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FIGURE 8.32
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The adaptive control offers search and contour-following modes. Up to three sensor signals can be used to guide the movements of the robot. The direction in which the robot is to move must be given for each signal. The displacement or velocity is proportional to the signal value generated by the displacement sensor. Both digital and analog signals produced by sensors are accepted. Digital signals may consist of 1 to 8 bits. The interrupt lines are used to start or stop a robot movement and to synchronize tasks.
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The computer used to control the system is microprocessor-based. The main processor unit (MPU) is a VME-bus-compatible single-board computer featuring a 68010 processor, 1-Mb dual-ported RAM, a 35-Mb Winchester disk, and a 1-Mb floppy disk. The system runs under the UNIX V operating system. Real-time performance is obtained by two special processing units (SPUs). The first SPU realizes the control and interfacing of the robot and the interfacing of the sensors. It links the VME bus to the G64 bus to which the robot, the VTS, the torque-force sensor, and the ultrasound sensor are interfaced. This processor controls the computer link and the adaptive control of the robot. The processor board consists of a 68000 processor and 48-kb RAM. The second SPU is the vision processing board. This board communicates with the vision boards and the other SPU via the VME bus. It consists of a 68010 processor, 256-kb RAM, and an NS16081 floating-point processor.
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8.12.2 Vision Sensor Modules
The vision module consists of two Primagraphics VME boards. One board contains the frame image of 768 576 pixels and 128 gray values. A frame-transfer solid-state camera is connected to the system. Force sensing is available and can measure three force and three torque components. Forces up to 200 N are measured with a resolution of 0.1 N. Torques up to 4 N m is measured with a resolution of 0.002 N m. The data rate ranges from 1.8 to 240 Hz. The torque-force sensor is controlled by a Texas Instruments 9995 microprocessor. Besides a high-speed RS-232 link 38400 board, an analog output is available. An ultrasonic range finder sensor has been interfaced to the G64 bus. A tactile array based on the piezoelectric material PVDF has been developed. A stereo vision system is incorporated to the system.
Software Structure
Because an important aim of the testbed is to investigate the use of sensors in an assembly process, it is essential that an optimal environment is present for program development and real-world testing. A user-friendly program environment is provided by the UNIX V operating system. Real-time operation is provided by the special processing units. Programs developed under the UNIX system can be downloaded to the SPUs via the VME bus. The assembly process consists of a sequence of assembly stages. A succeeding assembly stage is entered when certain entrance conditions are met. This means that the assembly process can be controlled by a state machine. An assembly stage may consist of a number of states. With this approach, a modular and hierarchical control structure is obtained in which certain processes are executed at the lowest level. The control software for the assembly task consists of three different levels: (1) state machine level, (2) executor level, and (3) driver level. At the highest level, a command interpreter activates certain states of the machine. The state machine activates another (nested) state machine or a process (executor). Executors may run in parallel. For instance, the vision system may analyze an image of a product while the robot is assembling. The synchronization of the processes is obtained from the required entrance conditions for the next state of the state machine. In general, this level requires a moderately fast response and may run under the UNIX system. At the second level, the executors are activated by the state machine. An executor performs a certain subtask and requires a real-time response. Examples are robot movements and image analysis routines. The executors reside in the SPUs and in the robot controller (robot programs). An executor is the only program that communicates directly with a driver. The drivers for the different subsystems form the third level and also reside in the SPUs. The drivers take care of the protocol conversion and of the error checking in the communication with the subsystems.
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