Interfacing Motors of PUMA 560 Robot with a PC
Contents
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4. Encoder Reading Yes Yes Speed Calculation Yes Yes Home Calibration Yes Yes Position Error 0 80 4 DESIGN APPROACH AND DETAILS 4 1 Design Approach Hardware Much time was spent on discovering the pinout diagrams for various parts in the robot and the control system All the information collected on the pinout diagrams has been summarized in Appendix C Figure 2 shows the wiring diagram for one axis system with detailed connections The wiring diagram shown in Figure 2 and the switch settings in Table C4 of Appendix C allows the controller to implement the control loop and sends the appropriate command input signals which will be discussed further in the software section Yellow PUMA ECE4007L01 10 Motor Driver Controller GND GND 5V wyo fo fu 5 M1 37 7 D1 10 12 M1 32 Note Shared ground for Analog Input Digital Grounds for Motion and Digital connectors Note Only Motors 1 3 have brake rated at 24V Note Use digital port for Index Encoder instead of designated Index Encoder pin Please refer to Software section for the reason Note Arrows indicate direction from output to input Note Enable and Fault pins from the motor driver were not connected in this phase to simplify wiring Note M1 denotes Motion I O Connector for Axis 1 4 and D1 denotes Digital I O Connector for Axes 1 4 Figure 2 Sample wiring for one axis Yellow PUMA
5. Vaux 5V With opto isolation enabled it is necessary to provide Ground and 5 V to J1 9 and J1 10 in addition to the 24 V powering the motor driver The enable pin J1 7 has to be pulled to the AUX Ground for the motor driver to start The Enable pin was hard wired into the Aux GND J1 9 and the Fault pin J1 8 was not connected However it is possible to control these two pins through the digital ports on the controller Yellow PUMA ECE4007L01 41 Controller Pinout The motors and motor drivers cannot be connected to the controller directly as breakout boxes are required to secure the connection There are four 68 pin VHDCI Very High Density Cable Interconnect connectors in the back of the NI PCI 7356 Four 68 pin breakout boxes were purchased as well as four male to male connectors Figure C3 gives a sample picture of the breakout box used Figure C3 Breakout box for the NI PCI 7356 Since there are a total of 272 pins coming out from the controller it is suggested to look at the datasheet for NI PCI 7356 5 Note that the pins for Axis 7 and Axis 8 are not available for this 6 axis controller Yellow PUMA ECE4007L01 42 APPENDIX D FINAL DEMO VI The FinalDemo vi is the main VI that needs to be opened using LabVIEW to run the software The purpose of the VI is to be able to read the encoder signals and the potentiometer signal from the motor control the rotation of the m
6. the while loop and stop the motor vj pi d 276 70 i OK Button Figure D4 Block diagram of manual run mode The auto run mode does the following tasks e The go button labeled as OK button in the block diagram blinks and disables the stop button e Calls the RampFinal VI once the go button is pressed For this purpose the event structure is used e Enables the stop button once the motion is completed Yellow PUMA ECE4007L01 48 Boolean Figure D5 Block diagram of the auto run mode Encoder and Pot Reading Loop The purpose of the encoder and pot reading loop section is to read and display the encoder position and the analog input signal from the potentiometer The block diagram of this section is shown in Figure D6 In order to graphically display the encoder position in terms of degrees the following calculation is performed CurrentPositionInDegrees Mod EncPos 1000 1000 360 Yellow PUMA ECE4007L01 49 Revolutions Encoder Position Figure D6 Block diagram of the encoder and pot reading section Speed Calculation Loop The purpose of the speed calculation loop is to calculate the speed of the rotation in RPM The block diagram of the speed calculation loop is shown in Figure D7 The speed calculation loop has a delay of 0 5 second between each loop run The time delay is to allow more encoder ticks over a longer period of time thus creating an averaging effect and make
7. with a Rockwell Automation motion control system However the project s motion control system was changed from Rockwell Automation to National Instruments due to the unavailability of the CompactLogix L45 in a timely manner Table 4 displays the proposed versus actual software specifications Yellow PUMA ECE4007L01 8 Table 4 Proposed vs Actual Software Specifications Proposed Actual Motion Controller Rockwell CompactLogix L45 NI PCI 7356 Programming Language Rockwell RSLogix5000 NI LabView 8 5 Driver Built in NI Motion 7 6 The software was intended to be able to read and display potentiometer and encoder signals from the six motors to the user and to control the analog output voltage signal for the six motors using the NI PCI 7356 card The software was also able to find and set the encoder index position as the motor home position calculate the speed of rotation and receive position input command in number of revolutions However the current software can control only one axis and the position command has an offset error of 80 Table 5 displays a list of the proposed software objectives and compares it to the actual specifications that were achieved Yellow PUMA ECE4007L01 Table 5 Proposed vs Actual Software Objectives Proposed Actual Number of Axes Controlled 6 1 Analog Input Reading POT Yes Yes Analog Output Control Yes Yes
8. 6 Gain Limit Select bit 1 Down The opto isolation is enabled to protect the PCI controller card in the case of an over current flow or a short circuit The motor driver was run in current mode because in voltage mode the amplification gain is fixed at 14 which translates a 10 V command signal to 140 V Furthermore the lowest current mode gain which is 0 2 was chosen to protect the motor from over current condition during bench testing Table C5 shows the setting for the Gain Limit Select bits Table C5 TA115 Gain and Current Limit Setting S1 5 bit0 51 6 bit D jus Gain nd Down Down 0 2 2 Up Down 0 4 4A Down Up 0 6 vee p Up 0 8 SA Yellow PUMA ECE4007L01 40 In current mode the gain limit select bits control the gain and in voltage mode the bits only control the maximum output current Even with the lowest setting the maximum output current is over the rated current for the small motors The pinout for the connectors is also necessary to complete the wiring Table C6 shows the information about each pin on the connectors Table C6 TA115 Motor Driver Pinout Connector J1 Connector J2 Pin Description Pin Description 1 Command Signal Input 1 Motor Power 2 Command Signal Input 2 Motor Power 3 Aux GND 3 GND 4 Aux GND 4 GND 5 Not Use 5 24 Used 6 Not Use 7 ENABLE 5 8 FAULT 5 9 Aux GND 10
9. 7 Table 8 shows the ADC conversion value range for the analog I O port Yellow PUMA ECE4007L01 17 Table 6 NI Motion LabVIEW VIs Implemented 10 Name Description Settings Name er Board ID Bd ID Out Initialize Initializes the motion Controller controller error in no error error out Axis Bitmap Disabled Enables the operating Sample PID Rate Enable Axes 2585 and defines the PID nem eee and trajectory update error in no error error out rate Phase A Index Configure Configures the encoder Board ID Bd ID Out Encoder Phase A Phase B and error in no error error out Polarity Index line polarities Phase B DAC Value 0 Board ID Bd ID Out ontrols the output DAC Resource Output Load DAC 1 P Inp Vect serror out vo tage error in no error Port Data Board ID Bd ID Out Reads the digital port Read I O Port 1 Resource Out P for encoder index Retn Vect eec error out ort reading error in no error Yellow PUMA ECE4007L01 18 Status Type Ret vect error in error loss error out Axis VS Map Disabled Board ID Bd ID Out Read Axis or Vector Space Resource Output Reference Reads the encoder index error out Status port error in no error Value Secondary Reset Position 0 Primary Reset Position 0 Board ID Bd ID Out nue solita Output Reset Resets the encoder value Inp Vect I error out Position t
10. Analog Value Range LabVIEW Value Range 0 to 5 0 to 465 535 5 to 5 32 768 to 432 767 0 to 10 0 to 465 535 10 to 10 default 32 768 to 432 767 Two of the analog value ranges in Table 8 are used for communication between the NI PCI 7356 and the rest of the system TA115 Motor Driver takes command voltage signal in the range of 10 V and the potentiometer gives analog output in the range of 0 V to 5 V Yellow PUMA ECE4007L01 20 The connection between the NI PCI card and the rest of the control system requires a VHDCI cable which is proprietary to NI devices 4 3 Constraints Alternatives and Tradeoffs Hardware Two power supplies HP E3630A and Agilent E3634A were provided by Dr Thomas Michaels The HP power supply does not have sufficient output power to power one or more motor driver Hence the Agilent power supply was required to power the motor driver and the HP power supply was used as the 5 V signal supply The HP power supply with analog voltage output is less precise compared to the digital voltage output on the Agilent power supply During motor testing broken brake and broken Encoder A were found inside of Motor 3 and Motor 4 respectively To ensure a properly working system both motors were replaced New motors were purchased through Dr Thomas Michaels and were made for the same type of robot to ensure matching mounting plate and specifications However because of the age of the arm robot these sp
11. ECE4007L01 11 Other Notes e Ensure the brakes on Motors 1 3 release before power is supplied to the motor to prevent any damages A clicking sound will occur when a brake is released e Index Encoder pulse width is very short The optimal oscilloscope setting is 1V and 2ms for reading the encoders e solid state relay is suggested in order to control the brakes from the software program solid state relay candidate information is listed below o Input Logic o Output Up to 60 V DC and upto3 A o Part No Digi Key CC1126 ND o Price 18 Software The main LabVIEW VI shown in Appendix D is used as a software interface to control the analog output port and read the analog and digital input ports of the motion controller The software is connected to Motor Axis 1 Therefore the parameters used in the software are specific to Motor 1 only In addition the motor has no load mounted on it The following features are implemented in the software GUI as shown in Figure 3 Yellow PUMA ECE4007L01 12 Figure 3 GUI displaying the manual and automated modes along the current encoder position potentiometer value and calculate RPM e Calibration to set the encoder index position as the home position This feature runs automatically when the software is turned on It runs the motor at the minimum voltage required to move the motor e Manual Auto Switch to switch between the manual voltage control
12. Final Report Interfacing Motors of PUMA 560 Robot with a PC based Controller ECE4007 Senior Design Project Section LO1 Yellow PUMA Team Josh Chao Team Leader Francis Fernandes Denny Lie Jackson Tanis Submitted May 1 2009 TABLE OF CONTENTS Executive Sumann dis iv 1 Introduction cp ees 1 O seede 1 2 A 2 Bonds 2 2 Project Description and Goals 3 3 Technical Specifications dd 4 4 Design Approach and Details sse 10 4 T DEIA A RASENE 10 4 2 Godes and Standards iia ia 17 4 3 Constraints Alternatives and Tradeoffs ooononncncnnnnononinanocinncnnononenanicnicicncnnon 21 5 Schedule Tasks and 22 6 Project DemonstPation ii 24 7 Marketing and Cost eene 25 T L Marketing Analysis Coe ei eie utei obere aa UL pedes er aa de inas 25 TT Dot 27 8 Summary and Conclusions ni 29 9 Ritas aa 30 KD GREENE EE Bamana 32 B vn 33 Appendi C 36 AG 43 Appendix E TR nase 52 Appendix S 55 ACTION Gas 61 Yellow PUMA ECE4007L01 Appendix Husdal Appendix Tune sees ias Yellow PUMA ECE4007L01 111 EXECUTIVE SUMMARY The Unimation PUMA Programmable Universal Machine for Assembly 560 robot is a six axis articulating arm robot Applications such as welding packaging
13. L01 57 e Rate of change of the Output Voltage 1 0 4 1000 0 0025 Volts tick e NewVoltage Prev Voltage 0 0025 NewEncoder PrevEncoder DAC a Cm Axis or Encoder Axis FLUR gt Desired Number of Revolutions am Figure F3 Block diagram of the voltage incline section Constant Voltage The constant voltage section runs the motor at a constant 2 V over the next 20 of the total distance A block diagram of the constant voltage section is shown in Figure F4 Yellow PUMA ECE4007L01 58 Figure F4 Block diagram of the constant voltage section Voltage Decline The block diagram of the voltage incline section is shown in Figure F5 The following calculation is performed in this section e The initial voltage is 2 V the target end voltage is 1 V and therefore the change in voltage over the last 40 of the distance is 1 V e Rate of change of the Output Voltage 1 0 4 1000 0 0025 Volts tick e NewVoltage Prev Voltage 0 0025 NewEncoder PrevEncoder Yellow PUMA ECE4007L01 59 No of Revolutions Completed un Figure F5 Block diagram of the voltage decline section Yellow PUMA ECE4007L01 60 APPENDIX PROPOSED PROJECT GANTT CHART See next page for project Gantt chart Yellow PUMA ECE4007L01 61
14. Low Lie Controller Setup Controller 2 days 3 31 2009 4 1 2009 Low Lie Order and Parts Delivery for Cables and Breakout 4 days 4 2 2009 4 7 2009 Low Fernandes Boards Controller Setup with Cables and Breakout 1 day 4 8 2009 4 8 2009 Milestone Fernandes Boards PE ad 14 days 4 9 2009 4 28 2009 Implementation Lie Reading Encoders and 4 days 4 9 2009 4 14 2009 High Lie Potentiometer 5days 4 16 2009 4 22 2009 High Fernandes Calibration Position Control 3 days 4 23 2009 4 27 2009 High Lie Final Demonstration 1 day 4 28 2009 4 28 2009 Milestone Fernandes PROJECT DEMONSTRATION The project demonstration took place on April 28 2009 at 12 00 pm in the Van Leer building Room 113 The goal of the demonstration was to show that the developed software could perform the following tasks e Read feedback information from encoder and potentiometer e Calculate the RPM of the motor e Regulate the output voltage to the motor manually e Tune the motor to start at the index pulse Yellow PUMA ECE4007L01 e Ramp up and down the voltage to the motor to the desired number of revolutions in forward and reverse mode The GUI shown in Figure 3 was divided into two controls manual and automatic The software is to calibrate to the home position and display the encoder position potentiometer value and the calculated RPM regardless of which control mode the software is executed The d
15. PUMA ECE4007L01 1 1 2 Motivation Even though the PUMA 560 robot could be considered as an old technology it is desirable to repair the robot because it can be used in different applications as previously mentioned Moreover the repair cost would be considerably lower than the purchase cost of a new six axis articulating arm robot In fact the functional system can be used by Dr Thomas Michaels the project sponsor as an automated measurement tool for research projects In addition this project shall provide the team members with practical learning experience in robotic system including the system interface the control system and the robot s electrical design This experience will prove useful for the team members in their future careers especially in robotic industry as articulating arm robots are widely used in manufacturing industries 1 3 Background Industrial Robots Industrial robots are reshaping the manufacturing industries Since 2003 North American manufacturing companies have spent up to 877 million for industrial robots 2 Depending on the structures industrial robots can be categorized into Selective Compliant Assembly Robot Arm SCARA Gantry Cartesian coordinate robot and Articulating Arm 3 Specifically articulating arm robots are widely used in manufacturing industries due to their wide range of motion and reach 4 Depending on the end effectors an articulating arm robot can perform different tasks
16. Yellow PUMA ECE4007L01 66
17. agram of the RampFinal input and output ports are shown in Figure F2 The input and output ports of the VI are listed in Table Fl Yellow PUMA ECE4007L01 55 Figure F1 Block diagram of the RampFinal VI Yellow PUMA ECE4007L01 56 RampFinal vi Desired Number of Revolutions Board ID Axis or Encoder DAC error out error in no error No of Revolutions Completed Figure F2 Diagram of the RampFinal VI Table F1 Ports of RampFinal VI Name Direction Description Desired Numer of Input The desired number of revolutions to perform Revolutions Board ID Input Number assigned and used by NI MAX to identify the PCI 7356 Axis or Encoder Input The encoder axis to read DAC Input The analog output port to control DAC Channel I means control the analog output channel 1 No of Revolutions Output The elapsed number of revolution performed Completed For analytical purpose the RampFinal VI can be broken down into 4 components e Initialization identical to the initialization section in the VI e Voltage incline e Constant voltage e Voltage decline Voltage incline The block diagram of the voltage incline section is shown in Figure F3 The following calculation is performed in this section e The initial voltage is 1 V the target end voltage is 2 V and therefore the change in voltage over the first 40 of the distance is 1 V Yellow PUMA ECE4007
18. ble Colors 1 Motor PWR Red 2 Motor PWR Black 3 Green 4 Encoder PWR 5V Yellow 5 White 6 Encoder GND Brown 7 Encoder I Purple 8 Pot PWR 5V Orange 9 Brake PWR 10 Brake RET 11 Pot RET Gray 12 Pot o p Blue Since all motors were disassembled from the robot matching female connectors were needed to test the motors on the bench Two 15 pin VGA connectors were obtained and made for the small motors as shown in Figure C2 Note that the color of the wires corresponds to Table C3 Yellow PUMA ECE4007L01 38 Figure C2 Connectors for Motor 4 6 Unfortunately since the matching female connector for the big motors could not be found the team implemented pin to pin connection to setup the big motor for bench testing Motor Driver Pinout and Control There are two connectors and one DIP switch on the motor driver Table C4 describes the setting on the DIP switch Note that the values on the right most column were used for the project Yellow PUMA ECE4007L01 39 Table C4 TA115 Switch Setting Switch S1 Description Up Description Down Value Used 1 User Supplied 5 V Vaux TA115 supplied 5 V U Opto isolation Vaux E Power OND and AUX Power GND and AUX 2 GND isolated Up d GND Shared Opto isolation 3 Fault Signal Active High Fault Signal Active Low Up 4 Voltage Mode Current Mode Down 5 Gain Limit Select bit 0 Down
19. cing Motors of PUMA 560 Robot with a PC based Controller 1 INTRODUCTION Many applications such as welding packaging palletizing and parts installation have been automated using industrial robots for higher efficiency and productivity In particular the six axis articulating arm robots are widely used for these applications due to their wide range of motion and reach 1 Georgia Tech s ME department has donated a broken Unimation PUMA 560 robot a six axis articulating arm robot to the ECE department The team was able to inspect the mechanical aspects of the robot and replace the broken motors In addition the broken controller was replaced with National Instrument 7356 PCI controller card The purpose of this project is to serve as groundwork for future ECE students project and the functional system can be used as an automated measurement tool for research projects 1 1 Objective Initially the team s objective was to interface the PUMA 560 robot with a PC based controller so that given a single or series of input the robot s end effectors shall move to the specified position in spatial coordinates However since the required control system was not available through the sponsor the final objective was changed to controlling a single axis of the robot using received feedback signals with a PC based controller The immediate purpose of this project is to serve as groundwork for future ECE senior design project Yellow
20. ct the home calibration section because there is a need to make sure that a certain task is completed before moving to the next task The home calibration section performs the following tasks e Senda I V signal to start the motor This is performed by sending a constant value of 3276 7 The analog output voltage ranges from 10 V to 10 V However the corresponding digital value range to send the signal is 32768 to 32767 Thus the value 1 V is equivalent to 3276 7 This condition is then held for 10 ms before moving to the next task e Next a 0 79 V signal is sent to the motor It is the minimum required voltage to move the motor without load Note that a higher voltage is needed to start the motor due to static friction Generally the static friction constant is higher than the dynamic friction constant Yellow PUMA ECE4007L01 46 Then the digital input port is constantly checked for positive encoder index reading Note that the encoder index is active low The parameters sent to the Read I O Port VI shows that the encoder index data is sent through the digital input port 1 digit O If the encoder index position is found the input port 1 digit O will go low the encoder position is reset to zero break out from the loop and set the output voltage to zero to stop the motor Figure D3 Block diagram of the home calibration section Run Mode Loop The case structure is used to construct the run mode loop because there ar
21. e fails to read all the encoder index signal occurrences The 200 RPM value is not the border line for the misreading problem the exact cutoff speed for the misreading problem is yet to be determined 5 SCHEDULE TASKS AND MILESTONES Table 9 displays the scheduled tasks duration start dates end dates level of difficulty and the main person responsible for the task January 12 marked the commencement of the project and April 28 was the end date The proposed Gantt chart of the project is shown in Appendix G However due to several changes in project definition and time constraints the proposed schedule was completely modified and the final Gantt chart is shown in Appendix H Yellow PUMA ECE4007L01 22 Table 9 Schedule Tasks and Milestones NE Wem Main Task Name Duration Stari Person Date Date Level Responsible Project Definition 23 days 1 12 2009 2 11 2009 Group Meet with Dr Thomas E Michaels to Define Goals 10 days 1 12 2009 1 23 2009 Low Chao and Objectives Define Project Scope 3 days 1 26 2009 1 28 2009 Low Tanis Research on Control System Software Motor 10 days 1 29 2009 2 11 2009 Low Tanis Drives and Motors A and 32days 2 12 2009 3 26 2009 Chao Tanis Disassemble Motors 7 days 2 12 2009 2 20 2009 High Chao Sv and days 2 23 2009 2 24 2009 Medium Tanis Test Motors I
22. e two possible run modes available the manual mode and the auto mode The case decision is based on the value sent by the Boolean control switch The block diagram of the manual mode is shown in Figure D4 and the block diagram of the auto mode is shown in Figure D5 The manual mode does the following tasks The integer constant 48 and the double constant 11 is used to make sure that the case condition inside the while loop is true during the first loop run The integer constant is compared with the axis value which is supposed to be one and the double constant is compared with the control knob voltage The current loop run axis value and the voltage value is then stored in the shift register for the next loop run After the first loop run the axis value will not change anymore Therefore as long as the control knob voltage value does not change the condition for the second case structure will remain false and the Load DAC VI is not called Yellow PUMA ECE4007L01 47 e Inside the condition true of the second case structure is the third case structure The third case structure is used to make sure that the appropriate factor is used in both negative and positive output voltage case The 1 V is equivalent to 3276 8 in Load ADC VI while 1 V is equivalent to 3276 7 This factor is than multiplied with the value from the voltage control knob to convert it to the corresponding Load ADC VI value e Pressing the stop button will break
23. ecific motors were difficult to spot and were more expensive than the equivalent counterpart used in the newer arm robots Software The software is developed in LabVIEW programming language rather than other languages like C or C because National Instruments provides NI Motion driver and LabVIEW VIs that handles all communication between the motion controller and LabVIEW In addition building a user interface in LabVIEW is a matter of drag and drop The encoder index from the motor is connected to the digital input port instead of the encoder index port in the motion controller because running the Read Reference Status VI together with the Wait Reference VI in a while loop results in a lower encoder index sampling Yellow PUMA ECE4007L01 21 rate than running the Read VO VI in the same while loop The idea behind connecting the Read Reference Status VI with the Wait Reference VI was to wait for the encoder index signal to ensure that the controller catches the signal However the Wait Reference VI only has a maximum sampling rate of 1 reading ms The situation can be improved by removing the Wait Reference VI and using the while loop rate to sample the encoder index signal In the home calibration the motor is moved by sending the lowest voltage necessary to move the motor The reason is because the encoder index signal is too short Running the motor faster than 200 RPM will result in an inconsistent encoder index reading i e the softwar
24. emonstration involved three runs one in manual mode and two in automatic mode e During the manual mode the motor first rotated at 0 75 V lowest voltage at which Motor 1 runs and stopped until the index pulse was found The voltage was then regulated manually between 2 00 V to 2 00 V to rotate the motor Whenever the motor was in motion the GUI displayed the current encoder position the potentiometer value and the calculated RPM of the motor numerically and graphically e desired positive number of revolutions was entered for the automated run Like the manual mode the motor first performed the home position calibration Once the GO button was clicked the motor ramped up from 1 00 V to 2 00 V during the first 40 of the number of revolutions stayed constant at 2 00 V for the next 20 and then ramped down from 2 00 V to 0 75 V during the last 40 of the revolutions e For the last run a negative number of desired revolutions was entered After the home position calibration and once the GO button was clicked the motor ramped up from 1 00 V to 2 00 V during the first 40 of the number of revolutions stayed constant at 2 00 V for the next 20 and then ramped down from 2 00 V to 0 75 V during the last 40 of the revolutions 7 MARKETING AND COST ANALYSIS 7 1 Marketing Analysis In 2004 approximately 5 to 15 of the industrial robots in injection molding industry were six axis articulated robots 11 leaving a large mark
25. et for PUMA 560 robots to grow However since the PUMA 560 robot was manufactured back in 1985 12 it is not equipped with modern technology such as high speed microprocessor and zero backlash mechanism such as the harmonic drive gearing 13 Compared to the KUKA 5 sixx R850 14 a modern arm robot in the same class the PUMA 560 robot is inferior in many aspects such as speed Yellow PUMA ECE4007L01 25 repeatability and payload as shown in Table 10 Although the PUMA 560 robot does not excel in comparison it is capable of completing any task where speed and accuracy are not critical Table 10 Comparison between PUMA 500 Robot and KUKA 5 sixx R850 Robot Technical Specifications PUMA 560 KUKA 5 sixx R850 Axes 6 6 Repeatability 0 1 mm 0 03mm Maximum Static Load 2 5 kg S kg Maximum Speed 0 508 m s 7 6 m s Reach 914 mm 814 mm Hand held teach pendants such as the Motoman NXC100 teach pendant are commonly used to program the movements of articulating arm robots in the industry 15 However according to 16 PC based controllers have recently become more popular as they provide an advantage of reduced cost improved robustness and open architecture platform With six degrees of freedom and re programming ability the PUMA 560 robot will be able to handle different types of tasks with changes only in the end effectors and software thereby reducing production cost and increasing its potential in t
26. fications and the method of open architecture implementation for PC based controller 2 PROJECT DESCRIPTION AND GOALS Mechanically the PUMA 560 robot has been inspected and two new motors have been purchased and properly tested to replace the broken motors Electrically the robot has not been interfaced with the controller because there was an issue with the sponsored Rockwell controller On March 26 2009 the team discovered that the sponsored controller CompactLogix L43 can Yellow PUMA ECE4007L01 3 only control up to four axes CompactLogix L45 which can control up to eight axes was requested but the team was not able to receive good response from Rockwell Automation As a result National Instruments PCI 7356 controller was selected as it met the needs for this project Due to the above mentioned issue and time constraints the team had set up new realistic goals to be achieved by the end of this project which includes e Establishing a system interface for the motor the motor driver and the NI controller e Providing a GUI for end users to read in feedback signals from the motor e Using the controller to control a single motor s position and speed e Establishing groundwork and proper documentation for future ECE students project Upon completion of this project the team will provide essential framework of the interface and control system and documentations of the robot the motor driver and the controller for the next
27. g Power Transmission Engineering Magazine pp 32 KUKA Roboter GmbH KR 5 sixx R850 Company Website Available http www kuka robotics com usa en products industrial robots small robots kr5 sixx r850 start htm Robot Worx Motoman NX100 Teach Pendant Company Website Available http www robots com motoman php controller nx 100 M Faroog Implementation of a new PC based Controller for a PUMA robot Journal of Zhejiang University Science A vol 8 no 12 pp 1962 1970 Nov 2007 W Bihr and F Degrange 1999 Interfacing of a Force Torque sensor on a PUMA 500 robot Georgia Institute of Technology Online Available http helix gatech edu Students Sioux Will project html Yellow PUMA ECE4007L01 31 APPENDIX A MATLAB CODE Shown below is the Matlab code used to determine the voltage constant oo vl and v2 represents the input voltage where rl and r2 represent the rpm corresponding to the input voltage This data are collected from actual testing vli 17353 v2 1 22 ri 040 80 120 155 195 220 275 305 340 380 420 460 500 545 585 630 660 690 720 725 760 795 828 867 903 940 976 1011 1053 1087 1124 1161 1197 1239 r2 12 111 225 335 446 560 664 782 887 1001 1117 1238 1345 1462 1573 1687 1809 1926 2044 2155 2272 2382 oe oe Determine and plot the 1st order best fitting polynomial Pl polyfit vl rl 1 new rl polyval P1 v1 P2 po
28. g the ticks seen in LabVIEW per revolution 1000 ticks were registered per revolution Assuming the program uses both encoders 90 out of phase from each other and counts both rising and falling edge 1000 ticks per resolution corresponds to 250 slots per encoder Circular potentiometer connects both extremes in the output voltage range together The potentiometer output resets to zero when it reaches the input voltage within the range of the output voltage from zero to the input voltage The potentiometer is geared down from the motor shaft but the gear ratio is not measured since it is not essential in completing the whole project Yellow PUMA ECE4007L01 7 Controller During the project the controller was switched from Rockwell Automation to Nation Instruments PCI 7356 to fully support all six axes on the robot Table 3 shows the I O pins for the controller and the required pins for the project Table 3 NI PCI 7356 I O Pins 8 Pinout Supports se ts Use Encoder 3 3 Encoder A B and I Analog Input 1 1 Potentiometer Analog Output 1 1 Motor Power Dita Po x el Various Switches Home 3 0 Currently no Plan for Limit etc Installation Other Notes More information on the robot and its specification is given in Appendix B to understand the operation and limitation of the arm robot when the arm robot is reassembled Software Previously the project was intended to interface the PUMA 560 robot
29. he market Yellow PUMA ECE4007L01 26 7 2 Cost Analysis Table 11 Lists of Parts and Labor Costs Item Description Retail Actual Value Value Robotic Arm PUMA Robot 560 Series 5 000 FREE 150 W Motors 1 Unimation Original Parts 600 600 30 W Motors 1 Unimation Original Parts 350 350 Servo Drives 6 TA115 4 200 4 200 PLC Controller NI PCI 7356 2 890 2 890 PCI Cables 4 68 Pin VHDCI M to MD68 M 220 220 Breakout Boards 4 68 Pin F Vertical Breakout 200 200 Desktop Dell GX260 350 FREE Miscellaneous Tools Wires Connectors 100 FREE Switches Electrical Components Labor 600 hours x 50 hour 30 000 FREE Total 43 910 8 460 Table 11 lists the parts and labor costs needed to work on the project The total actual cost for this project ended up to be 8 460 which is higher than the estimated cost in the proposal 5 150 The difference in the total cost was due to the purchase of NI PCI 7356 controller which was sponsored by Dr Michaels All other items except for the PCI cables and the breakout boards were also sponsored by Dr Michaels The PCI cables and the breakout boards which cost 420 dollars were purchased from Daqstuff a company that replicates connector cables and breakout boards for NI controllers using the team s senior design fund Labor spent to work on the project was estimated to be 600 hours with typical market engineer s salary of 50
30. hour which results in 30 000 dollars Table 12 shows the breakdown for the estimated labor hours for each team member Yellow PUMA ECE4007L01 27 Table 12 Estimated Labor Hours J Chao Hr J Tanis Hr D Lie r Y y Presentation 6 o s 6 Website development o o 0 Project Hours Project Research and Definition Robot Inspection and Testing Interface Components 31 Motor Driver Setup 8 OA Code Implementation 0 0 Final Testing EJ 5 Total per Person Total Hours In order to achieve the original goal which is to interface the whole PUMA 560 robot the only additional parts that may have to be purchased are wires and connectors for the entire wiring system For these parts additional cost of 250 dollars is estimated Additionally the team estimated that four hundred labor hours are needed for the following tasks e Reassemble the motors back to the robot s body e Implement kinematic equations on the controller e Implement the control PID loop for position and speed control e Test the overall system and make necessary adjustments Yellow PUMA ECE4007L01 28 8 SUMMARY AND CONCLUSIONS The initially proposed design goal was to program kinematic equations into the control system to make the end effectors of the robot move to a specified x y and z coordinate with a specified rotational direction within an error of I cm and 3 respectively Due to several problems that occu
31. lyfit v2 r2 1 new r2 polyval P2 v2 The voltage constant is the inverse of the lst order coefficient of the polyfit constant vel 1000 P1 1 vc2 1000 P2 1 hold on plot vl rl r v2 r2 o vl new rl k v2 new r2 k legend Motor 1 Motor 6 xlabel Input Voltage V ylabel Speed rpm title Input Voltage vs Speed Yellow PUMA ECE4007L01 APPENDIX B THE UNIMATION PUMA 560 ROBOT The arm robot has six revolute joints and each joint is driven by a DC servomotor The orientation of each axis and the angle of rotation of each joint are shown in Figure B1 This six axis configuration allows the robot to reach any point in its working envelope in any direction WAIST 320 JOINT 1 SHOULDER 250 JOINT 2 JOINT 3 JOINT 4 axis of rotation and maximum rotation range 16 EN I ELBOW 270 WRIST BEND 200 JOINT 5 FLANGE 532 JOINT 6 WRIST ROTATION 300 Figure B1 Schematic of Unimation PUMA 560 robot with joint angles Figure B2 provides detailed physical dimensions of the arm robot The information is necessary for the implementation of forward and inverse kinematics Yellow PUMA ECE4007L01 33 Figure B2 Schematic of Unimation PUMA 560 robot with dimensions of the robot in inches 17 Detailed technical specifications of the arm robot can be viewed in Table B1 Since the p
32. mode and the position input command mode If the switch is set to manual the motion of the motor is controlled by turning the voltage control knob If the switch is set to automatic the motion of the motor is controlled based on the input number of desired revolutions The maximum voltage produced by the automatic mode is 2 V when running in current mode with a gain of 0 2 The speed of the running is approximately 780 RPM e Voltage Control Knob to control the analog output voltage used to move the motor The range of the output voltage is between 10 V to 10 V The software has to be set to manual mode to enable the voltage knob e Input Number of Revolutions to command the motor to move a certain number of revolutions The software has to be set to automatic mode for the input command to Yellow PUMA ECE4007L01 13 work The motion is divided into 3 parts voltage incline 40 of distance constant voltage 20 of distance and voltage decline 40 of distance as seen in Figure 4 Motion profile in auto mode mn a m gt 3 a 5 o 10 20 30 40 50 60 70 80 90 Distance Figure 4 Motion profile in auto mode for explanation purposes only not measured data e Encoder Display to display the current encoder position numerically and graphically The numerical display shows the number of encoder ticks One complete revolution is equal to 1000 encoder ticks e POT Display to display the analog in
33. n si v EL ei 62 Yellow PUMA ECE4007L01 APPENDIX FINAL PROJECT GANTT CHART See next page for project Gantt chart Yellow PUMA ECE4007L01 63 60 82 ONL 160 22 7 VON GOZZI PIM 60 77 3NL 60 82 p 60 8 7 60 4 19 ONL 60 0 VON 60 39 60 8 7 60 4 97 3NL 60 LE E ONL 60 92 NUL GO ET E VON 60 3 60 8 p PAM 60 97 NUL 60 52 60 6 VON 60 9Z NUL 160 92 NUL 6O SZ E PAM 60 2 VON 60 9 Uy GO S E NUL 60 PZ Z ONL 160 02 2 4 60 9Z NUL PIM 60 82 PIM 60 EZ L UA 60 b LIZ PIM 60 8Z ONL 60 2 NUL 60 9L 7 nur 60 6 7 NUL 60 6 NUL 60 8 7 PAM NUL 60 LE E ONL 60 92 NUL 60 9zic NUL 60 8 7 PAM 60 Vv PAM GO LZ E Uy 60 9c NUL 60 61 NUL GOZE nur 60 6 VON 60 6 LOW 60 92 NUL 60 01 SNL PAM 60 9Z E NUL 60 PZ E ONL GO LIE 185 60 9 4 60 52 PAM 60 2 VON 60 Z We nur 6O Z LT NUL 60 62 1 NUL 60 97 14 VON 60 2171 VON GOZH sepe 5 y y sAep of sKep s sKep sKep sKep S sKep cz sKep zi gb S Bp zi sAep sep sKep zc sKep 01 sKep sKep 01
34. ndication that the home calibration is complete Yellow PUMA ECE4007L01 52 e Ifthe switch is set to manual use the voltage control knob to control the motor e If the switch is set to auto press the blinking go button to start position command e Press the stop button to close the software In auto mode user has to wait until the motion is completed before pressing the stop button The stop button is disabled during the auto mode motion The flowchart of the user interaction is shown in Figure El Troubleshooting Q Why does not the motor move during the home calibration mode A It means that the motor doesn t have enough voltage supply To solve this problem change the voltage value in the second sequence in the home calibration section to a value that is higher than 2600 26 0 79 V or wait until the mot warms up Yellow PUMA ECE4007L01 53 Manual Auto Switch LabVIEW Run Home Calibration Voltage Read Control Number of Knob Revolutions Figure El User interaction flowchart Yellow PUMA ECE4007L01 54 APPENDIX RAMP FINAL VI The RampFinal vi is called by the main VI in the run auto mode section The purpose of the RampFinal VI is to automatically create the motion profile as seen in Figure 7 which consists voltage incline 40 of the distance constant voltage 20 of the distance and voltage decline 40 of the distance The block diagram of the RampFinal VI is shown in Figure Fl The di
35. ndividually 7 days 2 25 2009 3 5 2009 Medium Tanis Motor Testing Complete I day 3 6 2009 3 6 2009 Milestone Tanis Order and Parts Delivery 15 days 4 7 2009 3 23 2009 Low Chao for 2 Motors Test New Motors 2 days 3 24 2009 3 25 2009 Medium Chao All Motors Working I day 3 26 2009 3 26 2009 Milestone Chao Rockwell Automation 18 days 3 4 2009 3 26 2009 Fernandes Controller Lie Setup Controller 5 days 3 4 2009 3 9 2009 Medium Fernandes Learn Ladder Logic 12 days 3 10 2009 3 25 2009 High Fernandes Switch to NI Controller day 3 26 2009 3 26 2009 Milestone Lie Interface all C 23 days 3 9 2009 4 8 2009 Chao Tanis omponents PE pave 3 days 3 9 2009 3 11 2009 Medium Tanis Amplifier Build Wiring System 5 days 3 12 2009 3 18 2009 Medium Chao Order and Parts Delivery 3 days 4 9 5009 3 23 2009 Low Chao for 6 Servo Amplifiers Complete Wiring for Moto TER I day 3 26 2009 3 26 2009 Milestone Chao Motor Driver Testing days 3 27 2009 3 31 2009 Medium Tanis with Motor Interfaced Controller to 5 days 4 1 2009 4 7 2009 Medium Chao Yellow PUMA ECE4007L01 23 6 Motor Driver and Motor Communication of all day 4 8 2009 4 8 2009 Milestone Chao Components Complete NI Controller Setup 10 days 3 26 2009 4 8 2009 Order and Parts Delivery for NI PCI 7356 3 days 3 26 2009 3 30 2009
36. o zero error in no error Encoder Position Reads the encoder _ Board ID Bd ID Out Read position One revolution Axis or Encoder Resource Output Positi 1 1000 d Retn Vect M DUE osition is equal to encoder error in no error ticks Analog Value Board ID Bd ID Out Reads the converted ADC Resource Output Read ADCs value from an ADC input channel Yellow PUMA ECE4007L01 19 Table 7 Initialization Parameters for NI Motion LabVIEW VIs 10 Parameter name VI Value Description Board ID Initialize 1 Number assigned and Controller used by NI MAX to identify the PCI 7356 Axis Bitmap Enable Axes True The value true means the axis is enabled There are 6 Axis Bitmap parameters Index Configure False The value false means Encoder Polarity that the encoder index is active low Phase A Configure False The value false means Encoder Polarity that the encoder A is active low Phase B Configure False The value false means Encoder Polarity that the encoder B is active low DAC Load DAC DAC Channel 1 The analog output port to control DAC Channel 1 means control the analog output channel 1 ADC Read ADCs ADC Channel 1 The analog input port to read Axis Reset Position Axis 1 The encoder axis to reset the position Axis Read Position Axis 1 The encoder axis to read the position Table 8 Analog Value Range vs LabVIEW Value Range 10
37. otor and provide a user interface to the user The block diagram of the VI is shown in Figure D1 In addition to LabVIEW and NI Motion VIs the FinalDemo vi also utilizes the developed RampFinal vi Yellow PUMA ECE4007L01 43 Figure D1 Block diagram of the FinalDemo VI Yellow PUMA ECE4007L01 44 For analytical purposes the FinalDemo vi can be broken down into 5 components e Initialization e Home calibration e Run mode loop e Encoder and pot reading loop e Speed calculation loop Initialization The parameters needed to properly control the motor is defined in the initialization section A block diagram of the initialization section is shown in Figure D2 The initialization section performs the following tasks e Initialize the voltage control value to zero e Initialize the motion control e Enable the operating axes e Configure the encoder polarity All encoders that are used are active low The assigned value that indicates active low is the Boolean false Yellow PUMA ECE4007L01 45 Axis Bitmap Disabled Phase Voltage Value Reinit To Default Reinit To Default Figure D2 Block diagram of the initialization section Home Calibration The purpose of the home calibration section is to find the encoder index position and set the index position as the home encoder zero position block diagram of the home calibration section is shown in Figure D3 The flat sequence structure is used to constru
38. palletizing and parts installation have been automated using such type of industrial robots for higher efficiency and productivity Georgia Tech s ME department has donated one such robot to the ECE department The robot s controller was not functional and the team tasks involved inspecting the mechanical aspects of the robot and replacing the robot s control system with a National Instruments controller The next phase involved interfacing all of the components PC controller motor drivers and motors Once these components were functional kinematic equations was to be programmed into the control system in order to make the end effectors of the robot move to a specified x y and z coordinate with a specified rotational direction However due to several problems that occurred during the semester and time constraints the final objective was changed to control a single motor using feedback received from the encoders and potentiometer With six degrees of freedom and re programming ability the PUMA 560 robot is able to handle different types of tasks with changes only in the end effectors and software thereby reducing production cost and increasing its potential in the market With all the prices combined the total cost was 8 460 With successful completion of the project the functional system can be used as an automated measurement tool for research and groundwork for future ECE students projects Yellow PUMA ECE4007L01 iv Interfa
39. put voltage from the motor s potentiometer The potentiometer is connected to a 5 V supply e RPM display to show the speed of the motor rotation The speed is calculated based on As At where At is 0 5 sec and As is the encoder ticks difference in 0 5 sec The result is than converted into revolutions per minute The NI PCI 7356 has a built in processor to read in the encoder signals By default it can read encoder data at a rate of up to 20MHz 8 National Instruments also provides the NI Motion driver that includes LabVIEW VIs needed to read the encoder data from the motion controller Yellow PUMA ECE4007L01 14 memory The low level communication procedure between the motion controller and the computer is handled within NI Motion The software flowchart is shown in Figure 5 The first step is to set the necessary parameters in order to run the motor The software then moves to the home calibration algorithm During this process it also runs two other while loops simultaneously which is necessary for encoder display and RPM calculation The RPM calculation while loop runs at a slower rate than the encoder while loop because larger At leads to more accurate and stable results After the home calibration is performed the software enters the run mode which can be either in manual mode or auto mode In both modes the software will run the third while loop necessary to control the analog output voltage Refer to Appendix E for block diag
40. rams and details on the software implementation Home calibration Output voltage control Hardware VERE Encoder readin Initialization g Analog input reading Handling Motor speed calculation Figure 5 Software implementation flowchart The encoder signal from the motor is connected to encoder port on the motion controller The motion controller is able to read the encoder signal at a rate of up to 20MHz 9 and stores Yellow PUMA ECE4007L01 15 the values in the memory The value is obtained in the software using the Read Encoder Data VI The encoder index signal is connected to the digital input port of the motion controller The VI that is used to read the digital input port is the Read I O VI The potentiometer is connected to the analog input port and the value is read using the Read ADCs VI All the VIs are listed in Table 6 The home calibration is done by moving the motor at a low speed while constantly reading the encoder index signal Once the encoder index signal is found the encoder value is reset to zero using the Reset Position VI and the motor is stopped The automatic run mode is done by controlling the output voltage over the period of encoder distance The motion consists of 40 voltage incline 20 constant voltage 40 voltage decline as shown in Figure 6 In the first 40 of the distance starting with the minimum voltage of 1 V the voltage is increased at a constant rate over the di
41. ring the semester e Define and discuss design goals with Dr Michaels e Research and gather technical specifications about the PUMA 560 and motors e Determine pin layout for the main wire harness connector ELCO 8016 e Check existence of limit switches e Remove all motors from the robot e Test brake release for the three big motors e Test Encoders A B and Index for all six motors e Test potentiometer output for all six motors e Replace and test the two broken motors e Learn to use the purchased motor driver e Build wiring system to connect the motor driver and motor e Replace Rockwell CompactLogix L43 controller with NI PCI 7356 controller e Interface the NI controller with the motor and motor driver e Develop a GUI to control the motor Yellow PUMA ECE4007L01 65 e Control the motor using command analog voltage Read encoder and potentiometer feedback signals e Calculate RPM of the motor in motion e Control the position and speed of the motor Below is the list of tasks that need to be achieved by future senior design teams e Implement the control PID loop for position and speed control e Add limit switches algorithm within the software program e Wire and interface all 6 motors e Program to control all 6 axes Install the 6 motors into the robot e Determine the actual limit switch values e Program forward and inverse kinematic equations e Test overall system and make necessary adjustments
42. roject only modifies the control system the actual performance of the robot should be close to these specifications Yellow PUMA ECE4007L01 34 Table B1 Detailed Technical Specifications of the Unimation PUMA 560 Robot Axes 6 revolute axes Drive Electric Brushed DC Servomotors Repeatability 0 1 mm Maximum Static Load 25 Maximum Straight Line Velocity 51 cm sec Reach 86 6 cm to the wrist 92 2 cm to the flange Weight 54 4 kg Yellow PUMA ECE4007L01 35 APPENDIX C PINOUT DIAGRAM Motor Pinout Two types of motors are used Motors 1 to 3 are shown in Figure C1 in the center and Motors 4 to 6 are shown in Figure to the right Figure C1 Two types of motor The sample pictures of the connector along with the pin numbering are provided in Table C1 and Table C2 Yellow PUMA ECE4007L01 36 Table C1 Motors 1 3 Pinout Diagram 3 1 6 4 9 7 12 11 10 Pin Numbers b Sample Picture Table C2 Motors 4 6 Pinout Diagram a 12 13 14 15 Pin Numbers b Sample Picture Table C3 gives the description of every pin Note that the pin number applies to all motors and the small motors have no brake Yellow PUMA ECE4007L01 37 Table C3 Pin Details for Motors in PUMA 560 robot Pin Description Motors 4 6 Ca
43. rred during the semester and time constraints the goal was not met However the re proposed goals of the project were successfully achieved e system interface is established for the motor the motor driver and the NI controller e AGUl is provided for end users to read in feedback signals from the motor e The controller is able to control a single motor s position and speed e Established groundwork and prepared documentation for future ECE students project Appendix I shows all the tasks that were completed during the semester and also provides a task list for future ECE senior design teams to achieve Other helpful resources are also made available on the Yellow PUMA website and can be accessed at the following link http www ece gatech edu academic courses ece4007 09spring ece4007101 ws5 index htm Yellow PUMA ECE4007L01 29 1 2 3 4 5 6 7 8 9 REFERENCES ATSI 2008 Articulating Arm Robot Online Available http www atsi cc articulating arm robot htm J M Pethokoukis 2004 Mar 7 Industrial robots are reshaping manufacturing U S News Online Available http www usnews com usnews biztech articles 0403 15 1 5eerobots htm ATSI 2008 Robot Basics Online Available http www atsi cc robotbasics htm RobotWorx 2009 Industrial Arc Welding Robot Application Online Available http www robots4welding com applications php app arc welding Au
44. s the result more stable and more accurate than the result performed by faster loop run The formula used to calculate the speed is RPM Abs AEncPos 1000 60 At Yellow PUMA ECE4007L01 50 Figure D7 Block diagram of the motor speed calculation Yellow PUMA ECE4007L01 51 APPENDIX E USER MANUAL The user manual is made available to guide the user in running the software application with ease In order to use the software the following items will be needed e Windows based PC capable of running NI LabVIEW e NI PCI 7356 Motion Controller e NI LabVIEW 8 5 software e NI Motion 7 6 software driver FinalDemo VI e RampFinal VI The current developed software is not a standalone application Therefore the correct version of NI LabVIEW NI Motion and the VIs listed above will be needed to run the software application Follow the steps below to run the software e Open the FinalDemo vi using NI LabVIEW e Switch between the manual manual voltage control using the knob and auto voltage is controlled automatically based on the input number of revolutions mode e Ifthe switch is set to auto put in the desired number of revolutions in the numeric control The numeric control accepts decimal input e Click the start button e The home calibration algorithm will run automatically wait until the home calibration is completed The motor will stop spinning and the encoder position will be reset This will be the i
45. senior design group to continue on this project 3 TECHNICAL SPECIFICATIONS Hardware Motor Drivers TA115 Motor Driver from Trust Automation was used The manufacture specified specification and actual specification used and measured are listed in Table 1 Yellow PUMA ECE4007L01 4 Table 1 Trust Automation TA115 Motor Driver Specification 6 Specified Values Actual Values Actual Values P Used Measured Supply Voltage V 15 48 24 N A Digital Signal I O TTL Level 1 0 Same N A Command Input 10V Same N A Current Mode Ratio 0 2 0 4 0 6 0 8 N A 0 2 0 4 0 6 0 8 Vi Voltage Mode Ratio 20 N A 14 minimize the number of power supplies used the 24V power supply was used to power both the motor drivers and the brakes for Motors 1 2 and 3 The actual voltage mode ratio differs from the manufacturer specifications With voltage mode ratio of 14 the output voltage is in the range of 140V In addition the motor driver supports opto isolation which connects the signal circuit to the power circuit with optical devices instead of hard wires Opto isolation protects the signal circuit from catastrophic disasters such as lightning strikes by stopping the flow of high voltage past the motor driver Motors The motors in the arm robot were disassembled from the robot and were tested on the bench Table 2 shows the results of the tests performed Yellow PUMA ECE4007L01 5
46. stance until the output voltage reaches 2 V The motor will then move at a constant voltage of 2 V for the next 20 of the distance and start declining to the minimum voltage required to keep the motor moving at 0 75 V during the last 40 of the position The implemented motion profile is shown in Figure 7 Encoder value is used to determine the necessary changes in output voltage The distance for the incline constant decline voltage and the rate of change of the output voltage are calculated in advance based on the given number of revolutions These values are calculated after the run button is pressed but before the motor starts spinning The automatic run mode algorithm is written in a separate VI shown in Appendix F This VI is called from the main software VI Yellow PUMA ECE4007L01 16 Parameters set up and 40 of distance 20 of distance 40 of distance calculations From 1V to 2V 2 From 2V to 0 76V Error Handling Figure 6 Flowchart of the RampFinal VI Motion profile in auto mode gt m E gt gt 5 o 10 20 30 40 50 60 70 80 90 Distance Figure 7 Implemented motion profile in auto mode for explanation purposes only not a measured data 4 2 Codes and Standards The NI Motion LabVIEW VIs that were used or explored in the development process of the software are listed in Table 6 based on NI Motion 7 7 and LabView 8 5 The initialization parameters needed are listed in Table
47. such as welding assembly painting and packaging Some of the commercial welding robots include Panasonic VR 006 Motoman UP6 Fanuc and ABB IRB 1600 1 Yellow PUMA ECE4007L01 2 National Instruments PCI 735x Controller National Instruments is a technology pioneer and leader in virtual instrumentation On June 8 2004 NI introduced high performance motion controller boards for PCI based integrated motion data acquisition applications The NI PCI 7350 series boards offer stepper and servo motion control various axis configurations and general purpose digital and analog I O suitable for machine control applications such as semiconductor manufacturing or automated component testing 5 In addition the PCI controllers would provide a customizable control architecture which makes the changes in the robot s configuration easy for different applications NI also provides flexibility in software choices to program the PCI controllers including NI Motion Assistant LabVIEW LabWindows CVI Measurement Studio for Microsoft Visual Basic C and C Other Related Research A similar project titled Implementation of an open architecture for PC based control of PUMA 560 was undertaken by a former research student in National University of Singapore Parasar Kodati 6 Although the ServoToGo motion control card by IBM was used in this project the project s report provided useful information about the PUMA 560 robot s technical speci
48. tomation com 2004 NI Introduces Four PCI Motion Controllers for Manufacturing and Test Applications Online Available https www automation com content ni introduces four pci motion controllers for manufacturing and test applications Trust Automation Inc April 2000 TA115 Datasheet Online PDF Available http trustautomation com Library pdf Datasheets TA I 15 pdf P Nagy The PUMA 560 Industrial Robot Inside Out Industrial Robot Journal pp 4 67 4 79 1988 National Instruments 2008 735x Datasheet Online PDF Available http www ni com pdf products us 735x pdf Parasar Kodati 2004 Aug Implementation of an open architecture for PC based control of PUMA 560 NUS Singapore Available http udel edu parasar documents puma report pdf Yellow PUMA ECE4007L01 30 10 11 12 13 14 15 16 17 National Instruments 2005 November NI Motion VI Help Microsoft Windows Help format Online Available http digital ni com manuals nsf websearch BF588B77C64200BE86257 11B0050D 137 M Knights Six axis robot where they fit in injection molding Plastics Technology Online Article October 1 2004 Available http goliath ecnext com coms2 summary 0199 1325378 ITM Unimation 1985 March PUMA Mark II Robot 500 Series Equipment Manual for VAL and VAL PLUS Operating System A Lauletta 2006 April The Basics of Harmonic Drive Gearin
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