NI自动化测试与自动系统控制解决方案

Automated

Test

System

Automation

&

ControlCase

Studies:

Solar

PowerAgendaSolar

Energy

FundamentalsAutomated

TestPhotovoltaic

(PV)

cellI‐V

characterizationSystem

Automation

and

ControlPVsemiconductor

process

control

and

monitoringPVpowerplant

electrical

monitoring

andsuntrackingcontrolAvailabilityWith

a

solar

cell

efficiency

of20

percent,

anareathesize

ofTexascould

supply

the

entire

world’senergy

demands

[1].The

black

dots

represent

the

land

area

required

toreplace

the

total

primary

energy

supply

withelectricity

from

solar

cells.Available

solar

energy

(left)

greatly

exceedsglobal

energy

consumption.The

Solar

Energy

MarketSolarenergy

technologies,

which

harness

the

sun’senergy

to

generate

electrical

power,

areone

of

thefastest

growingsourcesof

renewable

energy

on

the

market

today.US

Photovoltaic

Shipments,

1997-2006*Courtesy

US

Energy

InformationAdministrationSolar

Power

Generation

TechnologiesPhotovoltaic

(PV)

solar

cellsSolar

thermal

collectorsIndustry

Challenges

for

Solar

PowerDesign

more

efficient

solar

cellsIncreasing

the

amount

of

power

per

area(watt/m2)through

better

design

andtestingIncrease

theeconomic

viability

of

new

technologies,such

as

solartrackingtoincrease

solar

celloutputLower

the

production

costofsolar

cellsIncrease

automation

for

more

efficientmanufacturingwith

less

scrapAgendaSolar

Energy

FundamentalsAutomated

Testl ‐System

Automation

and

ControlPVsemiconductor

process

control

and

monitoringPVpowerplant

electrical

monitoring

andsuntrackingcontrolPhtoovoltaic(PV)celIVcharacerizationtCase

Study:

Automated

Semiconductor

Characterization

and

ValidationA

test

system

that

can

automaticallycharacterize

an

integrated

circuit

undervarying

conditionsEngineering

Challenge:

synchronizemultiple

instruments

and

maintain

verytight

timing

and

triggeringIC

Characterization

SystemThe

system

contains

a

mix

ofdigital

and

analog

instruments

forcontroland

measurement

including:100MHzfrequency

generators

to

triggersand

synchronizes

otherdevices

and

provide

a

common

base

clock.A

100

MS/s

arbitrary

waveform

generatorAhigh‐speed

digital

I/Omodule

to

output

amodulated

digital

pattern

tothe

chipKeyadvantages

of

this

implementationIntegrationof

the

analog

and

digital

instruments

in

one

systemVery

tight

controlover

timing,

minimizing

jitterSoftwareflexibilityto

adaptto

each

IC’s

controlrequirementsEnablingTechnologiesPrecision

DC

instrumentationMeasurement

of

voltage,

current,

resistance,andotherfactorsCharacterizingaSolarCell’sPerformanceMeasureVoltageandCurrentRatings(VOCandISC)MaximumCurrent,IscoccurswhentheloadisashortMaximumVoltage,VOCoccurswhentheloadisopenCalculateEfficiencyMaximumPower(PMAX)Power=0atIscandVOCPowerreachesmaximumatVMPandIMPFillFactorMainmeasureofcellqualityComparemaximumpower(PMAX)totheoreticalmaximumpower(PT)basedonIscandVocEfficiency(η)Ratioofoutputpower(POUT)toInputPower(PIN)Formaximumefficiency,POUT=PMAXPINistheproductofirradiance(W/m2)andtheareaofthecell(m2)PMAXPoutPinMAXPinFactorsthataffectEfficiencyEfficiencyisreducedbyparallelshunt(RSH)andseries(RS)resistancesApproximateRSHandRSfromIVcurveDirectSemiconductorResistivityMeasurement4pointprobeWidelyusedmethodtomeasureresistivityofsemiconductorFlowingcurrentintothecircuitconnectedto1,4pointofcontactMeasuringvoltageconnectedto2,3pointofcontactResistivityρisbelow:ρ=2πLp(V/I)1234MeasurementHardwareSourceMeasureUnit(SMU)Sourcesbothpositive&negativecurrents,thenmeasurestheresultingvoltageAlsousedtosink(ordissipate)currentwhentestingoutputshortcircuitcurrentsandleakagecurrentsNIPXI‐4130PowerSMU•+/‐20V,2Aisolatedoutput10nA/100uVsourceresolution5currentranges––2Ato200uA4‐quadrantoperation–upto10WSinkRemotesensecapabilitySMUChannelQuadrantDiagramDemo–SolarCellCharacterization4‐quadrantIVtracingLabVIEWanalysisanddisplayAgendaSolarEnergyFundamentalsAutomatedTestPhotovoltaic(PV)cellI‐VcharacterizationSystemAutomationandControlr•controlPVsemiconudctoproesscontrocdmonitoigrPVpowerplantleeccrtrialmonitoigadsntrackingunnnlanCaseStudy:GigaMatTechnologiesPerformautomatedsemiconductorwafersortingbaseduponphysicalandelectricalcharacteristicsMeetorexceedtheprecisionandrepeatabilityofindustrystandardequipmentbutwithgreaterthroughput,flexibilityanduserfriendliness,andatmuchlowercostGigaMatSortingSystemNILabVIEWisusedtosynchronizemotion,vision,andinstrumentationThisprojectwouldn’thavebeeneconomicallyviablewithoutLabVIEWandNIsynchronizedmotion,vision,andDAQproducts.EdmondAbrahamians,PresidentandCEOofGigamatEnablingTechnologiesSynchronizedmotion,automatedvisualinspection,andmeasurementReal‐time,deterministiccontrolManufacturingsilicon‐basedPhotovoltaic(PV)cellsRefiningrawmaterialMelting&growingcrystalSlicing&treatmentPoly-siliconIngotWaferEtching,coating,insertingelectrodeCircuitconnecting&PackingIntegratingwithcontrol/monitoringsystemPVCellPVModulesPlantSystemPVControl&MeasurementRequirementsPoly-silicon&IngotWaferPVcellPVmodulePlantsystemRequiredcontrol&measurementtechnologiesTemperaturemonitoringInspectionofcrystalgrowthTemperaturemonitoringMachinevisionGeneratedvoltageTemperaturecontrolI-VCurveTestI-VCurvetestMeasuringinsulatedresistorInvertercontrolSuntrackingElectricalProcesscontrolinspection4pointprobeMicrocrackinspectionMicrocrackinspectionpowerqualitymonitoringProgrammableAutomationControllers(PACs)PLCruggednessandreliabilityPCopennessandperformanceSynchronizedmeasurementandmotioncontrolMeasurementswithPACsVoltage,current,temperature,pressure,stress/strain,…Digital,counter/timers,pulsewidthmodulation,…Encoders,resolvers,LVDTs,…Acquisitionspeedsbeyond800,000Samples/secondNetworkingwithPACsStandardcommunicationtoPLCs,touchpanels,handheldsSupportforindustrialnetworkssuchasEthernet,Modbus,CANOPCServersLocalornetworkeddataloggingControlwithPACsDigitaltrue/falselogicStatechartsFPGA‐basedprotectioninterlocksHighspeedPIDcontrolAdvancedandcustomcontrolalgorithms(gainscheduling,modelpredictivecontrol,…)AttributesofaReal‐TimeSystemReliability24houroperationwithoutcrashesDeterminismEventResponseClosed-LoopControlDiscreteManufacturingPIDProcessControlImagescourtesyofSchlumbergerLimitedandDanaCorporationDemo–IntroductiontoLabVIEWReal‐‐TimeMotionControlSystemforSunTrackerKeyConcepts:TimedLoopsReadingandWritingI/OPIDcontrolDownloadingandexecutingcodeonareal‐timetargetNICompactRIOPACArchitectureReal‐TimeProcessorReconfigurableFPGAExtremeRuggedness‐40to70°Ctemperaturerange50gshock,5gvibrationI/OModules•I/OModuleswithbuilt‐insignalconditioningforconnectiontosensors/actuators•ReconfigurableFPGAforhigh‐speedandcustomI/Otiming,triggering,control•Real‐TimeProcessorfordeterministic,stand‐aloneoperation,loggingandanalysisLowPowerConsumption9to35VDCpower,7‐10WtypicalIntroductiontoFieldProgrammableGateArrays(FPGAs)•Whatisit?Asiliconchipwithunconnectedgates•HowitworksDefinebehaviorinsoftwareCompileanddownloadtothehardware•AdvantagesHighperformanceandreliabilityApplicationrunsindedicatedhardwareReplaceexpensivecustomPCBsExtremelyflexibleandreconfigurableFPGATechnology:UsingSoftwaretoDesignHardwareReplacecustomhardwarewithsoftware-programmableFPGAlogicHighspeedcontrol(1MHzdigital/counter-timer,200kHzmotioncontrol/analogPID)DedicatedlogicinsiliconforhighestreliabilitySignalprocessing(decodingindustrialsensorsignals)33LabVIEWFPGACodeAbstractionCoutnerAnalogI/OI/OwithDMALabVIEWFPGAVHDL66Pages~4000lineDemo‐IntroductiontoLabVIEWFPGAExploreLabVIEWFPGAmotorcontrolKeyConcepts:Pulsewidthmodulation(PWM)formotorcontrolHighspeedloopsexecutinginparallelFixedpointsignalprocessingforanalogencodersensorsMotionControlRequirementsPrecisionPositionControlMultiaxiscoordinationPickandplace,profilecuttingAutomatedtest,DUThandlingAccurateVelocityControlConveyors,variablespeedmotorsHighspeedI/Osynchr