Developing Scalable Networked Monitoring and

Control Systems with LabVIEW

Introduction
In theory, control systems can be condensed into a simple set of tasks measure your
system, make decisions based on the input, send a control signal to adjust your system to
expected operation, and then repeat. In reality, accomplishing each of these tasks can grow
complex, once you take into account the types of measurements you need to make to get
your inputs, the algorithms and logic needed to make the decisions, the distributed nature
of many control systems, the amount of I/O to manage, the speed of the control loop, and
so on. If your system is simple and digital, you may be able to find an off-the-shelf
inexpensive hardware controller to do the job. But as the system grows and requires more
functionality, you may want to reevaluate such controllers and choose tools that can meet
your existing system needs, and then scale to address future changes or technologies as they
arise.

Networked Monitoring and Control Systems

In the past, companies have been able to develop large yet simple control systems with
inexpensive hardware controllers. However, as trends are pushing for more integrated
systems and solutions, new control systems are being developed with the ability to
communicate to other terminals such as adjacent environmental monitoring systems and
system databases through Ethernet, the standard backbone of a company network. Even
existing systems are being retrofitted with Ethernet connectivity to connect to existing
enterprise systems, thus immediately delivering a more scalable architecture for building
future control systems.
For example, consider a process control unit monitoring and controlling a temperature,
which consists of measuring the temperature and turning on/off a heating coil or fan. When
this temperature must be logged for historical data tracking, an external black box data
logger may be required. Or the data can be logged locally and retrieved across the network
for postprocessing. If the temperature must be broadcast to several plant supervisors, a Web
page must be developed as well.
While there are abundant control engineering software tools to solve various simple control
applications, few of them manage to solve all aspects of these new integrated control
systems. When evaluating control software, key elements to consider include:

Flexibility

Ease of use

Reliability

Performance

Open network connectivity (scalability)

Integration with measurement and control hardware

The Integrated LabVIEW Software Platform

National Instruments LabVIEW provides an intuitive software development environment
designed to help you develop scalable, networked control systems with any kind of
measurements, analysis or algorithm development, and I/O you need, from simple to
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complex applications. The LabVIEW platform of software products, which includes

LabVIEW, the LabVIEW Datalogging and Supervisory Control Module, and the
LabVIEW Real-Time Module, provides powerful tools for sophisticated monitoring, data
logging, supervisory control, PID control, fuzzy logic, single point analysis, control
prototyping tools, machine vision, and more.
This integrated software platform empowers developers to rapidly build control systems
and modify them easily as the system requirements change. Developing a measurement and
control system (Figure 1) with this tightly integrated software framework delivers
numerous benefits, including:

Significantly increased productivity throughout the development, deployment,

maintenance, and modification process with an intuitive development approach
optimized for measurement and control applications

Higher performance for real-time monitoring and control systems.

Tighter system integration that brings together diverse measurement devices into
high-level systems that connect easily to other processes throughout the organization

Decreased costs throughout the product life cycle

Network

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Signal
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Pressure
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Figure 1. Integrated Measurement and Control System

National Instruments Corporation

Case Study Semiconductor Manufacturing Tools

Consider a machine for manufacturing semiconductors that consists of four chambers with
different temperature and pressure settings for wafer manufacture. A system must be
implemented that monitors and controls the temperature and pressure in each chamber
according to defined set points or according to a profile. An embedded control unit could
be controlling the temperature and logging the average temperature once a minute to local
storage while sending the current temperature data up to the host system for data logging.
An operator may need to log into the system to view previous values up to a previous days
worth of data. A process engineer who needs to load a new temperature profile for the
chambers could do this by logging in at a higher access level than the operator.
You can see that this typical monitoring and control application includes the following
components:

Data logging

Historical and real-time data viewing

Alarm and event management

Security

Networking

Embedded control and analysis

LabVIEW provides built-in tools to address these needs so that you can spend time
developing the core monitoring functionalities, rather than developing security tools, alarm
management, etc. Because the number of applications including some kind of monitoring
are spanning from R&D, to design and validation, and manufacturing, these same built-in
tools can be used for various distributed monitoring applications.

Viewing, Logging, and Retrieving Data

When setting up a monitoring application, the ability to log the data easily is a requirement.
Because the operator is not always able to or supposed to monitor the system, logging data
for later retrieval is essential for data integrity, consistent report generation, postacquisition
analysis, or audit trail purposes. Logging becomes even more important when the amount
of data involved increases with the complexity of the system you need to monitor. And in
such a system an efficient control of your monitored data needs to go necessarily through
the implementation of an alarm and event management mechanism to better track down any
possible failure in the process. The need for a robust system with software tools capable of
logging a large quantity of data, and retrieving it in a cost-effective, efficient way is a must
in todays competitive market.
An open programming language can certainly offer extensive flexibility in the development
process of a monitoring application with a small number of channels.
However, the approach changes when developing a larger system. You quickly realize that
logging your monitored data on a channel-by-channel basis using a standard API is
challenging and time-consuming.

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A configuration-based environment such as the LabVIEW Datalogging and Supervisory

Control Module offers a better approach. In such a system the I/O is treated as an inherent
part of the system. Different configuration settings and tasks such as logging, as well as
alarms and events, historical and real-time data viewing, and scaling are managed
automatically as a fundamental aspect of the system. By taking advantage of these tools you
can concentrate on the development of your measurement and automation application
rather than spending time developing fundamental tools to log, view, and manage your
real-time and historical data. Moreover, instead of starting right away with the application
development, you can easily use these built-in tools as troubleshooting and diagnostics
utilities to get a quick snapshot of what is happening in the system and verify that the
hardware has been properly configured and the channel connection has been established
correctly.

Securing Your Monitoring System

Security is undoubtedly an important piece in a monitoring system, particularly in an
industrial environment where operators, engineers, and technicians are constantly
operating around the machine or process being monitored. The need for a secured
environment is necessary to avoid unexpected behaviors due to improper manipulations by
unqualified people. Again, using a standard API to implement system level and operator
interface security can be very complex and require extra knowledge. For example, in the
application description, a process engineer could log in to download a new profile to the
embedded control device. This can be further extended to a third level of security.

Sharing Your Data Across the Enterprise

Finally, you want to be able to share your monitored data with other groups in the company
for data storing, offline analysis, report generation, or Web publishing. Industry standards
such as Ethernet with TCP/IP and OPC (OLE for Process Control) are used more and more
in PC-based monitoring systems to seamlessly share your data across the enterprise, from
the lab to the factory floor.
Ethernet is quickly moving from the office onto the factory floor because of its low cost,
high speed, and multiprotocol ability, clearly becoming the universal network at all levels
of the enterprise. Ethernet can be implemented not only at the higher level of the plant
hierarchy, but also at the control level to connect distributed I/O to PLCs and data
acquisition systems. Ethernet and TCP/IP form a solid framework for networking and Web
connectivity. However, to easily share multiple I/O and data acquisition devices with
multiple PCs, the application-level protocol plays an important role. The application-level
protocol basically defines the common language used to talk to the different devices. In the
industry, standards such as OPC and HTTP are rapidly gaining consensus.
OPC provides a whole new level of interoperability between automation software and
hardware, removing the obstacles created by proprietary industrial device interfaces and
drivers. It defines a standard for a common interface to communicate with a variety of
industrial devices and communication protocols.
OPC is the answer to multivendor connectivity problems, which are specifically critical in
monitoring applications.
National Instruments Corporation

Distributed Intelligent Networks

While security and data viewing are important components to the main operator station of
a monitoring and control system, they must integrate to the actual device-level control.
With the LabVIEW Real-Time Module, engineers can now download LabVIEW
applications to embedded dedicated hardware targets. Engineers can take advantage of the
built-in networking tools of LabVIEW such as NI DataSocket to easily integrate these
embedded systems with the main operator station for a seamless control solution. In
addition, the core functionality and tools of LabVIEW enable engineers to develop
sophisticated control applications with embedded PID control, data logging, frequency
analysis, etc. and download it into an independent real-time device. Choose from a variety
of RT Series hardware targets to create a system that meets your exact needs today, while
taking advantage of the modularity of the system as your system requirements grow:

RT Series PXI with the RT Series PXI option, you can control an entire chassis of
various PXI/CompactPCI for a high-performance stand-alone real-time data
acquisition and control system.

RT Series FieldPoint with the RT Series FieldPoint you can develop a distributed
network of compact, industrial modules with the built-in intelligence and easy-to-use
networking features of FieldPoint.

RT Series Data Acquisition with the RT Series data acquisition boards you can
integrate a real-time component into a larger measurement and automation application.

Figure 2. Download LabVIEW Real-Time to Run on Different RT Series Hardware.

Embedded Device-Level Control

As the industry moves toward embedded systems for control applications, National
Instruments has met these needs with networked embedded real-time devices ranging from
small footprint distributed I/O systems to modular high-performance PXI/CompactPCI
systems. With the high-performance PXI system, capable of 40 kHz real-time control
loops, engineers can create high-performance embedded systems such as a machine
condition monitoring system that analyzes vibration. The distributed FieldPoint systems
provide a low-cost, compact system that runs embedded LabVIEW code. This distributed
intelligent node can easily be placed around the any factory floor or manufacturing
environment for monitoring and control. With these hardware options, LabVIEW
Real-Time delivers the scalability to address future requirements.

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With the code running on a dedicated embedded processor, the systems deliver
deterministic performance with better reliability. For instance, an engineer can develop a
LabVIEW application on a Windows system and download it to an embedded FieldPoint
system. Once the LabVIEW application has been downloaded, the FieldPoint system is
now independent of the Windows system and can operate as a stand-alone device or be
integrated into a larger networked monitoring and control solution.

Integrated Measurement and Control

With the modularity of the RT Series hardware from National Instruments and the
LabVIEW Real-Time Module, you have the flexibility to define functionality through both
hardware and software. You can create a single custom application that does measurement
tasks as well as discrete control routines. One such system is more efficient than
implementing two systems with one performing measurement, such as temperature
monitoring, and the other performing temperature control. With a user-defined approach,
you can create a single system that consumes less space and more efficiently monitors and
controls your system.
With the RT Series FieldPoint and RT Series PXI hardware architecture, you can use a
network module and mix and match the I/O modules to create exactly what you need for a
given task. You can select from a variety of I/O types, which include analog I/O, discrete
I/O, relays, counters, pulse generators, and quadrature encoders. With an RT Series PXI
system, you can even incorporate signal conditioning, motion control, CAN, and
third-party hardware to address expanded I/O signal requirements. With the different I/O
modules, you can make direct signal connections to currents, voltages, thermocouples, and
more.

Logging Data
The RT Series FieldPoint and RT Series PXI hardware targets also have data storage
capability so they can acquire and store data for postprocessing or retrieval. The user has
access to both RAM for temporary storage and nonvolatile memory for permanent data
storage. The access to nonvolatile memory is done via the LabVIEW file I/O functions,
which use the convenient file system of the modules. For example, the RT Series FieldPoint
network modules can acquire data for a period of several days, run a signal analysis
function to determine its statistical importance, and finally send the compiled data to a host
system. Or it can continuously process and send data, and then store it temporarily if any
networking problems occur. At the same time, this data can be sent back up to the
monitoring system with the LabVIEW Datalogging and Supervisory Control Module,
which is storing data from multiple distributed FieldPoint systems.

Develop, Deploy, and Maintain Your System

Using the LabVIEW Real-Time Module and the RT Series hardware, you can rapidly
develop your networked system, and then easily deploy it to run on its own or within an
existing system. You can also reliably maintain and modify it after it has been in use. The
durability of the products during all three phases of use reduces your overall cost in both
initial development and long-term maintenance.

National Instruments Corporation

Using the LabVIEW graphical development environment to create real-time systems

reduces development time for measurement and automation applications. No new learning
curve is required to use the real-time embedded National Instruments devices because the
functionality of LabVIEW on Windows, including networking, data processing, and
acquisition, is simply downloaded to run on the target hardware. You use the same
LabVIEW development environment, which scales across both hardware platforms to
integrate different hardware targets. Debugging is also simplified because you can use
LabVIEW to connect through the Ethernet port to the program embedded in the RT target
hardware.
After your system is deployed, you may need to modify software or hardware to satisfy new
requirements. Because LabVIEW can download new programs through Ethernet, you can
upgrade or change your software without disturbing your hardware configuration.

Increase Your Productivity

With LabVIEW, National Instruments provides a software solution that satisfies these
monitoring requirements by eliminating the need to develop your own tools. With the
LabVIEW Datalogging and Supervisory Control Module, you have built-in tools to
perform traditional monitoring tasks, such as alarm handling, historical logging and
viewing, data management, and networking, for a significant increase in your productivity.
Also, with easy networking, distributed logging, built-in security, and OPC connectivity,
the LabVIEW Datalogging and Supervisory Control Module provides tremendous ease of
use to get your monitoring system up and running quickly; and by adding full OPC client
and server capabilities to your LabVIEW application, you can communicate with any OPC
server available on the market today.

This LabVIEW add-on module also adds an event-driven engine to your LabVIEW
application. This engine runs in the background and maintains the real-time database, logs
historical data, processes alarm information, and communicates with device servers. You
can then define your advanced control algorithms, supervisory control, analysis, and
monitoring in LabVIEW.
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The event-driven architecture of the engine greatly improves the performance of your
system by freeing up CPU time until an event occurs. An event is generated when a data
point changes, a switch is toggled, or an alarm is generated. When the event occurs, the
system is notified and executes the specified functionality. The clear advantage of such
architecture is that the system has more capacity for growth without performance
degradation.

Integrated Software Framework for Better Productivity

With the release of LabVIEW 6.1 and its modules for monitoring and real-time control,
National Instruments offers a unified environment to build your real-time applications as
well as your supervisory control and monitoring applications. By having a single
development environment that can do both, you can increase your productivity simply by
not having to learn and use more than one environment.
The LabVIEW Datalogging and Supervisory Control Module offers you built-in tools to
significantly increase in productivity by easily setting up your monitoring application
without worrying about developing fundamental monitoring tools to handle traditional
tasks such as alarm handling, historical logging, data management, security and
networking.
The LabVIEW Real-Time Module and RT Series hardware take the power and ease of use
of a PC-based system and extend that to a networked system of intelligent nodes for
measurement and control. Architectures such as RT Series FieldPoint embody a
convergence of major technology trends from smaller, more embedded intelligent systems,
to the growth of Ethernet on the factory floor, to Web-enabled applications, to the
integration of manufacturing and test. They deliver better productivity in developing,
deploying, and maintaining applications in design, test, and manufacturing.
Using PC-based industry standards such as TCP/IP and OPC, you can make real-time
plant-floor information easily accessible to the production and business applications. And
to go beyond the factory boundaries, Web-based capabilities, such as the built-in Web
server in LabVIEW 6.1, are opening up new doors for an even easier access to your plant
floor data from anywhere at any time with a simple browser.
By using National Instruments software and hardware, you also have a migration path to
other technologies. LabVIEW not only integrates a wide range of I/O, helping you reuse
your knowledge across many different applications, but also adapts quickly to new industry
technologies, making it easier for LabVIEW users to take advantage of them in their
solutions. For example, LabVIEW users can incorporate machine vision or motion control
into existing data acquisition applications while using the same environment, programming
concepts, and techniques they already know. National Instruments continuously expands
the capability of its software and hardware platform, making it as easy as possible for
migration by customers who want to expand and enhance existing systems.
Finally, over the past 15 years, LabVIEW software has grown to be an open industry
standard in test, measurement, and automation. The number of engineers and scientists
familiar with using LabVIEW continues to increase, which makes it easier to find expertise
for your application. In addition, the global support services of National Instruments with
its more than 700 Alliance Program partners worldwide help you remain successful.
National Instruments Corporation

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