Meet your Presenter

Bandan Jot Singh

Applications Engineer, NI India

Case Study

Using NI-LabVIEW Real-time and PXI Technology To Automate Gauge-Control In

Cold Rolling Mills

• Alternate Control System Platforms

• Problem Statement

• Formulation of Closed-Loop Control System

• Implementation Using LabVIEW RealTime and NI Hardware

• Leverage Achieved Using NI Equipments

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Agenda

Control System Platforms• Various Control System Platforms Available

• PLC: Programmed in Ladder Logic (Operation Specific)

• DCS: Collection of various PLC’s and RTU’s (Dedicated Systems)

• Applications using frequently changing control logic may not be efficient on such platforms because development time is more.

• Multiple hardware synchronization not supported

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• Useful for ferrous and non-ferrous metal industries

• Applications that require Real-Time Monitoring

• Control Systems that require high-precision monitoring and a short response time

To develop a PXI based Gauge monitoring and control system using LabVIEW RT and National Instruments

Data-Acquisition Systems

Gauge-Control In Cold Rolling Mills

• Position

• InitialThickness

• Rotating Speed

• Pressure Applied

Inputs

Sensors Used

Closed Loop Control System

• Process: Hydraulic Pump (to control position)

Implementation through NI Controller running LabVIEW RealTime

Choosing the Right Modules for the PXI System

• NI PXI – 6040E• 500 kS/s (1-Channel), 250 kS/s (Multichannel), 12-Bit, 16-Analog-

Input Multifunction DAQ

• Assimilation of Thickness and Pressure Data

Module for Measuring Speed of the Metal Strip

• NI PXI – 6602 Counter card• 8-channel, 32-bit up/down counter/timer module

• 80 MHz maximum source frequency

• 3 simultaneous high-speed DMA Transfer Capability

Module to Control Servo Valves

• NI PXI – 6711• High-Speed Analog Output -- 12-Bit, 1 MS/s per Channel

• Digital triggering and external clocking

• 2 up/down counter/timers, 24-bit resolution

Final System Setup

Implementation of Control System Using LabVIEW Real-Time Development Environment

• The virtual instrument can be developed using PID Control Toolkit and then targeted to the PXI controller running on LabVIEW Real time.

• Specialized for Time-critical data acquisition and control applications

• Download to a dedicated target for increased reliability.

Benefits of Using LabVIEW RT and NI DAQ Equipments

• The benefits of using LabVIEW and NI DAQ equipments compared to the traditional instruments and PLC :

– The development time for putting the whole system came down by a factor of 1/6.

– Increased flexibility in redesigning the control mechanism as per the requirements of different materials fed to the system.

– Enhanced quality in output because of reduction in response times. In a typical PLC based system the control loop rate is 100 to 500 milliseconds but in NI PXI based system, this is reduced to 10 ms.

– The capability of all the hardware to synchronize on the PXI RTSI bus is an added advantage.

Questions?

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Thank you

For more information, please visit ni.com

or contact us at

080-41190000ni.india@ni.com

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