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 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 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: RMS consists of different components: design systems, machines, controls, production lines, inventory and transportation sub-systems, etc. 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. 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 Machine Sensors Actuators Machine Controller (e.g. PLC, CNC, etc.) Remote Design E-maintenance Centre Internet Shop-Floor LAN Server

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

FPGA: Field Programmable Gate Array CLB-Slices: Configurable Logic Block units CLB-Slices: Configurable Logic Block units LVDS I/O: Low Voltage Differential Signal Input / Output LVDS I/O: Low Voltage Differential Signal Input / Output o Giga-bit Transceiver Giga-bit Transceiver Global on-Chip Routing Lines LVDS I/O Ports LVDS I/O Ports Embedded Power-PC CLB Slices CLB Slices CLB Slices CLB Slices CLB Slices CLB Slices Embedded Memory Embedded Memory Field of On-Chip Logic, Memory & Communication Resources 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 architecture is programmable form the external source but not fixed as it is in the existing Controllers (e.g. PLC) 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 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 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) 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) URPM hardware architecture is programmable form the external source but not fixed as it is in the existing Controllers (e.g. PLC) 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 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 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) 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)

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. 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. 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 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. 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 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 Operating Resources Reconfigurable Field of Memory Resources Reconfigurable Field of Memory Resources Reprogrammable Soft-Core Memory Reprogrammable Soft-Core Memory Real-Time Operating System Real-Time Operating System Reprogrammable Controller-Loader Reprogrammable Controller-Loader Reconfigurable Input / Output Interface Reconfigurable Input / Output Interface Network interface Network interface

Core1 Virtual Bus SkSiSn I/OS1S2 Data in #1 Data in #2 Data out Core 2 Optimization of Resources in URPM: Spatial Partitioning Data out

Optimization of Resources in URPM: Temporal Partitioning S i – statements of Data Flaw Graph of a Process S i – statements of Data Flaw Graph of a Process RSi – Period of configuration of FPGA resources for the statement S i RSi – Period of configuration of FPGA resources for the statement S i DFG: Data- Flow Graph Data-Frame Processing Schedule

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

CONCLUSIONCONCLUSION URPM approach improves the effectiveness of Reconfigurable Manufacturing System by: URPM approach improves the effectiveness of Reconfigurable Manufacturing System by: Unification of the Information processing modules Unification of the Information processing modules On-chip integration of data-acquisition, processing, memory, and network functions On-chip integration of data-acquisition, processing, memory, and network functions Upgrade of software and hardware components via high-bandwidth network Upgrade of software and hardware components via high-bandwidth network Optimization of resources using spatial and temporal partitioning of the FPGA micro-architecture 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 Remote troubleshooting and repair of hardware at any level of Information Processing System

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