Adaptive Mixed Signal Circuit Design for Real Time Process Control in Industrial Applications

This paper presents an adaptive mixed-signal circuit architecture for real-time industrial process control, implemented as a three-board system. The system is built around three interconnected boards. The Control Module (CM) board, powered by a Sigmastar SSD202D SoC with an ARM Cortex-A7 dual-core processor, serves as the master control unit for adaptive algorithms and communications. The Pasta Machine Current Monitor (PMCM) board provides precise motor current measurements via specialized connectors, while the Pasta Machine Control System (PMCS) board, acting as the slave unit, handles analog signal conditioning and digitization of sensor inputs. In the considered application, the designed boards monitor key operational parameters of the pasta machine - including cutter frequency, temperature, press frequency, and motor current - and dynamically adjust control outputs based on real-time sensor feedback. Experimental validation using a dedicated test bench demonstrates a signal-to-noise ratio (SNR) improvement of 15 dB and an adaptive response time of approximately 360 ms from disturbance to corrective output, with process deviations maintained below 5% of target values. These results underscore the system's robustness and scalability for Industry 4.0 (the fourth industrial revolution) applications in harsh industrial environments.