New Products Introduction Development of the “SMS-15” Industrial Personal Computer Shigeki Satou Masahiko Okamura Takahisa Sakuma “AML” is able to perform synchronous control for up to 1. Introduction 32 servo axes and I/O stations. However, the “SMS-10” CPU speed imposes some limits with “AML”. For example, Driven by the dramatic development of IT (Information the update rate of the multiple position commands needs Technology), industrial controls and monitoring devices to be lengthened as the number of SERCOS nodes in- have increasingly become computer-based and open ar- creases. In addition to faster update rates with higher chitecture. The resulting market for the industrial per- axis counts, further improvement of CPU speed was also sonal computer (Industrial PC) is expanding at a rapid required since “AML” has been extended to include new rate. functions such as linear/circular interpolation (“AML” Considering this market for Industrial PCs, the user Ver. 7.0). requirements are very diversified. Requirements include Traditional motion controls include a PC and built-in the normal increases in CPU speed but also includes a motion card (with separate CPU). However, in the case of scalable product system that can meet the unique needs “AML”, the only CPU in the control system is the CPU of of the user. the Industrial PC. The SERCOS motion bus connects Considering the full range of user needs, we have dis- “AML” to the fully-digital servo drives. Therefore, for all covered keywords such as “compact”, “larger display”, of the reasons above, increasing the CPU speed was a top “complete networking capability including Local Area priority for the new “SMS-15”. Network”, “optional assembly”, and “value-oriented price”. The “SMS-15” was developed with these require- 2.2 SERCOS interface ments in mind to complement the top-end market as compared with our existing “SMS-10”. This article re- The existing “SMS-10” has a SERCOS interface board views the background and features of the “SMS-15”. conforming to the PC/104 standard (IEEE 996.1). This PC/104 SERCOS board uses the SERCON410B ASIC to 2. Development Objectives support the SERCOS interface (available data rates are 2 and 4 Mbps). Fig.1 shows the “SMS-15” model which includes the The most recent ASIC for SERCOS is the SERCON816, SERCOS interface option. which has achieved the communication rate of 2, 4, 8, and 16 Mbps. For the “SMS-15”, we used the new ASIC and embedded the SERCOS interface circuit integral to the body in order to save space. The “SMS-15” with faster CPU and latest SERCOS ASIC allows the “AML” motion controller to have a faster response with higher axis count. 2.3 Consideration for Non-Motion Control Applications The “SMS-15” architecture is compatible with the standard PC/AT so the user can add off-the-shelf pe- ripherals and software as sold in computer stores. In addition to this flexibility, other design themes including “long-term stable products supplies” and “robustness” are Fig.1 “SMS-15” with the SERCOS interface our key concepts of making controllers. These character- istics are required not only for motion control applica- 2.1 CPU Speed tions but also for non-motion control applications in which PC/AT compatibles are used as controllers. We A concept of the earlier “SMS-10” is to eliminate all expect that the SMS-15 will be the type of controller that rotating parts such as the CPU cooler and hard disk. This can fulfill the various needs of customers in a wide range enhances the product reliability in an industrial envi- of fields. ronment. The AMD Am486DX5-133MHz CPU is used By supporting the added functions of the general pur- which allows the heat radiation of the CPU to completely pose PC such as large capacity memory, improved dissipate through the case. In addition, the “SMS-10” is graphic capability, increased processor speeds, and in- designed with a TYPE I Compact Flash Card in order to terfaces such as Ethernet and USB, we have extended have a solid-state disk instead of a conventional hard potential applications of this product to security systems disk. We feel the “SMS-15” needs to maintain the and many other general-purpose applications. elimination of all rotating parts. One purpose of the “SMS-10” is to run our motion control software, “AML”. In this case, the “SMS-10” is also equipped with the SERCOS interface. SANYO DENKI Technical Report No.14 Nov. 2002|34 3. Features The “SMS-15” has the following features to extend ap- plications beyond standard motion control while achiev- ing interchangeability with the “SMS-10”. 3.1 Diverse Product System Contrasted with the “SMS-10” which had separate modules for options such as the “VGA module” and “SERCOS module”, the “SMS-15” includes these func- tions by incorporating them into the “SMS-15” body. As a result, the “SMS-15” is reduced in space by approxi- mately 23% and is reduced in cost by approximately 30%. However, the height and depth of the “SMS-15” body are equal to the “SMS-10” so interchangeability is achieved as well. Fig.2 Block Diagram of CPU Part 3.2 Improvement of the CPU Speed Fig.3 Block Diagram of the SERCOS Part +5V 3.3V +3.3V(For FPGA) Power The “SMS-15” CPU is a Geode GX1-300MHz which is Power +5V Connector GND IC GND GND SERCON SRAM AXES Count Power Dip Switch Dip Switch Dip Switch LED made by National Semiconductor. The processor is 88 8 WDT_LED Address Bus SERCOS_Tx manufactured with 0.18-micron CMOS process and has G1 I/O Digital Input0 Connector Data Bus 8 Digital Input1 Digital Input2 achieved speed improvement and lower power consump- Digital Input3 Digital Output0 SMEMR- Digital Output1 FPGA SMEMW- Digital Output2 tion. In addition, the processor is supported by many IORD- Digital Output3 IOWR- WDTO Push Button Input operating systems such as various Windows OS, Traditional Interface IRQ_Out Low Voltage Error System Reset VxWorks, QNX, and Linux. IRQ9 IRQ10 Push Button 64 IRQ11 MHz 3.3 Improvement of Graphic and Diverse Interface Jumper System Reset for IRQ SERCON 16 ８１６ Functions TXD RXD +5V or VBat Power Supply +5V The “SMS-15” includes two USB 1.0 compatible Chip Low Voltage Error Reset VBat Select IC 3.0V Control System Reset 8 GND COM2 Logic interfaces and two 10/100BASE-T Ethernet ports to im- RS232 9 D-SUB SRAM RS485 9pin RS485/422 Selector 128 K Byte Connector Driver/ prove the networking speed as compared to the Receiver Keyboad COM2 Keyborad 6 Connector “SMS-10”. Connector Connector for PS2 Graphic function of the “SMS-15” supports 1280×1024 (with 256 colors) or up to 1024×768 (with 65,536 colors). 5. Specifications 3.4 Supports for Large-Capacity Device Table 1 shows the basic specifications of the “SMS-15”, The “SMS-15” includes a slot for a Type II compact Table 2 shows the SERCOS specifications, Table 3 shows flash card. This allows a large-capacity compact flash the general specifications, and Fig.4 shows the outside card or IBM micro drive (1GB or less) to be used. view. 4. System Configuration The system configuration of the “SMS-15” is shown in Fig.2 and Fig.3. The body is configured with two boards, one board is the CPU part with PC/AT compatible function while the second board is the SERCOS part including other peripherals. The PC/104 standard bus and the signals such as the serial interface and the key- board interface connect to each board. Fig.2 shows the block diagram of the CPU part while Fig.3 shows the block diagram of the SERCOS part. 35|SANYO DENKI Technical Report No.14 Nov. 2002 PC104 Offset PC104 Offset Connector B Connector A PC104 PC104 Connector B Connector A CS RD WR INT0 INT1 CONCLK LERRN RECACTN RAM_OE RAM_WE RAM_CS Traditional interface Table 1 Basic Specifications CPU NS Geode GX1-300MHz Companion I/O CX5530A System Memory 64MB or 128MB （1ｘ144 pin SO-DIMM） 10/100BASE－T（RJ-45 connector） LAN Interface with ACTIVITY、LINK display Chip Intel 82559 ｘ2 Display Built-in CX5530A chip set V-RAM Shared with the system memory （Set with BIOS up to 4MB） Resolu- 1280ｘ1024、256 colors tion or up to 1024ｘ768、65536 colors mm mm Serial Interface 2 ports COM2 can be set RS-232/422/485 ＵＳＢ Interface 2 ports、USB1.0 compatible Either TYPE1 or TYPE2 is usable. Compact Flash Card Allot the secondary IDE port PC/AT compatible keyboard, Keyboard, Mouse PS/2 mouse can be connected Interface Overflow Time: select from Watchdog Timer 64,32,16,8,4,2,1,0.5msec, watchdog timer error output Expansion Bus PC/104 bus General-purpose I/O Optical isolated input and output, four each Display LED POWER, DISK, WDT Input Power Supply DC5V ±5% Current Consumption 2.5A max Mass Approx. 1.2kｇ Outside Dimensions 57.6×180×123.7（mm, W×H×D） Table 2 SERCOS Specifications Fig.4 Outside View SERCON816 controller installed SERCOS Interface Follow IEC 61491 standard Communication 6. Conclusion 2,4,8,16Mbps Rate HFBR-1505A、HFBR-2505A Light Module (Agilent Technologies） This document introduced the development target of Memory Ad- the new “SMS-15” along with features and specifications. Allot 8kB out of D8000h ～ DFFFFh dress Two models were considered, one model with the SER- Interruption Select form INT0,INT1,DIVCLK,CONCLK COS interface (primarily used for motion control appli- Battery Backup 4096ｘ8 bit cations with “AML” software) and another model without RAM Backup Battery: CR2450 equivalent the SERCOS interface. The second model is more general S1（switch） State is readable with internal resistor. Display LED G1, ERR purpose in nature and is expected to be used as a server/terminal for security and remote services. Industrial PCs are often used continuously over an Table 3 General Specifications extended period of time in harsh environmental Operational Conditions conditions. We will continue to capture the needs of Power Supply Voltage DC5V±5％ various users and the computer market so that we can Operating Temperature 0～50℃ make every effort to develop new products like the Operating Ambient Humidity 90%Rh or less (w/o condensation） “SMS-15”. We feel the “SMS-15” provides users many 2 Vibration 4.9m/s 2 advantages based on the combined technologies of Sanyo Shock 49m/s Denki and the standard computer industry. Site Indoor Structure * The product name in the document is the registered trademark or the Material Aluminum alloy trademark of each company. Paint Color Dark gray （DIC F144 equivalent） Transportation and Storage Conditions Ambient Temperature -20～65℃ Ambient Humidity 90%RH or less （w/o condensation） 2 Vibration 9.8m/s 2 Shock 49m/s Other Specifications Earth The third-type earth Cooling Method Natural air-cooling SANYO DENKI Technical Report No.14 Nov. 2002|36 mm Shigeki Satou Masahiko Okamura Joined Company in 1984 Joined Company in 1985 Control Systems Division, 1st Solution Dept. Control Systems Division, 1st Solution Dept. Worked on the development of S-MAC com- Worked on the development of S-MAC ponents components Takahisa Sakuma Joined Company in 1991 Control Systems Division, 1st Solution Dept. Worked on the development of S-MAC components 37|SANYO DENKI Technical Report No.14 Nov. 2002