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Development of a Portable Process Data Acquisition

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1. Table 6 6 Demonstration of the generation of a time log event using a bitwise AND operation 3A logical AND operation results true when all operands are true otherwise the operation results false 7 Communication A sophisticated communication design is the basis to meet for several challenges such as data readout and remote maintenance As described in chapter 3 3 for a portable data acquisition system a good communication design is characterized by e connectivity e reachability e security To come up to this requirements the communication design is realized by using mobile telemetric standards and is integratable into existing network structures Past communication designs are based on the Global System for Mobile Communications GSM using direct data call connections 7 1 IP via GPRS The General Packet Radio Service GPRS is a packet oriented mobile data service based on the GSM network The technical innovation of GPRS in relation to classic GSM is the use of principle of packet switched communication The main benefit is an always online com munication charged per data volume in contrast to classic circuit switched communication where data transfer is billed per minute Additionally using GPRS instead of classic GSM makes modem hardware superfluous on the control center side The GPRS network stan dard comes with all typical features of digital communication such as encoding and digital
2. 9 3 Installation of a Digital Inputs 9 4 Pulse Counter Installation 9 4 1 Medaflex Clamp on Ammeter Installation 9 5 Temperature Installation 9 6 Installation of Analog Sensors 9 7 Advanced Configuration 10 Conclusion Bibliography A Input Adapter Module Schematic 35 35 36 41 42 44 45 45 48 48 49 51 53 55 55 56 58 59 60 61 62 63 63 64 65 66 67 69 List of Tables 5 1 5 2 6 1 6 2 6 3 6 4 6 5 6 6 7 1 7 2 8 1 Medaflex current sensor modes llle eae Describtion of different 1 Wire wiring types rs Comparison of the different x82 RTCU memory models Configuration string table demonstrating the available system parameters Overview on the data point map structure of the software including both VIDA350 and VIDA44M compilation versions 0 Data frame types in the binary dataformat Five examples demonstrating the different time bit mask results referring to the default minute interval configuration lll Demonstration of the generation of a time log event using a bitwise AND op run Cru Implemented HTTP responses mn nenn Valid HTTP query content 22e Peli Case 1400 internal dimensions List of Figures 2 1 2 2 2 3 2 4 2 5 3 1 3 2 4 1 4 2 4 3 4
3. 7 Communication 53 This implementation is a practicable solution being compatible to the existing My JEVis sys tem and enables the query for a single data point DP request Table 7 2 illustrates the valid HTTP queries Function HTTP Query Single DP from int FLASH DPx without time range where x stands for the DP number Single DP from int FLASH DPx lt start time gt lt end time gt with time range where x stands for the DP number All DPs from int FLASH without time range DPall All DPs from int FLASH DPall start time end time with time range All DPs from opt SD card SD without time range All DPs from opt SD card SD start time end time with time range Table 7 2 Valid HTTP query content The time formatting is defined without any seperators in the format DDMMYYYYhhmmss e g the date 2009 12 21 11 12 13 is stored as 21122009111213 7 4 Remote Maintenance Based on the IP communication the communication design contains a primary remote con trol service The remote control design is compatible to commonl software e g a telnet clientand supporting a direct IP socket communication as well The remote service allows the reading and writing of all system parameters Additionally the remote service offers the possibility to get several status informations out of the device and supports a time synchro nization The service port is conf
4. Internal FLASH Memory SD Memory Card e fused on board e optional mountable e max 512 KiByte capacity e up to 2 GiByte capacity e expensive to replace e easy to replace e difficult to access e easily accessible Table 6 1 Comparison of the different x32 RTCU memory models To gain a maximum benefit out of the different memory models the data storage functions will be allocated as shown in the following schedule The internal FLASH memory will be used for e system and program paramters e basic data logging The SD memory card will be optionally used for e advanced data logging e logging periods given in seconds e long time data acquisition To guarantee a continuous data logging all data storage services are implemented as a circuit buffer design 6 1 1 Internal FLASH Memory All x32 family RTCU units come with a 512 KiByte non volatile FLASH memory The Logic IO firmware devides the FLASH memory into five different allocation areas The figure 6 1 shows the memory map of the FLASH memory in a x32 family RTCU unit The upper addresses in FLASH memory are always locked in size and position This mem ory area is subdivided into reserved memory for system contents coming with the Logic IO firmware and into the so called persistant memory The lower adresses in FLASH memory are flexible The voice memory is located at the bottom of the FLASH memory and has at least the size of 1 KiByte including the directory informati
5. ble web browser The most common used web applications are the e JEChart e JEBench software modules The JEChart module is a graphical user interfaces GUI offering the illustration and com parison of data rows such as consumptions switching states or costs JEChart allows the drawing of line and bar charts and supports different additional graphical options such as zooming and color highlighted threshold visualization see figure 2 4 http www my jevis com 2 Background 17 Analyse Bearbeiten Info EI al Kunde Envidatec Gi Hauptdatenpunkt Stromhauptz hler Q Ane Daten Minimalwert 0 52 KW Ort Envidatec GmbH Demoanlage Zentrale Veritaskal 3 Untergeschoss Niederspannungshauptverteilu Maximalwert 33 38 KW Mittelwert 2 84 KW Cursor Wert 1 18 KW Mi 27 Do 28 R28 5230 1 Yergleichsdatenpunkt 1 Gashauptz hler Minimalwert 0 m 3 h Maximalwert 224 m 3 h Mittelwert 24 65 m 3 h Cursor Wert 20 0 m 3 h Vergleichsdatenpunkt 2 Minimalwert 0 Maximalwert 0 Mittelwert 0 Cursor Wert 250 200 ee 1504 1004 504 j 7 e oca Hr Set o 2 Vergteichsdatenpunkt 3 Wasserhauptz hler Minimalwert 0 17h Maximalwert 80 17h Mittelwert 1 28 1 h Cursor Wert 0 0 1 h Vergleichsdatenpunkt 4 Minimalwert 0 Maximalmert 0 Mittelwert 0 Cursor Wert 80 604 40 A h N o
6. time time value value Figure 5 1 Representation of the same pulse sequence in continuous and differential counting Differential Pulse Counter The differential pulse counter method works quite similar to the continuous pulse counter Unlike the progressional counting the differential pulse counter sums the pulses partitioned to a defined time window In contrast to the continuous pulse counter method the partitioned summation of pulses prevents a wrap around behavior wrap around describes the effect of an overwrite of the value margin 5 Data Input 30 5 2 Medaflex Clamp on Ammeter Integration Focused on an improved applicability for temporary metering installations the data input design contains the adaptation of the Medaflex clamp on ammeter made by the german producer MEDATEC The Medaflex clamp on ammeter is equipped with a flexible metering coil which is placeable around a power line without opening a wire 8 The metering principle of the Medaflex clamp on ammeter is based on the rogowski effect detecting the actual current by the interpretation of the inductive radiation field plug connection metering range selector 30 300 3000A 1 MEDAFLEX ES output gt controller MEDAFLEX rogowski coil Figure 5 2 MEDATEC Medaflex scheme The Medaflex core is based on a microcontroller circuit converting the rogowski coil values into digital or analog output signals The output mode can be s
7. 2010 06 06 14 30 2010 20 Peli Products UK Ltd http www peliproducts co uk access case dimensions html 2010 06 06 14 30 2010 21 United Nations Kyoto Protocol to the United Nations Framework Convention on Climate Change 1998 22 Helmut Kopka and Patrick W Daly editors Guide to LATEX Tools and Techniques for Computer Typesetting Addison Wesley fourth edition 2005 23 Dictionary of Contemporary English 3rd Edition Langenscheidt Longmann 1995 A Input Adapter Module Schematic v1 00_final TITLE InputAdapter Date 25 06 2010 02 38 21 Versicherung uber die Selbststandigkeit Hiermit versichere ich dass ich die vorliegende Arbeit im Sinne der Pr fungsordnung nach 825 4 ohne fremde Hilfe selbstst ndig verfasst und nur die angegebenen Hilfsmittel benutzt habe W rtlich oder dem Sinn nach aus anderen Werken entnommene Stellen habe ich unter Angabe der Quellen kenntlich gemacht Hamburg June 25 2010 Ort Datum Unterschrift
8. 21 2 217 562 6 362 348 564 N rnberg 10 05 20 972 668 3 022 321 862 Hannover 09 09 19 1 808 345 5 626 321 426 Passau 04 05 18 1 227 505 3 835 320 080 Stuttgart 21 05 17 1 130 551 3 575 316 238 Aachen 06 03 16 1 829 590 5 874 311 473 Halle 25 08 15 1 632 580 5 555 293 894 Hamburg 15 01 14 1 743 050 5 943 293 295 W rzburg 27 08 13 854 829 2 966 288 209 ISaarbr ck 05 02 12 630 359 2 196 287 049 Frankfurt 05 10 11 7 1 881 912 6 762 278 307 Flensburg 19 05 10 8 1 680 665 6 058 277 429 Leipzig 12 09 99 980 928 3 703 264 901 Bremen 03 04 85 1 449 550 5 517 262 742 K ln 22 04 7 834 046 3 242 257 263 17 41 Wilhelmsh 21 09 6 4 667 789 2 640 252 950 9 07 Essen 17 08 5 1 362 005 5 589 243 694 15 62 Kassel 02 09 4 6 1 625 010 6 891 235 816 10 01 Dresden 12 10 3 3 1 397 862 6 010 232 589 2 44 M nchen 30 05 2 2 696 456 3 223 216 089 4 90 D sseldorf 05 10 11 1 136 981 5 527 205 714 3 52 400 300 kWh Jahn m 2 Figure 2 5 The My JEVis Java based web application JEBench offering the ranking and sortation of data rows 3 System Requirements The development of a multi purpose portable process data acquisition system has to deal with a multitude of different requirements Creating a full integrated system solution puts several challenges on the system design The system design has to handle different software requests such as input control dat
9. Analog Values 22 222 mama a nn 3 1 4 Temperatures 222mm 3 2 Data Logging and the Storage of Data 3 3 Communication 2 020000 2 ee 94 Case Design a Bares eR ee oe ee be E eRe eR Programmable Hardware 4 1 The Logic IO x32 family RTCU Hardware 4 2 The Logic IO RTCU IDE ua ceo ea En EC E ee RR ES 43 Reusability of Code 2 25228 44 844 HRS RR RE ERE xS Data Input 5 1 Digital Input uou ncs xu gu Be a Se a ake a ra eC ELA war a ES 5 1 1 Digital States 22 2 2 24 5445 RR LS 44 RR om RR Xx 5 1 2 Pulse Counter 2 50 ok 2 aa see Be Br ad 5 2 Medaflex Clamp on Ammeter Integration rn 5 3 ACIDO rr C Sam doe boa we doe OBR ee Se eS 5 4 1 Wire Temperature Sensors 2 e a 10 11 13 13 14 15 18 19 19 19 20 20 21 21 22 23 24 24 26 Contents 6 Data Logging and the Storage of Data 6 1 Data Storage 6 1 1 Internal FLASH Memory 6 1 2 SD Memory Card 6 1 3 Data Formats 6 2 Log Event Handling 6 2 1 State Control 6 2 2 Time Control 7 Communication 7 1 IPviaGPRS 7 2 Virtual Private Network 7 3 Data Readout Interface 7 4 Remote Maintenance 8 Case Design 8 1 Peli Case 8 2 Front Panel 9 Realization 9 1 System Installation 9 2 Establishment of Communication
10. special configuration string Therefore a single system restart detects and configures all installed sensors A basic acquisition of temperatures can be configured using the graphical system menu System Menu Setup Menu Data Points Temperature A basic acquisition of temperatures can be configured using the graphical system menu All enabled temperatures are displayed peridocally in the LCD Temp 1 26 2 C Input 00000000 Figure 9 11 The LCD displays the enabled temperature sensors 9 6 Installation of Analog Sensors For the installation of an analog sensor the input signal is connected between analog input and the relating analog GND reference The GND has to be connected to the reference of the connected equipment By using onlywires of the same length and profile the metering accuracy is improved Analog Input Ond Input 1 Ond Input q E Gnd Input 3 Ond Figure 9 12 Four analog inputs with associated GND provided by the MC 350 The analog inputs are sensible to elecontrical interference so deviations may occur To reduce deviations avoid long unshielded wires and fast changing signals routed parallel to the analog signals The impedance of the analog inputs is 40kQ 5 9 Realization 65 All enabled analog values are displayed periodically with a 10 bit resolution 0 1023 Analogi 255 Input 60000000 Figure 9 13 The LCD displays analog values 9 7 Advanced Configuration
11. 4 Programmable Hardware Since the foundation in 2001 the Envidatec GmbH has developed several hard and soft ware applications Out of the experience from the early concern history the development of hardware devices became more and more insignificant in the main business concept Since 2007 the development of field devices is completely based on the use of programmable hardware combined with a custom designed software developed by the Envidatec GmbH The first data logger based on a programmable hardware manufactored by the danish Logic IO named VIDA88 was developed in 2007 In 2009 Logic IO has realeased a new so called x32 architecture hardware design The x32 architecture is a dynamic hardware design presenting a generic core for actual and intended Logic IO products Therefore the basic VIDA88 functionality was adapted on the Logic IO RTCU DX4 pro unit within a student project resulting the new VIDA350 version 1 00 application 1 Figure 4 1 Logic IO RTCU DX4 pro DIN rail device 5 To improve synergies for future data logger development the software design will be based on the VIDAS350 software version 1 00 The achievements of the software design developed in this thesis will result the VIDA350 2 00 software version http www logicio com 4 Programmable Hardware 24 4 1 The Logic IO x32 family RTCU Hardware The Logic IO x32 family RTCU product line is based on a 32 bit ARM7 processore with 1 MiByte RAM The
12. DIN rail allows an installation of DIN rail components The ex ternal 230VAC power is realized with a BELDEN IP67 power connector For safety reasons the mounting plane including the DIN rail is connected to the protective earth conductor of the external power supply Additionally the electronic system is secured by an extra fuse 8 2 Front Panel Peli Products offers a mounting bracket to install electronic or instrumentation panels The front panel made of anodized aluminum material provides a clear view on the functions All necessary connectors are integrated in the front panel The front panel layout is realized with the program Frontplatten Designer Version 4 01 provided by the Schaeffer AG To provide a quick and easy installation the front panel is equipped with screw clamps which allow to connect wires and pin plugs the same way The programming interface is accessible using acommon RS 232 connector Contrary to the common connector concept digital input 1 to 3 is equipped with a four pole connector suitable to the Medaflex clamp on ammeter The DIN rail components can be operated through a cut out in the center For the electric security the front panel is also connected to the protective earth conductor The finalized front panel is ordered and manufactured by transferring the layout file to the Schaeffer AG BELDEN prior Hirschmann is a producer for electronical equipment http www belden com http www schaeffer ag d
13. Positioning System GPS module Apart from this both devices differ only in the number of I Os Be cause the system design is based on the VIDA350 software core the GPS implementation is not further discussed in this thesis DP Index VIDA350 DP Index VIDA44M 1 8 Continuous Counter 1 8 1 4 Continuous Counter 1 4 9 16 Differential Counter 1 8 5 8 Differential Counter 1 4 17 24 Digital Input 1 8 9 12 Digital Input 1 4 25 42 Temperature 1 18 13 30 Temperature 1 18 43 System Temperature 31 System Temperature 44 47 Analog Input 1 4 32 33 Analog Input 1 2 34 GPS Latitude 35 GPS Longitude 36 GPS Speed 37 GPS Height 38 GPS Course 484 MODBUS I O Extension 39 MODBUS I O Extension Table 6 3 Overview on the data point map structure of the software including both VIDA350 and VIDA44M compilation versions 6 Data Logging and the Storage of Data 40 Data Logger To get access to the data logger memory within the internal FLASH chip the Logic IO SFL provides functions for initialization read and write operations The data logger has a circuit buffer structure replacing the oldest log entry with a new value if the data logger memory capacity is completely in use The number of data point values stored per log entry depends on the datalogger initialization DateTime 4 Time of logentry seconds since 1980 1 1 00 00 00 FEN Usersupplied Ta
14. RTCU product line constitutes of a combination of programmable control units with flexible digital and analog 1 0 GSM GPRS quad band communication and pro vides several possibilities to store data The x32 family units offer also the opportunity to expand the integrated peripherals by using the supported bus systems such as Modbus 1 wire CAN or using the serial interfaces RS 232 and RS 485 All x32 family RTCU devices are equipped with a Li lon battery pack for uninterruptible power supply 6 The Logic IO RTCU devices are established and proven equipment compliance with specified demands of industrial applications referring to e Ingress Protection IP Code IP 20 according to the International Electrotechnical Commission IEC 60529 e EN 61000 6 2 and EN 61000 6 3 according to the European Electromagnetic Compatibility EMC Directive e European CE marking conformity The Logic IO RTCU units can be programmed using the custom made high level language VPL which looks similar to Basic or Pascal syntax To facilitate easy access to the many different features the Logic IO units come with the Logic IO Standard Function Library SFL The Logic IO SFL provides a number of functions to be used by the programmer for develop ing a software application based on the available RTCU platform features without a detailed knowledge of the built in hardware realization 7 4 2 The Logic IO RTCU IDE The free available RTCU integrated develo
15. directives allow the selectiv in or exclusion of code for or from compilation depending on the specified conditions The conditions could either be defined by the DEF INE direc tive or could be defined in the RTCU IDE project settings The code example in figure 4 4 will demonstrate the compiler behavior DEFINE VIDA350 IFDEF VIDA350 OR VIDA44M THEN this code will be included for both VIDA350 and VIDA44M compilation WEHD IF IFDEF VIDA44M THEN this code will be included only for VIDA44M compilation END IF Figure 4 4 Exemplary conditional compiling structure realized with preprocessor commands This design aims to be compilable for the VIDA350 based on the RTCU DX4 pro and VIDA44M based on the RTCU MX2i pro product line and will change the parallel software development for two different products to one simultaneous development 5 Data Input Providing different input interfaces for the acquisition of process data is one of the most important system features The digital and analog input of the RTCU device should be used in a multi purpose way In order to this the design allows the definition of different data points relating to a single physical input 5 1 Digital Input The RTCU DXA pro device provides eight DC isolated digital inputs The signal level is 5 to 3VDC for a logical 0 signal and 6 to 40VDC for a logical 1 signal level The input state detection is based on the interrupt control functions featur
16. error checking The communication is based on using the standard Internet Protocol IP In opposition to further advanced communciation standards such as the Universal Mobile Telecommunications System UMTS the availability of GPRS is well developed world wide GPRS comes with a wider bandwith 56 114 kbit s than GSM 9 6 kbit s and allows a more fault tolerant communication especially at low signal strength The GPRS tariff price level is comparable with classic GSM communication costs 16 The always online infrastructure of GPRS allows 7 Communication 49 e increasing actuality of data e continuous automated maintenance e a short reaction time for problem solutions Additionally the GPRS modem should perform a common 24 hour automatic reconnect to increase the communication system stability The variety of advantages are accompanied by two particular disadvantages linked with typ ical GPRS communication 1 Only unidirectional communication initiated by the Subscriber Identity Module SIM client is possible A communication initiated from another side is not possible because the client network address is located behind a routing device on the side of the internet service provider ISP running a network address translation NAT 2 All communication takes place via the public internet transparent for and unprotected from third parties 7 2 Virtual Private Network Virtual Private Network VPN generally descr
17. of system settings and behavior to penetrate the system with possible fault cases H ii j T3338 ipu pee Er vo DIP switch and LED messages mmm 5 tee imm 51 tol imm 7 nter imum 55 F I veria WIV ADIONVIN T EI Y TIRE eee iat Cu Button LCD display External temperatur sensor GSM editor Figure 4 3 The Logic IO RTCU IDE integrated simulator tool boxes 7 4 3 Reusability of Code To increase the efficiency in software development of the Envidatec GmbH all results arising from this thesis should benefit the already established data logging products In addition the software design should constitute the universal basis for future RTCU based development As a consequence of this aim the design also attaches a great importance to the compati bility to other x32 based RTCU units such as the Mx and the advertised Logic IO Cx and Ax devices To ensure a wide reusability of code the software realization will base on generic x32 compatible functions coming with the Logic IO SFL All device specific parameters and func 4 Programmable Hardware 27 tions such as e g the number of I O special peripherals etc will be implemented using conditional compilation Conditional compilation describes the usage of directives which get checked before any other compilation happen so called preprocessor commands The con ditional
18. only stored once per file 250 200 150 ASCII at least 400 binary fixed reserverd memory in byte 50 number of data points Figure 6 4 The memory usage of the binary format compared to the ASCII format To guarantee a faultless interpretation two specifications must be defined 1 Every correct file has to start with a set frame 2 The specific data point variable size must be known for correct data interpretation The system will arrange a structure following the principle of one data directory per day to implement a clear directory structure 6 2 Log Event Handling The system has to handle several conditions to trigger a data storage The faultless detection of log events depending on time or state is an important system process To come up on this high priority the log event handling function gets triggered as often as possible in the so called real time 6 Data Logging and the Storage of Data 45 6 2 1 State Control For the logging of digital states an asynchron log event detection has to be realized The log event handle process directly polls the values of the variable referring to the digital states as described in the chapter 3 1 1 Digital Input 6 2 2 Time Control The system offers an individual time interval configuration for the continuous data acquisition by time To provide a system with a large degree of freedom the system design supplies up to eight free programmable time in
19. provides a direct access to the FLASH memory allowing the modifi cation of all configuration strings by using the hidden saveString command The direct modification of configuration strings is recommended only for trained users 9 3 Installation of a Digital Inputs All digital inputs are low pass filtered and transient protected 5 The digital inputs 4 to 8 are equipped with screw clamp connectors allowing the connection of 4mm plugs and conduc ters with a profile up to 1 5mm To record a digital state the signal line is directly connected 9 Realization 62 to a digital input The reference ground GND voltage is connected to the system GND located at the top right of the MC 350 Input 4 Inpu Figure 9 7 MC 350 digital inputs 4 to 8 The second LCD line is reserved for the status report of the digital inputs The eight dig its corresponds to the eight digital inputs The 0 indicates a logic low state and the I respectively the logic high state Digital input status Vidas56 v2 66 4 Input 2OOOOIOII f Figure 9 8 Illustration of the LCD displaying the status of the digital inputs 9 4 Pulse Counter Installation The digital input 4 up to 8 can be used to install a common pulse interface to the MC 350 Following the SO working principle the pulse interface is supplied by the MC 350 Therefore the SO input of the pulse counter is connected to the 24VDC power supply In order to record pulses coming from
20. where every line represents a single data point The line content is specified as lt time stamp gt lt data point number gt lt value gt where the lt time stamp gt represents the logging time formated in Universal Time Coor dinated UTC standard as we D MM YYYY hh mm ss seperated by comma followed by the specific data point number and the referring value 15 A correct formatting is shown in the example below Caused by the human readable formatting a single logged data point reserves at least 23 byte in memory The needed memory for additional data points is linear e g at least 230 byte in memory for a setup of ten synchron data points 6 Data Logging and the Storage of Data 43 29 04 2010 14 45 00 1 12 23 29 04 2010 14 45 00 2 169 13 29 04 2010 14 45 00 3 26 00 30 04 2010 15 00 00 1 13 12 30 04 2010 15 00 00 2 169 80 30 04 2010 15 00 00 3 26 20 Binary Data Format The big advantage of using a binary data format instead of an ASCII format is the con siderably reduced memory space needed The minimization of redudant information and formatation is achieved by e identic time stamps are saved only once e no formatation characters like seperators or new line are needed e each variable has a fixed size unafflicted by the specific content The advantages in memory usage when writing data binary into a file comes with the loss that the processing of data is only possi
21. 0 Synchronization Synchronization parameters 11 Heating Control Configuration of the heating control 12 Cooling Control Configuration of the cooling control 13 Clock Timer 1 Controls a digital output controller is coupled with the heating control 14 Clock Timer 2 Controls a digital output controller is coupled with the heating control 15 Clock Timer 3 Controls a digital output 16 Clock Timer 4 Controls a digital output 17 32 Alarm Configuration of 16 alarm controllers 33 Data Point Map Data point configuration Table 6 2 Configuration string table demonstrating the available system parameters 6 Data Logging and the Storage of Data 39 Data Point Map The data point map is a special group of configuration strings In contrast to the ordinary configuration strings that have always the same structure the data point map depends on the specific x32 family RTCU platform The data point map consists of a configuration string for every data point describing the individual behavior on log events The data point config uration starts with the abbreviation DP in combination with a serial numeration and a short describtion followed by the log event behaviors A typical configuration string defining the data point map looks like DP9 Differential Counter 1 0 0 Table 6 3 presents an overview of the data point map on the supported RTCU platforms As seen the VIDA44M relating MX2i RTCU platform supports an additional Global
22. 4 5 1 5 2 5 3 5 4 5 5 5 6 6 1 6 2 6 3 6 4 6 5 Plan Do Check Act PDCA cycle of an energy management system The visual detection of a water leakage as an example for process controlling using data monitoring o oo ze x mox a My JEVis system overview uos uoo o9 Ro a The My JEVis Java based web application JEChart allowing the drawing of line and bar charts aoao a a The My JEVis Java based web application JEBench offering the ranking and sortation of data rOowWS aoao aan Overview on the system requirements 2 2 2m nn nn Illustration of a SO interface according to DIN 43684 Logic IO RTCU DX4 pro DIN rail device llle The Logic IO RTCU IDE providing several programming tools The Logic IO RTCU IDE integrated simulatortoolboxes Exemplary conditional compiling structure realized with preprocessor com pao WT ee ee ee ee ee ee ee Se Re Representation of the same pulse sequence in continuous and differential COUNING 2424 amp ox RR ads 842845 xe Sox xo ROS b EON E RUE eR d MEDATEC Medaflex scheme a Four pole connector comming from the Medaflex controller 1 Wire sensor power supply possibilities lll Illustration of the available 1 Wire bus wiring structures 1 Wire sensor control scheme 2l lll Logic IO x32 family RTCU memory map nn Logic IO SFL datalogger init
23. For an advanced configuration of all system settings the MC 350 provides two possibilities to access the configuration strings directly 1 Using the RTCU IDE tools by a direct programming cable connection To establish a programming cable connection a common serial cable is connected to the RS 232 data port located at the bottom left of the front panel 2 Access the configuration via the remote control interface Unafflicted by the chosen connection the user should be aware of the impacts caused by the system modification 10 Conclusion Making process data visible is an essential measure for the implementation of projects fo cused on the increasing of energy efficiency As shown in the beginning of this study the nature of aimed projects are widely spread The present thesis discusses the concept of us ing programable hardware dealing with these versatile requirements Based on the versatile system core this design creates synergies between mobile and immobile applications The achievement of this thesis results in a prototype of a portable process data acquisition system building a new product fitting into the existing product line and development inter ests of the Envidatec GmbH The new product named MC 350 improves the prior VIDA350 software development and combines embedded customized software with modern commu nication structure leading to an integrated system solution In June 2010 the first prototype was successfully tes
24. For the saving of the world for future generations the global society has to come to a con clusion in counteracting the climate change In 1997 international governments adopted the Kyoto Protocol in addition to the United Nations Framework Convention on Climate Change UNFCCC The Kyoto protocol sets a landmark constraining greenhouse gas emissions with innovative meachanisms aimed reducing of emissions Today the Kyoto Protocol is legally binding in 186 countries beeing part of the UNFCCC 2 In order to fulfill the international agreement the number of national regulations within the member countries is increasing Examples for such regulations are for instance e The adoption of a new Eco tax regulation in 1999 and the Renewable Energy Law in 2000 in Germany Both regulations aim to control the energy costs for the improve ment of climate the so called green energies e The international standardization of the establishment of an energy management sys tem described in the DIN EN 16001 and ISO 50001 In the near future a certified energy management system may become an obligation for energy intensive compa nies e g for the refund of the Eco tax provision The variety of new regulations and the rising energy costs lead to new economical chal lenges These demands gain new interests in energy efficiency services and create new business areas e The creation of Joint Implementation Jl and Clean Development Mechanism CDM projec
25. Hochschule f r Angewandte Wissenschaften Hamburg Hamburg University of Applied Sciences Nils Heinrich Development of a Portable Process Data Acquisition System Diplomarbeit eingereicht im Rahmen der Diplompr fung im Studiengang Informations und Elektrotechnik Studienrichtung Digitale Informationstechnik am Department Informations und Elektrotechnik der Fakult t Technik und Informatik der Hochschule f r Angewandte Wissenschaften Hamburg Betreuender Pr fer Prof Dr Ing Franz Schubert Zweitgutachter Prof Dr Ing Michael R ther Abgegeben am 25 Juni 2010 Nils Heinrich Thema der Diplomarbeit Entwicklung eines portablen Systems zur Prozessdaten Erfassung Stichworte Datenlogger Daten Monitoring Daten Controlling Potenzial Analyse Energie Diens leistungen GPRS Kommunikation Kurzzusammenfassung Der Nutzen von der Erfassung von Prozessdaten erm glicht eine Basis f r das Auffin den von Einsparpotenzialen und die Beurteilung von Optimierungsma nahmen Aus diesem Grund steigt die Bedeutung von Systeml sungen die die Aufzeichnung ver schiedener Datenquellen erm glichen Dieses Projekt beschreibt ein Design das die Erstellung einer ganzheitlichen Systeml sung zum Ziel hat Nils Heinrich Title of the paper Development of a Portable Process Data Acquisition System Keywords Data Logger Data Monitoring Data Controlling Potential Analysis GPRS Communi cation Abstract The advantage of recording proc
26. P 1 0 standard which is easily accessible using a standard like web browser or a command line client To readout data from the device a minimal HTTP daemon performing a GET method imple mentation is sufficient The HTTP GET method is the common function to get contents out of the world wide web Everytime a web page is opened by standard web browser the browser connects to the HTTP service addressed by the Uniform Resource Locator URL and sends a GET command to request a data transfer e g GET index html In contrast to common web applications the HTTP service sends logged data to the respond ing client The HTTP daemon has to addressed in the following way lt IP address gt lt port gt If the port is set to the default value common HTTP clients will not need an explicit lt port gt statement The requested information is assigned by a slash followed by a string the so called HTTP query If the request is related correctly the HTTP starts sending a HTTP header according to the HTTP 1 0 standard and the data transfer is initiated The specific lt Content Type gt parameter depends on the transfered data format e g an ASCII CSV file or a binary data file Contrary to a correct request an unresolvable request will cause an error according to the HTTP 1 0 standard shown in table 7 1 18 HTTP 1 0 200 OK response HTTP 1 0 404 Not Found response HTTP 1 0 200 OK HTTP 1 0 404 Not Found Server VIDA HTTP DAEMON
27. Server VIDA HTTP DAEMON Connection close Connection close Content Type text csv Content Length size in byte Table 7 1 Implemented HTTP responses 7 Communication 52 The internal data acquisition and the optional SD card acquisition follow different methods in saving data Caused by this circumstance the data is available in several forms All data saved to the SD memory card is already formatted after logging and is sent in a ASCII or respectively binary data file In contrast to the SD card data storage values saved in the internal FLASH memory are stored unformatted To transfer data relating to a request the data has to be formatted into a structured file format To fulfill this intention the same formatting function implemented for ASCII mode in the SD memory design can be used wes Formatting Formatting LE a Figure 7 2 Data write and readout operation scheme For the post storage formatting another ASCII data format used by common Envidatec appli cations is implemeted The format starts with a preceding file header containing two lines description line caption 1 gt lt caption 2 gt lt caption 3 is followed by an arbitrary number of data lines as shown below lt value gt lt time gt lt date gt A complete example of a data file Env HQ Metering Station 1 Value Time Date 219 28 20 45 00 05 06 2009 207 6 21 00 00 05 06 2009 208 8 21 15 00 05 06 2009
28. Time hh mm 8 7 6 5 A 3 2 1 02 05 45 50 00 o lo ololo olo ololo oo0lolo oo0lolo o0 lolo l ojojo o awla 2122 Table 6 5 Five examples demonstrating the different time bit mask results referring to the default minute interval configuration In order to prevent difficulties with different time zones the system time should always be in UTC standard UTC is based on the International Atomic Time TAI and corresponds to Greenwich Mean Time GMT without a clock change for summer time The persistant memory includes a configuration string to define an offset between the local time zone and UTC e g to display the local time onto the included Liquid Crystal Display LCD of the RTCU DX4 pro device Unaffected by the local offset the data acquisition and other time based functions always run synchronously to the system RTC being set to the UTC standard 6 Data Logging and the Storage of Data 47 Figure 6 5 gives an overview of the log event handler behavior Figure 6 5 Log event handling scheme The event handler behavior is verified by a bitwise AND operation between the actual time bit mask and the referring data point configuration An example is shown in figure 6 6 Time 8 7 6 5 4 3 2 1 LogEvent DP 0 0 o Jo oloo TimeMask 0 0 0 0 1 0 11 1 Result oio oloi olo o
29. a meter the SO output has to be connected to one of the available digital inputs SO pulse counter ee SO Vcc SO Digital input igital inpu Figure 9 9 Pulse counter installation according to DIN 43864 9 Realization 63 A basic pulse counter configuration is configured using the graphical system menu System Menu Setup Menu Data Points Dig Counter 9 4 1 Medaflex Clamp on Ammeter Installation Digital inputs 1 2 and 3 are equipped with a suitable four pole connector to support an easy installation of up to three Medaflex clamp on ammeters The input connector 1 to 3 is directly linked to the customized adaption module Figure 9 10 Installation of a Medaflex clamp on ammeter The metering range can be 30 300 or 3000A selected using the integrated switch of the Medaflex controller The logging configuration is set according to the pulse counter using counter 1 to 3 9 5 Temperature Installation The MC 350 supports the installation of up to 18 1 Wire temperature sensors The sensors can be connected to the 1 Wire bus connectors at the bottom left of the front using a star tree or chain wiring structure At the startup the system performs a bus scan and automatically initializes all plugged in sensors To ensure a correct assignment of temperature data points even after restarting 9 Realization 64 the system the relation between installed sensors and referring data point is saved in a
30. a storage and communication as well as the mechanical demands and the need of a suitable infrastructure for remote operating The following partitioning will give an survey on the main design challenges and the involved requests gt p Communication structure Figure 3 1 Overview on the system requirements 3 System Requirements 19 3 1 Data Input In creating an data acquisition system the main point of interest is the recording of data To accommodate for this the system design has to support different interfaces to get data from a process The following subsections present the different interfaces and their applicability All provided data inputs should be acquirable in a reasonable time resolution With the focus on a central maintainability and an unproblematic exchangeability of devices all data is stored in raw data The interpretation of the referring values is perfomed on a higher level in the My JEVis system 3 1 1 Digital States A lot of processes in a facility can be monitored using digital states In many cases the information about a process state becomes essential to evaluate the impact of different pro cesses Accommodate to this the system should provide the recording of different switch states e g monitoring the run time of a production machine The state control should pro vide a periodically recording of event as well as the detection of state changes in real time 3 1 2 Pulse Counter A mu
31. an electricity meter once a month Because of the high dynamics of 2 Background 15 technical processes such a low resolution of available data will not offer the desired illus tration In order for a significant illustration the resolution actuality and availability are the key standards of quality for the process data To match with these demands a continuous aquisition with a high data resolution realized by automatic systems results in an economic profit in the majority of cases An automatic system with a short data refresh time enables a clear process overview and allows a immediate detection and reaction on erratic process behaviors Detection of a water leakage 3 increased base consumption Mo 19 04 04 Di 20 04 04 Mi 21 04 04 Fr 23 04 04 Mo 26 04 04 After optimization m 2 base consumption after optimization 0 Mo 05 07 04 Di 06 07 04 Mi 07 07 04 Do 08 07 04 Fr 09 07 04 Sa 10 07 04 So 11 07 04 Mo 12 07 04 Figure 2 2 The visual detection of a water leakage as an example for process controlling using data monitoring The detection of a broken water valve shown in figure 2 2 demonstrates a typical benefit of a data monitoring system 2 3 My JEVis System The My JEVis is a server based overlaying system for data processing and data visualiza tion provided by the Envidatec GmbH The general functionality of the My JEVis system is partitioned into e t
32. and is well known from mobile devices such as digital cameras handheld com puters or mobile phones Generally the SD memory card technology follows the principles of FLASH memory Therefore the SD memory has the same limitation of erase cycles But counterbalanced by the size of up to 2 GiByte that is supported by the x32 family architec ture makes the SD memory card become an interesting optional data storage device for special logging setups In addition to this File Allocation Table FAT compatible SD memory cards have an intelligent file system which allows to increase the life time using features like marking corrupted clusters instead of using them Further the SD memory card comes with big commercial advantages for instance the low memory costs and an economical replace ability The SD memory card becomes a good option for the storage of a large amount of data balancing life time and economic necessities In order to optimize the settings for a long time data acquisition or a high resoluted data acquisition two different operation modes are designed 1 Synchron Mode This operating mode uses the SD memory card synchron to the internal FLASH data logger for long time data acquisition Thus the system will synchronously log all log events coming from the internal data logger to the SD memory card The hold back time is depending on the chosen data format and can be increased up to many years 2 Asynchron Mode This operating
33. ble with an extra interpretation software The complexity of the data format should be minimized to enable an easy data conversion Due to this the binary data format will contain only two different types of data frames 1 Set frame The set frame content describes the active data point log events referring to the data point map configuration The payload is a 16 byte long bit stream where every single bit represents the active 1 or inactive 0 setting for each data point starting with 1 up to 128 2 Data frame The data frame contains the data point values referring to the order described in the valid set frame The frames are distinguished by the leading byte Mode Payload Content Set Frame 0x00 16 byte describing the active data point map Data Frame OxFF Time stamp followed by logged data in order and as desribed in the set frame Table 6 4 Data frame types in the binary data format 6 Data Logging and the Storage of Data 44 The result of this design is a compact data format reducing the reserved data space per logged data point scaling down with a raising number of active log events This design allows to store a great amount of data over a long time Ten data points with a resolution of 1 second can be stored about two years without overwriting an older value A setup of ten 32 bit counter will cause a fixed memory usage of 40 byte and a set frame of 17 byte With only one time setup the set frame is
34. chnology the Envidatec GmbH also has the expertise in meth ods that allow to identify energy saving potentials such as hard and software solutions 3 ENERGY EFFICIENCY ANALYSIS x EMS according CONTINUOUS CONTROL MONITOR AND OF IMPROVEMENT N MEASURE 4 DIN EN 16001 b OPTIMISATION Figure 2 1 Plan Do Check Act PDCA cycle of an energy management system 3 Energy efficiency analyses that are in accordance with legal regulations or necessary for the refund of the Eco tax provision are part of the repertoire of internal audits offered by the 2 Background 14 Envidatec GmbH The new requirements of ISO 50001 and DIN EN 16001 will be the main concern of the Envidatec GmbH in the next decade By reducing the energy consumption in companies we are making a significant contribution to reducing CO emissions We see this as our contribution to achieve the climate protection targets of the Kyoto Protocol Thomas Frank Envidatec GmbH CEO Recently the international inquiries for the Envidatec GmbH energy services are increas ing For this reason the Envidatec GmbH proceeds in expanding its network of competence constantly by establishing a global network of cooperating partners The Envidatec GmbH established corporations in Vienna in 2007 and Yekaterinburg Moscow in 2010 Thus the product management is focused on standardized products customized for the international market The main interest of the Envidatec GmbH
35. d indexes Starting with index number 1 the so called configuration strings contain all needed system parameters In order to have a clear view on the different software param eters the configuration string is sorted by functionality The configuration string arrangement starts with general system parameters at the lower index numbers followed by parameters for extended system functions The end of the persistant memory is used for the higher in dex numbers for an individual configuration string for each data point the so called data point map According to this structure the software configuration can be done by storing several configuration strings in the FLASH memory of the device The specific items of a string are separated by semicolons After clearing a string it will be filled with default configuration data at the next reset of the device Index Configuration Description 1 Location String Name of the device it is part of the alarm SMS 2 Minute Time Intervals Configuration of up to 8 minute time intervals 3 Second Time Intervals Configuration of up to 8 second time intervals 4 Local Time Offset Difference between UTC and local time 5 GPRS Configuration of the GPRS communication 6 Port Map Port configuration of the TCP services 7 SD Card SD Card configuration 8 System Control System status control configuration 9 Temperature IDs Temperature sensor ID configuration 1
36. e 8 Case Design 57 Frontplatten Designer Front_MC350_v1 0_final fpd Front MC350 vi 0 eb Figure 8 2 Schaeffer AG Frontplatten Designer version 4 01 9 Realization The following chapter shows the realization of the developed design The resulting product is named MC 350 The chapter starts with a gerneral overview on the MC 350 and further discusses different setup possibilities As described in the case design all system components are integrated into a robust Peli Case With all components the case weighs about 4kg In the closed state the internal is well protected against external exposur Figure 9 1 Top view on the MC 350 in closed state If opened the MC 350 is characterized by a functional user interface All needed connectors are directly accessible on the front panel 9 Realization 59 Figure 9 2 Front panel of the MC 350 9 1 System Installation To prepare the power supply of the MC 350 the included power connector is plugged to the MC 350 after removing the protection cap The power supply is applied by an external 230VAC source The integrated 24VDC power supply is activated by the included cutout switch A green LED indicates a faultess operation state Status LED Cutout switch ANDA OAOA A MA OT RA98071056 S Figure 9 3 MC 350 power 24VDC voltage supply integrated in the right middle of the front panel The boot process starts automatically when the power
37. ed by the Logic IO SFL Each of the eight digital inputs will open up the three single data points e digital state e continuous pulse counter e differential pulse counter beeing individually configurable 5 1 1 Digital States For the acquisition of switching operations the digital state control monitors the digital input behavior To come across to different monitoring interests the control allows to detect e the actual state e if ainput state changed e the state changing direction thus if a falling or rising edge happened In consequence of the demand of providing three individual data points per physical input the state control runs parallel unaffecting an optional count of pulses 5 Data Input 29 5 1 2 Pulse Counter According to the SO interface standard the count of pulses directly represents the energy consumption The counter design presents two different counter models Both counter mod els are synchronously available Continuous Pulse Counter The continuous pulse counter model summates all incoming pulses comparable to the func tionality of a common counter reading display Thus the acquisition of continuous pulse counter by time come close to an automated alternative in opposition to the manual notation of counter readings The progressional summation of pulses comes with the negative characteristic of a possible counter wrap around a Continuous Pulse Counter b Differential Pulse Counter
38. elected by an analog voltage reference Mode select voltage U Mode OV lt Um lt 12V analog output in VAC 12V lt Um lt 18V digital pulse output 18V lt Un lt 24V debug mode Table 5 1 Medaflex current sensor modes Operating in digital pulse mode the Medaflex controller acts similar to common pulse meters But unlike common pulse counter implementations the Medaflex controller perform a low signal level of 3 3VDC for a logic 1 signal For the purpose of the signal adaption the system design will contain an extra source driver 9 to support a signal level corresponding http www medatec com 5 Data Input 31 to the RTCU device logic level To allow three phase current analyses the adaption module supports the connection of up to three Medaflex rogowski coils to the acquisition system The Medaflex controller operates with a 5VDC power supply provides three switchable me tering ranges 30 300 3000A and is equipped with a four pole connector 1 output 2 3 e 2 mode select 3 5VDC 1 4 eo Figure 5 3 Four pole connector comming from the Medaflex controller In order to provide a 5VDC supply and an additional voltage referring to the operation mode the module will contain a DC DC power supply based on the well developed L200 voltage and current regulator IC 10 For more flexibility and an increased possibility of reuse both supplied voltages will be scaleable using an onboard potentiome
39. ess data stems from its ability to create a basis forthe finding of saving potentials and the valuation of optimization measures For that rea son system solution offering the acquisition of different data sources becomes more important This project discusses with a design focusing the creation of a portabel intregrated system solution Acknowledgment sincerely would like to thank Prof Dr Ing Franz Schubert for giving me the opportunity to perform this interesting and challenging work in his department Special thanks to Prof Dr Ing Michael Rother for his interest in providing the co corrector for this thesis My other special appreciation goes to the management of the Envidatec GmbH specifically to Dipl Ing Thomas Frank and Dr Stefan Kuck for providing me with the challenge to carry out my research work within the company Last but not least want to express my gratefulness to my family and friends for their support during the making of this thesis and the whole study Contents List of Tables List of Figures 1 Introduction 1 1 Motivation 2 2 2 m mn Background 2 1 Envidatec GmbH 344 4 2 54 4 4 4 86484 2204 Se 8 Ode dd 2 2 Data Monitoring 4 4 44 304 2A e 5043 44504 Sew RUP Des 2 3 My JEVis System 2 2 nn ana nn nn System Requirements SA Data WPM 2 2 20 200 So 200 wre ne ee ae 3 1 1 Digital States 22 2 42 Bs 2 2 RES REG EE RACE a Dar R 3 1 2 Pulse Counter 222 2 on nn nn 3 1 3
40. g Leistungsbeschreibung v2 00 Envidatec GmbH 2010 5 Logic IO Technical Manual for the RTCU DX4 pro Version 1 04 2009 6 Logic IO RTCU DX4 pro Product Datasheet UK v1 11 2009 7 Logic IO RTCU IDE User Manual v5 10 2009 8 MEDATEC Datenblatt Medaflex 450 800 2009 9 Allegro MicroSystems Inc Datasheet UDN 2981A thru UDN 2984A 2001 10 STMicroelectronics Datasheet L200 Adjustable Voltage and Current Regulator 2000 11 Maxim Integrated Products 1 Wire Products Design Guide 4th Edition 2009 12 Maxim Integrated Products Datasheet DS18B20 Programmable Resolution 1 Wire Digital Thermometer REV 042208 2008 13 Maxim Integrated Products Application Note 148 Guidelines for Reliable Long Line 1 Wire Networks 2008 14 Logic IO RTCU IDE Online Help System http www logicio com HTML index html 2010 04 08 09 30 2010 15 Maxim Lobashov ntegration des Beckhoff PC in das JEVis System v1 3 Envidatec GmbH 2008 16 Joachim Tisal editor The GSM Network GPRS Evolution One Step Towards UMTS Second Edition Wiley 2001 Bibliography 68 17 Dr Wolfgang B hmer editor VPN Virtual Private Networks Kommunikationssicher heit in VPN und IP Netzen ber GPRS und WLAN 2 Auflage HANSER 2005 18 T Berners Lee R Fielding and H Frystyk Hypertext Transfer Protocol HTTP 1 0 HTTP Working Group 1996 19 Peli Products UK Ltd http www peliproducts co uk cases 1400 htm
41. gvalue 128 127 Figure 6 2 Logic IO SFL datalogger initialization 7 The system design provides an initialization with one value per log entry providing a dynamic system with individually configurable data points The tag value seen in figure 6 2 will be equal to the data point number and refers to the data point map A general disadvantage of FLASH memory is a physically limited number of erase cycles until the memory looses the integrity of the storage The life time duration of FLASH memory is in direct relationship with the number of values stored per log entry This correlation is based upon the absolute size in memory per value In consequence of the design the initialization allows up to 51968 log entries into the data logger memory until the oldest log entry is replaced A minimum number of over 3 million write operations are guaranteed by the manufacturer 14 In regard to the limited number of erase cycles the internal FLASH memory data logger is only be used to store data with a logging resolution given in minutes The result is a reasonable hold back time An exemplary hold back time is 54 days for ten data points with a resolution of 15 minutes 6 Data Logging and the Storage of Data 41 Figure 6 3 Limitation of FLASH memory write operations depending on the data logger initialization 7 6 1 2 SD Memory Card The Secure Digital SD memory card technology was developed by Panasonic SanDisk and Toshiba
42. he readout of data gateways e the storage and allocation of data into a data base structure e the continuously processing of data such as individual calculations and alarming 2 Background 16 e the visualization of data onto the My JEVis web frontend The My JEVis stands in connection with all installed data gateways using several ways of communication Referring to the My JEVis system topology a data gateway is any generic data device This can be a FTP server a building control system or field device supporting a My JEVis system compatible data readout interface The data gets fetched periodically and is stored into an Oracle based data base structure The raw data imported by the readout of the data gateways are interpreted and continuously processed ei JEVis Network en P convene en SNVIDNTe lt Portal w He SA Pd Sapicet Canter Figure 2 3 My JEVis system overview 4 The My JEVis system provides a Java based web frontend exclusively developed by the Envidatec GmbH The My JEVis web frontend offers a central data monitoring solution fo cused on the visualization of acquired data To match with this the My JEVis system comes with web applications allowing a contemporary overview on all available data rows 4 A significant advantage of the My JEVis system is the applicability for a multitude of different data sources and the web based monitoring software running in any standard Java compati
43. ialization ll nn Limitation of FLASH memory write operations depending on the data logger initialization x 4 44 u ox a a Een X GE c CES WIE E PHUKET ERN The memory usage of the binary format compared to the ASCII format Log event handing scheme l llle List of Figures 9 7 1 Site to Site VPN structure between the Envidatec GmbH and the ISP network SITUCLUFE uon o m now xoxo 4o kok o3 x E 803 X x DRE SRE ESSERE RR m d 50 7 2 Data write and readout operationscheme 52 8 1 Peli Case 1400 aoaaa nn 55 8 2 Schaeffer AG Frontplatten Designer version 4 01 57 9 1 Top view on the MC 350 in closed state 58 9 2 Front panel of the MC 350 aoaaa nn 59 9 3 MC 350 power 24VDC voltage supply integrated in the right middle of the front panel 2 22 2 5442 ai pb 2 2 sand aa aan 59 9 4 Illustration of the LCD displaying the software version at startup 60 9 5 LCD with communcation status and signal strength 60 9 6 IP connection for remote maintenance using a standard telnet client 61 9 7 MC 350 digital inputs 4to8 lll 62 9 8 Illustration of the LCD displaying the status of the digital inputs 62 9 9 Pulse counter installation according to DIN 48864 62 9 10 Installation of a Medaflex clamp on ammeter 63 9 11 The LCD displays the enabled temperat
44. ibes a software based solution to connect sev eral physical networks e g Ethernet and GPRS to a collective network without any barriers in IP communication VPN does not stand for a standardized protocol VPN is rather a techni cal solution which can be realized in several ways Depending on the VPN implementation there are different possiblities to encrypt the transferred data As a benefit from an encrypted data transfer the communication is secured from man in the middle or manipulation attacks from third parties and can be established through an insecure network such as public inter net without increased security risks In this case the VPN technology will be used to connect the ISP with the Envidatec IT structure using a secure VPN tunnel realized by the Internet Protocol Security IPSec standard a so called Site to Site VPN 1 7 To realize this Site to Site VPN setup the SIM cards have access to a specific customer access point name APN in stead of connecting to the typical public ISP s APN The SIM client users are authenticated by password or by SIM card ID All data transfer coming from a successful authenticated SIM user is forwarded from a specific ISP router the so called VPN terminator The data is encrpyted by the IPSec protocol and forwarded to the Envidatec VPN concentrator All SIM cards getting forwarded through the IPSec tunnel have a fixed The man in the middle method describes an attack based on the redirectio
45. igurable and is running by default on telnet standard port number 23 7 Communication 54 To improve the availability a redundant remote control is implemented The redundant re mote control uses classic GSM based on a direct circuit switched data call to access the device The GSM fallback is realized with the Logic IO firmware and allows a direct serial connection by using the RTCU IDE 8 Case Design The basic idea for design is based on the integration of DIN rail components into a portable case Another important point is the creation of a clear user interface 8 1 Peli Case Peli Products is the trading name of Pelican Products Inc in Europe Peli Products is a producer of protection cases for military or industrial use The Peli Case 1400 made of high quality plastic material has the dimensions L 339 x W 295 x H 152 mm 19 Figure 8 1 Peli Case 1400 19 8 Case Design 56 Base Base Base Lid Lid Lid Total Length Width Depth Length Width Depth Depth A B C D E F 306 mm 234 mm 100 mm 306mm 234 mm 30 mm 130 mm Table 8 1 Peli Case 1400 internal dimensions 20 If closed the Peli Case 1400 is watertight and dustproof certificated according to the IP67 standard The Peli Case 1400 is robust and has a lifetime guarantee For the electronical installation a solid mounting plane is integrated into the Peli Case Upon the mounting plane a built in
46. in the development process of a portable data acquisition system is the creation of a versatile tool e for the implementation of national energy efficiency advice and assessment of mea sures deployed e for the analysis of potential savings in international projects in accordance with ISO 50001 or the Kyoto Protocol e as a basis for training focusing the improvement of the know how transfer for the ex tension of the competence network 2 2 Data Monitoring Monitoring is a generally used term describing a concept to acquire and observe a process The substantial interest of a monitoring implementation is to increase the transparency of specific processes taking place in an organization Because of the wide ranging nature of processes found in an organization the term is expanded to the term data monitoring to point on the aim to acquire technical process data recorded by appropiate metering installation The economical interest in data monitoring is to display the dependency between processes or building a basis for business decisions This can be realized by benchmarking of different processes According to the experience of energy managers the initiation of an energy pro cess data monitoring system and the implementation of solely organizational measures will typically effect 5 up to 15 of enhancement in energy efficiency A simple data monitoring can be realized by a periodical manual acquisition e g by noting the counter reading of
47. ious student research project 1 Creat ing a new system based on prior achievements follows the Envidatec s strategy to minimize the effort for soft and hardware development by improving synergy effects between different products Before going into the discussion some formal declarations are made 1 Allincluded english texts are written in accordance with american english orthography 2 Unit prefixes followed by an i are binary prefixes referring to a base of 1024 219 e g 1 KiByte means 1024 byte 3 Commands variables and special programming statements are highlighted by a type writer font style 4 All program source codes are stored at the Hochschule f r Angewandte Wis senschaften HAW Hamburg accessible at the office of Prof Dr Ing Franz Schubert 1 Introduction 11 1 1 Motivation Recently the climate change becomes an omnipresent topic in all domains of the modern society While the world climate has always varied naturally the majority of scientists agrees that the increasing concentrations of greenhouse gases in the atmosphere are a result of the economic and demographic growth In contrast to the natural variability the consequences of the human caused boost of emissions leads to a potentially irreversible climate change The required research of the causes as well as the immediate implementation of strategies dealing with the consequenses will be a big global challenge in the ongoing 21st century
48. is switched on While the boot process performs the LCD shows the software version If no configuration is loaded to the system memory e g starting a new system all system parameters will be set to the VIDA350 v2 00 9 Realization 60 default values After initializating all system services the LCD displays several system states The LCD is divided into two lines where the first line is reserved for variety system states By pushing any navigation key next to the LCD the integrated graphical system menu can be opened The system menu provides several options to view actual system states or to set up basic system functions The navigation keys are used to browse the menu where OK confirms and respectively ESC discards changes Periodically switching system informations Y Uida35H vz HH Input 60000000 Battery state Figure 9 4 Illustration of the LCD displaying the software version at startup The MC 350 is equipped with an internal battery pack allowing operations up to 12 hours without external power supply The actual charging state is displayed by a battery symbol located at the bottom right of the LCD If operating with internal power supply the LCD turns off 9 2 Establishment of Communication In order to establish the mobile communication the including GSM antenna has to be in stalled upon the antenna connector located at the top right of the front panel The MC 350 is equipped with a special SIM card providi
49. ltitude of processes need special metering installations that involve specific counters to measure consumptions Modern consumption meters for industrial use allow different methods for direct digital counter reading For a wide ranging coverage of applicability the design will focus on the pulse interface so called SO interface according to the DIN 43864 The SO interface is widely used by different types of e electric e gas e water e Oil e steam e heat e and compressed air 3 System Requirements 20 consumption meters The main principle of the pulse interface is based on a fixed number of current pulses referring to the metering value relating to a defined time window The pulses get generated by using potential free contact circuit based on an optocoupler which is applied by the external device peona S0 Process data Metering acquisition system S0 Figure 3 2 Illustration of a SO interface according to DIN 43684 The specific relation of pulses referring to the metering value depends on the counter and is pulses given as a gt factor 3 1 3 Analog Values The amount of different sensors providing the measurement of physical quantities is huge A majority of sensors convert the actual measured value into an analog voltage or current value The branch of analog sensors for industrial use is very multisided Analog sensors are often used for very special operation area
50. m T T T I Mi27 Do 28 Fr29 230 E Schalthandlungen 1 L ftungsstufe 1 1 4 Std Cursor Wert Ein Schalthandlungen 3 Beleuchtungsstufe 1 1 4 Std Cursor Wert Ein Schalthandlungen 2 L ftungsstufe 2 1 4 Std Cursor Wert Ein Schalthandlungen 4 Beleuchtungsstufe 2 1 4 Std Cursor Wert Ein n m mnm 2 3 i iii EE SS Mi27 Do 28 Fr29 Sa30 Figure 2 4 The My JEVis Java based web application JEChart allowing the drawing of line and bar charts Another component of the My JEVis web frontend is the JEBench benchmarking tool The JEBench module allows to create rankings over a wide range of data rows e g for the ranking of a series of buildings Analyse Bearbeiten Format Extras Hilfe Analyse analysis 001 Kunde Filialkunde Datenreihe Electroenergy consumption per year Fl che INKFlaecheMarkt Name Baujahr Platzier Wert Fl che Kennzahl Differenz in KWhJahr in mA2 in KWh Jah in Max Wert 30 10 28 2 871 428 5 555 516 909 2 42 Mittelwert 1 329 482 4 398 307 871 0 82 Min Wert 105 10 1 1 1 136 981 5 527 205 714 43 52 Erfurt 30 10 28 2 871 428 5 555 516 909 2 42 Rostock 08 08 27 410 330 996 411 978 1 20 Schwerin 25 12 26 966 577 2 458 393 237 Kel 107 10 25 1 367 750 3560 Berlin 20 02 24 2 238 930 5 907 Ulm 31 07 23 560 493 1 588 352 955 Magdeburg 18 09 22 1 049 758 2 978 352 504 Frankfurt 13 11
51. mode uses the SD memory card asynchron to the internal FLASH data logger making it possible to acquire data points with a high logging resolution Setting up the system to this operation mode will enable a logging behavior on the SD memory card which is independent from the internal data logger configuration Thus making it possible to log data periodical with time intervals given in seconds 6 Data Logging and the Storage of Data 42 To prevent problems caused by writing all data into a single file the system writes separated files during fixed periods 6 1 3 Data Formats The chosen data format is directly related to the needed data space per logged data point There are two principle ways to write data into a file writing binary data or writing American Standard Code for Information Interchange ASCII characters In order to create a system with a high degree of freedom both modes are implemented ASCII Data Format The big advantage of the ASCII data format is the readability An ASCII format is character ized by a clear structure aimed for intuitive human readability using only a simple text editor An unobstructed data importing into standard spreadsheet software such as Microsoft Excel or OpenOffice Calc is a key advantage In order to achieve the compatibility to the Envidatec My JEVis system import interfaces the design contains an implementation of an already exisiting data format The format is structured line by line
52. n of data streams to spy out or even manipulate data 7 Communication 50 Public Internet Public Internet Figure 7 1 Site to Site VPN structure between the Envidatec GmbH and the ISP network structure IP address which is bound to the user authentication The result of this architecture is a full service IP network which combines different physical interfaces The design follows state of art security aspects and has the possibility to be expandthe network further In summary the design of IP based communication via GPRS in addition with overlaying VPN technology comes with the advantages of e a separated private IP address range outside the public internet address range e fixed client IP relations e bidirectional communication e full IP network administration privilegs e PSec based encrypted communication which allows a functionality comparable with a local area network LAN 7 Communication 51 7 3 Data Readout Interface The GPRS VPN communication design offers a bidirectional IP communication that can be used to realize a remote data readout To transmit data from the data acquisition system to the data base server a communication protocol implemented on both sides is essential To avoid the effort for a new transfer protocol this design aims to implement standard protocol which also minimizes the complexity of the implementation The chosen transfer protocol is the Hypertext Transfer Protocol HTT
53. ng a flatrate tariff communication within 19 coun tries All GPRS parameters are preset in the VIDA350 v2 00 firmware thus no GPRS setup will be necessary to connect it to the My JEVis network The communication status is dis played by an antenna symbol located at the top right of the LCD Additionally the first display line periodically displays the actual signal strength in percent Signal strength Communication status Signal 57 Input 00000000 Figure 9 5 LCD with communcation status and signal strength The general GPRS configuration is accessible using the graphical system menu 9 Realization 61 System Menu Setup Menu gt GPRS After connecting to the My JEVis network the data readout is triggered by the My JEVis system Within the My JEVis system a direct connection to the TCP IP remote contro is possible by using a standard telnet client The remote interface offers direct access to the system status and provides different func tions allowing an easy system configuration pe character Welcome to the VIDA Telnet Serv with caution status t the device om amp ILU cLocation 3 cation m tTime Lem time fn g to t m m tTime E Lem time getDP st DP configuration ge r t t etDP to y parameter y parameter se connection help Show available commands Figure 9 6 IP connection for remote maintenance using a standard telnet client The remote interface
54. on for optional voice messages The data logger memory is addressed below the persistant memory The memory between the data logger memory and the voice memory is used for the program code The range of program memory is scalable offering to allocate more memory for data logger or voice messages 6 Data Logging and the Storage of Data 37 Top Reserved memory Persistark memory Data logger memory Program memory Voice directory Bottom Figure 6 1 Logic IO x32 family RTCU memory map 7 For the actual application requirements no voice messages are needed thus the memory range for voice messages is set to the minimum while the rest of memory is arranged simi larly for data logger and program code Configuration Strings For a flexible software design which is applicable to the specification depending on the project a configurable system setup is essential To keep the system parameters save during a long time without power supply the system configuration is stored into the persistant mem ory area of the internal FLASH memory The Logic IO SFL comes with functions to separate the persistant memory into up to 192 strings with a maximum length of 255 characters Each string is equipped with an index to specify the location in the persistant FLASH memory to read from or write to To store the system configuration the persistant memory strings are arranged with serially 6 Data Logging and the Storage of Data numbere
55. ontrol scheme 6 Data Logging and the Storage of Data In order to meet the demands of an automated data acquisition system the log event control and the storage design become an important point in the system architecture With the requirements arise a variety of challenges on the data storage design Referring to the system requirements discussed in chapter 3 2 the following subchapter presents the data storage design including the storage of system paramters and different types of data logging just as well as the control of data logging events 6 1 Data Storage The spectrum of requirements coming with the demand of creating an universal data acquisi tion system for a wide range of projects causes a big challenge on the data storage design The design aims to afford a suitable compromise between e non volatile storage of system and program parameters e storage of a multitude of data points data acquisition with long hold back times practicable data format for end user data processing e economically justifiable memory life time without restricting the user options of configuring The x32 RTCU unit type offers two different possibilities to save data in a non volatile way The internal FLASH memory on one hand and the optional use of the SD memory card on the other Both memory models come with different pro and contra aspects made clear in the comparison presented in table 6 1 6 Data Logging and the Storage of Data 36
56. pment environment IDE is the main development tool which Logic IO offers to their customers The RTCU IDE combines a common syntax highlighting editor and compiler bundle with a collection of useful tools to check and configure the state and behavior of the connected device The RTCU IDE also provides the needed interfaces to program the device by uploading the compilation using a serial cable direct data call or GPRS connection To enhance the testability of new software the RTCU IDE comes with additional simulator functionality The simulator function consists of a collection of several software tools repre senting the different RTCU hardware functions such as in and outputs GSM GPRS com munication real time clock etc seen in figure 4 3 For an intensive software analyzation the 4 Programmable Hardware 25 fin propres extents Phe beris Grewal compacted lamp in the greenhoane gel panpamm im that Tad ontot an pevaca feror Panem fpem Atmen thee const meee nm imi da vit nmm the setier met dwertinnen hm dump GPRS connection m i Sere vend slecm P NIU forent redi wipe om slane mu f GEF 9 be fy rene fre Voiem cali t gmane einen i qendioreennpeatie un Persistent memory editor Retrieve the datalog from the unit Figure 4 2 The Logic IO RTCU IDE providing several programming tools 7 4 Programmable Hardware 26 RTCU IDE integrated simulator supports simple ways for the manipulation
57. s for instance exhaust emission sensors Due to this the system should support the recording of analog values 3 1 4 Temperatures In a wide range of technical applications temperature is of big importance For the bench marking of such processes a relating temperature is essential Therefore an acquisition of different temperatures should be supported by the system design 3 System Requirements 21 3 2 Data Logging and the Storage of Data To make the acquisition of data possible the software design has to include an event han dler The event handler is responsible for the triggering of data storages Following the demands described in the data input requirements the design should support the control of log events e triggered by different time events e triggered by different digital state conditions In order to provide a variable system a free configurable time control and adjustable res olution in minute and second values is required In order to handle a big amount of data the data storage design should support a possibility to save a lot of data for a reasonable hold back time Additionally the data storage design should include a well structured method to save system parameters and software settings in a non volatile way 3 3 Communication Another main point in the system design is the remote communication A faultless communi cation between the field device and the control center is paramount for a plurality of
58. system features The availability of data depends on the remote accessability of the system In consequence of this relation the communication design should focus on an always online solution To accommodate for the data confidentiality a secured communication is required To fulfill the demand of an international applicable system the design should prefer the usage of a well developed technology Referring to the demand of getting data out of a monitoring installation the communication design should offer a remote data transfer interface The data readout interface should sup port a My JEVis compatible data format A lot of projects have to deal with changing demands during the project run time e g a modification or an upgrading of the metering installation In order to an economic mainte nance the communication design has to support the modification of all relevant parameters by remote control To increase the options of remote error diagnostic by remote control the design should also support the remote readout of general system states 3 System Requirements 22 3 4 Case Design A wide applicability comes up with different requirements focused on the case design To cope with the demands of industrial use the case design has to characterize itself by a robust case exposure In addition to the entitlement to create a portable system the design should feature a suitable dimension and an efficient wiring for temporary installations
59. ta Input 33 tree structure star circuit tree structure w short branches chain Figure 5 5 Illustration of the available 1 Wire bus wiring structures Wiring Type Recommendation Tree Structure Max 100m overall length only confined for small installations num senors lt 20 Tree Structure w short branches Max 300m overall length efficient utilization in length Chain Max 300m overall length optimum utilization in length Star Circuit Max 100m overall length only confined for small installations num senors lt 20 Table 5 2 Describtion of different 1 Wire wiring types 5 Data Input 34 To offer a well structured bus communication every 1 Wire sensor has an explicit ID number comparable to the Media Access Control MAC addresses well known from ethernet de vices The design will provide up to 18 installed DS18B20 1 Wire sensors at the same time The temperature sensors need no extra hardware and do not occupy any analog input The software design offers an automatic sensor detection The relation between installed sensors and the data point map is stored in an extra configuration string to provide a fixed binding even restarting the system In order to prevent command timeouts on the 1 Wire bus caused by an inactive sensor a not accessible sensor is ignored after a defined number of connection time outs OW ID 1 OWAD 2 OW ID n Figure 5 6 1 Wire sensor c
60. ted in a training program in Istanbul and Bangkok Out of the first experience the system present a new basis for the analysis and evaluation of process data applicable in a wide range of projects Additional tests in cooperation with an industrial customer are planed within July 2010 The feedback of these test results will be included into the further product development to ensure the marketability The recently aimed operation areas are for instance the establishment of JI projects in the Russian Federation or the control of the implementation of bio gas plants according to CDM placed in the Kingdom of Thailand An future refinement is the implementation of a Modbus interface and a development basic load management These add ons will allow the realization of interacting process controls and increasing the possibilities to adapt different data sources to the MC 350 Therefore the present design already be aware of the allowance within the software and case design Bibliography 1 Nils Heinrich Studienarbeit Entwicklung einer Softwarel sung zur Energie und Be triebsdatenerfassung Hochschule f r Angewandte Wissenschaften Hamburg 2009 2 United Nations Framework Convention on Climate Change A Guide to the Climate Change Convention Process Preliminary 2nd edition 2002 3 Envidatec GmbH http www envidatec com 2010 06 10 16 00 2010 4 Nils Heinrich DIN EN 16001 berwachen und Messen VIDA350 amp My JEVis System l sun
61. ter The schematic and board layout is designed via the CadSoft EAGLE version 5 10 layout software 5 3 Analog Input The analog inputs of the x32 family RTCU can be configured individually to work either as voltage or current measurement input selectable by an onboard jumper The measurement range in voltage mode is 0 to 10VDC and in current mode it is 0 to 20 mA In standard setup the analog inputs are set to voltage measurement With an A D converter resolution of 10 bit the system will display the value with 1023 if the input voltage is 10V respectively 512 if the voltage is 5V 5 The analog input values are sampled in real time and get averaged over an array of the last 32767 elements for stabilization 5 4 1 Wire Temperature Sensors The 1 Wire bus system was designed by Dallas Semiconductors Corporation as a commu nication solution for small devices The name 1 Wire may lead to some misunderstandings because the 1 Wire technology need at least two wires ground and data line The power Shttp www cadsoft de 5 Data Input 32 supply can be realized with the data line via the so called parasite power or with an ex ternal DC power supply The 1 Wire communication standard is similar to IC but operating with a lower data rate and comes with the possibility to bridge a longer overall length for communication 1 1 The Logic IO x32 family RTCU comes with an 1 Wire bus interface and additional standard functions to interact
62. tervals respectively for second and minute resolution Two configuration strings are reserved for the time intervals given in minutes and accordingly for the time intervals given in seconds Each configuration string has eight values separated by semicolons The user is free in choosing a integer value for the time interval where a 0 value means that the programmable interval is not in use Default values for intervals given in minutes Tbrt0s15 305 005 05 05 Default values for intervals given in seconds 1 2 5 10 15 20 30 60 The time intervals running synchronously with the internal real time clock RTC are de scribed by an eight bit mask Each bit represents the state of one time interval where 1 symbolizes a match The state of the first time interval up to the state of the eighth time interval are arranged from the least significant bit LSB to the most significant bit MSB The interval preferences are loaded from the according configuration string at run time The several time intervals are compared with the system time by using a MODULO operation This comparison is repeated continuously once per minute respectively once per second The state of the time bit mask is updated by a bitwise OR operation The MODULO operation finds the remainder of division of one number by another A logical OR operation results true whenever one or more of its operands are true 6 Data Logging and the Storage of Data 46
63. ts according to the Kyoto Protocol JI and CDM projects allow the trade of saved carbon emissions among countries being part of the UNFCCC focused on the im provement of international technology and know how transfer e The establishment of Public Private Partnership PPP projects offering an increased cooperation between research and economic development Against the background the motivation of this thesis is centered in the development of a universal integrated solution enabling the analyses of saving potentials The central point of 1 Introduction 12 interest is the development of a versatile product dealing with the multisided demands of the described project types 2 Background 2 1 Envidatec GmbH The Envidatec GmbH located in Harburg south of Hamburg was founded in 2001 out of the E ON competence center for energy efficiency Since then the Envidatec GmbH operates as an independent company and combines expertise from the fields of energy services energy and operational data management energy efficiency general bus systems and automation The major business area of the Envidatec GmbH is the detection of saving potentials with operation data controlling and energy management both with the energy services as well as with cooperating system solutions This ensures that each assignment is analyzed according to the individual needs of the establishment In addition to pose the necessary knowledge concerning energy efficient te
64. ure sensors 64 9 12 Four analog inputs with associated GND provided by the MC 350 64 9 13 The LCD displays analog values 2 22 2 Enno lll len 65 1 Introduction The present thesis was created within the Envidatec GmbH in Hamburg The Envidatec GmbH provides energy services and energy management Their major business area is the finding and analysing of saving potentials Therefore the collection and the evaluation of energy consumption information in customer s properties are essential To work with a high information resolution an automated application to acquire data and to make different data rows accessible is a fundamental need Existent tools in the company are able to realize immobile data monitoring installations But Furthermore the inquiries for temporary installation e g to evaluate the benefit of an immo bile installation first are increasing To confront the rising inquiries for the energy analyses and the energy efficiency measures a new portable process data acquisition system is nec essary The main purpose of this project is the design of an integrated system solution for the portable acquisition of process data Different data sources can be connected to the sys tem peripherals and are stored locally A new mobile communication structure allows a rea sonable remote maintenance and provides a secure readout of aquired data The design is based on the VIDA350 software resulting out a prev
65. with the Dallas Semiconductor DS18B20 1 Wire temperature sensor The DS18B20 temperature sensor is a well developed sensor which can be found in a multi tude of applications The DS18B20 perform a measuring range from 55 C up to 124 C For the operation above 100 C an external voltage supply is recommend as described in the sensor documentation This specification is caused by the limited power input being supplied from a 800pF capacitor charged by the data line when operating with parasite power 12 Figure 5 4 1 Wire sensor power supply possibilities To point out which outstanding improvements come along with this new design the advan tages in comparison to temperature measurement using analog sensors should be clari fied An 1 Wire temperature sensor includes an analog temperature sensor a communication bus according to the 1 Wire standard and performs a compensated conversion into digital val ues All featured peripherals are integrated in a single integrated circuit IC As a direct profit an additional error compensation that was realized in the past with a combined soft and hardware solution is not needed Extra installation costs and efforts caused by the compensation hardware the need for extensive three or four conducter wiring and an indi vidual calibration droped out As known from other bus systems the 1 Wire standard allows different options in bus wiring and affords a more flexible installation 13 5 Da

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