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
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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-platform cannot provide real-time control and
  thus needs to be interfaced to machine-specific
  real-time controller (e.g. PLC, CNC, etc.)
• PC-platform allows 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
Embedded Power-PC
Embedded Memory
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

• CLB-Slices Configurable Logic Block units
• LVDS I/O Low Voltage Differential Signal Input /
  Output

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Concept of URPM FPGA-based Uniform
Reconfigurable Processing Module

• URPM hardware architecture is programmable form
  the external source but not fixed as it is in the
  existing Controllers (e.g. PLC)
• URPM computing circuits are 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 incorporates on-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
I/O
S1
S2
Sk
Si
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
Xilinx Virtex II FPGA
LVDS I/O Port
LVTTL Control
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