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Project Case Study Aircraft Engine Part Inspection Using NI Smart Cameras & LabVIEW Mar 27, 2024 b4b8bc99-9b08-4b63-aa9d-d718c2f99464 b4b8bc99-9b08-4b63-aa9d-d718c2f99464 Home > Case Studies > *As Featured on NI.com Original Authors: Daniel Kaminský, ELCOM, a.s. Edited by Cyth Systems Turbine airfoils for aircraft engines The Challenge Automating the deburring and final inspection of turbine airfoils for aircraft engines. The Solution Building a robotics cell based on NI LabVIEW to precisely deburr and shape the turbine airfoils for quality inspection with an NI Smart Camera. To automate the deburring and inspection process for turbine airfoils for aircraft engines, AV&R Vision & Robotics designed a system that uses a six-axis robot to manipulate the airfoil to combine two critical operations. First, we debur the airfoil using tooling chosen specifically to deburr the dovetail of the part and create a radius on each edge. Then a vision system designed for surface inspection examines the part and records the data based on the part serial number, which is also read using the vision system. We originally developed the system for a large OEM aircraft-engine manufacturer based on a lean manufacturing workflow. The operator loads the airfoil into the work cell after the grinding operation. In addition, we designed the system to be programmable so we can easily adapt it for many other deburr and inspection applications including consumer goods such as wrenches, medical device implants, surgical tools, automotive components, and a variety of other aerospace engine components. There are difficulties regarding the system architecture which was needed to transfer over to the new robot cell which was created using NI Smart Camera and laser line scanners when required. The NI Smart Camera is a CPU and camera bundled in a compact design, which transfers data from the images taken directly over a local network or Ethernet. This allows the deployment of LabVIEW software directly to the camera to run a product inspection and give you data results in real-time. Left: Aircraft engine part undergoing line scan by laser for product profiling. Right: NI Smart Camera assisting with robot movement and part inspection. Automating the Deburring and Inspection Process In the past, operators inspected and deburred different complex and high-precision turbine airfoils using deburring tools to finish the parts and then manually inspected the airfoils to ensure the parts were within a specified tolerance. We developed a cell that can automatically perform these two processes, ensuring every part leaves the cell with the desired quality. After loading the part into the cell, the system initializes and a robot picks the part from the fixture and presents it to a deburring station that removes all the burrs from the root of each airfoil, breaks each edge, and creates a radius on specific edges as per the drawing specifications. Left: Aircraft engine foil being burred and polished using an automated process. Right: Robot cell created by AV&R for automated processes. After the deburring process, the robot presents the airfoil to an NI Smart Camera for inspection to look for random surface defects such as nicks, dents, scratches, and tooling marks on the critical surfaces. The defects are classified according to their shape using the particle analysis tools in the NI Vision Development Module. In addition, the vision system reads the serial number using NI optical character recognition (OCR) algorithms. After inspection, properly deburred parts are placed on the output of the cell and moved to the next production stage. We used two NI products in the finishing and inspection cell. For the vision system and the surface inspection, we chose the NI Smart Camera because of its industrial design and flexibility. We also used LabVIEW to implement the inspection sequences and for the user interface. Developing the human-machine interface (HMI) in LabVIEW allows the operator to see the status of the system, the part under inspection, and the statistics of each part as it is processed. The operator can view each of the parts presented to the vision system, a pass/fail counter that highlights the number and status of the parts processed, and the results of each inspection process on the HMI. We have used LabVIEW in similar inspection systems in which we built the code for a PC-based system. All the code previously used for the PC was easily transferred to the NI Smart Camera, which allowed us to take advantage of the common platform. By using NI hardware and software, we seamlessly combined the material removal and inspection solution using the framework for previously developed solutions. Original Authors: Daniel Kaminský, ELCOM, a.s. Edited by Cyth Systems

Cyth Systems | Whitepapers | Unmatched Performance, Flexibility, and Integration | Why Choose NI Embedded Systems? Why Choose NI Embedded Systems? Overview of NI Embedded Systems NI embedded systems include powerful platforms such as CompactRIO (cRIO), Single-Board RIO (sbRIO), and the latest System on Module (SOM) solutions. These platforms are engineered for applications requiring real-time performance, reconfigurable hardware, and modular I/O with deep software integration, primarily through LabVIEW. Key Platforms: CompactRIO (cRIO) : A rugged, modular control system featuring a real-time processor, FPGA, and C Series I/O modules for reliable operation in harsh environments. Single-Board RIO (sbRIO) : A compact, embedded solution that offers similar capabilities as CompactRIO in a smaller form factor for custom designs and lower-cost applications. NI System on Module (SOM) : A flexible embedded system that integrates an FPGA and processor onto a small board for applications requiring custom hardware design. 1. Comprehensive Software Integration with LabVIEW One of the most significant advantages of NI embedded systems is their seamless integration with LabVIEW, a graphical programming environment designed for measurement and control applications. Key Benefits: Graphical Development Environment : LabVIEW allows engineers to design, prototype, and deploy embedded applications without the need for extensive text-based programming. Its dataflow-based approach simplifies development, especially for complex systems. Real-Time and FPGA Programming : LabVIEW provides powerful tools like LabVIEW Real-Time and LabVIEW FPGA, enabling deterministic control, precise timing, and parallel processing within the same environment. Extensive Libraries and Toolkits : NI’s embedded software ecosystem includes toolkits for signal processing, control design, machine learning, and more, accelerating development and improving functionality. Applications: Rapid prototyping of control systems Real-time monitoring and control in automation High-speed data acquisition and signal processing 2. Modular and Scalable Hardware for Versatile Applications NI embedded systems are designed to be modular and scalable, allowing users to easily expand or customize their systems as needs evolve. Key Benefits: Flexible I/O Configuration : With NI’s extensive C Series modules and I/O options, users can select the exact configuration needed for their application. Whether it’s analog input, digital I/O, motion control, or communication interfaces, NI systems can be tailored to specific requirements. Scalability : As applications grow or change, additional modules or systems can be easily integrated into existing setups, making NI platforms highly adaptable to future needs. Multi-Vendor Support : NI embedded systems support third-party sensors, actuators, and communication devices, offering flexibility when integrating with existing equipment. Applications: Industrial automation and process control Distributed data acquisition systems Complex measurement and testing scenarios 3. High Performance and Real-Time Control Capabilities NI embedded systems are designed for applications requiring high performance, real-time operation, and deterministic control. This is achieved through the integration of powerful processors, reconfigurable FPGAs, and real-time operating systems (RTOS). Key Benefits: Real-Time Deterministic Control : NI’s real-time processors ensure predictable and consistent execution of control algorithms, critical for time-sensitive applications such as motion control, robotics, and high-speed data acquisition. Reconfigurable FPGA : The FPGA provides unparalleled flexibility, allowing users to customize signal processing, I/O timing, and control logic at the hardware level. This is particularly useful for applications that demand low-latency responses or complex parallel operations. Robust Performance in Harsh Environments : CompactRIO and other NI embedded systems are built to withstand extreme temperatures, vibration, and shock, ensuring reliability in demanding industrial environments. Applications: Precision control in robotics and automation High-speed signal analysis and real-time feedback loops Critical infrastructure monitoring in energy and transportation 4. Rugged and Reliable Design for Industrial Environments NI embedded systems are engineered for durability, making them ideal for deployment in challenging industrial environments. Key Benefits: Rugged Build Quality : CompactRIO systems are housed in robust enclosures that protect against dust, moisture, vibration, and extreme temperatures. They are designed to operate reliably in environments where other systems may fail. Extended Operating Temperature Range : NI embedded systems are designed for environments ranging from sub-zero conditions to high-heat scenarios, making them suitable for use in outdoor installations, automotive testing, and factory floors. Long Lifecycle Support : NI offers long-term support for its embedded platforms, ensuring that industrial applications remain operational for years, even in industries with strict maintenance and certification requirements. Applications: Oil and gas field monitoring and control Automotive testing and validation in extreme conditions Industrial IoT solutions in manufacturing and process control 5. Seamless Connectivity and Integration with Industrial Protocols NI embedded systems support a wide range of industrial communication protocols, enabling easy integration with existing control systems, networks, and sensors. Key Benefits: Support for Industry-Standard Protocols : NI platforms offer native support for protocols such as EtherCAT, CAN, Modbus, Ethernet/IP, and more. This ensures compatibility with a broad range of industrial equipment and simplifies integration into existing control networks. Remote Monitoring and Cloud Integration : NI embedded systems can be connected to cloud platforms for remote monitoring, data analysis, and control, enabling IIoT applications and Industry 4.0 initiatives. Scalable Network Architecture : With built-in Ethernet, serial, and wireless connectivity options, NI systems can be easily integrated into distributed control systems for multi-site monitoring and control. Applications: Industrial automation with real-time communication Smart grid monitoring and energy management Remote data acquisition and analysis in IIoT applications 6. End-to-End Solutions for Faster Time-to-Market NI’s embedded systems offer a complete platform from development to deployment, reducing development cycles and accelerating time-to-market. Key Benefits: Rapid Prototyping and Deployment : LabVIEW’s integrated development environment allows users to quickly prototype, test, and deploy applications on NI hardware without switching between multiple tools. Turnkey Solutions : NI provides a range of pre-built solutions and reference architectures for common applications, reducing the time needed to develop custom systems from scratch. Support and Services : NI offers extensive support, including training, consulting, and application engineering services, helping users optimize system performance and achieve faster deployment. Applications: Fast deployment of custom embedded control systems Reducing development time in R&D projects Scaling pilot projects to full production Conclusion NI embedded systems stand out in the market due to their combination of robust hardware, powerful software integration, and flexibility across a wide range of applications. Whether it’s for industrial control, high-speed data acquisition, or real-time signal processing, NI provides a proven platform that scales with your needs. By choosing NI embedded systems, companies gain a competitive advantage in developing reliable, high-performance solutions that meet today’s and tomorrow’s challenges.

Project Case Study Increasing Washing Machine Reliability with Hardware in the Loop Aug 23, 2023 811eb230-8c15-4008-9d59-e8c725bfcb8c 811eb230-8c15-4008-9d59-e8c725bfcb8c Home > Case Studies > *As Featured on NI.com Original Authors: G. Paviglianiti - Whirlpool Fabric Care, Advanced Development Edited by Cyth Systems Washing Machine The Challenge Increasing reliability standards and testing capabilities of our washing machine electronic control boards and implementing an automatic system for embedded firmware validation to save time and resources. The Solution Using NI VeriStand real-time testing software and NI PXI hardware to create a stand-alone system that tests and validates electronic control boards and automatically tests, calibrates, and validates smart algorithms that support Whirlpool 6th Sense Advanced Technology in domestic washing machines. Hardware-In-The-Loop simulation is a technique used for testing complex control systems. It is a system that can simulate scenarios for the testing of an electronic control board. HIL must be able to perform a test with high-speed analog and digital I/O data acquisition to ensure a boards proper function before deployment. We developed the 6th Sense smart control algorithms using rapid control prototyping systems based on the NI LabVIEW Real-Time Module and the LabVIEW Simulation Interface Toolkit. With our company-wide use of this system, we can test new concepts developed with simulation tools directly on a real washing machine. The development process also requires validating engineered control algorithm firmware on the production control board. Algorithm complexity is growing exponentially due to higher quality requirements and challenging cost targets associated with energy label, washing performance, low noise, and advanced features. To handle these new requirements, we designed and implemented a hardware-in-the-loop (HIL) system. Our system serves two main purposes: fast, automatic testing of the low-level signals processed and provided by the production control board for algorithm functionality and minimizing calibration and validation effort with considerable time and resource savings. Performance First We developed a washing machine mathematical model to simulate the main control loops inside the home appliance, such as mechanical, hydraulic, and thermodynamic subsystems. We adapted the I/O interfaces of the model to comply with production control boards. In conjunction with the mathematical model, we designed an external I/O board to act as a bridge and signal processor between the control mainboard and the PXI I/O interfaces. Simulating a whole washing machine requires real-time performance. To achieve this determinism, we chose a 2.2 GHz NI PXI-8110 Intel Core 2 Quad controller combined with an NI R Series Virtex-II multifunction reconfigurable I/O (RIO) module for high I/O capabilities and flexibility. We used NI VeriStand software to integrate our washing machine model. We developed the main part with MathWorks, Inc. MATLAB® and Simulink® software so it is possible to compile, deploy, and run the model on the PXI real-time controller. NI VeriStand performs all I/O mapping. Due to special requirements such as time constraints and numeric integration issues, we designed a specific part of the model directly on the field-programmable gate array (FPGA) RIO module using the LabVIEW FPGA Module. We used NI VeriStand to see and log all low-level signals coming from the control board. With the model inline parameters, we can simulate the behavior of different washing machine models with various external conditions. Beyond Rapid Prototyping As our next step, we integrated the HIL test system in our previously developed algorithm calibration system. This system, developed with LabVIEW, automatically drives the washing machine to perform specific tests and prompts the user with instructions to configure the washer load condition. Moreover, it performs defined test plans and automatically computes algorithm calibration parameters. To integrate the two systems, we implemented a LabVIEW application that remotely configures the NI VeriStand environment according to the test plan executed by the calibration system. This way, we can use plug and play architectures to integrate our HIL system with actual algorithm calibrations set up to rapidly scope how different sources of noise affect algorithm calibration. Conclusion We designed our system using LabVIEW and NI VeriStand for several reasons. First, Whirlpool and NI have a long history of more than 10 years that has successfully delivered high-performance features to customers. NI instrumentation and technology are flexible, so we can use the development environment in other product categories. Whirlpool used NI VeriStand for the first time with this project and found it modular and intuitive. Even nonsoftware-expert resources agreed. Furthermore, the backward compatibility and easy customization of NI VeriStand helped us reuse VIs already developed for algorithm calibration applications. With LabVIEW software and NI hardware, we can store technical data in an easy, suitable way, such as the Technical Data Management Streaming (TDMS) format. In addition, laboratory resources can preliminarily manage test data files thanks to user-friendly NI DIAdem software. This has a big impact on the day-by-day task scheduling between engineers and lab tech resources, resulting in overall team efficiency. The MATLAB and Simulink environments can also process the TDMS format, which facilitates synergy between company departments and easy, quick, specific data analysis. The powerful combination of the NI VeriStand platform, LabVIEW FPGA, the real-time PXI module, and years of fast prototype development and experience with NI products helped us quickly and easily design and develop the whole HIL system. Original Authors: G. Paviglianiti - Whirlpool Fabric Care, Advanced Development Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Ultra-high vacuum equipment manufacturer developed high-precision rotor balancing system in five weeks using the NI USB-9234 DSA, LabVIEW, and the NI Sound and Vibration Measurement Suite. *As Featured on NI.com Original Author: Gerard Johns, Edwards Edited by: Cyth Systems Edwards turbomolecular pump CAD rendering Project Summary Ultra-high vacuum equipment manufacturer developed high-precision rotor balancing system in five weeks using the NI USB-9234 DSA, LabVIEW, and the NI Sound and Vibration Measurement Suite. System Features & Components Integrated IEPE signal conditioning of NI USB-9234 enabled direct accelerometer connection without external amplification NI sound and vibration measurement software included signal reconstruction and analysis functions that facilitated quick implementation of custom processing algorithms LabVIEW software enabled rapid prototyping , automated code generation, and implementation of parallel processing architecture Parallel processing architecture balancing of two pumps simultaneously per station enhanced balancing operation throughput capability through Interactive operator guidance tools translating phase angle and magnitude calculations into correction mass assembly instructions Outcomes Complete system development from concept to production deployment in under five weeks Dynamic input range exceeding all commercially available balancing systems Parallel balancing and correction operations per NI USB-9234 increased production throughput at a fraction of the cost of a typical commercial system Class-leading vibration measurement performance enabled successful product launch  Technology at-a-glance Hardware: NI USB-9234 Dynamic Signal Analyzer (obsolete  – comparable NI C Series module NI-9234 ) Accelerometers Digital photo sensor for rotor position detection Software: NI LabVIEW NI Sound and Vibration Measurement Suite (obsolete – replaced by LabVIEW Sound and Vibration Toolkit) Ultra-High Vacuum Pumps Laboratory mass spectrometers and electron microscopes require ultra-high vacuum environments where even minimal vibration compromises measurement accuracy. Edwards, a leading manufacturer of vacuum equipment serving semiconductor and pharmaceutical industries, faced a critical challenge when developing their nEXT Turbo Molecular Vacuum Pump. They wanted to achieve world-class vibration performance, which required rotor balancing tolerances that were impossible to measure with existing solutions available on the market. Edwards needed a custom balancing system that could measure vibration with unprecedented precision for rotors spinning at high velocities. Measurement & Data Analysis Challenges The nEXT Turbo Molecular Vacuum Pump utilized a turbine rotor spinning at 60,000 rpm, with blade-tip velocities approaching 90% of the speed of sound. These unparalleled capabilities of this technology presented a few critical manufacturing challenges for Edwards. Inaccessible measurement location:  Rotor assembly contained within sealed pump housing prevented direct vibration measurement at the source, deviating from standard balancing methodology Manual calculatios:  Off-the-shelf balancing solutions required operators to perform manual calculations and balancing compensation, which greatly slowed production and increased the potential for human error Compressed timeline:  Product launch was weeks; Edwards needed to take their concept through validation to production deployment relying only on their internal teams for development Measurement precision:  Dynamic input range required for the detection of minute vibrations and high rotor speeds exceeded all commercially available rotor balancing solutions Due to technical and timeline constraints, Edwards knew they could not rely on the conventional balancing solutions commercially available. They decided to leverage an NI-based technology stack to accelerate development while staying within budget. Left: OEM vacuum pumps by Edwards, Right: the inside fan blades of a turbomolecular pump. High Measurement Accuracy Edwards' engineering team selected the a few key pieces of NI platform to prototype and deploy a custom balancing solution. Core Platform Selection: NI LabVIEW software:  Graphical programming environment enabled rapid prototyping and robust application development into production environments NI Sound and Vibration Measurement Suite: Domain-specific libraries with signal reconstruction functions and vibration analysis algorithms NI USB-9234 dynamic signal analyzer:  Precision measurement hardware with 51.2 kS/s sample rate per channel, 24-bit resolution, and 102 dB dynamic input range Integrated IEPE signal conditioning:  Direct connection from USB-9234 to the accelerometer simplified system architecture and reduced potential signal degradation points This development approach enabled Edwards to accelerate prototyping and application development without sacrificing the high measurement accuracy critical for this application. Rapid Prototyping Through Production The NI Sound and Vibration Measurement Suite signal reconstruction functions enabled interfacing a digital photo sensor with analog inputs for rotor position detection. An accelerometer attached to the pump body captured vibration data. The Sound and Vibration Assistant automatically generated LabVIEW code from the prototype configuration, eliminating weeks of manual coding and providing a validated foundation for production application development. Edwards built production-ready features on the LabVIEW foundation: Automated calibration functions to maintain measurement accuracy across multiple balancing rigs Proprietary calculation algorithms for measuring pump imbalance through the housing rather than directly at the tip of the rotor Interactive operator guidance tools to translate phase angle and magnitude calculations into straightforward instructions for rotor balancing Using LabVIEW's parallel processing architecture, Edwards configured the USB-9234's remaining channels to balance two pumps simultaneously. This effectively doubled production capacity from a single hardware platform at a fraction of the cost of purchasing two commercial systems. In less than five weeks, Edwards took their proof of concept through validation and into production deployment. Increased Production & Enhanced Sustainability Edwards’ augmented technical capabilities far exceeded commercially available balancing equipment. The key technical features enabled by the NI USB-9234 included: Detection and correct of vibrations in rotors spinning at 60,000 rpm 102 dB dynamic input range enhanced measurement flexibility and enabled quick accommodation for variations in pump models and rotor configurations Leveraging the NI technology stack, Edwards increased their rotor balancing operation efficiency: Cost Savings: Parallel, dual-pump rotor balancing capability delivered two complete balancing rigs at fraction of the price for a single commercial system Improved cycle time: Automated imbalance calculations and operator guidance tools reduced balancing cycle time and training requirements Operational control: Internal solution support eliminated vendor dependencies and enabled direct implementation of system enhancements as product line expanded Platform standardization: LabVIEW and NI hardware as accepted standards across Edwards’ production test, global service centers, and R&D laboratories, resulting in reduced training complexity and enhanced knowledge transfer In five weeks, Edwards used LabVIEW, the USB-9234, and the Sound and Vibration Measurement Suite to rapidly develop a custom solution for high-speed rotor balancing that outperformed commercial alternatives. Original Author: Gerard Johns, Edwards Edited by: Cyth Systems

Medical device manufacturer achieved 100% quality verification in 12 weeks by implementing an automated battery testing solution built with Cyth BatteryFlex and NI PXI. BatteryFlex platforms battery tests and analysis of portable ventilator batteries. Project Summary Medical device manufacturer achieved 100% quality verification in 12 weeks by implementing an automated battery testing solution built with Cyth BatteryFlex and NI PXI. System Features & Components NI PXI data acquisition platform provided high-accuracy voltage and current measurements to enable comprehensive battery characterization Cyth BatteryFlex multi-channel testing architecture enabled simultaneous test of multiple batteries to maximize testing throughput LabVIEW user interface provided operators with live test data visualization Scalable platform architecture accommodated increased production volumes without additional capital investment Outcomes 100% individual battery verification achieved , eliminating field failures due to battery capacity issues Test cycle time and cost of test significantly reduced through parallel test of multiple batteries Turnkey automated test solution delivered in 12 weeks leveraging Cyth BatteryFlex platform Technology at-a-glance NI PXI platform LabVIEW  software Cyth BatteryFlex Verifying OEM Component Performance When designing new products, manufacturers must verify that every component in the bill of materials (BOM) performs to OEM specifications, ensuring that the product delivers on promises made to end-users. Some components influence a devices overall performance more than others. For example, a defective or substandard battery built into a in a life-critical application can result risks to patient safety and an enormous liability burden for the device manufacturer. Manual Testing Limits Scalability The device manufacturer’s manual battery testing methodology was not capable of addressing their quality assurance needs. Measurement accuracy limitations prevented the acquisition of the high-precision voltage and current measurements necessary for comprehensive battery characterization. Testing inefficiencies of manual processes created bottlenecks in production timelines. Quality uncertainty resulting from the lack of individual battery verification resulted in deployment risks for life-critical applications. Scalability constraints of manual testing prevented the manufacturer from increasing production volumes. Left: The customer's portable ventilator, Right: Traditional ventilator. To hold their supplier accountable and ensure patient safety, the device manufacturer needed a high-accuracy, automated solution to verify the quality of the batteries built into their portable ventilators. They decided to partner with Cyth Systems to address their automated testing needs because of their proven expertise designing high-throughput automated test solutions. Comprehensive Battery Characterization Cyth deployed their BatteryFlex architecture, an automated battery testing platform for comprehensive battery characterization leveraging the high-accuracy measurement capabilities of NI’s PXI platform. The programmatic execution of numerous test protocols simultaneously across multiple batteries enabled the device manufacturer to drive test time and test cost down substantially. Key hardware capabilities: NI PXI data acquistion for high-accuracy voltage and current measurements Cyth BatteryFlex multi-channel architecture enabled simultaneous battery testing Custom test fixtures ensured secure battery connection and consistent test conditions Key software capabilities: LabVIEW-based user interface for live data visualization Automated test sequencing for five critical battery characterization protocols Open Circuit Voltage (OCV) Power Cycle Test Capacity Testing (Static, Script, Pattern/Pulse) DC Internal Resistance (DCIR) AC Internal Resistance (ACIR) Battery capacity identification and quality verification for each individual battery Left: PXI data acquisition platform, Right: BatteryFlex LabVIEW user interface (UI) showing live test data. 100% Quality Verification The turnkey test solution transformed the device manufacturer’s battery quality assurance from a manual bottleneck into an automated, scalable process. Quality assurance: 100% individual battery verification prior to deployment eliminated field failures from battery capacity issues Testing efficiency: Simultaneous testing of multiple batteries substantially reduced cycle time and overall cost of test Production flexibility: Scalable platform accommodates increased testing volumes without additional capital investment Risk mitigation: High-accuracy measurements ensure that only specification compliant batteries are deployed into life-critical ventilators Rapid deployment: BatteryFlex reference design accelerated solution development time; everything from proof-of-concept to turnkey test system deployed in 12 weeks. Now, the medical device manufacturer operates with confidence, knowing that every single battery deployed into their portable ventilators meets their exact capacity specifications, ensuring reliable performance in life-critical patient care.

*As Featured on NI.com Original Author: Mats Alaküla, Lund Univerisity Edited by: Cyth Systems Project Summary Lund University integrated the NI CompactRIO into its power electronic lab, teaching students real-time power electronics with research-grade systems. System Features & Components Real-time operating system (RTOS) enabled speed control and PID optimization FPGA-level logic enabled implementation of hysteresis bounds and the simplification of overall system architecture Live data visualization and parameter adjustment enabled through HMI Outcomes Achieved “fast computer” model levels of determinism , enabling real-world levels of system responsiveness Reliable control loop execution delivers continuous live monitoring Equipped undergraduate students with hands-on experience using research-grade control systems Technology at-a-glance Hardware: NI cRIO-9063 chassis NI cRIO-9038 chassis Software: LabVIEW LabVIEW FPGA LabVIEW Real-Time Control Theory in Practice In university electrical engineering labs, students learn how motor drives and power electronics operate. These types of systems require microsecond-level precision to ensure continuous and smooth operation of motors. For educators, it can be a challenge to bridge the gap between theoretical “fast computer” models and real-world control systems that introduce computational delays. At Lund University in Sweden, they needed to address this education gap needed to ensure their students could experience firsthand how control theory performs in a real-world context. Determinism Requirements Professor Mats Alaküla needed to teach students how to control electrical motor drives and power electronics systems with sub-milisecond time constraints. Maintaining currents within safe operating limits require voltage controll within hundreds of microseconds. Their existing MATLAB/Simulink and DSpace technology platform could not keep pace with modern electrical drives requiring increasingly higher frequencies. The Windows-based monitoring system interfered with control, disrupting the simulation of a realistic control system. The majority of students’ time was spent creating workarounds for hardware limitations, not mastering control algorithms themselves. Lund University needed a solution that would prepare their students for the real-world scenarios they would encounter in ther future careers. Hysteresis Control Enabled The university chose to adopt the NI CompactRIO platform, paired with LabVIEW Real-time and FPGA Modules to implement a control architecture that would eliminate computation delays. NI cRIO-9063 & NI cRIO-9038 CompactRIO controllers. System Architecture & Capabilities FPGA-based current control: time-critical electrical current control implemented directly on the FPGA Real-time processing: slower control loops, for ensuring optimal system performance, run on real-time operating system (RTOS), including engine speed trajectory following and continuous PID parameter recalculation Windows OS: live data visualization and datalogging enabled through user interface housed on the Windows OS Integrated resolver signal processing: cRIO I/O availability and measurement speed capabilities eliminated the need for dedicated resolver circuits Hysteresis control capability: FPGA measurement speed enabled direct current control with real-time three-phase current visualization in real-imaginary planes Sub-100 microsecond voltage control: implemented on FPGA and RTOS to maintain current within acceptable intervals required by electrical drives The responsiveness of the cRIO enabled the implementation of control methods that their previous solution couldn’t support. Direct current control via hysteresis required high determinisim to keep current within precise tolerances. Applied Motion Stepper Motor Drives, controlled and communicated with using NI LabVIEW software. Traditional rotor position measurement requires high-frequency input signals and additional processing circuits. The measurement speed and I/O flexibility of the NI cRIO platform were capable of directly handling resolver signal processing and simplifying the system architecture students interact with. The self-contained nature of the cRIO, paired with its ability to push live updates to host computers eliminated the Windows OS interference problems that previously disrupted control loops. Real-World "Fast Computer" The architecture enabled by the technology platform eliminated the gap between theory and practice for these students, as the solution responds as theoretical “fast computer” models would, making control theory directly applicable to real-world systems. Lund University’s introduction of the NI CompactRIO platform to undergraduate students enabled continuity and best practice sharing with graduate students already using the platform for advanced electrical machine development. The university is now fully capable of preparing their students for their future careers by enabling them to gain hands-on experience with the optimal control strategies driving the pace of development in modern power electronics engineering. Original Author: Mats Alaküla, Lund Univerisity Edited by: Cyth Systems