Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
1
Indus ial obo ics o ERP con olled sma
ac o ies
Fe enc Taj i
MTA-ELTE Compa a i e E hology Resea ch G oup (MTA:
01 031), Dp o Mecha onics Op ics and Enginee ing
In o ma ics, Facul y o Mechanical Enginee ing
Budapes Uni e si y o Technology and Economics
Budapes , Hunga y
[email p o ec ed]me.hu
Géza Szaye
Depa men o Mecha onics Op ics and Enginee ing
In o ma ics, Facul y o Mechanical Enginee ing, Budapes
Uni e si y o Technology and Economics
Budapes , Hunga y
Bence Ko ács
Depa men o Mecha onics Op ics and Enginee ing
In o ma ics, Facul y o Mechanical Enginee ing, Budapes
Uni e si y o Technology and Economics
Budapes , Hunga y
Pé e Ko ondi
Depa men o Mecha onics Op ics and Enginee ing
In o ma ics, Facul y o Mechanical Enginee ing, Budapes
Uni e si y o Technology and Economics
3MTA- BME Con ol Enginee ing Resea ch G oup
Budapes , Hunga y
Abs ac —A p oduc manu ac u ing he ime- o-ma ke
ac o , he p o i abili y and he deli e ed alue de ine he success
o an en e p ise. The inc easing numbe o modules in En e p ise
Resou ce Planning (ERP) p og ams is a acing p oblem, when
he e is a ma gin be ween he manu ac u ing cells and he ERP.
Nowadays, he connec ion be ween he indus ial machines and
he ERP is an impo an equi emen especially a au oma ed
wa ehouses and sma ac o ies. O he conce ns a
manu ac u ing a e he main enance schedules o he machines,
and lexible and easy econ igu a ion o he p oduc ion lines o
he p oduc ion cells. In o ma ion echnology p o ides solu ions
and so wa e en i onmen s o implemen complex p oduc ion
supe iso ERPs a sma ac o ies. A a p oduc ion line o an
au oma ed wa ehouse se e al echnical pa ame e s and
in o ma ion can in luence he planning o he esou ces a he
en e p ise, like main enance, machine e o , s ockpile, p oduc
ID, de ec i e p oduc a ios, e c. When he e is machine
main enance, he company needs o o de he se ice pa s, as
well as schedule he se ice ime and he s op o he p oduc ion
line. In case o a machine e o , he sys em can es ima e he
leng h o he se ice ime om e o messages, and eo ganize
o de s, anspo a ion, o e en main enance schedules o o he
machines. Ou plug and play ype obo and indus ial
au oma ion con olle p ojec gi es a solu ion o hese ha dwa e
demanding needs.
Keywo ds— In elligen sys ems; Robo con ol; Au oma ion;
I. INTRODUCTION
Ha dwa e solu ions can be easily con igu ed wi h any
indus ial machine o au oma ion cell, and de eloped o
LinuxCNC, which is an open sou ce Linux so wa e
en i onmen . The co e o he sys em is a PCI based mo ion
con ol ca d wi h se e al IOs and u he RS485 and CAN
based modules. Acco ding o he open sou ce s uc u e, any
in o ma ion o he sys em (like main enance, machine e o ,
s ockpile, o p oduc ID) can be moni o ed, sa ed and
ansmi ed ia elne o o he PC compa ible communica ions.
In his pape we p esen he de eloped PCI d i e and he
ha dwa e en i onmen a ound LinuxCNC. A au oma ed
wa ehouses wi h p oduc and p oduc pa IDs he e o a e
and he cause o he p oblems can be in es iga ed, and he
s ockpiles can always be upda ed and compa ed o he
expec ed alues [1, 2]. The ERP o a sma ac o y equi es
special machine in o ma ion. E en in he same ac o y and he
same machine he ype o he in o ma ion depends on he
applica ion [3]. Fo example he ool ab asion, he ool
amo iza ion and ool change can be also es ima ed and
scheduled. When an indus ial obo is used o pain ing, he
equi ed in o ma ion is he amoun o pain , bu a a selec ion
scena io i can be he colo o he pa s. A a p oduc ion line
he messages and he e o s ha e di e en p io i ies. The
amoun o he ed and g een colo ized pa s is no as impo an
as an e o message. A obo se o aul e o will s op he
whole machine, and in mos o he cases he whole p oduc ion
line. I a pa is b oken, ha also gene a es e o messages, bu
i in luences only he e o a e, and i wa ns he sys em o
check he p e ious p ocess o he supplie . A comme cial
indus ial obo s he access o in o ma ion o a machine is
limi ed, especially a PLC based p oduc ion cells [4]. I is
usually enough o no mal sys em equi emen s, bu no o
special needs [5-8]. A he open sou ce au oma ion con ol
sys em di e en modules can be ins alled, implemen ed o
de eloped like a he ERPs [9, 10]. The de elopmen o
LinuxCNC was s a ed om p e ious p ojec s in he Uni ed
S a es Pa en and T adema k O ice. Acco ding o he open
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
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sou ce and modula so wa e en i onmen we could
implemen a PCI d i e , ha moni o s all o he a iables in
he embedded sys em and a he RS485 and CAN modules as
well. The PCI mo ion con ol ca d is an FPGA and PCI-b idge
based ASIC (Applica ion Speci ied In eg a ed Ci cui ) o
in e acing wi h he mos possible sys em elemen s ha can be
ound in an au oma ed obo ic cell.
II. SOFTWARE
A. In e ace be ween ERP solu ions and manu ac u ing
As he PCI ca d can be ins alled o any gene al pu pose PC
o indus ial PC solu ions as well, i can be connec ed o ERP
se e s ia all con en ional p o ocols, like E he ne o wi eless
ne wo k. Fo a eady o use solu ion, he LinuxCNC ke nel
can communica e on Telne in e ace ia E he ne o WiFi
[11-13]. (See Figu e 1).
Figu e 1 The block diag am o he ERP sys em wi h ou obo
con olle concep
B. Sys em desc ip ion
In he so wa e enginee ing sense he co e o he sys em is
he LinuxCNC ( he Enhanced Machine Con olle ), an open-
sou ce so wa e en i onmen o compu e con ol o
indus ial machines like milling machines, obo s and la hes.
The use can in eg a e sel -de eloped so wa e modules in o
he LinuxCNC, like a PCI ca d d i e , di ec , in e se
kinema ics, and communica ion ames ia any PC-based
communica ion in e aces and any o he so wa e modules.
Fo example du ing a machine con ol wi h CAN bus and
RS485, he PCI ca d handles he OSI L1-L3 laye s o machine
speci ic CAN and RS485 communica ion, while he
LinuxCNC d i e handles PCI communica ion and all he
highe OSI Laye s o machine in e aces.
C. LinuxCNC
As men ioned in he in oduc ion, he de elopmen o
LinuxCNC was s a ed om p e ious p ojec s in he Uni ed
S a es Pa en and T adema k O ice. Sou ce code is hos ed by
open sou ce communi y using GIT e sion con ol sys em.
The open sou ce communi y mo i a es, and p o ides suppo
o de elope s o add housands o lines o new code and
many new modules o LinuxCNC e e y mon h. LinuxCNC
in eg a o s may con igu e which modules o use and how o
connec hem. A e a so wa e de elopmen pe iod is closed,
all modi ica ions a e app o ed and es ed, and he ac i e and
suppo i e communi y publishes he nex main e sion on he
o icial websi e wi h he addi ional unc ions, modules and
documen a ion.
LinuxCNC so wa e modules can be se up and con igu ed
based on he Ha dwa e Abs ac ion Laye concep , like many
ope a ing sys ems. In his model, all so wa e modules ha e
well-de ined inpu s, ou pu s and unc ions. These so wa e
modules a e compiled, bu no connec ed in compile ime.
LinuxCNC in eg a o s de ine connec ions and con igu e
module pa ame e s in HAL iles. HAL iles a e loaded e e y
ime he p og am s a s, so in eg a o s do no need o compile
so wa e. The LinuxCNC has di e en so wa e modules like
kinema ics, HAL iles, use in e aces, scopes, ladde
diag ams, e c. These so wa e pa s can be added and
connec ed wi h each o he . Fo example he ollowing HAL
so wa e modules will be con igu ed o implemen ed in he
case o an indus ial CNC machine wi h au oma ic wo k piece
handling: kinema ics, ouch sc een op imized use iendly
GUI (see Figu e 2), compu e ision sys em and he ladde
diag am o some PLC unc ions. This open and highly
modula concep enables LinuxCNC o con ol many di e en
physical sys ems [14]. and LinuxCNC can be con olled on
highe le el by ERP.
Figu e 2 The ouch-sc een-op imized GUI o he Linux CNC
in e aces.
D. Cus om PCI d i e
LinuxCNC uns on Real-Time Linux ke nel (Linux RTAI).
A new ke nel module was de eloped o con ol cus om PCI
ca ds, as well as o in e ace cus om obo s and o he indus ial
machines o LinuxCNC so wa e en i onmen . I emains as a
challenge o he so wa e and ha dwa e speci ica ion o
suppo new machine in e aces, like CAN o E he ne based
ield buses, bu i suppo s con en ional obo ics and
au oma ion in e aces as well, like inc emen al pulse mo ion
e e ence signals.
In case o inc emen al posi ion e e ence, he s ep signals
and amp unc ions a he sys em a e gene a ed by he PCI
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
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ca d. The mos in e es ing implemen a ion is he s ep
gene a ion, bu he me hods below a e used a leas pa ly a
he analogue, E he ne based, and o he CAN based e e ences
and con ol me hods, like CAN-Open o De ice-Ne . (See
Figu e 3)
Linux CNC HAL
PCI Ca d
PCI Ca d D i e
...
Ca d 0. Axis Connec o 0. 1,3,4
(Encode ) Pins
0/3,3 V
FPGA
PLX
loa
gm.0.posi ion- b.0
Ca d 0. Axis Connec o 0. 7,8
(STEP/DIR) Pins
0/3,3 V
FPGA
PLX
loa
gm.0.s epgen.0.pos-cmd
S epgen Componen s
0.posi ion-cmd
0.s ep
0.di
1.posi ion-cmd
PCI Componen s
Axis.0.Di gm.0.s epgen.0.di
Axis.0.S ep
2.posi ion-cmd
0.posi ion- b
1.s ep
1.di
1.posi ion- b
2.s ep
2.di
2.posi ion- b
STEP
DIR
gm.0.s epgen.0.s ep
...
...
Se o communica ion
Cyclic bu e
E o handling
CAN Componen s
...
Mo ion componen s
T ajec o y planne Fb.
Re .
PCI
Figu e 3 The block diag am o he HAL laye
The inpu o he s ep gene a o (in line wi h he cons an
a iables) is he posi ion e e ence, and he ou pu s a e he s ep
and he di signals. The basic p inciple o his speed con ol
based in e pola ion is ha he in e pola o uns a a ixed
pe iod in e up , and calcula es he equi ed speed o he
mo o in e e y ime s ep, ollowing he equi ed mo ion
p o ile. To s a and s op he mo o in a smoo h way wi hou
s eady s a e posi ion e o o posi ion o e shoo , con ol o he
accele a ion and decele a ion is needed. The ela ion be ween
(angula ) accele a ion (see equa ion 1), speed (see equa ion 2)
and posi ion (see equa ion 3) is he de i a ion. (See igu e 4).
(1)
(2)
(3)
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
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The posi ion e o (see equa ion 4) is calcula ed by he
sub ac ion o he ac ual posi ion om he e e ence posi ion,
o “posi ion command”.
(4)
Figu e 4 Posi ion, speed and accele a ion ime unc ions
Ini ially, he speed has o be calcula ed om he posi ion e o
cons ained by he gi en maximum decele a ion ha d i es he
mo o exac ly o he a ge posi ion. In o he wo ds, he speed
has o be limi ed o p e en ing posi ion o e shoo . Fo his,
we ha e o exp ess he speed om he posi ion and speed
mo ion equa ions (see equa ion 5).
(5)
The second cons ain is he calcula ed speed which doesn’
cause posi ion o e shoo , and has o be limi ed o a maximum
alue ha he mo o can ollow. The las cons ain ha has o
be conside ed is he maximum accele a ion ha can dec ease
he ac ual speed ou pu o he in e pola o . (See Figu e 5) The
eques ed accele a ion can be calcula ed by nume ic
de i a ion, by sub ac ing he las calcula ed speed om he
ac ually calcula ed one. Then i can be sa u a ed by simple
b anches. I he equi ed accele a ion is highe , he new speed
ou pu will be equal o he las speed ou pu inc emen ed by
he maximum accele a ion.
Speed
Max. decele a ion
Max. speed
Max. acc.
Figu e 5 The amp unc ion
The calcula ed speed in s ep/s has o be con e ed o ime
coun pe iod o e alua ing he s ep gene a ion (see equa ion
6).
(6)
The pe iod can be calcula ed only i he speed ou pu is non-
ze o. Ano he a iable has o indica e i he mo o has o be
s opped. Hence he pe iod does no include he di ec ion
in o ma ion; he di ec ion has o be s o ed in ano he logic
a iable, he alue o which depends on he sign o he speed.
The ime compa e egis e s alue has o be calcula ed o he
nex s ep in each in e up . The pe iod a iable is gi en in
ime coun s. So he nex compa e alue can be calcula ed by
adding he pe iod o he las compa e alue, bu he egis e
and he ime o e low ha e o be handled. I he pe iod
exceeds he ime op alue, and o e low coun e has o be se
depending on he numbe o o e lows. The e is no s ep
gene a ion in e e y in e up eques in his case, only when
he o e low coun e is ze o again. The so wa e is composed
om a ixed and a a iable pe iod ime in e up s. The ixed
s ep in e up is p ac ically execu ed in be ween 1~10 ms. The
posi ion e o , he speed, he ime pe iod and he di ec ion a e
calcula ed in o de in his in e up . Fi s , he ime compa e
egis e s nex alue is calcula ed in he a iable pe iod (s ep
gene a ion) ime in e up . Then one s ep should be
gene a ed, i he Run lag is ac i e. A e a s ep, he ac ual
posi ion has o be upda ed o gi ing posi ion eedback o he
in e pola o . The speed is calcula ed in he ixed pe iod
in e up , and du ing decele a ion, he ze o speed should be
gi en when he posi ion e o is ze o. Bu in mos cases, mo e
han one s ep is gene a ed in he a iable pe iod ime in e up
wi h he las speed command; hence posi ion o e shoo and
oscilla ion occu . (See Figu e 6)
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
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5
Speed
Fixed pe iod
in e up
Figu e 6 The o e shoo unc ion
To a oid his si ua ion, he condi ions o he inal s op ha e o
be handled in he a iable pe iod ime in e up in case o all
s eps. (See Figu e 7) The condi ions a e as ollows: I he
posi ion e o is ze o, and he speed is unde a low speed
h eshold, hen do no gene a e any mo e s eps ( ed poin in
Figu e 7). P ac ically, a low speed lag should be se o clea ed
in he ixed pe iod in e up , o imp o ing he execu ion
e iciency ( ls (Speed)). The compa ison o he signed 16 bi
alues is done in he ixed pe iod in e up . And only he low
speed lag is checked o e e y s ep in he a iable pe iod
(high speed) in e up .
Fixed pe iod in e up :
In e pola o
Va iable pe iod ime in e up :
S ep gene a ion
Calcula e posi ion e o :
s = Re e encePos - Ac ualPos
Calcula e speed [s ep/sec] conce ning
s (s ~ „b ake dis ance”):
Speed = b ake(s)
Sa u a e speed o maximum:
Speed = maxspeed(Speed, MaxSpd)
Limi speed conce ning accele a ion:
Speed = maxacc(Speed, Las Speed,
MaxAcc)
Calcula e s ep pe iod om Speed:
Time Pe iod = pe iod(Speed)
&
Speed == 0 -> Run = 0
&
Calcula e di ec ion om sign o Speed:
Di = di (Speed)
&
Calcula e low speed lag:
LowSpeed = ls (Speed)
Global a iables:
Time Pe iod,
Run,
Di ,
LowSpeed
Calcula e nex ime
compa e egis e alue:
Compa e = comp(Pe iod)
i (LowSpeed)
{
I (Re e encePos - Ac ualPos == 0)
Run=0;
}Gene a e one s ep wi h
di ec ion i (Run== 1)
Calcula e ac ual posi ion:
Inc emen /dec emen wi h
one s ep
Global a iable:
Ac ual Posi ion
Re e ence
posi ion
Figu e 7 The de ailed block diag am o he s ep gene a ion

Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
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III. HARDWARE
A. Sys em desc ip ion
The sys em can be con igu ed wi h di e en se o
applica ions and PLC unc ions. The cen e o he con olle is
he PCI based mo ion con ol ca d. The main goal o he
de elopmen is o ollow he newes pa adigms in he iew o
obo con ol heo y, wha means ha he sys em should be
open sou ce and plug and play. A he in eg a ion o a
manu ac u ing cell a a p oduc ion line, di e en kind o signs
and in o ma ion o he obo may need o be obse ed a a
sma ac o y sys em [15]. A a no mal indus ial obo con ol
sys em jus he ypical in o ma ion can be moni o ed, like he
posi ion and he o ien a ion o he obo , he join coo dina es
and he numbe o he wo king cycles e c. A an open sou ce
and plug and play ype au oma ion con olle all o he
pa ame e s, a iables and signs can be moni o ed du ing he
manu ac u ing o he s o age p ocess. The PCI ca d can be
used in a no mal PC wi h a eal- ime Linux OS. Teach
pendan wi h VGA, ouch in e ace wi h USB, E he ne ,
came a ision sys em and o he PC based o cus om
in o ma ics de ices can be used wi h he machine in he iew
o in o ma ion science and ERP-s.
In he iew o obo con ol heo y he ca d has a PLX
con olle wi h PCI based communica ion, and i is connec ed
o a Xilinxs Spa an III FPGA ia a 32 bi pa allel bus. (See
Figu e 8) The FPGA and he PCI d i e handle he connec ion
be ween he ha dwa e and he so wa e laye . Mos o he
obo con olle s canno handle PLC unc ions and canno be
connec ed o a ne wo k as lexible as a no mal eal- ime Linux
based PC. The analog and digi al RS485 IOs can be con olled
by a no mal C code o he ladde diag am edi o o he
so wa e en i onmen like a no mal PLC-s. Wi h he di e en
isola o , di e en ial line d i e , IO, and b eakou modules a a
p oduc ion line mos o he elemen s can be con olled
including he p oduc ion speci ic special machines like a i e
axis milling machine, which p oduces oo h implan s o
den is s. In hese cases he machine is designed by mechanical
enginee s and i canno be in eg a ed in o a manu ac u ing cell
wi hou a con olle . The sys em can be connec ed o hese
specialized machines wi hou any long ime demanding
so wa e and elec ical enginee ing de elopmen [16]. The
CAN based, analog o inc emen al se o ampli ie s o he
machine can be connec ed o he PCI ca d di ec ly o ia op o-
isola ed and di e en ial d i e modules. Six axes can be
in e pola ed wi h one ca d and he LinuxCNC so wa e
en i onmen can handle wo ca ds and can in e pola e up o
nine axes. The RS485 bus can handle 16 modules ( elay
ou pu , op o-isola ed inpu , ADC and DAC, Teach Pendan )
wi h one ca d. (See Figu e 9)
CONTROLLER CASE
PCI ca d
FPGA
Xilinx Spa an III
(TQFP208)
32-bi
pa allel bus
PCI- bus
Faul
Enabled
Encode
(A,B,Z)
S ep/Di ,
CW/CCW,
A/B, CAN,
±10V
PC - Real ime Linux
Open Sou ce Robo ic
Pla o m: Linux CNC
PLX PCI-bus
in e ace
(TQFP176)
IN-OUT MODULES:
Relay ou pu module
Op o-isola ed inpu
module
ADC/DAC module
INTERFACE
MODULES
SERVO
MODULES
(Posi ion,
speed o
cu en
modes)
CUSTOM
TOOLS/
DEVICES
Ex.: Kinec 3D
came a,
i-Space, Mo ion
cap u e,
RT-Middlewa e
componen s
TEACH
PENDANT
Touch-sc een,
Joys ick, o he
UI elemen s
CAN-Open/De ice Ne
E he ne
E he CAT
RS485-bus
Figu e 8 The de ailed block diag am o he sys em
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
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Figu e 9 The block diag am o a sample obo con olle
B. PCI ca d
As i is de ailed below he ca d has a PLX-Xilinx
embedded sys em and i can be implemen ed in a p oduc ion
line wi hou ha dwa e enginee ing de elopmen . This
ad an age comes om he modula i y, he ac ha he
so wa e en i onmen is open sou ce, and he pe iphe ies o
he PCI ca d (see Figu e 10). The main ha dwa e elemen s o
he pe iphe ies a e he pa s o he ca d, like he isola ed CAN,
he RS485 anscei e s, he op o-couple s o he machine
speci ic pins, he moni o ing LEDs, six axes connec o s, and
ou connec o s o gene al pu pose IO pins. The RS485,
CAN, inc emen al se o, axis DAC and o he modules can be
connec ed di ec ly o he ca d.
Figu e 10 The PCI ca d
Some o he egis e s can be w i en o (like s ep a iables)
and some o he egis e s can be ead (like encode a iables).
A disc e e con ol (se ies o coo dina es) o he obo we
only calcula e he nex poin (posi ion, join coo dina e), and
he pa h is no p esc ibed be ween he cu en and he nex
posi ion. A con inuous con ol he in e pola o o he sys em
makes con inuous calcula ions o ge pa h poin s equen ly
and c ea e a smoo h mo ion be ween he s a and he end
posi ion and o ien a ion. The so wa e en i onmen w i es he
join coo dina es o hese posi ions and o ien a ions o he
co esponding egis e s du ing he mo ion. The mo ion con ol
ca d and he PCI d i e gene a e he physical o m o he da a
like s ep signs o he inc emen al se o ampli ie s. The
posi ion o speed con olle s a e calcula ed on he se o
ampli ie s. In case o an old analogue sys em he posi ion and
speed con ol me hods can be calcula ed on he PCI ca d. This
me hod can handle decen alized mo ion con ols. In case o a
cen alized mo ion con ol we can implemen he in e se
dynamical equa ions o he machine so o que (cu en )
e e ences can be gi en o he se o ampli ie s. Some o he
con ol me hods and pa ame e s a e calcula ed on he PCI ca d
e en o decen alized mo ion con ol. Fo example a a s ep
signal gene a ion we can de ine he maximal accele a ion, he
maximal speed and he maximal decele a ion, wha desc ibes
he de ini ion o he eloci y- ime unc ion o an axis. The
leng h o he s eps, he di ec ion delay, he leng h o he s ep
spaces and he s ep/uni can also be adjus ed. The amp
unc ion gene a es he s ep signals be ween wo disc e e ime
s eps du ing he mo ion con ol.
C. Se o applica ions
The se o mo o s o he indus ial obo s a e usually PMSM o
BLDCs and a olde obo s a e b ushed DC mo o s. The se os
ampli ie s a e usually sold in pai wi h he mo o s, which can
ge posi ion, eloci y, o o que e e ences ia inc emen al,
CAN based, o analog signal e e ences.
The ollowing ypical example connec ions can be easily made
be ween he PCI ca d and he se o ampli ie s wi h he
de eloped modules o he sys em:
Analogue sys em wi h encode eedback
 Inc emen al digi al sys em wi h encode eedback and
di e en ial ou pu
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
8
 Inc emen al digi al sys em wi h encode eedback and
TTL ou pu (see Figu e 11)
 Inc emen al digi al sys em wi h di e en ial ou pu
 Inc emen al digi al sys em wi h TTL ou pu
 Absolu e digi al (CAN based: CAN-Open) sys em (see
Figu e 12)
 Absolu e digi al (CAN based: CAN-Open) sys em wi h
con en ional (A/B/I) encode eedback
Each o he se o connec ions has a de ailed block
diag am. In each applica ion he signals be ween he se o
ampli ie s and he PCI ca d a e isola ed, and posi ion eedback
can be made o moni o he acking e o s o he TCP o he
join s in he LinuxCNC. A he implemen a ion o he sys em,
du ing he uning phase o he con ol me hods (usually PI,
PD, PID, o PID wi h an i windup) a he se o ampli ie s, he
s ep esponse can be moni o ed wi h he scope module o he
LinuxCNC. The ha dwa e pa ame e s like he encode CPR,
he s ep/ adian o s ep/mm, e c. can be de ined in he HAL
(Ha dwa e Abs ac ion Laye ) iles a he con igu a ion o he
sys em. (See below in sec ion 3.)
PCI Ca d/
Axis connec o
RJ50
TTL
TTL
Isola o
RJ50
RJ50
RJ45
SK2P
5V in
SERVO &
Encode Enc.
D i e
SERVO
MODUL
S ep/Di
CW/CCW
A/B D i e
Enc.
RS-422
Di .
Encode B eakou
RJ45 SK10P
RJ50
Di e en ial
Line D i e
RJ50 SK10P
Figu e 11 The block diag am o he di e en ial axis con ol example
PCI Ca d/
Axis connec o RJ50
CAN
SERVO
MODUL
CAN D i e
Enc.
SERVO &
Encode
D i e
Enc.
Figu e 12 The block diag am o a CAN-based axis con ol example
D. RS485 modules
The PLC unc ions, ool magazines, con eyo bel s,
capaci i e o in a ed senso s can be handled by he de eloped
RS485 modules o he sys em. In mos o he machines one
PCI ca d and one eal- ime Linux based PC a e enough o he
con ol o he se o modules and he pe iphe ies. All o he
modules a e isola ed, and ha e double connec o s o c ea e
om module o module wi es, wi h he PCI ca d a he s a o
he bus, and wi h end esis o s a he end o he bus (See
Figu e 13). The sys em's IO capabili y is lexible: One inpu
module can handle 8 isola ed inpu s, and a elay ou pu
module has 8 ou pu s. The analogue module has 4 DAC and 8
ADC channels. One ca d can handle 16 modules, so a
complex CNC can be con olled e en i i equi es 50 elays o
handle all o he pe iphe ies. The a iables o he RS485
modules ( he alues o he inpu s and ou pu s) can be
connec ed a he HAL iles wi h any pa s o he LinuxCNC
so wa e, o example wi h a bu on a he ouch in e ace o
he elne module o u he da a handling.
The communica ion is a 9 bi RS485, whe e e e y module
has a 4 bi add ess and a 4 bi command and he 9 h bi
indica es i i is a da a message o an add ess/command
message. The end o he communica ion he e is a checksum.
A he open sou ce PCI d i e , cus om RS495 (and CAN)
based communica ion p o ocol can be also de ined by he use .
I allows o he use p oduc s om di e en dis ibu o s o
e en sel designed modules o op imize he manu ac u ing cell
in he enginee ing sense.
Fi s Node
BUS
powe ed
side
(12V)
Op ical
isola ion
B
U
S
24V in
Field
powe ed
side En i omen
Las Node
BUS
powe ed
side
(12V)
Op ical
isola ion
24V in
Field
powe ed
side En i omen
...
RJ12RJ12
PCI Ca d
/
RS485 connec o
RJ12
End
Resis o s
Figu e 13 The block diag am o he RS485 modules
IV. DISCUSSION
The de elopmen o his open sou ce con olle s a ed in
2009, wi h he goal o c ea e a adi ional bu easy o in eg a e,
plug & play con olle which can be cus omized o speci ic
Recen Inno a ions in Mecha onics (RIiM) Vol. 2. (2015). No. 1-2.
DOI: 10.17667/ iim.2015.1-2/6.
9
needs. The expe ience o he las ou yea s showed us an
ongoing pa adigm shi in he in eg a ion o indus ial
con olle s in o he ERP ne wo k o he sma ac o ies. Due o
he open sou ce p ope y, hese con olle s become a good
pla o m o de eloping no el unc ions such as ERP
in eg a ion.
V. CONCLUSION
In he pas yea s, wo o he i s cus om CNC con olle s
a e in eg a ed in o a cus om ERP sys em which was de eloped
o au oma ed den al milling cells. These con olle s ge hei
manu ac u ing in o ma ion om a highe le el managemen
and esou ce planne sys em which handles he o de s, wo k
pieces, CAD/CAM iles. And du ing manu ac u ing hey send
p ocess and diagnos ic eedback in o ma ion o epo ing and
eal- ime moni o ing.
Acknowledgmen
This esea ch was unded by he Hunga ian Academy o
Sciences (MTA 01 031). The au ho s wish o hank he
suppo o he Hunga ian Resea ch Fund (OTKA K100951).
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