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FPGA-PLC-based multi-channel position measurement system.

Dhruv M Patel1, Ankit K Shah2

  • 1Instrumentation and Control Engineering, Gujarat Technological University, Gujarat, India.

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|January 18, 2021
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Summary
This summary is machine-generated.

A new Field Programmable Gate Array (FPGA) based High Speed Counter (HSC) module offers improved flexibility and speed for industrial control. This FPGA-PLC-HSC module enhances accuracy in position, speed, and direction measurements.

Keywords:
Field Programmable Gate ArrayHigh speed phase countersPosition measurementProgrammable Logic Controller

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Area of Science:

  • Industrial Automation and Control Systems
  • Embedded Systems Design
  • Digital Signal Processing

Background:

  • Traditional Programmable Logic Controllers (PLCs) using microprocessors or micro-controllers face limitations in flexibility and speed for high-speed industrial applications.
  • Existing PLC-based High Speed Counter (HSC) modules exhibit performance degradation due to serial execution and fixed hardware.

Purpose of the Study:

  • To propose and evaluate a novel Field Programmable Gate Array (FPGA) based PLC multi-channel High Speed Counter (HSC) module.
  • To enhance performance, flexibility, and accuracy in industrial instrumentation and control applications compared to conventional PLC-HSC modules.

Main Methods:

  • Implementation of a 2-phase, 2-Input counter with 1X, 2X, and 4X resolutions using FPGA technology.
  • Utilizing feedback node and shift register methods within LabVIEW FPGA for module implementation and device utilization analysis.
  • Experimental validation using an optical encoder connected to an NI-myRIO-1900 FPGA platform.

Main Results:

  • Simulation results indicate faster scanning times, improved linearity, enhanced resolution, and higher input/counting frequencies for the FPGA-PLC-HSC module.
  • Experimental results confirm the proposed module's superior scanning time, accuracy, and linearity across 1X, 2X, and 4X resolutions.
  • The FPGA-based approach demonstrates significant performance gains over traditional PLC-HSC modules.

Conclusions:

  • The proposed FPGA-PLC-HSC module significantly outperforms existing PLC-HSC solutions in terms of speed, accuracy, and flexibility.
  • This novel FPGA-based design is well-suited for high-speed industrial applications requiring precise measurement of position, speed, and direction.
  • The study validates the effectiveness of FPGA implementation for advanced industrial counter modules.