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<p>This paper presents hardware and circuit-level enhancements to the programmable logic controller (PLC)-based control system for 51 high-power pulse modulators at the Pohang Accelerator Laboratory X-ray Free Electron Laser (PAL-XFEL) facility. The system addresses two critical operational challenges: severe electromagnetic interference (EMI) from thyratron switching and stringent dynamic interlock response-time requirements in a 60 Hz environment. An Analog Signal Filter Module (ASFM) was developed to convert noisy analog signals (beam voltage, beam current, and end-of-line clipper current) into stable DC outputs via multi-point sampling. The entire signal processing cycle is completed within approximately 11&#xa0;µs. To meet the critical interlock response requirement of less than 2&#xa0;ms, conventional mechanical relay modules were replaced with custom high-speed optical converter boards employing TLP620 photocouplers, and analog-to-digital conversion timing was optimized. These modifications reduced the total interlock response time from 15.4&#xa0;ms to approximately 1.7&#xa0;ms, ensuring rapid shutdown of the capacitor-charging power supply upon fault detection. The integrated solution improves operational reliability, stability, and safety while providing a cost-effective alternative to standalone high-speed interlock hardware. However, the system’s performance is currently validated primarily under 60&#xa0;Hz operation; scalability to higher repetition rates and the long-term reliability of the optical components under continuous EMI exposure remain limitations that require future investigation.</p>

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High-speed dynamic interlock and noise-resilient signal conditioning for PLC-based pulse modulators at PAL-XFEL

  • 期刊论文

  • 发表日期：

    2026年6月19日

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  • Sang-Hee Kim,
  • Chang-Ki Min,
  • Jaeyu Lee

摘要

This paper presents hardware and circuit-level enhancements to the programmable logic controller (PLC)-based control system for 51 high-power pulse modulators at the Pohang Accelerator Laboratory X-ray Free Electron Laser (PAL-XFEL) facility. The system addresses two critical operational challenges: severe electromagnetic interference (EMI) from thyratron switching and stringent dynamic interlock response-time requirements in a 60 Hz environment. An Analog Signal Filter Module (ASFM) was developed to convert noisy analog signals (beam voltage, beam current, and end-of-line clipper current) into stable DC outputs via multi-point sampling. The entire signal processing cycle is completed within approximately 11 µs. To meet the critical interlock response requirement of less than 2 ms, conventional mechanical relay modules were replaced with custom high-speed optical converter boards employing TLP620 photocouplers, and analog-to-digital conversion timing was optimized. These modifications reduced the total interlock response time from 15.4 ms to approximately 1.7 ms, ensuring rapid shutdown of the capacitor-charging power supply upon fault detection. The integrated solution improves operational reliability, stability, and safety while providing a cost-effective alternative to standalone high-speed interlock hardware. However, the system’s performance is currently validated primarily under 60 Hz operation; scalability to higher repetition rates and the long-term reliability of the optical components under continuous EMI exposure remain limitations that require future investigation.