FPGA-Based Fused Smart Sensor for Dynamic and Vibration Parameter Extraction in Industrial Robot Links

Intelligent robotics demands the integration of smart sensors that allow the controller to efficiently measure physical quantities. Industrial manipulator robots require a constant monitoring of several parameters such as motion dynamics, inclination, and vibration. This work presents a novel smart sensor to estimate motion dynamics, inclination, and vibration parameters on industrial manipulator robot links based on two primary sensors: an encoder and a triaxial accelerometer. The proposed smart sensor implements a new methodology based on an oversampling technique, averaging decimation filters, FIR filters, finite differences and linear interpolation to estimate the interest parameters, which are computed online utilizing digital hardware signal processing based on field programmable gate arrays (FPGA)

Fused Smart Sensor Network for Multi-Axis Forward Kinematics Estimation in Industrial Robots

Flexible manipulator robots have a wide industrial application. Robot performance requires sensing its position and orientation adequately, known as forward kinematics. Commercially available, motion controllers use high-resolution optical encoders to sense the position of each joint which cannot detect some mechanical deformations that decrease the accuracy of the robot position and orientation. To overcome those problems, several sensor fusion methods have been proposed but at expenses of high-computational load, which avoids the online measurement of the joint’s angular position and the online forward kinematics estimation. The contribution of this work is to propose a fused smart sensor network to estimate the forward kinematics of an industrial robot. The developed smart processor uses Kalman filters to filter and to fuse the information of the sensor network. Two primary sensors are used: an optical encoder, and a 3-axis accelerometer. In order to obtain the position and orientation of each joint online a field-programmable gate array (FPGA) is used in the hardware implementation taking advantage of the parallel computation capabilities and reconfigurability of this device. With the aim of evaluating the smart sensor network performance, three real-operation-oriented paths are executed and monitored in a 6-degree of freedom robot

FPGA-based Fused Smart Sensor for Real-Time Plant-Transpiration Dynamic Estimation

Plant transpiration is considered one of the most important physiological functions because it constitutes the plants evolving adaptation to exchange moisture with a dry atmosphere which can dehydrate or eventually kill the plant. Due to the importance of transpiration, accurate measurement methods are required; therefore, a smart sensor that fuses five primary sensors is proposed which can measure air temperature, leaf temperature, air relative humidity, plant out relative humidity and ambient light. A field programmable gate array based unit is used to perform signal processing algorithms as average decimation and infinite impulse response filters to the primary sensor readings in order to reduce the signal noise and improve its quality. Once the primary sensor readings are filtered, transpiration dynamics such as: transpiration, stomatal conductance, leaf-air-temperature-difference and vapor pressure deficit are calculated in real time by the smart sensor. This permits the user to observe different primary and calculated measurements at the same time and the relationship between these which is very useful in precision agriculture in the detection of abnormal conditions. Finally, transpiration related stress conditions can be detected in real time because of the use of online processing and embedded communications capabilities

EMMNet: Sensor Networking for Electricity Meter Monitoring

Smart sensors are emerging as a promising technology for a large number of application domains. This paper presents a collection of requirements and guidelines that serve as a basis for a general smart sensor architecture to monitor electricity meters. It also presents an electricity meter monitoring network, named EMMNet, comprised of data collectors, data concentrators, hand-held devices, a centralized server, and clients. EMMNet provides long-distance communication capabilities, which make it suitable suitable for complex urban environments. In addition, the operational cost of EMMNet is low, compared with other existing remote meter monitoring systems based on GPRS. A new dynamic tree protocol based on the application requirements which can significantly improve the reliability of the network is also proposed. We are currently conducting tests on five networks and investigating network problems for further improvements. Evaluation results indicate that EMMNet enhances the efficiency and accuracy in the reading, recording, and calibration of electricity meters

Virtual Sensor for Kinematic Estimation of Flexible Links in Parallel Robots

The control of flexible link parallel manipulators is still an open area of research, endpoint trajectory tracking being one of the main challenges in this type of robot. The flexibility and deformations of the limbs make the estimation of the Tool Centre Point (TCP) position a challenging one. Authors have proposed different approaches to estimate this deformation and deduce the location of the TCP. However, most of these approaches require expensive measurement systems or the use of high computational cost integration methods. This work presents a novel approach based on a virtual sensor which can not only precisely estimate the deformation of the flexible links in control applications (less than 2% error), but also its derivatives (less than 6% error in velocity and 13% error in acceleration) according to simulation results. The validity of the proposed Virtual Sensor is tested in a Delta Robot, where the position of the TCP is estimated based on the Virtual Sensor measurements with less than a 0.03% of error in comparison with the flexible approach developed in ADAMS Multibody Software.This work was supported in part by the Spanish Ministry of Economy and Competitiveness under grant BES-2013-066142, UPV/EHU's PPG17/56 projects, Spanish Ministry of Economy and Competitiveness' MINECO & FEDER inside DPI-2012-32882 project and the Basque Country Government's (GV/EJ) under PRE-2014-1-152 and BFI-2012-223 grants and under recognized research group IT914-16

A New Methodology for Vibration Error Compensation of Optical Encoders

Optical encoders are sensors based on grating interference patterns. Tolerances inherent to the manufacturing process can induce errors in the position accuracy as the measurement signals stand apart from the ideal conditions. In case the encoder is working under vibrations, the oscillating movement of the scanning head is registered by the encoder system as a displacement, introducing an error into the counter to be added up to graduation, system and installation errors. Behavior improvement can be based on different techniques trying to compensate the error from measurement signals processing. In this work a new “ad hoc” methodology is presented to compensate the error of the encoder when is working under the influence of vibration. The methodology is based on fitting techniques to the Lissajous figure of the deteriorated measurement signals and the use of a look up table, giving as a result a compensation procedure in which a higher accuracy of the sensor is obtained

A Survey on FPGA-Based Sensor Systems: Towards Intelligent and Reconfigurable Low-Power Sensors for Computer Vision, Control and Signal Processing

The current trend in the evolution of sensor systems seeks ways to provide more accuracy and resolution, while at the same time decreasing the size and power consumption. The use of Field Programmable Gate Arrays (FPGAs) provides specific reprogrammable hardware technology that can be properly exploited to obtain a reconfigurable sensor system. This adaptation capability enables the implementation of complex applications using the partial reconfigurability at a very low-power consumption. For highly demanding tasks FPGAs have been favored due to the high efficiency provided by their architectural flexibility (parallelism, on-chip memory, etc.), reconfigurability and superb performance in the development of algorithms. FPGAs have improved the performance of sensor systems and have triggered a clear increase in their use in new fields of application. A new generation of smarter, reconfigurable and lower power consumption sensors is being developed in Spain based on FPGAs. In this paper, a review of these developments is presented, describing as well the FPGA technologies employed by the different research groups and providing an overview of future research within this field.The research leading to these results has received funding from the Spanish Government and European FEDER funds (DPI2012-32390), the Valencia Regional Government (PROMETEO/2013/085) and the University of Alicante (GRE12-17)