Embedding Linux to Control Accelerators and Experiments

A scientific laboratory in Europe depends on Linux for controlling equipment used in their research.
Embedding Linux

Having chosen Linux as our OS, we chose VME (for historical reasons) and PC/104 for our hardware. Strictly speaking, VME is not an embedded controller. It is a bus-based system which offers the ability to plug many I/O cards into a single crate. The I/O cards can communicate with the hardware without being aware of any other cards in the crate, or they can rely on other cards to do part of the work. This is one of the strengths of VME.

Why talk about VME if it is not a true embedded controller? Because we configure our VME systems like embedded controllers. They are totally diskless, i.e., they have only RAM on board, boot a generic image from the network, and in fact, resemble a general purpose I/O embedded controller (see Figure 2).

PC/104 is, however, a true embedded controller. It is a small-format PC which can be stacked together with I/O cards to form a dedicated controller. It is low-cost, low in power consumption, small and ideal for performing dedicated tasks. How do we configure Linux to boot and run on these two formats? Read on....

Figure 2. Paolo standing next to a medium-sized TacoBox with a PC-104 CPU inside being used as a dedicated SCSI controller to control a data acquisition system. The beast in the background is a robot for manipulating silicon wafers in the x-ray beam.

Figure 2

PC/104 alias TacoBox

The TacoBox project was started at the ESRF in 1995 with the goal of creating a low-cost, networked I/O device controller for distributed control systems. TacoBox is a very simple device with an I/O interface for the physical device to be controlled. The I/O interface is specified by the TACO I/O class as a set of commands possible to use with the physical device. Imagine a TacoBox as a black box which speaks TACO protocol as input and process I/O as output. The user interface is accessed via Ethernet using two major protocols. The configuration and (some) maintenance operations of the I/O interface can be done using an ordinary web browser.

We use the PC/104 form factor CPU and I/O boards to build TacoBoxes. A PC/104 is essentially an IBM-compatible PC in an embedded, industrial format. It is built around a 104-pin stack-through connector which is electrically compatible with the 8- and 16-bit ISA bus (PC-XT and PC-AT). The PC/104+ has an additional 32-bit bus, electrically compatible with the PCI bus. The PC/104 form factor is small, 90 x 95 mm. It is stackable, which means you can build a PC/104 system in a very small space. In a recent survey, PC/104-based systems were the third best-selling embedded bus system standard after VME and CompactPCI. The first prototypes of PC/104 ran under commercial real-time operating systems (RTOS) with limited on-board resources. When we got interested in Linux, we immediately wanted to install it on TacoBox. At first, we started with the same configuration as we used with those RTOS installations. We learned quite a bit about the different embedded Linux distributions out there. But we also learned that with just a little more money, we could get a Pentium-90 level PC/104 Single Board Computer (SBC) with 20MB of DRAM, IDE-interface, plus Ethernet (we used JUMPTec's MOPS/586). Add a hard disk and floppy drive, a SVGA card, a screen, a keyboard and a mouse and you have an “old-fashioned” desktop PC. On a desktop PC, you can install Linux without any problem, thanks to some great Linux distributions. At the ESRF, SuSE Linux 5.3 was installed on our desktop machines. Within a few hours, we had a desktop PC/104.

We fit all that in a box by removing the spinning hard disk first and replacing it with a solid-state, IDE-compatible, 24MB FlashPROM hard disk. It piggybacks neatly on the SBC. You do not want to write on a FlashPROM too often, because it is slow and will not support many continuous writing operations. Therefore, the root file system on the FlashPROM is mounted read-only and all the live files and directories are placed on the initial RAM disk, the /initrd. How do you fit a SuSE Linux distribution in 24MB? You give up Perl, Apache and man pages to get to that size. Again, it is a question of money, since FlashPROM disks with up to 200MB are available. What about the SVGA, the screen and other desktop decoration? Configure a serial line system console, and rip them all out.

VME

A farm of 250 VME bus-based systems is running here. All are running diskless and booting from a UNIX machine using BOOTP/TFTP protocols. The VME Single Board Computers used at the ESRF (see Figure 3) are MVME-167, with 8, 16 or 32MB of memory, and MVME-162-522, with 8 or 16MB of memory. When we wanted to install Linux on this platform, we looked for information on the Internet and were pleasantly surprised to find Richard Hirst's site about Linux for 680x0-based VME boards. What a relief to find such professional support for what we thought would be a major job for months to come.

Figure 3. Example of diskless VME crates used as general purpose input/output boxes. The lower crate (with the box of tacos in it) is running Linux and being used to control a high-resolution encoder card. The upper crate is running a commercial OS to control a variety of input/output cards. Work is in progress to port all the software from the commercial OS to Linux while staying in VME format.

Figure 3

Richard's distribution is for disk-based systems, so he helped us sort out some problems with the NFS-root-based systems. A very useful package that we added on our systems is Nick Holgate's TFTPLILO package, which allows us to have just one Linux boot image for all our Linux/68k VME systems.

We keep boot images for Linux/68k VME systems, as they are used on our FTP server (ftp://ftp.esrf.fr/pub/cs/ess/linux/). This allows all our collaborators to test device drivers and other software in a similar configuration as ours. It also allows any owner of a MVME-167 or a MVME-162-522 board to try Linux/68k without any investment or other hassle.

If you have already jumped on your keyboard, you may have noticed we are using the Debian file system and the 2.0.33 kernel. The good news is that Debian now includes support for MVME-16x, MVME-17x and BVM VME bus Single Computer Boards.

Writing a device driver for a VME bus-based Linux computer requires knowing something about the VME bus and its principles of operation. Briefly, VME bus is an asynchronous bus that allows multiple bus masters, but (luckily) only one arbiter. It has seven daisy-chained interrupt lines that on most SBCs can be re-mapped to different local interrupt levels. The access to VME bus I/O boards is entirely memory-mapped, again with some physical translation between the local memory address and the VME bus address. All this is usually managed by some complex chips, such as Vmechip2 from Motorola. Writing a device driver for VMEbus requires some understanding of the interface chip. Our ftp site contains examples of general purpose Vmechip2 device drivers. It is good idea to read through those drivers before moving ahead to more complex device drivers.

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