Semiconductor Testing

Automated test equipment (ATE) is computer-controlled test and measurement equipment that allows for testing with minimal human interaction. The tested devices are referred to as a device under test (DUT). The advantages of this kind of testing include reducing testing time, repeatability, and cost efficiency in high volume. The chief disadvantages are the upfront costs of programming and setup.
Automated test equipment can test printed circuit boards, interconnections, and verifications. They are commonly used in wireless communication and radar. Simple ATEs include volt-ohm meters that measure resistance and voltages in PCs; complex ATE systems have several mechanisms that automatically run high-level electronic diagnostics.
ATE is used to quickly confirm whether a DUT works and to find defects. When the first out-of-tolerance value is detected, the testing stops and the device fails.

Semiconductor Testing

For ATEs that test semiconductors, the architecture consists of a master controller (a computer) that synchronizes one or more sources and capture instruments, such as an industrial PC or mass interconnect. The DUT is physically connected to the ATE by a machine called a handler, or prober, and through a customized Interface Test Adapter (ITA) that adapts the ATE's resources to the DUT.
When testing packaged parts or directly on the silicon wafer, a handler is used to place the device on a customized interface board and silicon wafers are tested directly with high precision probes.

Test Types

Logic Testing

Logic test systems are designed to test microprocessors, gate arrays, ASICs and other logic devices.
Linear or mixed signal equipment tests components such as analog-to-digital converters (ADCs), digital-to-analog converters (DACs), comparators, track-and-hold amplifiers, and video products. These components incorporate features such as, audio interfaces, signal processing functions, and high-speed transceivers.
Passive component ATEs test passive components including capacitors, resistors, inductors, etc. Typically, testing is done by the application of a test current.
Discrete ATEs test active components including transistors, diodes, MOSFETs, regulators, TRIACS, Zeners, SCRs, and JFETs.

Printed Circuit Board Testing

Printed circuit board testers include manufacturing defect analyzers, in-circuit testers, and functional analyzers.
Automated Test Equipment imageManufacturing defect analyzers (MDAs) detect manufacturing defects, such as shorts and missing components, but can't test digital ICs as they test with the DUT powered down (cold). As a result, they assume the ICs are functional. MDAs are much less expensive than other test options and are also referred to as analog circuit testers.
In-circuit analyzers test components that are part of a board assembly. The components under test are "in a circuit." The DUT is powered up (hot). In-circuit testers are very powerful but are limited due to the high density of tracks and components in most current designs. The pins for contact must be placed very accurately in order to make good contact. They are also referred to as digital circuit testers or ICT.
A functional test simulates an operating environment and tests a board against its functional specification. Functional automatic test equipment (FATE) unpopular due to the equipment not being able to keep up with the increasing speed of boards. This causes a lag between the board under test and the manufacturing process. There are several types of functional test equipment and they may also be referred to as emulators.

Interconnection and Verification Testing

Test types for interconnection and verification include cable and harness testers and bare-board testers.
Cable and harness testers are used to detect opens (missing connections), shorts (open connections) and miswires (wrong pins) on cable harnesses, distribution panels, wiring looms, flexible circuits, and membrane switch panels with commonly-used connector configurations. Other tests performed by automated test equipment include resistance and hipot tests.
Bare board automated test equipment is used to detect the completeness of a PCB circuit before assembly and wave solder.

Exploiting LabVIEW Libraries

Have you ever viewed a LabVIEW VI Hierarchy and become frustrated with not being able to locate a VI you needed to open?
Do you have large applications composed of similar modules but fear to jump, with both feet, into the learning curve of LVOOP?
Did you ever try to duplicate a sub-VI at the start of a new set of functions and find yourself deep in a nest of cross-linked VIs, or save a VI only to realize that the most suitable name has already been used?
Then using LabVIEW Libraries may be useful to you
Libraries are a feature available in the LabVIEW project or they can be created stand-alone*. They have a number of features that allow you to specify shared properties and attributes of related VIs and custom controls.
In short, many of the features of LVOOP are available without the complications required for Dynamic Dispatching. The remainder of this document will serve as a tutorial that demonstrates how to create, define, and clone a library. Additional notes are included to illustrate how these features can be exploited to help you develop more robust applications that are easier to support than applications that do not use libraries.
*Libraries can be created stand-alone from the LabVIEW splash screen using the method:
File >>> New … >>> Other Files >>> Library
You can create a new library from the project by right-clicking the “My Computer” icon and selecting “New >>> Library”. Save it to a unique folder that will contain all of the files associated with the library.
Open the properties screen and then open the icon editor) to compose a Common Icon for the library and its members.
Take a little time to create the icon because it will be shared by all of the members of the library. Do not get carried away and fill-up the entire icon. Leave some white space so that the icons of the component VIs can be customized to illustrate their role in the functionality of the library.
Create virtual folders in the library to help organize the VIs contained in it. I usually use three folders but you can use more or less depending on your needs and preferences. I use one to hold the controls, and another pair for the public and private VIs. I do not use auto-populating folders for a number of reasons.
I can control which VIs are included and which are not. Occasionally temporary VIs are created to do some basic testing and they are never intended to be part of the library. If functionality changes and the temporary VI breaks due to the change, the library may cause a build to fail due to the broken VI.
I can easily move a VI from private to public without having to move the VI on disk and then properly updating source code control to reflect the change.
I can keep the file paths shorter using the virtual folders while maintaining the structure of the project.
Additional virtual folders can be added if you want to further break-down the organization of the VIs in the library. If developing a library that will be used by other developers and or be as a tool for others, you may want to include a folder for the VIs that define the API your library offers. The API can also be divided into additional virtual folders to break-down the interface into functional areas if you wish. Implement the Logical Grouping of sub-VIs as needed for your library.
Set the Access Scope of the private virtual folder to private. While the private folder and the setting of the access scope can be optional, taking advantage of this options will help you and the users of your library identify which VIs are not intended for use outside of the library. Attempting to use a VI with a private scope from outside the library itself will break the calling VI and make it very obvious that the VI is not intended for public use.
Developing applications using libraries differs little from developing without libraries with one exception; there is no additional work to use them. The exception is illustrated in Figure 8 where the name of the VI is highlighted. While the VI named in the project is shown as “Init_AI.vi” the actual name of the VI is “DAQ.lvib:AI.lvlib:Init_AI.vi”. The difference is the result of what is called “Name Mangling”. The actual name of the VI is prefixed by the library names that own the VI. This is a powerful feature that goes a long way toward avoiding cross-linking and will let us easily clone a library to be used as the starting point of a similar library.
The Save as the screen for the library will not only let us define the library name but also where in the project the library will be placed. This is handy for nested libraries but not critical. The libraries can be moved around in the project or between libraries as need using the project window. When a library is cloned using the Save As an option, all of the VIs contained in the original library are duplicated and re-linked to the VIs in the new library. There is NO chance of cross-linking when Cloning a library!
Libraries can help in all phases of an application from initial development to long-term support through to knowledge transfer. Remember, “Libraries” are your friend!

9 Things to Consider When Choosing Automated Test Equipment

Automated test equipment (ATE) have the ability to reduce the costs of testing and make sure that lab teams can focus on other, more important tasks. With ATE, productivity, and efficiency is boosted to a maximum level due to cutting out the unnecessary tasks and daily activities.
However, you should not just cash out and invest in automated test equipment, there are elements that factors that are important to find the system that suits you best. Our team at ReadyDAQ has prepared 12 things you should consider before choosing automated test equipment.

1. Endurance and Compactness

One of the most important things is that the ATE system your company picks is designed for optimal performance over the long-term. Take a careful look at connections and components and make a conclusion whether they will survive over repeated use.Many lab teams are often struggling to find large areas for their testing operations. The automated test equipment should also be compact.

2. Customer Experience

Are other customers satisfied the support and other things they went through? Does the company you bought ATE from provide full support? You don't have to be the expert in automated test equipment, but they do. And their skills and expertise have to be available to you for when you need it. Customer support and the overall customer experience is a huge factor!

3. Scalability and Compatibility

One purchase does not have to be final. It often isn't You should check whether the equipment you ordered can be expanded or scaled over time. Your needs might change and you want ATE to adapt to your needs.
When compatibility comes to mind, we want to make sure that the equipment is built following all industry standards. Cross-compatibility is often important in situations where we no longer need or have lost the access to certain products. Better safe than sorry.

4. Comprehensive

Think of all the elements needed for testing. Even better, make a list. Does the equipment you have in mind cover ALL required elements? Don't forget about power and signaling, are they included too?

5. High Test Coverage and Diagnostics 

The ATE system has to be able to provide full coverage and give insights on all components of the processed product. This can help decrease the number of possible errors and failures later on.
How about diagnostics? Does the testing system provide robust diagnostic tools to make sure the obtained results are reliable and true?

6. Cost per Test

How much does a single test cost? You have to think and plan long-term, so a single test cost can help you calculate and make an assumption whether the system provides real value for the money invested.

7. Testimonials and Warranty 

Are other customers satisfied? Can the company direct you to testimonials from previous customers? What do their previous customers have to say about the systems and their performance?
Also, you don't want to be left hanging in case the systems starts malfunctioning or simply stops working. Does the ATE system come with a comprehensive warranty? Make sure you’re protected against damages that might happen in testing and see that the warranty covers that too.

8. Manufacturer Reputation

When did you first hear about the company? How? Did someone (besides them) say anything good about them? Is the company known for the high quality of their equipment? Discuss their past projects and learn more about the value their products provide.

9. Intuitive Performance

At first sight, is the system easy to use or way too complicated that it would require weeks of training for everyone in the lab? Does it offer intuitive performance within the testing procedure? Your team should be able to begin testing without having to go over every point in the technical manual in pinpoint detail.
Our team at ReadyDAQ is here to help you select the perfect automated test equipment for your lab.

IoT: Standards, Legal Rights; Economy and Development

It is safe to say that, at this point, the fragmented nature of IoT will hinder, or even discourage the value for users and industry. If IoT products happen to be poorly integrated, or inflexible regarding connectivity or are complex to operate, these factors can drive users as well as developers away from IoT. Also, poorly designed IoT devices can have negative consequences for the networks they connect to. Therefore, standardization is a logical next step as it can bring appropriate standards, models, and best practices. The standardization can, in turn, bring about user benefits, innovation and economic benefits.

 

Moreover, a widespread use of IoT devices brings about many regulatory and legal issues. Yet, since IoT technology is rapidly changing, many regulatory bodies cannot keep up with the change, so these bodies also need to adapt to the volatility of IoT technologies. But one of the issues which frequently comes in action is what to do when IoT devices collect data in one jurisdiction and transmit it to another jurisdiction with, for example, more lenient laws for data protection. Also, the data collected from IoT devices are often times liable to misuse, potentially causing legal issues for some users.

 

Other burning legal issues are the conflict between lawful surveillance and civil rights; data retention and ‘the right to be forgotten’; and legal liability for unaware users. Although the challenges are many in number and great in scope, IoT needs laws and regulations which protect the user and their rights but also do not stand in the way of innovation and trust.

 

Finally, Internet of Things can bring great and numerous benefits to developing countries and economies. Many areas can be improved through IoT: agriculture, healthcare, industry, to name a few. IoT can offer a connected ‘smart’ world and link aspects of people’s everyday lives into one huge web. IoT affects everything around it, but the risks, promises and possible outcomes need to be talked about and debated if one is to pick the most effective ways to go forward.

IoT: Summary

The Internet of Things (or shortened ‘IoT’) is a hot topic in today’s world which carries extraordinary significance in socio-economic and technical aspects of everyday life. Products designed for consumers, long-lasting goods, automobiles and other vehicles, sensors, utilities and other everyday objects are able to become connected among themselves through the Internet and strong data analytic capabilities and therefore transform our surroundings. Internet of Things is forecast to have an enormous impact on the economy; some analysts anticipate almost 100 billion interconnected IoT devices. On the other hand, other analysts proclaim that IoT devices shall input into the global economy more than $11 trillion by 2025.

However, the Internet of Things comes with many important challenges which, if not overcome, could diminish or even put a stop to the progress of it thus failing to realize all its potential advantages. One of the greatest challenges is security: the newspapers are filled with headlines alerting the public to the dangers of hacking internet-connected devices, identity theft and privacy intrusion. These technical and security challenges remain and are constantly changing and developing; at the same time, new legal policies are emerging.

This document’s purpose is to help the Internet Society community find their way in the discourse about the Internet of Things regarding its pitfalls, shortcomings and promises.

Many broad ideas and complex thoughts surround the Internet of Things and in order to find one’s way, the key concepts that should be looked into as they represent the foundation of circumstances and problems of IoT are:

- Transformational Potential: If IoT takes off, a potential outcome of it would be a ‘hyperconnected world’ where limitations on applications or services that use technology cease to exist.

- IoT Definitions: although there is not one universal definition, the term Internet of Things basically refers to several connected objects, sensors or items (not considered computers) which create, exchange and control data with next to none human intervention.

- Enabling Technologies: Cloud computing, data analytics, connectivity and networking all lead to the ability to combine and interconnect computers, sensors and networks all in order to control other devices.

- Connectivity Models: There are four common communication models and are as following: Device-to-Device, Device-to-Cloud, Device-to-Gateway, and finally Back-End Data-Sharing. These models show how flexible IoT devices can be when connecting and when providing value to their respective users.

LabVIEW Projects you should Know

STÄUBLI LABVIEW INTEGRATION LIBRARY

The DSM LabVIEW-Stäubli Control Library is created to simplify communications between a host PC running LabVIEW and a Stäubli robotic motion controller so as to control the robot from the LabVIEW environment. 

Stäubli Robots are usually found in the automation industry. The standard Staubli programming language, VAL3, is an adjustable language allowing for a wide variety of tasking. Although the VAL3 language works well in its environment, there are limited options for connecting the robot to an existing PC-based test & measurement system. The LabVIEW language, on the other hand, has been created from the start to run systems found in a research environment. The DSM LabVIEW-Staubli Integration Library lets the user promptly create applications for a Staubli robot using the familiar LabVIEW programming language.

 

 

AUTOMATED CRYOGENIC TEST STATION

A test station was built with the intent in mind to automate cyclic cryogenic exposure.  A LabVIEW program was inserted to automate the process and collect data. The software featured:

• Checked the temperature of up to 8 thermocouples

• Checked the life status of test specimens twice per cycle

• Automated backups to allow for data recovery

• System was integrated with a pneumatic control board and safety features

 

 

TENSILE TESTER CONTROL PROGRAM

This system is able to record high-resolution x-ray imagery of test subjects of aerospace alloys while they are under tensile and cyclic fatigue tests.  This capability can improve understanding of how grain refinement is used to enhance material properties.  The tensile tester can function in multiple modes of operation. The sample can be fully rotated within the tester, permitting three-dimensional imagery of samples.

 

DYNAMOMETER TEST STATION

A test station designed to characterize piezoelectric motors was built, with programmable current source and a DC motor integrated into the system to apply a range of resistive torque loads to the tested motor.  A torque load cell and a high-resolution encoder were used to measure torque and speed, which is collected at each resistive torque level, forming a torque curve. A LabVIEW project was programmed to run the test. Test settings were configured in the program and data was collected by an NI DAQ card. The program also included data manipulation and analysis.

 

OPEN-LOOP ACTUATOR CONTROLLER

The goal is to characterize the actuator's performance in open-loop so that a closed-loop control scheme can be developed. This program can output voltage waveforms as well as voltage steps up to 40V. Voltage duration is programmable down to the millisecond and an encoder is integrated into the system and readings are real time. The encoder features resolution on a micron level and experiences exceptional noise due to the vibrations present in the system. The data is filtered after the test to report accurate, low-noise data.

About I²C

I²C is a multi-master protocol that uses two signal lines. The two I²C signals are named ‘serial data’ (SDA) and ‘serial clock’ (SCL). There is no need of chip select (servant select) or compromise logic. Basically, any number of servants and any number of masters can be united onto these two signal lines and correspond to each other using a protocol that specifies:

 

• 7-bits servant addresses: every device united to the bus has got such a unique address;

• certain control bits for governing the communication commence, end, and direct for any acknowledgement mechanism.

• data are divided into 8-bit bytes

 

The data standard must be chosen betwixt 100 kbps, 400 kbps and 3.4 Mbps, accordingly called standard mode, a fast mode and high-speed mode. Some I²C variations contain 10 kbps and 1 Mbps as genuine speeds.

Physically, the I²C bus comprises the two active wires SDA and SCL and a ground connection. The effective wires are both bi-directional. The I2C protocol necessity states that the IC that begins a data transfer on the bus is treated the Bus Master. Therefore, at the time, all the other ICs were considered to be Bus Servants.

 

At electrical rank, there is literally no conflict at all if multiple instruments try to put any logic rank on the I²C bus lines together. If one of the drivers attempts to write a logical zero and the other a logical one, then the open-drain and pull-up arrangement ensure that there will be no shortcut and the bus will indeed see a logical zero transiting on the bus. In other words, in any conflict, a logic zero always ‘scores’.

Furthermore, the I²C protocol likewise helps at dealing with communication problems. Any apparatus present on the I²C listens to it permanently. Promising masters on the I²C encountering a START condition will wait until a STOP is encountered to attempt a new bus admission. Servants on the I²C bus will decode the device address that follows the START condition and checks if it doubles theirs. All the servants that are not addressed will wait until a STOP status is issued before listening repeatedly to the bus. Likewise, since the I²C protocol foresees active-low acknowledge bit after each byte, the master/servant couple can identify their counterpart presence. Ultimately, if anything else goes bad, this would signify that the apparatus ‘talking on the bus’ would know it by simply comparing what it sends with what is seen on the bus. If a difference is detected, a STOP case must be issued, which discharges the bus.

Basics and Applications of Optical Sensor

An optical sensor is one that converts light rays into a computerized signal. To measure a physical quantity of light and, depending on the sort of sensor, translate it into a form that is readable by some unified measuring device is the purpose of an optical sensor. Optical sensors can be both external and internal. External sensors assemble and address an appropriate quantity of light, while internal sensors measure the bends and other small changes in direction.

Types of Optical Sensors

There are various kinds of optical sensors, and here are the most common types.

Through-Beam Sensors

The usual system consists of two independent components. The receiver and the transmitter are placed opposite to each other. That transmitter projects a light beam onto the receiver. A breach of the light beam is explained as a switch signal by the receiver. It is insignificant where the interruption appears.
Its advantage is that large operating distances can be attained and the recognition is separated from the object’s surface structure, colour or reflectivity.
It must be assured that the object is sufficiently huge to interrupt the light beam completely, to ensure a high operational dependability.

Diffuse Reflection Sensors

Both receiver and transmitter are in one housing. The transmitted light is reflected by the object that must be identified.
The diffused light intensity at the receiver serves as the switching condition. Regardless of the sensitivity setting the front part regularly reflects worse than the rear part and this leads to the after effect of false switching operations.

Retro-Reflective Sensors

Here, both transmitter and receiver are in the same house. Through a reflector, the radiated light beam is conducted back to the receiver. An interruption of the light beam commences a switching operation. It is not influential where the interruption occurs.
Retro-reflective sensors set up large operating distances with switching points, which are completely reproducible demanding little escalating effort. Any object interfering the light beam is precisely detected independently of its colour or surface structure.

How Stack Machines Meet the Needs of Various Systems

There are various characteristics which need to be met in order for these machines to be suitable and to be fully and successfully implemented into real time systems. These characteristics are as follows: size and weight, power and cooling, operating environment, cost and performance.

Size and Weight 

It has been observed that stack computers are very simple in regards to processor complexity. However, it is the overall system complexity that determines overall system size and weight. The solution to overcoming the size and weight issue is to keep component count small. That is why stack machines are less complex than other machines and are also more reliable.

Power and Cooling

If the processor is complex, it can affect the amount of power it needs. That amount of power is related to how many transistors there are in a processor and how many pins are on the processor chip. Moreover, processors that need a lot of power-consuming high-speed memory devices can also be burdensome regarding power. Of course, power consumption directly affects cooling requirements, since all power used by a computer is eventually transmuted into heat. The cooler operation of processor components can reduce the number of component failures, thus improving reliability.

Operating Environment

Embedded processing systems are well known for extreme operating conditions. The processing system must deal with heat and cold, vibration, shock, and even radiation. Also, in remotely installed applications, the system must be able to survive without field service technicians to make repairs. The general rule to avoiding problems caused by operating environments is to keep the component count and a number of pins minuscule. Stack machines, with their low system complexity and high levels of integration, do well under these conditions.

Cost

Since the cost of a chip is related to the number of transistors and to the number of pins on the chip, low complexity stack processors are basically low in cost.
Computing Performance. Computing performance in a real time embedded control environment is not simply defined. Although raw computational performance is important, there are other factors which influence the system. An additional desirable feat is a fantastic execution in programs that are filled with procedure calls reducing program memory size.

How do RS-232, RS-422, and RS-485 compare to each other?

RS-232 (ANSI/EIA-232 Standard) is the most widespread serial interface and it is used to ship as a standard component on most Windows-compatible desktop computers. Nowadays, it is more frequent to use RS-232 rather than using a USB and a converter. One downfall is that RS-232 only permits for one transmitter and one receiver on each line. RS- 232 also employs a Full-Duplex transmission method. Some RS-232 boards sold by National Instruments support baud rates up to 1 Mbit/s, but most devices are restricted to 115.2 kbit/s. On one hand, RS-422 (EIA RS-422- A Standard) is the serial connection employed primarily on Apple computers. It provides a mechanism for sending and receiving data up to 10 Mbits/s. RS-422 sends each signal employing two wires in order to increase the maximum baud rate and cable length. RS-422 is also specified for multi-drop applications where only one transmitter is linked to and sends and receives a bus of up to 10 receivers. On the other hand, RS-485 is a superset of RS-422 and expands on the capabilities of that previous model. RS-485 was manufactured to deal with the multi-drop limitation of RS-422, letting up to 32 devices to communicate through the same data line. Any of the subordinate devices on an RS-485 bus can communicate with any other 32 subordinate or ‘slave’ devices without the master device receiving any signals. Since RS-422 is a subset of RS-485, all RS-422 devices can be controlled by RS-485.
Finally, both RS-485 and RS-422 have multi-drop capability installed in them, but RS-485 allows up to 32 devices and RS-422 has a limit of only 10 devices. For both communication protocols, it is advisable that one should provide their own termination. All National Instruments RS-485 boards will work with RS-422 standards.

How to keep multicloud complexity under control

Using multiple cloud providers provides needed flexibility, but it also multiplies the work and risk of getting out of sync
“Multicloud” means that you use multiple public cloud providers, such as Google and Amazon Web Services, AWS and Microsoft, or all three—you get the idea. Although this seems to provide the best flexibility, there are trade-offs to consider.
The drawbacks I see at enterprise clients relate to added complexity. Dealing with multiple cloud providers does give you a choice of storage and compute solutions, but you must still deal with two or more clouds, two or more companies, two or more security systems … basically, two or more ways of doing anything. It quickly can get confusing.
For example, one client confused security systems and thus inadvertently left portions of its database open to attack. It’s like locking the back door of your house but leaving the front door wide open. In another case, storage was allocated on two clouds at once, when only one was needed. The client did not find out until a very large bill arrived at the end of the month.
Part of the problem is that public cloud providers are not built to work together. Although they won’t push back if you want to use public clouds other than their own, they don’t actively support this usage pattern. Therefore, you must come up with your own approaches, management technology, and cost accounting.
The good news is that there are ways to reduce the multicloud burden.
For one, managed services providers (MSPs) can manage your multicloud deployments for you. They provide gateways to public clouds and out-of-the-box solutions for management, cost accounting, governance, and security. They will also be happy to take your money to host your applications, as well as provide access to public cloud services.
If you lean more toward the DIY approach, you can use cloud management platforms (CMPs). These place a layer of abstraction between you and the complexity of managing multiple public clouds. As a result, you use a single mechanism to provision storage and compute, as well as for security and management no matter how many clouds you are using.
I remain a fan of the multicloud approach. But you’ll get its best advantage if you understand the added complexity up front and the ways to reduce it.

Automation to Replace Human Hands?

As we move deeper into the technologically advanced methodologies and manufacturing processes, we realize the power of the human mind. The mind which has developed a new league of technical procedures which have made our lives easy and working easier. Manual labor is on the way to extinction in a few years from now, thanks to the highly advanced machinery and automation industry. Automation, combined with the words automatic and execution have enabled a major chunk of processes to be executed without the human component. And with the amount of innovation taking place around the globe, it is surprising how robots and machinery have taken over the daunting human tasks.

But why do we support the intrusion of automation into our development process and how is it benefiting the industries? There is no doubt in the fact that machines can outperform humans in every aspect.

The precision and efficiency of an automatic machine are way better than a hundred humans working together. This is the most important reason as to why people prefer machines over man. While a human would numerous hours to assemble a product, a machine can manufacture and assemble the same within minutes. This not only saves a lot of time but expense as well. Automation in industries is a one-time investment which gives you long term benefits and efficient output. No doubt the machines demand maintenance, but it is still economical when compared to manual labor.

In huge manufacturing units, automation is a widespread concept which has taken over the human hand mainly because of the demand and supply chain where there is an excessively large need for manufactured goods.

But, it should also be noted that with an efficient hardware that goes into automating a factory, compatible and complementing software is also necessary. It is an intelligent software system that makes the machine efficient in providing optimum output. For this reason, ReadyDAQ your one stop shop for all the development needs has been created. It offers solutions to your software problems and is programmed to handle all operational devices such as pumps, motors, and sensors. A plug and play medium for devices, it helps the automation process in factories and industries by allowing the users to connect devices and without any major configuration or development operating it. It comes with a 30-day trial version to get a feel of the working before you actually make a purchase. So get yours today!

Setting up LabVIEW Project

Complete the following steps to set up the LabVIEW project:

 

1. Launch LabVIEW by selecting Start»All Programs»National Instruments»LabVIEW.
2. Click the Empty Project link in the Getting Started window to display the Project Explorer window. You can also select File»New Project to display the Project Explorer window.
3. Select Help and make sure that Show Context Help is checked. You can refer to the context help throughout this process for information about items in the Project Explorer window and in your VIs.
4. Right-click the top-level Project item in the Project Explorer window and select New»Targets and Devices from the shortcut menu to display the Add Targets and Devices dialog box.
5. Make sure that the Existing target or device radio button is selected.
6. Expand Real-Time CompactRIO.
7. Select the CompactRIO controller to add to the project and click OK.
8. Select FPGA Interface from the Select Programming Mode dialog box to put the system into FPGA Interface programming mode.
9. Tip Tip  Use the CompactRIO Chassis Properties dialog box to change the programming mode in an existing project. Right-click the CompactRIO chassis in the Project Explorer window and select Properties from the shortcut menu to display this dialog box.
10. Click Discover in the Discover C Series Modules? dialog box if it appears.
11. Click Continue.
12. Drag and drop the C Series module(s) that will run in Scan Interface mode under the chassis item. Leave any modules you plan to write FPGA code for under the FPGA target.

Real-Time Processor

An industrial 400 MHz Freescale MPC5200 processor that deterministically acquires one’s LabVIEW Real-Time applications on the reliable Wind River VxWorks real-time operating system features the CompactRIO installed the system. Built-in operations for transferring data between the real-time processor within the CompactRIO embedded system and the FPGA are available in LabVIEW. One can pick from more than 600 built-in LabVIEW functions to frame its multithreaded installed system for real-time analysis, control, data logging, and communication. To save on development time, one can likewise combine existing C/C++ code with LabVIEW Real-Time code.

Starting a New CompactRIO Project in LabVIEW

One should commence by creating a new project in LabVIEW, where one can manage some hardware resources and code.

1.       By selecting File » New Project, one creates a new project in LabVIEW.

2.        Right-click on the Project feature at the top of the tree and by selecting New » Targets and Devices, one adds existing CompactRIO system to the project.

3.      One can add offline systems, or discover, by this dialogue, systems on existing network. To enlarge the Real-Time CompactRIO folder, select existing system, and click OK. Note: LabVIEW might not find it on the network if the existing system is not listed. Ensure that the existing system is well configured with a valid IP address in Measurement & Automation Explorer. One can likewise select to manually enter the IP address if the existing system is on a remote subnet.

Select the Appropriate Programming Model

Two programming models are granted by LabVIEW for CompactRIO systems. If one has LabVIEW FPGA and LabVIEW Real-Time on the existing development CPU, the one can be incited to pick which programming model he/she would like to use. In the LabVIEW Project, the one can change this setting later, if needed.

Scan Interface (CompactRIO Scan Mode) option allows a person to programme the real-time processor of the already existing CompactRIO system on a computer, but not the FPGA. NI provides a pre-defined personality for the FPGA that regularly scans the I/O and allocates it in a memory map, in this mode, making it accessible to LabVIEW Real-Time. For applications that lack single-point access to I/O at rates of a few hundred hertz, CompactRIO Scan Mode is sufficient. If someone wants to learn more about scan mode, the one should read the “Using CompactRIO Scan Mode” with “NI LabVIEW” white paper and sight the benchmarks.

LabVIEW FPGA Interface option allows a person to unlock the true power of CompactRIO throughout customising the FPGA personality in addition to the programming of the real-time processor and accomplishing performance that would typically lack custom hardware. One can implement custom triggering and timing, off-load signal analysis and processing, create custom protocols, and access I/O at its maximum rate by using LabVIEW FPGA.

After that, one should select the appropriate programming model for the existing application.

Consequently, LabVIEW will then try to detect C Series I/O modules present in the existing system and automatically add them to the LabVIEW Project and the chassis. Note: If a person’s existing system was not discovered and one chooses to add it offline, one will need to add the chassis and C Series I/O manually. For scan mode and FPGA mode, The LabVIEW Help online discusses this operation.

CompactRIO Scan Mode Tutorial

This section will teach a person how to create a basic control application on CompactRIO using scan mode. One should see the LabVIEW FPGA Tutorial if the choice is to use the LabVIEW FPGA Interface. One should then have a new LabVIEW Project that consists of the existing CompactRIO system, including the controller, C Series I/O modules, and chassis. An NI 9211 Thermocouple input module will be used in this tutorial; nonetheless, for any analogue input module, the process can be followed.

1.       The project is saved by selecting File»Save and entering Basic control with scan mode. Click OK.

2.       This project will only consist of one VI, which is the LabVIEW Real-Time application that runs installed on the CompactRIO controller. Right-clicking on the CompactRIO real-time controller in the project and selecting New»VI saves the VI as RT.vi.This one is created by the VI.

3.       Three routines are included in the key operation of this application: start up, run, and shutdown. An effortless way to accomplish this order of operation is a flat sequence structure. Place with three frames on the existing RT.vi block diagram a flat sequence structure.

4.       Then, a timed loop to the Run frame of the sequence structure should be inserted. The capability to synchronise code to various time basis, including the NI Scan Engine that reads and writes scan mode I/O is provided by timed loops.

5.       If the timed loop is to be configured, one should double-click on the clock icon on the left input node.

6.       Now, select Synchronise to Scan Engine as the Loop Timing Source. Click OK. This will cause the code in the timed loop to execute once, instantly after each I/O scan, assuring that any I/O values used in this timed loop are the most recent ones.

7.      To run synchronised to the scan engine, the step before constructed the timed loop. Now, by right-clicking on the CompactRIO real-time controller in the LabVIEW Project and picking Properties, one should configure the rate of the scan engine itself.

8.       Then, choose Scan Engine from the categories on the left and enter 100ms as the Scan Period and all the I/O in the CompactRIO system to be updated every 100ms (10Hz). From this page, the Network Publishing Period can also be set, which regulates how often the I/O values are published to the network for remote monitoring and debugging. After that, click OK.

9.       Now that one has constructed the I/O scan rate, it is time to add the I/O reads to the existing application for control. One can simply drag and drop the I/O variables from the LabVIEW Project to the RT block diagram when using CompactRIO Scan Mode. Expand the CompactRIO real-time controller, chassis, and the I/O module the one would like to log. By clicking on it, select AI0, then drag and drop it into the timed loop on your RT.vi diagram.

10.   Now, in this project for speciality digital Pulse Width Modulated output, one should configure the digital module so the one can use a PWM signal to control the imaginary heater unit. Right click on the existing digital module in the project and select Properties, to do this. Select Specialty Digital Configuration and a Speciality Mode of Pulse-Width Modulation in the C Series Module Properties dialogue. Speciality Digital mode allows the existing module to perform to pattern based digital I/O at rates significantly faster than is available with the scan interface. Click OK and the existing module will now be in PWM mode.

11.   Then a person is ready to add the actual PWM output to the block diagram. To do so, widen the Mod2 object in the project and drag and drop the PWM0 item to the block diagram as it has been done with the AI0 I/O node in the previous step.

12.   After that, somebody will want to join the PID control logic to this program. Right click the block diagram to open the functions palette and click on the Search button in the top right of the palette, if one wants to do such a thing.

13.   Scan for PID and pick PID.vi in the Control Design and Simulation Palette and drag it to the actual block diagram of the timed loop and wire the PID VI.

14.   The set point input is not wired now. That is because it is best practice to keep user interface (UI) objects out of actual high priority control loop. If someone wants to interact with and adjust the actual set point at the run time, the one will want to create a control that can be interacted with in the lower priority loop. Also, if someone wants to create single process shared variables for I/O in the already existing high priority control loop, two controls in our application (set point and stop) are needed to create two new single process shared variables.

A single process is created and the variable is shared by right click on the actual RT CompactRIO Target in the LabVIEW Project and New >> Library should be selected. Rename the library into something perceptive like RTComm. Then, one should right click on the new library and select New>>Variable. That will open the Shared Variable Properties dialogue. The variable should be named SetPoint (for example, the name depends on person’s imagination) and “Single Process” should be selected for the variable type in the Variable Type drop down box. Finally, click on the RT FIFO option in the left-hand tree and click the Enable RT FIFO check box.

15.   In the library that has just been created, another single-process shared variable should be made. This variable is for the Stop control that is going to be created that will stop the program when it is needed. All the same settings as the previous Set Point variable except for the type this new variable should possess, and it should be Boolean.

16.   Next, some user interface should be created. Such a thing is done in Slide control, Waveform Chart, Numeric control, and Stop (Boolean) control.

17.   This program is supposed to be finished now by creating a secondary (non-timed) loop for the actual UI objects and finishing wiring the existing block diagram.

18.   Note the extension of I/O to the configuration and shutdown states to ensure that already existing I/O is in a known state when the program begins and ends. The basic control application should be ready to run.

INTRODUCTION TO RS232 SERIAL COMMUNICATION - PART 2

Assume we want to send the letter ‘A’ over the serial port. The binary representation of the letter ‘A’ is 01000001. Remembering that bits are transmitted from least significant bit (LSB) to most significant bit (MSB), the bit stream transmitted would be as follows for the line characteristics 8 bits, no parity, 1 stop bit, 9600 baud.

LSB (0 1 0 0 0 0 0 1 0 1) MSB
The above represents (Start Bit) (Data Bits) (Stop Bit)
To calculate the actual byte transfer rate simply divide the baud rate by the number of bits that must be transferred for each byte of data. In the case of the above example, each character requires 10 bits to be transmitted for each character. As such, at 9600 baud, up to 960 bytes can be transferred in one second.
The first article was talking about the “electrical/logical” characteristics of the data stream. We will expand the discussion to line protocol.
Serial communication can be half duplex or full duplex. Full duplex communication means that a device can receive and transmit data at the same time. Half duplex means that the device cannot send and receive at the same time. It can do them both, but not at the same time. Half duplex communication is all but outdated except for a very small focused set of applications.
Half duplex serial communication needs at a minimum two wires, signal ground, and the data line. Full duplex serial communication needs at a minimum three wires, signal ground, transmit data line and receive data line. The RS232 specification governs the physical and electrical characteristics of serial communications. This specification defines several additional signals that are asserted (set to logical 1) for information and control beyond the data signals and signals ground.
These signals are the Carrier Detect Signal (CD), asserted by modems to signal a successful connection to another modem, Ring Indicator (RI), asserted by modems to signal the phone ringing, Data Set Ready (DSR), asserted by modems to show their presence, Clear To Send (CTS), asserted by modems if they can receive data, Data Terminal Ready (DTR), asserted by terminals to show their presence, Request To Send (
RTS), asserted by terminals when they want to send data. The section RS232 Cabling describes these signals and how they are connected.
The above paragraph alluded to hardware flow control. Hardware flow control is a method that two connected devices use to tell each other electronically when to send or when not to send data. A modem in general drops (logical 0) its CTS line when it can no longer receive characters. It re-asserts it when it can receive again. A terminal does the same thing instead with the RTS signal. Another method of hardware flow control in practice is to perform the same procedure in the previous paragraph except that the DSR and DTR signals are used for the handshake.
Note that hardware flow control requires the use of additional wires. The benefit to this, however, is crisp and reliable flow control. Another method of flow control used is known as software flow control. This method requires a simple 3 wire serial communication link, transmit data, receive data, and signal ground. If using this method, when a device can no longer receive, it will transmit a character that the two devices agreed on. This character is known as the XOFF character. This character is generally a hexadecimal 13. When a device can receive again it transmits an XON character that both devices agreed to. This character is generally a hexadecimal 11.

Introduction to RS232 Serial Communication - Part 1

Serial communication is basically the transmission or reception of data one bit at a time. Today’s computers generally address data in bytes or some multiple thereof. A byte contains 8 bits. A bit is basically either a logical 1 or zero. Every character on this page is actually expressed internally as one byte. The serial port is used to convert each byte to a stream of ones and zeroes as well as to convert streams of ones and zeroes to bytes. The serial port contains an electronic chip called Universal Asynchronous Receiver/Transmitter (UART) that actually does the conversion.
The serial port has many pins. We will discuss the transmit and receive pin first. Electrically speaking, whenever the serial port sends a logical one (1) a negative voltage is effected on the transmit pin. Whenever the serial port sends a logical zero (0) a positive voltage is effected. When no data is being sent, the serial port’s transmit pin’s voltage is negative (1) and is said to be in the MARK state. Note that the serial port can also be forced to keep the transmit pin at a positive voltage (0) and is said to be the SPACE or BREAK state. (The terms MARK and SPACE are also used to simply denote a negative voltage (1) or a positive voltage(0) at the transmit pin respectively).
When transmitting a byte, the UART (serial port) first sends a START BIT which is a positive voltage (0), followed by the data (general 8 bits, but could be 5, 6, 7, or 8 bits) followed by one or two STOP BITs which is a negative(1) voltage. The sequence is repeated for each byte sent.
At this point, you may want to know what is the duration of a bit. In other words, how long does the signal stay in a particular state to define a bit? The answer is simple. It is dependent on the baud rate. The baud rate is the number of times the signal can switch states in one second. Therefore, if the line is operating at 9600 baud, the line can switch states 9,600 times per second. This means each bit has the duration of 1/9600 of a second or about 100 µsec.
When transmitting a character there are other characteristics other than the baud rate that must be known or that must be setup. These characteristics define the entire interpretation of the data stream.
The first characteristic is the length of the byte that will be transmitted. This length, in general, can be anywhere from 5 to 8 bits.
The second characteristic is parity. The parity characteristic can be even, odd, mark, space, or none. If even parity, then the last data bit transmitted will be a logical 1 if the data transmitted had an even amount of 0 bits. If odd parity, then the last data bit transmitted will be a logical 1 if the data transmitted had an odd amount of 0 bits. If MARK parity, then the last transmitted data bit will always be a logical 1. If SPACE parity, then the last transmitted data bit will always be a logical 0. If no parity then there is no parity bit transmitted.
A third characteristic is a number of stop bits. This value, in general, is 1 or 2.
Stay tuned for part two, it will be published soon.

Computerized Outputs

Digital Outputs require a similar investigation and large portions of indistinguishable contemplation from advanced data sources. These incorporate watchful thought of yield voltage go, greatest refresh rate, and most extreme drive current required. In any case, the yields likewise have various particular contemplations, as portrayed beneath. Relays have the benefit of high off impedance, low off spillage, low on resistance, irresoluteness amongst AC and DC flags, and implicit segregation. Be that as it may, they are mechanical gadgets and consequently give bring down unwavering quality and commonly slower reaction rates. Semi-conductor yields regularly have a favorable position in speed and unwavering quality.
Semiconductor changes additionally have a tendency to be littler than their mechanical reciprocals, so a semiconductor-based advanced yield gadget will commonly give more yields per unit volume. When utilizing DC semiconductor gadgets, be mindful so as to consider whether your framework requires the yield to sink or source current. To fulfill varying necessities,

Current Limiting/Fusing

Most yields, and especially those used to switch high streams (100 mA or something like that), offer some kind of yield security. There are three sorts most normally accessible. The first is a straightforward circuit. Cheap and dependable, the primary issue with circuits, is they can't be reset and should be supplanted when blown. The second sort of current constraining is given by a resettable breaker. Ordinarily, these gadgets are variable resistors. Once the current achieves a specific edge, their resistance starts to rise rapidly, at last constraining the current and stopping the current.
Once the culpable association is evacuated, the resettable circuit returns to its unique low impedance state. The third kind of limiter is a real current screen that turns the yield off if and when an overcurrent is recognized. This "controller" limiter has the upsides of not requiring substitution taking after an overcurrent occasion. Numerous usage of the controller setup additionally permits the overcurrent outing to be determined to a channel by channel premise, even with a solitary yield board.

What are String Pots?

String pots are intended to gauge direct uprooting. They are ordinarily lower cost than LVDTs and can offer any longer estimation separations. As their name suggests, the reason for string pot is a string or link, and a potentiometer. Fundamentally, a string and a spring are connected to the wiper screw of the potentiometer and as the string is pulled, the potentiometer resistance changes. The string pot gives an adjustment element that depicts what uprooting is spoken to by a rate of resistance change.
As a basic variable resistance gadget, with a direct yield, most string pots are interfaced to standard A/D sheets. The most widely recognized association arrangement interfaces a voltage reference to the one side of the string pot with the opposite side associated with ground.
The "wiper" is then associated with an A/D input channel. With the string totally withdrawn, the deliberate voltage will be equivalent to either reference voltage or zero. With the string totally developed, the voltage measured will be the inverse (either zero or the reference voltage). At any middle of the road string expansion, the voltage measured will be corresponding to the rate of string "out".
Make sure your voltage reference has the yield current ability to drive the string pot resistance. Your estimation will be a blunder by an indistinguishable rate from any voltage reference mistake. At times, it might be advantageous to drive the string pot with a higher limit, bring down exactness voltage source. Should you require higher exactness than the voltage source gives, you may dependably devote an A/D channel to quantify the voltage source.
This makes the framework for all intents and purposes safe to blunders in the voltage source. Another note is that string pots are single finished, disengaged gadgets. While associating a string pot to a differential information, make sure to interface the string pot/reference ground and the A/D channel's low or "- " input. Neglecting to make this association somehow will probably bring about problematic and even "odd" conduct as the information "- " terminal buoys all through the info enhancer's normal mode go.

Other types of DAQ Hardware - Part 2

Monotonicity 

In spite of the fact that it's sound judgment to accept that on the off chance that you charge your yield to go to a higher voltage, it will, paying little respect to the general precision. In any case, this is not really the situation. D/A converters show an error called differential non-linearity (DNL). Generally, DNL error speaks to the variety in yield "step estimate" between adjoining codes. In a perfect world, instructing the yield to increment by 1LSB, would make the yield change by a sum equivalent to the general yield resolution. Notwithstanding, D/A converters are not immaculate and expanding the advanced code kept in touch with a D/A by one may make the yield change .5 LSB, 1.3 LSB, or some other subjective number. A D/A/channel is said to be monotonic if each time you increment the advanced code kept in touch with the D/A converter, the yield voltage does undoubtedly increment. In the event that the D/A converter DNL is under ±1 bit, the converter will be monotonic. If not, charging a higher yield voltage could in truth make the yield drop. In control applications, this can be extremely risky as it turns out to be hypothetically workable for the system to "bolt" onto a false set point, inaccessible from the one wanted. 2.1.5 Output Type Unlike analog inputs, which arrive in a bunch of sensor-particular input designs, analog yields ordinarily come in two flavors, voltage yield and current yield. Make certain to determine the correct sort of your system. A few gadgets offer a blend of voltage and current yields, however, most offer just a solitary sort. In the event that your system requires both, you might need to consider a present yield module, as the present yields can frequently be changed over to a reasonable voltage yield with the straightforward establishment of a shunt resistor. Take note of the exactness of the shunt resistor-made voltage yield is extremely subject to the precision of the resistor utilized. Additionally, take note of, the shunt resistor utilized will be in parallel with any heap or gadget associated with it. Make sure the input impedance of the gadget driven is sufficiently high not to influence the shunt work.