Design And Implementation Of Reconfigurable Industrial Controller Based On FPGA

Industrial controller is the core of management and organization of industrial control system,which directly determines the performance of industrial control system.Industrial controller uses industrial field bus communication protocols to communicate with various types of equipment and control system.However,with the opening of industrial field bus communication protocol,content and type of protocols are also constantly changing and increasing.This is a huge challenge to implement an industrial controller with perfect function,high universality and application flexibility.Based on the background of industrial automatic control and combining with actual industrial application,this paper proposes a reconfigurable industrial controller based on FPGA to achieve an industrial controller with complete function,high versatility,stability,real-time,easy extensibility and low power consumption as the goal.This paper gives the functional and non-functional requirements of reconfigurable industrial controller based on FPGA according to the industrial application environment of poly carboxylic acid water reducing agent automated production lines.On the basis of the requirements analysis,the paper elaborates the design of the architecture of reconfigurable industrial controller based on Virtex-5 FPGA.And in this architecture,the logic function modules are divided,and the detail design of static modules and reconfigurable modules is provided.Static modules are used to realize functions except communication protocols.These functions include switch control,material dropping control,material feeding control and material discharging control,and do not change as the communication protocol changes.Reconfigurable modules are used to realize the communication between the host computer and various sensors,so as to realize the replacement of the communication protocol without interrupting the work itself.On the basis of the logic function division design,the paper gives the design for trigger mode of dynamic partial reconfiguration and method of configuration loading.For trigger mode of dynamic partial reconfiguration,two methods are designed and implemented: manual reconfiguration and automatic reconfiguration.For manual reconfiguration,the dynamic partial reconfiguration is triggered by human to achieve the switching of the communication protocol.For automatic reconfiguration,the changing of communication protocol is automatically detected by FPGA and the dynamic partial reconfiguration is triggered automatically.For FPGA configuration,a new configuration method,SD card configuration,is designed in this paper.In this method,the SD card is used to replace the host computer,and the FPGA logic and Microblaze application function are used to replace the traditional download software.On the one hand,it makes the industrial controller being able to work independently from the PC.On the other hand,it makes the replacement of industrial controller function becoming simpler and easier to use,and avoid users to learn FPGA softwares to pay the unexpected learning costs.At the end of the paper,according to the practical application environment of poly carboxylic acid water reducing agent automated production lines,an application platform is built by connecting the industrial controller with host computer and actual sensors to verify the correctness of the basic function and the protocol reconfiguration function.The innovation of this paper lies in applying dynamic partial reconfiguration technology in industrial controller,which makes the industrial controller can realize the seamless switching between different communication protocols without power-off.SD card configuration way at the same time this paper also makes the replacement and expansion of communication protocol is more convenient.At the same time,the design of SD card configuration in this paper also makes the communication protocol replacement and expansion more convenient.The actual operating results show that,the reconfigurable industrial controller based on FPGA,compared with the general industrial controller,greatly improves the real time performance,versatility,flexibility and expansibility of the industrial controller,reduces the power consumption,and provides a new research idea and implement method for the development of the next generation of industrial control technology.