- Date: 2011
- Owned and developed by: CISIUM, Inc.
- Customers: Industrial companies
- Creators: Raúl Bartolomé and team
- Raúl’s contribution: Project manager, engineering manager, chief engineer, and senior engineer for electronic design and firmware development
- Market: Industrial automation
- Product category: Control electronics / PCBA
In 2011, Raúl Bartolomé and CISIUM, Inc. developed a replacement control board for the Haruchika HP-043 lens polishing machine, an industrial system that had become obsolete and unsupported by its manufacturer. The goal was to revive damaged machines by designing a modern, reprogrammable controller that replicated the behavior of the original system while using state-of-the-art components.
Challenge
The original automation was based on analog and digital discrete components, many of which were obsolete and difficult to source. Standard solutions such as PLCs were rejected due to space constraints, and simple PCB reverse engineering was not feasible. Instead, CISIUM created a new control system from scratch, implementing the original functionality with modern technology.
Solution — CPLD-Based Design
The new control board was designed around the Xilinx CoolRunner-II CPLD XC2C64A, enabling flexible and reprogrammable control logic. This architecture allowed smooth reconfiguration without hardware changes, ensuring long-term serviceability.
Key design elements included:
- VHDL programming with a state-machine approach, simulated in ISE WebPACK for accurate system modeling and integration
- 12V tolerant inputs with hysteresis and filtering, preserving robust noise immunity comparable to the original machine
- Comparator-based input stage using LM2901 low-power quad comparators for stability and noise rejection
- Output drivers upgraded with BDX53B Darlington power transistors for higher current gain and improved robustness
Technical Highlights
- CPLD optimized for 1.8V systems, with low power consumption and fast pin-to-pin delays
- Full IEEE 1532 JTAG programming and IEEE 1149.1 boundary scan for testing
- Multi-voltage I/O operation (1.5V–3.3V) for flexible system integration
- Enhanced input robustness with 5V noise immunity and 1V hysteresis
- High-current, low-saturation transistor outputs suitable for industrial loads
Raúl’s Contribution
As project manager and chief engineer, Raúl led the design and implementation of the new control system, from architecture definition to firmware and hardware validation. He combined leadership with hands-on engineering, ensuring the solution was both technically advanced and practical for industrial deployment.
Legacy
The project extended the lifespan of critical manufacturing equipment, demonstrating CISIUM’s ability to modernize obsolete systems with innovative, cost-effective solutions. By replacing a fixed, hardwired control board with a flexible, programmable system, Raúl and his team provided industrial clients with a reliable path forward — keeping equipment in service and improving maintainability.
