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Development of a Linux-based small-size controller using PoE technology

Development of a Linux-based small-size controller using PoE technology. T. Masuda, T. Fukui, R. Tanaka SPring-8 ICALEPCS2005, Oct. 10-14, Geneva, Switzerland. Contents. Motivation PoE technology Development of new controller CPU card I/O cards Software

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Development of a Linux-based small-size controller using PoE technology

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  1. Development of a Linux-based small-size controller using PoE technology T. Masuda, T. Fukui, R. Tanaka SPring-8 ICALEPCS2005, Oct. 10-14, Geneva, Switzerland

  2. Contents • Motivation • PoE technology • Development of new controller • CPU card • I/O cards • Software • Temperature measurement using new controller • Installation plans • Summary ICALEPCS2005@Geneva, Switzerland

  3. Motivation • We need temperature measurements in the accelerator buildings at many points in SPring-8. Investigate correlation between • temperature and orbit distortion of electron beams. • … ICALEPCS2005@Geneva, Switzerland

  4. Motivation (cont’d) • Generally, we have to handle signals scattered around a large facility site. • Temperature, • Humidity, • … • Total number becomes large. • But a few signals at each place. How should we handle these signals? ICALEPCS2005@Geneva, Switzerland

  5. Motivation (cont’d) • How about VME or PC? => • It is not cost-effective to install VME or PC for each place. VME or PC are too much. ICALEPCS2005@Geneva, Switzerland

  6. Motivation (cont’d) • How about off-the-shelf, network-based dedicated devices? Temperature and humidity measurement instrument Ether-to-GPIB controller These devices provide easy start-up, but… ICALEPCS2005@Geneva, Switzerland

  7. Motivation (cont’d) • Unstable • We needed 1 year to fix the firmware bug by a company. • We had to go over there to reset when it hung up. • We needed protocol conversions to fit the framework. => We need more flexible and stable controllers. ICALEPCS2005@Geneva, Switzerland

  8. No AC adaptors Electric power comes from a network cable. New controller • Small size • Linux support • Various I/O cards available • Temperature measurement card • GP-IB controller card • Power over Ethernet support No AC power lines No AC adaptors 130mm 100mm 30mm ICALEPCS2005@Geneva, Switzerland

  9. PoE technology

  10. What is “Power over Ethernet”? AC power line Before PoE Legacy HUB Network device power Ethernet cable data AC adapter Network devices demand AC power lines in addition to Ethernet cables. AC power line ICALEPCS2005@Geneva, Switzerland

  11. power AC adapter AC power line What is “Power over Ethernet”? AC power line PoE HUB After PoE PoE Network device power Ethernet cable data PoE network devices can receive power from Ethernet cables as well as data. ICALEPCS2005@Geneva, Switzerland

  12. What is “PoE”?(cont’d) • IEEE standard : 802.3af (June 2003) • Extension to the existing Ethernet standards. => We can mix PoE devices and non-PoE devices together. PoE HUB Non-PoE device PoE device AC power line power power ICALEPCS2005@Geneva, Switzerland

  13. Powered Device (PD) : • Max. input power : 12.95W Max. cable length : 100m Standard cable available The PoE standard • Power Sourcing Equipment (PSE) : • Output voltage : 48V DC (typ.) • Max. output power : 15.4W / 1port PSE power PD power PD ICALEPCS2005@Geneva, Switzerland

  14. The PoE standard (cont’d) While a PD is not connected, PSE does not apply voltage to the cables. PSE x PD x PD ICALEPCS2005@Geneva, Switzerland

  15. PSE detects a signature resistance in the PD. Then PSE starts power supplying. 25kW signature resistance power power The PoE standard (cont’d) PSE PD PD ICALEPCS2005@Geneva, Switzerland

  16. power power The PoE standard (cont’d) PSE detects absence of the PD, then PSE stops power. PSE x x PD The PoE provides safer operation of the power. PD ICALEPCS2005@Geneva, Switzerland

  17. Management tools for PSE • By using this tool, • We can control power supplying. • We can monitor power sourcing status. If you want to turn off the power to port 1, ICALEPCS2005@Geneva, Switzerland

  18. Management tools for PSE Select port number push set button Select power supplying status We can monitor the status changes of the port 1. ICALEPCS2005@Geneva, Switzerland

  19. Management tools for PSE We don’t need to rush there to reset the device when the device hangs up. We can reset the connected device remotely. We can monitor the status change of the port 1. ICALEPCS2005@Geneva, Switzerland

  20. Development of new controller

  21. CPU card • CPU: 240MHz SH-4 • Original architecture by Hitachi • 32bit RISC CPU with MMU • Low power consumption • PCI I/F for an I/O card • Extendable for new I/O card • 64MB SDRAM • 32MB Flash Memory • 10/100baseT/Tx Ethernet I/F with PoE • USB 2.0 120mm 92mm ICALEPCS2005@Geneva, Switzerland

  22. Temperature measurement card • 4-channel inputs of 3-wire Pt100 RTD* sensors • Measurement range : -20~80˚C • Accuracy : 0.1˚C • Resolution : 0.001˚C 120mm • 4-channel 20-bit  A/D converter • Full scale error : 4ppm of Vref =2.5V (typ.) • 50Hz/60Hz notch filter 92mm *RTD : Resistance Temperature Detector ICALEPCS2005@Geneva, Switzerland

  23. Temperature measurement instrument • Assembled from the CPU card and the temperature measurement card. • Combined with a dedicated PCI connector. • Power consumption : 3.7W (typ.) Typical assembly of the temperature measurement instrument CPU card Dedicated PCI connector Temperature measurement card ICALEPCS2005@Geneva, Switzerland

  24. GP-IB controller • Assembled from the CPU card and the GP-IB controller card. • Power consumption : 4.1W (typ.) ICALEPCS2005@Geneva, Switzerland

  25. Software • We ported SH-Linux 2.4.14 to the CPU card. • We developed device drivers for the I/O cards. • We introduced disk-less Linux system. • The system has root file system on an NFS server. • Any of control software (TANGO, EPICS, …) will work. • We ported RPC server software of the MADOCA framework. ICALEPCS2005@Geneva, Switzerland

  26. Temperature measurement using new controller • Can we use the PoE technology for precise measurement system? • Can it work with a shielded twisted pair (STP) cable? • Is voltage drop by a long Ethernet cable a problem? => We tested. ICALEPCS2005@Geneva, Switzerland

  27. Measurement system PSE Temperature measurement instrument 5m-long STP cable Sampling rate : 1Hz 100m-long STP cable 99.950W high-precision resistance for reference. stability : 5ppm/1˚C Equivalent to -0.128˚C in a Pt100 sensor ICALEPCS2005@Geneva, Switzerland

  28. Result • The instrument worked well with a STP cable. • Overall accuracy of 0.1˚C was achieved. • agreed with the expected value ( -0.128 ˚C). • errors < 0.002 ˚C • Voltage drop by a long Ethernet cable did not affect the measured value. ICALEPCS2005@Geneva, Switzerland

  29. Installation plans- Temperature measurement instrument • Install into the SCSS* prototype accelerator. • Measurement of air and wall temperatures of the machine tunnel. • Install into the machine tunnel with radiation protection boxes. Because of low heat generation and PoE support. => • Reduce the wiring of Pt100 sensors. • Enhance the measurement accuracy. *SCSS : SPring-8 Compact SASE Source ICALEPCS2005@Geneva, Switzerland

  30. Installation plans- GP-IB controller • Replace VME GP-IB boards. • Because the GP-IB board makes troubles on the VMEbus. • Replace the off-the-shelf dedicated GP-IB controllers. ICALEPCS2005@Geneva, Switzerland

  31. Summary • We succeeded in developing the new Linux-based small-size controllers using PoE. • PoE maximizes degree of freedom of the installation without AC power lines. • PoE enhances controllability of the distributed controllers by using PSE management tool. • We can apply PoE technology to precise analog measurement as well as digital devices. ICALEPCS2005@Geneva, Switzerland

  32. Thank you for your attention.

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