New control systems at KSTAR compatible with ITER standard technologies

New control systems at KSTAR compatible with ITER standard technologies

Fusion Engineering and Design 129 (2018) 94–98 Contents lists available at ScienceDirect Fusion Engineering and Design journal homepage: www.elsevie...

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Fusion Engineering and Design 129 (2018) 94–98

Contents lists available at ScienceDirect

Fusion Engineering and Design journal homepage: www.elsevier.com/locate/fusengdes

New control systems at KSTAR compatible with ITER standard technologies ⁎

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Woongryol Lee , Taegu Lee, Giil Kwon, Taehyun Tak, Jinseop Park, Myungkyu Kim, Yeon-jung Kim, Jaesic Hong National Fusion Research Institute, Daejeon, Republic of Korea

A R T I C L E I N F O

A B S T R A C T

Keywords: KSTAR EPICS SDN TCN MTCA.4 Real-time application

Through the lessons learned during the ITER control, data access and communication (CODAC) tasks and the interaction with various domestic and overseas communities, the KSTAR control system is being improved with new functions. We have adopted ITER synchronous data bus network (SDN) and time communication network (TCN) to increase the flexibility of control system design and improve system performance. Absolute time-based discharge operations and high-speed data communication interfaces are standardized as KSTAR standard software components. We used the reconfigurable I/O (RIO) library provided by CODAC for the renovation of a fast interlock system, and effectively implemented a real-time core structure through ITER for the next generation real-time control systems. A new hardware platform standard has been adopted for system standardization and convenience of maintenance international collaboration.

1. Introduction

developed a feedback control system that complies with the CODAC standards and have used plasma density control experiments. In addition to building regional control systems, the installation, analysis and evaluation tasks of the operation applications of ITER are ongoing. Fig. 1 shows the overall CODAC system configuration at KSTAR. The system typically consists of two diagnostic systems, two fuel injection systems, and a plasma controller, which includes all the high performance network interfaces and the data archiving system. In addition, a standard operation interface (OPI) was developed based on a 4Khuman-machine interface (HMI) system, and the ITER operation applications showed stable synchronous operation ability through the KSTAR experiment. Lessons learnt from the CODAC task were utilized in the maintenance and long-term improvement plans at KSTAR. Some components and schemes were evaluated and subsequently incorporated into the KSTAR control system. World-time-based operation methods using TCN and high-bandwidth real-time interfaces were reflected in KSTAR system upgrades. The design philosophy for next-generation hardware platforms and real-time control applications has been inspired by CODAC system evaluation.

The KSTAR control team is responsible for developing not only the ordinary machine control systems but also the data acquisition system for diagnostics and real-time control. Our development efforts are naturally concentrated on the system automation and standardization. More than 20 control systems have been implemented based on standard custom libraries [1]. However, the KSTAR control team is constantly facing new challenges such as the necessity to reflect the latest systems and requirements added each year, system instability owing to aging, and long-term experimental planning. Fortunately, we have been continuously improving system performance through active exchanges with various control communities including the ITER control team, and we were able to cope with future problems in advance. This paper briefly describes the CODAC standard system installed in KSTAR. Subsequently, we introduce several newly constituted elements at KSTAR. 2. Overview of the CODAC control system at KSTAR Since KSTAR and ITER have similar engineering characteristics and the KSTAR control system also uses the experimental physics and industrial control system (EPICS) as a middleware, it is close to the standard model of the ITER control system. Therefore, we have been performing functional and performance evaluation tasks of CODAC standard technologies for the past several years. Consequently, we have



Corresponding author. E-mail address: [email protected] (W. Lee).

https://doi.org/10.1016/j.fusengdes.2018.02.077 Received 15 June 2017; Received in revised form 19 February 2018; Accepted 20 February 2018 0920-3796/ © 2018 Elsevier B.V. All rights reserved.

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Fig. 1. Entire CODAC control system interconnection at KSTAR for real-time density feedback control.

3. Expansion of KSTAR control system by using CODAC technologies 3.1. Improvement of network infrastructure The native KSTAR time synchronization system is primarily aimed at synchronizing clocks/triggers with a single clock source and supplying them directly to the controller. It has a star topology connection and provides a high-precision time protocol. It has a resolution of up to 5 ns, provides more than 50 programmable multi-trigger chains, and a 1–100 MHz output clock. The EPICS input output controller (IOC) built into the ARM® processor provides an efficient operating environment [2]. Most installed data acquisition (DAQ) control systems were designed and developed through an in-house manufacturing process. However, some DAQ systems are far from standard because they are installed independently. In order to provide the correct time stamp to a non-standard system, the pulse automation system adopts global positioning system (GPS) time protocol for the discharge start event instead of a software timer. Moreover, system time synchronization is set up based on the ITER TCN interface, which provides a more precise time resolution for a control application. Fig. 2 shows the finalized KSTAR timing system interconnection. In order to achieve real-time data communication performance, KSTAR uses a hardware-driven communication device, i.e. a reflective memory (RFM) card. It has benefited from the low communication latency on dissimilar hardware platforms running different operating systems, and the lack of software overhead. However, higher data rate and faster response time are required. The lack of diagnostic tools motivates us to seek an alternate solution. ITER SDN is based on UDP/IPv4 multicast over 10 Gb Ethernet. SDN software supports for the publish/subscribe paradigm for its data communication. During previous plasma experiments which are

Fig. 2. KSTAR time distribution diagram with ITER TCN.

performed at KSTAR, it was confirmed highly available and deterministic transport performance for real time feedback control. There are advantages of using various diagnostic tools, i.e. WhatsUP gold, PRTG, ping, ipuf, ipscan etc. We decided to use the SDN for the high-speed control network interface, and developed a real-time gateway between the RFM and SDN, i.e. SDN-gateway, for gradually migrate from RFM to SDN [3]. Fig. 3 shows the current design and progress of SDN infrastructure. There are three categorized control systems that are intended to use the SDN interface. The second neutron beam injection (NBI) system, high-speed control cluster nodes, and real-time diagnostics are intended to use the SDN interface.

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Fig. 3. SDN interconnection scheme with star topology.

methodology for the implementation of a real-time application. Inspired by the design philosophy of the ITER real-time framework (RTF) [5], we adopted a function block (FB) based high abstraction layer for the implementation of a real-time application. In order to evaluate the feasibility, we agilely prototyped an EPICS IOC, which is configured with several libraries including real-time core engine, named tool for advanced control (TAC) engine, from ITER. The TACengine shares software design concept, common libraries, and internal logic functions with the CODAC standard software packages. Fig. 4 shows the basic software components of the real-time core engine based EPICS IOC application. By developing an intuitive web-based HMI system, we will provide a convenient communication and configuration logging system. In order to determine the likelihood of this process, we developed and tested an application that supports a simple but flexible drag and drop user interface. Fig. 5 shows conceptual diagram from a Web based dynamic configuration application with a drag-and-drop interface. Each FB and thread group has a property field, which can be easily modified. This application translates the contents as an xml file, which can be used in the core engine. Currently, we are configuring a single-node hardware environment based on CCS v5.4 as follows and porting a customized real-time core engine inside the KSTAR standard EPICS IOC.

3.2. New software components for system I&C KSTAR does not use an integrated project development solution (e.g. sdd-editor) for control system development, but provides standard libraries, templates, and example codes. A standard software framework library (sfwLib) is widely used as a fundamental core library in IOC. The sfwLib has a device support structure, which provides nonblocking behavior through message queues. Additional new features have been implemented based on the CODAC standards recently. SDN support library is re-generated as a standard form of site library. We have applied a time synchronization mechanism to sfwLib, and verified that the library works correctly in the CODAC environment. The TCN service is intended to operate in a non-CODAC system. A new fast interlock system (FIS) is being reconstructed based on the CODAC technology. KSTAR is equipped with a programmable logic controller (PLC) based classical machine interlock system, which is classified as a slow controller. A more flexible and logical protection mechanism is implemented in the central control system (CCS) together with time synchronization system (TSS) and customized interface device. The FIS is designed to reduce damage to the plasma facing components (PFC) and other materials owing to overheating and improper operational state of heating systems after starting the discharge sequence [4]. However, Fast detection and propagation of plasma disruption and plant system error are implemented on several local systems at KSTAR i.e. Central Control System, Real Time Monitoring System, Pulse Automation System. Distributed control logic is difficult to maintain with consistency. Eventually, we decided develop an integrated FIS with similar system architecture as the ITER central interlock system (CIS). The new FIS uses National Instruments (NI) RIO libraries, which is a component of CODAC standards. A second NBI system is under construction and will be operational from the 2018 campaign. It is designed to provide off-axis current drive using 3-beam injection with vertical steering on the equatorial plane. Three ion sources are equipped and designed to generate a maximum total beam power of 6 MW. The NBI system is divided into three major parts: beam line, ion source, and power supply. The NBI control system design placed an integrated control system (ICS) at the top layer. The ICS manipulates the local control systems (LCS) of each power supply and beam line, and performs a sequential logic control according to the beam initiation time. It generates a predefined/arbitrary reference waveform synchronized to the PCS command with a maximum speed of 10KHz. Hence, the ICS demands a more flexible and stable

• MRG-R kernel 3.10.33-rt32.52 (Fast Controller based on CCS v5.4)

Fig. 4. An example of an EPICS IOC for real-time applications based on the TAC-engine and additional plug-ins.

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Fig. 5. Conceptual diagram for density feedback control based on the FB using real-time core engine.

• Intel Xeon E5-2620 v3 2.4 GHz (Single Socket) • Chelsio - S320E-CT-CR (standard SDN card) • TCN driver with i350 chipset ®

®

precision clock and trigger through the backplane, intelligent system management interface, modular structure of high-speed links, and allows flexible reconfiguration of system functionality. Diverse local systems require different analog-to-digital converter (ADC) rates and can be categorized into several performance grades. Most systems demand sampling speeds in the range of 10 KSPS–2MSPS. We decided to build our own base device through practical experience and strategic factors. Eventually, a bespoke KSTAR multifunction control unit (KMCU) with the benefit of modular design was manufactured. So far, two KMCU series with the same system-on-chip concept have been developed through international collaboration. A base advanced mezzanine card (AMC) module was manufactured by a domestic company. The rear transition module for analog signal interface and intelligent platform management interface (IPMI) were achieved through international collaboration. A special optical PCI up-link solution reused the CODAC catalogue product and we improved it. The key specifications are described in Table 1. The product appearance and related institutes and companies are shown in Fig. 7. Several DAQ systems were renovated or newly developed using KMCU-Z30 so far. We have retrofitted the magnetic diagnostic DAQ system to support unlimited data acquisition time. Mirnov Coils and Halpha monitoring systems were reconfigured to achieve higher sampling rates. A new DAQ system for multi-chord photo-elastic modulator based motional stark effect (MSE) system was also developed using KZ30. Another MSE, from the PPPL/MIT multi-spectral line-polarization MSE system, also used K-Z30. We consider using the K-series AMCs for a small-sized diagnostics and control system by means of standalone operability.

Fig. 6 shows the typical results of execution time of each FB of realtime application in our environmental conditions. Although it is still in the initial stages, a real-time core program with added functionality for the second NBI will be developed in the next campaign. 3.3. Device standardization for system instrumentation & control CODAC recommends several hardware platforms for a fast I/O system depending on performance grades. The peripheral component interconnect (PCI) extensions for instrumentation (PXI) is the most widely used platform for control system I&C at ITER. However, KSTAR requires a simpler platform for easy maintenance, which should also satisfy the demands of high-performance systems in the future. After investigating the new trends in the market and control communities, KSTAR adopted the MTCA.4 standard for systematic standardization of high-speed controllers [6]. An extension of micro telecommunications computing architecture (MTCA) initiated by the physics community, MTCA.4, provides a high-

Table 1 Key features of custom AMC modules. Item

KMCU-Z30 (K-Z30)

KMCU-Z35 (KZ35)

FPGA Memory Front Interface

XC7Z30T 1GB DDR3 – 2 × SFP + cadge Ethernet RJ45 microSD for Linux LEMO CLK/TRIG PCIe × 1(port 4) Gen 2 Ethernet port-0 TCLK, FCLK Class D1.0.

XC7Z35T ⟵ 1xLPC FMC site 1 × SFP + cadge ⟵ ⟵ ⟵ PCIe x4(port 4–7) ⟵ ⟵ ⟵

Backplane interface

Zone 3

Fig. 6. Measured execution time of each FB.

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both hardware and software infrastructure. By adopting TCN and SDN, we decided to improve the performance of control infrastructure and increase the flexibility of system design. We will use the core engine to reflect the real-time framework design concept and use it for the integrated control of the second NBI system. KSTAR adopted the MTCA.4 standard for the systematic standardization of a fast controller and real-time diagnostics. Acknowledgments This work was supported by the Ministry of Science, ICT and Future Planning. We would like to thank KSTAR teams. References [1] Woongryol Lee, Mikyung Park, Taegu Lee, Sangil Lee, Sangwon Yun, Jinsup Park, et al., Design and implementation of a standard framework for KSTAR control system, Fusion Eng. Des. 84 (2009) 867–874. [2] Woongryol Lee, Taegu Lee, Jaesic Hong, Development of a processor embedded timing unit for the synchronized operation in KSTAR, Fusion Eng. Des. 112 (2016) 800–803. [3] Giil Kwon, Woongryol Lee, Bauvir Bertrand, Taegu Lee, Jaesic Hong, Development of real-time network translator between ITER synchronous data bus network and reflective memory, Fusion Eng. Des. 123 (2017) 955–959. [4] Jaesic Hong, Woongryol Lee, Taegu Lee, et al., Development and operation of fast protection for KSTAR, Fusion Eng. Des. 112 (2016) 742–746. [5] A. Winter, B.R. Bauvir Lange, Software Architecture and Design Document for the ITER Real-time Framework, (2018) ITER_IDM_PKT5S7 v2.2. [6] Woongryol Lee, et al., MicroTCA.4 based data acquisition system for KSTAR tokamak, 20th IEEE-NPSS Real Time Conference (2016).

Fig. 7. Manufactured standard control board based on MTCA.4.

4. Conclusion ITER CODAC technologies were successfully evaluated in the reallife environment of an operational tokamak. KSTAR has been investigating the next generation control platforms and new standards for

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