Instrumentation & Measurements Lab-1

Engr. Usman Mushtaq

Department of Electrical Engineering University of Lahore, Lahore Room No. NE 124 (1st Floor) Email: usman.mushtaq@ee.uol.edu.pk

Rules and Regulation

Everyone should be in lab at 11:00 am Lab_Report/Assignment should be submitted by due date (No plagiarism) 10-15 min, Lab quiz at the start of lab Grading: Lab_Reports+Assignments+Quizes = 12% Final Exam = 8%

Introduction to Controller Hardware

Microcontroller FPLD PLC DCS

Microcontroller
An integrated electronic computing device that includes three major components on a single chip
Microprocessor (MPU) Memory I/O (Input/Output) ports

Microcontroller
Microcontrollers are 'single chip' computers specifically designed to:
Read input devices, such as buttons and sensors Process data or information Control output devices, such as lights, displays, motors and speakers

Microprocessor vs. Microcontroller

A microprocessor is the brain of a computer system Generally referred to as the central processing unit (CPU), the microprocessor by itself is practically useless To be useful, one must have means of communicating with it using input and output devices One must also add memory (ROM and RAM) so that the system can be programmed.

Microprocessor vs. Microcontroller

A microcontroller is a computer chip designed for control-oriented applications Unlike ordinary microprocessors, microcontrollers have built-in features that make them operate almost independent of additional circuitry This is possible because microcontrollers contain things like
memory (ROM, EPROM, RAM, etc) input and output ports timers serial and parallel communication capability analog-to-digital converters

RISC vs CISC
RISC = Reduced Instruction Set Computer CISC = Complex Instruction Set Computer Microcontrollers = mostly RISC Microcomputer for PC = x86 is CISC Pipelining = easier in RISC

Applications
Embedded Inside:
Automotive systems Airplanes Toys Medical Devices Furniture

Billions of units

Examples: Refrigerator

Examples: Car Door

Examples: Autonomous Robot

Microcontroller Packaging and Appearance

From left to right: PIC 12F508, PIC 16F84A, PIC 16C72, Motorola 68HC05B16, PIC 16F877, Motorola 68000

Advantages
Design and Simulation: Reduces chances of Errors, while coding Flexibility: Easy to Reprogram using Flash, EEPROM and EPROM High Integration: I/O devices Cost Easy to Use

Microcontroller Manufacturers
Analog Devices Atmel Dallas Semiconductor Freescale Semiconductor Hitachi Semiconductor Intel Microchip National Semiconductor Renesas STMicro Texas Instruments Zilog

FPLDs
Before we move to FPLDs: Compare the Standard Logic Circuits and Programmable Logic Circuits

What are FPLDs??

Component function is defined by users program. Logic Cells Fields are interconnected by programming. Advantages:
Flexible design that changes by reprogramming, ease of design changes Reduce prototype-product time Large scale integration (over 100 000 gates) Reliability increased, low financial risk Smaller device, low start-up cost

FPLDs Representatives
PLA - Programmable Logic Arrays PAL - Programmable Array Logic

CPLD - Complex Programmable Logic Devices

FPGA - Field Programmable Gate Arrays

Why CPLDs???
For larger applications, we could simply increase the number of inputs and outputs in a conventional SPLD
e.g., 16V8 20V8 22V10 why not keep this trend going 32V16 128V64 ?

Problems:
n times the number of inputs and outputs requires n2 as much chip area too costly logic gets slower as number of inputs to AND array increases

Solution:
multiple PLDs with a relatively small (fast) programmable interconnect less general than a single large PLD, but we can use software to partition our design into smaller PLD blocks

How to make CPLDs???

To create a CPLD device:
put a lot of Simple PLDs on the same chip add wires between them whose connections can be programmed (interconnect) use fuse/EEPROM technology for the connections

Examples of CPLDs

Programming Complex PLDs

Some CPLDs are programmed using a PAL programmer
this method becomes inconvenient for devices with hundreds of pins

A second method of programming

solder the device to its printed circuit board program it with a serial data stream from a personal computer the CPLD decodes the data stream and configures itself to perform a specified logic function

Structure of a CPLD: A Closer Look

Who makes the CPLDs?

Manufacturer Altera Altmel Cypress Lattice Philips Vantis Xilinx CPLD Products MAX 5000, 7000 & 9000 ATF & ATV FLASH370, Ultra37000 ispLSI 1000 to 8000 XPLA MACH 1 to 5 XC9500

Field Programmable Gate Array

A Field-Programmable Gate Array (FPGA) is an integrated circuit that can be configured by the user to emulate any digital circuit as long as there are enough resources An FPGA can be seen as an array of Configurable Logic Blocks (CLBs) connected through programmable interconnect (Switch Boxes)

Xilinx Spartan-3E
Hardware: Xilinx Spartan-3E Software: Xilinx ISE
FPGA
LEDs

switches

FPGA Structure

CLB

SB

CLB

SB

SB

SB

Configurable Logic Blocks CLB SB CLB Interconnection Network

I/O Signals (Pins)

Simplified CLB Structure

Look-Up Table (LUT)

MUX

SET

CLR

FPGA Families

Comparing CPLDs to FPGAs:

CPLD devices are faster, cheaper and have fewer gates than FPGAs Meant for interfacing rather than heavy computation Include built-in flash memory
FPGAs need external memory

PLC
A Programmable controller is a solid state user programmable control system with functions to control logic, sequencing, timing, arithmetic data manipulation and counting capabilities. It can be viewed as an industrial computer that has a central processor unit, memory, input output interface and a programming device. It accepts data, status information from various sensing devices like limit switches, proximity switches, executes the user control program store in the memory and gives appropriate output commands to devices like solenoid valves, switches etc.

PLC Architecture
PLCs contain three basic sections: Central processing unit (CPU). 2. Memory: EPROM, RAM, and so on. 3. Input/output section for communication with peripherals (ADC, DAC).

Manual relay panels-1960

PLC Internal Architecture

BENEFITS OF PROGRAMMABLE CONTROLLERS

As made up of solid state components, so provide high reliability. Flexibility/Expandability and easy installation is possible. Use of PLC results in appreciable savings in Hardware and wiring cost. They are compact and occupy less space. Eliminate hardware items like Timers, counters and Auxiliary relays. The presence for timers and counters has easy accessibility. PLC can control a variety of devices and eliminates the need for customized controls. Easy diagnostic facilities are provided as a part of the system. Diagnosis of the external systems also becomes very simple. Thus easy service/maintenance. Programming devices provide operator friendly interface with the machine. It has total protections against obsolescence and has wide scope for up gradation.

Applications of PLC
The batch processes in chemical, cement, food and paper industries which are sequential in nature, requiring time of event based decisions is controlled by PLCs. In large process plants PLCs are being increasingly used for automatic start up and shut down of critical equipment. A PLC ensures that equipment cannot be started unless all the permissive conditions for safe start have seen established. It also monitors the conditions necessary for safe running of the equipment and trips the equipment whenever any abnormality in the system is detected. The PLC can be programmed to function as an energy management system for boiler control for maximum efficiency and safety. In automation of blender reclaimers In automation of bulk material handling system at ports. In automation for a ship unloader. Automation for wagon loaders. For blast furnace charging controls in steel plants. In automation of brick moulding press in refractories. In automation for galvanizing unit. For chemical plants process control automation.

In automation of a rock phosphate drying and grinding system. Modernization of boiler and turbogenerator set. Process visualization for mining application. Criteria display system for power station. As stored programmed automation unit for the operation of diesel generator sets. In Dairy automation and food processing. For a highly modernized pulp paper factory. In automation system for the printing industry. In automation of container transfer crane. In automation of High-speed elevators. In plastic moulding process. In automation of machine tools and transfer lines. In Mixing operations and automation of packaging plants. In compressed air plants and gas handling plants. In fuel oil processing plants and water classification plants. To control the conveyor/classifying system.

DCS
DCS (Distributed Control System) is a computerized control system used to control the production line in the industry

DCS was introduced in 1975 by Honeywell (TDC2000) and Yokogawa (CENTUM) Other vendors: ABB (Bailey etc), Foxboro, Emerson (Fischer, Rosemount etc)

DCS Architecture