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UNICOS A FRAMEWORK TO BUILD INDUSTRY LIKE CONTROL SYSTEMS PRINCIPLES & METHODOLOGY. Renaud Barillère CERN IT-CO Philippe Gayet CERN AB-CO. Outline. Industrial Control in CERN Accelerator Control Industrial Control Framework Objectives Process Control Analysis UNICOS Model

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unicos a framework to build industry like control systems principles methodology

UNICOS A FRAMEWORK TO BUILD INDUSTRY LIKE CONTROL SYSTEMS PRINCIPLES & METHODOLOGY

Renaud Barillère CERN IT-CO

Philippe Gayet CERN AB-CO

outline
Outline
  • Industrial Control in CERN Accelerator Control
  • Industrial Control Framework Objectives
  • Process Control Analysis
  • UNICOS Model
  • Process Control Specification
  • Application Production
  • Conclusion

Philippe Gayet CERN

industrial control architecture
Industrial Supervision Layer

Operator Consoles

Interface to operators

(Monitoring & Command emission)

<5 Years

SCADA Servers

Real time DB & Archiving

Industrial Control layer

PLC Process Control

Ethernet Network & TCPIP communication services

One Communication protocol per supplier

Life time

Control Logic Actions

PLC Process Control & Field interface

COTS from different supplier

Industrial Field layer

PLC Field interface

>10 Years

control system connection to the process directly or through field-buses

Fieldbus Networks

Industrial Control Architecture

Link to other accelerator control system

And services (alarms, logging,…)

Accelerator Presentation Tier

Accelerator Middle Tier

Accelerator Resource Tier

Philippe Gayet CERN

industrial control framework objectives
First

Cryogenic commissioning

Cryogenic Startup

Control project

Start up

LHC Startup

2000

2001

2007

Late Specifications

Workload

2006

Industrial Control Framework Objectives
  • Integrates industrial control layers together respecting interlayer independence
  • Integrates the Industrial Control to the accelerator control infrastructure and services (alarms, Logging,..)
  • Offers a methodology to produce functional analysis directly programmable by application development teams
  • Supplies Application Development Tools available for various development teams (CERN, Experiment collaboration, Outsourcing)
  • Allows long term maintenance by reduced CERN teams
  • Offers homogenous and efficient user interface for operation crew from equipment commissioning to long term operation

Philippe Gayet CERN

slide6
Unit

Equipment Modules

Equipment Modules

Equipment Modules

Equipment Modules

Equipment Modules

Equipment Modules

Equipment Modules

Control Modules

Control Modules

Control Modules

Control Modules

Control Modules

Process control Analysis

IEC 61512-1

Physical model

Philippe Gayet CERN

slide7
Control

Valve

AI

M value

PID

An Input

position

An Output

position

Equipment module

On-Off Valve

DI

End switch

UNIT

Equipment module

I/O Boards

DO

position

AI

M value

PID

Control

Valve

AI

position

Equipment module

AO

position

On-Off Valve

DI

End switch

DO

position

Process Control Objects

I/O devices

Field devices

UNICOS Break Down

  • IN UNICOS
  • Each control module or equipment module is a device
  • Each device type is an Object Class
  • Each device is instantiated in the control layer as PLC Object
  • Equipment modules and Units are embedded in a unique object class : Process Control Object
  • All PLC Object classes are based on the same model

Philippe Gayet CERN

object model control part
Operator

Parent Object

Objects status

Process inputs

Manual Requests

Auto. Requests

Parameters

PLC internal Object Logic

Programmer

Status

Orders

Process output

Information to

or

other object

Child Auto Requests

or to

operator

Object Model (Control Part)

PLC Object

Philippe Gayet CERN

plc objects interactions
Object status

Object status

Object status

Output

Object

Input

Object

Field

Object

Manual Requ.

Manual Requ.

Manual Requ.

Process Inputs

Process Inputs

Process Inputs

Parameters

Parameters

Parameters

Object logic

Object logic

Object logic

Auto. Requests

Auto. Requests

Auto. Requests

Orders

Orders

Orders

I/O Board or

Fieldbus

Input Channel

Output Channel

PROCESS

PLC Objects Interactions

Philippe Gayet CERN

slide10
Operator

UNICOS Operation Principles

  • Operation team must be able to act on each device
  • In degraded operation conditions operation crew can overcome process logic requests

Philippe Gayet CERN

slide11
Object status

SCADA

Proxy

PLC Object

Human

Manual Requ.

Requests

SCADA Object

HMI

Process Inputs

Parameters

Object logic

Parameters

Information

display

Auto. Requests

Orders

Object status

Manual Request

Process

Layers Integration

In the Supervision layer a proxy is associated to each object

This proxy will present the relevant object info to the operator

And allow manual command emission

Industrial Supervision Layer

Industrial Control Layer

Philippe Gayet CERN

application basic components
Graphical components (Widgets / Faceplaces)
  • Navigation tools
  • Objects explorer
  • Trends and alarms handling
  • Access control
  • Interconnection to accelerator services
Application Basic Components

Supervision

UNICOS FW

UNICOS SCADA Middleware

UNICOS PLC Middleware

UNICOS object

library

PLC

Philippe Gayet CERN

objects specification
I/O devices

Field devices

PCO devices

Objects Specification

Philippe Gayet CERN

application generation
Instantiation generation

device type templates

Supervisiondevice

instance

Devices Specification

Device instantiation

devices

DB

Scripts

Instance Generator

PLC device instance

Device instantiation

Application Generation

Supervision

UNICOS FW

UNICOS time stamped Middleware

UNICOS library

PLC

Philippe Gayet CERN

introducing process logic
Introducing Process Logic

Philippe Gayet CERN

unicos process control object model
Input objectsStatus

Or other objects status

Parent PCO Control Logic

Operator

Process Inputs

PCO Process dependant part

Interlock

Logic

Configuration

Logic

Manual Requests

Auto Requests

PCO predefined inputs

PCO standard logic

Parameters

PCO predefined outputs

Programmer

PCO Standard part

Global control logic

Status

Dependent Object

control logic

Dependent Device

control logic

Information to other objects or to operator via SCADA

..

Order

Order

Order

Device instantiation

Child Process Control Objects and Child Field Objects

Auto Request

Place holders for process

Dependent logics

UNICOS Process Control Object Model

Philippe Gayet CERN

pco placeholder specification
Interlock Logic

Configuration logic

Global logic

Dependent Object

control logic

PCO Placeholder Specification

For Each PCO the process engineers supply the logic associated to each PCO in a template document

Logic Placeholders

Interlock Logic

Configuration logic

Global logic

Dependent Object

control logic

Dependent Object

control logic

Dependent Object

control logic

Philippe Gayet CERN

logic skeleton generation
Instantiation generation

device type templates

Supervisiondevice

instance

Devices Specification

Device instantiation

devices

DB

Scripts

Instance Generator

PLC device instance

Basic Logic generation

Device instantiation

Logic Generator

Logic Files

Logic DB

Logic skeleton

Logic templates

Placeholder

Skeletons

Logic Skeleton Generation

Supervision

UNICOS FW

UNICOS time stamped Middleware

UNICOS baseline

PLC

Philippe Gayet CERN

process logic hmi production
Synoptic Specification

Synoptic views, …

Manual

production

Logic Specification

Control Logic

Manual

production

Process Logic & HMI Production

Supervision

UNICOS FW

Device instantiation

UNICOS time stamped Middleware

Device instantiation

UNICOS baseline

PLC

Philippe Gayet CERN

model based generation
Instantiation generation

device type templates

Supervisiondevice

instance

META-MODEL

Device instantiation

devices

DB

Scripts

Instance Generator

Meta-Model

PLC device instance

Meta-ModelGenerator

Logic generation

Device instantiation

Logic Generator

Logic Files

Logic DB

Complete Logic code

Logic templates

Replace generic skeleton

By

Actual logic model

Model based Generation

Supervision

UNICOS FW

UNICOS time stamped Middleware

UNICOS baseline

PLC

Philippe Gayet CERN

conclusion
Conclusion
  • Concepts:
    • Process breakdown
    • CLOSE to IEC 61512-1
    • Operation and Diagnostics oriented
  • Methods
    • From process analysis to code production
  • Tools
    • Common language for process experts and developers
    • Versatile suite of tools open to extension
  • UNICOS based application
    • LHC GCS, experiment magnets
    • LHC accelerator and experiment cryogenic

Philippe Gayet CERN

generator principle
PROGRAM $Application$_AI_$PLC Nb$_Status

VAR

$Application$_AI_$PLC Nb$_Status_Crono : CRONO;

$Application$_AI_$PLC Nb$_Status_WTB : WORD_TO_BIT;

$Application$_AI_$PLC Nb$_Status: SECT_CTRL;

_TimeRef : DINT;

$Equipment$_$Location$_$Name$_StsReg01 AT %QW$StsReg01$ : WORD;

$Equipment$_$Location$_$Name$_HFSt AT %QD$HFSt$ : REAL;

$Equipment$_$Location$_$Name$_PosSt AT %QD$PosSt$ : REAL;

$Equipment$_$Location$_$Name$_AuMoSt : BOOL;

$Equipment$_$Location$_$Name$_FoMoSt : BOOL;

$Equipment$_$Location$_$Name$_IoErrorW : BOOL;

$Equipment$_$Location$_$Name$_IoSimuW : BOOL;

$Equipment$_$Location$_$Name$_FoDiPro : BOOL;

END_VAR

PLC code or SCADA DB Template

Produced code or DB

Generator Principle

Specification DB

Philippe Gayet CERN

slide25
First

Cryogenic commissioning

Cryogenic Startup

2000

2001

2007

Late Specifications

Workload

Control project

Start up

LHC Startup

2006

Philippe Gayet CERN

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