Uniform Reconfigurable Processing Module for Design and Manufacturing Integration

1. 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

2. 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.

3. 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.)

4. 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.

5. 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

6. 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)

7. URPM based Information Processing System

8. 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

9. 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

10. Architecture of Uniform Reconfigurable Processing Module(URPM)

11. 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

12. 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

13. 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

14. 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

15. 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

16. Thank You