Field transmitter & condition monitoring reference designs for factory automation applications

Welcome to the factory automation control update In today’s session, we’re going to talk about a field transmitter and the condition monitoring We are starting with an introduction to TI’s reference designs and system block diagrams Afterwards, we present to you our isolated power and data interface for low power applications reference design TDA-010018 followed by the introduction to the RTD replacement for cold junction compensation in thermocouple temperature transmitters TIDA-010019 And finally, we’re going to talk about our industrial wireless condition monitoring reference design To get to the [INAUDIBLE] block diagram, you start from TI.com by clicking afterwards to Application and Designs Here you can select one area of interest, for example, Factory Automation Control From the Factory Automated Control page, you can then select the application you’re interested in For example, if you’re looking into field transmit and process sensors and specifically into temperature transmitter, you can click on this application link On this site now, you will see the block diagram of a typical temperature transmitter And by selecting the different variants, you can switch, for example, from a thermocouple implementation to an RTD implementation And the block diagram will change accordingly So if we are now looking at thermocouple with cold junction temperature transmitter, here you have the block diagram And then you can select within the diagram different subsystems For example, if you’re interested in digital processing, you can click here digital processing block Or for example, if you want to look into details of the analog front-end implementation of a thermocouple temperature transmitter, you click in this building block By clicking in those blocks, you will realize that on the right-hand side the content for the reference designs is going to change as well as on the product tab You will get different recommendations So let’s have a look at the recommendation for the products first In case you’re looking for an ADC for your analog front-end, you can click key into the data converter tab And then you get the list of recommended parts for a temperature transmitter By clicking then on the different parts, you will end up on the product page for this specific ADCs Alternatively you can also look for reference design in the area of interest As an example here, for the isolated DC/DC power supply, we are showing you several reference designs Isolated power and data interface for low-power application Let’s have a look at this one The landing page of our reference designs providing lots of information, starting with a block diagram over to a schematic design guide and also the design files The design guide gives you a detailed overview of the system You have a description, an overview of which hardware is being used, and finally, the most important, are the different test results of this reference design So let’s have a closer look into this specific reference design, isolated power and data interface for low-power applications In this reference design– RTD replacement for cold junction compensation and thermocouple temperature transmitter– we’re investigating the performance of PT100 element versus a silicon based temperature transmitter By using such a temperature sensor, there is no excitation current required Also there is no high precision reference resistor needed In case you’re using a temperature sensor with a digital sensor output, also no additional ADC input is needed So overall, We have a simplified design And we are also reducing the power consumption The first implementation is using silicon based temperature sensors with an analog output This is, for example, case 2 and case 3 where we’re using the LMT70 and the TMP235, which we are comparing to what’s the PT100 performance The second part we are using a digital sensor LMT01 and TMP117 and compare this also against the PT100 performance For the analog sensors, we still need an ADC channel– which is multiplexed in this particular case– whereas in the digital sensor, we do not need an ADC channel So the signal chain portion is simplified In all of our use cases, there is no current excitation required and also no reference resistor needed The initial uncalibrated test results showed that the silicon based temperature sensors are better than a PT100 element And this without having the excitation current and also without having the external reference system

for ratiometric measurement Hello I’d like to talk to you about the isolated power and data interface for low power applications reference design, TIDA-010018 My name is Juergen Schneider I’m working as a systems engineer with TI Let’s first have a look to such a low power application In this case, we are talking about 4 to 20 milliamps system where we have the transmitter here on the left side and the PLC as a receiver of the 4 to 20 milliamp AM signal here on the right side The transmitter itself consists of a sensor front-end It has an internal power regulator, for example, a step down converter or an LDO, has an [INAUDIBLE] and has finally also a [INAUDIBLE] converter A [? HART ?] modem is able to complete the 4 to 20 milliamp interface here on the transmitter side And there might be also a pre-regulator, which converts the loop voltage, which can be in a range let’s say from 8 to 36 volt down to an intermediate voltage here in this example of 5 volt The block encircled by that line shows another TI reference design, which is called RTD replacement for code junction compensation in thermocouple temperature transmitters So the number of this reference design is TIDA-010019, and it shows exactly the same sensor from– and of the back, or LDO and the MCU, as you have seen before And it shows also that the ground, the input ground and the output ground are electrically connected together However, if you have, for example, a thermocouple temporary transmitter, it’s very often required that you have an isolated design, which means that the ground on the input needs to be different from the ground here on the output, and there needs to be an isolation in between How this can be achieved will be shown on the next slide The electrical isolation between the left and the right side of this transmitter can be achieved by cutting the four direct connections, which are shown here, and replacing them by the TIDA-010018 reference design, which basically provides the isolation for the power and provides also the isolation here for the data Talking about isolation, I have summarized here a number of different TI devices, which are usable in isolated solutions The power level of those devices can address ranges from tens of milliwatt up to let’s say 5 to 7 watt of output power So usable in low power application, but not necessarily fitting exactly what we need because for our loop power at 4 to 20 milliamp type of application, we are talking about power levels for the internal power supply of the electronics in the range of hundreds of microwatt up to tens of milliwatt only To specifically address this ultra-low power level of hundreds of microwatt up to tens of milliwatt, TI came out with a number of reference designs, which are listed here, and where have the most recent one here in this right column, which is this isolated power and isolated data reference design we are talking in this topic about It works for an input voltage ranging from 4.4 to 5.25 volt, so this is our intermediate voltage we generate, which I explained at the very beginning of the presentation And it shows a power efficiency of almost 80%, so in detail 78% for a voltage conversion from the 5 volt rate to a regulated, isolated 3.3 volt [INAUDIBLE] at 10 milliwatt of power level The details of this reference design are provided here It contains the subsystems to convert non-isolated design into an isolated design Beside the power efficiency, it also highlights the performance of a digital isolator, which is ultra-low power It contains three forward and one reverse channel, where every channel consumes only 16 microamp for a data rate of 100 kilobyte per second It consists of BUCK regulator It consists of post regulators, here, LDOs used as post regulators to generate, really, a noise-free output voltage on the non-isolated side– on the isolated side, and it contains, here, those four data

channels in total The reference board allows an easy evaluation in the standalone test set-up by using headers which we have populated on the top side of the board The headers are usable for connecting power input, power output, data input, and data output And we have also optimized test points on the board which allow a noise-free measurement, for example, of output voltage [INAUDIBLE] The bottom side of the PCB contains an additional power and data interface connector, which can be seen here in the block diagram, but also here on the PCB itself This additional power and data interface connector allows to use the board itself as a plug-on board on the specifically-designed hardware For example, on the TIDA-010019 We have, in addition, a power input selection header implemented which allows to select either the power input coming from the headers on the top side, which is J12, or from the power and data interface connector on the bottom side, J9 The performance of the reference design have been evaluated in depth The results of this evaluation are contained as performance graphs in the user guide of the design, which can be downloaded from the web A special kind of performance graph is shown here The specific graphs highlight the combined efficiency and the total input current versus the output current So we have done loading of the output on the isolated side, as well as on the non-isolated side We added both power levels together and we divided this by the input power, which gave us the total or the combined efficiency, which is represented here by the solid lines Whereas, the dashed lines show us simply the total input current of the system This total input current of the system is especially very helpful for our application example of loop powered 4 to 20 milliamp transmitter Because the internal electronic of such a 4 to 20 milliamp loop power transmitter must not have any higher power or current consumption than, let’s say, 3 to 4 milliamp, so there is a given input current budget which needs to be kept And let us do this example here assuming this input current budget is given with 3 milliamp for this 4 to 20 milliamp transmitter example, and assume furthermore that we have 1 milliamp of output current drawn from the non-isolated BUCK So this is represented here by this dashed line, and this is that non-isolated BUCK, which is used as a [? parameter. ?] So the current consumption from the non-isolated BUCK which is used as [? parameter ?] which is, in our case, 1 milliamp So this is the curve, here, we should look And then we need to look to the interception point between the 3 milliamp with this curve And if we go down to the horizontal axis, which gives out the output current for the isolated BUCK, then we can read, here, a value of roughly 2.5 or 2.6 milliamp, which means this is the output current which can be drawn from the isolated BUCK when the non-isolated BUCK has a load of 1 milliamp and when the input current of our design must not be larger than 3 milliamp And you can do also, here, a cross-checking by combining the efficiency and comparing this with the solid line here of the 1 milliamp curve If you do the calculation, you would get to 78% efficiency And if you look here, you have exactly this 78% As mentioned, the reference design demonstrates not only the isolation of power, but also the isolation of data And here, for the isolation of data, we have used our new ultra-low power digital isolator, the ISO7041, which contains three channels here from the non-isolated side and one channel in the direction from the isolated side to the non-isolated side Both data input and data output are

available as header on the board They are also connected to this specific power and interface connector on the bottom side, so they can be easily evaluated A special feature is also that we have, here, a refresh feature which is able to manage even the transmission of static signals when you have this refresh enabled This can be done here by the jumper setting on those two headers And again, the power consumption is ultra-low Current consumption, roughly 4 microamps per channel, instant by 15 microamp at 100 kilobits and 116 microamp at 1 megabit per second data rate per channel The temperature range is extended, ranging from minus 55 degrees C to plus 125, and the wide supply voltage range goes from 2.25 volts to 3.6 volts in this specific case The supply current per channel performance of the digital isolator is represented here in the two graphs, and those are basically the graphs out of the data sheet But the measurement we have been done with the reference design showed that there is a very good match to those graphs out of the data sheet So the last slides which I like to show within this topic is the complete schematic which shows you, here, the isolated DC-DC This is the driver This is the half bridge transformer This is a voltage doubler on the isolated, on the secondary side We have a step-down converter on the non-isolated side We have the LDO as post regulator Similarly, we have a configuration showing a BUCK and the LDO on the isolated side And we have, here, the ISO data block More details you can find in the User Guide You can find also in the design folder All is on ti.com, available simply typing in TIDA-010018, and you will get the ability to access all the documents we have on our website Thank you very much This was the topic about this isolated power and data interface for low-power applications And I gave you an introduction into the reference design Thanks, again Bye Hello, and welcome to this training video on the industrial wireless condition monitoring reference design, TIDA-010012 This reference design can be used to quickly establish a wireless network that connects various types of sensors for condition monitoring directly to the cloud My name is Thomas Schneider, and I’m a Systems Engineer in the Industrial Systems Team Condition monitoring is used to monitor the condition of machines and systems in a wide variety of application areas Compared to the frequently used preventive maintenance, condition monitoring is a more efficient and safe alternative Preventive maintenance means that parts of an engine are replaced too early, due to fixed maintenance intervals on machines As a result, terms are shortened unnecessarily Capital is given away Likewise, this method is not able to detect and accurately locate defective components before failure Defective components can cause considerable damage and downtime during machine operation With condition monitoring, both can be realized now One example of where a condition monitoring system is useful is a wafer fab with several hundreds of vacuum pumps installed, for example Without condition monitoring of the vacuum pumps equipment, engineering has the problem that they would have only selective pump data for error analysis Pump failures are not identifiable immediately due to manual maintenance This would mean [INAUDIBLE] cleaning and high maintenance costs Without condition monitoring, facility could not identify uncontrolled consumption of water, electricity, and nitrogen, consumption values that, as electricity and gas, are not detectable for individual devices Large energy consumers would not be identifiable For production, if a vacuum pump fails, this would mean wafer scrap, tool downtime, post-processing of wafers, of the process aborts,

increased throughput times, and additional costs for unplanned qualifications In the picture on the left, you can see how a typical vacuum pump station looks like The pumps are already measuring data like oil level, water flow, nitrogen flow, temperature, current consumption, operating hours, faults, leaks, or the exhaust pressure The problem in a large factory floor is the missing cabling, different interfaces and communication protocols at the pumps to get the data centrally collected for condition monitoring With this reference design board connected to the vacuum pumps, the permanent measurement data can now be sent wirelessly and easily accessed through the internet This collection enables the possibility for trend analysis and predictive maintenance This is an overview of the industrial wireless condition monitoring reference design TIDA010012 The features of this design are multi-protocol support like 6LowPAN plus Bluetooth Low Energy, Wi-Fi Internet-on-a-chip It has RS232 and RS422 or RS485 interfaces on the board It has a 3-wire RTD temperature sensor input and the 4 to 20 milliamp interface on the board It has isolated digital inputs from 24 volts up to 60 volts on the board It supports IO-Link up to COM3 speed, and the minimum cycle time of 400 microseconds, and it has an onboard humidity sensor This reference design consists of three different boards The main board with the MSP432, P4111, and the wired interfaces like RS232, RS485, or IO-Link The Wi-Fi and display board with the CC3220 module and the CC2652 adapter board for the mesh network and Bluetooth Low Energy communication A mesh network using the CC2652 can be established with this reference design With this wireless mesh network, the vacuum pumps can be connected to a central gateway, and the pump data can be collected for condition monitoring Mesh networks make radio systems more reliable by allowing radios to forward messages for other radios For example, if a node the TIDA010012 board cannot send a message directly to another node, the mesh network forwards the message through one or more intermediary nodes On this reference design, the 6LowPAN protocol has been used 6LowPAN networks are self-healing mesh networks If a node fails or drops out of the network, the routing protocol is smart enough to find a new way around the failing device A BeagleBone Black board connected to a CC2650 sensor tag forms the Edge Router to the Internet The CC2650 sensor tag acts as the route node The BeagleBone Black gateway is running a web server A standard web browser like the Internet Explorer, Firefox, or Google Chrome can be used to connect to the BeagleBone Black web server and view the sensor nodes In addition to the mesh network protocol, the CC2652 can also run Bluetooth Low Energy communication for the configuration and maintenance of the TIDA-010012 board Different vacuum pumps are used in the factory with different interfaces and data types for condition monitoring Depending on which pump the TIDA-010012 is connected to, it needs to run different protocols on RS232 or RS422 or RS485 to read out the data from the vacuum pumps With the Bluetooth Low Energy interface on the CC2652 adapter board A smartphone or a tablet can be used to configure the TIDA-010012 board for the different pump types After the configuration with Bluetooth Low Energy, the CC2652 will switch from Bluetooth to the mesh network protocol to continuously send the data from the pumps for condition monitoring This picture shows the actual connection of the TIDA-010012 boards in the mesh network The orange dots are the nodes connected to the pumps, and the green dot is the gateway For test purposes, 22 nodes have been installed Clicking on the different nodes show the actual vacuum pump data On this slide, you can see an extract of collected condition monitoring data of 1 vacuum pump The oil status, nitrogen flow, water flow,

and temperature of one pump are shown, in this case, over several days This collection enables the possibility for trend analysis and predictive maintenance The vacuum pump data are also sent to a cloud for condition monitoring On this reference design, the CC3220 MOTT is used to connect via Wi-Fi to the IBM Watson IoT service using the MQTT Client library API from Texas Instruments The IBM Watson platform offers a quick-start service which allows devices to connect without being registered to evaluate the platform and verify connection set up It has pre-integrated support for TI evaluation boards, enabling developers to quickly begin prototyping IoT applications On this slide, the temperature of one vacuum pump is shown on the IBM Watson IoT platform