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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 l.jpg

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 l.jpg

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.


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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.)


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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.


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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


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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)


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URPM based Information Processing System


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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


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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


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Architecture of Uniform Reconfigurable Processing Module(URPM)


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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


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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


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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


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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


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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


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Thank You


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