CODESYS Virtual Control Demo Automate 2024
The Setup
- Orchestration:
CODESYS Automation Server hosted on device
- Virtual Controller:
2x CODESYS Virtual Control, 2 x CODESYS Virtual Safe Control
- Container:
Podman enabled for Intel TCC with CAT
- Operating system:
Red Hat Enterprise Linux (RHEL 9.2 with PREEMPT_RT kernel based on RedHat Enterprise Linux for Real Time
- Hardware:
Multi-core IPC with Intel Time Coordinated Computing (TCC) and Cache Allocation Technology (CAT)
Advantech server ACP-2000
Green Edge Computing Corp. Gecco server
Remote I/Os from Beckhoff and Phoenix
- Network:
Cisco Catalyst Industrial Ethernet switch
Virtual Control
2 x CODESYS Virtual Control
1 x CODESYS Virtual Safe Control
1 x CODESYS Edge Gateway
More information: CODESYS Virtual Control SL
Container
Podman enabled for Intel® TCC with CAT
1 x CODESYS Edge Gateway
Operating system
Red Hat Enterprise Linux (RHEL) 9.2 with PREEMPT_RT
kernel based on Red Hat Enterprise Linux for Real Time
Red Hat Device Edge provides the flexibility to deploy and manage workloads on small, resource constrained devices at scale. It combines Red Hat Enterprise Linux with MicroShift, a lightweight Kubernetes distribution from Red Hat OpenShift, so users can deploy anything from traditional Linux workloads to complex containerized services using Kubernetes.
Hardware
Multi-core IPC with Intel® Time Coordinated Computing (TCC) » Real-Time Computing at the Edge (intel.com)
and Cache Allocation Technology (CAT) » https://www.intel.com/content/www/us/en/developer/articles/technical/intel-sdm.html
Intel® Core(TM) i7-1185GRE Tiger Lake UP3
To learn more about CODESYS Virtual Control, OpenVINO™, Intel® TCC and this demo, please JOIN THE WEBINAR HERE!
Network
Cisco Catalyst Industrial Ethernet switches to provide resilient, secure access for production assets (I/O, machines, etc) to the software defined automation
Cisco SD-Access Architecture Network Components “Fabric in a box”
More information:
https://blogs.cisco.com/internet-of-things/is-it-time-to-virtualize-your-factory-floor?ccid=cc002643&oid=pstit031879
I/O System and I/O Devices
- EtherCAT Safety (FSoE), protocol stack as CODESYS library
► Compiled and downloaded with controller application - Weidmüller EtherCAT FSoE
AI-Application / workload consolidation
- Live Stream object segmentation with OpenVINO™ YOLOv8 AI container.
- Models accelerated in the hardware using OpenVINO™
- OpenVINO™ is an open-source toolkit to optimize a deep learning model from almost any framework and deploy it with best-in-class performance on a range of Intel® processors and other hardware platforms.
- Yolov8 is a state of art model from Ultralytics that detects and segments pre-defined objects
Measurements of Bundle Setups
Application
100 FB calls
100 operators
50 Profisafe host instances
Simple mapping Input → Output
Cycle time 5 ms
CODESYS Virtual Control SL
with AI Workload Intel CAT disabled
Cycle Time: 27 us
Max. Task Jitter: 77 us
Avg. Ethernet Send Time: 4,5 us
Avg. Ethernet Recv Time: 3,4 us
with AI Workload Intel CAT enabled
Cycle Time: 20 us
Max. Task Jitter: 11 us
Avg. Ethernet Send Time: 2,8 us
Avg. Ethernet Recv Time: 3,2 us
CODESYS Virtual Safe Control SL
with AI Workload Intel CAT disabled
Cycle Time: 2,3 ms
Roundtrip time safe protocol: 25 ms
with AI Workload Intel CAT enabled
Cycle Time: 1,6 ms
FSoE Roundtripp time: 10 ms
ADVANTAGES CODESYS VIRTUAL CONTROL
Orchestration
CODESYS Automation Server hosted on device
Scalability & Flexibility
Choose the right license and turn a virtual controller into any desired device such as compact controller, motion controller, or high-performance controller at a mouse click.
Reduced space and wiring requirements
The space in your control cabinet is packed? Your 24VDC power supply is already at capacity? Don't worry: For an additional CODESYS Virtual Control, you don't need new cables or additional power supply on your central computer. And your I/Os can be connected via Industrial Ethernet anyway.
Flexible Orchestration: Set-up / delete virtual controllers with or completely without Linux knowledge.
Like to use web tools or want to concentrate exclusively on your automation tasks as an automation engineer? Just use Linux scripts and tools such as Kubernetes/OpenShift to set up CODESYS Virtual Control - or use the CODESYS Automation Server administration platform. The latter works completely without Linux knowledge. And the bonus on the latest Intel platforms with Intel® TCC Cache Allocation Technology: it ensuress real-time schedules for your CODESYS Virtual Control PLCs!
Security-by-Design: CODESYS Virtual Control makes it easy - just like microservices in IT.
To protect your control system split up application parts and encapsulate them in the containers - just like microservices in IT. For updates or other events, you can easily shut down and restart affected parts - without impairing the overall system.
Maintenance made easy: update your firmware or application within seconds.
Security vulnerability discovered! Hundreds of Controllers are affected. You have to update the firmware or application as soon as possible. This can take days, weeks or even months! Unless your Controllers run as virtual systems on a central computer. In that case, with a CODESYS Virtual Control it takes you seconds to perform the update.
SoftSafety
Deploy a virtual Safety controller according to IEC 61508 SIL3 through 'diversified encoding'.
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