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.