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E-raamat: Industrial Robotics Control: Mathematical Models, Software Architecture, and Electronics Design

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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 theyve 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 youll 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.
About the Author xiii
About the Technical Reviewer xv
Preface xvii
Chapter 1 Industrial Robots
1(18)
Nomenclature
2(4)
Mechanical Configurations
6(5)
Structure of a Robot Control System
11(3)
Digital Twin
14(3)
Summary
17(2)
Part I Robot Geometry
19(86)
Chapter 2 Geometrical Framework
21(28)
Reference Frames
21(3)
Frame Operations
24(2)
Frame Translations
26(1)
Frame Rotations
27(4)
Properties of a Rotation Matrix
31(1)
Composing Rotations: Euler Angles
32(2)
Decomposing a Rotation Matrix
34(2)
Column Vectors
36(2)
Expressing Rotations
38(1)
Combining Translations and Rotations
39(4)
Example
43(3)
Inverted Transformation
46(2)
Summary
48(1)
Chapter 3 Forward Kinematics
49(26)
Mechanical Structure
50(4)
Step-by-Step Solution
54(6)
Combined Transformation Matrix
60(2)
Numerical Test
62(4)
Zero Frame
66(3)
Tool Frame
69(1)
Mechanical Coupling
70(3)
Summary
73(2)
Chapter 4 Inverse Kinematics
75(30)
Closed-Form Derivation
76(2)
Nonlinear Problem
78(1)
Nonunique Solution
79(3)
Singularities
82(3)
IK Step 1: Decoupling
85(2)
IK Step 2: Solve the Arm
87(5)
IK Step 3: Solve the Wrist
92(4)
Numerical Test
96(4)
Zero Frame
100(1)
Tool Frame
101(2)
Mechanical Coupling
103(1)
Summary
104(1)
Part II Robot Movements
105(158)
Chapter 5 Path-Planning
107(44)
PTP Movements
109(4)
Path Movements
113(2)
Quaternions
115(4)
SLERP
119(5)
Line
124(1)
Circle
125(4)
Spline
129(7)
De Casteljau's Algorithm
136(2)
Round Edges
138(4)
Transitions
142(4)
Path Length
146(2)
External Path Corrections
148(1)
Summary
149(2)
Chapter 6 Workspace Monitoring
151(30)
Linearization
154(3)
Safe Zones
157(1)
Forbidden Zones
158(3)
Wire-frame Model
161(2)
Safe Orientation
163(2)
Self-Collision
165(2)
Capsules
167(3)
Exclusive Zones
170(3)
Collision Detection
173(6)
Summary
179(2)
Chapter 7 Trajectory Generator
181(46)
S-Curve Profile
183(12)
Sinusoidal Profile
195(4)
Bezier Profile
199(4)
Time-Optimal Movements
203(5)
Differential Kinematics
208(3)
Path Speed Definitions
211(3)
Optimal Motion in Practice
214(3)
Time Filtering
217(5)
External Path Corrections
222(3)
Summary
225(2)
Chapter 8 Statics and Dynamics
227(36)
Statics
227(5)
Singularities
232(4)
Dynamics
236(4)
Dynamic Model
240(2)
Lagrangian Method
242(3)
Newton-Euler Method
245(2)
Parameters Identification
247(3)
Torque Feed-Forward
250(2)
Trajectory Optimization
252(3)
Teach by Hand
255(3)
Motor Sizing
258(2)
Summary
260(3)
Part III Robot Software
263(160)
Chapter 9 Firmware
265(60)
Human-Machine Interface
266(5)
Interpreter
271(14)
Main Controller
285(9)
Kernel Interface
294(5)
Servo Drives
299(6)
Electronic Commutation
305(18)
Summary
323(2)
Chapter 10 Calibration
325(20)
Robot Calibration
326(4)
Tool Calibration
330(8)
Cell Calibration
338(6)
Summary
344(1)
Chapter 11 Commissioning
345(22)
Safety
345(7)
Tuning
352(12)
Summary
364(3)
Chapter 12 Simulation
367(22)
Unity 3D
367(2)
Building a Scene
369(2)
Importing CAD Models
371(2)
Programming Scripts
373(4)
Communication Functions
377(2)
User Interface
379(1)
Machine Learning
380(8)
Summary
388(1)
Chapter 13 Machine Vision
389(34)
Smart Camera
391(6)
Vision Functions
397(7)
Deep Learning
404(8)
Convolutional Networks
412(7)
Summary
419(4)
Part IV Robot Hardware
423(130)
Chapter 14 Motors
425(26)
DC Motors
429(2)
Stepper Motors
431(2)
Brushless Motors
433(4)
Linear Motors
437(4)
Motor Sizing
441(8)
Summary
449(2)
Chapter 15 Encoders
451(18)
Hall Sensors
455(2)
Quadrature
457(4)
SSI
461(3)
Tamagawa
464(3)
Summary
467(2)
Chapter 16 Servo Drives
469(30)
Power Switches
473(9)
Gate Driver
482(6)
Current Sensing
488(9)
Summary
497(2)
Chapter 17 Power Management
499(20)
DC Bus Voltage
500(8)
Protection Functions
508(8)
Voltage Converter
516(1)
Summary
517(2)
Chapter 18 Main Controller
519(18)
Microcontroller
519(3)
10s
522(6)
Fieldbus
528(2)
Integrated Solution
530(4)
Display
534(2)
Summary
536(1)
Chapter 19 Fabrication
537(16)
PCB Design
537(11)
Mechanics
548(3)
Summary
551(2)
Appendix: Kinematic Models 553(48)
Index 601
Fabrizio Frigeni is a multi-cultural engineer, hobbyist, teacher and entrepreneur. Hailing from Italy, he holds a degree in Electrical Engineering from the Polytechnic University of Milan; then worked on laser physics for his Masters degree at the University of Illinois at Chicago, USA; and later completed a doctoral degree in microelectronics at the Technical University of Dresden, Germany.





He has gained extensive experience in the fields of automation, robotics, computer vision, and machine learning, while working for several years on assignments in Austria, Brazil, India and China. He has been based in Shanghai since 2009, where he has first managed local engineering teams, and then started his own company to teach, consult, and design control systems for automated machines and robots.