Dynamic Partial Reconfiguration for Adaptive Sensor Integration in Highly Flexible Manufacturing Systems

Abstract

As new production system concepts emerge to face an increasing demand for individualized production, sensor integration for Industry 4.0 functions is becoming a major challenge. Flexibility- and scalability-focused concepts rely on reconfigurable machines that automatically replace smart end effectors between production steps. To ensure adaptability to future demands, these smart components, comprising the main tool and sensors, are connected to the static part of the machine via a unified electro-mechanical interface. In robot-based concepts, these components are furthermore space- and weight-constrained and should be cost-optimized. With respect to sensor integration, this leads to the challenge of interfacing sensors using different communication protocols and electrical signal properties through a fixed, minimal set of signal lines. In this paper, an architecture for an adaptive sensor integration unit is presented, targeting highly flexible production systems. Leveraging dynamic partial FPGA reconfiguration to exchange communication logic and an extensible hardware module located in the static part of the machine, it efficiently supports alternating communication protocols over static signal lines. It thereby reduces the number of signal lines as well as the need for protocol conversion units in the exchangeable components. A prototype implementation using industrial bus protocols shows its suitability and is evaluated concerning relevant timing characteristics and resource usage.