Industrial Robotics Control: Mathematical Models, Software Architecture, and Electronics Design (Maker Innovations Series)

Build a complete control system for industrial robots, learning all the theory and practical tips from the perspective of an automation engineer. Explore the details of kinematics, trajectories, and motion control, and then create your own circuit board to drive the electric motors and move the robot. After covering the theory, readers can put what they’ve learned in practice by programming a control firmware for the robot. Each software component is described in detail, from the HMI and the interpreter of motion commands, to the servo loop controller at the core of each servo drive. In particular, the author presents the commutation algorithm and the servo loop controller for brushless synchronous motors, which are typically employed in robotics applications. Readers will also learn how to calibrate the robot, commission it to the end-user, and design a digital twin to test and monitor the entire workcell in a safe simulated environment. Finally, the book delves into hardware, covering how to select and use electric motors and encoders, how to build servo drives and motion controllers, and how to design your own PCBs. Different electronic components and their application circuits are analyzed, showing the advantages and drawbacks of each. By the end of the book you should be able to design and build electronic boards and write their core firmware to control any kind of industrial robot for all sorts of different practical applications. What you’ll learn Solve kinematics models of robots Generate safe paths and optimal motion trajectories Create a digital twin of your robot to test and monitor its movements Master the electronic commutation and closed-loop control of brushless motors Design electronics circuit boards for motion applications Who This Book Is For Robotics engineers (and students) who want to understand the theory behind the control of robotics arms, from the kinematic models of their axes to the electronic commutation of their motors. Some basic calculus and linear algebra is required for the understanding of the geometrical framework, while some electronics foundations are helpful to grasp the details of the circuits design. Table of Contents About the Author About the Technical Reviewer Preface Chapter 1: Industrial Robots Nomenclature Mechanical Configurations Structure of a Robot Control System Digital Twin Summary Part I: Robot Geometry Chapter 2: Geometrical Framework Reference Frames Frame Operations Frame Translations Frame Rotations Properties of a Rotation Matrix Composing Rotations: Euler Angles Decomposing a Rotation Matrix Column Vectors Expressing Rotations Combining Translations and Rotations Example Inverted Transformation Summary Chapter 3: Forward Kinematics Mechanical Structure Step-by-Step Solution Combined Transformation Matrix Numerical Test Zero Frame Tool Frame Mechanical Coupling Summary Chapter 4: Inverse Kinematics Closed-Form Derivation Nonlinear Problem Nonunique Solution Singularities IK Step 1: Decoupling IK Step 2: Solve the Arm IK Step 3: Solve the Wrist Numerical Test Zero Frame Tool Frame Mechanical Coupling Summary Part II: Robot Movements Chapter 5: Path-Planning PTP Movements Path Movements Quaternions SLERP Line Circle Spline De Casteljau’s Algorithm Round Edges Transitions Path Length External Path Corrections Summary Chapter 6: Workspace Monitoring Linearization Safe Zones Forbidden Zones Wire-frame Model Safe Orientation Self-Collision Capsules Exclusive Zones Collision Detection Summary Chapter 7: Trajectory Generator S-Curve Profile Sinusoidal Profile Bezier Profile Time-Optimal Movements Differential Kinematics Path Speed Definitions Optimal Motion in Practice Time Filtering External Path Corrections Summary Chapter 8: Statics and Dynamics Statics Singularities Dynamics Dynamic Model Lagrangian Method Newton-Euler Method Parameters Identification Torque Feed-Forward Trajectory Optimization Teach by Hand Motor Sizing Summary Part III: Robot Software Chapter 9: Firmware Human-Machine Interface Interpreter Main Controller Kernel Interface Servo Drives Electronic Commutation Summary Chapter 10: Calibration Robot Calibration Tool Calibration Cell Calibration Summary Chapter 11: Commissioning Safety Tuning Summary Chapter 12: Simulation Unity 3D Building a Scene Importing CAD Models Programming Scripts Communication Functions User Interface Machine Learning Summary Chapter 13: Machine Vision Smart Camera Vision Functions Deep Learning Convolutional Networks Summary Part IV: Robot Hardware Chapter 14: Motors DC Motors Stepper Motors Brushless Motors Linear Motors Motor Sizing Summary Chapter 15: Encoders Hall Sensors Quadrature SSI Tamagawa Summary Chapter 16: Servo Drives Power Switches Gate Driver Current Sensing Summary Chapter 17: Power Management DC Bus Voltage Protection Functions Voltage Converter Summary Chapter 18: Main Controller Microcontroller IOs Fieldbus Integrated Solution Display Summary Chapter 19: Fabrication PCB Design Mechanics Summary Correction to: Industrial Robotics Control Correction to: Appendix: Kinematic Models COBOT SCARA PALLETIZER DELTA Index