Development of Control System and OLP for Dual Arm Robot

Seok-Jo Go Division of Computer Applied Mechanical Engineering, Dongeui Institute of Technology, Busan, Korea Email: sjgo@dit.ac.kr Kwang-Suck Boo Dept. of Mechanical and Automotive Engineering, Inje University Kyungnam, Korea Email: mechboo@inje.ac.kr Young-Jin Lee Autopower Co., LTD, Kyungnam, Korea Email: ceo@autopower.co.kr Yoon-Seong Shin Naval Armament System Dept., Wia Co., LTD, Kyungnam, Korea Email: ys1082@wia.co.kr
between the controller and the developed dual arm robot. An OLP system has been also developed to provide the trajectory data to the robot system with 15 degrees of freedom.

Abstract In this study, a control system for a dual arm robot has been developed to provide a real-time connection between the controller and the robot by using a MEIs ZMPSynqNet-PCI board. The dual arm robot consists of two arms with six degrees of freedom and a body with three degrees of freedom. The trajectory data can be generated from CAD(computer aided design) data or through a developed OLP(Off-Line Programming) system consisting of 4 modules: a geometric module, a CAD data exchange module, a trajectory data generation module, and a graphic simulator. Index TermsDual Arm Robot, MEIs ZMP PCI board, OLP

II.

DESIGN OF DUAL ARM ROBOT

I. INTRODUCTION Robotic manipulators are increasingly deployed in complex environments or to perform complex tasks. Oftentimes, redundancy is necessary to cope with the increasing complexity. Redundancy is defined whenever a robot possesses more input degrees of freedom than required by the task at hand. Studies on dual arm robots have been continually carried out in robotics areas to provide robots in dangerous environments, similar to those which human beings would be normally in, without a special change to the working environment.[1,2] The final aim of this research is to develop the dual arm robot for applying to the actual manufacturing. The dual arm robot consists of two arms with six degrees of freedom and a body with three degrees of freedom. In this study a control system has been designed to provide a real-time connection
This work was supported in part by the Ministry of Commerce, Industry and Energy under Grant No. 10025003(development of dual arm robot controller with visual servoing)

The dual arm robot has been designed to automate the assembly process and has the configuration in shown in Fig. 1. The dual arm robot is composed of two six-axis arm and a two-axis body. The robot is controlled by the MEIs ZMP PCI controller. The developed control system can decrease commercial price while increasing the flexibility in developing the system. A host computer can not only generate a trajectory data on the robot system through the OLP, but also interface with a human. A. Controller for Dual Arm Robot Many valuable robot designs have seen limited use because of the difficulty in relating the position and movement of the robots actuators to the position and movement of the end-effector. This study investigated PCbased robot controllers, PMAC and ZMP. The PMAC and ZMP are made from Delta Tau Data Systems and MEI. The PMAC permits the installation of user-written kinematics routines, completely customizable to a unique mechanism.[3] It will automatically execute these routines at the appropriate points in real time, permitting all subsequent programming to be done in terms of the end-effector position, usually in Cartesian coordinates.

Fig. 1. Schematic diagram of the dual arm robot. TABLE 1 CHARACTERISTICS OF ZMP AND PMAC Item Max Axes MEI (ZMP) Supports up to 32 tightly Coordinated axes Universal PCI, CPCI, VME, PMC, EtherNet 10/100, RS232C Memory Interface: 32bits Direct Memory Map Motorola MPC8245 PowerPC (ZMP Series) - 64bit floating point - 8MB SDRAM / 133MHz DELTA TAU (PMAC) Up to 2,4,8(32) and 16axis coordinated

The ZMP is an ultra-performance SynqNet motion controller that provides users with the ultimate in highperformance motion control.[4] The 64-bit ZMP controller utilizes the Motorola MPC8245 PowerPC processor for optimum flexibility and speed. SynqNet motion control networks provide a 100Mbps synchronous real-time connection between motion controller and torque drives, stepper drives, and I/O modules. SynqNet is the only highspeed digital motion control network that offers fault tolerance, real-time node data collection, firmware downloads, wide servo vendor support, and requires no network programming. The ZMP-SynqNet-PCI offers servo update rates up to 24kHz, allowing optimum control of machines requiring high level of coordination and synchronization between axes. Table 1 shows differences between ZMP and PMAC. It is a difficult job that is to assemble the parts had freeform surfaces. And, it is required the high precision and speed. Therefore, this study selected ZMP because of realtime motion control and high-speed synchronous network connection. B. Schematic diagram of control system

Board Interface

PCI, CPCI, VME, Ether Net10/100 MultiPort Communication with SCHEDULER Motorola DSP5633xx - 24bit floating point - 20/40/60/80MHz (Default 40MHz)

In this study, the control system was designed to control the position of the dual-arm robot. The schematic diagram of the control system is shown in Fig. 2. The specifications of the selected servo drives are listed in Table 2.

CPU

- Update Rate: User Programmable - 4 Axes Update Rate: Servo Loop Max 24kHz - 8 Axes Update Rate: Max 16kHz Kinematic Ranges Position, velocity, Acceleration, Jerk - 64 bit floating point Synqnet Node I/O & Motor I/O depending on Supplier Oriented Object C Library (MPI) ActiveX (MPX) Motion Console, Motion Scope, Controls ToolKit, Mechaware SynqNet (based Ethernet) - Speed: 200Mbps or 100Mbps - Shield Cable (Ethernet) - Up to 32 node - Max Cable Length: 100 Meter between Node to Node

Ring Update Rate: 2.5KHz

Position, velocity, Acceleration, Jerk - 40 bit floating point Option boards or Macro Peripherals Motion Language will be MODULAR, PMAC &C COMPATIBLE

User I/O

Software

Utility

N/A

Network

N/A

Fig. 2. Schematic diagram of control system.

TABLE 2 SPECIFICATIONS OF THE SERVO DRIVES IN SINGLE ARM connection motor SGMPS-08A2A6C 1,2 ABS, KEY(TAP), BRAKE SGMAS-04A2A6C 3 ABS, KEY(TAP), BRAKE SGMAS-02A2A6C 4 ABS, KEY(TAP), BRAKE SGMAS-01A2A6C 5,6 ABS, KEY(TAP), BRAKE SGDS02A01A SGDS04A01A SGDS08A01A Po: JZSPCMM9-2 En: JZSPCMP9-2 Po: JZSPCSM9-2 En: JZSPCSP9-2 Po: JZSPCSM9-2 En: JZSPCSP9-2 Po: JZSPCSM9-1 En: JZSPCSP9-2 servo I/O: 3M50P En:JZSPCMP9-1 BATTERY CASE: JUSP-BA01 BATTERY: (a) Dual Arm Robot JZSP-BA01

Axis

Motor

Servo

SGDS01A01A

Fig. 3. Basic architecture for OLP.

III. OLP(OFF LINE PROGRAM) FOR DUAL ARM Off-line programming may be considered as the process by which robot programs are developed, partially or completely, without requiring the use of the robot itself.[5] This includes generating point coordinate data, function data, and cycle logic. Thus, the developed OLP could have some functions such as creation of motion path, cycle time estimation and optimization, programming and validation of complete production programs, collision detection and visualization, feasibility studies and reach ability tests, programming and simulation of I/Os and easy evaluation of standard components. Advantages of the OLP are to increase robot efficiency, to move away to the operations of the danger area, to simplify programming languages, able to integrate CADCAM systems and to simplify complex tasks. The developed OLP for the dual arm robot consists of three major modules such as kinematic, post process and interface modules as shown in Fig. 3.

(b) Coordinate System Fig. 4. The dual arm robot and definition of the coordinate system.

A. Kinematic module of the OLP The dual arm robot considered in this study features revolutionary 15-axis design to provide high speed motion with two six axis arms and "Human-Like" flexibility of movement presented in Fig. 4. The dual-arm robot is ideally suited for a wide variety of assembly, part transfer, machine tending and other handling tasks that formerly could only be done by people. Both robot arms can work together to double the payload or accomplish intricate tasks and can perform tasks independently without degradation of throughput. Table

3 and Fig. 4 show dynamic parameters and coordinate system for the dual arm, respectively. Fig. 5 shows also DenavitHartenberg parameters of the dual arm robot for kinematic analysis.[6] Forward and inverse kinematic analysis have been performed based upon the coordinate system and the DH parameters for kinematic emulation of the dual arm robot. Path planning emulation could be also performed based upon the defined system parameters to estimate robot cycle time and collision accident. B. Post process module of the OLP Post process module has two sub modules such as 3D animator and 3D and 2D graphic module. This post process module has been developed based upon OpenGL which was originally developed in 1992 by Silicon Graphics and DirectX which was also developed as game platform for Windows by Microsoft. IGES(Initial Graphics Exchange Specification) and STEP(Standard for the Exchange of Product Model Data) are utilized as graphic file formats for the OLP which may be designed as either a two-dimensional, three-view drawing layout or a full three-dimensional model with associated drawing views and dimensions. Fig. 6 shows CAD file import system which imports and processes BREP solid-based CAD geometry files stored in ASCII or Binary file formats. Solid based CAD data is composed of bodies which contain one or more shells, and each shell contains one or more faces. Graphic viewer sub module is presented in the Fig. 7. C. Interface module of the OLP Human and controller interface methods are handled in the interface module. Result windows for human machine interface are shown in Fig. 8. The first sub-task is the development of R-code(Controller programming language) language translator. Compiler-compiler software utilities Flex and PRECCX(Prettier Compiler-Compiler Extended) have been used for lexical analysis and parsing of the R-code language. Parser action statements have been written to emit Workspace Simulation Language (Visual Studio for Applications based simulation language, which contains calls to the functions of the motion planner via Component Object Model RRS interface) code. Also, all the Realistic Robot Simulation services called from the parser's action statements have been designed and implemented in the motion planner module of the simulation platform software. Knowing all the path parameters defined during simulation and taking into account the grammar of the R-code programming language, the C++ source code has been written to recent all the path data into sequence of SERVO machine instructions. The flow chart on Fig. 3 shows the interactions among the modules written by the modules of the software package built-in the development platform.

The generated RRS language could be downloaded to the robot controller and the current states of the RRS could be uploaded from the controller through a RS-232C series communication or TCP/IP protocol.
TABLE 3 DYNAMIC PARAMETERS OF THE DUAL ARM ROBOT JOINTS

or

Fig. 5. Denavit-Hartenberg parameters for a robot arm of the dual arm.

IV. CONCLUSION This study developed the control system and OLP for the dual arm robot. The control system provides a synchronous real-time connection between controller and drives. The operation of robots is also frequently less efficient and effective than expected. In order to make the operation of the robot easier, this study developed an integrated program. The developed OLP has been capable of dealing with kinematic modeling of the dual arm robot, check of the robots workrange, linear trajectory, and operation patterns. REFERENCES
[1] [2] [3] [4] [5] [6] http://www.robotics.utexas.edu http://www.automatica-muenchen.de Product Manual, DELTA TAU Data Systems, Inc. Product Manual, MEI, Inc. R. Bernhardt, G. Schreck, and C. Willnow, "Realistic robot simulation," Computing & Control Engineering Journal, pp. 174-176, 1995. K. S. Fu, R. C. Gonzalez, and C. S. G. Lee, Robotics, McGRAW-HILL, 1987. Fig. 6. CAD file import system.

Fig. 7. Architecture of the graphic viewer.

Fig. 8. Resulted HMI window for the Dual Arm OLP.