IST 37652 Hard Real-time CORBA

HRTC

WP4 / M. Rodríguez / Lund 16 September 2003

WP4: Process Control Testbed

WP4: Process Control Testbed

Universidad Politécnica de Madrid

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

OutlineOutline

OverviewOverviewNon HRTP Implementation Non HRTP Implementation HRTP ImplementationHRTP ImplementationConclusionsConclusions

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

OverviewOverview

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

ObjectiveObjective

The main objective of the distributed process control testbed is to identify requirements for distributed control systems and perform experiments in conditions of systems heterogeneity and legacy integration. Experiments will be done using conventional IIOP and the new real-time protocol.

Overview & previous workOverview & previous work

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Previous WorkPrevious WorkOverview & previous workOverview & previous work

PCT Requirements specificationPCT Requirements specificationPCT DesignPCT DesignPCT ProcurementPCT Procurement

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Overview & previous workOverview & previous work

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Overview & previous workOverview & previous work

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Main Activities Main Activities

Non HRT ImplementationNon HRT ImplementationNon HRT TestingNon HRT TestingPCT DocumentationPCT Documentation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

IntroductionIntroduction

Non HRTP ImplementationNon HRTP Implementation

Purpose & experiment definitionHardware implementationSoftware implementationTesting

For every experiment the following pattern is presented:

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Ethernet Control LoopEthernet Control LoopTo demonstrate the use of CORBA components for the implementation of control loops.

A simple regulatory control loop with three components:

1. Sensor

2. Actuator

3. Controller

built as independent nodes connected through the Ethernet. Also there are two additional nodes:

1. HMI

2. Historical Database

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Non HRTP ImplementationNon HRTP Implementation

SW SW ImplementationImplementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

The experiment has been conducted in two stages:

First stage: Start the process only (without control). The pumps were manually controlled and the sensor values were monitored.

Second stage: Run the process with the control loop closed (automatic mode).

In order to test the capacity of CORBA the time cycle of the loop was reduced decrementing the time between controller calls to the pH sensor and actuator.

All the PCs were synchronized using NTP. 

TestingTesting

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HMIHMINon HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Integration of legacy systemsIntegration of legacy systems

The purpose of this experiment is to demonstrate the integration of legacy systems in a CCS.

A commercial Honeywell TPS distributed control system is wrapped to become another CORBA node in the system

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Non HRTP ImplementationNon HRTP Implementation

SW SW ImplementationImplementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

1. Limitations of the connection

2. Use of the TPS controller with CCS sensor and actuator

3. Use of CCS controller with TPS sensor and actuator

4. Use of TPS sensor with CCS controller and actuator

TestingTesting

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Interaction of simulation & Interaction of simulation & controlcontrol

The purpose of this experiment is to test and identify requirements for the use of simulation objects on a CCS.

A simulation node shall be introduced on a Ethernet network with the CCS control loop configuration. This node should interact in several ways with the control agents

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Non HRTP ImplementationNon HRTP Implementation

SW SW ImplementationImplementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Operators training (interaction between the simulation and the HMI nodes). In this case the process and the control system are simulated. The HMI sends and receives data from the simulator. The time of execution of the simulation is slowed down to resemble the actual time of the process.  Hardware in the loop (interaction between the simulation and the actual controller). In this test the system simulated is the process plant with the sensors and actuators. The pH controller is left out of the model. The real pH controller implemented in a separate CORBA node is used to control the simulated plant.

TestingTesting

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Intensive data trafficIntensive data traffic

The purpose of this experiment is to check capacity limits of the system when the number of control elements increases.

During the test, the number of instances of simulated sensors and actuators on their respective nodes is increased progressively, as well as the corresponding number of controllers

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

SW SW ImplementationImplementation

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

•Every node with single functionality (all the virtual sensors are in a PC, all the actuators in another PC...)

•Every node has multiple functionality (In every node there are virtual sensors, actuators and controllers – not sending messages between them)

• Heavy network loads (by transferring huge amount of data between the network PCs).

TestingTesting

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Concurrency accessConcurrency access

The purpose of this experiment is to identify concurrency issues in CCS.

In this test multiple nodes try to access concurrently to a sensor node. As in the previous test, the number of client instances increases progressively.

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

Non HRTP ImplementationNon HRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

TestingTesting

Non HRTP ImplementationNon HRTP Implementation

Only some testing with multiple virtual objects(regulators) accesing a single node (sensor) has been conducted.

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

TTP/C Control LoopTTP/C Control Loop

To demonstrate the use of CORBA components for the implementation of control loops.

A simple regulatory control loop with three components:

1. Sensor

2. Actuator

3. Controller

built as independent nodes connected through the TTP/C network. Also there are two additional nodes:

1. HMI

2. Historical Database

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Asynchronous event Asynchronous event managementmanagement

To test the ability of CCS for implementing sequence of events register functionality. This is a measure of the accomplishment of the timing properties required by a distributed real-time control

A sequence of asynchronous events occurring in different nodes is generated in a short period of time. This events are registered in a central database with their time-stamps.

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

Network bridgingNetwork bridging

To identify requirements and limits for the use of several (possibly heterogeneous) segments in a CCS network.

Two CCS network segments shall be communicated through a bridge.

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HW HW ImplementationImplementation

HRTP ImplementationHRTP Implementation

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

ConclusionsConclusions

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

ConclusionsConclusionsThere haven’t been major problems in integrating

the control loop elements. CORBA is an alternative for process control systems not only where OPC operates but even at lower levels (field level)

Although existing DCS may be integrated under CORBA there are a lot of functionalities that cannot be accessed due to the lack of openness of the DCS.

Simulator integration have been easy as ABACUSSII is provided as a library and only an interface has been to be added.

Process control systems cannot sacrifice flexibility for predictability.

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

More experiments in Non HRTP implementation (mainly concurrent access)

Complete Software development of HRTP implementation

Perform HRTP testsComplete Documentation and evaluation of the

PCT.

Work pendingWork pending

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IST 37652 / Hard Real-time CORBA

WP4 / M. Rodríguez / Lund 16 September 2003

HRTC