FPGA Based Data Acquisition System For Machine Tool Spindle

Volume 8, Issue 5, May 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
FPGA based Data Acquisition System

for Machine Tool Spindle
P. S. Jadhav1*, C. B. Patil1, G. B. Jirage1, R. R. Mudholkar 2
1: Department of Electronics Vivekanand College Kolhapur (Autonomous), INDIA
2: Department of Electronics Shivaji University, Kolhapur INDIA
Abstract:- This article presents implementation of FPGA MDSPlus and Matlab interface. The interface and control
based data acquisition system to measure the logic have been implemented by using VHDL on CPLD
temperature of spindle of a machine tool. Field (Complex programming language) [3]. DAQ system using
Programmable Gate Array (FPGA) is the heart of the Xilinx Virtex- II Pro FPGA has been implemented. They
system which is configured and programmed to obtain have used both power PC and MicroBlaze processor for
real time temperature of spindle machine tool using developing the network based controller [4]. FPGA based
temperature sensor IC LM-35. In order to acquire systems allows the hardware/software co-design. It improves
analog to digital data (ADC), Serial peripheral Interface significantly the system performance by providing the less
(SPI) communication protocol has been used. The data time delay among the simulation and response. This co-
acquisition system is designed and developed using evolutionary co-operation is used to increase the computing
quartus II version 15.1 and implemented on Cyclone IV speed of the system [5][6]. The most commonly measured
E FPGA device. The measured output is stored on PC environmental quantity is temperature. This is
and plotted using MATLAB software. understandable given that temperature affects nearly all
physical, electrical, chemical, mechanical, and biological
Keywords:- FPGA; data acquisition;, Altera Cyclone IV E;, systems. Certain chemical reactions, biological activities,
Quartus and even electronic circuits work best when temperatures are
kept within a specific range. Control systems that keep
I. INTRODUCTION temperature within prescribed limits are frequently utilized
The machine tool spindle affects the performance of when these processes need to be optimized [7]. IC sensors
machine and the flexibility of the production system. As the have been accustomed to measure the temperature, since it
spinning speed of spindle increases its temperature increases has good linearity, wide power range, and are small and easy
and when cutting speed increases then also temperature to install so that no compensating circuit is needed. It is able
increases. Therefore to manufacture product with high to test a temperature range from 55°C-150°C [8].
precision, accuracy, good quality, it is essential to record the II. DATA ACQUISITION SYSTEM
temperature of spindle.
FPGA based DAQ is designed and developed to
In the scientific and technological research and observe and collect the spindle temperature. DAQ system
industrial production, a variety of parameters such as sound, includes machine tool spindle unit. The spindle temperature
temperature, pressure etc. are often needed to be collected has been monitored using temperature sensor. The
and processed. The physical data of parameters is in analog temperature data is digitized using ADC ADS 7841 with
form. In the digital domain of Electronics to handle data FPGA Processor. Further the temperature data has been sent
using processor one has to convert the analog data in digital to the PC through serial communication using RS 232
form so that processor can read, interpret and manipulate the Protocol. The recorded data is in text form and sampling rate
data. The DAQ system samples signals and measures an is 1 second. The temperature status of spindle is monitored
analog physical quantity converts them into digital quantity from LED’s on the FPGA Board. The LED’s represents the
that can be understood, measured, processed by digital binary value of recorded temperature also it is displayed and
device and provide output in analog form [1]. A DAQ stored on PC in decimal value. The system is portable.
system plays imperative role in process control, data “Fig.1” displays FPGA Based Data Acquisition System.
detection, and data acquisition. Earlier different data
acquisition systems have been estimated with different
functionalities, Methodologies and cores. Literature reveals
that microprocessors, microcontrollers, and DSP platform
can be employed for developing the data acquisition system.
These devices have slower speed, insufficient on-chip
memory and do not allow flexibility for the user in
configuring devices according to the requirement due to the
hardware configuration [2].
As in [3] data acquisition system on embedded PC/104

framework has been designed and developed. A system
designing criteria is to deal with the existing data acquisition
system of Aditya Tokamak for plasma diagnosis which has Fig. 1: FPGA Based Data Acquisition System
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ISSN No:-2456-2165
III. SYSTEM COMPONENT
A. Machine Tool Spindle
Fig. 2: Machine Tool Spindle Unit
As in “Fig 2”. The spindle is externally driven by the sensors, whose analog output voltage is comparative to the
motor using belt pully system. Variable Frequency Drive temperature in centigrade. It operates from 550 C to 1000C.
(VFD) has been used to obtain variable speed of spindle. Its scale factor is 10 mV/o C (millivolt per degree centigrade)
The rotational speed (rpm) of spindle is measured by using and output is in range from 0 V to 5V [9]. The +5 V supply
non-contact tachometer. In the present system load is not is applied to the temperature sensor direct from the FPGA
present, hence braking system is designed to apply radial board and output is given to the ADC.
friction on spindle. As the rotational speed increases
temperature of spindle increases. Therefore with applied C. ADC ADS7841
friction heat will be generated. Temperature of spindle has The ADC ADS 7841 is a 12 bit sampling successive
been measured using data acquisition system. approximation ADC with 4 channels. It has Serial
Synchronous Interface. It operates from 2.7 Volt to 5 Volt. It
B. Temperature Sensor is 16 pin IC and functions over temperature range of - 45OC
The analog IC sensor LM-35 is used to measure the to 125OC. It is Low power, high speed ADC and has on
temperature, since it has good linearity, wide power range, board multiplexer. This facility makes ADC ADS 7841
and is small and easy to install. It can measure the portable multichannel data logger [10]. The system make a
atmosphere temperature around it or machine tool use of SPI in which ADC ADS 7841 works as slave where
temperature to which it is connected or the human body as FPGA acts as Master. The connections required by ADC
temperature. The LM35 are precision integrated-circuit ADS 7841 are as in “Fig 3”.
Fig. 3: Pin Connection of ADC
D. Processing Unit available. The 50 MHz clock is available and external clock
The processing unit is Altera Cyclone IV E can be applied. It has 40 general purposes I/O (GPIO) Pins.
EP4CE115F29C7 (DE2-115) with Nios-II Processor. DE2- It has 114,480 logic elements. In this system GPIO works on
115 FPGA development board is displayed as in “Fig.4”. It 3.3 V. The programming has been performed by using
contains cyclone @IV 4CE115 FPGA device and the Serial Quartus II Software. The FPGA GPIO pins are utilized for
Device EPCS64. It supports Active Serial Programming interfacing with ADC [11].
(AS) and JTAG. The USB Blaster for programming is

ISSN No:-2456-2165
Fig. 4: DE2-115 FPGA Development Board
E. Computer/PC desired system is implemented merely by selecting the

Computer/PC is used to visualize the output of required components as processor core, memory, I/O ports
application. The real time temperature response of spindle of and stating the parameters required for the system using
a machine tool is observed on PC with the terminal emulator Qsys Builder. The Qsys tool let the users to utilize already
software. available and/or custom components for system
development. After interconnecting components the design
IV. HARDWARE- SOFTWARE CO-DESIGN is downloaded into the FPGA board. The system is reduced
IMPLEMENTATION with the use of Qsys tool. The errors get reduced, debugged
easily and performance is optimized because of this small
It is performed by Altera Qsys Builder existing in the system. The system generated by Qsys tool contains VHDL
Quartus II prime edition 15.1. The Qsys Builder is system code of each element and structure [12].
integration tools that save time and exertion in the design
process by connecting IP functions and subsystems. The
Fig. 5: System Component, Connections with base addresses
After selecting and specifying the all desired system components for the implementation (“Fig 5”.), the system is generated.
The specified system is saved by the name ‘ADS’, then the VHDL code generated by clicking generate option as displayed in
“Fig 6”.
Fig. 6: VHDL Code Generation

ISSN No:-2456-2165
After VHDL code generation Qsys system integrated board. For Implementation of application on FPGA board
into Quartus II project, implements hardware modules into .sof file is created. After running the program the result is
the FPGA design. Here pin locations are assigned, timing displayed on FPGA Board and stored on PC (“Fig.7”) for
requirements are assigned and other design constraints are further processing.
applied. Then the hardware design compiled for target
Fig. 7: Temperature Measurement of Machine Tool Spindle
V. RESULT ANALYSIS
The complete DAQ system is implemented on Altera’s Cyclone IV E FPGA Development Board. After successful
compilation (“Fig.7”) device utilization summary is obtained as in (“Fig.8”).
Fig. 8: Compilation Report
Table 1: Device Utilization Report

Used Available Utilization
Total Logic Elements 1,778 114,480 2%
Total combinational functions 1,653 114,480 1%
Dedicated logic registers 952 114,480 <1%
Embedded Multiplier 9-bit elements 0 532 0
Total registers 952 -------- ------
Total Pins 47 529 9%
Total memory bits 1,648,640 3,981,312 41 %
Total PLLs 0 4 0%
Table 1 shows that total logic elements available are are used that is only 9% pins are utilized. Component used
114,480 out of which 1,778 logic elements are used that is by this system is very less. The temperature recorded by
only 2% logic elements are utilized. Out of 529 pins 47 pins DAQ System is given in Table 2.

ISSN No:-2456-2165
Table 2: Temperature Readings of machine tool spindle
The system was successfully implemented for of 10 sec. The temperature reading of spindle of a machine
monitoring the temperature of machine tool spindle at 1000 tool has been displayed in Table 2. The temperature of
rpm . The photograph of tested system was displayed in machine tool spindle varies from 28.30 c to 32.230 c at 1000
“Fig.7”. The real time temperature response of machine tool rpm.
spindle has been displayed in “Fig.9”.The sampling rate is
Fig. 9: Real time temperature response of spindle at 1000 rpm
VI. CONCLUSION volumes, accommodate various sensors, and offer low

latency and power consumption, this system plays an
In conclusion, the temperature data acquisition system important role in enabling advanced data-driven decision-
designed for industrial applications has proven to be a making, control and optimization in industrial settings.
valuable asset in monitoring temperature-related processes.
Through the implementation of this system, several REFERNCES
significant findings and outcomes have been observed. This
system successfully collected and recorded real-time [1.] D. S Kumar and R. Ganesh, “FPGA Implementation
temperature data from the machine spindle tool with high of Real Time Data Acquisition System Using
accuracy and precision. This enabled the identification of MicroBlaze Processor”, International Journal of
temperature patterns providing valuable insights into the Science and Engineering Applications, vol.l2, No.7,
performance of industrial processes. In this FPGA based pp: 151-154, 2013.
data acquisition system minimum off-board components are [2.] Bora and K. C. Sarma, “Design of a USB based
used. FPGA-based DAQ system provides a powerful and Multichannel, Low Cost Data Acquisition System
flexible solution for industrial applications that require high- using PIC Microcontroller”, International Journal of
speed data acquisition, precise synchronization, and real- Computer Applications, Vol.59, No.6, pp: 5 - 8, 2012.
time processing. With the ability to handle large data

ISSN No:-2456-2165
[3.] R. Rajpal, J. Patel, J. P .Kumari, V. Panchal, P. K
.Chattopadhyay, H .Pujara and Saxena, Y.C.
“Embedded data acquisition system with MDSPlus”,
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[4.] C. W Robson, A. Bousselham and Bohm, C. “An
FPGA- Based General-Purpose Data Acquisition
Controller”, IEEE Transactions On Nuclear Science,
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[5.] M. S. Masmoudi, I. Song, F. Karray, M. Masmoudi,
and N. Derbel, “Hardware/Software Approach for
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[6.] J. M. Ramos-Arreguin, E. Guillen-Garcia, , S.
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[7.] National Semiconductor’s Temperature Sensor
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www.national.com/appinfo/tempsensors/files/temphb.
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[8.] P. C. Tseng and J. L. Ho, “A Study of High-Precision
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[9.] LM 35 Precision Centigrade Temperature Sensors
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[10.] ADS 7841, 12 Bit, 4 channel Serial output sampling
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[11.] DE2-115 board User Manual-FTP Directory Listing-
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FPGA Based Data Acquisition System For Machine Tool Spindle

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Volume 8, Issue 5, May 2023 International Journal of Innovative Science and Research Technology

FPGA based Data Acquisition System

As in [3] data acquisition system on embedded PC/104

IJISRT23MAY2420 www.ijisrt.com 2599

A. Machine Tool Spindle

Fig. 2: Machine Tool Spindle Unit

Fig. 3: Pin Connection of ADC

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Fig. 4: DE2-115 FPGA Development Board

E. Computer/PC desired system is implemented merely by selecting the

Fig. 5: System Component, Connections with base addresses

Fig. 6: VHDL Code Generation

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Fig. 7: Temperature Measurement of Machine Tool Spindle

Fig. 8: Compilation Report

Table 1: Device Utilization Report

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Fig. 9: Real time temperature response of spindle at 1000 rpm

VI. CONCLUSION volumes, accommodate various sensors, and offer low

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