Industrial control programmable logic based on ADuC7124/ADuC7126 application...

The ADuC7124/ADuC7126 are fully integrated 1 MSPS, 12-bit data acquisition systems that integrate high-performance multi-channel ADC, 16-bit/32-bit MCU and Flash/EE memory in a single chip. ADC has up to 12 single-ended inputs. In addition, 4 ADC input channels can also be multiplexed with 4 DAC output pins. ADC can work in single-ended mode or differential input mode, ADC input voltage range is 0 V to VREF. The low-drift bandgap voltage reference, temperature sensor and voltage comparator complete the ADC peripheral settings. The DAC output range can be set to one of three voltage ranges through programming. The DAC output has an enhanced feature that can maintain its output voltage during the watchdog or software reset sequence.

These devices generate a 41.78MHz internal high-frequency clock signal through an on-chip oscillator and phase-locked loop (PLL). The clock signal is relayed through a programmable clock divider, in which the MCU core clock operating frequency is generated. The core of the microcontroller is ARM7TDMI®, which is a 16-bit/32-bit RISC machine with peak performance up to 41 MIPS. 32 KB SRAM and 126 KB non-volatile Flash/EE memory are integrated on-chip. The ARM7TDMI core treats all memories and registers as a linear array.

ADuC7124 built-in an advanced interrupt controller. The vectored interrupt controller (VIC) can assign a priority to each interrupt. It also supports nested interrupts, each IRQ and FIQ allows up to 8 levels of nesting. If IRQ and FIQ interrupt sources are combined, a total of 16 levels of nested interrupts can be supported. The on-chip factory firmware supports online download through the UART serial interface port or I2C port, and supports non-intrusive simulation through the JTAG interface. These features are integrated in the low-cost QuickStart™ development system that supports this MicroConverter® series. The device has a built-in 16-bit PWM that provides 6 output signals. To facilitate communication, the device has two built-in I2C channels, which can be independently configured as master mode or slave mode. In addition, an SPI interface that supports both master and slave modes is provided. In addition, there are 2 UART channels, and each UART channel has a built-in configurable 16-bit FIFO with receive and transmit buffers.

These devices have an operating voltage range of 2.7 V to 3.6 V and are rated for an industrial temperature range of −40°C to +125°C. When the operating frequency is 41.78 MHz, its typical power consumption is 120 mW. The ADuC7124 is available in 64-pin LFCSP and 80-pin LFQFP packages.

ADuC7124/ADuC7126 application:

Industrial control and automation system

Smart sensors, precision instruments

Base station system, optical fiber network

Patient monitoring

Analysis of design challenges and solutions for industrial control programmable logic controllers based on ADuC7124/ADuC7126 applications

Figure 1. ADuC7124/ADuC7126 functional block diagram

ADI PLC (Programmable Logic Controller) solution

The PLC system is composed of power supply, CPU and multiple analog and digital I/O modules, which can control, execute and monitor complex machine variables; PLC is designed for multiple input and output configurations, with extended temperature range and excellent electrical noise suppression Performance, shock resistance and impact resistance.

The PLC system includes power supply, control and communication modules and a variety of analog input, analog output, digital input and digital output modules.

Industrial PLC system design considerations and main challenges

In order to obtain a suitable PLC system design, designers must consider many different system requirements, including accuracy, bandwidth, and input range.

• Analog input type and range: TC (thermocouple) and RTD minimum _10 mV; actuator controller maximum ±10 V, and the current in the process control system is 4 mA to 20 mA.

• Analog output type and range: generally include _5 V, _10 V, 0 V to 5 V, 0 V to 10 V, 4 mA to 20 mA, and 0 mA to 20 mA. Sometimes over-range performance is required.

• Resolution and accuracy of the input/output modules; the typical range is 12 to 16 bits, and the accuracy is 0.1% in the industrial temperature range.

• Provides connectivity to different industrial networks, such as analog, fieldbus, CAN, Ethernet, and USB

• Isolation: between system power modules and low-power electronic components; between input and output; between I/O and central control unit; isolation levels vary from 1 kV to 2.5 kV.

• Analog input/output and power input protection: fault condition voltage or current and EMC considerations, including surges and fast pulse transients and ESD.

• As the size of circuit boards decreases, power efficiency, thermal management and heat dissipation will become an increasingly important issue for miniaturized devices. In addition, more channels or nodes need to be placed in the same space, which requires a high-density system. For this, the size must be reduced. This means that the housing is smaller, which brings about power management and heat dissipation problems, so a solution for intelligent power management through integrated dynamic power control is required.

In the past, the realization of this type of I/O system required a large number of high-performance discrete components, resulting in a large and expensive system. Recent advances in integration technology have allowed system designers to adopt smaller, lower power, and lower-cost solutions with performance comparable to those of large systems. Continuous technological advancement requires that these solutions can be continuously promoted to integrate, while also improving their performance and diagnostic capabilities.

ADI has tailor-made solutions for market needs and helps design. These solutions use industry-leading technology and provide numerous design options: from the implementation of discrete devices to fully integrated solutions, everything.

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