3 Reasons to Use FPGAs in Industrial Applications

Jason Chiang Industrial and Automotive Business Unit MIC Division February 2011

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Agenda
Introduction 3

reasons to use FPGAs in industrial applications

Design integration Flexibility to change Performance scaling

Partner

ecosystem solutions Summary

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Introduction

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PLDs in Industrial Applications

Programmable

logic devices (PLDs) are widely used in industrial applications

Industrial automation, motion and motor control and drives,

I/O expansion, image processing, and others

PLDs

include CPLDs and FPGAs, often used for glue logic and coprocessing FPGAs are migrating into system-on-chip (SoC) solutions
SoC Solutions

Coprocessors and Glue Logic Solutions

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Key Industrial Trends Driving FPGA Adoption

Demand for more easily managed factory networks at lower total cost of ownership (TCO)
Migration to changing Industrial Ethernet and safety standards Usage of Ethernet equipment and cables to lower costs

Demand for high-performance, energy-efficient, and safe controllers

More than 66% of energy consumed in factories

comes from inefficient motors

Within 5 years, more than 70% of drive and motion control

systems worldwide need to be functionally safe (IEC 61508)

Advancement in surveillance cameras

Wide dynamic range (WDR) sensors enable

human eye-like sensitivity

Analytics moving from control or DVR side to camera side

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FPGAs in Industrial Equipment

I/O modules, servo drives, valves, programmable logic controllers (PLCs), and human-machine interfaces (HMIs) Computer numeric controller (CNC) machines, printing machines, robots, and mobile cranes Machine vision and video surveillance Factory automation systems and power distribution systems Transportation systems such as ships, trains, and off-highway vehicles

PLC
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Servo Drives

PCB Assembly

Robotics

3 Reasons to Use FPGAs in Industrial Applications

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Key Design Challenges

Key Design Challenges of Industrial Designs

System Integration and Safety

Design Flexibility and Networking

Embedded Processing Performance

TCO and Product Life Cycle

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Design Integration: FPGA as Coprocessor

Offloads the digital signal processing (DSP) block or microcontroller unit (MCU) Adapts to evolving standards and system functions Saves hardware and software development costs

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Design Integration: FPGA as SoC

Enables integration of processors, DSP functions, I/O interfaces, and others

expertise

Capitalizes on existing OS, board support package (BSP), and application software

Adapts to changing standards, systems functions, and performance Lowers TCO through SoC methodology with device longevity
Simplifies development as applications run on one FPGA platform

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Flexibility to Change: Fieldbus Migration to Industrial Ethernet

MCU or FPGA

MCU/DSP/ASSP/ASIC designs attempt to integrate all applications on one device

Still require optional fieldbus-

MCUs/DSPs lack performance to process Industrial Ethernet in parallel to motion and motor control tasks
One solution is the discrete

specific ASIC for industrial communications

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adoption of Industrial Ethernet using dual MCUs or an MCU with an FPGA

Design Integration: FPGA as Coprocessor and SoC

Ethernet PHY Ethernet

DSP
Motors for Direction, Zoom, etc.

or

Flash
Sensor Processing

DDR-SDRAM

Encoding Network Control Motor Control

Acts as a coprocessor for WDR ISP functions Provides integration of multiple system functions and design flexibility to become the SoC solution Lowers BOM and TCO costs through SoC methodology

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Design Integration: FPGA as SoC

Sensor Processing Encoding Network Control Motor Control

Motor for Direction, Zoom, etc.

Ethernet PHY

Ethernet

or

Flash

DDR-SDRAM

Enables integration of WDR image sensor pipeline (ISP), encoding, networking, and analytics Adapts to changing standards, systems functions, and performance Lowers BOM and TCO costs through SoC methodology

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Performance Scaling
MCU/DSP/ASSP/ASIC devices will reach a performance ceiling Three ways to scale performance with FPGAs

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Custom Instructions

Extends CPU performance

CPU fetches math and logical operations For example: floating-point and

bit-manipulation operations In-line hardware is much faster than software 120 Iterations/Second 100 80 60 40 20 0 Software Only Custom Instruction
27X Faster

Custom Logic A + << >> B & Custom Instruction Logic Out

Example: Cyclic Redundancy Check (CRC) 64-Kb Buffer

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Hardware Accelerators to Clear Bottlenecks

Concurrent data coprocessing

CPU starts and stops coprocessor Coprocessor fetches data and stores results CPU runs application code concurrently Ideal for block data operations (for example: DSP blocks)

CPU

CRC Coprocessor

Iterations/Second

2,500 2,000 1,500 1,000 5,000 0 Software Only Custom Instruction Coprocessor
Program Memory Data Memory Data Memory
27X Faster

530X Faster

Arbiter

Arbiter

Example: CRC 64-Kb Buffer

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Partner Ecosystem Solutions

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Partner Ecosystem Solutions

Solutions
Functional safety

Platforms
Available as the Functional Safety Data Package with diagnostic intellectual property (IP)

Partner Ecosystems
TV Rheinland-qualified tools, tool flow, and IP and silicon data with Quartus II software v9.0 SP2 Kontrons Intel Atom Processor E6xx Series Starter Kit Terasic Industrial Networking Kit (INK) with Altera Industrial Networking Partner Program GigE Vision and Camera Link

I/O companion

Industrial networking

Machine vision

Motor control

Arrow MotionFire, EBV FalconEye, and networking partners Apical (ISP), WDR sensors, and H.264 encoders

Video surveillance

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Summary

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Summary: Key FPGA Advantages

Integration of all system functions on one FPGA

Increases reliability and

lowers manufacturing cost

Flexibility to meet changing standards and features Performance scaling through hardware acceleration Additional benefits of FPGAs include
Maximizing your market share through fast time to market Lowering risk of obsolescence through long FPGA life cycles Lowering your total cost of ownership over the lifetime of your product

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Thank You
To learn more about Altera Industrial Solutions, please visit www.altera.com/industrial

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