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

Advanced control system for stand-alone diesel engine driven-permanent magnetic generator sets

The main focus is on the development of an advanced control system for variable speed standalone diesel engine driven generator systems. An extensive literature survey reviews the historical development and previous relevant research work in the fields of diesel engines, electrical machines, power electronic converters, power and electronic systems. Models are developed for each subsystem from mathematical derivations with necessary simplifications made to reduce complexity while retaining the required accuracy. Initially system performance is investigated using simulation models in Matlab/Simulink. The AC/DC/AC power electronic conversion system used employs a voltage controlled dc link. The ac voltage is maintained at constant magnitude and frequency by using a dc-dc converter and a fixed modulation ratio VSI PWM inverter. The DC chopper provides fast control of the output voltage by dealing efficiently with transient conditions. A Variable Speed Fuzzy Logic Core (VSFLC) controller is combined with a classical control method to produce a novel hybrid controller. This provides an innovative variable speed control that responds to both load and speed changes. A new power balance based control strategy is proposed and implemented in the speed controller. Subsequently a novel overall control strategy is proposed to co-ordinate the hybrid variable speed controller and chopper controller to provide overall control for both fast and slow variations of system operating conditions. The control system is developed and implemented in hardware using Xilinx Foundation Express. The VHDL code for the complete control system design is developed and the designs are synthesised and analysed within the Xilinx environment. The controllers are implemented with XC95108-PC84 and XC4010-PC84 to provide a compact and cheap control system. A prototype experimental system is described and test results are obtained that show the combined control strategy to be very effective. The research work makes contributions in the areas of automatic control systems for diesel engine generator sets and CPLD/FPGA application that will benefit manufacturers and consumers.EPSR

Evolutionary computing and particle filtering: a hardware-based motion estimation system

Particle filters constitute themselves a highly powerful estimation tool, especially when dealing with non-linear non-Gaussian systems. However, traditional approaches present several limitations, which reduce significantly their performance. Evolutionary algorithms, and more specifically their optimization capabilities, may be used in order to overcome particle-filtering weaknesses. In this paper, a novel FPGA-based particle filter that takes advantage of evolutionary computation in order to estimate motion patterns is presented. The evolutionary algorithm, which has been included inside the resampling stage, mitigates the known sample impoverishment phenomenon, very common in particle-filtering systems. In addition, a hybrid mutation technique using two different mutation operators, each of them with a specific purpose, is proposed in order to enhance estimation results and make a more robust system. Moreover, implementing the proposed Evolutionary Particle Filter as a hardware accelerator has led to faster processing times than different software implementations of the same algorithm

Development of FPGA based Standalone Tunable Fuzzy Logic Controllers

Soft computing techniques differ from conventional (hard) computing, in that unlike hard computing, it is tolerant of imprecision, uncertainty, partial truth, and approximation. In effect, the role model for soft computing is the human mind and its ability to address day-to-day problems. The principal constituents of Soft Computing (SC) are Fuzzy Logic (FL), Evolutionary Computation (EC), Machine Learning (ML) and Artificial Neural Networks (ANNs). This thesis presents a generic hardware architecture for type-I and type-II standalone tunable Fuzzy Logic Controllers (FLCs) in Field Programmable Gate Array (FPGA). The designed FLC system can be remotely configured or tuned according to expert operated knowledge and deployed in different applications to replace traditional Proportional Integral Derivative (PID) controllers. This re-configurability is added as a feature to existing FLCs in literature. The FLC parameters which are needed for tuning purpose are mainly input range, output range, number of inputs, number of outputs, the parameters of the membership functions like slope and center points, and an If-Else rule base for the fuzzy inference process. Online tuning enables users to change these FLC parameters in real-time and eliminate repeated hardware programming whenever there is a need to change. Realization of these systems in real-time is difficult as the computational complexity increases exponentially with an increase in the number of inputs. Hence, the challenge lies in reducing the rule base significantly such that the inference time and the throughput time is perceivable for real-time applications. To achieve these objectives, Modified Rule Active 2 Overlap Membership Function (MRA2-OMF), Modified Rule Active 3 Overlap Membership Function (MRA3-OMF), Modified Rule Active 4 Overlap Membership Function (MRA4-OMF), and Genetic Algorithm (GA) base rule optimization methods are proposed and implemented. These methods reduce the effective rules without compromising system accuracy and improve the cycle time in terms of Fuzzy Logic Inferences Per Second (FLIPS). In the proposed system architecture, the FLC is segmented into three independent modules, fuzzifier, inference engine with rule base, and defuzzifier. Fuzzy systems employ fuzzifier to convert the real world crisp input into the fuzzy output. In type 2 fuzzy systems there are two fuzzifications happen simultaneously from upper and lower membership functions (UMF and LMF) with subtractions and divisions. Non-restoring, very high radix, and newton raphson approximation are most widely used division algorithms in hardware implementations. However, these prevalent methods have a cost of more latency. In order to overcome this problem, a successive approximation division algorithm based type 2 fuzzifier is introduced. It has been observed that successive approximation based fuzzifier computation is faster than the other type 2 fuzzifier. A hardware-software co-design is established on Virtex 5 LX110T FPGA board. The MATLAB Graphical User Interface (GUI) acquires the fuzzy (type 1 or type 2) parameters from users and a Universal Asynchronous Receiver/Transmitter (UART) is dedicated to data communication between the hardware and the fuzzy toolbox. This GUI is provided to initiate control, input, rule transfer, and then to observe the crisp output on the computer. A proposed method which can support canonical fuzzy IF-THEN rules, which includes special cases of the fuzzy rule base is included in Digital Fuzzy Logic Controller (DFLC) architecture. For this purpose, a mealy state machine is incorporated into the design. The proposed FLCs are implemented on Xilinx Virtex-5 LX110T. DFLC peripheral integration with Micro-Blaze (MB) processor through Processor Logic Bus (PLB) is established for Intellectual Property (IP) core validation. The performance of the proposed systems are compared to Fuzzy Toolbox of MATLAB. Analysis of these designs is carried out by using Hardware-In-Loop (HIL) test to control various plant models in MATLAB/Simulink environments

Implementation of Block-based Neural Networks on Reconfigurable Computing Platforms

Block-based Neural Networks (BbNNs) provide a flexible and modular architecture to support adaptive applications in dynamic environments. Reconfigurable computing (RC) platforms provide computational efficiency combined with flexibility. Hence, RC provides an ideal match to evolvable BbNN applications. BbNNs are very convenient to build once a library of neural network blocks is built. This library-based approach for the design of BbNNs is extremely useful to automate implementations of BbNNs and evaluate their performance on RC platforms. This is important because, for a given application there may be hundreds to thousands of candidate BbNN implementations possible and evaluating each of them for accuracy and performance, using software simulations will take a very long time, which would not be acceptable for adaptive environments. This thesis focuses on the development and characterization of a library of parameterized VHDL models of neural network blocks, which may be used to build any BbNN. The use of these models is demonstrated in the XOR pattern classification problem and mobile robot navigation problem. For a given application, one may be interested in fabricating an ASIC, once the weights and architecture of the BbNN is decided. Pointers to ASIC implementation of BbNNs with initial results are also included in this thesis

Validation and verification of the interconnection of hardware intellectual property blocks for FPGA-based packet processing systems

As networks become more versatile, the computational requirement for supporting additional functionality increases. The increasing demands of these networks can be met by Field Programmable Gate Arrays (FPGA), which are an increasingly popular technology for implementing packet processing systems. The fine-grained parallelism and density of these devices can be exploited to meet the computational requirements and implement complex systems on a single chip. However, the increasing complexity of FPGA-based systems makes them susceptible to errors and difficult to test and debug. To tackle the complexity of modern designs, system-level languages have been developed to provide abstractions suited to the domain of the target system. Unfortunately, the lack of formality in these languages can give rise to errors that are not caught until late in the design cycle. This thesis presents three techniques for verifying and validating FPGA-based packet processing systems described in a system-level description language. First, a type system is applied to the system description language to detect errors before implementation. Second, system-level transaction monitoring is used to observe high-level events on-chip following implementation. Third, the high-level information embodied in the system description language is exploited to allow the system to be automatically instrumented for on-chip monitoring. This thesis demonstrates that these techniques catch errors which are undetected by traditional verification and validation tools. The locations of faults are specified and errors are caught earlier in the design flow, which saves time by reducing synthesis iterations

Automated Debugging Methodology for FPGA-based Systems

Electronic devices make up a vital part of our lives. These are seen from mobiles, laptops, computers, home automation, etc. to name a few. The modern designs constitute billions of transistors. However, with this evolution, ensuring that the devices fulfill the designer’s expectation under variable conditions has also become a great challenge. This requires a lot of design time and effort. Whenever an error is encountered, the process is re-started. Hence, it is desired to minimize the number of spins required to achieve an error-free product, as each spin results in loss of time and effort. Software-based simulation systems present the main technique to ensure the verification of the design before fabrication. However, few design errors (bugs) are likely to escape the simulation process. Such bugs subsequently appear during the post-silicon phase. Finding such bugs is time-consuming due to inherent invisibility of the hardware. Instead of software simulation of the design in the pre-silicon phase, post-silicon techniques permit the designers to verify the functionality through the physical implementations of the design. The main benefit of the methodology is that the implemented design in the post-silicon phase runs many order-of-magnitude faster than its counterpart in pre-silicon. This allows the designers to validate their design more exhaustively. This thesis presents five main contributions to enable a fast and automated debugging solution for reconfigurable hardware. During the research work, we used an obstacle avoidance system for robotic vehicles as a use case to illustrate how to apply the proposed debugging solution in practical environments. The first contribution presents a debugging system capable of providing a lossless trace of debugging data which permits a cycle-accurate replay. This methodology ensures capturing permanent as well as intermittent errors in the implemented design. The contribution also describes a solution to enhance hardware observability. It is proposed to utilize processor-configurable concentration networks, employ debug data compression to transmit the data more efficiently, and partially reconfiguring the debugging system at run-time to save the time required for design re-compilation as well as preserve the timing closure. The second contribution presents a solution for communication-centric designs. Furthermore, solutions for designs with multi-clock domains are also discussed. The third contribution presents a priority-based signal selection methodology to identify the signals which can be more helpful during the debugging process. A connectivity generation tool is also presented which can map the identified signals to the debugging system. The fourth contribution presents an automated error detection solution which can help in capturing the permanent as well as intermittent errors without continuous monitoring of debugging data. The proposed solution works for designs even in the absence of golden reference. The fifth contribution proposes to use artificial intelligence for post-silicon debugging. We presented a novel idea of using a recurrent neural network for debugging when a golden reference is present for training the network. Furthermore, the idea was also extended to designs where golden reference is not present