A New Methodology for a Retrofitted Self-tuned Controller with Open-Source FPGA

Servo systems are feedback control systems characterized by position, speed, and/or acceleration outputs. Nowadays, industrial advances make the electronic stages in these systems obsolete compared to the mechanical elements, which generates a recurring problem in technological, commercial and industrial applications. This article presents a methodology for the development of an open-architecture controller that is based on reconfigurable hardware under the open source concept for servo applications. The most outstanding contribution of this paper is the implementation of a Genetic Algorithm for online self tuning with a focus on both high-quality servo control and reduction of vibrations during the positioning of a linear motion system. The proposed techniques have been validated on a real platform and form a novel, effective approach as compared to the conventional tuning methods that employ empirical or analytical solutions and cannot improve their parameter set. The controller was elaborated from the Graphical User Interface to the logical implementation while using free tools. This approach also allows for modification and updates to be made easily, thereby reducing the susceptibility to obsolescence. A comparison of the logical implementation with the manufacturer software was also conducted in order to test the performance of free tools in FPGAs. The Graphical User Interface developed in Python presents features, such as speed profiling, controller auto-tuning, measurement of main parameters, and monitoring of servo system vibrations.