FPGA Based Real Time Simulations of the Face Milling Process

The article presents a successful implementation of the milling process simulation at the Field-Programmable Gate Array (FPGA). By using FPGA, very rigorous Real-Time (RT) simulation requirements can be met. The response time of the FPGA simulations is significantly reduced, and the time synchronization is better than in a typical RT system implemented in software. The FPGA-based approach is characterized by enormous flexibility when it comes to input and output operations that can be implemented deterministically in RT. Complex simulation software has been implemented using the High Level Synthesis technique, which is a relatively easy and fast approach for FPGA programming without using complex Hardware Description Languages. The hardware functions are based on procedures written in high-level C programming language. The mathematical descriptions of simulations, results of computer simulations, Hardware-in-the-Loop Simulation experiments, and real experiments are presented. The approach presented in this paper can be used to simulate the dynamics of various mechatronic systems.