Publicação
Retrofitting industrial robotics: an embedded system approach to controller enhancement
| Resumo: | The increase in productivity and efficiency caused by the presence of robots in industries and in automation processes, whether they are mobile robots or manipulator robots, encourages research and makes the area of robotics widely studied in academic scope around the world. The development methodology began with a study of the functioning of the internal modules of the original FANUC RJ Controller model, including the main controllers, circuits responsible for driving the motors and emergency systems, in order to assess which modules could be reused in the new architecture proposed for the controller. As a result, in addition to the robot’s mechanical unit, the FANUC Servo Amplifiers, the EMG Board, the Power Supply Unit, the Dynamic Brake Unit and the Main AC Power Distribution were reused in the development of the proposed controller, and a detailed study of these components was carried out. The proposed controller architecture includes the modularization of the motor position controllers, where the Dual Axis Control Board was developed, a system capable of controlling two PMSM motors via the FANUC Servo Amplifier, requiring three groups of these systems to control the robot’s six motors. To calculate the kinematics and trajectory, an ESP32-S3 was used, which receives the user’s commands, calculates the trajectory and angles of each joint of the robot and sends the angular references so that the motor controllers can act to move the robot. To integrate the systems, the Main Board Controller was developed, responsible for ensuring communication between the ESP32-S3 and the Dual Axis Control Boards, as well as providing auxiliary circuits for the emergency signals sent and received from the EMG Board. In order to improve interaction with the user and visualization of the trajectories executed by the robot, a graphical interface was developed capable of receiving positioning com- mands from the user using its own programming language and displaying the robot’s positioning using a 3D model of the FANUC S-420FD developed and incorporated into the system. Tests and validations carried out with the circuits developed showed that the signal processing and conditioning achieved the expected results, proving that the PCBs work. The algorithms developed to perform the kinematics and trajectory calcula- tions were also validated, with high accuracy and processing times in line with the rest of the system. It can therefore be concluded that the results presented make it possible to achieve the objectives initially proposed. |
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| Autores principais: | Grilo, Vinicius F.S.B. |
| Assunto: | Controller Industrial robot Kinematics Trajectory control Graphical user interface |
| Ano: | 2024 |
| País: | Portugal |
| Tipo de documento: | dissertação de mestrado |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Instituto Politécnico de Bragança |
| Idioma: | inglês |
| Origem: | Biblioteca Digital do IPB |
| Resumo: | The increase in productivity and efficiency caused by the presence of robots in industries and in automation processes, whether they are mobile robots or manipulator robots, encourages research and makes the area of robotics widely studied in academic scope around the world. The development methodology began with a study of the functioning of the internal modules of the original FANUC RJ Controller model, including the main controllers, circuits responsible for driving the motors and emergency systems, in order to assess which modules could be reused in the new architecture proposed for the controller. As a result, in addition to the robot’s mechanical unit, the FANUC Servo Amplifiers, the EMG Board, the Power Supply Unit, the Dynamic Brake Unit and the Main AC Power Distribution were reused in the development of the proposed controller, and a detailed study of these components was carried out. The proposed controller architecture includes the modularization of the motor position controllers, where the Dual Axis Control Board was developed, a system capable of controlling two PMSM motors via the FANUC Servo Amplifier, requiring three groups of these systems to control the robot’s six motors. To calculate the kinematics and trajectory, an ESP32-S3 was used, which receives the user’s commands, calculates the trajectory and angles of each joint of the robot and sends the angular references so that the motor controllers can act to move the robot. To integrate the systems, the Main Board Controller was developed, responsible for ensuring communication between the ESP32-S3 and the Dual Axis Control Boards, as well as providing auxiliary circuits for the emergency signals sent and received from the EMG Board. In order to improve interaction with the user and visualization of the trajectories executed by the robot, a graphical interface was developed capable of receiving positioning com- mands from the user using its own programming language and displaying the robot’s positioning using a 3D model of the FANUC S-420FD developed and incorporated into the system. Tests and validations carried out with the circuits developed showed that the signal processing and conditioning achieved the expected results, proving that the PCBs work. The algorithms developed to perform the kinematics and trajectory calcula- tions were also validated, with high accuracy and processing times in line with the rest of the system. It can therefore be concluded that the results presented make it possible to achieve the objectives initially proposed. |
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