Factory AutomationOverview

22

Objectives

• Understand National’s Factory Automation Campaign

• Review National products that are used in Factory Automation

• Gain better understanding of the solution needs in Factory Automation and how National’s solutions and products support those application needs

33

Overview

• Market

– Factory Automation Market > $1B total analog content. (IMS)

– 16 largest suppliers address < 50% of segment sales (IMS).

• Key trends:

– Drive to more energy efficient systems

– Expanding competitive situation world wide is driving need for increase productivity, quality and throughput (need better / finer control)

– Increased diagnostics to reduce maintenance and down time

– Increase adoption of wireless for non critical applications (802.15.4: Hart, Zigbee, WISA,)

44

Factory Automation Market

Major Industry Segments:

• Manufacturing

– Pharmaceutical Manufacturing

– Consumables Manufacturing

– Automotive Manufacturing

– Material Handling

• Process

– Refining

– Chemical

– Food & Beverage

– Pulp and Paper

Nationals Focus Areas

• DCS (Distributed Control Systems)

• PLCs (programmable controller and I/O modules)

• CNC (computer numerical control)

• Embedded computer board

• Sensors / Measurement Equipment

• Motor control

• Motion control

• Machine vision

55

IndustrialFactory Automation Overview

Module: I/O Module

8/20/09

Module:Control Networks

7/9/09Module: Motor Control

Sensing 7/23/09

Module: Machine Vision

TBD

Module: Sensing 6/25/09

Automation Control Networks in Factory Automation

77

Control NetworkTrends and Challenges

• What is the challenge?– More products at a faster rate and

with higher quality

• Trend to use Ethernet based control network – Replaces RS-485 or proprietary bus

• Trend to synchronize devices on a factory network

• Synchronization provides– High speed sort and diverter

– Motion position and velocity control for coordinated drives and robotics

88

Automation Control Network Example

• System sorts defective parts off of a conveyor belt

• Network uses fieldbus protocols on a 10/100 Ethernet network with IEEE 1588 time synchronization support

HMI

Distributed I/O

Ethernet Switch

Motion Controller

Drive Controller Motion Controller

Good product

Bad productIndustrial Camera

Pick and place

MS

S S S

GPS Time

99

PHYTER® Family of Industrial Ethernet Single / Dual Port 10/100 Ethernet PHY

Basic Application Requirements

Key Features Supported in the Product Family

Family Speed

interface

Temp Support IEEE1588

Single Port

10/100

MII/RMII

Commercial

Industrial

Extreme

NO

• Commercial, Industrial, and Extreme Temp Support

• Low Latency

• JTAG Support

•Auto-MDIX

Dual Port (2) 10/100

(2) MII/RMII

Commercial

Industrial

NO

• Flexible Port Management

•JTAG Support

•Cable Health Diagnostics

•Fiber Support

IEEE 1588 10/100

MII/RMII

Industrial YES

•Time Sync up to 3.5 ns on single link

• High Precision Packet Timestamping

•Cable Health Diagnostics

•Fiber Support

Sensing Solutions in

Factory Automation

1111

Trends

• Expanding competitive situation world wide is driving need for increase need for better / finer control– Increased measurement / sensing nodes

– Move to higher performance “Smarter” transducers

• Portable applications are growing, driving the need for lower power more energy efficient sensors and measurement systems

• Increased need in system diagnostics to reduce maintenance driving the need for more process measurement

1212

Challenges / Solutions

• Solutions must cover a wide range of sensing parameters– National’s Op Amp / ADC solutions address complete classes of

applications (e.g. virtually all pressure sensor MEMS applications)

– Pin and function compatible product families allow customers to standardize board layouts

• Growth in portable applications is driving the need for lower energy consumption solutions– National has some of the lowest power Op Amps and ADC in the

market. All ADCs have a very efficient power down feature.

• Customer has limited design resources to determine a solution and validate their design– Webench Sensor Designer® generates signal path solutions

based on a sensor’s specifications and parameters

1313

Focus Areas

• Sensors Interface Solutions– 4-20mA– Voltage output– Signal path (SPI, I2C)

• Key Sensing Areas– Pressure– Temperature (Thermocouple, RTD)– Optical– Chemical– pH

1414

Sensing Solutions in Factory Automation example:Pressure

Product Selection• LMP7715/7716 and ADC121S021

for the signal path is a good starting point . LMP7702 is good for the cc drive

– Supports most popular performance ranges

• Alternatives• ADC based choice based on signal

path performance– 8 bit ADC is ±0.4%

– 10 bit ADC is ±0.10%

– 12 bit ADC is ±0.024%

• Opamps can be chosen to optimize signal path for a variety of applications

– Higher Bandwidth

– Low Noise

– Low Input Offset Voltage

– Low Power

Voltage Drive Current Drive

or

1515

Recommended Products

Recommended Opamps

Recommended ADCs

Base PartResolution

(bits) ChannelsSample Rate Range (Ksps)

Signal Accuracy

INL (LSB) [MAX]

ENOB (bits) [Min] Interface

ADC121S021 12 1 50 to 200 ±0.024% ± 1.0 11.3 SPIADC101S021 10 1 50 to 200 ±0.1% ± 0.7 9.8 SPIADC081S021 8 1 50 to 200 ±0.4% ± 0.3 7.8 SPIADC121C021/27 12 1 5.5 to 189 ±0.024% ± 1.0 11.3 I2CADC101C021/27 10 1 5.5 to 189 ±0.1% ± 0.7 9.9 I2CADC081C021/27 8 1 5.5 to 189 ±0.4% ± 0.25 7.8 I2C

Base Part Channels

Gain Bandwidth (MHz)

Voltage Noise (nV/root(Hz))

Max Input Bias Current (nA) TcVos (uV/˚C)

CMRR (dB)

Supply Voltage

LMP7715/16 1/2 17 5.8 0.1 1 100 1.8 to 5VLMP2011/12 1/2 3 35 0.005 0.015 130 2.7 to 5VLMP2021/22 1/2 5 11 0.025 0.004 139 2.2 to 5.5VLMP7701/2/4 1/2/4 2.5 9 0.05 1 130 2.7 to 12V

LMP2231 1 0.13 60 0.001 0.3 97 1.6 to 5.5V

Machine Vision inFactory Automation

1717

Machine VisionTrends and Challenges

• What is the challenge?– Inspect products at higher speeds

and with more detail

• Trend to use high resolution and fine resolution image systems

• Trend to support high bandwidth cameras using SerDes devices

• SerDes devices provide– Support for higher bandwidth image

transfer without software support– Smaller cables for improved

robustness– Small form-factor to support nano-

head camera form factor

1818

Machine Vision Imaging Example

Sensing Unit

Display

Control

Processing Unit

Storage

Sensor

LNA AFE

Ser/Des

Control Path

Data Path

FPGASer/Des

Key Requirements : High resolution, Multi-lane, Longer reach

FPGA

Control Network

1919

Industrial Imaging Interface Portfolio : Plug-and-Go! Devices

Basic Application Requirement

Other System RequirementsFamily Data Throughput

Max Cable Reach*

Data Type

FPGA-Link

1.25 to 3.125 Gbps

40m of CAT-6 @ 1.25 Gbps

20m of CAT-6 @ 3.125 Gbps

ANY • Redundancy & Daisy chaining

• FPGA friendly, LVDS parallel interface

• Low system BOM, design time

FPD-Link 2

120 to 2700 Mbps

4m to 8m of CAT-6 @ 2 Gbps

ANY • 10/16/18/24/32 bit data interface

• Lock to random data, low EMI

• FPGA/ASIC as logic interconnect

Channel Link

(Camera-Link)

500 to 5000 Mbps

4m to 8m of MDR cable at 2.5 Gbps

ANY • 21/28/48 wide bus interface

* Cable length is for reference only, various system conditions impact the maximum reach

Data Data Data Data DataPlug and Go! = Seamless Video

Data Header Data Header Data8b/10b Headers =

Interruptions in Data

Motor Control Sensing in Factory Automation

2121

Trends, Challenges / Solutions

Trends• Increasing energy costs driving the need to reduce energy

consumption on the factory floor– Instrumentation of motors to improve energy efficiency (Motors

are one of the largest energy consumers on the factory floor)

• Drive to lower cost AC/Servo motor control sensing solutions – Hall effect + SAR ADC versus optically isolated ΣΔ ADCs

Challenges / Solutions• Need for high performance, high value AC/ Servo Motor solutions

– National’s Simul. Sampling ADCs + Hall Effect sensors address the most popular “High Side” AC Motor sensing applications

– National’s Simul. Sampling ADCs are in very small packages with sample rates up to 1Msps ideal for encoder applications

2222

Focus Areas

• Why is Motor Control Sensing Important

• AC Motors Sensing Interface

• Servo Motors Sensing Interface

• Low Side Sensing

• High Speed Motor Synchronization

2323

Motor Control Sensing Example:Servo Motor Control Sensing

Power

ACMotor

CurrentSense

ADC

ADC122SXXX

ADC

I nverter

Controller

Rectifier

HV isolation barrier

Ethernet

LM4132 / LM4128

Ref

DP83640/848I/849I

ADC122SXXX

AD

C

AD

C

Encoder / Resolver

AMP AMPLMP7702

LM4132 / LM4128

Ref

ADCADC

ADC161S626

AMP

LM4132 / LM4128

Ref

LMP7731

LM73

Temp Sensor

Isolation barrier

LM4132 / LM4128

Ref

ADC121S021ADC121S625

AD

C

Power

ACMotor

CurrentSense

ADC

ADC122SXXX

ADC

I nverter

Controller

Rectifier

HV isolation barrier

Ethernet

LM4132 / LM4128

Ref

DP83640/848I/849I

ADC122SXXX

AD

C

AD

C

Encoder / Resolver

AMP AMPLMP7702

LM4132 / LM4128

Ref

ADCADC

ADC161S626

AMP

LM4132 / LM4128

Ref

LMP7731

LM73

Temp Sensor

Isolation barrier

LM4132 / LM4128

Ref

ADC121S021ADC121S625

AD

C

Power

ACMotor

CurrentSense

ADC

ADC122SXXX

ADC

I nverter

Controller

Rectifier

HV isolation barrier

Ethernet

LM4132 / LM4128

Ref

DP83640/848I/849I

ADC122SXXX

AD

C

AD

C

Encoder / Resolver

AMP AMPLMP7702

LM4132 / LM4128

Ref

ADCADC

ADC161S626

AMP

LM4132 / LM4128

Ref

LMP7731

LM73

Temp Sensor

Power

ACMotor

ACMotor

CurrentSense

ADC

ADC122SXXX

ADC

CurrentSense

ADCADC

ADC122SXXX

ADC

I nverter

Controller

Rectifier

HV isolation barrier

Ethernet

I nverterInverter

ControllerController

RectifierRectifier

HV isolation barrier

EthernetEthernet

LM4132 / LM4128

Ref

LM4132 / LM4128

Ref

DP83640/848I/849I

ADC122SXXX

AD

C

AD

C

Encoder / Resolver

AMP AMPLMP7702

LM4132 / LM4128

Ref

ADC122SXXX

AD

C

AD

C

AD

CA

DC

AD

CA

DC

Encoder / Resolver

AMP AMPLMP7702

Encoder / Resolver

AMP AMPLMP7702 AMP AMPLMP7702 AMP AMPLMP7702

LM4132 / LM4128

RefLM4132 / LM4128

Ref

ADCADC

ADC161S626

AMP

LM4132 / LM4128

Ref

LMP7731

ADCADC

ADC161S626

AMPADC

ADCADC

ADC161S626

AMP

LM4132 / LM4128

Ref

LM4132 / LM4128

Ref

LMP7731

LM73

Temp Sensor

LM73

Temp Sensor

Isolation barrier

LM4132 / LM4128

Ref

ADC121S021ADC121S625

AD

C

LM4132 / LM4128

RefLM4132 / LM4128

Ref

ADC121S021ADC121S625

AD

CA

DC

• Servo drives are AC drives with the addition of an encoder or resolver to provide finer control.

• Encoders provide better performance than resolvers, however a resolver can be used over a wider temperature range and can tolerate higher shock and vibration.

• The encoder may provide voltage output directly to an ADC or there may be an Op Amp in front of the ADC

2424

Product Initial AccuracyReference Voltage (V)

Tempco (ppm/°C)

Output Current (mA)

Input Voltage

LM4128 ±0.1, ±0.2, ±0.5 3, 3.3, 4.096 75, 100 20 2 to 5.5LM4132 ±0.1, ±0.2, ±0.4, ±0.5 2.048, 4.096 1, 10, 20, 30 20 2.2 to 5.5LM4140 ±0.1 1.25, 4.096 3, 6, 10 8 1.8 to 4.366

Recommended Products

References

Op AmpsProduct Channels Vs (V) Is (mA)

GBW (MHz)

Vos max (mV)

Output Drive (mA) RR Packaging

LMP2015/16 1/2 2.7 to 5 1.2 3 ±0.005 8 RRO SOT/SOIC/MSOPLMP7701/02/04 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOPLMP7707/08/09 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP

LMP8601 1/2/4 3 to 5.5 1.1 0.06 ±1 42 RRIO SOIC NARROWLMV841/2/4 1/2/4 2.7 to 12 1.02 4.5 ±0.5 30 RRIO SC70/SOIC

LMV712 2 2.7 to 5 1.22 5 ±3 35 RRIO LLP-10, MSOP-10

Simultaneous Sampling Differential ADCs

Product Resolution channelsSample Rate

(kSPS) INL ENOBTemperature

Range Packaging

ADC122S625 12 2 50 to 200 ±1.0 LSB 11.25 Bits -40 to 105°C MSOP-10ADC122S655 12 2 200 to 500 ±1.0 LSB 11.25 Bits -40 to 105°C MSOP-10ADC122S706 12 2 500 to 1000 ±1.0 LSB 11.25 Bits -40 to 105°C TSSOP-14

Data Acquisition in Factory Automation

2626

Trends, Challenges / Solutions

Trends• Expanding competitive situation world wide is driving need for

increase need for better / finer control

– Increase in distributed control

• Increased need in system diagnostics to reduce maintenance and production costs

Challenges / Solutions• Solutions need to cover a wide range of IO module parameters,

features and specifications

– National’s Op Amp / ADC solutions provide both integrated and discrete solutions to allow customers to develop a solution that meets their specific needs

2727

Focus Areas

• IO Module (Input)

• IO Module (Output)

• Data Acquisition - Single Channel

• Data Acquisition - Multi-Channel

2828

Data Acquisition in Factory Automation Example:Data Acquisition

• Single channel and multi-channel data acquisition

MicrocontrollerLM35

Thermocouple

+V

RG1 RF 1

-

+

Metal A

Metal B

CF2

CF1

RG2

RF2

A3

ReferenceJunction

ADC

BridgeSensor

VREF

DIFF _Av=(1+2RF/RG)

CM _Av =1

+

-

AMP

+

-A2

RF

RG

+V

+IN

-IN

R F

+VOUT

-VOUT

VREF

+V

SPI Port

VREF

16 bit Diff ADC

AMP

4-20mACurrent Loop 10

RR

470 pF

180

100nF

A2 = LMP8601

+V

AMP

LM34

AMP

2929

Recommended Products

Op AmpsProduct Channels Vs (V) Is (mA)

GBW (MHz)

Vos max (mV)

Output Drive (mA) RR Packaging

LMP2015/16 1/2 2.7 to 5 1.2 3 ±0.005 8 RRO SOT/SOIC/MSOPLMP7701/02/04 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOPLMP7707/08/09 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP

LMP8601 1/2/4 3 to 5.5 1.1 0.06 ±1 42 RRIO SOIC NARROWLMV841/2/4 1/2/4 2.7 to 12 1.02 4.5 ±0.5 30 RRIO SC70/SOIC

LMV712 2 2.7 to 5 1.22 5 ±3 35 RRIO LLP-10, MSOP-10

Single Ended Input ADCs

Product Vs (V) Res (bits/˚C)Conversion/Startu

pTime (ms) Interface Package

LM73 2.7 to 5.5 ±1.0˚C 10.1 to 80.8 SMBus/I2C TSOTLM94022 1.5 to 5.5 ±1.5˚C 0.8 Analog SC70

Temperature

Product Resolution Channels

Sample Rate

(kSPS) INL ENOBTemperature

Range Packaging

ADC121S021 12 1 50 to 200 ±1.0 LSB 11.7 Bits -40 to 85°C SOT23-6ADC124S051 12 4 200 to 500 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10ADC128S052 12 8 200 to 500 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10ADC128S102 12 8 500 to 1000 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10

3030

Product Resolution ChannelsSettling time

(µsec)Temperature

Range Packaging

DAC121C081/85 12 1 8.5 -40 to 125°C SOT, LLP, MSOPDAC121S101 12 1 10 -40 to 105°C SOT, MSOPDAC122S085 12 2 8.5 -40 to 105°C MSOP, LLPDAC124S085 12 4 8.5 -40 to 105°C MSOP, LLPDAC128S085 12 8 8.5 -40 to 125°C TSSOP, LLP

Product Initial AccuracyReference Voltage (V)

Tempco (ppm/°C)

Output Current (mA)

Input Voltage

LM4128 ±0.1, ±0.2, ±0.5 3, 3.3, 4.096 75, 100 20 2 to 5.5LM4132 ±0.1, ±0.2, ±0.4, ±0.5 2.048, 4.096 1, 10, 20, 30 20 2.2 to 5.5LM4140 ±0.1 1.25, 4.096 3, 6, 10 8 1.8 to 4.366

Recommended Products

References

Differential Input ADCs

DACS

Product Resolution Channels Sample Rate INL ENOBTemperature

Range Packaging

ADC121S625 12 1 50 to 200kSPS +0.6, -0.3 LSB 11.7 Bits -40 to 85°C MSOP-8ADC121S655 12 1 200 to 500kSPS ±0.95 LSB 11.25 Bits -40 to 85°C MSOP-8ADC121S705 12 1 500Ksps to 1Msps ±0.95 LSB 11.25 Bits -40 to 105°C MSOP-8ADC141S626 14 1 50 to 250kSPS ±0.95 LSB 13.7 Bits -40 to 105°C MSOP-10ADC161S626 16 1 50 to 250kSPS ±2.0 LSB 14.5 Bits -40 to 85°C MSOP-10

3131

Summary

• National’s product line supports a wide range of Factory Automation applications

• Webinars on Control Networks, Sensing, Motor Control, Machine Vision and I/O modules will be available as part of the Industrial Campaign

• Webinars provide solutions for sensing, I/O controls, motion controllers, automation control networks and machine vision applications.

• Does the material provided address your application concerns? If not let us know.

3232

Factory Automation Webinars

• Sensing Solutions in Factory Automation 6/24/09

• Control Networks 7/9/09

• Motor Control Sensing 7/23/09

• I/O Module 8/20/09

• Machine Vision TBD

3333

For Additional Information

• Released webinars in this series can be viewed at: • Powerwise® Design University

– http://www.national.com/analog/training

• Factory Automation signal path solutions can be found on Nationals technical and application support web sites

• SIGNAL PATH Solutions– http://www.national.com/signalpath

• SIGNAL PATH Designer– http://www.national.com/analog/signalpath/designer

• Technology Edge– http://www.national.com/analog/nationaledge

• Webench Sensor Designer® Tools– http://www.national.com/analog/webench/sensor