UC13 - Industrial Drives for Motion Control

Industrial drives are the backbone of every automated industrial process. Motion control is an essential part for machinery construction and industrial automation. Motion control platforms aim to precisely and timely control electric motors (e-motor) under consideration of safety and security requirements. They are usually realized as Programmable Logic Control (PLC) applications based on microcontroller, FPGA and ASIC solutions. Industrial drives might be operated in insecure and safety-critical environment. Typical applications are wood/ceramics/glass/stone processing, handling systems, packaging, plastics and textile machines, milling machines, lathes, handling systems, grinders, laser processing, storage and retrieval machines, extruders, winders, rolling machines, tooling machines and many more .
UC13
Industrial Robotics

Industrial Drives Motion Control systems are often built with PLCs (Programmable Logic Controller) and power inverters for controlling electrical motors. Modern motion control systems have strict requirements on precise and timely control. These requirements are accompanied by mandatory compliance with safety standards (IEC 61508:2010) and security standards (IEC 62443 ).  

The baseline of this use case is an Industrial Drives for Motion Control prototype realized in two ways, namely a real-world system and a digital twin. 

The physical Prototpye consist of an FPGA-based legacy controller, power board, PMSM (Permanent Magnetic Synchronous Motor), Remote Control Terminal, Ethernet Switch. 

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Physical Prototype

While the digital twin virtualizes the real-world system behavior by modelling and simulation with SystemC, QEMU (legacy microcontroller , Linux, FreeRTOS (Free Real Time Operating System), AMESim.

‎With this digital Twin a PMSM motor is modelled in the multi-physics simulation tool AMESim. The Motor Control Platform has hardware peripherals (for digital-analog conversion, encryption/decryption, etc.). One core, based on an microcontroller with QEMU, runs Field-Oriented Control software on top of FreeRTOS. It is separated from the second core running a server application software in Linux for handling Remote Control Application commands (ethernet interface) that are exchanged with the first core via Shared Memory. The simulation engines for QEMU, SystemC and AMESim are synchronized. 

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Industrial Drives Digital Twin 

In the evaluation scenario, the underlying CPU Subsystem is exchanged from a legacy CPU towards RISC-V, which is a very promising open processor architecture . The VALU3S project and especially the collaborations planned  perfectly complements the baseline work with respect to the focus on V&V. Especially the change towards the new processor architecture causes significant verification efforts of safety and security features where effective fault and attack injection techniques can bring high value. 

Use case Evaluation Scenarios
Workflows
VALU3S Framework
Contents
Motor keeps running as long as there is valid position data available

The motor keeps running at the specified RPM as long as there is still at least 1 position value channel providing valid values. When three channel fail the motor must go into 0 RPM. * Preconditions: During runtime. * Input conditions / steps: Motor is commanded to run at specified RPM. Fault injection is used to change the sensor data values: One channel fail, two channel fail, three channel fail.