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05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear WeldingCristiano Steffens, Valquíria Hüttner, Bruno Leonardo, Vagner Rosa, and Silvia Silva da Costa Botelho
Universidade Federal do Rio Grande – FURG
Centro de Ciências Computacionais
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Introduction
What? Linear Welding robotization through Machine Vision Programmable Logic
Why? Linear Welding activities can not be programmed Teach and Playback is not an option Welding is an unhealthy work
Goals Robot control / Automated Actuation Power source and wire feed control Vision Based Measurement system Runtime recognition of the groove dimensions and
welding
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Typical linear welding robot installation
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Operational prototype
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Sensors
Continuous Rotation Potentiometers Hall Effect Encoders Optical Encoders Voltage Transducer Current Transducer Camera (5MP)
Analog Signals are decoded using an 8-bit ADC
FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Overview of Digital Control System
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Image Capture Module
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Image Preprocessing Module
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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SDRAM Control Module
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Modbus protocol structure
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Results:Compilation Report
Specification DescriptionFPGA Device EP4CE22F17C6Total Logic Elements 6,351 / 22,320
(28%)Combinational Functions 5,720 / 22,320
(26%)Dedicated logic registers 3,378 / 22,320
(15%)FPGA PLLs 1/4 (24%)I/O pins (external) 111 / 154 (72%)Embedded Multiplier 9-bit 0 / 132 (0%)Total memory bits 42,992 /
608,256(7%)
FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Results:Image Processing throughout the VBM system
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Results:Measurement [mm] of the VBM system when applied to a ½ inch thick steel plate
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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Estimated Production Costs
Description USDDE0-Nano Development and Education Board 79,005 Mega Pixel Digital Camera Package 80,00SparkFun FTDI Basic Breakout 15,00Raspberry Pi 2 Model B + SD Card 60,00Shielded Cables and Terminals 200,00Discrete Electronic Components 100,00Shields and Cases 150,00Software Licences 0,00Total 684,00
05/01/2023 FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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What’s next?
Closed Loop control of the welding parameters Improved actuation (PID or RMRAC) Floating Point Operations Electrical Protection Mechanical Protection
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Thank you!
FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
CristianoSteffens@furg.br
Thanks to:
FPGA-Based Sensor Integration and Communication Protocols for Automated Robot Control in Linear Welding
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