ScilabTEC 2015 - Bavarian Center for Agriculture

Presented on SCILABTEC2015 Paris (France) 02.06.2015

(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 1

Bavarian State Research Centerfor Agriculture

Dr.-Ing. Zoltan Gobor

Institute for Agricultural Engineering andAnimal Husbandry

Development of a diagnostic tool for performance analysis during the testing of

agricultural implements

Data acquisition and automated data analysis illustrated by the example of the prototype for

automated attachment of the supporting wires in hop gardens

Institute for Agricultural Engineeringand Animal Husbandry

Hop production – state of the art

● Germany: aproximately 18 000 hacultivated area under hop

● Predominantly 7 or 8 m high trellissystems

● Annual replacement of the supporting wires (1.2 – 1.4 mm thick iron wire)

● Manual fastening of the support wire:

– 3 workers-platform 12 man-hours and 3 tractor-hours per ha

– 2 workers-platform 15 man-hours and 5 tractor-hours per ha

● Problems during manual fastening:

– Accident risk

– Ergonomically very uncomfortable task

– Dependent on the weather conditions

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Gobor-ILT 5-15002 2




Automated attachment of the supporting wires

● The private limited company Soller (Geisenfeld, Germany) protected the idea by a patent in 2002

● A joint project (2008-2010) funded by the German Federal Agency for Food and Agriculture (BLE) was realised

– Main task – optimisation of the system and development of a new prototype based on the gained insights

● A joint project (2014-2016) funded by the German Federal Agency for Food and Agriculture (BLE) and Rentenbank within the DIP (Agricultural Innovation Partnership) programme

– Main task –improvement of the existing prototype and the necessary diagnostic tools in order to produce the zero series device

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Gobor-ILT 5-15002 3


Design of the device – optimisation and development

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Gobor-ILT 5-15002 4

Subsystem for positioning

Subsystem for wire attaching

Intermediate storage of the wire

External hydraulic power supply unit




Design of the device – optimisation and development

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Gobor-ILT 5-15002 5

(1) Telescopic leader mast

(2) Subsystem for wire attaching

(3) Intermediate storage of the wire

(4) Wire coil

(5) External hydraulic power supply unit

(6) Subsystem for positioning

(7) Electrical cabinet with embedded programmable logic controller (PLC)


Hydraulic parameters and PLC signals acquisition

● Phase 1

– Compact modular data logging system NI cDAQ-9172

– Pressure sensors MBS 3250 060 G1 869 (Danfoss)

– Turbine flow sensor RE 4 (Hydrotechnik)

– Software solution for data acquisition (LabVIEW)

– 9 AI (pressure + flow rate)

– up to 27 DI (PLC signals)

– 2 counters

● Phase 2

– NI cRIO-9033 Controller With 1.33 GHz Dual-Core CPU, 160T FPGA with NI Linux RT

– Up to: 18 AI (pressure, flow rate); 32 DI (PLC signals); 2 counters

– Test bench; prototype; zero series machine

– Software (LabVIEW Real Time and FPGA)

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Gobor-ILT 5-15002 6




Software phase 1 (concept)

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Gobor-ILT 5-15002 7

Core 1

Core 2

Producer - Consumer

Data streaming NIUSB -> PC

Data logging

State machine

Enqueue

DequeueFIFO

States:

•Initialise •Configure•Load configuration•Save configuration•Measure •Stop


Software for data acquisition - Front panel (HMI)

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Software - Front panel (measurement)

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TDMS file in Excel

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● File format with similar footprint and precision as a binary file (combination of binary and XML data)

● Self descriptive structure with three-level hierarchy: file-specific information; meta-data; row-data

● Data streaming - segmented or writing at once into the TDMS file depending on the required speed and amount of data




Semi-automated off–line data analysis (Scilab)

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● Scilab function for direct reading of the TDMS files not available

● Intermediate steps: open in MS Excell, save as XLS and read with xlsread or xls_open in Scilab

● Developed function allows automated analysis considering defined parameters and graphical and statistical analysis by simply entering the TDMS (XLS) file name into the function


https://www.youtube.com/watch?v=q5MNtrRoVmo

Tw

istin

g

Wire

atta

chin

g S

ubsy

stem

up

Wire attaching cycle simulation

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Wire

feed

ing

slow

(wire

pre

para

tion)

Cut

ting

Wire

feed

ing

mid

d

Wire

atta

chin

g S

ubsy

stem

dow

n

Ben

der u

p

Ben

der d

own

Wire

feed

ing

fast




Measurement results before optimisation–hydraulic parameters and PLC signals

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Optimisation - hydraulic power unit with 2 pumps

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Pump 1− Vertical Positioning− Horizontal Positioning− Intermediate storage

(recharging)

Pump 2− Cutter− Wire attaching

− Positioning of the subsystem

− Wire feeding− Twining− Cutting− Bending




Results – duration of selected wire attaching sequences

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2009 2011

Area capacity 0.21 – 0.23 ha/h

Average operating speed 1.45 – 1.65 km/h


Measurement results after optimisation–hydraulic parameters and PLC signals

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Hydraulic parameters and PLC signals acquisition

● Phase 1

– Compact modular data logging system NI cDAQ-9172

– Pressure sensors MBS 3250 060 G1 869 (Danfoss)

– Turbine flow sensor RE 4 (Hydrotechnik)

– Software solution for data acquisition (LabVIEW)

– 9 AI (pressure + flow rate)

– up to 27 DI (PLC signals)

– 2 counters

● Phase 2

– NI cRIO-9033 Controller With 1.33 GHz Dual-Core CPU, 160T FPGA with NI Linux RT

– Up to: 18 AI (pressure, flow rate); 32 DI (PLC signals); 2 counters

– Test bench; prototype; zero series machine

– Software (LabVIEW Real Time and FPGA)

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Software aproach 1: LabVIEW with embedded Scilab code

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Core 1

Core 2

Producer - Consumer

Data streaming NIUSB -> PC

Data logging

State machine

Enqueue

Dequeue




Software approach 2: Multicore

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Core 1

Core 2

Producer - Consumer

Data acqisition

Data logging

Core 3

Core 4

Online analyse

Data streaming


Software HMI (concept)

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System diagnosticsProcess simulation




Considerations 1: LabVIEW to Scilab Gateway

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Source: http://sine.ni.com/nips/cds/view/p/lang/de/nid/210055 (20.05.2015)


Considerations 2: LabVIEW MathScript RT Module

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Source: http://www.ni.com/labview/mathscript/ (20.05.2015)




Software HMI (concept)

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Hardware: NI cRIO-9033

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Source: http://sine.ni.com/nips/cds/view/p/lang/en/nid/212720 (20.05.2015)




Software (LabVIEW FPGA+RT)

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Test bench (simulator) in order to allowdevelopment of the software withoutnecessity to test it directly on the machine:

– FPGA RT Controller: NI cRIO-9033

– Simulator of the manual HMI

– Universal simulator of the mainactuators and sensors

Development of a test bench

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Development of a test bench

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Testing:

�� Testing of the

manual control (simulator of the manual HMI)

�� Testing of the

actuators and sensors considering vertical positioning

1

5 6

4

2

3


Conclusions

● Using contemporary design and analysis tools (acquisition of relevant parameters combined with automated analysis, digital

prototyping and capturing of high-speed videos) allowed faster and more reliable development

● The analysis of the oil pressure, flow and PLC signals provided new insights in the dynamics of the system and a new prototype with external hydraulic power unit was developed

● Logging and analysis of the PLC and sensor signals provided information (start and end of single operation, required time for execution of single operation, duration of every wire attaching

cycle, time required for headland turn and failure correction) for further improvement of the system

● Development of the test bench will allow more easier and faster development of the software for diagnostic inspection

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Improvement possibilities

● The developed data acquisition system can and will be used for performance analysis and diagnostic inspection in case of outage

● Communication between the cDAQ an PLC using OPC need to be tested (jitter)

● Possibility to integrate additional signals from the tractor using e.g. CAN bus need to be discussed

Comprehensive testing and improvement of the system will be continued

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THANK YOU FOR YOUR ATTENTIONGobor-ILT 5-15002 30

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http://www.lfl.bayern.de/ilt/mechatronik/index.php

Presentations & Public Speaking

ScilabTEC 2015 - Bavarian Center for Agriculture