fpga controlled laser assembly fpga controlled laser assembly project dec03-07october 8, 2003 client...
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FPGA Controlled Laser AssemblyFPGA Controlled Laser AssemblyProject Dec03-07 October 8, 2003
ClientClient
National InstrumentsNational Instruments
Faculty AdvisorsFaculty Advisors
ProfessorProfessor Mani MinaMani Mina
Professor Diane RoverProfessor Diane Rover
Team MembersTeam Members
Raymond BakerRaymond Baker
Adam PritzAdam Pritz
Jeremy BooherJeremy Booher
Joel SchneiderJoel Schneider
Presentation OutlinePresentation Outline
Initial materialsInitial materials
Introductory materialsIntroductory materials
Project activity descriptionProject activity description
Resources and schedulesResources and schedules
Closing materialsClosing materials
AcknowledgmentAcknowledgment
National Instruments for providing the National Instruments for providing the FPGA hardware and software and also the FPGA hardware and software and also the LabVIEW software. LabVIEW software.
Professor Mani Mina for providing the Professor Mani Mina for providing the stages and stepper motor apparatus.stages and stepper motor apparatus.
Problem StatementProblem Statement
General Problem StatementGeneral Problem Statement - A procedure must be controlled using - A procedure must be controlled using the LabVIEW FPGA module. This procedure must not only simply the LabVIEW FPGA module. This procedure must not only simply control the motion of an object, but it must also get feedback from control the motion of an object, but it must also get feedback from the object to control another aspect of the movement. The the object to control another aspect of the movement. The movement needs to be precise to a standard agreed upon by the movement needs to be precise to a standard agreed upon by the group. The FPGA module will control an array of stages and group. The FPGA module will control an array of stages and stepper motors that will allow movement on three axes.stepper motors that will allow movement on three axes.
General Solution-Approach StatementGeneral Solution-Approach Statement - The LabVIEW FPGA - The LabVIEW FPGA module will be used to control the laser. The first control loop will module will be used to control the laser. The first control loop will control the motion of the laser. The position of the laser in space control the motion of the laser. The position of the laser in space will be controlled. The limits of the stages will be monitored. The will be controlled. The limits of the stages will be monitored. The inputs and outputs will be controlled and monitored simultaneously. inputs and outputs will be controlled and monitored simultaneously.
Operating EnvironmentOperating Environment
The operating environment of the finished The operating environment of the finished product will be in a lab environment. The product will be in a lab environment. The lab will be clean and kept at a steady lab will be clean and kept at a steady normal temperature. The end product will normal temperature. The end product will not be easily portable and would have to not be easily portable and would have to be disassembled to be moved.be disassembled to be moved.
Intended Users and UsesIntended Users and Uses
Intended Users – The users of this product Intended Users – The users of this product will need to be familiar with LabVIEW will need to be familiar with LabVIEW since the interface to the product will be in since the interface to the product will be in this language. this language.
Intended Uses - As a demonstration of Intended Uses - As a demonstration of FPGA for National Instruments to show FPGA for National Instruments to show their customers. their customers.
AssumptionsAssumptions
The stages and stepper motors are The stages and stepper motors are functionalfunctionalAll necessary hardware will be provided by All necessary hardware will be provided by National Instruments or another provider.National Instruments or another provider.There will be no bugs in the LabVIEW or There will be no bugs in the LabVIEW or FPGA parts and they will be compatible FPGA parts and they will be compatible with each otherwith each otherNational Instruments will provide us with National Instruments will provide us with the necessary support if neededthe necessary support if needed
LimitationsLimitations
FPGA is not capable of floating point FPGA is not capable of floating point calculationscalculations
It is a new product and can not implement It is a new product and can not implement all the functionality of LabVIEWall the functionality of LabVIEW
Time span that product is to be Time span that product is to be implemented inimplemented in
End Product and Other End Product and Other DeliverablesDeliverables
The end product will be a laser mounted The end product will be a laser mounted on a three dimensional motion device that on a three dimensional motion device that will be controlled by the LabVIEW FPGA will be controlled by the LabVIEW FPGA apparatus.apparatus.
Present AccomplishmentsPresent Accomplishments
Stages within budgetStages within budget
Familiarity with Familiarity with LabVIEW FPGALabVIEW FPGA
Great relationships Great relationships with NIwith NI
On track to provide On track to provide high-quality demohigh-quality demo
Approaches ConsideredApproaches Considered
NI Motion software NI Motion software with data monitoringwith data monitoring
Control motors Control motors directly in hardwaredirectly in hardware
22ndnd approach chosen approach chosen
Why?Why?
Project Definition ActivitiesProject Definition Activities
Defining project - impossible until nowDefining project - impossible until now
Definition: Control stages deterministically in Definition: Control stages deterministically in hardware using LV FPGAhardware using LV FPGA
Group goal: Pioneer control demo for NIGroup goal: Pioneer control demo for NI
Research ActivitiesResearch Activities
FPGA’sFPGA’s
Motion solutionMotion solution
Hardware interface of Hardware interface of motor drivesmotor drives
Control algorithms: Control algorithms: Arc, 3-axes Arc, 3-axes simultaneouslysimultaneously
Design ActivitiesDesign Activities
Modifying control Modifying control algorithm to match algorithm to match our hardware our hardware interfaceinterface
Control algorithm Control algorithm from scratchfrom scratch
Rapid prototyping – Rapid prototyping – very beneficialvery beneficial
Implementation ActivitiesImplementation Activities
Product Testing ActivitiesProduct Testing Activities
Hardware VerificationHardware Verification
Determine that motors are working Determine that motors are working properly without FPGA softwareproperly without FPGA software
Determine motor input and output signalsDetermine motor input and output signals
Product Testing ActivitiesProduct Testing Activities
Software TestingSoftware Testing
Send single pulses to motors to verify Send single pulses to motors to verify connections to all motor input pinsconnections to all motor input pins
Send signal to motor to contact limit to test Send signal to motor to contact limit to test motor feedbackmotor feedback
Program full images and send to motorProgram full images and send to motor
Personnel EffortsPersonnel Efforts
0
20
40
60
80
100
120
140
160
Adam Joel Raymond Jeremy
Ho
urs Estimated
To-Date
Other Resource RequirementsOther Resource Requirements
Cost to group: $95
PosterLaserWires
Financial RequirementsFinancial Requirements
Financial Requirements (without labor)
Poster
Laser
Wires
LabView FPGA
LabView
NI PXI
PK-3 Motor Drive (3)
Linear Sliding Stage(3)
Financial Requirements (with labor)
Poster
Laser
Wires
LabView FPGA
LabView
NI PXI
PK-3 Motor Drive (3)
Linear Sliding Stage(3)Labor
ScheduleSchedule
ID T a sk Na me Ja n 0 3 F e b 0 3 Ma r 0 3 Ap r 0 3 Ma y 0 3 Ju n 0 3 Ju l 0 3 Au g 0 3 Se p 0 3 O ct 0 3 No v 0 3 D e c 0 3
1 Pro je ct De fin itio n 1
2 Pro je ct D e fin itio n C o mp le tio n 2
3 En d Use rs En d Use s 3
4 C o n stra in t Id e n tifica tio n 4
5 Te ch n o lo gy Co n sid e ration s 5
6 Id e n tifica tio n o f T e ch n o lo g ie s 6
7 Id e n tifica tio n o f C r ite r ia 7
8 T e ch n o lo g y R e se a rch 8
9 T e ch n o lo g y Se le ctio n 9
1 0 En d -Pro d uct De sig n 1 0
1 1 Id e n tifica tio n o f R e q u ire me n ts 1 1
1 2 D e sig n Pro ce ss 1 2
1 3 D o cu me n t D e sig n 1 3
1 4 Pro to typ e Imp le me n tatio n 1 4
1 5 Id e n tifica tio n o f L im ita tio n s 1 5
1 6 Imp le me n ta tio n o f Pro to typ e 1 6
1 7 En d -Pro d uct Te stin g 1 7
1 8 T e st P la n n in g 1 8
1 9 Actu a l T e stin g 1 9
2 0 R e su lts Eva lu a tio n 2 0
2 1 En d -Pro d uct Do cu me n tatio n 2 1
2 2 En d -Use r D o cu me n ta tio n 2 2
2 3 Ma in te n a n ce D o cu me n ta tio n 2 3
2 4 En d -Pro d uct De mo n stratio n 2 4
2 5 D e mo n stra tio n P la n n in g 2 5
2 6 F a cu lty Ad viso rs D e mo n stra tio n 2 6
2 7 In d u str ia l R e v ie w Pa n e l D e mo 2 7
2 8 Pro je ct Re p ortin g 2 8
2 9 Pro je ct P la n 2 9
3 0 Pro je ct Po ste r 3 0
3 1 D e sig n R e p o rt 3 1
3 2 F in a l R e p o rt 3 2
3 3 W e e kly Ema il R e p o rtin g 3 3
Spring 2003 Schedule Fall 2003 Schedule
Project EvaluationProject Evaluation
Milestone 1: Finding appropriate control algorithm Fully Met
Milestone 2: Implement control algorithm in LV FPGA Software In Progress
Milestone 3: Control motors using LabVIEW FPGA hardware In Progress
Milestone 4: Deterministically control motion device In Planning
Milestone 5: Adding other control variables (optional) In Planning
Milestones Status
CommercializationCommercialization
Is commercialization possible for this project?
Yes, if the application was more complex and robust.
1. What might be the cost to produce the product?
$7000
2. What might be the street selling price of the product?
$10,000
3. What might be the potential market for the product?
Precise controlled motion applications
Recommendations for Additional Recommendations for Additional WorkWork
Possibilities for Additional Work
● An enhanced prototype version of the product
Create an application that requires a more precise design.
Create an application that requires more stringent timing.
● A redesign of the product
Make a non-FPGA based LabVIEW application without the determinism and parallel I/O of the FPGA. This would hit a different segment of the market and would cost less to create.
Lessons LearnedLessons Learned1. What went well?
Group work and problem solving
2. What did not go well?
Delay in receiving Software
Inability to acquire hardware in a timely manner
3. What technical knowledge was gained?
Programming using FPGA hardware capabilities
Real Time programming
4. What non-technical knowledge was gained?
Project management
Overcoming shortcomings
5. What would be done differently if the project was to be done again?
Obtain hardware and software during the first month
Risk and Risk ManagementRisk and Risk Management1. The anticipated potential risks and planned management thereof?
We anticipated the risk of hardware and software did not operate as assumed.
We anticipated a lack of money and time to create a robust application.
2. The anticipated risks encountered and the success in management thereof?
We were not able to obtain a laser capable of cutting or engraving a surface, so we adapted our design to create a trace.
3. The unanticipated risks encountered and the attempts to manage that were used?
We did not receive the software within the timeframe we assumed, so we managed around it by finding other parts of the project to tackle.
We did not receive the hardware we assumed NI was offering, so Professor Mina offered the use of motors and stages ISU had.
4. The resultant changes in risk management that were made as a result of encountering the unanticipated risks?
We have learned to assume all risks as possible. Now we always plan a second option if the first is unavailable.
Closing SummaryClosing Summary
The Problem
Control a motion device using LabVIEW FPGA
The Approach
Create a 2-axis motion application that controls a laser that reliably traces a pre-set pattern
The Solution
Use NI’s PXI Controller with LabVIEW FPGA hardware and software to control Parker stepper motors and stages in a 2-D plane. The
digital output from the FPGA interface with the stepper motors while it digital inputs gather feedback data from the stages.
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