Motion Controller Dual Processor Bus Mastering
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Solution Overview
Problem
Current motion controllers in simulation systems rely on expensive and complex real-time operating systems (RTOS), which increase costs and complexity, and lack user-friendly interfaces due to their reliance on industrially packaged PC hardware for supervisory and communication roles, limiting their ability to provide low latency and stability in hardware-in-the-loop testing.
Innovation Solution
A motion controller architecture that employs a secondary processor with bus mastering capabilities, allowing it to independently manage data transactions on the I/O bus, reducing the need for a real-time operating system in the primary processor and enabling the use of a general-purpose operating system like Microsoft Windows, while maintaining low latency through direct communication with reflective memory interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a real-time operating system (RTOS) is used in the primary processor, then low latency and stability are achieved, but design costs and complexity increase
Solution Approach 1:
The system divides functionality between two processors: the primary processor handles supervisory control and communications using a general-purpose operating system, while the secondary processor handles hard real-time control algorithms. This segmentation allows each processor to be optimized for its specific function, reducing the complexity burden on the primary processor while maintaining real-time performance.
Solution Approach 2:
A secondary processor is introduced as an intermediary between the primary processor and the motion control system. This secondary processor acts as a mediator that handles the computationally intensive real-time control algorithms, freeing the primary processor from real-time constraints and allowing it to use a less complex general-purpose operating system.
2Loss of time
If a real-time operating system (RTOS) is used in the primary processor, then low latency is achieved, but design costs increase
Solution Approach 1:
The system divides functionality between two processors: the primary processor handles supervisory control and communications using a general-purpose operating system, while the secondary processor handles hard real-time control algorithms. This segmentation allows each processor to be optimized for its specific function, reducing the complexity burden on the primary processor while maintaining real-time performance.
3Ease of operation
If the primary processor manages all data transactions, then system control is centralized, but latency increases due to processing overhead
Solution Approach 1:
The system divides functionality between two processors: the primary processor handles supervisory control and communications using a general-purpose operating system, while the secondary processor handles hard real-time control algorithms. This segmentation allows each processor to be optimized for its specific function, reducing the complexity burden on the primary processor while maintaining real-time performance.
Solution Approach 2:
The secondary processor is capable of independent bus mastering, allowing it to autonomously manage data transactions between the reflective memory interface and the motion control system without requiring intervention from the primary processor. This self-service capability reduces latency by eliminating unnecessary processing steps while maintaining system control through the primary processor's supervisory role.
Data Source
AI summary
A motion controller including a computer comprising a primary processor or a central processing unit and an input/output communication bus. The primary processor is in communicative connection with the bus and is adapted to communicate with other devices in communicative connection with the bus via the bus. The motion controller also includes at least one secondary processor in communicative connection with the bus. The secondary processor is adapted to execute at least one control algorithm for one or more axes of motion associated therewith. The secondary processor is further adapted to communicate with other devices in communicative connection with the bus via the bus independently of the primary processor (that is, the secondary processor is can effect bus mastering). The operating system of the computer can, for example, be a general purpose operating system.