- Email: [email protected]
Recent Advances of Application and Technology of Industrial Computers in Japan
Copyright © IFAC Real Time Programming Kyoto. Japan. 1981
RECENT ADVANCES OF APPLICATION AND TECHNOLOGY OF INDUSTRIAL COMPUTERS IN JAPAN H. Kuwahara and T. Miura* Omika Works, Hitachi Ltd" 5-2-1 Omika, Hitachi, Japan *Systems Development Laboratory, Hitachi Ltd" 1 099 Ozenjz', Tama-ku, Kawasaki, Japan
Abstract. The industrial computers are now widely used throughout various kinds of industries to control and optimize the industrial processes. This paper describes the recent advances of application and technology of industual computers in Japan where most advanced industries are utilizing varions kind of computers to improve production efficiency, to improve product quality and to improve life of people. Recent topics in various major industries are discussed and recent advances of hardware and software technology of industrial computers are presented. Keywords. Industrial computer; Application of industrial computer; Software productivity improvement.
INTRODUCTION In these days, the application of industrial computers for industrial processes have been quite common throughont varions kind of industres like power generation, power distribution, steel making, chemical processes, production automation, traffic control and others. The more industrial computers are used the more new needs are coming out to achieve better results out of using them. New needs are faster machine, reliable hardware and software, more intelligent application algorithms, cheaper software production cost and better software tools to achieve it and so forth. If we look at the present status of application of industrial computers in various industries and if we look at the present trends of industrial computers being developed, and if we watch the technology trends surrounding them, we will be able to know how and where we are going to achieve better life of mankind by utilizing technology advancement.
RATIO OF NUMBERS INSTALLED IN '979 _-rr-'r--. CHEMICAL
OEM 29 ,8 %
TOTAL NUMBER INSTALLED : 3,570 TOTAL V : 95,8BV DATA : BY JEIDA
TRAFFIC
FIG. 1
PRESENT TRENDS OF APPLICATION OF INDUSTRIAL COMPUTERS IN JAPAN
APPLICATION OF INDUSTRIAL COMPUTERS IN JAPAN
In power generation, application of computers have passed the age of simple date-logging, but now fully automated power generation plant is becoming not new in modern large capacity plants. In nuclear application areas, faster calculation speed is needed to have better look at the plant status by knowing nuclear furnace performance from the results of sophisticated calculations. Also efficient ways of transmitting data through various sub-systems are being tried by utilizing optical fiber link system.
Figure 1 shows the application of industrial computers in Japan installed in 1979. Basic industries like power generation, steel making, and chemical industries have stable installations and larger number of installations are observed in rather new application areas like production automation, laboratory automation, medical automation and so forth.
15
H. Kuwahara and T. Miura
16
I
POWER GENERATION
l
H
FORSIL POWER
NUCLEAR POWER
]------1
l OlL TO COAL, LNG FASTER LOAO CHANGE
{
I
BREADER REACTOR J NEW ENERGY
ADVANCED DDC CONTROL UTILIZING MATHEMATIC MODELS OF TARGET PROCESS
SAFETY ------- BETTER CONTROLABILlTY
------t R~r~Y~fsQUISITION
TRACKING OF MATERIALS AND THEIR OPTIMUM F LOW CONTROL
AND
ENERGY SAVING CONTROL
J {
EXPERIMENTAL DATA ------- ANALYSIS AND CONTROL
TOPICS •
TOPICS •
TABLE ORIVEN TYPE CONTROL SOFTWARE (POL) FOR START-UP AND SHUT-DOWN CONTROL OF POWER PLANT
•
NEEDS OF FASTER CALCULAT)ON SPEED FOR REACTOR ANALYSIS OF NUCLEAR POWER PLANT
•
SERIAL DATA LINK BETWEEN SUBSYSTEMS )N NUCLEAR POWER PLANT
•
APPLICATION OF MULTIPDEXER USING OPTICAL TRANSMISSION TECHNOLOGY IN NUCLEAR POWER PLANT FIG_ 2
TOTALlZED DISTRIBUTED CONTROL SYSTEM USING OPTICAL FIBER DATAWAY CENTRALIZATION OF SOFTWARE MAINTENANCE OF THE SYSTEM INCLUDING MICRO-PROCESSORS CONNECTED TO THE DATAWAY
•
APPLICATION OF DDA (DIGITAL DIFFERENTIAL ANA LYSER) PROCESSOR FOR PRECISE CALCULATION OF MATHEMATIC MODELS. APPLICATION OF VOICE AREA
•
FIG. 4
In steel making industry, we can see most advanced and sophisticated use of industrial computers to control the total operation of plant. Because larger computing capabilities are needed, in many cases multi-computer configulations are applied and in these systems redundant computer operation is one of the merits to keep continuous operation of plant. Optical fiber link system (Hitachi's Data Free Way) have been first applied and now working without single failure for more than two years. The biggest topics here is centralized and distributed system utilizing optical fiber link between several computers, larger multi-configured computers in the center and many small-scaled microprocessors along the data link.
DEVICES IN TESTING
MULTI-COMPUTER SYSTEMS
POWER GENERATION
SCADA (Ssanning, Alarming and Data Aquisition) system is becoming common practice in power line control systems, and now this system is being enhanced to accomodate the capability of security analysis of power line network and automatically control the switching of networks in emergency cases to keep alive the power line as much as possible. Here we can see typical examples of using color CRT display sytems as means of manmachine commumications.
RESPONCE
STEEL MAKING INDUSTRY
Manufacturing automation is becoming larger and larger to contain total automatic operation of a manufacturing plant. Typical total system has big business machines at its top, industrial control computers in the middle to control typically a daily optimum control of production flow and quite a few micro-processor based sequence controllers, sometimes with logical calculation capabilities in them, at its bottom. Coming trends are utilization of sophisticated pattern recognition devices with advanced recognition algorithms, of advanced micro-processor based terminals for man-machine communication, of shop-computer, which is the machine with both capability of office computer and process control computer, of robot systems directly connected to industrial control computers for total optimization. Factory Automation or Flexible Automation are symbol names in the coming manufacturing automation.
MANUFACTURING AUTOMATION MACHINE CONTROL PRODUCT ION FLOW CONTROL
The purpose is the centratization of software and hardware maintenance and di-centralization of functions which require faster responce time.
' SEQUENCE CONTROL { DNC IDIRECT NC ) r ORTIM IZATION - . , (TRACKING AND SCHEDULING) ,SYNCHRON IZATION OF PARTS
IN VEN TORY CONTROL TOPICS
SCADA
f------1I
DATA ACQUISITION (POWER LINE STATUS ACQUIS ITION)
f------11 COLOR SEMI-GRAP HIC BASED MAN / MACHINE
TOTALlZED PRODUCTION CONTROL SYSTEM IMAIN FRAME INDUSTRIAL COMPUTER MICRO SYSTEMS )
I
PATTERN RECOGNITION ANO ITS SENSOR (NEED FOR HIGHSPEEO PATTERN RECOGNITION PROCES· SORt
I
COMMUNICATION AND CONTROL AUTOMATIC SWITCHING CONTROL POWER LINE STABILITY AND SERCURITY ANA L YSIS TOPICS •
TRACKING METHOD IIDENT I FICATION METHOD; CARD, MAGNETIC STRIPE CARD, OTHERS)
I
I
TOKEN
INTRODUCTION OF SHOP -COMPUTER PH I LOSOPHY •
CONNECTIONS WITH ROBOT SYSTEMS AG. 5
MANUFACTURING AUTOMATION
NEEDS OF FASTER CALCULATION SPEED FOR SECURITY ANALYSIS OF POWER LINE SYSTEMS. (NEEDS FOR SPECIAL ARRAY PROCESSOR AND OTHERS) GRAPHIC PICTURE GENERATION SOFTWARE ADVANCED GRAPHIC SYSTEMS
•
FASTER DISPLAY SPEED OF PICTURES ON CRT SCREEN
•
NEEDS FOR LARGE SCREEN DISPLAY FlG.3
SCADA
Traffic control and Laboratory automation are another major area of industrial control computers. Functions performed and topics we have there are described in Figure 6 and 7.
17
Recent Advances of Application and Technology ADVANCES IN INDUSTRIAL COMPUTER SYSTEM/PROCESSOR/OPERATING SYSTEM ARCHITECTURE
TABLE DRIVEN TRAFFIC CONTROL L-_____ "'10 . TIME ELECTRIC POWER DISPATCHING 0
r-----'-------
CONTROL
. {OOPTIMUM ROUTE GUIDANCE DISPATCHING
r-------, '--_ _ _ _...J
"
.
0
OF SPECIAL VEHICLES (PATROL·CAR, AMBULANCE, NEWSPAPER DISPATCHING CAR ETC .)
"'10REMOTE CONTROL EOUIPMENT •
o
OF TUNNEL
DRIVING GUIDE DISPLAY
TOPICS FULLY REDUNDANT SYSTEM ARCHITECTURE
o
HIGH ·RELlABILlTY OF SOFTWARE (STRONG AGAINST EXTERNAL DISTURBANCES) PATTERN RECOGNITION AT TOLLGATE
o
DISPATCHING ALGORITHM OPTICAL DATA TRANSMISSION (DIGITAL DATA, INDUSTRIAL TV PICTURE, ETC.) FIG.6
System architecture of industrial computers is now advanced to Distributed Network System in larger applications. This is backed up by micro-processor technology, which gave us low cose, high performance intelligent controllers distributed along production lines or process lines. Totalization requirement pushed the use of high-speed, reliable data transmission line of fiber optic technology. Needs for Distributed Network System, major functions and technologies in the background are shown in Figure 9 and 10.
TRAFTIC CONTROL
DISTRIBUTED NETWORK SYSTEM DATA ANALYSIS MU L TI·COMPUTE R SYSTEM
MEASURING EQUIPMENT CONTROL '--_ _---j
MULTI·PROCESSOR SYSTEM MUL TI JOB· PROCESSORS AND SPECIAL PROCESSORS
~~~~~~~:~~ OF DATA TO VISIBLE
l
TOPICS o
32 BIT, VIRTUAL SYSTEM PHILOSOPHY, SMALLER OS OVERHEAD, CONVERSATIONAL PROGRAMMING
HIERARCHY AND TOTALIZED NETWORK SYSTEM (MAIN FRAME - MINI'S) HIGH ·SPEED DATA LINK BETWEEN PROCESSORS (OPTICAL DATA TRANSMISSION)
o
SPECIAL PROGRAMMING LANGUAGES (REAL ·TIME BASIC, NOADAL ETC.)
o
UL TRA ·HIGH SPEED SCANNING DEVICES IN HIGH ENERGY PHYSICS FIG. 7
LABORATORY AUTOMATION
New application areas of industrial control computers are expanding in numbers and scopes. Most promissing areas new are image processing, where sophisticated system configulation is needed to get faster image processing speed and varions kinds of unique peripherals are essential, and pattern recognition which is long demanded for material handling, quality checking, target identification and others. There will definitely be needs for very high speed special processors and advanced LSI technology will play significant roles to achieve them.
FIG.9
SYSTEM/COMPUTER ARCHITECTURE
NEEDS FOR DISTRIBUTION
• RISK DISTRIBUTION • FASTER RESPONCE • LOAD SHARING NEEDS FOR CENTRALIZATION
• EFFICIENT
OPERATION AND MAINTENANCE • BETTER CONTROL OF TOTAL SYSTEM TECHNOLOGY
ADVANCE • L51 • OPTICAL LINK • NETWORK
FIG.l0
o
LAND MAP GENERATION
o SEA-WATER TEMPERATURE
DETECTION o AIR AND SEA·WATER POLLUTION DETECTION o SEARCH FOR NATURAL RESOURCES o OTHERS
. [0 PRODUCTION '---------'
'.
0
o o
CONTROL
~~:~~~N~)HECKING
SORTING OTHERS
TOPICS o
ULTRA-H I GH SPEED IMAGE PROCESSING PROCESSOR
o
PATTERN RECOGNITION PROCESSOR
o
DETECTION ALGORITHM
FIG.8
NEW APPLICATION
-DISTRIBUTED • OPERATION AND MAINTENANCE -CENTRALIZED
DISTRIBUTED NETWORK SYSTEM
The first optical data-way systems were installed in Nippon Steel Company's Kimitsu plant in 1979 and system functions have been greatly expanded to now contain five mega-minis in the center and many micro processor based intelligent satellite control systems connected to the data-way. They are the biggest installation of optical data-way system at present. Layont of the system are shown in Figure 11. Now as a next target, we are tring to develop very high speed of about 1,000 mega-hertz data-way for faster transmission of data through the loop and reliable centralized data-file as a total system's data-base media. There will be needs for faster optical data transmitter/receiver and very high speed LSI technology to accomodata them.
H. Kuwahara and T. Miura
18
FARMWARE
(20% OF STEPS, 50% OF RUN TIME STEPS)
•
OS
•
DISTRIBUTED OS ARCHITECTURE KERNEL IN JOB PROCESSOR (RESOURCE ALLOCATION , SCHEDULING ETC. ) •
•
VIRTUAL SYSTEM PHILOSOPHY •
•
m
0L'~~~_590
AG.l1
OPTICAL DATA HIWAY SYSTEM INSTALLED AT STEEL MAKING PLANTS
If we need to lood at the typical advancement of system architecture of industrial computers. Hitachi V90/50 Industrial Computer gives us most advanced architecture and technology. It has multi-processor based architecture to achieve very high performance, serial I/O loop bus of optical fiber to accomodate slow speed I/O's, high-speed optical data-way to connect many numbers of intelligent controllers to realize total network system and as many as maximum of eight computers conld be connected together to conform multi-computer system for reliable and redundant configulation. Main features of this machine are shown in Figure 12 as typical technology advancement in industrial control computers. Figure 13 shows software technologies for the machine and biggest target we are aiming at is virtual system philosophy where we can divide system design to logical design and physical design for eassiness and correctness of system engineering and design.
•
1/ 0 CONTROL AND ERROR ANALY SIS IN DISTRIBUTED PROCESSORS
VI RTUAL MEMORY
•
VI RTUAL 1/ 0
•
VIRTUAL INTERFACE WITH PROCESS DATA
ADVANCED FILE CONTROL SYSTEM •
INDEPENDENCE BETWEEN ACCESS METHOD
•
POWERFUL FILE CAPAB I LITY IN LANGUAGE
DATA
STRUCTURE
AND
EFFICIENT SOFTWARE PRODUCTION TOOLS
OPERATING SYSTEM OF INDUSTRIAL COMPUTERS
AG, 13
SOFTW ARE PRODUCTIVEITY IMPROVEMENT Software productivity is becoming mor e and more important to improve return-on-investment for modernization, babor saving, energy saving and rationization of industrial process. Software cost is now about 45 percent of the total system cost as an avarage and bigger new application system requires software cost of more than 60 percent. To improve software productivity, we have to look at effective two approaches, prevention of bugs and detection and correction of bugs in early stage of software production process. These are shown in Figure 14.
ION OF BUGS
f--_ _ ________--=C~O;M;"PL;:;E.T;.;'O:-..-N
(PRINCIPLES)
CD PRE V ENTION
OF CREEPING BUGS ,
o
EAR L Y DETECTION AND CORRECTION OF BUGS CREPT IN .
TIME
AG. 14
PRI'IClPLES OF' PRODUCTIVITY IMPROVEMENT
MULTI ·PROCESSOR ARCHITECTURE • JOB PROCESSOR, lOP, FCP, CMP, DWP, • SPECIAL PROCESSORS, DDA, ARRAY P, VECTOR P, IMAGE P • SUPERVISORY PROCESSOR JOB PROCESSOR • • 1/ 0
•
32 BITSI WORD VIRTUAL SPACE ,
4GB
LINKAGE SERIAL DOUBLE LOOP BUS
NETWORK ARCHETECTURE DATAWAY (OPTICAL FIBER TRANSMISSION ) NETWORK SUPPORT SOFTWARE (COMMON FILE, PROGRAM • MING SUPPORT, CENTRALIZED ERROR LOGGING ETC ,) MULTI ·COMPUTER CONFIGULATION • GLOBAL MEMORY • COMPUTER ·TO ·COMPUTER LINK BUS • 1/ 0 SHARE BY 1/ 0 LOOP BUS
AG. 12
SYSTEM ARCIfTECTUl[
or
KlUSTRIAl COMPUTEIIS
Considerable amount of experimental works are being done by various groups and companies associated in software production, and some sign of success is being observed in even system design areas. The philosophy of software work-bench or workstation is now becoming popular to stimulate people's intension to have some kind of intelligent tools for better production efficiency of software. Typical tools and methodologies for this are shown in Fig. 15 and you can see whole software production process phases are now targets of them. In many cases we have to change our own ways of making software to apply these tools and methodologies and perpaps different philosophy for co m-
Recent Advances of Application and Technology puter hardware and capability itself may be needed to dramatically improve software productivity. To improve software productivity, right understanding of system itself is essential and approaches are shown in Fig. 16. IMPLEMENTATION
DESIGN
• NEEDS A N A L VSI S PRE V EN TION OF
(KJ METHOD . PPDS I • REO . DEFI N ITION !
BUGS
RATIO
I
1rJ't
1rJ't
MAINTEN A NCE
• SOFTWARE DESIG N METHO D (J ACKSON METHOD , PA D, .1
OFFLlNE -
ONLlNE -
TEST
TEST
ANAL YS IS (SADl , • TOP· DOWN S.P (SP L, PROTEL , SSA, SAMM , PSLlPSA, RSl/ ASA, RD UR OA , ADA , I
CREEPING
100%\ MANMONTH
19
A UTO MATI C
I
DOC UMENTATION
OFF LINE·
ONLlNE
OFFLlNE ·
TEST
TEST
TEST
ONLlNE ·
TEST
POl
EARL Y DETE CTION & COR A Ee
• REO. TESTING (PRQTOT YPI NG, EXECUTA BL E A EO
liON OF
LANG .I
BU GS CR EPTIO N
• TOP -DOWN TESTIN G
FIG. l.
• SYSTEM AT IC T EST ING (HIT EST ,
PR OD UCT
PROJECT MANAGEME NT
MGT .
MA NA GEMENT
I
PWB F AC ILITI ES
The philosophy of Software Work Bench is now being improved and enhanced to realize easiness and effectiveness of total software production process starting wi th system definition through final system test at the plant. There are many rooms for improvement in this area and more and more efforts will be necessary to satisfy ourselves by having efficient tools. An example of PWB shown in Figure 19 is the middle stage towards future more efficient one but here we can see direct connection between off-line programming tools and target machine where we load our programs in to control industrial plant.
SOFTW A RE WO RK ST A TI ON
FIG. 15
BUG FINOABlUTY ( SPL '" HITEST/F )
SOlDA , APTS. TPL/ .1 F.
REQUIRED TOOLS '" METHOOOLOGIES
SOFTWAR E PRODUCTION CENTE R
• GENERA L PU RPOSE COMPU TE (HIT AC·M) $Pl PROGRAM STRUCTURE (C RT TE RM IN A LS)
FIG.16
STRUCTURAL FEATURES OF COMPUTER CONTROL SYSTEMS
• INDUSTR IAL COM PU TERS (I-I I DIC)
,,-------------+=::::;-~M .
Fig. 17 shows example of non-destructive test system for programs. In conventional way, we have to put test procedures in programs to be tested and this is not practical to test programs. independently of person who wrote the program. HITEST IF, nick-name for the tool, gives us independent testing capability and easiness of testing.
SOF TWA RE TOOLS
TE STI NG ROOM
FIG. 19
AN EXAMPLE CIF PWB FOA COMPUTER CONT11OLL SYSTEMS
CONCLUSION SPEC
CONVENTIONAL TESTING
HITEST / F TESTING
~-----------------------------+----------------~ PROG RAM TO BE TESTE
PROG RAM TO BE TESTED
c. 'CSW -'§@"§ I
'
.
,
J
,
~
-
,,,",
,
.
n ~
t SEPERATED
-
~T
~ => STATE M ENTS FOR TESTI N G
FIG. 17
HITEST/ F NON - DESTRUCTIVE TESTING
Figure 18 shows the difference in performance of software production by utilizing different tools. PCL is Fortran like Process Control Language, and SPL is Structural Programming language for enable us to structurely make programs. Data proves the principles of software production process shown in Fig. 14.
Present trends of Japanese Industrial Computer Conro! Systems are presented. As software production efficiency is becoming more and more important, hardware design philosophy is needed to achieve significant change to give us virtual system design concept together with advanced software tools to go with it.
RECENT ADVANCES OF APPLICATION AND TECHNOLOGY OF INDUSTRIAL COMPUTERS IN JAPAN H. Kuwahara and T. Miura* Omika Works, Hitachi Ltd" 5-2-1 Omika, Hitachi, Japan *Systems Development Laboratory, Hitachi Ltd" 1 099 Ozenjz', Tama-ku, Kawasaki, Japan
Abstract. The industrial computers are now widely used throughout various kinds of industries to control and optimize the industrial processes. This paper describes the recent advances of application and technology of industual computers in Japan where most advanced industries are utilizing varions kind of computers to improve production efficiency, to improve product quality and to improve life of people. Recent topics in various major industries are discussed and recent advances of hardware and software technology of industrial computers are presented. Keywords. Industrial computer; Application of industrial computer; Software productivity improvement.
INTRODUCTION In these days, the application of industrial computers for industrial processes have been quite common throughont varions kind of industres like power generation, power distribution, steel making, chemical processes, production automation, traffic control and others. The more industrial computers are used the more new needs are coming out to achieve better results out of using them. New needs are faster machine, reliable hardware and software, more intelligent application algorithms, cheaper software production cost and better software tools to achieve it and so forth. If we look at the present status of application of industrial computers in various industries and if we look at the present trends of industrial computers being developed, and if we watch the technology trends surrounding them, we will be able to know how and where we are going to achieve better life of mankind by utilizing technology advancement.
RATIO OF NUMBERS INSTALLED IN '979 _-rr-'r--. CHEMICAL
OEM 29 ,8 %
TOTAL NUMBER INSTALLED : 3,570 TOTAL V : 95,8BV DATA : BY JEIDA
TRAFFIC
FIG. 1
PRESENT TRENDS OF APPLICATION OF INDUSTRIAL COMPUTERS IN JAPAN
APPLICATION OF INDUSTRIAL COMPUTERS IN JAPAN
In power generation, application of computers have passed the age of simple date-logging, but now fully automated power generation plant is becoming not new in modern large capacity plants. In nuclear application areas, faster calculation speed is needed to have better look at the plant status by knowing nuclear furnace performance from the results of sophisticated calculations. Also efficient ways of transmitting data through various sub-systems are being tried by utilizing optical fiber link system.
Figure 1 shows the application of industrial computers in Japan installed in 1979. Basic industries like power generation, steel making, and chemical industries have stable installations and larger number of installations are observed in rather new application areas like production automation, laboratory automation, medical automation and so forth.
15
H. Kuwahara and T. Miura
16
I
POWER GENERATION
l
H
FORSIL POWER
NUCLEAR POWER
]------1
l OlL TO COAL, LNG FASTER LOAO CHANGE
{
I
BREADER REACTOR J NEW ENERGY
ADVANCED DDC CONTROL UTILIZING MATHEMATIC MODELS OF TARGET PROCESS
SAFETY ------- BETTER CONTROLABILlTY
------t R~r~Y~fsQUISITION
TRACKING OF MATERIALS AND THEIR OPTIMUM F LOW CONTROL
AND
ENERGY SAVING CONTROL
J {
EXPERIMENTAL DATA ------- ANALYSIS AND CONTROL
TOPICS •
TOPICS •
TABLE ORIVEN TYPE CONTROL SOFTWARE (POL) FOR START-UP AND SHUT-DOWN CONTROL OF POWER PLANT
•
NEEDS OF FASTER CALCULAT)ON SPEED FOR REACTOR ANALYSIS OF NUCLEAR POWER PLANT
•
SERIAL DATA LINK BETWEEN SUBSYSTEMS )N NUCLEAR POWER PLANT
•
APPLICATION OF MULTIPDEXER USING OPTICAL TRANSMISSION TECHNOLOGY IN NUCLEAR POWER PLANT FIG_ 2
TOTALlZED DISTRIBUTED CONTROL SYSTEM USING OPTICAL FIBER DATAWAY CENTRALIZATION OF SOFTWARE MAINTENANCE OF THE SYSTEM INCLUDING MICRO-PROCESSORS CONNECTED TO THE DATAWAY
•
APPLICATION OF DDA (DIGITAL DIFFERENTIAL ANA LYSER) PROCESSOR FOR PRECISE CALCULATION OF MATHEMATIC MODELS. APPLICATION OF VOICE AREA
•
FIG. 4
In steel making industry, we can see most advanced and sophisticated use of industrial computers to control the total operation of plant. Because larger computing capabilities are needed, in many cases multi-computer configulations are applied and in these systems redundant computer operation is one of the merits to keep continuous operation of plant. Optical fiber link system (Hitachi's Data Free Way) have been first applied and now working without single failure for more than two years. The biggest topics here is centralized and distributed system utilizing optical fiber link between several computers, larger multi-configured computers in the center and many small-scaled microprocessors along the data link.
DEVICES IN TESTING
MULTI-COMPUTER SYSTEMS
POWER GENERATION
SCADA (Ssanning, Alarming and Data Aquisition) system is becoming common practice in power line control systems, and now this system is being enhanced to accomodate the capability of security analysis of power line network and automatically control the switching of networks in emergency cases to keep alive the power line as much as possible. Here we can see typical examples of using color CRT display sytems as means of manmachine commumications.
RESPONCE
STEEL MAKING INDUSTRY
Manufacturing automation is becoming larger and larger to contain total automatic operation of a manufacturing plant. Typical total system has big business machines at its top, industrial control computers in the middle to control typically a daily optimum control of production flow and quite a few micro-processor based sequence controllers, sometimes with logical calculation capabilities in them, at its bottom. Coming trends are utilization of sophisticated pattern recognition devices with advanced recognition algorithms, of advanced micro-processor based terminals for man-machine communication, of shop-computer, which is the machine with both capability of office computer and process control computer, of robot systems directly connected to industrial control computers for total optimization. Factory Automation or Flexible Automation are symbol names in the coming manufacturing automation.
MANUFACTURING AUTOMATION MACHINE CONTROL PRODUCT ION FLOW CONTROL
The purpose is the centratization of software and hardware maintenance and di-centralization of functions which require faster responce time.
' SEQUENCE CONTROL { DNC IDIRECT NC ) r ORTIM IZATION - . , (TRACKING AND SCHEDULING) ,SYNCHRON IZATION OF PARTS
IN VEN TORY CONTROL TOPICS
SCADA
f------1I
DATA ACQUISITION (POWER LINE STATUS ACQUIS ITION)
f------11 COLOR SEMI-GRAP HIC BASED MAN / MACHINE
TOTALlZED PRODUCTION CONTROL SYSTEM IMAIN FRAME INDUSTRIAL COMPUTER MICRO SYSTEMS )
I
PATTERN RECOGNITION ANO ITS SENSOR (NEED FOR HIGHSPEEO PATTERN RECOGNITION PROCES· SORt
I
COMMUNICATION AND CONTROL AUTOMATIC SWITCHING CONTROL POWER LINE STABILITY AND SERCURITY ANA L YSIS TOPICS •
TRACKING METHOD IIDENT I FICATION METHOD; CARD, MAGNETIC STRIPE CARD, OTHERS)
I
I
TOKEN
INTRODUCTION OF SHOP -COMPUTER PH I LOSOPHY •
CONNECTIONS WITH ROBOT SYSTEMS AG. 5
MANUFACTURING AUTOMATION
NEEDS OF FASTER CALCULATION SPEED FOR SECURITY ANALYSIS OF POWER LINE SYSTEMS. (NEEDS FOR SPECIAL ARRAY PROCESSOR AND OTHERS) GRAPHIC PICTURE GENERATION SOFTWARE ADVANCED GRAPHIC SYSTEMS
•
FASTER DISPLAY SPEED OF PICTURES ON CRT SCREEN
•
NEEDS FOR LARGE SCREEN DISPLAY FlG.3
SCADA
Traffic control and Laboratory automation are another major area of industrial control computers. Functions performed and topics we have there are described in Figure 6 and 7.
17
Recent Advances of Application and Technology ADVANCES IN INDUSTRIAL COMPUTER SYSTEM/PROCESSOR/OPERATING SYSTEM ARCHITECTURE
TABLE DRIVEN TRAFFIC CONTROL L-_____ "'10 . TIME ELECTRIC POWER DISPATCHING 0
r-----'-------
CONTROL
. {OOPTIMUM ROUTE GUIDANCE DISPATCHING
r-------, '--_ _ _ _...J
"
.
0
OF SPECIAL VEHICLES (PATROL·CAR, AMBULANCE, NEWSPAPER DISPATCHING CAR ETC .)
"'10REMOTE CONTROL EOUIPMENT •
o
OF TUNNEL
DRIVING GUIDE DISPLAY
TOPICS FULLY REDUNDANT SYSTEM ARCHITECTURE
o
HIGH ·RELlABILlTY OF SOFTWARE (STRONG AGAINST EXTERNAL DISTURBANCES) PATTERN RECOGNITION AT TOLLGATE
o
DISPATCHING ALGORITHM OPTICAL DATA TRANSMISSION (DIGITAL DATA, INDUSTRIAL TV PICTURE, ETC.) FIG.6
System architecture of industrial computers is now advanced to Distributed Network System in larger applications. This is backed up by micro-processor technology, which gave us low cose, high performance intelligent controllers distributed along production lines or process lines. Totalization requirement pushed the use of high-speed, reliable data transmission line of fiber optic technology. Needs for Distributed Network System, major functions and technologies in the background are shown in Figure 9 and 10.
TRAFTIC CONTROL
DISTRIBUTED NETWORK SYSTEM DATA ANALYSIS MU L TI·COMPUTE R SYSTEM
MEASURING EQUIPMENT CONTROL '--_ _---j
MULTI·PROCESSOR SYSTEM MUL TI JOB· PROCESSORS AND SPECIAL PROCESSORS
~~~~~~~:~~ OF DATA TO VISIBLE
l
TOPICS o
32 BIT, VIRTUAL SYSTEM PHILOSOPHY, SMALLER OS OVERHEAD, CONVERSATIONAL PROGRAMMING
HIERARCHY AND TOTALIZED NETWORK SYSTEM (MAIN FRAME - MINI'S) HIGH ·SPEED DATA LINK BETWEEN PROCESSORS (OPTICAL DATA TRANSMISSION)
o
SPECIAL PROGRAMMING LANGUAGES (REAL ·TIME BASIC, NOADAL ETC.)
o
UL TRA ·HIGH SPEED SCANNING DEVICES IN HIGH ENERGY PHYSICS FIG. 7
LABORATORY AUTOMATION
New application areas of industrial control computers are expanding in numbers and scopes. Most promissing areas new are image processing, where sophisticated system configulation is needed to get faster image processing speed and varions kinds of unique peripherals are essential, and pattern recognition which is long demanded for material handling, quality checking, target identification and others. There will definitely be needs for very high speed special processors and advanced LSI technology will play significant roles to achieve them.
FIG.9
SYSTEM/COMPUTER ARCHITECTURE
NEEDS FOR DISTRIBUTION
• RISK DISTRIBUTION • FASTER RESPONCE • LOAD SHARING NEEDS FOR CENTRALIZATION
• EFFICIENT
OPERATION AND MAINTENANCE • BETTER CONTROL OF TOTAL SYSTEM TECHNOLOGY
ADVANCE • L51 • OPTICAL LINK • NETWORK
FIG.l0
o
LAND MAP GENERATION
o SEA-WATER TEMPERATURE
DETECTION o AIR AND SEA·WATER POLLUTION DETECTION o SEARCH FOR NATURAL RESOURCES o OTHERS
. [0 PRODUCTION '---------'
'.
0
o o
CONTROL
~~:~~~N~)HECKING
SORTING OTHERS
TOPICS o
ULTRA-H I GH SPEED IMAGE PROCESSING PROCESSOR
o
PATTERN RECOGNITION PROCESSOR
o
DETECTION ALGORITHM
FIG.8
NEW APPLICATION
-DISTRIBUTED • OPERATION AND MAINTENANCE -CENTRALIZED
DISTRIBUTED NETWORK SYSTEM
The first optical data-way systems were installed in Nippon Steel Company's Kimitsu plant in 1979 and system functions have been greatly expanded to now contain five mega-minis in the center and many micro processor based intelligent satellite control systems connected to the data-way. They are the biggest installation of optical data-way system at present. Layont of the system are shown in Figure 11. Now as a next target, we are tring to develop very high speed of about 1,000 mega-hertz data-way for faster transmission of data through the loop and reliable centralized data-file as a total system's data-base media. There will be needs for faster optical data transmitter/receiver and very high speed LSI technology to accomodata them.
H. Kuwahara and T. Miura
18
FARMWARE
(20% OF STEPS, 50% OF RUN TIME STEPS)
•
OS
•
DISTRIBUTED OS ARCHITECTURE KERNEL IN JOB PROCESSOR (RESOURCE ALLOCATION , SCHEDULING ETC. ) •
•
VIRTUAL SYSTEM PHILOSOPHY •
•
m
0L'~~~_590
AG.l1
OPTICAL DATA HIWAY SYSTEM INSTALLED AT STEEL MAKING PLANTS
If we need to lood at the typical advancement of system architecture of industrial computers. Hitachi V90/50 Industrial Computer gives us most advanced architecture and technology. It has multi-processor based architecture to achieve very high performance, serial I/O loop bus of optical fiber to accomodate slow speed I/O's, high-speed optical data-way to connect many numbers of intelligent controllers to realize total network system and as many as maximum of eight computers conld be connected together to conform multi-computer system for reliable and redundant configulation. Main features of this machine are shown in Figure 12 as typical technology advancement in industrial control computers. Figure 13 shows software technologies for the machine and biggest target we are aiming at is virtual system philosophy where we can divide system design to logical design and physical design for eassiness and correctness of system engineering and design.
•
1/ 0 CONTROL AND ERROR ANALY SIS IN DISTRIBUTED PROCESSORS
VI RTUAL MEMORY
•
VI RTUAL 1/ 0
•
VIRTUAL INTERFACE WITH PROCESS DATA
ADVANCED FILE CONTROL SYSTEM •
INDEPENDENCE BETWEEN ACCESS METHOD
•
POWERFUL FILE CAPAB I LITY IN LANGUAGE
DATA
STRUCTURE
AND
EFFICIENT SOFTWARE PRODUCTION TOOLS
OPERATING SYSTEM OF INDUSTRIAL COMPUTERS
AG, 13
SOFTW ARE PRODUCTIVEITY IMPROVEMENT Software productivity is becoming mor e and more important to improve return-on-investment for modernization, babor saving, energy saving and rationization of industrial process. Software cost is now about 45 percent of the total system cost as an avarage and bigger new application system requires software cost of more than 60 percent. To improve software productivity, we have to look at effective two approaches, prevention of bugs and detection and correction of bugs in early stage of software production process. These are shown in Figure 14.
ION OF BUGS
f--_ _ ________--=C~O;M;"PL;:;E.T;.;'O:-..-N
(PRINCIPLES)
CD PRE V ENTION
OF CREEPING BUGS ,
o
EAR L Y DETECTION AND CORRECTION OF BUGS CREPT IN .
TIME
AG. 14
PRI'IClPLES OF' PRODUCTIVITY IMPROVEMENT
MULTI ·PROCESSOR ARCHITECTURE • JOB PROCESSOR, lOP, FCP, CMP, DWP, • SPECIAL PROCESSORS, DDA, ARRAY P, VECTOR P, IMAGE P • SUPERVISORY PROCESSOR JOB PROCESSOR • • 1/ 0
•
32 BITSI WORD VIRTUAL SPACE ,
4GB
LINKAGE SERIAL DOUBLE LOOP BUS
NETWORK ARCHETECTURE DATAWAY (OPTICAL FIBER TRANSMISSION ) NETWORK SUPPORT SOFTWARE (COMMON FILE, PROGRAM • MING SUPPORT, CENTRALIZED ERROR LOGGING ETC ,) MULTI ·COMPUTER CONFIGULATION • GLOBAL MEMORY • COMPUTER ·TO ·COMPUTER LINK BUS • 1/ 0 SHARE BY 1/ 0 LOOP BUS
AG. 12
SYSTEM ARCIfTECTUl[
or
KlUSTRIAl COMPUTEIIS
Considerable amount of experimental works are being done by various groups and companies associated in software production, and some sign of success is being observed in even system design areas. The philosophy of software work-bench or workstation is now becoming popular to stimulate people's intension to have some kind of intelligent tools for better production efficiency of software. Typical tools and methodologies for this are shown in Fig. 15 and you can see whole software production process phases are now targets of them. In many cases we have to change our own ways of making software to apply these tools and methodologies and perpaps different philosophy for co m-
Recent Advances of Application and Technology puter hardware and capability itself may be needed to dramatically improve software productivity. To improve software productivity, right understanding of system itself is essential and approaches are shown in Fig. 16. IMPLEMENTATION
DESIGN
• NEEDS A N A L VSI S PRE V EN TION OF
(KJ METHOD . PPDS I • REO . DEFI N ITION !
BUGS
RATIO
I
1rJ't
1rJ't
MAINTEN A NCE
• SOFTWARE DESIG N METHO D (J ACKSON METHOD , PA D, .1
OFFLlNE -
ONLlNE -
TEST
TEST
ANAL YS IS (SADl , • TOP· DOWN S.P (SP L, PROTEL , SSA, SAMM , PSLlPSA, RSl/ ASA, RD UR OA , ADA , I
CREEPING
100%\ MANMONTH
19
A UTO MATI C
I
DOC UMENTATION
OFF LINE·
ONLlNE
OFFLlNE ·
TEST
TEST
TEST
ONLlNE ·
TEST
POl
EARL Y DETE CTION & COR A Ee
• REO. TESTING (PRQTOT YPI NG, EXECUTA BL E A EO
liON OF
LANG .I
BU GS CR EPTIO N
• TOP -DOWN TESTIN G
FIG. l.
• SYSTEM AT IC T EST ING (HIT EST ,
PR OD UCT
PROJECT MANAGEME NT
MGT .
MA NA GEMENT
I
PWB F AC ILITI ES
The philosophy of Software Work Bench is now being improved and enhanced to realize easiness and effectiveness of total software production process starting wi th system definition through final system test at the plant. There are many rooms for improvement in this area and more and more efforts will be necessary to satisfy ourselves by having efficient tools. An example of PWB shown in Figure 19 is the middle stage towards future more efficient one but here we can see direct connection between off-line programming tools and target machine where we load our programs in to control industrial plant.
SOFTW A RE WO RK ST A TI ON
FIG. 15
BUG FINOABlUTY ( SPL '" HITEST/F )
SOlDA , APTS. TPL/ .1 F.
REQUIRED TOOLS '" METHOOOLOGIES
SOFTWAR E PRODUCTION CENTE R
• GENERA L PU RPOSE COMPU TE (HIT AC·M) $Pl PROGRAM STRUCTURE (C RT TE RM IN A LS)
FIG.16
STRUCTURAL FEATURES OF COMPUTER CONTROL SYSTEMS
• INDUSTR IAL COM PU TERS (I-I I DIC)
,,-------------+=::::;-~M .
Fig. 17 shows example of non-destructive test system for programs. In conventional way, we have to put test procedures in programs to be tested and this is not practical to test programs. independently of person who wrote the program. HITEST IF, nick-name for the tool, gives us independent testing capability and easiness of testing.
SOF TWA RE TOOLS
TE STI NG ROOM
FIG. 19
AN EXAMPLE CIF PWB FOA COMPUTER CONT11OLL SYSTEMS
CONCLUSION SPEC
CONVENTIONAL TESTING
HITEST / F TESTING
~-----------------------------+----------------~ PROG RAM TO BE TESTE
PROG RAM TO BE TESTED
c. 'CSW -'§@"§ I
'
.
,
J
,
~
-
,,,",
,
.
n ~
t SEPERATED
-
~T
~ => STATE M ENTS FOR TESTI N G
FIG. 17
HITEST/ F NON - DESTRUCTIVE TESTING
Figure 18 shows the difference in performance of software production by utilizing different tools. PCL is Fortran like Process Control Language, and SPL is Structural Programming language for enable us to structurely make programs. Data proves the principles of software production process shown in Fig. 14.
Present trends of Japanese Industrial Computer Conro! Systems are presented. As software production efficiency is becoming more and more important, hardware design philosophy is needed to achieve significant change to give us virtual system design concept together with advanced software tools to go with it.