Factory Automation

Overview

July 2009
Panelists

• Harold Joseph
– Sr. Marketing Manager

• Alex Tan
– Product Marketing Manager

2
Objectives

• Understand National’s Factory Automation

Campaign

• Review National products that are used in Factory

Automation

• Gain better understanding of the solution needs in

Factory Automation and how National’s solutions
and products support those application needs

3
 Overview

• Market
– Factory Automation Market > $1B total analog content. (IMS)
– 16 largest suppliers address < 50% of segment sales (IMS).

• Key trends:
– Drive to more energy efficient systems
– Expanding competitive situation world wide is driving need for
increase productivity, quality and throughput (need better / finer
control)
– Increased diagnostics to reduce maintenance and down time
– Increase adoption of wireless for non critical applications
(802.15.4: Hart, Zigbee, WISA,)

4
 Factory Automation Market
Major Industry Segments:
• Manufacturing
– Pharmaceutical
Manufacturing
– Consumables Manufacturing
– Automotive Manufacturing
– Material Handling
• Process
– Refining
– Chemical
– Food & Beverage
– Pulp and Paper
Nationals Focus Areas
• DCS (Distributed Control Systems)
• PLCs (programmable controller and
I/O modules)
• CNC (computer numerical control)
• Embedded computer board
• Sensors / Measurement Equipment
• Motor control
• Motion control
• Machine vision
5
Industrial
Factory Automation Overview

Module: Sensing
6/25/09

Module:
Control Networks
Module: 7/9/09
Motor Control Module:
Sensing 7/23/09 I/O Module
8/20/09

Module:
Machine Vision
TBD

6
Automation Control Networks in
Factory Automation
Control Network
Trends and Challenges
• What is the challenge?
– More products at a faster rate and
with higher quality
• Trend to use Ethernet based
control network
– Replaces RS-485 or proprietary bus
• Trend to synchronize devices on
a factory network
• Synchronization provides
– High speed sort and diverter
– Motion position and velocity control
for coordinated drives and robotics

8
Automation Control Network Example

• System sorts defective parts off of a conveyor belt

• Network uses fieldbus protocols on a 10/100 Ethernet network with IEEE
1588 time synchronization support
HMI
GPS Time Industrial Camera Bad product

Pick and place

S M

Good product

S S S
Motion
Controller

Drive Controller Motion Controller

Distributed I/O

Ethernet Switch

9
 PHYTER® Family of Industrial Ethernet
Single / Dual Port 10/100 Ethernet PHY

Basic Application Requirements

Family Speed Temp Support IEEE Key Features Supported in the
1588 Product Family
interface
Commercial • Commercial, Industrial, and Extreme Temp
Support
Single 10/100 Industrial NO
• Low Latency
Port MII/RMII Extreme
• JTAG Support
•Auto-MDIX
• Flexible Port Management

Dual Port (2) 10/100 Commercial NO •JTAG Support

(2) MII/RMII Industrial •Cable Health Diagnostics
•Fiber Support
•Time Sync up to 3.5 ns on single link

IEEE 1588 10/100 Industrial YES • High Precision Packet Timestamping

MII/RMII •Cable Health Diagnostics
•Fiber Support

10
 Sensing Solutions
in
Factory Automation
Trends

• Expanding competitive situation world wide is driving

need for increase need for better / finer control
– Increased measurement / sensing nodes
– Move to higher performance “Smarter” transducers

• Portable applications are growing, driving the need

for lower power more energy efficient sensors and
measurement systems

• Increased need in system diagnostics to reduce

maintenance driving the need for more process
measurement

12
 Challenges / Solutions

• Solutions must cover a wide range of sensing parameters

– National’s Op Amp / ADC solutions address complete classes of
applications (e.g. virtually all pressure sensor MEMS applications)
– Pin and function compatible product families allow customers to
standardize board layouts

• Growth in portable applications is driving the need for

lower energy consumption solutions
– National has some of the lowest power Op Amps and ADC in the
market. All ADCs have a very efficient power down feature.

• Customer has limited design resources to determine a

solution and validate their design
– Webench Sensor Designer® generates signal path solutions
based on a sensor’s specifications and parameters
13
Focus Areas

• Sensors Interface Solutions

– 4-20mA
– Voltage output
– Signal path (SPI, I2C)

• Key Sensing Areas

– Pressure
– Temperature (Thermocouple, RTD)
– Optical
– Chemical
– pH

14
Sensing Solutions in Factory Automation example:
Pressure
Voltage Drive Current Drive
Product Selection
• LMP7715/7716 and ADC121S021 or
for the signal path is a good
starting point . LMP7702 is good
for the cc drive
– Supports most popular
performance ranges

• Alternatives
• ADC based choice based on signal • Opamps can be chosen to optimize
path performance signal path for a variety of
– 8 bit ADC is ±0.4% applications
– 10 bit ADC is ±0.10% – Higher Bandwidth
– 12 bit ADC is ±0.024% – Low Noise
– Low Input Offset Voltage
– Low Power
15
 Recommended Products

Recommended ADCs
Resolution Sample Rate Signal INL (LSB) ENOB (bits)
Base Part (bits) Channels Range (Ksps) Accuracy [MAX] [Min] Interface
ADC121S021 12 1 50 to 200 ±0.024% ± 1.0 11.3 SPI
ADC101S021 10 1 50 to 200 ±0.1% ± 0.7 9.8 SPI
ADC081S021 8 1 50 to 200 ±0.4% ± 0.3 7.8 SPI
ADC121C021/27 12 1 5.5 to 189 ±0.024% ± 1.0 11.3 I2C
ADC101C021/27 10 1 5.5 to 189 ±0.1% ± 0.7 9.9 I2C
ADC081C021/27 8 1 5.5 to 189 ±0.4% ± 0.25 7.8 I2C

Recommended Opamps
Gain
Bandwidt Voltage Noise Max Input Bias CMRR Supply
Base Part Channels h (MHz) (nV/root(Hz)) Current (nA) TcVos (uV/˚C) (dB) Voltage
LMP7715/16 1/2 17 5.8 0.1 1 100 1.8 to 5V
LMP2011/12 1/2 3 35 0.005 0.015 130 2.7 to 5V
LMP2021/22 1/2 5 11 0.025 0.004 139 2.2 to 5.5V
LMP7701/2/4 1/2/4 2.5 9 0.05 1 130 2.7 to 12V
LMP2231 1 0.13 60 0.001 0.3 97 1.6 to 5.5V

16
 Machine Vision in
Factory Automation
Machine Vision
Trends and Challenges
• What is the challenge?
– Inspect products at higher speeds
and with more detail
• Trend to use high resolution and
fine resolution image systems
• Trend to support high bandwidth
cameras using SerDes devices
• SerDes devices provide
– Support for higher bandwidth image
transfer without software support
– Smaller cables for improved
robustness
– Small form-factor to support nano-
head camera form factor

18
Machine Vision Imaging Example

Key Requirements : High resolution, Multi-lane, Longer reach

Display

Sensing Unit
Processing
Data Path
Unit
LNA AFE

Ser/ Ser/
Sensor FPGA FPGA Control
Des Des

Control Path

Control
Network Storage

19
 Industrial Imaging Interface Portfolio :
Plug-and-Go! Devices
Basic Application Requirement
Family Data Max Cable Data Other System Requirements
Throughput Reach* Type
1.25 to 3.125 40m of CAT-6 @ ANY • Redundancy & Daisy chaining
Gbps 1.25 Gbps
FPGA-Link • FPGA friendly, LVDS parallel interface
20m of CAT-6 @ • Low system BOM, design time
3.125 Gbps
120 to 2700 4m to 8m of CAT-6 @ ANY • 10/16/18/24/32 bit data interface
Mbps 2 Gbps
FPD-Link 2 • Lock to random data, low EMI
• FPGA/ASIC as logic interconnect
Channel 500 to 5000 4m to 8m of MDR ANY • 21/28/48 wide bus interface
Link Mbps cable at 2.5 Gbps
(Camera-
Link)
* Cable length is for reference only, various system conditions impact the maximum reach

Data Data
Plug and Go! =
Data Data Data
Seamless Video
8b/10b Headers = Data Header Data Header Data
Interruptions in Data

20
Motor Control Sensing in
Factory Automation
 Trends, Challenges / Solutions

Trends
• Increasing energy costs driving the need to reduce energy
consumption on the factory floor
– Instrumentation of motors to improve energy efficiency (Motors
are one of the largest energy consumers on the factory floor)
• Drive to lower cost AC/Servo motor control sensing solutions
– Hall effect + SAR ADC versus optically isolated ΣΔ ADCs

Challenges / Solutions
• Need for high performance, high value AC/ Servo Motor solutions
– National’s Simul. Sampling ADCs + Hall Effect sensors address
the most popular “High Side” AC Motor sensing applications
– National’s Simul. Sampling ADCs are in very small packages with
sample rates up to 1Msps  ideal for encoder applications
22
Focus Areas

• Why is Motor Control Sensing Important

• AC Motors Sensing Interface

• Servo Motors Sensing Interface

• Low Side Sensing

• High Speed Motor Synchronization

23
 Motor Control Sensing Example:
Servo Motor Control Sensing
• Servo drives are AC drives with the addition of an encoder or resolver to
provide finer control.
• Encoders provide better performance than resolvers, however a resolver
can be used over a wider temperature range and can tolerate higher
shock and vibration.
• The encoder may provide voltage output directly to an ADC or there may
be an Op Amp in front of the ADC

AC
Rectifier Inverter Motor

HV isolation barrier
ADC121S021
ADC121S625 Current Encoder /
ADC

LM4132 / Sense Resolver

Ref
LM4128
Isolation barrier

LMP7731 ADC161S626 ADC122SXXX

LMP7702 AMP AMP
ADC
AMP ADC ADC
Controller
ADC ADC122SXXX
Ref

ADC

ADC
LM4132 / LM4128 LM4132 / Ref
Temp Sensor Ref LM4128
LM73 LM4132 / LM4128

Ethernet

DP83640/848I/849I Power
24
 Recommended Products

Op Amps GBW Vos max Output

Product Channels Vs (V) Is (mA) (MHz) (mV) Drive (mA) RR Packaging
LMP2015/16 1/2 2.7 to 5 1.2 3 ±0.005 8 RRO SOT/SOIC/MSOP
LMP7701/02/04 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP
LMP7707/08/09 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP
LMP8601 1/2/4 3 to 5.5 1.1 0.06 ±1 42 RRIO SOIC NARROW
LMV841/2/4 1/2/4 2.7 to 12 1.02 4.5 ±0.5 30 RRIO SC70/SOIC
LMV712 2 2.7 to 5 1.22 5 ±3 35 RRIO LLP-10, MSOP-10

Simultaneous Sampling Differential ADCs

Sample Rate Temperature
Product Resolution channels (kSPS) INL ENOB Range Packaging
ADC122S625 12 2 50 to 200 ±1.0 LSB 11.25 Bits -40 to 105°C MSOP-10
ADC122S655 12 2 200 to 500 ±1.0 LSB 11.25 Bits -40 to 105°C MSOP-10
ADC122S706 12 2 500 to 1000 ±1.0 LSB 11.25 Bits -40 to 105°C TSSOP-14

References Reference Tempco Output Input

Product Initial Accuracy Voltage (V) (ppm/°C) Current (mA) Voltage
LM4128 ±0.1, ±0.2, ±0.5 3, 3.3, 4.096 75, 100 20 2 to 5.5
LM4132 ±0.1, ±0.2, ±0.4, ±0.5 2.048, 4.096 1, 10, 20, 30 20 2.2 to 5.5
LM4140 ±0.1 1.25, 4.096 3, 6, 10 8 1.8 to 4.366

25
Data Acquisition in
Factory Automation
Trends, Challenges / Solutions

Trends
• Expanding competitive situation world wide is driving need for
increase need for better / finer control
– Increase in distributed control
• Increased need in system diagnostics to reduce maintenance
and production costs

Challenges / Solutions
• Solutions need to cover a wide range of IO module parameters,
features and specifications
– National’s Op Amp / ADC solutions provide both integrated
and discrete solutions to allow customers to develop a
solution that meets their specific needs

27
Focus Areas

• IO Module (Input)

• IO Module (Output)

• Data Acquisition - Single Channel

• Data Acquisition - Multi-Channel

28
Data Acquisition in Factory Automation Example:
Data Acquisition

• Single channel and multi-channel data acquisition

+V

+
+IN
V REF AMP
A2
-
RF +V OUT V REF

SPI Port
DIFF _ Av =(1 + 2R F /RG )
Bridge CM _Av =1 RG 16 bit Diff ADC
Sensor
+V
RF -V OUT
- V REF
-IN AMP
+

LM35 Microcontroller
CF1
R G1 RF 1

Metal A LM34 +V
-
Thermocouple Metal B RG2 A3 AMP
+
ADC
Reference
Junction CF2F2
R

+V
4-20mA
RR
180 W
Current Loop 10W AMP
470 pF
100nF

A2 = LMP8601

29
 Recommended Products
Op Amps GBW Vos max Output
Product Channels Vs (V) Is (mA) (MHz) (mV) Drive (mA) RR Packaging
LMP2015/16 1/2 2.7 to 5 1.2 3 ±0.005 8 RRO SOT/SOIC/MSOP
LMP7701/02/04 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP
LMP7707/08/09 1/2/4 2.7 to 12 1.1 2.5 ±0.2 50 RRIO SOT/SOIC/MSOP
LMP8601 1/2/4 3 to 5.5 1.1 0.06 ±1 42 RRIO SOIC NARROW
LMV841/2/4 1/2/4 2.7 to 12 1.02 4.5 ±0.5 30 RRIO SC70/SOIC
LMV712 2 2.7 to 5 1.22 5 ±3 35 RRIO LLP-10, MSOP-10

Single Ended Input ADCs Sample

Rate Temperature
Product Resolution Channels (kSPS) INL ENOB Range Packaging
ADC121S021 12 1 50 to 200 ±1.0 LSB 11.7 Bits -40 to 85°C SOT23-6
ADC124S051 12 4 200 to 500 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10
ADC128S052 12 8 200 to 500 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10
ADC128S102 12 8 500 to 1000 ±1.0 LSB 11.8 Bits -40 to 105°C MSOP-10

Temperature
Conversion/Startu
Product Vs (V) Res (bits/˚C) pTime (ms) Interface Package
LM73 2.7 to 5.5 ±1.0˚C 10.1 to 80.8 SMBus/I2C TSOT
LM94022 1.5 to 5.5 ±1.5˚C 0.8 Analog SC70

30
 Recommended Products

Differential Input ADCs Temperature

Product Resolution Channels Sample Rate INL ENOB Range Packaging
ADC121S625 12 1 50 to 200kSPS +0.6, -0.3 LSB 11.7 Bits -40 to 85°C MSOP-8
ADC121S655 12 1 200 to 500kSPS ±0.95 LSB 11.25 Bits -40 to 85°C MSOP-8
ADC121S705 12 1 500Ksps to 1Msps ±0.95 LSB 11.25 Bits -40 to 105°C MSOP-8
ADC141S626 14 1 50 to 250kSPS ±0.95 LSB 13.7 Bits -40 to 105°C MSOP-10
ADC161S626 16 1 50 to 250kSPS ±2.0 LSB 14.5 Bits -40 to 85°C MSOP-10

References Reference Tempco Output Input

Product Initial Accuracy Voltage (V) (ppm/°C) Current (mA) Voltage
LM4128 ±0.1, ±0.2, ±0.5 3, 3.3, 4.096 75, 100 20 2 to 5.5
LM4132 ±0.1, ±0.2, ±0.4, ±0.5 2.048, 4.096 1, 10, 20, 30 20 2.2 to 5.5
LM4140 ±0.1 1.25, 4.096 3, 6, 10 8 1.8 to 4.366

DACS Settling time Temperature

Product Resolution Channels (µsec) Range Packaging
DAC121C081/85 12 1 8.5 -40 to 125°C SOT, LLP, MSOP
DAC121S101 12 1 10 -40 to 105°C SOT, MSOP
DAC122S085 12 2 8.5 -40 to 105°C MSOP, LLP
DAC124S085 12 4 8.5 -40 to 105°C MSOP, LLP
DAC128S085 12 8 8.5 -40 to 125°C TSSOP, LLP

31
Summary

• National’s product line supports a wide range of

Factory Automation applications
• Webinars on Control Networks, Sensing, Motor
Control, Machine Vision and I/O modules will be
available as part of the Industrial Campaign
• Webinars provide solutions for sensing, I/O controls,
motion controllers, automation control networks and
machine vision applications.

• Does the material provided address your application

concerns? If not let us know.

32
Factory Automation Webinars

• Sensing Solutions in Factory Automation 6/24/09

• Control Networks 7/9/09

• Motor Control Sensing 7/23/09

• I/O Module 8/20/09

• Machine Vision TBD

33
For Additional Information

• Released webinars in this series can be viewed at:

• Powerwise® Design University
– http://www.national.com/analog/training

• Factory Automation signal path solutions can be found on

Nationals technical and application support web sites
• SIGNAL PATH Solutions
– http://www.national.com/signalpath
• SIGNAL PATH Designer
– http://www.national.com/analog/signalpath/designer
• Technology Edge
– http://www.national.com/analog/nationaledge

• Webench Sensor Designer® Tools

– http://www.national.com/analog/webench/sensor

34
Contact Information

• Harold Joseph
– Sr. Marketing Manager
– harold.joseph@nsc.com
– (408) 721-5783

• Alex Tan
– Product Marketing Manager
– alexander.tan@nsc.com
– (408) 721-5561

35
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