Advanced industrial control technology

Cover Page
......Page 1
Front Matter
......Page 2
Copyright
......Page 3
BACKGROUND......Page 4
ORGANIZATION......Page 6
SUGGESTIONS......Page 8
SOURCES......Page 9
Acknowledgments......Page 10
CHAPTER 11 - Networking devices
......Page 11
The hardware architecture of embedded control systems......Page 13
The software architecture of embedded control systems......Page 14
Implementation methods......Page 15
Control function mapping for hardware implementation......Page 16
Control logic modeling for software implementation......Page 17
Definition and functions......Page 19
Predictable operation result......Page 20
Programmable peripheral devices (memory chips)......Page 22
Multitask scheduling......Page 23
Resource sharing......Page 26
Implementation methods......Page 27
Microprocessor chipset......Page 29
Real-time programming......Page 30
Real-time task engine......Page 32
Program bugs......Page 33
Principles and functions......Page 34
Architectures and elements......Page 39
I/O subsystem......Page 40
History module......Page 41
The OSI network model......Page 42
The TCP/IP network model......Page 43
Implementation techniques......Page 44
Redundancy solution for sensors......Page 45
Redundancy solution for connection buses......Page 46
Further Reading......Page 47
Fixed-time task switching......Page 602
Definition and functions......Page 49
Application layer......Page 50
Black box models......Page 51
Pressure process control......Page 52
Temperature process control......Page 54
Processor core......Page 163
Upper and lower bound......Page 55
Gain ratio......Page 56
Industrial panel-mount computers......Page 355
Local advanced programmable interrupt controller (APIC) unit......Page 164
A room heating system......Page 57
Form error......Page 369
NVRAM......Page 437
PID control......Page 60
Optimum control......Page 61
Configurable locks......Page 439
Simple I/O module......Page 62
Torque control......Page 63
Valve actuators......Page 102
Servo control......Page 64
Software interrupts......Page 176
Motion control systems......Page 65
Solaris MC......Page 689
CNC program formats......Page 286
Motor power transformation......Page 68
Operating principles......Page 69
System install and configure routines......Page 71
Computerized control technologies......Page 72
Hierarchical Architecture......Page 73
Hydraulic valves......Page 115
Hierarchical database......Page 74
CMOS chipset......Page 251
Digital multiplexer......Page 586
Time-division multiplexer......Page 587
Automation controllers and software......Page 75
Industrial robot types......Page 76
Transparent bridging......Page 187
Further Reading......Page 78
INDUSTRIAL OPTICAL SENSORS......Page 79
Operating principle......Page 80
Three-field color sensors......Page 81
Operating principle......Page 82
Supervisory models......Page 84
Transfer to operating system......Page 597
Operating system of a multiprocessor system......Page 599
Dome illuminator for diffuse illumination......Page 85
Operating principle......Page 86
CMOS image sensors......Page 87
Assemblies, disassembly, and reassembly......Page 535
Hierarchy of buses in an embedded system......Page 733
Temperature sensors......Page 90
Read-only memory (ROM)......Page 170
Basic types of bimetallic sensors......Page 91
Distance sensors......Page 95
Cycle time......Page 96
Force sensors......Page 99
Configuring PCI-PCI bridges: assigning PCI bus numbers......Page 739
Maximum number of nodes......Page 103
Electric actuators......Page 104
Operating principle......Page 105
Distributed servo control......Page 335
Magnetic actuators......Page 107
Hall effect sensors and switches......Page 108
Magnetoresistive sensors and switches......Page 110
Pneumatic actuators......Page 112
Linear pneumatic actuators......Page 113
Hydraulic actuators......Page 114
Hydraulic motors and rotary actuators......Page 116
Operating principle......Page 117
Basic types......Page 118
IEC 60870-5 protocols......Page 382
Piezoelectric motors......Page 119
Multilayer piezoelectric benders......Page 120
FSK bus......Page 489
Further Reading......Page 121
Operating principle......Page 123
Non-remote memory access (NORMA) multiprocessors......Page 676
Transmission gate and tristate buffer......Page 126
Full-duplex transmission mode......Page 128
Logic-BIST......Page 365
Magnetic proximity sensors and switches......Page 129
Fiber-optic proximity sensor or switch......Page 130
Data communication......Page 372
Ultrasonic transducers......Page 131
Simple logic module......Page 231
Immersion transducers......Page 132
Linear and rotary variable differential transformers......Page 133
INPUT/OUTPUT DEVICE DRIVERS......Page 541
Routing tracks......Page 235
Rotary shaft valves......Page 138
Special valves......Page 139
Steam conditioning valves......Page 140
Human-machine Interfaces in SCADA systems......Page 543
Valve accessories......Page 142
Check valves......Page 143
Swing check valves......Page 145
Device Driver status......Page 146
MOSIX......Page 690
HART devices......Page 152
Manifold valves......Page 153
Float switch......Page 154
Flow valves......Page 155
Gas flow switches and liquid flow switches, volumetric......Page 156
Further Reading......Page 158
CHAPTER 18 -
Industrial control system operation routines......Page 258
SINGLE-CORE MICROPROCESSOR UNITS......Page 159
Industrial motherboards......Page 348
Prediction......Page 160
Block diagram of a microprocessor unit......Page 161
Scheduling policies......Page 679
Intel Architecture registers......Page 162
Industrial personal computers and workstation computers......Page 353
The fetch, decode, execute engine......Page 165
Processor cache......Page 166
MMX technology......Page 167
Memories......Page 168
Sequential logic module......Page 169
Microprocessor interrupt operations......Page 171
Bus-off......Page 370
Interrupt process......Page 173
Number of connectable AS-Interface slaves......Page 473
Drive......Page 331
Interrupt vectors......Page 174
Model predictive control......Page 782
Internal models and robust controls......Page 177
Basic input/output interfaces......Page 178
The basic input interface......Page 179
Bus operations......Page 181
Address phase......Page 182
Data phase......Page 183
Bus system arbitration......Page 184
Interrupt routing......Page 185
BIST, header, latency, CLS......Page 186
Mathematical modeling......Page 297
Cache coherence......Page 189
Multithreading......Page 190
Types and architectures......Page 191
Homogeneous and heterogeneous multicore processors......Page 192
Cell processor......Page 194
The synergistic processing element (SPE)......Page 195
Intel and AMD multicore architectures......Page 196
Core microarchitecture......Page 199
Cache memories......Page 200
Cooperative caching technique......Page 202
Typical transaction on the SBF......Page 203
Elements of the shared bus fabric......Page 204
Crossbar interconnection system......Page 205
Network-on-chip for multicore processors......Page 206
Software implementation......Page 208
Inter-core communication......Page 210
Interrupt control......Page 211
Scheduling I/O resources......Page 212
Multicore programming compilers......Page 213
Multicore communication API......Page 214
Hyper-Threading Technology......Page 216
Further Reading......Page 217
CHAPTER 6 -
Programmable-logic and application-specific integrated circuits (PLASIC)......Page 219
Kernel......Page 220
Basic input/output system (BIOS)......Page 722
Classification of signals......Page 221
Dynamic memory allocation......Page 222
Minimizing interrupt response time......Page 605
Standard-cell design......Page 223
Gate-array design......Page 224
CSMA/CD protocol......Page 366
The ASIC design flows......Page 225
Preemptive multitasking......Page 228
Iterative identification......Page 230
Combinatorial logic module......Page 232
SCSI (small computer system interface) ports......Page 236
The functional model......Page 237
Antifuse programming technology......Page 238
Programmable-logic devices (PLD)......Page 240
User-programming switch technologies......Page 241
ASIC packaging technologies......Page 242
DIAGNOSIS ROUTINES......Page 576
Programmable peripheral I/O ports......Page 245
Programmable interrupt controller chipset......Page 247
HDLC controller......Page 585
Direct memory access controller chipset......Page 252
Active cycle......Page 254
Further Reading......Page 256
PLC components and architectures......Page 259
Task scheduling and synchronization......Page 260
Multiplexing transmission modes......Page 556
Extension lines......Page 262
Timers and counters......Page 263
System address......Page 264
I/O addresses......Page 265
Image table addresses......Page 266
Designs of human-machine interactions......Page 531
I/O bus......Page 267
Programming......Page 270
Ladder diagram instructions......Page 272
Compact......Page 273
CNC software......Page 278
Machine control unit......Page 279
CNC control mechanism......Page 280
CNC coordinate system......Page 281
SINGLE-PROCESSOR BOOT SEQUENCES......Page 475
Cutter radius compensation......Page 285
Programming methodologies......Page 287
CNC part programming languages......Page 291
Logical inference......Page 292
Random-number generators......Page 293
Defuzzification......Page 294
Interrupt handlers......Page 295
Fuzzy control modeling......Page 296
Network bridging algorithms......Page 448
Fuzzy three-term (PID-like) controllers......Page 299
A case study of fuzzy industrial controls......Page 301
The direct fuzzy controller......Page 302
Supervisory fuzzy controller......Page 303
Further Reading......Page 305
PID control mechanism......Page 307
PID controller implementation......Page 308
Proportional control......Page 310
Active hubs......Page 363
Combined PID control......Page 311
PID controller tuning rules......Page 312
PCI (peripheral component interconnect) bus......Page 313
PID controller software design......Page 314
BPC (BATCH PROCESS CONTROL) CONTROLLERS......Page 317
ANSI/ISA-88......Page 319
ANSI/ISA-95......Page 320
Batch control systems......Page 321
Data collection......Page 774
Managing batch processes......Page 323
Batch data handler......Page 324
User-machine interfaces in local control systems......Page 534
PCI-ISA bridges......Page 325
Batch control center and batch planning......Page 326
Hierarchical and plant-unit neutral recipes......Page 327
SMC (SERVO MOTION CONTROL) CONTROLLERS......Page 329
Servo control systems......Page 330
Typical human-machine interface software system architecture......Page 371
Motor......Page 332
PCI-PCI bridge numbering: step 1 (the Linux approach)......Page 333
Network communication requirements......Page 337
Device install and configure routines......Page 338
Servo motors......Page 339
DC motors......Page 341
Resolvers......Page 342
Further Reading......Page 343
CHAPTER 9 -
Industrial computers......Page 345
Industrial single-board computers......Page 349
Master boot record (MBR)......Page 352
Interface models......Page 525
Industrial computer configurations......Page 354
INDUSTRIAL COMPUTER PERIPHERALS AND ACCESSORIES......Page 356
Further Reading......Page 359
Introduction......Page 360
CAN systems......Page 361
Power supplies and repeaters......Page 364
Message-based communication......Page 368
Routable (routed) and non-routable (non-routed) protocols......Page 373
Industrial simulation software......Page 374
Field data interface devices......Page 375
The second-generation of network operating system: control plane modularity......Page 692
Network routing processes......Page 376
Contention communication model (peer-to-peer)......Page 377
Field instrumentation......Page 378
SCADA software and firmware......Page 379
DNP3 protocols......Page 380
System topology......Page 383
Addressing......Page 384
UCA protocols......Page 385
STEP 1: regular vulnerability assessments......Page 386
SCADA system reliability......Page 387
Calibration methods......Page 388
QoS (quality of service) and redundancy......Page 389
Industrial Ethernet hardware......Page 390
Link master......Page 503
IGMP snooping......Page 392
Memory access control......Page 648
Linkages......Page 505
Industrial Ethernet network communication......Page 393
Profinet......Page 394
Power over Ethernet......Page 395
Industrial Ethernet network redundancy......Page 397
INDUSTRIAL ENTERPRISE NETWORKS......Page 399
User-defined datatypes......Page 716
Industrial enterprise networking example: Texas Instruments......Page 401
LAN architectures......Page 402
Star......Page 404
Routers......Page 405
LAN protocols......Page 406
LAN media-access methods......Page 408
Virtual local area network (VLAN)......Page 409
Service-based VLANs......Page 410
Port-based VLAN configuration (layer 1, physical layer oriented)......Page 412
Implementing VLAN......Page 413
VLAN standards......Page 415
Wireless local area network (WLAN)......Page 416
Wireless router......Page 417
Wireless networking operational modes......Page 418
Direct sequence spread spectrum (DSSS)......Page 419
Frequency roaming for wireless networking......Page 420
Frequency interference in wireless networking......Page 421
Wireless networking industrial solutions......Page 422
Further Reading......Page 423
Overview......Page 427
USB hubs......Page 430
Round-robin (RR) scheduling......Page 431
Overview......Page 432
Control phase......Page 435
Basic router configuration......Page 440
Protocols and algorithms for network routing......Page 441
Routing tables......Page 442
Routing protocols......Page 443
Open Shortest Path First (OSPF)
......Page 444
Border Gateway Protocol (BGP)......Page 445
The distance-vector routing approach......Page 446
Network bridges......Page 447
Simple prioritized interrupt handler......Page 449
Network gateways......Page 451
Enable and disable interrupts......Page 636
Data tunneling......Page 452
Protocol gateways......Page 453
Security gateways......Page 454
Specifications and configurations of network gateways......Page 455
Industrial network repeaters......Page 456
Serial interface repeaters......Page 457
Specifications and configurations of network repeaters......Page 458
Further Reading......Page 459
CHAPTER 12 -
Field interfaces......Page 460
HUMAN-MACHINE INTERACTIONS......Page 461
AS-Interface safety at work......Page 463
AS-Interface architecture: type 2......Page 464
AS interface slaves......Page 465
Principles and mechanisms......Page 466
Master-slave principle......Page 467
NUMA and NORMA memory management......Page 468
Information and data structure......Page 469
The operating phases......Page 470
Interface functions......Page 471
Systems and environments......Page 472
User-machine interface software......Page 539
Connectivity......Page 474
Device drivers......Page 624
HART communication protocol......Page 479
Wired HART networks......Page 482
Memory-mapped read and write......Page 484
Fault location by structural analysis......Page 485
Demodulator for receiving data......Page 487
Bus for split-range operation......Page 488
Fieldbus systems......Page 490
Foundation Fieldbus......Page 491
Profibus......Page 497
ControlNet......Page 498
PVM system......Page 704
Fieldbus networks and protocols......Page 499
The application layer......Page 500
Foundation Fieldbus......Page 501
Foundation Fieldbus H1......Page 502
UNIX semantics......Page 712
Blocks......Page 504
Foundation Fieldbus HSE......Page 506
Layered communications model......Page 507
Profibus Fieldbus......Page 508
Message-passing interface (MPI)......Page 509
Physical layer......Page 510
Network topology......Page 511
Data-link layer......Page 512
Profibus device management......Page 513
Generic station description (GSD)......Page 514
Function block model......Page 515
Further Reading......Page 519
CHAPTER 14 -
Data transmission interfaces......Page 549
Models for human-machine interactions......Page 520
Model behaviors......Page 522
Determinism and high-speed message passing......Page 604
User factors: task, knowledge, and ability......Page 524
Functional models......Page 526
Stuck-at fault testing......Page 529
Design process......Page 532
USER-MACHINE INTERFACES......Page 533
IDE (integrated drive electronics) ports......Page 568
Industrial control pendants......Page 536
Typical human-machine interface software library modules......Page 540
Further Reading......Page 547
DATA TRANSMISSION BASICS......Page 550
Electric and electromagnetic signal transmission modes......Page 555
Mechanistic models......Page 768
I/O buses......Page 557
PCI bus configurations......Page 558
PCI bus interrupts......Page 559
ISA (industry standard architecture) bus......Page 560
USB (universal serial bus) bus......Page 562
Attachment of USB devices......Page 563
Firewire or IEEE-1394 Bus......Page 564
IEEE-488 bus......Page 565
AGP (accelerated graphics port) port......Page 566
RS-232......Page 573
RS-422......Page 574
RS-499 and RS-530......Page 575
Universal synchronous/asynchronous receiver-transmitter (USART)......Page 578
USART asynchronous mode......Page 580
Device driver content......Page 581
USART synchronous master reception......Page 582
SDLC controller......Page 583
BIOS......Page 591
Boot program......Page 594
Initiate hardware components......Page 596
Microprocessors in multiprocessor systems......Page 598
Boot sequence of a multiprocessor system......Page 600
Real-time operating systems for single-microprocessor platforms......Page 607
Scheduling algorithms......Page 608
Cooperative multitasking......Page 610
Task types......Page 611
Task stack and heap......Page 612
Full-replication algorithm......Page 613
Task states......Page 614
Task creation and termination......Page 615
Task queue......Page 616
Task context switch......Page 617
Task scheduler of common operating systems......Page 619
The task scheduler of real-time operating systems......Page 620
Task threads......Page 622
PCI BIOS functions......Page 626
Interrupt-driven I/O......Page 627
Interrupt overview......Page 628
Vectored interrupts......Page 629
Interrupt latency......Page 630
Network protocol simulation software......Page 789
Non-nested interrupt handler......Page 631
Nested interrupt handler......Page 632
Re-entrant nested interrupt handler......Page 634
Prioritized interrupt handler......Page 635
Self-calibration......Page 755
Interrupt service routines......Page 639
MEMORY MANAGEMENT......Page 640
Paging......Page 641
Swapping......Page 642
Segmentation......Page 644
Static memory allocation......Page 645
Paging......Page 646
Dual-mode operation......Page 647
Event notification service......Page 649
Event triggers and broadcasts......Page 650
Message passing......Page 651
Access......Page 652
Message queue types......Page 653
Pipes......Page 654
SEMAPHORES......Page 657
Semaphore depth and priority......Page 658
Creating a semaphore......Page 659
Signaling......Page 660
Mutex......Page 661
Multiplex......Page 662
TIMER......Page 663
Kernel timers......Page 664
Working mechanism......Page 665
Timeout interval......Page 666
Self-test......Page 668
Task timers......Page 669
Timer creation and expiration......Page 670
Further Reading......Page 671
CHAPTER 17 -
Distributed operating systems......Page 673
Shared-memory multiprocessors......Page 674
Heavyweight processes to lightweight processes......Page 678
Dynamic partitioning......Page 680
Intelligent modeling methods......Page 771
Hand-off scheduling......Page 681
Some remarks......Page 682
PCI address spaces......Page 734
Migration algorithm......Page 683
Process control......Page 684
Barrier locks......Page 685
Event brokers......Page 686
Interprocess communications......Page 687
MULTICOMPUTER OPERATING SYSTEMS......Page 688
Generic kernel design......Page 693
Parallel operating systems......Page 696
Parallel operating facilities......Page 698
Coupling and transparency......Page 699
Device component test routines......Page 700
Implementation......Page 701
Algorithms......Page 702
Dynamic process group in PVM with UNIX......Page 706
Remote procedure call (RPC)......Page 707
External data representation (XDR)......Page 709
Using RPC......Page 710
Distributed file systems (DFS)......Page 711
Remote service......Page 713
Parallel file system......Page 714
Process group......Page 715
Point-to-point communication......Page 717
Global computation routines......Page 718
Further Reading......Page 719
SELF-TEST ROUTINES......Page 721
System booting self-test routines......Page 723
System shutdown self-test routines......Page 724
Embedded processors in SoC architecture......Page 726
Hardware-based embedded processor self-test......Page 728
Software-based embedded processor self-test......Page 731
Delay fault testing......Page 732
PCI configuration headers......Page 735
PCI I/O and PCI memory addresses......Page 736
PCI-PCI bridges......Page 737
PCI-PCI bridges: configuration cycles and bus numbering......Page 738
PCI-PCI bridge numbering: step 3 (the Linux approach)......Page 740
PCI-PCI bridge numbering: step 4 (the Linux approach)......Page 741
PCI firmware......Page 742
Combinational fault diagnosis method......Page 746
Fault database: fault table and fault dictionary......Page 747
Fault location by edge-pin testing......Page 748
Generating tests to distinguish faults......Page 749
Guided-probe testing......Page 750
Fault detectors and fault recorders......Page 751
Fiber-optic fault locators......Page 752
System NVM read and write routines......Page 753
Fault/error log routines......Page 754
Accuracy......Page 758
Temperature calibrations......Page 759
Pressure calibrations
......Page 760
Position calibrations......Page 761
Scale calibrations......Page 762
Further Reading......Page 764
CHAPTER 19 -
Industrial control system simulation routines......Page 766
MODELING AND IDENTIFICATION......Page 767
Qualitative models......Page 769
Industrial system modeling......Page 770
Online adaptation......Page 772
Predefined adaptation......Page 773
Identification calculations......Page 775
Industrial process simulation......Page 776
Qualities, test, and evaluation......Page 777
Industrial system simulation......Page 778
Global synchronization and node tasking......Page 779
Communication models......Page 780
Industrial control simulation......Page 781
Physical-model-based control......Page 783
Events......Page 786
Continuous simulation software......Page 787
Network simulators......Page 788
Computer-based circuit layout editor......Page 790
SIMULINK......Page 791
ModelSim......Page 793
Further Reading......Page 794
A......Page 796
B......Page 797
C......Page 798
D......Page 801
E......Page 803
F......Page 804
G......Page 806
I......Page 807
L......Page 810
M......Page 811
N......Page 815
P......Page 816
R......Page 819
S......Page 821
T......Page 825
V......Page 826
Z......Page 827