MOTOROLA MVME162-012 Embedded Controller

I. Overview

II. Technical Specifications

(1) Core Computing and Storage Parameters

Processor and Chipset

• Processor: Adopts Motorola 68040 microprocessor with optional clock frequencies of 25MHz/33MHz. It is equipped with a 32-bit address bus and a 32-bit data bus, with integer computing performance of 12 MIPS (Millions of Instructions Per Second) and floating-point computing performance of 0.5 MFLOPS (Million Floating-Point Operations Per Second). It can efficiently handle complex logical operations and real-time data calculations in industrial control (such as PID control algorithms and multi-device collaborative control logic).

• Coprocessor: Integrates a 68882 floating-point coprocessor (standard in some models), enhancing floating-point computing capabilities to adapt to scenarios requiring high-precision data processing (such as flow/power calculation in energy metering and speed closed-loop control in rail transit).

• Chipset: Adopts MVME162 dedicated control chipset, integrating core peripheral control modules such as interrupt controllers, DMA controllers, and timers. This simplifies the design of external circuits and improves system stability.

Storage System

• Memory: Standard configuration includes 8MB DRAM (expandable to 16MB), using industrial-grade wide-temperature memory chips and supporting parity check function. It can automatically detect and correct memory data errors, avoiding system crashes caused by memory failures.

• Storage Media: Built-in 512KB EPROM (for storing system boot programs and solidified firmware) and 2MB Flash (optional, for storing application programs and configuration data). It supports permanent data storage after power failure, without relying on external hard drives, making it suitable for industrial scenarios without mechanical hard drives.

• Storage Expansion: Supports 1 SCSI-2 interface (data transfer rate of 10MB/s), which can be connected to external storage devices such as SCSI hard drives and optical drives to meet the needs of large-capacity data storage (such as historical operation logs and process parameter databases).

(2) Interface and Expansion Parameters

Standard Communication Interfaces

• Serial Ports: 2 RS-232C serial ports (compatible with RS-422/RS-485, switchable via hardware jumpers) with a maximum baud rate of 115200bps. They support industrial communication protocols such as Modbus and Profibus, and can be connected to devices like serial printers, modems, and remote IO modules.

• Parallel Interface: 1 Centronics standard parallel interface, used for connecting parallel devices such as industrial printers and data collectors, supporting bidirectional data transmission.

• Ethernet Interface: 1 10Base-T Ethernet interface (RJ45 port), compatible with TCP/IP protocol stack and supporting industrial Ethernet communication. It can be connected to the factory local area network to realize remote monitoring and data upload (e.g., uploading equipment operation data to the SCADA system).

Expansion Slots and Module Interfaces

• Local Bus Expansion: Equipped with 2 MVME local bus slots, supporting the connection of MVME series expansion modules (such as MVME310 digital IO module and MVME460 analog acquisition module). It expands the number of interfaces and functions to adapt to control requirements of different scales.

• ISA Bus Expansion: 1 16-bit ISA bus slot (equipped in some models), compatible with traditional ISA interface industrial cards (such as data acquisition cards and communication cards), ensuring compatibility in the upgrading of outdated equipment.

• Front Panel Interfaces: The front panel is equipped with power indicator lights, status indicator lights (operation/fault/interruption), a reset button, and a debugging serial port, facilitating on-site personnel to check the system status and perform debugging operations.

(3) Physical and Environmental Parameters

Physical Specifications

• Dimensions: 234mm (length) × 160mm (width) × 25.5mm (height), conforming to the size of industrial standard single-board computers. It can be installed in a 19-inch standard cabinet (3U height) or an embedded equipment chassis, saving installation space.

• Weight: Approximately 400g. The lightweight design is suitable for scenarios sensitive to equipment weight, such as vehicle-mounted and shipborne applications.

• Installation Method: Supports rack mounting and panel mounting, with standard mounting holes compatible with the slide rails and fixed brackets of industrial cabinets.

Environmental Adaptability

• Operating Temperature: -40℃~+70℃ (industrial wide-temperature range), meeting the operation requirements of extremely cold areas (such as outdoor control cabinets in Northeast China) and high-temperature workshops (such as near rolling mills in metallurgical plants). No preheating is required for startup at -40℃, and the startup time is ≤ 30s.

• Storage Temperature: -55℃~+85℃, adapting to harsh transportation and storage environments (such as equipment warehouses in plateau and coastal areas).

• Humidity: 5%~95% RH (non-condensing, conforming to IEC 60068-2-3 standard). In coastal high-humidity and high-salt-fog environments, the circuit board is coated with three-proof paint (waterproof/dustproof/corrosion-proof), and key interfaces are gold-plated to avoid corrosion and poor contact.

• Vibration and Shock Resistance: Vibration resistance grade of 10g (10Hz~2000Hz, conforming to IEC 60068-2-6), capable of withstanding continuous vibration during the operation of industrial equipment (such as vibration transmission from fans and compressors); shock resistance grade of 50g (1ms pulse, conforming to IEC 60068-2-27), able to resist instantaneous shocks during equipment handling and maintenance.

(4) Power Supply and Reliability Parameters

• Power Supply Requirement: Single-channel +5V DC power supply (current ≤ 3A), supporting a wide voltage input range (4.75V~5.25V), suitable for industrial on-site power environments with large fluctuations. It is equipped with overvoltage protection (automatic output cut-off when ≥ 6V) and overcurrent protection (current limiting triggered when ≥ 4A) to prevent core components from being damaged by abnormal power supply.

• Electromagnetic Compatibility (EMC): Conforms to EN 55022 Class A (radiated emission) and EN 55024 (immunity) standards. It has electrostatic discharge (ESD) protection of ±8kV (contact discharge)/±15kV (air discharge) and radio frequency radiation immunity of 10V/m (80MHz~1GHz). In strong interference environments such as high-voltage motors and frequency converters, the system operates without crashes and data loss.

• Reliability Index: Mean Time Between Failures (MTBF) ≥ 200,000 hours (Telcordia SR-332 standard, at 25℃), with a design life of ≥ 15 years. Key components (processors, memory, interface chips) adopt industrial-grade wide-temperature selection, and pins are gold-plated to improve long-term operation stability.

• Fault Diagnosis: Built-in hardware-level fault diagnosis function, capable of detecting issues such as "memory errors", "power supply abnormalities", and "expansion module connection failures". Fault codes (e.g., "E01 = memory check error", "E03 = power overvoltage") are output through front panel indicator lights and serial ports, facilitating quick fault location.

III. Functional Features

(1) Industrial-Grade Stable Operation, Adapting to Complex Environments

• Wide-Temperature and Anti-Interference Design: From component selection to circuit layout, industrial-grade standards are followed. Core components such as processors and memory adopt wide-temperature models with a range of -40℃~+70℃. The circuit board has a copper-clad thickness of 1.6mm, enhancing anti-electromagnetic interference capabilities; the power module is equipped with an EMC filter circuit to reduce the impact of external power noise on the core circuit. For example, in the rolling mill control system of a steel plant, the MVME162-012 is installed close to a 100kW frequency converter but can still operate stably without data transmission errors or control command delays.

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• Redundancy and Fault-Tolerance Mechanism: The memory supports parity check, which can automatically detect and correct single-bit errors, avoiding program crashes caused by memory data errors; the power interface is equipped with reverse connection protection to prevent equipment damage due to incorrect wiring by on-site personnel; the system boot program (in EPROM) supports a "fault self-recovery" function. When the application program crashes, it can automatically restart and load the backup program, with a recovery time ≤ 5s, reducing manual intervention.

(2) Rich Expansion Interfaces, Compatible with Various Peripherals

• Multi-Protocol Communication Compatibility: The serial port supports RS-232/RS-422/RS-485 switching, enabling connection to industrial equipment with different communication methods (such as distributed IO modules connected via RS-485 bus and intelligent meters connected via RS-232); the Ethernet interface supports protocols such as TCP/IP and UDP, and can be connected to the factory Ethernet to realize bidirectional data interaction with upper computers (such as SCADA and MES systems).

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• Modular Expansion Capability: Functional modules such as digital IO, analog acquisition, and motion control can be expanded through MVME local bus slots. During the expansion process, there is no need to modify the core program; only the module address needs to be configured through software, adapting to the functional upgrading of the control system. For example, during production line transformation, adding an MVME460 analog acquisition module can add 8-channel temperature signal acquisition function to realize closed-loop control of the heating furnace temperature, with an expansion cycle of only 1 day.

(3) Convenient Debugging and Maintenance, Reducing Operation and Maintenance Costs

• Visual Status Monitoring: The front panel is equipped with four types of indicator lights: power, operation, fault, and interruption. On-site personnel can quickly judge the system operation status through the indicator light status (e.g., "flashing operation light = normal operation", "steady-on fault light = core component fault"); the debugging serial port supports viewing system logs and real-time data through terminal software, enabling fault troubleshooting without disassembling the equipment.

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• Convenient Firmware and Program Upgrading: The Flash memory supports in-circuit programming (via Ethernet or serial port), allowing remote upgrading of application programs and system firmware without on-site equipment disassembly. This is especially suitable for equipment in remote areas (such as oilfield wellhead monitoring units), reducing operation and maintenance costs by 60%.

(4) Strong Adaptability to Outdated Systems, Extending Equipment Service Life

• Hardware Compatibility with Traditional Modules: The ISA bus slot is compatible with industrial ISA cards from the 1990s to the early 21st century (such as early data acquisition cards and communication cards), avoiding the replacement of a large number of peripherals due to the upgrading of core control units and reducing transformation costs.

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• Software Compatibility with Legacy Systems: It supports traditional embedded real-time operating systems such as VxWorks 5.5 and pSOS+. Application programs in outdated systems (such as control algorithms developed based on VxWorks) can be directly ported without re-development, shortening the system upgrade cycle (from 3 months to 2 weeks).

IV. Application Fields

(1) Industrial Automation Control

• Core Control of Production Lines: In automobile parts assembly lines, as the core control unit, it controls conveyors, robotic arms, and testing equipment by expanding digital IO modules (such as MVME310) to realize automated connection of processes; it collects parameters such as welding temperature and assembly pressure through analog acquisition modules (such as MVME460) and realizes precise control combined with PID algorithms, increasing the product qualification rate by 12%.

• Process Control and Monitoring: In the chemical reaction kettle control system, it runs process control software (such as DeltaV and InTouch), connects temperature, pressure, and liquid level sensors through serial ports to collect process parameters in real time, and controls the operation status of feed valves and stirring motors according to preset logic. It ensures the reaction temperature control accuracy of ±1℃ and pressure control accuracy of ±0.05MPa, avoiding safety accidents caused by parameter out of control.

(2) Rail Transit Field

• Train Signal Processing: In the on-board control system of subway trains, as a signal processing unit, it receives dispatching instructions from the track signal system through the Ethernet interface, calculates the train's operating speed and stopping position combined with GPS positioning data and speed sensor signals, and controls the train's traction and braking systems, ensuring the train punctuality rate of ≥ 99.8%.

• Station Equipment Control: In the platform door control system of high-speed railway stations, it connects platform door controllers (one controller for each carriage) through the RS-485 bus. After receiving the train arrival signal, it synchronously controls the opening and closing of platform doors with a response time ≤ 1s, ensuring the safety of passengers getting on and off the train.

(3) Energy and Power Industry

• Power Equipment Monitoring: In the power distribution monitoring system of substations, as a distributed control node, it connects data collectors through the SCSI interface to collect parameters such as transformer temperature, bus current, and switch status, and uploads the data to the substation monitoring center (SCADA system) via Ethernet; when current overload (exceeding 120% of the rated value) is detected, it automatically sends instructions to cut off the corresponding switch to protect equipment safety.

• New Energy Control: In the wind turbine control system of wind farms, it runs wind turbine control algorithms, collects parameters such as wind speed, wind direction, and blade angle through analog acquisition modules, calculates the optimal power generation, and controls the pitch system and yaw system of the wind turbine, increasing wind energy utilization rate by 5%~8% compared with traditional control systems.