Advanced Digital Technologies Universidad Pontificia Bolivariana October 2011

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IMPLEMENTATION OF A PID CONTROLLER EMBEDDED IN A FPGA FOR
POSITIONING A DC MOTOR

Edgar Rodrigo Mancipe Toloza
e-mail: ing.rodrigo.mancipe@gmail.com


ABSTRACT: The main objective of this paper is
to present the steps of how to program a PID controller
in a FPGA, and in that way to control a DC motor using
Pulse Width Modulation. Also we want to give some
ideas to people interested in program embedded
controllers in hardware.

During the project we will use some tools to help us
to visualize the behavior of the controller on the
computer screen through rs232 communication and
LabView chart to plot, and LCD display for visualize the
Set Point, gains and the current value.

KEYWORDS: PID, Control, FPGA, DE0-Nano,
Embedded.

1 INTRODUCTION

Nowadays FPGAs have increased their popularity
due the many ways to acquire it, reliability, and low
costs. As a consequence of that, we can see more
FPGAs applications in control systems.

For many years, microcontrollers used to be on the
top of this field due their low-cost, but through years
FPGAs have turned into a striking option, thanks to its
main property of control many systems in parallel in the
same embedded system.[1]

In this project we want to show in a quick way, how
to program a PID control in FPGA using Verilog
language, also we will change the values of Gain
variables to see the behavior of the controlled value.

This article is not intended to give a definitive PID
algorithm, the intention is to introduce and give some
ideas for the readers of how create and implement their
own PID equation embedded in FPGA.

2 MATERIALS

This section will show the name of the main objects
used in the analog and digital interface of the project for
signal conditioning and power circuit.

2.1 DE0-NANO BOARD

The development board selected for this Project is
the DE0-Nano, which contains the next characteristics:
[2]


Altera FPGA Cyclone IV EP4CE22F17C6
Analog-to-digital converter ADC128S022
Configuration device EPCS16 for non-volatile
data storage
4 dip-switch
2 push buttons
8 LEDs


Figure 1. DE0-Nano Board.

2.2 GEARMOTOR

The gearmotor selected have the next
characteristics:

Torque 18Kg*cm
80RPM
Power supply 12Vdc
Quadrature encoder of 8384 pulses per round
3.3v.


Figure 2. Gearmotor. [3]






Advanced Digital Technologies Universidad Pontificia Bolivariana October 2011

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2.3 DISPLAY HD44780 2x16

Monochromatic display 2X16 that will be use to
visualize de set-point, current variable, proportional,
integral and derivative gain


Figure 3. LCD 2x16. [4]

2.4 H BRIDGE

In order to coupling the control circuit and power
circuit, a L293D H Bridge is the selected option, so in
that way the control circuit send digital signals to the chip
for select the rotation of the motor. [5]


Figure 4. L293D Block Diagram.

2.5 SERIAL-TO-USB CONVERTER

For visualize the behavior of the variables in the
computer screen, we decided to use a serial-to-usb
converter FTDI FT232RL. So through a serial RS232
algorithm coming from the embedded we can send the
information of the datas. [6]


Figure 5. Serial-to-USB converter FT232RL.

3 BLOCK DIAGRAM OF THE
CONTROLLER

Before start to program the FPGA, is necessary
defining a strategy through a block diagram. In the Figure
6, we can see that the Set Point is selected using a Dip-
switch and the feedback signal is coming from the
quadrature encoder coupled to the DC motor. The error
is the difference between Set Point and feedback
(Encoder), and the error sign define the rotation of the
motor through the H Bridge. A Pulse Width Modulation
(PWM) is the output signal of the PID algorithm that will
change its Duty Cycle depending of the controller result.


Figure 6 Block Diagram of the controller.

4 PROGRAMMING

Once defined the strategy for the controller, we
proceed to program the algorithm in HDL Verilog, using
Quartus II. In this case we divided the entire Project in
different sub-modules that will allow us to interpret and
design in modular way, so that is going to be an
advantage at the moment of write and understand the
program lines.

4.1 SET POINT

For the Set Point there are 5 predefined positions
that will be selected through a dip-switch. Due that the
encoder coupled to the gearmotor generates 8384
pulses per round is necessary to calculate the value for
each position.

8S84
S6u
Su = 699 Pulscs

8S84
S6u
4S = 1u48 Pulscs

8S84
S6u
9u = 2u96 Pulscs

8S84
S6u
18u = 4192 Pulscs

8S84
S6u
27u = 6288 Pulscs

Once we have the number of pulses for each
position of the motor we proceed to program the set point
selector, the next image will show the SP program:

Advanced Digital Technologies Universidad Pontificia Bolivariana October 2011

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Figure 7. Algorithm for the Set Point.

4.2 CURRENT VALUE

For know the value of the current value is
necessary to read and interpret de data received by the
encoder coupled to the DC motor. So in that case we
use a circuit that will allow us to interpret the 2
quadratures signals into a counter that increment and
decrement its value depending of the rotation of the
encoder. [7]


Figure 8. Quadrature decoder coupler circuit.

In the figure 8 we can see that the count direction
will determine if the counter will ascend or descend, also
the count enable will be the clock pulse that determines
the moment to calculate.

The interpretation of this circuit in Verilog is shown
in the Figure 9.


Figure 9. Verilog algorithm for quadrature decoder
coupler circuit.

4.3 ERROR SIGNAL

The error signal is calculated with the difference
between Set Point and Feedback as we can see in
algorithm shown in the figure 10.


Figure 10. Verilog algorithm for error.

But its important to take note that when the
feedback value is bigger than set-point value, it will be a
negative saturation so its necessary identify when this
happen with a signed bit, also put a condition if the
signed bit tells that the value its negative, do a twos
complement. The next figure shows a possible way to do
that: [8]


Figure 11. Verilog algorithm for twos complement.

4.4 CONTROL

Before start to write the control algorithm was
necessary to define the expression to use, in this case
we consulted the incremental PID algorithm as shown in
the next equation: [9]

m(k) = m(k -1) + _Kp +
KJ
I
+
Ki I
2
] c(k)
+ _
Ki I
2
- Kp -
2 KJ
I
] c(k - 1)
+ _
KJ
I
] c(k - 2)

After that we proceed to program the equation
using a Finite State Machine (FSM) using each state for
doing a operation, and add and substract at the end, as
shown in the next figure:


Figure 12. Verilog algorithm for PID controller

Another important aspect to have in account is the
anti-windup, due the abrupt change of the set point, the
control signal can saturate into a max value or a min
value (0-64000 on this case), in order to avoid that, an
anti-windup algorithm is necessary, a possible way to
describe that algorithm is shown in the next figure:

Advanced Digital Technologies Universidad Pontificia Bolivariana October 2011

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Figure 13. Verilog algorithm for Anti-windup.

4.5 PWM

As we saw in figure 6, a PWM signal is going to be
associated to the controller, so the duty cycle of the
signal will change according to the value of m(k) that is
the result of the PID equation.

Before writing an algorithm for a PWM signal, its
necessary to think on how it works for an analog PMW
circuit, a voltage comparator between a DC voltage level
and a ramp wave, as we can see in the figure 14. [10]


Figure 14. Voltage comparator.

Using that concept, an algorithm is written with a
counter as a ramp wave, and the DC level will be the
output of the control equation, giving as result a PWM.


Figure 15. PWM algorithm.

4.6 ROTATION

The rotation is given by the signal bit coming from
the error acquisition, depending of this value the PWM
signal will be assigned to one of the two controls pins of
the H Bridge. A hysteresis is added when the error is
close to cero in order to avoid oscillations.


Figure 16. Rotation algorithm.

5 IMPLEMENTATION

On this stage we will present a test of the algorithm
performance using labview and RS232 communication
for send the data to the pc. Due that the importance of
this document its to present the controller, we are not
going to focus in the RS232 algorithm that is also
embedded in the FPGA. Another document will present
the steps of how to use and program a serial-USB
converter FT232.

5.1 TEST 1

Parameters:
Input: Step
Set Point: 180
Kp=5
Ki=0
Kd=0

In figure 17 we can see a higher position error,
when Ki is 0, and Kp is very low.


Figure 17. Response of test 1.

5.2 TEST 2

Parameters:
Input: Step
Set Point: 180
Kp=10
Ki=0
Kd=0

When we raise Kp, we get closer to the desired
value (180), also the controller is faster, but is not the
set point reached yet, is shown in figure 18.


Figure 18. Response of test 2.

Advanced Digital Technologies Universidad Pontificia Bolivariana October 2011

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5.3 TEST 3

Parameters:
Input: Step
Set Point: 180
Kp=5
Ki=3
Kd=0

Now we decrease Kp to 5 again, but this time Kp
have a different value than 0. In figure 19 we can see
that the response tents to reach the set point value
slowly but with a small amount of overshoot (less than
5%).


Figure 19. Response of test 3.

5.4 TEST 4

Parameters:
Input: Step
Set Point: 180
Kp=10
Ki=3
Kd=0

Increasing the Kp value will make the response
faster, but also will increment the overshoot, as shown in
figure 20.


Figure 20. Response of test 4.

5.5 TEST 5

Parameters:
Input: Step
Set Point: 180
Kp=10
Ki=17
Kd=0

In this case we can see that increasing the Ki value
to high, will make oscillate the system before stabilize,
figure 21 is the result of the test 5.



Figure 21. Response of test 5.

6 ASSEMBLY IMAGES


Figure 22. Complete project.


Advanced Digital Technologies Universidad Pontificia Bolivariana October 2011

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Figure 23. LCD with Current Variable, Set-Point,
Proportional Gain, Integral Gain and Derivative Gain
values.


Figure 24. Serial-USB converter.

7 CONCLUSION

In this project we saw that is viable the
implementation of a PID controller in a FPGA, and the
modular design allow us to think and resolve one
problem at once.

Trough the test made to the controller we manage
to saw the behavior of the controlled variable when we
change the values of the proportional an integral gains,
as we saw, the proportional gain will give more speed to
the controller but it also can increase the overshoot
percent, in other way the integral gain can give a more
accurate response getting closer to the set-point.

There were also a test changing the derivative gain,
however the response was always saturated because of
the noise derived, so still pending the implementation of
an additional filter to solve this problem.



8 REFERENCES

[1] Allen Houng. Interfacing a DC Motor with an FPGA. Terasic
Technologies. Aug 10 , 2011
[2] Terasic Technologies. DE0-Nano Board. DE0-Nano
Development and Education Board [Online]. Available:
http://www.terasic.com.tw/cgi-
bin/page/archive.pl?Language=English&CategoryNo=165&
No=593&PartNo=1
[3] Gearmotor, [Online]. Available:
http://www.dynamoelectronics.com/components/com_virtue
mart/shop_image/product/Motoreductor_18K_4c73f49babdc
a.png
[4] LCD monochromatic display, [Online]. Available
http://www.dynamoelectronics.com/components/com_virtue
mart/shop_image/product/04-03-
02%20LCD%2016x2%20verde.jpg
[5] SGS-Thomson Microelectronics. L293D Datasheet. [Online].
Available: www.datasheetcatalog.com
[6] FTDI. FT232RL. Datasheet. [Online]. Available:
http://www.ftdichip.com/Support/Documents/DataSheets/ICs
/DS_FT232R.pdf
[7] Jean P. Nicolle. Quadrature Decoder. Feb. 13 2008.
[Online]. Available:
http://www.fpga4fun.com/QuadratureDecoder.html
[8] Twos Complement Numbers [Online]. Available:
http://www.vb-helper.com/tutorial_twos_complement.html
[9] Antonio Visioli. Practical PID control. Springer-Verlag
London Limited 2006
[10] BUSO, Simone y MATTAVELLI, PAOLO. Digital Control in
Power Electronics. Morgan & Claypool, 2006, pp. 13-31.


Links:
Video:
http://www.youtube.com/watch?v=tVvWEDh8Xc
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