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Uniform Reconfigurable Processing Module for Design and Manufacturing Integration. V. Kirischian, S. Zhelnokov, P.W. Chun, L. Kirischian and V. Geurkov Presenter: Lev Kirischian, Ph.D., P.Eng. Embedded and Reconfigurable Systems Laboratory Department of Electrical and Computer Engineering

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Uniform Reconfigurable Processing Module for Design and Manufacturing Integration

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Uniform Reconfigurable Processing Module for Design and Manufacturing Integration

V. Kirischian, S. Zhelnokov, P.W. Chun, L. Kirischian and V. Geurkov

Presenter: Lev Kirischian, Ph.D., P.Eng.

Embedded and Reconfigurable Systems Laboratory

Department of Electrical and Computer Engineering

RYERSON University, Toronto

2005


Reconfigurable Manufacturing Systems (RMS)

  • The US National Science Foundation (NSF) has identified RMS as the new paradigm for future development of intelligent manufacturing systems

  • RMS consists of different components:

    design systems, machines, controls, production lines, inventory and transportation sub-systems, etc.

  • RMS components can be rapidly adjusted for the product demand fluctuation and technology changing by reconfiguration of the components functionality and links between components.


Computer Integrated Manufacturing (CIM): General Approach

Server

Shop-Floor LAN

Internet

Machine

Sensors

Remote Design

E-maintenance Centre

Actuators

Machine Controller (e.g. PLC, CNC, etc.)


Limitations of PC based CIM

  • PC-platform plays the role of the uniform information processing and LAN / WAN communication center in existing CIMs

  • PC-platformcannot provide real-time control and thus needs to be interfaced to machine-specific real-time controller (e.g. PLC, CNC, etc.)

  • PC-platformallows upgrading only software components via Internet but cannot upgrade or repair hardware remotely.


FPGA: Field Programmable Gate Array

o

Field of On-Chip Logic, Memory & Communication Resources

Giga-bit

Transceiver

Giga-bit

Transceiver

Global on-Chip Routing Lines

  • CLB-Slices: Configurable Logic Block units

  • LVDS I/O: Low Voltage Differential Signal Input / Output

Embedded

Memory

Embedded

Power-PC

Embedded

Memory

LVDS

I/O

Ports

LVDS

I/O

Ports

CLB

Slices

CLB

Slices

CLB

Slices

CLB

Slices

CLB

Slices

CLB

Slices

  • Configuration Static Memory:

  • Creates links between on-chip components

  • Programs logic functions into CLB slides

  • Loads programs to the Embedded Power-PC

Configuration

Controller


Concept of URPM: FPGA-based Uniform Reconfigurable Processing Module

  • URPM hardware architectureis programmable form the external source but not fixed as it is in the existing Controllers (e.g. PLC)

  • URPM computing circuitsare internally interfaced with the embedded PC-core instead of external PC-interface usual for existing Controllers (e.g. PLC)

  • URPM creates LAN using multiple on-chip transceivers instead of conventional shop-floor LAN where multiple Controllers are connected to the shared media LAN (e.g. MODBUS)

  • URPM incorporateson-chip data-acquisition, processing, data storage and network communication functions instead of distribution the above functions between different units (e.g. PLC)


URPM based Information Processing System


Advantages of the URPM Concept: System-to-Process Adaptation

  • Rapid adaptation of control, data-acquisition and communication functions to the updated manufacturing process by reconfiguration of hardware resources and reprogramming embedded PC-core in the URPM.

  • Hardware / software modifications (data-processors, interfaces, communication protocols, process controllers, etc.) may be done remotely via multi-gigabit network.

  • Rapid adjustment of each element, sub-system and complete Reconfigurable Manufacturing System to the new or modified manufacturing process using direct access from the Design Centre to each URPM


Advantages of the URPM Concept: E-maintenance and E-repair

  • Remote troubleshooting, repair or run-time upgrade of hardware components inside the URPM without interruption of the rest of processes running in the URPM.

  • Ability for self-restoration of faulty functions by self-repair of hardware faults caused by radiation effects, wafer corruption or hidden manufacturing defects in the FPGA


Architecture of Uniform Reconfigurable Processing Module(URPM)


URPM: Major Components

  • Reconfigurable Field of Operating Resources

  • Reconfigurable Field of Memory Resources

  • Reprogrammable Soft-Core Memory

  • Real-Time Operating System

  • Reprogrammable Controller-Loader

  • Reconfigurable Input / Output Interface

  • Network interface


Optimization of Resources in URPM: Spatial Partitioning

Data in #1

Data in #2

Data out

Core1

Core 2

S1

S2

I/O

Si

Sk

Sn

Virtual Bus

Data out


Optimization of Resources in URPM: Temporal Partitioning

DFG: Data-Flow Graph

Data-Frame Processing Schedule

  • S i – statements of Data Flaw Graph of a Process

  • RSi – Period of configuration of FPGA resources for the statement S i


Implementation: URPM coupled with PCI-Interface Card for Mini-RMS

LVTTL Control

LVDS I/O Port

Xilinx Virtex II FPGA

Static Memory

Controller-Loader

URPM

PCI-Interface Card


CONCLUSION

URPM approach improves the effectiveness of Reconfigurable Manufacturing System by:

  • Unification of the Information processing modules

  • On-chip integration of data-acquisition, processing, memory, and network functions

  • Upgrade of software and hardware components via high-bandwidth network

  • Optimization of resources using spatial and temporal partitioning of the FPGA micro-architecture

  • Remote troubleshooting and repair of hardware at any level of Information Processing System


Thank You


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