Description
System Architecture & Operational Principle
The MOTOROLA MVME5100 is a 6U VMEbus single board computer (SBC) designed for industrial and embedded applications requiring reliable real-time processing. It serves as the computational core in VME-based systems, interfacing with field devices (sensors, actuators) and external networks (SCADA, DCS) via a combination of VME64 backplane communication and high-speed I/O ports.
Core Functional Blocks
The SBC is composed of four primary functional blocks, each optimized for industrial/embedded use:
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Processing Unit:
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CPU: PowerPC MPC7400/7410 (with AltiVec technology for vector processing) or MPC750/755 processor, featuring 32 KB L1 instruction cache, 32 KB L1 data cache, and up to 2 MB backside L2 cache for improved data processing speed.
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Memory: On-board ECC SDRAM (64 MB–512 MB standard, expandable to 1 GB via optional RAM500 mezzanine) for reliable data storage, plus up to 17 MB Flash memory (1 MB socketed + 16 MB surface-mount) for firmware and application storage.
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Bus Interface:
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VME64: Compliant with VME64 standards, supporting A16/A24/A32 addressing and D8/D16/D32 data widths for seamless connectivity with VME-based I/O and system controllers.
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PCI: 64-bit PCI mezzanine connector enabling further expansion with PMC modules (e.g., I/O, communication, video).
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I/O Subsystem:
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Ethernet: Dual 10BaseT/100BaseTX Ethernet ports for high-speed network connectivity, supporting redundant or segmented networks.
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Serial: Dual 16550-compatible async serial ports (RS-232 typical) for console/modem/device communication.
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PMC Expansion: Dual 32/64-bit IEEE P1386.1-compliant PMC slots for adding specialized functionality (e.g., A/D conversion, communication cards).
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Power & Cooling:
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Power Consumption: Operates on VME standard power supplies (+5V DC, ±12V DC), with typical power consumption varying by processor and configuration.
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Cooling: Forced-air cooling recommended for reliable operation in harsh environments (-40°C to +85°C).
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Operational Workflow
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Power-Up: The SBC draws power from the VME backplane and initializes the firmware (stored in Flash memory).
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Boot Process: The firmware configures the PowerPC processor, memory, and I/O interfaces, then boots the operating system (e.g., VxWorks, Linux).
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Task Execution: The PowerPC processor executes real-time control programs (e.g., signal processing, PID loops) and communicates with field devices via VME64 or Ethernet.
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Data Transfer: High-speed data transfer between the SBC and VME backplane, while the Ethernet ports handle network communication (e.g., uploading data to SCADA systems).
Motorola MVME5100
Core Technical Specifications
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Parameter
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Specification
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Processor
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PowerPC MPC7400/7410 (AltiVec) or MPC750/755; 266 MHz–450 MHz
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Cache
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32 KB L1 I-cache/32 KB L1 D-cache; up to 2 MB backside L2 cache
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Memory
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Up to 1 GB ECC SDRAM (expandable via RAM500 mezzanine); 17 MB Flash memory
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VMEbus Interface
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VME64-compliant, A16/A24/A32 addressing, D8/D16/D32 data widths
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I/O Ports
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Dual 10/100BaseTX Ethernet, 2x RS-232 serial, dual PMC slots
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Expansion
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64-bit PCI mezzanine connector (for additional PMCs)
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Operating Temperature
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-40°C to +85°C (extended industrial range)
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Power Supply
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VME standard (+5V DC, ±12V DC)
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Form Factor
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6U VME (single slot)
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Certifications
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CE, UL, MIL-STD-810F (vibration/shock)
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Customer Value & Operational Benefits
1. Reliable Real-Time Processing
The PowerPC processor and ECC SDRAM enable the MVME5100 to handle complex control algorithms (e.g., PID loops, motion control) and large datasets (e.g., from 100+ I/O channels). This is critical for applications like industrial automation (robotic control) and energy (turbine control).
2. Rugged Durability for Harsh Environments
The -40°C to +85°C operating temperature range and forced-air cooling make the SBC suitable for:
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Aerospace: Avionics systems (e.g., flight control computers).
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Defense: Naval sonar processing, armored vehicle control.
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Industrial: Oil & gas refineries, power generation (turbine control).
3. Flexible Expansion for Custom Applications
The dual PMC slots and 64-bit PCI mezzanine connector allow users to add custom functionality (e.g., A/D conversion modules for sensor data acquisition, communication cards for legacy device integration) without modifying the core SBC. This flexibility is ideal for prototype development and system upgrades.
4. Legacy System Compatibility
The MVME5100 maintains pin-level and software continuity with older MVME series modules, enabling phased modernization projects without requiring a total system overhaul. Engineers can port proven real-time code or OS images with minimal modification, preserving certification and validation cycles.
Motorola MVME5100
Field Engineer’s Notes (From the Trenches)
When installing the MVME5100, always verify the VME backplane voltage (+5V DC, ±12V DC) with a multimeter before powering up—incorrect voltage can damage the SBC. I once saw a technician fry a board because he used a non-regulated power supply.Check the PMC slot alignment before inserting expansion cards—misalignment can damage the slot pins. Use the guide rails on the chassis to ensure proper alignment.Test the Ethernet ports (ping the device’s IP address) after installation—use a crossover cable if connecting directly to a laptop. I’ve spent hours troubleshooting “no comms” faults only to find a bad Ethernet cable.
Real-World Applications
1. Industrial Automation: Robotic Assembly Lines
A automotive manufacturer uses the MVME5100 as the core of its robotic assembly line control system. The SBC’s PowerPC processor executes PID loops to adjust robot arm movements, while the PMC slots add A/D conversion modules for sensor data acquisition. The -40°C to +85°C operating range ensures reliable operation in the factory floor environment.
2. Aerospace: Flight Simulation Systems
A defense contractor uses the MVME5100 to power flight simulation systems for pilot training. The SBC’s VME64 interface connects to flight sensors (e.g., accelerometers, gyroscopes), while the Ethernet port streams data to the simulation software. The forced-air cooling ensures reliable operation during extended training sessions.
