General overview of control
systems and philoshophy
Richard Farnsworth
Lead Controls systems
Engineer
Australian Synchrotron
We have a small team delivering beamlines
controls and instrumentation services –
therefore standards are critical.
Five permanent Instrumentation and
Controls staff planned– four Engineers
and one IT specialist.
Much will be outsourced
Australian Synchrotron
Two Instrumentation Controls specialist
engineers are working on specifications at
the moment:
Dr Mark Clift – a background in similar
systems in research and commercial IT
Mr Wayne Lewis – A background in large
distributed industrial control systems.
Australian Synchrotron
The essential dilemma:
The controls team wants standards because
• Software support is greatly reduced.
• Hardware spares and logistics are easier.
• Expertise on Beamlines is transferable.
• Off the shelf solutions are less expensive.
• Integration is easier.
Australian Synchrotron
The essential dilemma II:
The users like non standard solutions
because;
• The standard hardware is not always the
best device for the job
• The standard software may not drive the
device in an optimum fashion
• The complexity for a given task is greater
– therefore less reliable
Australian Synchrotron
Insisting on standards all the time will only
lead to “Tears” and “blood on the floor”
But without any standards will lead to
Late delivery, interface problems, and
difficult to use software
Australian Synchrotron
As usual in most Engineering, a compromise
is the way forward: the philosophy being:
Standardise where you can;
Customise where you must;
Australian Synchrotron
Drivers of standards include:
Generic Technology e.g.
• Communications standards TCP/IP, Ethernet,
RS232
• Hardware standards (e.g. PCI, VME, VXI)
• Wiring standards (Red or Brown ?)
• Interface standards (active high or low)
Australian Synchrotron
Drivers of standards include:
Site specific technology choices e.g.:
• Stepper motor Controllers
• Supervisory software (e.g. EPICS)
• GUI Software
• GUI style (red = danger, green = safe vs Red =
stop, green = go)
• Operating systems (Unux, Windows)
Australian Synchrotron
We are here discuss these issues. Our agenda will
include the possibilities of standardisation where
possible AND convenient, but not eliminating the
possibilities of other standards or choices
Australian Synchrotron
However:
The Accelerator is using EPICS and it is very
suitable for much beamline work. However we
are not using traditional EPICS hardware – we
are using Linux and PC based hardware.
Australian Synchrotron
In consultation with the Beamlines Scientists
EPICS has been chosen as the most suitable
control system for the Protein crystallography
line (PX). We will prefer, but not mandate
Hardware.
The User Interface will be Blu-ice.
Many of the stepper motor controllers will be
Standardised.
Australian Synchrotron
The PX beamline will be beamline 1 and will be a
“Production” type beamline – that is the
beamline itself will not be experimental.
The user interfaces will be regular and controlled
The machine control will be a service to the user
and not exposed.
Australian Synchrotron
There are two common types of systems across
most Beamlines
These are the Personnel Safety Systems (PSS)
and the Equipment Protection systems (EPS)
These systems will be separated from the rest of
the Beamlines and are prime candidates for
standardardisation.
Australian Synchrotron
The Accelerator is using Pilz SIL3 rated safety
systems and Schneider PLC based equipment
protection systems,
We have standard software interfaces from EPICS
to Modbus devices also to Labview and
applications.
Others interfaces are around.
Possibilities
Australian Synchrotron
Systems Development planning
System requirements - Systems plan
in first release
Development model – least risk, most
important features first
System Engineering Support
Australian Synchrotron
Systems Engineering iterative
Australian Synchrotron
Australian Synchrotron
System Engineering – requirements for
accelerator
Documented over 500 control systems
requirements:
•Components e.g. Timing, vacuum, RF,
EPS…(bulk)
•Functional requirements e.g. Safety, stats,
Operator interface..)
•Non Functional (e.g. Network, Comms, Time
synch, security, standard
Australian Synchrotron
Summary of Accelerator contracts
• Levels of integration requirements will vary
depending on capability of supplier
• EPICS is now common enough in the
community for it to be leveraged on, industry can
supply.
• EPICS is being specified to ease integration
problems and risk. This approach is consistent with
the general project approach.
• IOC’s - in general will not be free issued
• Suppliers if not capable can now seek
independent help .
Australian Synchrotron
EPICS details
Using late version (n-1). Next major release due after
first turn.
Training - Epics course included Industry reps –
EPICS collaboration Meeting.
Hardware – will use commercial off the shelf as much
as possible
IOC selection - favour RT Linux
Australian Synchrotron
The development system
•Purchased hardware – still being configured
•Includes dedicated build machines
•Configuration Management (Perforce – Front end to
CVS),
•bug tracking (Bugzilla – integrated browser),
Webserver,
•specialist coding machines and
•Machines Simulator.
Australian Synchrotron
EPICS Toolbox selections
• EDM for simple displays, bulk displays
Linux + Windows OS
• Matlab – MCA, rewritten by us, incredibly
powerful, for complex displays and high level control
(e.g. SOFB)
• Archivers – latest version very powerful
• EPICS CA Gateways for security and separation
• Standard Alarm Handling until after
commissioning, others may be required later.
Australian Synchrotron
Driver developments
•
•
•
Bench development of Controllers
Varian
Gamma
• HPS guage controller
• PLC Modicon (Schneider + Pilz)
•Now it only takes few days to get most simple
devices talking to EPICS
MCA - Matlab Channel access
Australian Synchrotron
Work on MCA
•Removed 1000 Channel Limit
•Matlab “Monitor Callbacks” now fully supported
•Is favoured by our Accelerator Physicists
•Will use for complex displays and some processing
•Slots into Accelerator Toolbox - Important for us to
simulate as we have no machine.
• Lets us be “close” to the AP
Australian Synchrotron
Simulate everything at the start and then replace.
Separate development and production
Systems engineering, Configuration management
Development and Support System