Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System

Second Author's Department

Electronics & Communications Engineering Department

Third Author's Department

Electronics & Communications Engineering Department

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https://doi.org/10.3390/designs9030056

All Authors

Gehad I. Alkady Ramez M. Daoud Hassanein H. Amer Yves Sallez Hani F. Ragai

Document Type

Research Article

Publication Title

Designs

Publication Date

6-1-2025

doi

10.3390/designs9030056

Abstract

This paper proposes a fault-tolerant flexible manufacturing system (FMS) that features a dual-level fault tolerance mechanism at both the workcell and system levels to enhance reliability. The workcell controller was implemented on a Field Programmable Gate Array (FPGA). Reconfigurable duplication was used as the first level of fault tolerance at the workcell level. It was shown how to detect and recover from FPGA faults such as Single Event Upsets (SEUs), hard faults, and Single Event Functional Interrupts (SEFIs). The prototype of the workcell controller was successfully implemented using two Zybo Z7-20 AMD boards and an Arduino DUE. Petri Nets were used to prove that controller reliability increased by 346% after 1440 operational hours. The second level of fault tolerance was at the FMS level; the Supervisor (SUP) took over the responsibilities of any malfunctioning workcell controller. Riverbed software was used to prove that the system successfully met the end-to-end delay requirements. Finally, Matlab showed that there is a further increase in performability.

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