industrial intelligent plcs expand the internet of...

28 | 2014 | 9 th Edi t ion | Embedded Innovator | inte l .com/embedded-innovator

The emerging Internet of Things (IoT) is creating new opportunities to optimize factory operations. By bringing cloud connectivity to the production line, manufacturers can harness

machine data for better decision making and control at all levels of the organization. Remote monitoring, asset tracking, and predictive maintenance are just a few of the possible benefits.

The challenge is finding a way to transform isolated, fixed- function equipment into a network of intelligent machines. Until now, programmable logic controllers (PLCs) and other small form factor equipment were usually limited to localized operations. The restrictive space and thermal budgets available in these devices made it difficult to deliver enough performance for securely net-worked devices that could intelligently respond to both local and remote inputs.

The new Intel® Atom™ processor E3800 product family (formerly code-named “Bay Trail”) solves these problems with groundbreaking pro-cessing and graphics performance in a thermal design power (TDP) starting at 5 W. This new power-efficient platform can bring a new level of capabilities to PLCs and other equipment throughout the fac-tory. What’s more, the new chip is the first embedded Intel® Atom™ processor with error-correcting code (ECC) memory and a true sys-tem-on-chip (SoC) design, giving it the reliability and reduced footprint essential for small form factor industrial applications.

In this article we will review the features and benefits of the Intel Atom processor E3800 product family. We will then examine off-the-shelf solutions from the Intel® Intelligent Systems Alliance. From modular components to market-ready industrial systems, Intel and

the 250+ global member companies of the Alliance provide the performance, connectivity, energy efficiency, manageability, and security developers need to create smart, connected systems. Close collaboration with Intel and each other enables Alliance members to innovate with the latest technologies, helping developers deliver first-in-market factory automation solutions to improve manufac-turing efficiency.

The IoT AdvantageToday’s factories rely on a variety of computing systems in different applications, including motion control, human machine interface (HMI), equipment monitoring, and asset tracking. These historically isolated systems can take advantage of the IoT by incorporating solutions that are connected, managed, and secured – in other words, they must be more intelligent.

By enabling the IoT, connected systems allow manufactures to harness the big data within their factories, helping them optimize operations. Consider the benefits of adding intelligence and cloud connectivity to a PLC. By monitoring the condition of attached machinery, a smart PLC can determine when preventative mainte-nance is needed and alert off-site maintenance staff before a failure occurs. This avoids damage to expensive equipment and allows maintenance to be performed during scheduled downtime instead of disrupting production.

The benefits of smart connectivity extend all the way to headquarters, enabling better decision making at all levels of an organization. By con-necting quality control equipment to the cloud, for example, the home office can track defect trends in near real time. This allows them to quickly detect problems and take remedial actions such as changing suppliers.

The Intel Atom processor E3800 product family provides the perfor-mance and connectivity needed to enable advanced capabilities like these. Based on Intel’s leading-edge 22 nm process technology, this

I n d u s t r i a l

Intelligent PLCs Expand the Internet of Things

inte l .com/embedded-innovator | Embedded Innovator | 9 th Edi t ion | 2014 | 29

SoC provides up to 3x better performance per watt than the earlier Intel® Atom™ processor N2000/D2000 family. This remark-able improvement in efficiency allows the Intel Atom processor E3800 product family to bring a new level of performance and functionality to PLCs and other small fanless designs. Let’s look closer at some of the key features.

High Performance at Low PowerThe Intel Atom processor E3800 product family offers one to four CPU cores based on the new Silvermont microarchitecture. This new architecture delivers a significant performance upgrade, offering over 3x the processing performance of the Intel Atom pro-cessor N2000/D2000 family in a TDP of only 5 W to 10 W. Standby power is also reduced to the mil-liwatt range, enabling very low power consumption for devices that spend significant time in sleep states. On top of all this, the Intel Atom processor E3800 product family can support an industrial junction temperature range (-40 °C to +110 °C), allowing it to operate in unconstrained thermal environments without active cooling. By bringing high performance to low-power, rugged applications, the Intel Atom processor E3800 product family enables PLCs and other small form factor devices to take on a whole range of new IoT capabilities.

As shown in Figure 1 (Page 30) the Silvermont microarchitecture is based on modules that pair two cores with a shared 1 MB L2 cache. In addition to providing a 2x larger L2 cache than its predecessors, the new architecture offers dual 64-bit DRAM memory channels for excellent memory performance. The DRAM interface can also be configured as a single ECC channel for applications where reliability is the highest priority.

Previous Intel Atom processors relied on a separate chipset for memory and other interfaces. In contrast, the Intel Atom processor E3800 product family uses a true SoC design that integrates these features on a single chip. This design enables a smaller footprint, yet it also allows for a rich set of I/O that includes both high performance interfaces like PCI Express* (PCIe*) Gen 2.0 and USB 3.0, as well as legacy I/ O like SMBus and LPC.


Smart Automation with the New Intel® Atom™ ProcessorsBy Murray Slovick, Roving Reporter, Intel® Intelligent Systems Alliance

Intelligent PLCs Expand the Internet of Things

The SoC design has several benefits beyond a smaller footprint. While earlier processors relied on a front-side bus (FSB) to communicate with an external chipset, the Silvermont microarchitecture adopts the in-die interconnect (IDI) from the Intel® Core™ proces-sors to communicate with the internal interfaces. In addition to improving available bandwidth, this design allows a system agent to reorder memory requests to optimize for performance. Thus the new bus and cache structure reduce resource contention and improve real-time responsiveness.

The Silvermont microarchitecture incorporates several other features from Intel Core processors, including Secure Boot, Intel® Advanced Encryption Standard New Instructions (Intel® AES-NI), and Intel® Virtualization Technology (Intel® VT). All of these fea-tures provide important security enhancements – a critical consideration for cloud-connected devices. Intel Secure Boot ensures that the platform boots into a known, verified state. Intel AES-NI accelerates data encryption and decryption, helping secure communi-cations and storage. And Intel VT enables support for McAfee* DeepSAFE, which functions below the oper-ating system (OS) to provide real-time kernel monitoring that can detect and block advanced hidden threats such as stealth rootkits.

Intel VT also enables consolidation, which can reduce costs and pre-serve precious floor space. For example, developers can consolidate previously separate motion control and HMI hardware into a single platform. Intel VT supports consolidation by accelerating the hyper-visor, a software layer that enables multiple OSs to run on the same hardware platform. For example, a quad-core Intel Atom processor E3800 product family could devote two cores to Microsoft* Windows* for HMI and general supervisory control, one core to Linux* for a net-working and security stack, and one core to Wind River* VxWorks* for motion control (Figure 2).

The Intel Atom processor E3800 product family is a particularly great platform for HMI consolidation – and for general HMI use – thanks to its excellent graphics performance. The chip is the first Intel Atom processor to take advantage of Intel® HD Graphics, providing 5x improvement in 3D graphics performance over the previous-generation Intel Atom processor N2000/D2000 product family. Like many other features, the new graphics engine is borrowed from the Intel Core processor family, the main difference being a smaller number of execution units in the Intel Atom processor implementation.

With the upgraded graphics engine, developers can create advanced

HMIs that improve operator performance and simplify training. The processors can support two independent displays with resolutions up to 2560 x 1600, enabling complex multi-screen designs. The pro-cessors also support hardware HD encode/decode/transcode at up to 1920p for applications where video is important.

Rapid Design with Off-The-Shelf SolutionsTo take full advantage of the new processors, developers can turn to a wide range of off-the-shelf solutions from the Alliance. These solutions can help simplify development and speed time to market, while providing the long


I n d u s t r i a l

The Intel® Atom™ processor E3800 product family employs numerous architectural enhancements and a high level of integration.

Figure 1.

PowerManagement

Controller

Intel® HD Graphics

DisplayPort,Embedded DisplayPort,

HDMI, and VGA

Video Accelerators

Image SignalProcessor

Core Core

1 MB L2 Cache

Core Core

1 MB L2 Cache

Low Power IO:SPI, I2C, HS

UART

Legacy IO:LPC, SMBUS, etc.

Audio

DDR3LMemory Downwith SO-DIMM

Up to 2 Channels,Configurable as OneChannel with ECCUp to Two Ranks

Per Channel

2x SATA GEN 2 Security Engine3x USB 2.0 Host Ports1x USB 3.0 Host Port 3x USB 2.0 HSIC Ports

4x PCI Express*Gen 2.0

High Bandwidth Switching Fabric

Virtualization enables multiple operating systems to run on the same hardware platform (Source: https://www-ssl.intel.com/content/dam/www/public/us/en/documents/ white-papers/reducing-cost-complexity-industrial-system-consolidation-paper.pdf).

Figure 2.

QNX* Neutrino* Wind River* Linux* Microsoft* Windows*

Soft PLC

Real-TimeOperating System

Data Acquisition

General-PurposeOperating System

Other Applications(e.g., HMI)


QNX* Neutrino* Wind River* Linux* Microsoft* Windows*

Soft PLC

Real-TimeOperating System

Data Acquisition


Other Applications(e.g., HMI)


Hypervisor

Intel® Atom™ Processor E3800 Product Family with Virtualization Technology


life and rugged design needed for industrial applications. Figure 3 shows a representative sample of the hardware solutions available from Alliance members. Note that some of these solutions use the Intel® Celeron® J1900 and N2920 processors, two variants of the Intel Atom processor E3800 product family that offer significantly higher graphics performance but support a narrower commercial junction temperature range of 0 °C to +105 °C.

The ADLINK Matrix MXC-2300 shown in Figure 4 illustrates the impressive potential of the new SoC. Featuring a quad-core Intel® Atom™ processor E3845 and up to 8 GB memory, this industrial computer ships with a wide array of built-in I/O, including dual-port isolated CAN and 16-channel isolated digital I/O, quad serial ports, five USB ports, dual Gigabit Ethernet (GbE), and both DisplayPort (DP) and DVI-I interfaces. As if this weren’t enough, the MXC-2300 also offers three PCI expansion slots, one of which can be configured as a PCIe x4 slot for higher performance add-ons. The box also supports ADLINK Smart Embedded Management Agent (SEMA), a set of deeply embedded functions that simplify configuration and remote management. Together these features give developers an out-of-the-box solution for industrial I/O that retains the flexibility needed for custom solutions.

Designers looking to create their own hardware can choose from a range of boards and modules as a starting point. The Kontron COMe-mBTi10 shown in Figure 5 is a good example. This COM Express* Mini module is available with single- to quad-core processor options and 4 GB DDR3L memory with optional ECC support. For the first time on this form factor, the Kontron COMe-mBTi10 offers USB 3.0. Other I/O includes 8x USB 2.0 and SDIO. The module features a rugged, industrial-grade design with optional support for extended temperatures.

Another good example is the Portwell WADE-8078 shown in Figure 6, Page 32. This Mini-ITX board provides power-efficient performance and flexibility for functional

A wide array of industrial solutions are available from the Intel® Intelligent Systems Alliance. Shown here is a representative sample.

Figure 3.

Vendor Product Form Factor Notable Features

Kontron COMe-mBTi10

COM Express* Mini

Intel® Atom™ Processor E3800 Product Family Up to Quad Core, 4 GB DDR3L with OptionalECC, 1x USB 3.0, 8x USB 2.0, SDIO

Portwell WADE-8078 Mini-ITX BoardIntel Atom Processor E3800 Product Family Up to Quad Core, Up to 4 GB DDR3L (ECC Only), 1x PCIe x4 Slot (with PCIe x2 Lanes), 2x USB 2.0, 1x USB 3.0 Port, VGA/HDMI, 1x GbE, 1x SATA 3 Gbps, Portwell CFEX Flash

ADLINK Matrix MXC-2300

Fanless, Expandable Embedded Computer

Intel® Atom™ Processor E3845, Up to 8 GB DDR3L, 2x PCI + 1x PCIe x4 or 3x PCI Expansion Slots, 2x Isolated CAN, 16-Channel Isolated Digital I/O, 1x DisplayPort (DP), 1x DVI-I, 2x Gigabit Ethernet (GbE) with Teaming, 1x USB 3.0, 4x USB 2.0, 2x RS-232/422/485, 2x RS-232

Axiomtek CAPA841 3.5” BoardIntel® Atom™ Processor E3845/E3826, Up to 4 GB DDR3L, 4x Serial, 4x USB 2.0, 2x GbE, 1x SATA 3 Gbps, CFast, Digital I/O, Full-Size PCIe Mini Card with mSATA, Half-Size mini PCIe

IEI NANO-BT EPIC SBCIntel Atom Processor E3800 Product Family Up to Dual Core, VGA/HDMI/LVDS, 2x GbE, 1x USB 3.0, 2x USB 2.0, 2x Full-Size PCIe Mini, 1x SATA 6 Gbps, 1x mSATA, 4x COM, 1x PC/104-PLUS

MSC Q7-BTQseven* Module

Intel Atom Processor E3800 Product Family Up to Quad Core, Up to 8 GB DRAM (Soldered, Optional ECC), Up to 32 GB Flash Disk (Soldered); PCIe, SATA, USB 3.0, USB 2.0, SMB, SPI, I2C, UART, LPC, HDMI, DP, eDP, LVDS

SBS Science & Technology Co. COMe9600

COM Express Type 10

Intel Atom Processor E3800 Product Family Up to Quad Core, Up to 4 GB LPDDR3, 1x LVDS and 1x DDI with Dual Independent Display, 3x PCIe x1, 1x GbE, 2x SATA 3 Gbps, 6x USB 2.0, 1x USB 2.0, SMBus, I2C, SPI, LPC Bus, GPIO, 2x UART, Optional SSD, +12V Power Supply with +5V Standby

The ADLINK Matrix MXC-2300 provides a rich array of built-in I/O and expansion options.

Figure 4.

The Kontron COMe-mBTi10 is the first COM Express* Mini module with USB 3.0.

Figure 5.


expansion. Available with a single-, dual-, or quad-core Intel Atom pro-cessor E3800, the board features dual-display VGA and HDMI outputs, one mini PCIe socket, and one PCIe x4 socket that can be configured with PCIe x1 lanes or PCIe x2 lanes. Other features include two USB 2.0 ports and one USB 3.0 port; one GbE port; one SATA 3 Gbps port; and a slot for Compact Flexibility from Embedded eXtension (CFEX) cards. This new standard for Compact Flash introduced by Portwell supports SATA 3.0, SPI, and other extensions. CFEX cards enable new function-ality, such as a RAID controller, to be added quickly and easily.

Extending the IoTIndustrial customers looking to harness the big data in their factories

have an excellent solution in the Intel Atom processor E3800 product family. By combining high-performance computing and graphics, advanced security, and a host of I/O, these low-power SoCs provide an effective option for enabling the IoT in a wide range of industrial applications. With these new capabilities in hand, manufacturers can look forward to a new era of productivity and efficiency.

For information about industrial solutions from the Alliance, see intel.com/SD-industrial

For more on connecting, consolidating, and optimizing industrial automation, see intel.com/embedded-industrial

Contact Intel From modular components to market-ready industrial systems, Intel and the 250+ global

member companies of the Intel® Intelligent Systems Alliance (intel.com/intelligentsystems/alliance) provide the performance, connectivity, energy efficiency, manageability, and security developers need to create smart, connected systems.

Kontron (intel.com/ea-kontron) and Portwell (intel.com/ea-portwell) are Premier members of the Alliance. ADLINK (intel.com/ea-adlink), Axiomtek (intel.com/ea-axiomtek), IEI (intel.com/ea-iei), Microsoft (intel.com/ea-microsoft), SBS (intel.com/ea-sbs), and Wind River (intel.com/ea-windriver) are Associate members, and MSC (intel.com/ea-msc) is an Affiliate member.

C

M

Y

CM

MY

CY

CMY

K

The Portwell WADE-8078 Mini-ITX board provides flexibility for functional expansion.

Figure 6.

I n d u s t r i a l

© 2013 Dell Inc. All rights reserved. Dell, the DELL logo, the DELL badge are trademarks of Dell Inc. Other trademarks and trade names may be used in this document to refer to either the entities claiming the marks and names or their products. Dell disclaims proprietary interest in the marks and names of others.

Put the power of the new Dell Venue 8 Pro and Dell Venue 11 Pro in the palm of your hands, and at the heart of your product offerings. Contact Dell about integrating these new quad-core Intel® Atom™ processor-based tablets into your solutions.

Learn more at Dell.com/OEM

industrial intelligent plcs expand the internet of...

Documents