Modeling and Simulation Methodologies for Digital Twin in Industry 4.0

The concept of Industry 4.0 represents an innovative vision of what will be the factory of the future. The principles of this new paradigm are based on interoperability and data exchange between dierent industrial equipment. In this context, Cyber- Physical Systems (CPSs) cover one of the main roles in this revolution. The combination of models and the integration of real data coming from the field allows to obtain the virtual copy of the real plant, also called Digital Twin. The entire factory can be seen as a set of CPSs and the resulting system is also called Cyber-Physical Production System (CPPS). This CPPS represents the Digital Twin of the factory with which it would be possible analyze the real factory. The interoperability between the real industrial equipment and the Digital Twin allows to make predictions concerning the quality of the products. More in details, these analyses are related to the variability of production quality, prediction of the maintenance cycle, the accurate estimation of energy consumption and other extra-functional properties of the system. Several tools [2] allow to model a production line, considering dierent aspects of the factory (i.e. geometrical properties, the information flows etc.) However, these simulators do not provide natively any solution for the design integration of CPSs, making impossible to have precise analysis concerning the real factory. Furthermore, for the best of our knowledge, there are no solution regarding a clear integration of data coming from real equipment into CPS models that composes the entire production line. In this context, the goal of this thesis aims to define an unified methodology to design and simulate the Digital Twin of a plant, integrating data coming from real equipment. In detail, the presented methodologies focus mainly on: integration of heterogeneous models in production line simulators; Integration of heterogeneous models with ad-hoc simulation strategies; Multi-level simulation approach of CPS and integration of real data coming from sensors into models. All the presented contributions produce an environment that allows to perform simulation of the plant based not only on synthetic data, but also on real data coming from equipments

Rapid prototyping from algorithm to FPGA prototype

Abstract. Wireless data usage continuously increases in today’s world setting higher requirements for wireless networks. Ever increasing requirements result in more complex hardware (HW) implementation, especially telecommunication System-on-Chips (SoC) performance is playing a key-role in this development. Complexity increases design workload, therefore, it makes design flow times longer. High-Level Synthesis (HLS) tools have been designed to automate and accelerate design by moving manual work on a higher level. This Master’s Thesis studies MathWorks HLS workflow usage for rapid prototyping of Wireless Communication SoC Intellectual Property (IP). This thesis introduces design and FPGA prototyping flow of Application-Specific Integrated Circuit (ASIC). It presents good design practices targeted for HLS. It also studies MathWorks Hardware Description Language (HDL) generation flow with HDL Coder, possible problems during the flow and solutions to overcome the problems. The HLS flow is examined with an example design that scales and limits the power of IQ-data. This work verifies the design in a Field-Programmable Gate Array (FPGA) environment. It concentrates on evaluating the usage and benefits of MathWorks HLS workflow targeted for rapid prototyping of SoCs. The Example IP is a Simulink model containing MATLAB algorithms and System Objects. The design is optimized on algorithm level and synthesized into VHDL. The generated Register-Transfer Level (RTL) is verified in co-simulation against the algorithm model. Optimization and verification methods are evaluated. The HDL model is further processed through logic-synthesis using the 3rd party synthesis tool run automatically with a script created by MathWorks workflow. The generated design is tested on FPGA with FPGA-in-the-loop simulation configuration. FPGA prototyping flow benefits for rapid prototyping are evaluated. Coding styles to generate synthesizable HDL code and simulation methods to improve simulation speed of hardware-like algorithm were discussed. MathWorks HLS workflow was evaluated for rapid prototype purposes from algorithm to FPGA. Optimization methods and capability for production quality RTL for ASIC target were also discussed. MathWorks’ tool flow provided promising results for rapid prototyping. It generated human-readable HDL that was successfully synthesized on FPGA. The FPGA model was simulated in FPGA-in-the-loop configuration successfully. It also provided good area and speed results for the ASIC target when the algorithm was written strictly from the hardware perspective. The process was found to be distinct and efficient.Nopea prototypointi algoritmista FPGA-prototyypiksi. Tiivistelmä. Langattoman datan käyttö kasvaa jatkuvasti nykymaailmassa ja asettaa korkeammat vaatimukset langattomille verkoille. Kasvavat vaatimukset tekevät laitteistototeutuksesta kompleksisempaa, erityisesti tietoliikenteessä käytettävien järjestelmäpiirien (SoC) tehokkuus on avainasemassa. Tämä kasvattaa suunnittelun työmäärää ja näin ollen suunnitteluvuohon kuluva aika pidentyy. Korkean tason synteesi (HLS) on kehitetty automatisoimaan ja nopeuttamaan digitaalisuunnittelua siirtämällä manuaalista työtä korkeammalle tasolle. Tämä diplomityö tutkii MathWorks:n HLS-vuon käyttöä langattomaan viestintään suunniteltavien SoC:ien tekijänoikeudenalaisten standardoitujen lohkojen (IP) nopeaan prototypointiin. Työ esittelee perinteisen asiakaspiirin (ASIC) suunnitteluvuon, FPGA-prototypointivuon ja suunnitteluperiaatteet HLS:ää varten. Työssä käydään läpi MathWorks:n laitteistokuvauskielen (HDL) generointivuo HDL Coder:lla, mahdollisia ongelmakohtia vuossa ja ratkaisuja ongelmiin. HLS-vuota tutkitaan esimerkkimallin avulla, joka skaalaa ja rajoittaa IQ-datan tehoa. Esimerkkimallin toiminta tarkistetaan ohjelmoitavan logiikkapiirin (FPGA) kanssa. Työ keskittyy arvioimaan MathWorks:n HLS-vuon käyttöä ja hyötyä nopeaan prototypointiin SoC:ien kehityksessä. Esimerkkinä käytetään Simulink-mallia, joka sisältää MATLAB-funktioita ja System Object-olioita. Algoritmitasolla optimoitu malli syntesoidaan VHDL:ksi ja rekisterinsiirtotason (RTL) mallin toiminta tarkistetaan yhteissimulaatiolla alkuperäistä algoritmimallia vasten. Optimointi- ja verifiointimenetelmien toimivuutta ja tehokkuutta arvioidaan. Generoitu HDL-malli syntesoidaan kolmannen osapuolen logiikkasynteesi-työkalulla, joka käynnistetään MathWorks:n työkaluvuon generoimalla komentosarjalla. Luotu malli ohjelmoidaan FPGA:lle ja sen toiminta tarkistetaan FPGA-simulaatiolla. Syntesoituvan HDL-koodin generointiin vaadittavia koodaustyylejä ja algoritmimallin simulointinopeutta parantavia menetelmiä tutkittiin. MathWorks:n HLS-vuon soveltuvuutta nopeaan prototypointiin algoritmista FPGA-prototyypiksi pohdittiin. Lisäksi optimointimenetelmiä ja vuon soveltuvuutta tuotantolaatuisen RTL:n generoimiseen arvioitiin. MathWorks:n työkaluvuo osoitti lupaavia tuloksia nopean prototypoinnin näkökulmasta. Se loi luettavaa HDL-koodia, joka syntesoitui FPGA:lle. Malli ajettiin onnistuneesti FPGA:lla. Vuon avulla saavutettiin hyviä tuloksia pinta-alan ja nopeuden suhteen, kun malli optimoitiin asiakaspiirille. Tämä vaati mallin kuvaamista tarkasti laitteiston näkökulmasta. Prosessi oli kokonaisuudessaan selkeä ja tehokas

High Performance Computing via High Level Synthesis

As more and more powerful integrated circuits are appearing on the market, more and more applications, with very different requirements and workloads, are making use of the available computing power. This thesis is in particular devoted to High Performance Computing applications, where those trends are carried to the extreme. In this domain, the primary aspects to be taken into consideration are (1) performance (by definition) and (2) energy consumption (since operational costs dominate over procurement costs). These requirements can be satisfied more easily by deploying heterogeneous platforms, which include CPUs, GPUs and FPGAs to provide a broad range of performance and energy-per-operation choices. In particular, as we will see, FPGAs clearly dominate both CPUs and GPUs in terms of energy, and can provide comparable performance. An important aspect of this trend is of course design technology, because these applications were traditionally programmed in high-level languages, while FPGAs required low-level RTL design. The OpenCL (Open Computing Language) developed by the Khronos group enables developers to program CPU, GPU and recently FPGAs using functionally portable (but sadly not performance portable) source code which creates new possibilities and challenges both for research and industry. FPGAs have been always used for mid-size designs and ASIC prototyping thanks to their energy efficient and flexible hardware architecture, but their usage requires hardware design knowledge and laborious design cycles. Several approaches are developed and deployed to address this issue and shorten the gap between software and hardware in FPGA design flow, in order to enable FPGAs to capture a larger portion of the hardware acceleration market in data centers. Moreover, FPGAs usage in data centers is growing already, regardless of and in addition to their use as computational accelerators, because they can be used as high performance, low power and secure switches inside data-centers. High-Level Synthesis (HLS) is the methodology that enables designers to map their applications on FPGAs (and ASICs). It synthesizes parallel hardware from a model originally written C-based programming languages .e.g. C/C++, SystemC and OpenCL. Design space exploration of the variety of implementations that can be obtained from this C model is possible through wide range of optimization techniques and directives, e.g. to pipeline loops and partition memories into multiple banks, which guide RTL generation toward application dependent hardware and benefit designers from flexible parallel architecture of FPGAs. Model Based Design (MBD) is a high-level and visual process used to generate implementations that solve mathematical problems through a varied set of IP-blocks. MBD enables developers with different expertise, e.g. control theory, embedded software development, and hardware design to share a common design framework and contribute to a shared design using the same tool. Simulink, developed by MATLAB, is a model based design tool for simulation and development of complex dynamical systems. Moreover, Simulink embedded code generators can produce verified C/C++ and HDL code from the graphical model. This code can be used to program micro-controllers and FPGAs. This PhD thesis work presents a study using automatic code generator of Simulink to target Xilinx FPGAs using both HDL and C/C++ code to demonstrate capabilities and challenges of high-level synthesis process. To do so, firstly, digital signal processing unit of a real-time radar application is developed using Simulink blocks. Secondly, generated C based model was used for high level synthesis process and finally the implementation cost of HLS is compared to traditional HDL synthesis using Xilinx tool chain. Alternative to model based design approach, this work also presents an analysis on FPGA programming via high-level synthesis techniques for computationally intensive algorithms and demonstrates the importance of HLS by comparing performance-per-watt of GPUs(NVIDIA) and FPGAs(Xilinx) manufactured in the same node running standard OpenCL benchmarks. We conclude that generation of high quality RTL from OpenCL model requires stronger hardware background with respect to the MBD approach, however, the availability of a fast and broad design space exploration ability and portability of the OpenCL code, e.g. to CPUs and GPUs, motivates FPGA industry leaders to provide users with OpenCL software development environment which promises FPGA programming in CPU/GPU-like fashion. Our experiments, through extensive design space exploration(DSE), suggest that FPGAs have higher performance-per-watt with respect to two high-end GPUs manufactured in the same technology(28 nm). Moreover, FPGAs with more available resources and using a more modern process (20 nm) can outperform the tested GPUs while consuming much less power at the cost of more expensive devices

Continuous Integration for Fast SoC Algorithm Development

Digital systems have become advanced, hard to design and optimize due to ever-growing technology. Integrated Circuits (ICs) have become more complicated due to complex computations in latest technologies. Communication systems such as mobile networks have evolved and become a part of our daily lives with the advancement in technology over the years. Hence, need of efficient, reusable and automated processes for System-on-a-Chip (SoC) development has been increased. Purpose of this thesis is to study and evaluate currently used SoC development processes and presents guidelines on how these processes can be streamlined. The thesis starts by evaluating currently used SoC development flows and their advantages and disadvantages. One important aspect is to identify step which cause duplication of work and unnecessary idle times in SoC development teams. A study is conducted and input from SoC development experts is taken in order to optimize SoC flows and use of Continuous Integration (CI) system. An algorithm model is implemented that can be used in multiple stages of SoC development at adequate complexity and is “easy enough” to be used for a person not mastering the topic. The thesis outcome is proposal for CI system in SoC development for accelerating the speed and reliability of implementing algorithms to RTL code and finally into product. CI system tool is also implemented to automate and test the model design so that it also remains up to date

Comparison of different design alternatives for hardware-in-the-loop of power converters

This paper aims to compare different design alternatives of hardware-in-the-loop (HIL) for emulating power converters in Field Programmable Gate Arrays (FPGAs). It proposes various numerical formats (fixed and floating-point) and different approaches (pure VHSIC Hardware Description Language (VHDL), Intellectual Properties (IPs), automated MATLAB HDL code, and High-Level Synthesis (HLS)) to design power converters. Although the proposed models are simple power electronics HIL systems, the idea can be extended to any HIL system. This study compares the design effort of different coding methods and numerical formats considering possible synthesis tools (Precision and Vivado), and it comprises an analytical discussion in terms of area and speed. The different models are synthesized as ad-hoc modules in general-purpose FPGAs, but also using the NI myRIO device as an example of a commercial tool capable of implementing HIL models. The comparison confirms that the optimum design alternative must be chosen based on the application (complexity, frequency, etc.) and designers’ constraints, such as available area, coding expertise, and design effor