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
21.05.2015
Gobor-ILT 5-15002 2
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 2
Institute for Agricultural Engineeringand Animal Husbandry
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
21.05.2015
Gobor-ILT 5-15002 3
Institute for Agricultural Engineeringand Animal Husbandry
Design of the device – optimisation and development
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Subsystem for positioning
Subsystem for wire attaching
Intermediate storage of the wire
External hydraulic power supply unit
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 3
Institute for Agricultural Engineeringand Animal Husbandry
Design of the device – optimisation and development
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(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)
Institute for Agricultural Engineeringand Animal Husbandry
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
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 4
Institute for Agricultural Engineeringand Animal Husbandry
Software phase 1 (concept)
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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
Institute for Agricultural Engineeringand Animal Husbandry
Software for data acquisition - Front panel (HMI)
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Gobor-ILT 5-15002 8
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 5
Institute for Agricultural Engineeringand Animal Husbandry
Software - Front panel (measurement)
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Gobor-ILT 5-15002 9
Institute for Agricultural Engineeringand Animal Husbandry
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
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 6
Institute for Agricultural Engineeringand Animal Husbandry
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
Institute for Agricultural Engineeringand Animal Husbandry
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
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 7
Institute for Agricultural Engineeringand Animal Husbandry
Measurement results before optimisation–hydraulic parameters and PLC signals
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Gobor-ILT 5-15002 13
Institute for Agricultural Engineeringand Animal Husbandry
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
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 8
Institute for Agricultural Engineeringand Animal Husbandry
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
Institute for Agricultural Engineeringand Animal Husbandry
Measurement results after optimisation–hydraulic parameters and PLC signals
21.05.2015
Gobor-ILT 5-15002 16
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 9
Institute for Agricultural Engineeringand Animal Husbandry
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)
21.05.2015
Gobor-ILT 5-15002 17
Institute for Agricultural Engineeringand Animal Husbandry
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
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 10
Institute for Agricultural Engineeringand Animal Husbandry
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
Institute for Agricultural Engineeringand Animal Husbandry
Software HMI (concept)
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System diagnosticsProcess simulation
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 11
Institute for Agricultural Engineeringand Animal Husbandry
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)
Institute for Agricultural Engineeringand Animal Husbandry
Considerations 2: LabVIEW MathScript RT Module
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Source: http://www.ni.com/labview/mathscript/ (20.05.2015)
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 12
Institute for Agricultural Engineeringand Animal Husbandry
Software HMI (concept)
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Institute for Agricultural Engineeringand Animal Husbandry
Hardware: NI cRIO-9033
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Source: http://sine.ni.com/nips/cds/view/p/lang/en/nid/212720 (20.05.2015)
Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 13
Institute for Agricultural Engineeringand Animal Husbandry
Software (LabVIEW FPGA+RT)
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Institute for Agricultural Engineeringand Animal Husbandry
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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Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 14
Institute for Agricultural Engineeringand Animal Husbandry
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
Institute for Agricultural Engineeringand Animal Husbandry
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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Presented on SCILABTEC2015 Paris (France) 02.06.2015
(c) Dr.-Ing. Zoltan Gobor; Bavarian State Research Center for Agriculture Freising (Germany) 15
Institute for Agricultural Engineeringand Animal Husbandry
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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Institute for Agricultural Engineeringand Animal Husbandry
THANK YOU FOR YOUR ATTENTIONGobor-ILT 5-15002 30
21.05.2015
http://www.lfl.bayern.de/ilt/mechatronik/index.php