Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System
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 w...
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| Language: | English |
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MDPI AG
2025-05-01
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| Series: | Designs |
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| Online Access: | https://www.mdpi.com/2411-9660/9/3/56 |
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| author | Gehad I. Alkady Ramez M. Daoud Hassanein H. Amer Yves Sallez Hani F. Ragai |
| author_facet | Gehad I. Alkady Ramez M. Daoud Hassanein H. Amer Yves Sallez Hani F. Ragai |
| author_sort | Gehad I. Alkady |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-de14842eb4fb44a99c6dcadc5a9cdf7e |
| institution | Kabale University |
| issn | 2411-9660 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Designs |
| spelling | doaj-art-de14842eb4fb44a99c6dcadc5a9cdf7e2025-08-20T03:24:39ZengMDPI AGDesigns2411-96602025-05-01935610.3390/designs9030056Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing SystemGehad I. Alkady0Ramez M. Daoud1Hassanein H. Amer2Yves Sallez3Hani F. Ragai4Electronics and Electrical Communications Department, Faculty of Engineering, Ain Shams University, Cairo 11566, EgyptElectronics and Communication Engineering Department, The American University in Cairo (AUC), New Cairo 11835, EgyptElectronics and Communication Engineering Department, The American University in Cairo (AUC), New Cairo 11835, EgyptLAMIH, UMR CNRS 8201, Université Polytechnique Hauts-de-France, 59300 Valenciennes, FranceElectronics and Electrical Communications Department, Faculty of Engineering, Ain Shams University, Cairo 11566, EgyptThis 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.https://www.mdpi.com/2411-9660/9/3/56flexible manufacturing systemsfield programmable gate arraysfault-tolerant systemsPetri Netsreliability |
| spellingShingle | Gehad I. Alkady Ramez M. Daoud Hassanein H. Amer Yves Sallez Hani F. Ragai Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System Designs flexible manufacturing systems field programmable gate arrays fault-tolerant systems Petri Nets reliability |
| title | Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System |
| title_full | Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System |
| title_fullStr | Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System |
| title_full_unstemmed | Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System |
| title_short | Dual-Level Fault-Tolerant FPGA-Based Flexible Manufacturing System |
| title_sort | dual level fault tolerant fpga based flexible manufacturing system |
| topic | flexible manufacturing systems field programmable gate arrays fault-tolerant systems Petri Nets reliability |
| url | https://www.mdpi.com/2411-9660/9/3/56 |
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