A microsystem design for controlling a DC motor by pulse width modulation using MicroBlaze soft-core

This paper proposes a microsystem based on the field programmable gate arrays (FPGA) electronic board. The preliminary objective is to manipulate a programming language to achieve a control part capable of controlling the speed of electric actuators, such as direct current (DC) motors. The method proposed in this work is to control the speed of the DC motor by a purely embedded architecture within the FPGA in order to reduce the space occupied by the circuit to a minimum and to ensure the reliability of the system. The implementation of this system allows the embedded MicroBlaze processor to be installed side by side with its memory blocks provided by Xilinx very high-speed integrated circuit (VHSIC) hardware description language (VHDL), Embedded C. The control signal of digital pulse-width modulation pulses is generated by an embedded block managed by the same processor. This potential application is demonstrated by experimental simulation on the Vertix5 FPGA chip

FPGA design methodology for industrial control systems—a review

This paper reviews the state of the art of fieldprogrammable gate array (FPGA) design methodologies with a focus on industrial control system applications. This paper starts with an overview of FPGA technology development, followed by a presentation of design methodologies, development tools and relevant CAD environments, including the use of portable hardware description languages and system level programming/design tools. They enable a holistic functional approach with the major advantage of setting up a unique modeling and evaluation environment for complete industrial electronics systems. Three main design rules are then presented. These are algorithm refinement, modularity, and systematic search for the best compromise between the control performance and the architectural constraints. An overview of contributions and limits of FPGAs is also given, followed by a short survey of FPGA-based intelligent controllers for modern industrial systems. Finally, two complete and timely case studies are presented to illustrate the benefits of an FPGA implementation when using the proposed system modeling and design methodology. These consist of the direct torque control for induction motor drives and the control of a diesel-driven synchronous stand-alone generator with the help of fuzzy logic

Motion control design of a PMSM and FPGA implementation for the Beam Wire Scanner at CERN

This thesis work describes the modelling, simulation, implementation and testing of a motion controller for a Permanent Magnet Synchronous Motor, used as an actuator for the Beam Wire Scanner at CERN. The dissertation, after a brief introduction to the subject, focuses on the design of the control system starting for the basics of motion control and the mathematical equations describing the various parts of the system. The architecture of the controller is explained as well as the design choices and their reasons. It consists in a three-level cascade feedback loop, regulated through three variable structure, saturated PID controllers with anti-windup architecture. Also, three feedforward actions are included, as well as a static decoupler and a steady-state Kalman filter. In the last chapters, the implementation of the control system on an ALTERA FPGA board is described and its performances are verified through a serie of experiments

Control and supervision of an AGV with energy consumption optimization

Os veículos guiados autónomos (AGVs) ganharam enorme importância e interesse no campo da indústria. Estes são soluções populares para o transporte de bens materiais para diferentes partes das fábricas. No entanto, em muitas fábricas, os armazéns estão localizados à parte da linha de produção ou em edifícios separados, exigindo que o transporte de bens materiais seja feito exteriormente. Os ambientes exteriores representam um desafio particular para os AGVs. Por um lado, estes ambientes causam mais desgaste nos componentes dos veículos e o clima na Europa pode atingir extremos opostos, dependendo da estação do ano e das regiões. Por outro lado, estes ambientes aumentam as preocupações de segurança, uma vez que outros veículos ou peões podem circular no mesmo espaço e ao mesmo tempo. Neste projecto, um rebocador eléctrico XXL será transformado num AGV, que opera em ambiente exterior. Este veículo é responsável pelo transporte de mercadorias do final da linha de produção para o armazém exterior numa fábrica de automóveis. O principal objectivo é assegurar o seu funcionamento contínuo durante um turno de 16 horas, garantindo o mínimo de interrupções para v«carregamento da bateria. Desta forma, nesta dissertação foram abordados dois capítulos distintos: para a análise e estudo do consumo energético foi simulado a powertrain de um veículo eléctrico. Neste, foi considerado um motor de indução cujo método de controlo aplicado foi o Field Oriented Control (FOC). Para além do comportamento eléctrico, também foi simulado o modelo físico da carga, bem como o cálculo da energia eléctrica consumida. Para a navegação, foi estudada uma solução baseada na integração do GPS com o INS. Dadas as restrições temporais, apenas a solução GPS foi testada e a técnica Loosely Coupled foi abordada como uma possível solução de integração.Autonomous guided vehicles (AGVs) have gained enormous importance and interest in the industry field. These are popular solutions for transport of good and material to different parts of the factories. However, in many factories, warehouses are located apart from the factory floor or in separate buildings, requiring the transport of material goods to be done outdoors. Outdoor environments represent a particular challenge for AGVs. On one hand, these environments causes more wear and tear on vehicle components and the weather in Europe can reach opposite extremes depending on the season and regions. On the other hand, these environments increase safety concerns since other vehicles or pedestrians can circulate in the same space at the same time. In this project, an electric tugger XXL will be transformed into an AGV, which operates in outdoor environment. This vehicle is responsible for transporting goods from the end of the production line to the outside warehouse in a car manufacturing plant. The main objective is to ensure its continuous operation during a 16-hour shift, and guarantee the minimum battery charging actions. In this way, in this dissertation two distinct chapters were approached: for the analysis and study of the energy consumption it was simulated the powertrain of an electric vehicle. In this one it was considered an induction motor whose control method applied was the Field Oriented Control (FOC). Besides the electrical behaviour, also the physical model of the load was simulated as well as the calculation of the consumed electrical energy. For navigation, a solution based on the integration of GPS with INS was studied. Given the temporal constraints, only the GPS solution was tested and the loosely coupled technique was approached as a possible integration solution

Toward Green Vehicles Digitalization for the Next Generation of Connected and Electrified Transport Systems

This survey paper reviews recent trends in green vehicle electrification and digitalization, as part of a special section on “Energy Storage Systems and Power Conversion Electronics for E-Transportation and Smart Grid”, led by the authors. First, the energy demand and emissions of electric vehicles (EVs) are reviewed, including the analysis of the trends of battery technology and of the recharging issues considering the characteristics of the power grid. Solutions to integrate EV electricity demand in power grids are also proposed. Integrated electric/electronic (E/E) architectures for hybrid EVs (HEVs) and full EVs are discussed, detailing innovations emerging for all components (power converters, electric machines, batteries, and battery-management-systems). 48 V HEVs are emerging as the most promising solution for the short-term electrification of current vehicles based on internal combustion engines. The increased digitalization and connectivity of electrified cars is posing cyber-security issues that are discussed in detail, together with some countermeasures to mitigate them, thus tracing the path for future on-board computing and control platforms.publishedVersio

Modelling and Control of Stepper Motors for High Accuracy Positioning Systems Used in Radioactive Environments

Hybrid Stepper Motors are widely used in open-loop position applications. They are the choice of actuation for the collimators in the Large Hadron Collider, the largest particle accelerator at CERN. In this case the positioning requirements and the highly radioactive operating environment are unique. The latter forces both the use of long cables to connect the motors to the drives which act as transmission lines and also prevents the use of standard position sensors. However, reliable and precise operation of the collimators is critical for the machine, requiring the prevention of step loss in the motors and maintenance to be foreseen in case of mechanical degradation. In order to make the above possible, an approach is proposed for the application of an Extended Kalman Filter to a sensorless stepper motor drive, when the motor is separated from its drive by long cables. When the long cables and high frequency pulse width modulated control voltage signals are used together, the electrical signals difer greatly between the motor and drive-side of the cable. Since in the considered case only drive-side data is available, it is therefore necessary to estimate the motor-side signals. Modelling the entire cable and motor system in an Extended Kalman Filter is too computationally intensive for standard embedded real-time platforms. It is, in consequence, proposed to divide the problem into an Extended Kalman Filter, based only on the motor model, and separated motor-side signal estimators, the combination of which is less demanding computationally. The efectiveness of this approach is shown in simulation. Then its validity is experimentally demonstrated via implementation in a DSP based drive. A testbench to test its performance when driving an axis of a Large Hadron Collider collimator is presented along with the results achieved. It is shown that the proposed method is capable of achieving position and load torque estimates which allow step loss to be detected and mechanical degradation to be evaluated without the need for physical sensors. These estimation algorithms often require a precise model of the motor, but the standard electrical model used for hybrid stepper motors is limited when currents, which are high enough to produce saturation of the magnetic circuit, are present. New model extensions are proposed in order to have a more precise model of the motor independently of the current level, whilst maintaining a low computational cost. It is shown that a significant improvement in the model It is achieved with these extensions, and their computational performance is compared to study the cost of model improvement versus computation cost. The applicability of the proposed model extensions is demonstrated via their use in an Extended Kalman Filter running in real-time for closed-loop current control and mechanical state estimation. An additional problem arises from the use of stepper motors. The mechanics of the collimators can wear due to the abrupt motion and torque profiles that are applied by them when used in the standard way, i.e. stepping in open-loop. Closed-loop position control, more specifically Field Oriented Control, would allow smoother profiles, more respectful to the mechanics, to be applied but requires position feedback. As mentioned already, the use of sensors in radioactive environments is very limited for reliability reasons. Sensorless control is a known option but when the speed is very low or zero, as is the case most of the time for the motors used in the LHC collimator, the loss of observability prevents its use. In order to allow the use of position sensors without reducing the long term reliability of the whole system, the possibility to switch from closed to open loop is proposed and validated, allowing the use of closed-loop control when the position sensors function correctly and open-loop when there is a sensor failure. A different approach to deal with the switched drive working with long cables is also presented. Switched mode stepper motor drives tend to have poor performance or even fail completely when the motor is fed through a long cable due to the high oscillations in the drive-side current. The design of a stepper motor output fillter which solves this problem is thus proposed. A two stage filter, one devoted to dealing with the diferential mode and the other with the common mode, is designed and validated experimentally. With this ?lter the drive performance is greatly improved, achieving a positioning repeatability even better than with the drive working without a long cable, the radiated emissions are reduced and the overvoltages at the motor terminals are eliminated

Survey of FPGA applications in the period 2000 – 2015 (Technical Report)

Romoth J, Porrmann M, Rückert U. Survey of FPGA applications in the period 2000 – 2015 (Technical Report).; 2017.Since their introduction, FPGAs can be seen in more and more different fields of applications. The key advantage is the combination of software-like flexibility with the performance otherwise common to hardware. Nevertheless, every application field introduces special requirements to the used computational architecture. This paper provides an overview of the different topics FPGAs have been used for in the last 15 years of research and why they have been chosen over other processing units like e.g. CPUs

Soft Sensor-based Servo Press Monitoring

The force that a servo press exerts forming a workpiece is one the most important magnitudes in any metal forming operation. The process force, along with the characteristics of the die, is what shapes the workpiece. When the process force is greater than the maximum force for which the servo press was designed, the servo press integrity can be damaged. Therefore, the knowledge of the process force is of great interest for both, press manufacturers and users. As such, the metal forming sector is seeking systems that can monitor the process force and the operation of the servo press to analyse process’s performance and predict future deviations in the forming operation. Servo press users want to guarantee the quality of the formed parts and reduce facility downtimes due to malfunctions of the press. This dissertation addressed the monitoring of the process force and the dynamic performance of a servo press based on a model based statistical signal processing algorithm known as the dual particle filter (dPF). Initially both, the developed model of a servo press and the proposed dPF, have been experimentally evaluated and validated in a reduced scale test bench. The test bench has been designed and manufactured based on a design methodology that allows to replicate the kinematic and dynamic behaviour of different servo press facilities in the same test bench. The experimental validation has been also carried out in an industrial servo press under three different metal forming processes. The estimation results have proved the ability of the dPF to track the process force throughout the evaluated processes, obtaining a deviation lower than 5% with respect to the measured force signals at the maximum force position. The dPF algorithm has been accelerated by means of a field programmable gate array (FPGA) to achieve a real time estimation.Serbo prentsa batek pieza gordin bat eraldatzeko egindako prozesuko indarra edozein konformatu eragiketako magnitude garrantzitsuenetarikoa da. Prozesuko indarra da, trokelaren ezaugarriekin batera, pieza gordina eraldatzen duena. Prozesuko indarra prentsak diseinuaren arabera jasan dezakeena baino handiagoa bada, prentsak kalteak izan ditzake bere osotasunean. Beraz, prozesuko indarraren ezagutza interes handikoa da, prentsa egileentzat zein erabiltzaileentzat. Hori dela eta, metal eraldatzearen sektoreak prozesuko indarra eta prentsa beraren funtzionamendua monitoriza ditzaketen sistemen bila diardute, prentsaren jarduera aztertu eta eraldatzeko operazioetan etorkizunean izan daitezkeen desbideraketak aurreikusteko. Prentsa erabiltzaileek fabrikatutako piezen kalitatea bermatzea eta funtzionamendu akatsengatiko prentsaren geldialdiak murriztea bilatzen dute. Tesi honek servo prentsa baten prozesuko indarra eta portarea dinamikoaren monitorizazioa jorratzen ditu, dual particle filter (dPF) izeneko modeloetan oinarritutako seinalaren prozesamendu estadistikoko algoritmo baten bitartez. Lehenik eta behin, garatutako servo prentsaren modeloa eta proposatutako dPFa eskalatutako entsegutarako banku batean ebaluatu eta balioztatu dira. Eskalatutako entsegutarako bankua serbo prentsa desberdinen portaera zinematiko eta dinamikoa erreplikatzea ahalbidetzen duen metodologia baten bitartez diseinatu eta gauzatu da. Esperimentu bidezko balioztatzea serbo prentsa industrial batean ere gauzatu da hiru konformatuko prozesu desberdinetan. Estimazio emaitzek dPFak prozesuko indarrari jarraitzeko duen ahalmena forgatu dute, neurtutako indarrarekiko %5ekoa baino txikiagoko desbideraketa lortuz indar maximoa egiten den puntuan. dPF algoritmoa field programmable gate array (FPGA) baten bitartez azeleratu da, denbora errealeko estimazioa lortzeko.La fuerza que una servo prensa ejerce conformando una pieza es la magnitud más importante en cualquier operación de conformado. La fuerza aplicada, junto a las características del troquel, es la magnitud que da forma a la pieza. Cuando la fuerza de proceso es más grande que la fuerza máxima para la que fue diseñada la servo prensa, la integridad de ésta puede verse afectada. Por lo tanto, el conocimiento de la fuerza de proceso es de gr´an interés tanto para los fabricantes de prensas como para los usuarios de las mismas. Así pues, el sector del conformado está buscando sistemas capaces de monitorizar la fuerza de proceso y el funcionamiento de la servo prensa para analizar el proceso y predecir futuras desviaciones de las operaciones de conformado. Los usuarios de las servo prensas quieren garantizar la calidad de las piezas fabricadas y reducir las paradas de las servo prensas debidas al mal funcionamiento de las mismas. Esta tesis aborda la monitorización de la fuerza de proceso y el comportamiento dinámico de una servo prensa mediante un algoritmo de tratamiento estadístico de la señal conocido como el dual Particle Filter (dPF). Inicialmente, tanto el modelo desarrollado como el dPF propuesto han sido evaluados y validados experimentalmente en un banco de ensayos de escala reducida. El banco de ensayos ha sido diseñado y fabricado mediante una metodología de diseño que permite replicar el comportamiento cinem´atico y din´amico de distintas servo prensas en el mismo banco. La validación experimental también se ha llevado a cabo en una servo prensa industrial mediante tres procesos de conformado distintos. Los resultados de estimación han provado la habilidad del dPF para seguir la fuerza de proceso en los procesos evaluados, obteniendo una desviación menor que un 5% con respecto a las señales medidas en el punto donde se da la fuerza máxima. El algoritmo dPF ha sido acelerado mediante un filed programmable gate array (FPGA) para lograr estimaciones en tiempo real

Runtime Hardware Reconfiguration in Wireless Sensor Networks for Condition Monitoring

The integration of miniaturized heterogeneous electronic components has enabled the deployment of tiny sensing platforms empowered by wireless connectivity known as wireless sensor networks. Thanks to an optimized duty-cycled activity, the energy consumption of these battery-powered devices can be reduced to a level where several years of operation is possible. However, the processing capability of currently available wireless sensor nodes does not scale well with the observation of phenomena requiring a high sampling resolution. The large amount of data generated by the sensors cannot be handled efficiently by low-power wireless communication protocols without a preliminary filtering of the information relevant for the application. For this purpose, energy-efficient, flexible, fast and accurate processing units are required to extract important features from the sensor data and relieve the operating system from computationally demanding tasks. Reconfigurable hardware is identified as a suitable technology to fulfill these requirements, balancing implementation flexibility with performance and energy-efficiency. While both static and dynamic power consumption of field programmable gate arrays has often been pointed out as prohibitive for very-low-power applications, recent programmable logic chips based on non-volatile memory appear as a potential solution overcoming this constraint. This thesis first verifies this assumption with the help of a modular sensor node built around a field programmable gate array based on Flash technology. Short and autonomous duty-cycled operation combined with hardware acceleration efficiently drop the energy consumption of the device in the considered context. However, Flash-based devices suffer from restrictions such as long configuration times and limited resources, which reduce their suitability for complex processing tasks. A template of a dynamically reconfigurable architecture built around coarse-grained reconfigurable function units is proposed in a second part of this work to overcome these issues. The module is conceived as an overlay of the sensor node FPGA increasing the implementation flexibility and introducing a standardized programming model. Mechanisms for virtual reconfiguration tailored for resource-constrained systems are introduced to minimize the overhead induced by this genericity. The definition of this template architecture leaves room for design space exploration and application- specific customization. Nevertheless, this aspect must be supported by appropriate design tools which facilitate and automate the generation of low-level design files. For this purpose, a software tool is introduced to graphically configure the architecture and operation of the hardware accelerator. A middleware service is further integrated into the wireless sensor network operating system to bridge the gap between the hardware and the design tools, enabling remote reprogramming and scheduling of the hardware functionality at runtime. At last, this hardware and software toolchain is applied to real-world wireless sensor network deployments in the domain of condition monitoring. This category of applications often require the complex analysis of signals in the considered range of sampling frequencies such as vibrations or electrical currents, making the proposed system ideally suited for the implementation. The flexibility of the approach is demonstrated by taking examples with heterogeneous algorithmic specifications. Different data processing tasks executed by the sensor node hardware accelerator are modified at runtime according to application requests