SPOF—Slave Powerlink on FPGA for Smart Sensors and Actuators Interfacing for Industry 4.0 Applications
Abstract
:1. Introduction
- we propose an innovative framework (SPOF) that allows upgrading old equipment of industrial control systems based on Programmable Logic Control (PLC) devices, connected to sensors and actuators throughout the POWERLINK fieldbus. In particular, the framework allows strongly customizing the final hardware platforms that implement the control, in order to tailor it for the application field, throughout the use of Intellectual Property cores (IP-cores), specifically provided by the framework, to be implemented on Field Programmable Gate Arrays (FPGAs).
- We enrich the SPOF framework with the possibility to introduce a non-intrusive run-time monitoring system within the final hardware platform.
- We validate the proposed framework on a real industrial control system provided by B&R ACOPOS [18].
2. Background and State of Art
2.1. Background
2.2. State of Art
3. The Design Methodology
- Support to integration, i.e., to support on the integration of sensors and actuators with the equipment already present on-site, for maximum reuse purpose.
- Support to edge computing, i.e., to offer the possibility to implement smart functionality at the edge by means of new modules, in order to perform some kind of pre-processing, to enforce security and safety of the new control system and to act smarter for a specific process.
- Support to monitoring, i.e., to offer the possibility to implement smart sensing solutions, in order to observe specific triggers that drive reconfiguration and adaptation.
- Functional Requirements, where users indicate the required functionality for the SPOF-slave. These requirements cover the (a) and (c) points above indicated, while the point (b) is related only to the interfacing with POWERLINK bus;
- Monitorability Requirements, where users indicate the required monitoring actions on the SPOF-slave. We provide these additional requirements to support on the implementation of smart sensing solutions.
4. The Proposed Framework
- a configurable number of slave POWERLINK nodes;
- a configurable number of SPI-slave interfaces;
- a configurable number of I2C-slave interfaces;
- a configurable number of UART-slave interfaces
- counting the number of user-defined events;
- measuring the time between two user-defined events
4.1. Main Core and System Bus
4.2. Monitoring System
5. Validation Activities
- the capability to satisfy the three characteristics that we identified for new tools and platforms for developing future industrial control systems, i.e., support to integration, support to monitoring and support to edge-computing (Section 3);
- the impact of SPOF in terms of logic occupied area;
- the impact on the development flow time to port the old equipment functions on FPGA.
5.1. Test Scenario
5.2. Support to Integration
5.3. Support to Monitoring
- Fault Recovery Triggering: in case of hardware fault of SPI controller, the system had to switch, in real-time, to a new SPI controller already implemented as redundancy on FPGA. The monitoring system has been implemented using a time monitor from the SPOF monitoring library, and it was able to guarantee a recovery action of 50 clock cycles by switching to the new SPI controller.
- Run-time Verification of Custom Behaviours: a monitoring system able to verify the correctness of working of slave POWERLINK node has been developed. It monitors the causality of the phases of the POWERLINK protocol and it stores traces in case of a fault. The goal is to allow an offline debug. The monitoring system has been implemented using an event monitor from the SPOF monitoring library, together with a Direct Memory Access (DMA) to flush out traces.
5.4. Support to Edge Computing
5.5. Area Occupation
6. Conclusions
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Logic Elements | SPOF Area | Total Area | Percentage | Monitor Area |
---|---|---|---|---|
Logic elements | 12,099 | 114,480 | 11% | 1% |
Combinational functions | 10,268 | 114,480 | 9% | 2% |
Dedicated logic registers | 7746 | 114,480 | 7% | |
Registers | 7881 | - | - | - |
Pins | 240 | 529 | 45% | - |
Memory bits | 265,952 | 3,981,312 | 7% | 2% |
Embedded Multiplier | 4 | 532 | <1% | - |
9-bit elements | ||||
PLLs | 1 | 4 | 25% | - |
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Valente, G.; Muttillo, V.; Muttillo, M.; Barile, G.; Leoni, A.; Tiberti, W.; Pomante, L. SPOF—Slave Powerlink on FPGA for Smart Sensors and Actuators Interfacing for Industry 4.0 Applications. Energies 2019, 12, 1633. https://doi.org/10.3390/en12091633
Valente G, Muttillo V, Muttillo M, Barile G, Leoni A, Tiberti W, Pomante L. SPOF—Slave Powerlink on FPGA for Smart Sensors and Actuators Interfacing for Industry 4.0 Applications. Energies. 2019; 12(9):1633. https://doi.org/10.3390/en12091633
Chicago/Turabian StyleValente, Giacomo, Vittoriano Muttillo, Mirco Muttillo, Gianluca Barile, Alfiero Leoni, Walter Tiberti, and Luigi Pomante. 2019. "SPOF—Slave Powerlink on FPGA for Smart Sensors and Actuators Interfacing for Industry 4.0 Applications" Energies 12, no. 9: 1633. https://doi.org/10.3390/en12091633
APA StyleValente, G., Muttillo, V., Muttillo, M., Barile, G., Leoni, A., Tiberti, W., & Pomante, L. (2019). SPOF—Slave Powerlink on FPGA for Smart Sensors and Actuators Interfacing for Industry 4.0 Applications. Energies, 12(9), 1633. https://doi.org/10.3390/en12091633