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Three Reasons to Use FPGAs in Industrial Designs Slide 6
The first application example is a motion and motor controller that uses an FPGA as both a DSP-offload engine and as a communications co-processor. The user can apply the co-processing architecture to industrial designs, including PLCs, HMIs, and I/O modules. The diagram on this slide shows a typical motion and motor controller based on a primary processor such as a microcontroller or a digital signal processing device. The primary, or host, processor runs the control algorithm to drive the motor or motion controller. Most of these applications are still single axis, but designs that are more complex are expanding to two- and three-axis motor control, which can tax the capabilities of the main processor. Often, when more performance is needed, the operating frequency can be increased to boost processing performance. However, this may drive up power consumption. Also, there is a limit to the maximum frequency of the processor. When the DSP or MCU devices run out of performance, or when it is necessary to add functions, the designer can start with an FPGA as a co-processor to serve as an offload engine to the primary DSP or MCU device for the control algorithms. Many DSPs and MCUs also run out of bandwidth when trying to perform both control tasks and industrial communications concurrently. Designers often end up adding an additional dedicated ASSP, MCU or FPGA device for this task. Additionally, different fieldbus and Industrial Ethernet communication protocols may require a specific ASSP, MCU or FPGA to meet differing MAC hardware and software protocol stack requirements which adds complexity to the design. This networking aspect will be covered in more detail on the next slide. Meanwhile, a system design partitioned across several discrete components and boards adds design complexity and cost. This runs counter to the goal which is to streamline the platforms to achieve a lower total cost of ownership. As illustrated on this slide, a low-cost FPGA like a Cyclone IV® device can be used to offload the primary MCU or DSP processor and integrate new features as needed. Also an FPGA can be used as the communications processor. With an FPGA on either board, fewer boards will be needed in the long run, which saves on hardware development costs and reduces software development costs.
PTM Published on: 2011-09-08