Industrial robotics for ERP controlled smart factories

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. 2 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. 3 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. 4 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. DOI: 10.17667/ iim.2015.1-2/6. 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. 6 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. 7 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). Re e ences [1] Anke J., Kabi zsch K., “Cos -based Deploymen Planning o Componen s in Sma I em En i onmen s”, in Eme ging Technologies and Fac o y Au oma ion, ISBN: 0-7803-9758-4, pp. 1238-1245, P ague, Sep embe 2006. [2] Pé e Tamás, No be Szakály, “Decision help sys em suppo ed da a- mining me hod”, in Biomechanica Hunga ics, ISSN: 2060-0305, Pape A0023, 2013. [3] Yi Wu, Fengping Wu, “Resea ches on SAP-CRM's applica ion in ciga e e manu ac u ing ac o y”, in A i icial In elligence, Managemen Science and Elec onic Comme ce (AIMSEC), ISBN: 978-1-4577-0535- 9, pp. 4762-4765, Augus , 2011. [4] Mahi Du sun, Semih Özden, “PC-based da a acquisi ion sys em o PLC-con olled linea swi ched eluc ance mo o ”, in Tuskish Jou nal o Elec ical Enginee ing & Compu e Sciences, 2013/21, doi:10.3906/elk- 1105-24, pp. 71-80, Janua y, 2013. [5] Wol B., He zig P., Beh ens I., Majumda A., “Da a s eam p ocessing in ac o y au oma ion”, in Eme ging Technologies and Fac o y Au oma ion (ETFA), ISBN: 978-1-4244-6848-5, pp. 1-8, Bilbao, 2010. [6] Sa io D., Ka noukskos S., Mo iei a Sa de Souza L., T i a V., “Reac i e business p ocesses o ac o y au oma ion”, in Indus ial In o ma ics Con e ence, ISBN: 978-1-4244-3759-7, pp. 620-625, Ca di , Wales, June, 2009. [7] Rashid M.A., Riaz Z., Tu an E., Haskilic V., Sunje A., Khan N., “Sma ac o y: E-business pe spec i e o enhanced ERP in ai c a manu ac u ing indus y”, in Technology Managemen o Eme ging Technologies (PICMET), ISBN: 978-1-4673-2853-1, pp. 3262-3275, Vancou e , BC, Augus , 2012. [8] an Pu en, B.-J., Kues ne , M., Rosja , M., “The Fu u e Fac o y Ini ia i e a SAP Resea ch”, in Eme ging Technologies & Fac o y Au oma ion, ISBN: 978-1-4244-2727-7, pp. 1-4, Mallo ca, Sep embe , 2009. [9] Ding Lijie, Tang Hao, Zhou Lei, “The Applica ion o Pee o Pee SAP- based Q-Lea ning in Task Assignmen o Mul iple Robo s”, in Con ol Con e ence, ISBN: 978-7-81124-055-9, pp. 536-539, Hunan, June, 2007. [10] Hameed B., Khan I., Du F., Ro he mel K., “An RFID based consis ency managemen amewo k o p oduc ion moni o ing in a sma eal- ime ac o y”, in In e ne o Things, ISBN: 978-1-4244-7413-4, pp. 1-8, Tokyo, Decembe 2010. [11] Zubia J.G., Pa a I.T., “WEB 2.0 con ol a chi ec u e o indus ial obo s”, in Eme ging Technologies and Fac o y Au oma ion (ETFA), ISBN: 978-1-4244-6848-5, pp. 1-8, Bilbao, Sep embe , 2010. [12] Al a es A.J., de Souza J.L.N., Teixei a E.L.S., Fe ei a J.C.E., “A me hodology o web-based manu ac u ing managemen and con ol”, in Au oma ion Science and Enginee ing, ISBN: 978-1-4244-2022-3, pp. 668-673, A ling on, VA, Augus , 2008. [13] Beh ouz Shahgholi Ghah a okhi, Nase Mo ahedinia, “Con ec ga he ing and managemen o cen alized con ex -awa e hando e in he e ogenous mobile ne wo ks”, in Tuskish Jou nal o Elec ical Enginee ing & Compu e Sciences, 2012/6, doi:10.3906/elk-1101-1042, pp. 914-933, June, 2012. [14] E winski, K. Pap ocki, M. ; G zesiak, L.M. ; Ka wowski, K. ; Waw zak, A. “Applica ion o E he ne Powe link o Communica ion in a Linux RTAI Open CNC sys em” in IEEE T ansac ion on indus ial elec onics, ISSN: 0278-0046, pp. 628-636, Feb ua y, 2013. [15] Ty in I., Vylegzhanin A., Kozhe niko S., Kuzne so O., Skobele P., Kolbo a E., Shepilo Y., “Mul i-agen sys em “Sma Fac o y” o eal- ime wo kshop managemen : Resul s o design & implemen a ion o Izhe sk Axion-Holding Fac o y”, in Eme ging Technologies & Fac o y Au oma ion (ETFA), ISBN: 978-1-4673-4735-8, pp. 1-4, K akow, Sep embe , 2012. [16] Mesnil P.C., Ulme C., Gomez L., “Web based communica ion be ween embedded sys ems and an ERP”, in Indus ial In o ma ics (INDIN), ISBN: 978-1-4244-3759-7, pp. 551-556, Ca di , Wales, June, 2009.