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QNX and ForceControl 6.0 High-Voltage Pulse Power Supply Monitoring

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QNX ForceControl 6.0 High-Voltage Pulse Power Supply Real-Time Control EAST Tokamak Optical Fiber Communication Hybrid Control System NBI Heating Embedded Systems

QNX and ForceControl 6.0 High-Voltage Pulse Power Supply Monitoring

This paper details the design of a high-voltage pulse power supply monitoring system for the EAST tokamak neutral beam injection (NBI) heating system. The system manages a 100 kV / 100 A pulse power supply using 104 series-connected 1.1 kV / 100 A modules with Pulse Step Modulation (PSM) technology. A hybrid real-time control and supervisory system was implemented using QNX and ForceControl 6.0, ensuring fast turn-on (<20 µs), turn-off (<5 µs), and safe operation under high voltage, with optical fiber communication for isolation and reliability.

🔧 System Overview
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The system integrates:

  • QNX (Field & Remote PCs) for deterministic real-time control.
  • ForceControl 6.0 (Monitoring PC) for HMI and supervisory functions.
  • Optical fiber communication to electrically isolate high-voltage pulse modules.
  • DSP + CPLD boards in each module for fast IGBT/thyristor switching and local control.

Simulation and testing with 15 pulse modules validated system performance and real-time reliability.

🏗 System Architecture
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Hardware Structure
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  • Remote Control PC (QNX): Sets voltage waveforms, collects feedback.
  • Field Control PC (QNX): Executes core real-time control, module switching computation, feedback loops, and protection mechanisms.
  • Monitoring PC (Windows + ForceControl 6.0): Supervisory visualization, status monitoring, fault handling via optical fiber TCP/IP.
  • High-speed I/O cards (A/D MIC-3714, D/I-O CPCI-7249) for precise data acquisition.
  • DSP + CPLD boards in each module for fast switching control.

Software Design
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Real-Time Control (QNX)
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  • Receives preset waveform from Remote PC.
  • Computes module turn-on counts per time step.
  • Outputs control signals via digital I/O cards.
  • Implements closed-loop feedback and fast over-current protection (>180 A cutoff).
  • Ensures synchronized pulse sequence across all modules.

Supervisory Monitoring (ForceControl 6.0)
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  • Monitors 8 digital and 3 analog signals per module.
  • Displays module status, voltage/current trends, and alarms.
  • Supports manual control and fault handling.
  • Optical fiber TCP/IP ensures low-latency, safe communication with 15 power modules.

⚡ Simulation and Testing
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  • Sequential and simultaneous turn-on/off of 15 modules demonstrated precise timing.
  • Turn-off delay from IGBT command to voltage zero ≈ 3 µs, meeting <5 µs specification.
  • Minor overshoot observed due to module differences, within acceptable limits.
  • High-voltage probe and oscilloscope confirmed accuracy of voltage steps and synchronization.

🏁 Conclusion
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The QNX + ForceControl 6.0 hybrid system achieves:

  • Deterministic real-time control of 100 kV / 100 A pulse modules.
  • Safe, synchronized operation across multiple modules.
  • Comprehensive monitoring, fast protection, and optical isolation.
  • Scalability for future NBI system upgrades.

Innovation Highlights:

  • Hybrid QNX real-time control with ForceControl supervisory monitoring.
  • Optical fiber isolation for high-voltage safety.
  • High-speed IGBT module control with synchronized sequencing.

🔮 Modern Perspective (2026)
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Upgrades could include:

  • QNX SDP 8.x for enhanced multi-core and safety-certified profiles.
  • EtherCAT / TSN for tighter fieldbus synchronization.
  • Modern web-based SCADA HMIs or Ignition integration.
  • Containerized RTPs with enhanced trace and core dump tools for maintainability.

This architecture provides a robust, safe, and high-performance solution for EAST tokamak NBI pulse power systems.

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