Machine Condition Monitoring for remote assets can save thousands of dollars in technician costs but it requires a distributed network of rugged monitoring and recording devices. CompactRIO provides a rugged industrial distributed I/O platform for monitoring vibration, stress, oil particulate counts, temperature, speed, and additional health and operational parameters. This example program, builds on the CompactRIO vibration data logger reference to illustrate a condition monitoring system for distributed machine assets. Using the real-time controller and FPGA of the CompactRIO, data is monitored, acquired and stored on the CompactRIO controller and status updates are sent via UDP communication. Through a remote Windows Host, the data logger can be controlled and monitored, in addition to transferring saved data logs off of the CompactRIO controller using FTP communication.
This example program builds on several example components, including the CompactRIO Vibration Data Logger Reference Design. These required components are listed below. All of these have been bundled into the Installer folder in the download at the end of this document for completeness.
In addition, the example program requires the following development tools:
A cost effective getting started hardware kit includes the following:
To start, download the CompactRIO Vibration Data Logging Example (and its required components - see above section). Follow these steps to adapt this example for your CompactRIO system.
NOTE: Please disable the Use localized decimal point option under Tools>Options>Front Panel before proceeding.
Figure 1. Project files for the cRIO Logger Deploy project
When deploying CompactRIO data logger systems it is often desirable to remove front panel controls. This allows for easy creation of a startup EXE as well as remote configuration and monitoring. [RT 05] Main_Logger Advanced Deploy.vi is configured as a ready for deployment startup VI or EXE on a CompactRIO controller. This is done by substituting an XML configuration file for standard front panel controls. The VI [Host] Create Advanced Config XML.vi is provided to create and download this XML configuration file to the CompactRIO Data Logger.
This configuration utility will create an XML configuration file based on the configuration settings provided by the user in the various tabs such as channel configuration and acquisition parameters like sample rate. This XML file is then sent by FTP to the targeted CompactRIO Data Logger controller for use by the [RT 05] VI or EXE.
Figure 2. Front panel of [Host 05] Create Advanced Config XML.vi
The [RT 05] VI runs on the CompactRIO Data Logger and performs the actual data logging functions, including triggering conditions for data logging as well as UDP and TCP/IP communication with a monitoring application. In place of a user interactive front panel it loads the XML configuration file that was created in the first step. This VI is made to run in conjunction with [Host] Combined Monitor which can perform the remote monitoring and configuration duties.+
Figure 3. The front panel of the real-time VI that runs on the CompactRIO controller
The [Host 05] Combined Monitor VI allows monitoring and control of the CompactRIO Data Logger from a single application running a Windows machine. This VI includes XML configuration and download, FTP and Syslog statuses, live data monitoring, and file playback with spectral analysis. This is especially useful for remote monitoring of data logging systems in difficult to access locations such a wind turbines. The following provides an overview of the combined host application.
The XML Configuration and Download tab is shown below. All of the configuration items are the same as noted in the earlier section of this document. Additionally there is a feature of being able to list out multiple deployable CompactRIO Targets and then select from an editable drop down list which one to target the XML configurations to.
To create a new XML file for the CompactRIO configure your settings appropriately and then, with the FTP to Target? button depressed, press the Create XML button. You will then need to press the Restart cRIO with New Configuration button. This will restart the CompactRIO controller, restarting the [RT 05] VI with the new XML configuration file.
Figure 4. The XML Configuration and Download tab of [Host 05] Combine Monitor.vi. Notice that the configuration settings are the same as those shown earlier.
The FTP Status tab shows information related to moving data log files off of the CompactRIO controller and onto the host monitoring machine. There are options to select file dump locations as well as status information about how many files remain on the CompactRIO controller as well as the current FTP status.
Figure 5. The FTP Status tab of [Host 05] Combine Monitor.vi
The Live Monitor tab displays the data currently being acquired by the CompactRIO Data Logger transmitted through TCP communication. The live data for all channels is shown in a table view and selectable channels are shown in the graphical display. There is also a button to force a trigger on the CompactRIO to begin a data logging operation.
Figure 6. The Live Monitoring tab of [Host 05] Combined Monitor.vi displays live information as it is acquired on the CompactRIO Data Logger by transferring it over TCP communication.
The File Playback tab offers file playback and spectral analysis options for previously recorded and transferred data logs. The channel monitor displays a level indication of each channel in the file and also provides an option to pop-up a time-domain waveform graph of individual channels as shown in the pop-up figure further below. There is also a tab control so that both time domain waveforms of all channels or the frequency spectrum of a specified channel can be configured and displayed.
Figure 7. The File Playback tab of [Host 05] Combined Monitor.vi allows playback of files that have been recorded on the CompactRIO Data Logger and transferred off to the host computer.
When selecting a file, a dialog box will appear as shown below, requesting which file to open. On the file selection pop-up, a specific file that has been FTP’d from the CompactRIO Data Logger can be chosen and time waveform channels from the file can be selected or excluded.
The accompanying graph is an example of the time waveform pop-up from the channel monitor in the Live Playback tab.
Figure 8. The pop-ups from the File Playback tab of [Host 05] Combined Monitor.vi
Description-Separate-2
Example code from the Example Code Exchange in the NI Community is licensed with the MIT license.
Hi, after download the source code and install the package, I found the code lost some subvi, like the deltasig main, some custom controls, etc.
Can you please update the code, it is really useful for me to implement it on our project, thanks in advance.