monitor the Beijing National Stadium, the main venue for the 2008 Summer Olympics for stability, reliability, and livability.


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The main objective of this major civil engineering project is to develop a state-of-the-art solution to monitor structural health characteristics, including stability, reliability, and livability, in real time by using contemporary computing, sensor, and communication technology. CGM Engineering Inc., a California-based company and a National Instruments Alliance Partner, won the international bid to develop a solution for this project with a remote demonstration. During this demonstration, officials in China observed the real-time client application detecting the vibrations generated by a paper clip dropped onto a table. Subsequently, we designed nine 64-channel and two 36-channel embedded monitoring systems using CompactRIO embedded controllers that use remote network monitoring and configuration for deployment by the CEA. Performing Continuous, Real-Time Structural Health Monitoring

Figure 2: Screen Capture of Systems Panel to capture the vibration signatures of a structure and detect any sudden shifts of structural characteristics Based on LabVIEW and CompactRIO, our systems are designed to capture the vibration signatures of a structure and detect any sudden shifts of structural characteristics. Detected vibrations can be caused by a variety of stimuli, ranging from natural geotechnical waves to event spectators. Much like cardiologists diagnose human heart disease by measuring pulse and blood pressure, structural

engineers determine structural performance by continually monitoring the natural frequency, damping ratio, and hysteresis diagram derived from the acceleration time history that accelerometers measure. For example, if a high-rise office building incurred permanent deformation from an earthquake in its key structural members, such as beams or columns, there will likely be a decrease of its natural frequency (function of rigidity over mass). Two key requirements for the system were continuous and real-time structural monitoring. Because most disasters strike in an abrupt and unpredictable manner, emergency management and effective reactions to sudden disasters must be based on real-time knowledge of how a structure performs during and immediately after adverse events. Additionally, because the health of structures gradually degrades over time, by performing continuous monitoring and capturing early symptoms of health decay, engineers can compare key health indicators against previously recorded levels. Developing Structural Health Monitoring Systems with LabVIEW and CompactRIO Using the NI platform, we developed two different customized systems to meet the CEA’s SHM requirements. Nine 64-channel and two 36-channel systems in a client-server architecture encapsulated in a rugged NEMA enclosure – which permits the systems to operate in high-humidity environments and in temperatures ranging from -40 to +70 °C –are deployed at critical points in the six selected sites throughout China.


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Figure 3: Each unit consits of two or three CompactRIO systems, multiple accelerometers for vibration measurements, and a GPS receiver for real-time synchronization. The nine 64-channel units each consist of three CompactRIO systems, while the two 36-channel devices each contain two. Each device also incorporates multiple accelerometers for vibration measurements as well as a GPS receiver for real-time synchronization. We use the LabVIEW FPGA Module and the

GPS disciplined clocks to achieve real-time, intrachassis synchronization within ±10 µs. In areas where GPS signals are not available, engineers can synchronize the systems using a computer clock. Additionally, we use the LabVIEW Real-Time Module for user-configurable filtering to improve the accuracy of the low-frequency measurements the system is taking and to prevent unwanted noise. The acquired data are stored on embedded single-board computers (SBCs) within each system. By using the LabVIEW shared variable engine in the system software architecture, multiple users can remotely access and analyze recorded data concurrently, in real time, from the embedded SBC via the Internet. We can also configure the systems, using a single or multivariate architecture, to notify offline users via e-mail when an event has occurred.

Figure 4: The Beijing National Aquatics Center, also a main venue for the 2008 Olympics, has two SHM systems from CGM Engineering monitoring the building’s structural health.


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Advantages of a System Based on NI Software and Hardware There were several reasons the CEA chose our solution based on LabVIEW over our competitors’ solutions. Two key factors were the highly accurate, real-time GPS synchronization capabilities and the ability to remotely access data from any location in the world. Our system also offers the highest channel count for the lowest cost. By designing our system based on CompactRIO and modular NI C Series I/O hardware, we can achieve any channel count, up to 128, at an average per-channel cost of about $500 USD for a 16-bit system and $800 USD for a 24-bit system (excluding sensors), and use GPS synchronization to extend to higher channel counts. Additionally, our system offers a simple out-of-the-box setup with a variety of off-the-shelf I/O options that can be quickly and easily reconfigured to meet changing system requirements.

Figure 5: The 240 m concrete arch dam in Ertan is also monitored by the SHM system based on LabVIEW

Using National Instruments hardware and software, we designed, prototyped, and deployed a high-channel-count, SHM system with GPS synchronization in less than one year. We deployed an embedded monitoring system with unmatched competitive accuracy, price, and flexibility by using LabVIEW and CompactRIO as the computing platform. With this combination, we provided the CEA a system that is 10 times more accurate than initially thought possible, at the lowest cost per system.


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The Future of Structural Health Monitoring In China According to The World Bank, by 2015, half of the world’s new building construction will take place in China. Because most large structures located in countries such as the United States were built before the development of advanced monitoring systems, the opportunity is now available to monitor these buildings and perform research that will ultimately help improve the safety of future buildings and reduce the number of lives lost from catastrophic events. A National Instruments Alliance Partner is a business entity independent from NI and has no agency, partnership, or joint-venture relationship with NI. Author Information: For more information on this Case Study, contact: Chris McDonald CGM Engineering, Inc. 882 N. Fairoaks Ave Pasadena, CA 91103 United States Tel: 626-441-3884 [email protected]


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Meazza Stadium Uses NI CompactRIO to Usher in a New Frontier in Structural Monitoring


Author(s): A. Caprioli - The Politecnico di Milano M. Vanali - The Politecnico di Milano Giovanni Moschioni - The Politecnico di Milano A. Cigada - The Politecnico di Milano Industry: Process Industries, Education Products: LabVIEW, CompactRIO The Challenge: Creating a new, continuous, real-time vibration monitoring system for the evaluation of the structural integrity of the Meazza Stadium in Milan The Solution: Developing a sensor network in strategic points of the structure with distributed acquisition and data storage using the NI CompactRIO platform

"With LabVIEW, it is possible to easily change anything at any time without specific skills in software programming."

Meazza Stadium in Milan (also known as San Siro) suffers from the typical problems that plague large structures, including building stress induced by people using the facility, (think of synchronized choruses or pop concerts). Milan municipality asked the Politecnico di Milano (the largest technical university in Italy) to conduct a detailed study of the Meazza stadium and to design an innovative monitoring system to measure vibration within a tenth of a point, evolution of corrosion on metallic parts, and other physical parameters. It was important that the system be durable enough to withstand the stadium-environment and its high mechanical, thermal, and electromagnetic stresses. The Meazza stadium in Milan was built in 1925 and was expanded in the 1950s with a second ring. Its current three-ring structure was completed in the late 1980s for the 1990 Soccer World

Figure 1: The vibration monitoring system, developed using NI LabVIEW and CompactRIO, is shown here taking vibration measurements during a U2 concert.


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Championships for a capacity of 80,000 people. The stadium was originally built for soccer, but starting in the late 1980s, its use was extended to nonsporting events such as music concerts. Occasionally, during concerts and soccer matches, vibratory events have been noted. Such phenomena are associated with the jumping and movement of thousands of people in sync with the rhythm of the music. The Politecnico addressed this problem with a study of the state of the stadium with structural evaluations, modal analyses, dynamic and static measurements, and assessments of corrosive phenomena. In the first phase such issues have been systematically evaluated through detailed experimental campaigns to characterize the stadium and the physical phenomena involved. This first round of tests yielded a large amount of clear data. These results proved the necessity of a monitoring system for vibrations, stress, temperature, and other physical quantities so as to assess these trends over long periods, to dynamically characterize the stadium, and to point out reliable indicators of hazardous conditions. During concerts at the stadium, people sway, wave, or jump in rhythm with the songs, causing structural vibration. The vibration level is proportional to the alternated force applied by the audience. Moreover, if the rhythm of the song (and thus of the people) matches a natural frequency of the structure, the vibration amplitude gets significantly larger. During a concert, the vibration level depends on the size of the crowd and the rhythm of the music. For some songs, the rhythm is synchronized with the structure’s natural frequency and the vibration levels are higher than average. Thus, it is necessary to measure this phenomenon, and keep it under control before to the vibrations reach hazardous levels. This monitoring system has to continuously measure the parameters in the frequency range of 0 to 50 Hz, requiring reliable data acquisition, storage, and transmission. The Mechanical and Thermal Measurement Group of the Politecnico di Milano has a remarkable reputation for its creation of long-term monitoring systems for both modern and aged structures. For the Meazza Stadium challenge, we developed a state-of-art system based on the CompactRIO platform and powered by a multilayer software program developed using the NI LabVIEW graphical programming environment.

Figure 2: This LabVIEW screen shows the vibration levels during a U2 concert, with the horizontal axis representing time and the vertical axis representing vibration.

The role of the sensors is quite obvious; it is only to be outlined that in a

measurement-quality perspective, the cable between a transducer and its conditioning unit must be as


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short as possible. From a network (and economic) perspective, it should be as long as possible since the number of conditioning units is thus minimized. Therefore, a compromise has to be reached. Since the measurements are currently carried out with accelerometers, the adoption of ICP standard is of great help under this point of view. The PC, installed in a protected place, serves as the “master” of the system. Under normal operating conditions it primarily collects and analyzes data stored in peripheral nodes, thus becoming the final destination of all data. In setup phases, it acts as the user-interface for nodes configuration and sensor calibration. The PC is also the gateway for remote access to the system through the Internet. The central idea of the proposed measurement system is to distribute the acquisition nodes so as to have the best solution logistically and economically. An essential goal is to reduce signal cable length to improve measurement quality in an environment with interference from tens of thousands of mobile phones, hundreds of television antennas, and numerous power lines. With a network of CompacRIO nodes, the system enjoys the benefits of distributed data-acquisition nodes and the distribution of data storage independent from the network status. Normally, the master PC coordinates the nodes and controls data retrieval and storage. If the central unit or network fails, each CompactRIO node can retrieve and store data for several days independently from other nodes. CompactRIO also provides superior computation and storage capabilities, small dimensions, and resistance to humidity and other environmental agents. Additionally it was important that any choice regarding the measurement system does not prevent the addition of new monitoring solutions in the future. A scalable system in terms of nodes and type of signal conditioning was critical. A critical point for dynamic measurement systems, namely the filtering, was solved by choosing analog and digital filters with high frequency samplings and online decimation. LabVIEW was chosen to meet the ease of use requirement. The group of mechanical researchers must be able to directly interact with the system. With LabVIEW, it is possible to easily change anything at any time without specific skills in software programming. The software for the system management offers superior flexibility and usability at different levels and gives access to the system for routine controls and low-level configurations. Finally, over long periods of time, the autodiagnosis and calibration process implemented in the proposed solution gives the measurement system the desired reliability. The authors thank the Milan Municipality and football teams of F.C. Internazionale and A.C. Milan for their support. Author Information: For more information on this Case Study, contact: Giovanni Moschioni The Politecnico di Milano Tel: 39-0-2-2399-8584


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Deploying LabVIEW to Monitor Pipelines at the Ormen Lange in the North Sea

Oil and Gas

Author(s): Marco Schmid - Schmid Engineering Harald Månum - Bjørge AS Industry: Oil and Gas, Energy/Power Products: Embedded Module for Blackfin Processors, LabVIEW The Challenge: Developing and installing a long-term monitoring system for a 120 km pipeline off the coast of Norway. The Solution: Using a custom, flexible system developed in LabVIEW and deployed with the Schmid Engineering ZMobile™ hardware deployment platform based on the LabVIEW Embedded Module for Blackfin Processors.

"With the rugged conditions and size of the Ormen Lange natural gas field, tight timelines and innovative approaches were required to solve a variety of engineering challenges."

The Ormen Lange is the largest natural gas field under development on the Norwegian continental shelf. The pipeline traverses the Storegga rock slide off the coast of Norway, which is one of the longest rock slides to exist on a continental shelf. Extreme Conditions Require New Solutions A massive mound of rubble has accumulated over thousands of years, causing an extremely rough seabed for laying natural gas pipelines. The installation of a real-time vibration monitoring system on the subsea pipeline is required to predict and quickly react to any damage.

The Ormen Lange pipeline traverses the coast of Norway


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The Norwegian high-tech firm of Bjørge AS, which specializes in intelligent underwater instrumentation and condition monitoring, has developed a long-term monitoring system entirely in LabVIEW for installation at the Ormen Lange. Schmid Engineering, a Swiss system integrator that offers solutions for mechatronics applications and embedded systems, is deploying this system using the Schmid Engineerig Zbrain™ hardware deployment system. North Sea Requirements for Subsea Pipeline Monitoring System The monitoring system must survive extreme sub-sea conditions including strong underwater currents, low visibility, limited power, Gulf Stream currents, water turbulence due to the uneven seabed, and changes in internal pipeline flow. In addition to these extreme conditions, the project required a tight development timeline to meet production targets, a very low power off-the-shelf hardware deployment platform, and a highly reliable system with built-in logging capabilities. Meeting Development Timelines with LabVIEW C-code Generation With the LabVIEW Embedded Module for Blackfin Processors, one engineer was able to reduce development time by generating more than 50,000 lines of C code from the LabVIEW graphical environment in less than 12 months. The graphical code and generated C code consisted of eight asynchronous threads, four of which required inter-thread communication. Based on Bjørgesurveys, 77 percent of respondents stated that an average embedded programmer can produce 1000 lines or fewer of debugged C code per month. With intuitive LabVIEW graphical programming, this engineer was able to produce more than 4-6 times the code predicted by this rule of thumb. Deploying to Off-the-Shelf Embedded Hardware Bjørge was able to deliver a software solution on schedule by combining LabVIEW software with an embedded Analog Devices Inc. (ADI) Blackfin digital signal processing (DSP) chip. Using graphical programming techniques and the software tools in the LabVIEW Embedded Module for Blackfin Processors, Bjørge-NAXYScreated an application that compiles C code and targets off-the-shelf, embedded ADSP-533 Blackfin Processors from ADI. We combined this technology with the embedded expertise of Schmid Engineering, which built the ZMobile OEM core module, based on the ADI Blackfin processor, with built-in integrated nonvolatile and removable memory, power management tools and analog, digital and communications I/O. Reliable Low Power Consumption Battery Operated System with Built-in Logging It is a direct requirement from the government to monitor pipeline vibrations. To record vibrations in all three axis directions, synchronized measuring points called clamp sensor packages (CSPs) are attached to the pipeline at regular intervals. An inertial master sensor package (MSP) installed on the seabed controls the CSP. This MSP also records water currents, salinity,


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temperature and pressure for complete characteristics. The links between CSP and MSP units are wireless through acoustic modems. The monitoring system offers three basic modes of operation.

1. Long term data logging: The MSP wakes up at a configurable time interval, typically every three hours. At first, it measures the distance to each CSP for compensation purpose. Then, the MSP initiates distributed analog data recording at 10 to 20 Hz for 10 to 30 minutes by sending a group call to all CSP nodes. Next, the MSP starts reading water current, salinity temperature and pressure through serial interfaces. When logging has finished, the MSP processes the data and stores it to removable memory. After programming the next wakeup, the MSP and CSPs go to sleep and the whole process repeats.

2. Event monitoring: In parallel with data monitoring, the lowest power, intelligent mixed signal circuitry continuously monitors all vibrations and water current levels for limiting values. If any CSP detects a high acceleration while asleep, it wakes up and sends a signal to the MSP to initiate the logging scheme. Likewise, the MSP will wake up and initiate logging if a high water current level is detected while asleep.

3. ROV rendezvous: A remote operated underwater vehicle (ROV) installs and maintains the monitoring system. Through acoustic communication with an ROV or a top side modem, engineers can change all vital parameters at run time, as well as upload sampled data or Fourier analyzed data for a requested time period. An ROV is able to request data from either a CSP or an MSP at any time and in parallel to its current mode of operation. This reliable communication interface is a key feature of the embedded hardware and software.

Built-in Redundancy Redundancy is a big challenge in this system. Every action is monitored. In the event of an error, a node performs a self correction and informs its caller about the situation. All nodes communicate to decide if the error is within the node itself or any other nodes. If the real MSP fails, any CSP can become the new MSP to sustain the operation. The pipeline monitoring system has a lifetime of several years, and will be submerged for at least six months at a time; thus, the highest demands are placed on hardware and software reliability, in-program error handling and efficient energy management. With the rugged conditions and size of the Ormen Lange natural gas field, tight timelines and innovative approaches were required to solve a variety of engineering challenges. Bjørge was able reuse off-the-shelf hardware based on ADI Blackfin Processors and apply graphical programming to generate the code required for deployment. With the LabVIEW Embedded Module for Blackfin Processors, our engineer generated more than 50,000 lines of C code from the LabVIEW graphical environment in less than 12 months. Author Information: For more information on this Case Study, contact: Marco Schmid Schmid Engineering [email protected]


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Oil Well Fracture Pump Monitoring and Analysis using LabVIEW and NI RIO Technology

Oil and Gas Author(s): Robert Stewart, Senior Vice President - Supreme Electrical Services, Inc Industry: Oil and Gas Products: CompactRIO, Real-Time Module, LabVIEW, Single-Board RIO, FPGA Module The Challenge: Building an advanced monitoring system that can survive being mounted directly to an oil well servicing pump in a rugged environment while performing advanced analysis on sensor data The Solution: Using NI CompactRIO and NI Single-Board RIO hardware along with NI LabVIEW software to design a pump monitoring system that monitors the operating parameters of a reciprocating pump used in well servicing applications.

"LabVIEW has made the software development side much quicker than our past experiences in C-based programming. What most C programmers take two years to do, we can accomplish in a couple of months. We can use that time savings to get to market quicker and capitalize on our competitors’ lag time."

At Supreme Electrical Services Inc., we want to be the best packager and integrator of controls and instrumentation technology for any industry in which we compete. Our goal is to package with the best off-the-shelf hardware available and to package it in such a way that it withstands the harshest environments commonly found in the oil field. We feel that NI hardware and LabVIEW software provide the optimal solution for our application, and we have made them the backbone of our entire control system.

Figure 1: While our protoype monitoring system is built using CompactRIO, since CompactRIO and NI Single-Board RIO have the same hardware architecture, we can switch easily between the two form factors without any major coding changes.


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Other hardware solutions we considered were not able to provide the high-speed I/O and analysis to catch the momentary pressure spikes and vibration indications of these oil well service fracturing pumps. The field-programmable gate array (FPGA) and ability to perform fast Fourier transform (FFT) analysis on the data make CompactRIO, NI Single-Board RIO, and LabVIEW a perfect solution for this application. Oil Well Monitoring System

Figure 2: Both the engine and the transmission come equipped with an electronic interface that monitors critical functions and provides diagnostic information as the unit is running. Our oil well monitoring system is designed to monitor the performance of vital pump components during operation. Our preliminary product is focused on monitoring high-pressure fracturing pumps in well-stimulation applications. Each fracturing unit has a high horsepower diesel engine and transmission mated to a triplex or

quintaplex pump. Both the engine and the transmission come equipped with an electronic interface that monitors critical functions and provides diagnostic information as the unit is running. The engine and transmission output the data they monitor via an SAE J1939 communication protocol. Currently, pumps in this industry do not contain more than a couple of discrete sensors that monitor their critical operating parameters. Typically, discharge pressure, RPM, lube oil pressure, and lube oil temperature are monitored. Each of these parameters is measured with an individual sensor and signal cable that goes back to the main control console.

Figure 3: The goal of our product is to monitor several operating parameters and transmit that data back to the main control console.

The goal of our product is to monitor these functions as well as several others and transmit that data back to the main control console via the same SAE J1939 controller area network (CAN) protocol. Our system needs to look for data characteristics outside the normal operating envelope and failure conditions. With this real-time information, operators can determine if they should discontinue operation or continue based on real performance indications from the pump. Ultimately, this system should reduce the number of pump failures as well as overall pump


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maintenance costs. Rugged Deployment with CompactRIO and LabVIEW For what we do, there is not a more capable hardware package than CompactRIO. We also like that we can develop software in LabVIEW faster than most other programming environments. LabVIEW has made the software development side much quicker than our past experiences in C-based programming. What most C programmers take two years to do, we can accomplish in a couple of months. We can use that time savings to get to market quicker and capitalize on our competitors’ lag time. We are using the LabVIEW software platform to program the real-time processor, FPGA, and I/O with the CompactRIO system and interface to control and monitor every aspect of the well servicing and stimulation equipment commonly found in our industry. We believe that the modular I/O and the rugged CompactRIO system are perfect because they can handle the shock and vibration and wide-ranging temperatures experienced while mounted to a mobile piece of equipment that is dragged up and down oil field roads around the world. The openness of LabVIEW and National Instruments hardware make it easy to interface to a variety of sensors, software, and protocols such as the following:

• Sensors – Pressure transducers, magnetic pickup sensors, digital encoders, temperature sensors, nuclear densitometers, magnetic flow meters, Correollis flow meters, and so on

• Software – Coiled-tubing fatigue, wellbore-simulation software

• Operating systems – Windows XP Embedded, Windows CE, Linux®

• Industry-specific protocols – SAE J1939, J1587, J1708; Modbus; Ethernet, 802.11; PROFIBUS

Customized Deployment with NI Single-Board RIO Because of the small form factor and the low cost of NI Single-Board RIO, we see great value in using this hardware to provide a customized solution to our customers. With both CompactRIO and NI Single-Board RIO, we are able to offer the ability to create different form factors and price points for our monitoring systems. Fortunately, the transition from CompactRIO to NI Single-Board RIO is a very quick and seamless process because of the standard NI reconfigurable I/O (RIO) hardware architecture and LabVIEW. NI Single-Board RIO has the same hardware architecture as CompactRIO, so we are able to reuse our LabVIEW code in our NI Single-Board RIO hardware without any major coding changes. The Advantage of a Solution from National Instruments We are very pleased with the quality of products and support we have received from NI. NI has handled our technical issues with urgency and followed through to help us complete our application. Everyone at NI, from support engineers to the direct sales engineers, has in-depth technical and


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business knowledge of their product lines. It has truly been a pleasure working with such a supportive and professional group. Author Information: For more information on this Case Study, contact: Robert Stewart, Senior Vice President Supreme Electrical Services, Inc [email protected]


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CompactRIO Helps Nexans Spider Dredging System Level Seabed for Oil and Gas Exploration

Oil and Gas

Author(s): Halvor Snellingen - Nexans Industry: Oil and Gas Products: CompactRIO, LabVIEW The Challenge: Preparing the ocean floor for a pipeline to extract natural gas from the enormous Ormen Lange gas field off the coast of Norway in the North Sea The Solution: Using National Instruments LabVIEW and CompactRIO to control hydraulic systems on the Nexans Spider remote operated vehicle (ROV) as it levels the seabed and clears a path for the pipeline

"The LabVIEW platform has helped Nexans develop a system that is easy to maintain due to the consistent programming paradigm for both HMI and embedded control, even in extreme conditions."

In 1997, the Ormen Lange gas field was discovered off the western coast of Norway. It was the second-largest natural gas discovery on the Norwegian shelf and has the potential to produce around 20 billion cubic meters of gas each year. Ormen Lange, which means “the long serpent,” is approximately 40 kilometers long and eight kilometers wide and lies about 1,000 meters below sea level. The gas field will be operational in 2007 and will be equipped with seabed installations at depths ranging from 800 to 1,100 meters. The gas will be transferred through a pipeline from production platforms to a processing plant at Nyhamna, Norway, and then exported via a 1,200-kilometer undersea pipeline to Easington on the east coast of the United Kingdom, and to other locations on the coast of continental Europe via a distribution center on the island of Sleipner in the North Sea.

Nexans uses NI LabVIEW and CompactRIO to control hydraulic systems on the Spider, a remote operated vehicle designed to operate on the ocean floor. Photo courtesy of Norsk Hydro.


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Extreme conditions at the site, including below-freezing temperatures, stormy seas, and strong underwater currents, put great demands on the tools needed to complete the project. Because of these conditions, the Ormen Lange gas field will not use conventional offshore platforms. Instead, wellheads on the ocean floor will be connected directly by pipes to the onshore processing facility at Nyhamna. In addition to the harsh environmental conditions, the topography of the ocean floor is very rugged. The pipelines must be routed through the rocky terrain in such a way that unsupported sections of pipe will not be vulnerable to damage. To solve this problem, Nexans has developed the Spider, a remote-controlled underwater excavator designed to prepare the seabed for pipe-laying on steep slopes and rocky terrain far below the water’s surface. The Spider is based on a Swiss forestry machine that has been outfitted to work on steep slopes underwater. It will be used to level the seabed for placement of the pipeline. The Spider is controlled using newly developed 3D software, sensors on all movable parts of the machine, and a network of acoustic transmitters placed on the ocean floor. The 3D model of the seabed is updated in real time using a National Instruments LabVIEW human-machine interface (HMI) to show terrain changes. In addition, a remote-controlled underwater vessel with an echo sounder carries out a detailed daily inspection. The Spider can be controlled with 10-20 centimeter precision, even at a depth of 1,000 meters. National Instruments LabVIEW software is used for presentation and control of the Spider, which is operated from a control room onboard a ship. The operator has a complete overview of the Spider through a number of different LabVIEW screens. Live video is also displayed from several cameras mounted on the Spider. The excavation process is displayed in a 3D ActiveX control on the LabVIEW front panel. The 3D display shows a model of the seabed and, through a number of sensors on the Spider, a real-time image of the machine’s position. The Spider and its grabber are controlled using an off-the-shelf joystick. LabVIEW reads the commands from the joystick through the joystick VIs and sends control signals over a fiber link to the Spider, even at depths of up to 1,000 meters. Three distributed industrial control and acquisition NI CompactRIO systems, located in IP62 enclosures, are exposed to the rough marine environment for extended periods onboard our ships in the North Sea, subjected to extreme temperature ranges, salty sea air, and high humidity. They perform heave compensation, winch, and power control and communicate with the main LabVIEW application. These algorithms run in real time on CompactRIO. The LabVIEW platform has helped Nexans develop a system that is easy to maintain due to the consistent programming paradigm for both HMI and embedded control, even in extreme conditions. Author Information: For more information on this Case Study, contact: Halvor Snellingen Nexans Tel: 4790038384 [email protected]


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Developing a Safety Monitoring System for Exposed Gas Pipelines Oil and Gas

Author(s): Sung-Kyung Hong - Research Development Institute, Korea Gas Corporation, Industry: Oil and Gas Products: cRIO-9103, cRIO-9004, NI 9201 The Challenge: Developing a safety management system to monitor exposed city gas pipelines attached to bridges The Solution: Using NI CompactRIO hardware to create a highly reliable system that is not subject to downtime, even in an environment with poor conditions, for monitoring exposed gas pipelines.

"We used CompactRIO hardware to install our highly reliable system in environments with poor conditions, such as construction fields or bridges, to continuously monitor and secure the safety of the exposed gas pipelines."

Figure 2: City Gas Pipelines Attached to a Bridge

We designed the safety management system to monitor the structural safety of exposed gas pipelines. With these exposed pipelines, the city cannot stop gas provision, which can lead to extensive large-scale damage if an accident occurs. In addition, many of the exposed gas pipelines are attached to bridges. Even though the bridges were initially

Figure 1: Exposed Subway Pipelines


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constructed properly, many factors including secular changes, fewer support members to hook up the pipeline, problems related to the bridge structure, and intentional damage to the pipeline make it difficult to implement safety management systems during bridge development. To ensure complete safety, we needed a highly reliable, 24-hour monitoring system that was not subject to downtime, even in environments with poor conditions. Drilling construction, also known as “other construction,” occurs in areas where pipelines are buried below ground level of the gas pipeline view, such as subway and ground lamp construction. When this type of construction begins, we implement suspension protection to guard the exposed pipelines. Because exposed pipelines increase the risk of accidents, we set up on-site management or shortened the inspection period to reinforce safety management by performing more frequent inspections. System Characteristics We used CompactRIO hardware to install our highly reliable system in environments with poor conditions, such as construction fields or bridges, to continuously monitor and secure the safety of the exposed gas pipelines. We also developed this system to be free from erroneous operations, even when the warning alarm was triggered. System Composition We developed the system using the NI cRIO-9004 embedded real-time controller and the NI cRIO-9103 four-slot, 3M gate reconfigurable embedded chassis. We used a microelectromechanical-based accelerometer to measure the exposed pipeline oscillation. This accelerometer was less expensive than an integrated electronic piezoelectric (IEPE) accelerometer because its signal was slightly diminished by the increase of the line length and it used regular cabling instead of a coaxial type. Therefore, we used the NI 9201 C Series analog input module instead of the NI 9233 C Series four-channel dynamic signal acquisition module. With the NI 9237 bridge and strain measurement module, we measured the stress change of the exposed pipelines. Because we needed the strain gage to measure the length of the pipeline we installed the half bridge to decrease the noise impact by the line length. We also installed equipment to generate the short message service (SMS) using code division multiple access (CDMA) so that the safety management field workers could receive the warning alarm at any position via cell phone. We installed the CDMA equipment as the serial interface and programmed the system to sound a warning alarm when anything regarding oscillation or strain exceeded the levels initially established. Reliable and Durable Safety Management with NI Hardware We created the reliable safety management system to secure 24-hour monitoring of the exposed pipelines. We used dependable NI hardware that did not experience downtime so that the system could operate properly if accidents occurred, even in environments with poor conditions. Moreover, we chose to use CompactRIO as the system hardware because it was dependable and durable, which influenced how we applied the sensors.


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Figure 3: Overview Map of the Safety Management System for the Exposed Gas Pipeline

Author Information: For more information on this Case Study, contact: Sung-Kyung Hong Research Development Institute, Korea Gas Corporation, South Korea

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