Development and Control of Networked Servo System

Control systems where the control loops are closed through a communication network are called Networked Control System (NCS). Research on NCS has received increased attention in recent years due to the advancement of control,computation and communication technologies. NCS makes the design and implementation of control systems with reduced complexity due to simpler installation and easy maintenance. But the insertion of the communication network in the feedback control loop introduces delay from sensor to controller and controller to actuator, that degrades the control system performance and also causes system instability.This thesis focuses on development of a networked DC Servo control system using LabVIEW and Peripheral Component Interconnect(PCI) card.The controller design for a NCS can be categorized into indirect and direct approach. An indirect approach controller design considers ¯rst without delay followed by design a suitable delay compensation technique. A PID controller with a Smith predictor as a compensater is implemented in real-time networked control of servo system. The above PID controller is tuned using gain margin and phase margin speci¯cations and Zigler-Nichols method are implemented. A direct NCS design approach in the other hand considers the delay as well as packet loss characteristics with system dynamics at one go.This approach gives more information about each instant of the system.It uses Lyapunov approach to design of asymptomatic stabilization of the system, the above stabilization uses a switched approach for NCS sta- bilization with packet loss and delay is proposed. The switched approach divides the NCS as di®erent subsystems considering both delay and packet loss, then designing of controllers for each subsystem. According to packet loss, the subsystems and controllers are switched to stabilize the NCS. In this approach the feedback gains are calculated by solving Linear Matrix Inequalities (LMIs). Both direct and indirect controller design approach are simulated using MATLAB and SIMULINK. Some Hardware in Loop simulations are also performed on a Servo System.A realtime networked servo control system has been developed using LabVIEW. Only indirect controller approach is implemented in this environment to remotely control the servo system. The results obtained by using PID controller and Smith predictor have been analyzed and it is conrmed that these controller provide good performances

Design and implementation of a modular controller for robotic machines

This research focused on the design and implementation of an Intelligent Modular Controller (IMC) architecture designed to be reconfigurable over a robust network. The design incorporates novel communication, hardware, and software architectures. This was motivated by current industrial needs for distributed control systems due to growing demand for less complexity, more processing power, flexibility, and greater fault tolerance. To this end, three main contributions were made. Most distributed control architectures depend on multi-tier heterogeneous communication networks requiring linking devices and/or complex middleware. In this study, first, a communication architecture was proposed and implemented with a homogenous network employing the ubiquitous Ethernet for both real-time and non real-time communication. This was achieved by a producer-consumer coordination model for real-time data communication over a segmented network, and a client-server model for point-to-point transactions. The protocols deployed use a Time-Triggered (TT) approach to schedule real-time tasks on the network. Unlike other TT approaches, the scheduling mechanism does not need to be configured explicitly when controller nodes are added or removed. An implicit clock synchronization technique was also developed to complement the architecture. Second, a reconfigurable mechanism based on an auto-configuration protocol was developed. Modules on the network use this protocol to automatically detect themselves, establish communication, and negotiate for a desired configuration. Third, the research demonstrated hardware/software co-design as a contribution to the growing discipline of mechatronics. The IMC consists of a motion controller board designed and prototyped in-house, and a Java microcontroller. An IMC is mapped to each machine/robot axis, and an additional IMC can be configured to serve as a real-time coordinator. The entire architecture was implemented in Java, thus reinforcing uniformity, simplicity, modularity, and openness. Evaluation results showed the potential of the flexible controller to meet medium to high performance machining requirements

Reducing Communication Delay Variability for a Group of Robots

A novel architecture is presented for reducing communication delay variability for a group of robots. This architecture relies on using three components: a microprocessor architecture that allows deterministic real-time tasks; an event-based communication protocol in which nodes transmit in a TDMA fashion, without the need of global clock synchronization techniques; and a novel communication scheme that enables deterministic communications by allowing senders to transmit without regard for the state of the medium or coordination with other senders, and receivers can tease apart messages sent simultaneously with a high probability of success. This approach compared to others, allows simultaneous communications without regard for the state of the transmission medium, it allows deterministic communications, and it enables ordered communications that can be a applied in a team of robots. Simulations and experimental results are also included

Wide-Area Surveillance System using a UAV Helicopter Interceptor and Sensor Placement Planning Techniques

This project proposes and describes the implementation of a wide-area surveillance system comprised of a sensor/interceptor placement planning and an interceptor unmanned aerial vehicle (UAV) helicopter. Given the 2-D layout of an area, the planning system optimally places perimeter cameras based on maximum coverage and minimal cost. Part of this planning system includes the MATLAB implementation of Erdem and Sclaroff’s Radial Sweep algorithm for visibility polygon generation. Additionally, 2-D camera modeling is proposed for both fixed and PTZ cases. Finally, the interceptor is also placed to minimize shortest-path flight time to any point on the perimeter during a detection event. Secondly, a basic flight control system for the UAV helicopter is designed and implemented. The flight control system’s primary goal is to hover the helicopter in place when a human operator holds an automatic-flight switch. This system represents the first step in a complete waypoint-navigation flight control system. The flight control system is based on an inertial measurement unit (IMU) and a proportional-integral-derivative (PID) controller. This system is implemented using a general-purpose personal computer (GPPC) running Windows XP and other commercial off-the-shelf (COTS) hardware. This setup differs from other helicopter control systems which typically use custom embedded solutions or micro-controllers. Experiments demonstrate the sensor placement planning achieving \u3e90% coverage at optimized-cost for several typical areas given multiple camera types and parameters. Furthermore, the helicopter flight control system experiments achieve hovering success over short flight periods. However, the final conclusion is that the COTS IMU is insufficient for high-speed, high-frequency applications such as a helicopter control system

A framework for flexible integration in robotics and its applications for calibration and error compensation

Robotics has been considered as a viable automation solution for the aerospace industry to address manufacturing cost. Many of the existing robot systems augmented with guidance from a large volume metrology system have proved to meet the high dimensional accuracy requirements in aero-structure assembly. However, they have been mainly deployed as costly and dedicated systems, which might not be ideal for aerospace manufacturing having low production rate and long cycle time. The work described in this thesis is to provide technical solutions to improve the flexibility and cost-efficiency of such metrology-integrated robot systems. To address the flexibility, a software framework that supports reconfigurable system integration is developed. The framework provides a design methodology to compose distributed software components which can be integrated dynamically at runtime. This provides the potential for the automation devices (robots, metrology, actuators etc.) controlled by these software components to be assembled on demand for various assembly applications. To reduce the cost of deployment, this thesis proposes a two-stage error compensation scheme for industrial robots that requires only intermittent metrology input, thus allowing for one expensive metrology system to be used by a number of robots. Robot calibration is employed in the first stage to reduce the majority of robot inaccuracy then the metrology will correct the residual errors. In this work, a new calibration model for serial robots having a parallelogram linkage is developed that takes into account both geometric errors and joint deflections induced by link masses and weight of the end-effectors. Experiments are conducted to evaluate the two pieces of work presented above. The proposed framework is adopted to create a distributed control system that implements calibration and error compensation for a large industrial robot having a parallelogram linkage. The control system is formed by hot-plugging the control applications of the robot and metrology used together. Experimental results show that the developed error model was able to improve the 3 positional accuracy of the loaded robot from several millimetres to less than one millimetre and reduce half of the time previously required to correct the errors by using only the metrology. The experiments also demonstrate the capability of sharing one metrology system to more than one robot