Mahirut Power Electronics Solutions
Comprehensive Power Electronics Solutions
Rapid Control Prototyping (RCP) with FPGA
Problem Statement
As control systems evolve to become faster, smarter, and more application-specific, traditional development methods struggle with:
- Long Development Cycles
- Early-Stage Validation Issues
- Processor Limitations
- Low Flexibility
- Integration Risks
- Poor Scalability
Solution Summary
Mahirut’s Rapid Control Prototyping (RCP) Solutions using FPGA platforms enable engineers to test and validate control algorithms in real time—on hardware that mimics the final system environment. Our solution leverages the high-speed, parallel-processing power of FPGAs to emulate embedded systems with sub-microsecond precision. Whether you’re developing motor drives, converters, autonomous systems, or grid interfaces—Mahirut helps you test early, iterate fast, and deploy with confidence.
- Long Development Cycles: Time-consuming transition from simulation to real hardware delays deployment
- Early-Stage Validation Issues: Limited ability to test control logic effectively during initial design phases
- Processor Limitations: Generic processors often lack the speed needed for high-performance applications
- Low Flexibility: Difficult to adapt and test custom algorithms across varied use cases
- Integration Risks: Inadequate testing leads to failures during final hardware integration
- Poor Scalability: Challenges in scaling solutions across different system configurations and iterations
Benefits
- Real-Time Execution: Low-latency control loops deliver high-speed performance, ideal for fast-switching power & control systems.
- Hardware-in-the-Loop Prototyping: Run real-world tests using actual sensors, actuators, and loads to validate control logic under live conditions
- Flexible Logic Reconfiguration:Easily adapt to changing requirements with reprogrammable hardware and modular interface support.
- Early Error Detection & Tuning:Identify issues, optimize behavior, and refine performance before committing to ASIC or PCB fabrication.
- Model-Based Design Integration:Works natively with MATLAB, Simulink, and HDL tools, ensuring smooth co-design and verification.
- Faster Product Development:Eliminate repeated hardware cycles and accelerate time-to-market with early-stage system validation.
Our Approach
How it Works
-
Model the Control Algorithm
- Design your control strategy in Simulink, HDL, or other supported environments.
-
Deploy to FPGA Board
- Use Mahirut’s supported platforms (e.g., Xilinx Zynq, Intel/Altera) to generate bitstreams and deploy logic.
-
Connect to Physical Systems
- Interface with sensors, actuators, power electronics, or test rigs using analog/digital I/O and serial protocols.
-
Run Real-Time Tests
- Execute control loops at microsecond resolution—observe timing, latency, and response dynamics.
-
Tune and Debug
- Use external host tools or onboard diagnostics to fine-tune parameters and monitor live performance.
-
Iterate and Optimize
- Make fast changes to logic, parameters, and architectures without full hardware redesign.
Key Features
Electric Vehicles & Motor Drives
Implement FOC, DTC, or sensorless control for PMSM, BLDC, or SRM motors.
Power Converters
Prototyping of high-speed DC-DC, DC-AC, or multilevel inverters.
Robotics & Automation
High-precision motion control, joint coordination, and real-time feedback loops.
Industrial Control Systems
PID, cascaded loops, and state machines for manufacturing and process control.
Aerospace & Defense
Custom guidance, navigation, and power systems validation in real-world scenarios.
Smart Grids & Energy Systems
Real-time control of converters, FACTS, energy storage interfaces, and microgrid systems.
Hardware-in-the-Loop (HIL) Simulation Solutions
Problem Statement
As embedded systems grow more complex and safety-critical, traditional tests fail to capture real-world performance. Simulating software without hardware poses risks—especially in automotive, aerospace, power, and control engineering. Engineers need real-time testing that integrates virtual models and physical components to validate systems before deployment.
Solution Summary
Mahirut’s Hardware-in-the-Loop (HIL) Simulation Solutions provide a safe, scalable, and precise platform for real-time validation of embedded control systems. Our HIL environments connect simulated models of the plant (mechanical, electrical, or fluid systems) with the actual control hardware under test. This closed-loop simulation enables engineers to evaluate how real controllers behave in real-time—without risking physical assets—dramatically improving development speed, reliability, and safety.
Benefits
- Real-Time System Validation: Validates embedded controllers with low-latency, high-fidelity plant models.
- Safe Fault Simulation: Tests fault and edge conditions without risking hardware damage.
- Accelerated Test Cycles: Detects bugs early and reduces dependency on physical prototypes.
- Versatile Interface Support: Supports CAN, LIN, SPI, PWM, Ethernet, and analog/digital I/O protocols.
- Reliable Test Automation: Enables repeatable, traceable regression testing with consistent inputs.
- Proven Industry Workflows: Trusted in automotive, aerospace, energy, and power electronics domains.
Our Approach
How it Works
-
Model the Plant
- Create a high-fidelity real-time simulation model of the target physical system (motor, inverter, grid, vehicle, etc.).
-
Connect the Controller
- Interface real hardware (ECU, DSP, FPGA, PLC) to the simulator via I/O boards and communication buses.
-
Close the Loop
- Allow the controller to interact with the simulated environment in real time—processing feedback and issuing control actions.
-
Inject Faults and Scenarios
- Simulate failures, disturbances, or boundary conditions to test system robustness.
-
Log, Analyze, and Validate
- Record outputs, analyze timing behavior, and compare against expected performance.
-
Iterate and Optimize
- Modify control logic, re-test rapidly, and prepare for deployment with confidence.
Key Features
Automotive
ECU testing, ADAS development, EV motor drive simulation, battery management systems.
Power Electronics
Inverter control, grid-connected converters, protection systems.
Energy & Renewables
Microgrid simulation, solar and wind integration, smart inverters.
Aerospace & Defense
Flight control systems, navigation and avionics validation.
Industrial Automation
PLC testing, robotic arm controllers, motion drive validation.
R&D and Academia
Research labs and engineering institutes for real-time simulation and prototyping.
Rapid Control Prototyping (RCP) with DSP
Problem Statement
As control systems become smarter and more application-specific, traditional development cycles struggle to keep pace. Engineers often build control algorithms in simulation but face challenges when migrating to embedded targets—especially under real-time constraints. Debugging on the final hardware is time-consuming and error-prone, delaying project timelines. There’s a critical need for a fast, hardware-based approach to test and tune algorithms early—without compromising precision, performance, or safety.
Solution Summary
Mahirut’s DSP-Based Rapid Control Prototyping (RCP) Solutions offer a real-time hardware platform for fast testing and refinement of control algorithms. Using powerful DSPs such as TI C2000, Analog Devices Blackfin, or ARM Cortex-M processors, engineers can validate code with the actual timing and constraints of their final product. Our DSP RCP platform is ideal for motor control, digital power, industrial automation, and embedded systems—where loop precision, deterministic execution, and real-time tuning are non-negotiable
Benefits
- Real-Time Performance: DSPs ensure deterministic control with ultra-low latency for fast current and voltage loops.
- Hardware-Accurate Testing: Run control algorithms on the same processor class used in the final product to maintain timing fidelity.
- Live Parameter Tuning: Adjust gains and settings on-the-fly via GUI or serial interface—no recompilation required.
- Rapid Prototyping: Transition quickly from simulation to hardware, minimizing debug and integration time.
- Comprehensive I/O Support: Includes ADC, PWM, UART, CAN, I²C, SPI, and more for flexible system integration.
- Tailored for Control Applications: Optimized for real-time motor drives, power converters, sensor interfacing, and embedded DSP tasks.
Our Approach
How it Works
-
Develop the Control Algorithm
- Model your control logic in Simulink, Code Composer Studio, or any supported environment.
-
Deploy to DSP Platform
- Use JTAG or serial flashing to run the control code on your target DSP (e.g., TI C2000 LaunchPad).
-
Interface With Hardware
- Connect your DSP to real sensors, actuators, or power stages through analog and digital I/O.
-
Tune and Debug
- Adjust gains, filter constants, or limits via serial interfaces, real-time data logs, or tuning GUIs.
-
Capture Real-Time Data
- Monitor system behavior, loop timing, response dynamics, and overcurrent/overvoltage protection.
-
Finalize for Deployment
- Once validated, transition seamlessly to production hardware with minimal code changes.
Key Features
Motor Control & Drives
Test vector control (FOC), BLDC/SRM drives, and real-time torque-speed loops.
Digital Power Control
DC-DC converters, resonant topologies, and grid-tied inverter prototyping.
Industrial Automation
Embedded control of actuators, servo systems, and process loops with real-time constraints.
Aerospace & Defense Systems
Flight control surface actuation, real-time telemetry, and adaptive filtering.
Smart Energy Devices
Digital PFC, renewable energy MPPT algorithms, and battery management systems.
Mechatronics & Embedded Systems
Feedback-intensive systems such as robotics, gimbals, and embedded sensors.
