1028:PICARSOSven Paschburg2 System Process Design Problems Design Specifications Hardware Painting...
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Transcript of 1028:PICARSOSven Paschburg2 System Process Design Problems Design Specifications Hardware Painting...
1028:PICARSO
Ian HOOI
Samuel OOSTERHOLT
Sven PASCHBURG
Joyce PHAN
Neil YEOH
Supervisor: A/Prof Ben CAZZOLATO
PROGRAMMABLE INTERFACE CONTROLLER WITH
AUTONOMOUS ROBOTIC SPRAYING OPERATION
Sven Paschburg 21028:PICARSO
Seminar Outline
System Process
Design Problems
Design Specifications
Hardware
Painting System
Image Processing
Control Software
Testing and Results
Project Outcomes
Future Work
Sven Paschburg 31028:PICARSO
System Process
Hardware Painting System
Image Processing
Control Software
PICARSO:Cable-driven robotProcess standard image formatsReproduce images on vertical surface
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Processed
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Design Problems
Image Output
End-Effector
Original Painted
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Design Specifications
Cables
End-Effector
Motor 1
Motor 2Motor 3
Vertical Wall
CablesImage Processing Toolbox RS232
Graphical User Interface Design Environment(GUIDE)
(Mathworks 2010)
MATLAB
61028:PICARSO Samuel Oosterholt
Hardware
Design Problem
Design Specifications
System Architecture
Hardware
Painting System
Image Processing
Control Software
Testing and Results
Project Outcomes
Future Work
Samuel Oosterholt 7
Hardware Goals
Goals: Develop mechanical system
Scalable work space sizeUp to 3×3m
Manipulate and stabilise the end-effectorMounting the system:
in operation andin testing
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Samuel Oosterholt 81028:PICARSO
Hardware: Previous Work
Image producing robots Scalable workspace size
Cable driven
Hektor (Franke & Lehni 2002) Viktor (Lehni & Rich 2008)
Hektor’s actuator configuration
Viktor’s actuator configuration
PICARSO’s actuator configuration
Two actuators ‘V’ Configuration Relies on gravity
Four actuators ‘X’ Configuration
91028:PICARSO Samuel Oosterholt
Mechanical System
Three motors
‘Y’ configuration
Cables
Upper motors control position
Lower stabilises Reduces cost
Full System
Render of PICARSO system
101028:PICARSO Samuel Oosterholt
Mechanical System
Base Plate
Motor
Motor Controller
Spooling System
Cable feeding system
Motor Mount
111028:PICARSO Samuel Oosterholt
Mechanical System
Motor Mount
Motors parallel to painting surface
Plate mounts to painting surface
Double spool and bearing
Two cables Reduce yaw
and pitch Minimise
kickback
12
Cables: Spiderwire (Braid
fishing line) Ø = 0.30mm Tmax = 13.6kg Small elasticity
10m of cable 7×7m workspace
Cables attach to turnbuckles
Reorientated by eyebolts and pulleys
Can move pulleys and eyebolts Proximity to canvas Stability
1028:PICARSO Samuel Oosterholt
Mechanical System
180°Motor Mount
Lower mount uses fairleads 180° sweep
13
Drive System Hardware Specifications
Hardware selected from Maxon MotorsNumerous operation
modesModular componentsDiscounted cost & support
1028:PICARSO Samuel Oosterholt
250W EC45 Motors and Maxon EPOS2
70/10 Motor Controller
14
Mounting for Testing
Canvas implementedSimulate surfaceReduces ripple in wind
1028:PICARSO Samuel Oosterholt
PICARSO’s easel in the Vibrations Laboratory
PICARSO’s easel in the FSAE shed
PICARSO’s canvas
Not feasible to wall mount for testing 3.6 × 3.2m easel (working area: 2.8 × 2.8m) Constrained by testing environment
151028:PICARSO Neil Yeoh
Painting System
Design Problem
Design Specifications
System Architecture
Hardware
Painting System
Image Processing
Control Software
Testing and Results
Project Outcomes
Future Work
Neil Yeoh 16
Painting System Goals
Goals: Design an appropriate painting system
which: Produces circular patterns (< 3cm) Is fast (> 1Hz) and light (< 3kg) Does not cause instabilities Houses suitable paint capacity Is reliable, durable, and repeatable
1028:PICARSO
Circular Patterns ( <3cm)
Fast ( >1Hz)
Light ( <3kg)
No Instabilities
Paint Capacity
Reliable
Durable
Repeatable
Spray Can Airbrush Spray Gun*1 *2 *3
Painting Mechanisms
Three types of painting mechanisms
1028:PICARSO Neil Yeoh 17
** Image references at end of slides
Neil Yeoh 181028:PICARSO
Spray System Schematic
Paint Line
Air Line
Electrical Signal
Compressed Air Line
Electrical Air Compressor
Air Regulator
Automatic Pressure-fedSpray Gun
Personal Computer
SolenoidPressurised
Paint Canister
Paint Regulator
*4
*5
*6
*8
*7
*9
** Image references at end of slides
Neil Yeoh 19
Spray Gun Choice
Anest IwataSGA-101 Automatic Pressure-fed Spray Gun
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Fluid Adjust Knob
Fitting Knob
Paint Line
Pattern Adjust Knob
Air Line
Nozzle
Neil Yeoh 201028:PICARSO
Spray Gun Settings
Testing procedure Ideal Settings identified:
Results:Consistent < 3cm black circles
Specification Setting
Air Pressure 2.0 bar
Paint Pressure 0.5 – 1.0 bar
Spray Distance 5 – 10 cm
Fluid Adjust Knob Half Turn
Spray Duration 0.2 – 1.0 s
Spray Duration
Rep
eata
bilit
y
Neil Yeoh 211028:PICARSO
Painting System: Spray Gun Housing
Neil Yeoh 221028:PICARSO
Spray Gun Housing
Small Sleeve
Large Sleeve
BearingsEyebolts
Sleeve Shaft
Bearing Spacer
Spray Gun
231028:PICARSO Neil Yeoh
Spray Gun Housing
241028:PICARSO Ian Hooi
Image Processing
Design Problem
Design Specifications
System Architecture
Hardware
Painting System
Image Processing
Control Software
Testing and Results
Project Outcomes
Future Work
Ian Hooi 25
Image Processing Goals
Goals: Develop image processing software to:
Transform input image to user specified settings
Reproduce input image in binary formOutput in Raster (pixel-by-pixel) form
Extension Goal:Output in Vector (line) form
1028:PICARSO
Ian Hooi 26
Image Transformations Procedure
1. Input image
2. Resized to appropriate resolution
3. Stretching and refitting
4. Greyscale formScaled from 0-1 where 0 is black, 1 is white
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Resized GreyscaleOriginal
27
Fill and Edge Binary Images
1028:PICARSO Ian Hooi
Fill Image Edge Image
Fill Images: Direct conversion from greyscale binary
Edge Images: outlines of the image
Fill Image Edge Image
Ian Hooi 28
Binary Image Threshold Settings
Converted to binary formThreshold filter
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Original Binary: Threshold = 0.25
Binary: Threshold = 0.5 Binary: Threshold = 0.75
Original Binary: Threshold = 0.25
Binary: Threshold = 0.5 Binary: Threshold = 0.75
Ian Hooi 29
Output Type: Raster vs. Vector
Raster: pixel by pixel approach Vector: line based approach
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10 20 30 40 50 60
20
30
40
50
60
70
Optimal
Raster Based Output
10 20 30 40 50 60
20
25
30
35
40
45
50
55
60
65
70
Vector Based Output
10 20 30 40 50 60
20
30
40
50
60
70
Optimal
Raster Based Output
10 20 30 40 50 60
20
25
30
35
40
45
50
55
60
65
70
Vector Based Output
Ian Hooi 30
Raster Based Approach
Image output in binary form1 represents white0 represents black
Read and processed by Control Software Slow to paint
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1020
3040
5060
20 30 40 50 60 70
Optim
al
1020
3040
5060
20 25 30 35 40 45 50 55 60 65 70
=
0 1 1 1 0
1 0 1 0 1
1 1 0 1 1
1 1 0 1 1
1 0 0 0 1
0 0 0 1 1
Ian Hooi 31
Vector Based Approach
Aim: Raster Vector Searching Algorithm based on Portrayer
(Benedettelli 2008) and Erik’s XY Plotter (2007)
Adjacent pixels chains Control software
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=10 20 30 40 50 60
20
30
40
50
60
70
Optimal
10 20 30 40 50 60
20
25
30
35
40
45
50
55
60
65
70
321028:PICARSO Joyce Phan
Control Software
Design Problem
Design Specifications
System Architecture
Hardware
Painting System
Image Processing
Control Software
Testing and Results
Project Outcomes
Future Work
Joyce Phan 33
Control Software Goals
Goals: Software for Raster Mode
Convert Image Processing output to:• Control motors• Control spray gun
Extension Goals: Software for Vector Mode Graphical User Interface (GUI)
1028:PICARSO
341028:PICARSO Joyce Phan
Control Software Flow Diagram
ImageProcessing
Output
Inverse Kinematics
Motor Commands
CableLengths
PositioningCommands
CartesianCo-ordinates
Spray Gun Commands
xy
L1 , L2 , L3
1 0 0 1
on off
turns
Motor Turn Units
ControlSoftware
OutputCommands
351028:PICARSO Joyce Phan
Vector Mode
Positioning Commands
0 1 1 1 0
1 0 1 0 1
1 1 0 1 1
1 1 0 1 1
1 0 0 0 1
0 0 0 1 1
Image ProcessingOutput
Raster Mode
361028:PICARSO Joyce Phan
Inverse Kinematics
371028:PICARSO Joyce Phan
Communication
PC Master
SolenoidRS232
Digital Output
RS232
RS232
Motor Controller 1 Slave
Motor Controller 2 SlaveMotor Controller 3 Slave
• Instructions from Master to Slaves via 3 Parallel RS232 links
• Outputs controlled in Maxon RS232 Communication Protocol
Joyce Phan 38
Motor Operation Modes
1028:PICARSO
Motor 3 Motor 2
Motor 1
Position Mode Position Mode
Current Mode
• Position Mode• Driven in steps
• Current Mode• Provides tension• Minimises instabilities
39
Click icon to add picture
1028:PICARSO Joyce Phan
Graphical User Interface (GUI)
• Easy access to user settings during operation
Sven Paschburg 401028:PICARSO
Testing and Results
Design Problem
Design Specifications
System Architecture
Hardware
Painting System
Image Processing
Control Software
Testing and
Results
Project Outcomes
Future Work
Sven Paschburg 41
Testing and Results
Goals: Scaled system – µAngelo Full scale system – PICARSO Image processing software Control software Graphical User Interface (GUI)
Extension Goals: Vector-based painting Touch screen interface
1028:PICARSO
Sven Paschburg 421028:PICARSO
Testing and Results
Kinematics test bedTri-motor Y-configuration proof of concept
Scaled System - µAngelo
Oblique angle picture of µAngelo
Front view picture of µAngelo
Picture of µAngelo’send-effector
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Testing and Results
Raster painting functionalityScalable across a vertical surface
• Up to 3×3m workspace areaComplete a picture in 1 hour
Full Scale System - PICARSO
Accuracy & PrecisionReliabilityWorkspace Resolution
Pixel SizeStabilitySpeed
Test Metrics
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100 mm
50 mm10 mm
25 mm1028:PICARSO
Testing and ResultsRaster Painting Functionality
Specifications Achievement
Accuracy ± 10 mm
Precision ± 5 mm
Workspace Resolution
10 – 100 mm
Workspace Resolution (ideal)
10 – 25 mm
Sven Paschburg 451028:PICARSO
Testing and Results
Parameter Achievement
Pixel Size (min.) 8 mm
Pixel Size (ideal) 10 mm
Raster Painting Functionality
0.2 s 0.25 s 0.5 s 1.0 s
8 mm 10 mm 16 mm 20 mm
Sven Paschburg 461028:PICARSO
Testing and Results
Specifications Achievement
Stability ± 25 mm (z – axis)
Raster Painting Functionality
x
z
y
Side view of the end-effector
Bottom view of the end-effectoryaw
pitch
roll
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Testing and ResultsScalable across a vertical surface
Specifications Achievement
Workspace Area 0.5 × 0.5 m to7.0 × 7.0 m
A picture showing the ability of the end-effector to move around the workspace
Sven Paschburg 48
Goals: Scaled system – µAngelo Full scale system – PICARSO Image processing software Control software Graphical User Interface (GUI)
1028:PICARSO
Project Outcomes
A 1.8 × 1.8m painted ‘fills’ image of the Mona Lisa
Oblique angle picture of µAngelo
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Future Work
Extension Goals: Analog communication Complete a picture in 1 hour Vector-based painting Touch screen interface
Future years: Colour painting Wireless communication Commercial product
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Sven Paschburg 501028:PICARSO
Questions and Comments?
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References
Benedettelli, D. 2008, NXT Portrayer Robot, viewed 11th April 2010 <http://robotics.benedettelli.com/portrayer.htm>
Convict Episcopal de Luxembourg, 2007, Erik’s XY-Plotter, viewed 11th April 2010, <http://www.convict.lu/Jeunes/ultimate_stuff/Erik_s_xx_plotter/E_xy_plotter.htm>.
Franke, U & Lehni, J 2002, Hektor, viewed 29 December 2009, <http://www.hektor.ch/Book/Hektor.pdf/>.
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Painting System References
1. Spray can - http://comps.fotosearch.com/comp/UNN/UNN113/spray-can_~u14072509.jpg
2. Airbrush - http://imgs.tootoo.com/e1/00/e10006f419523aa3bb036a77fb5038dd.jpg
3. Spray gun - http://image.made-in-china.com/2f0j00DaTQeBfgIEMJ/HVLP-Spray-Gun-RP8021-2S-H827-S-.jpg
4. Air Compressor - http://toolmonger.com/wp-content/uploads/2006/05/aircompressor.jpg
5. Festo Air Regulator - http://www.festo.com/rep/nl-be_be/assets/LR_2008_1314u.jpg
6. Pressurised Paint Canister - http://www.smitsgroup.co.nz/images/objectimages/PT2-Paint-Tank.jpg
7. Festo Solenoid Valve - http://www.luconda.com/artikeldetails/27/29/xx/bilder/2093457-1-Festo-CPE18-M1H-3GL-1-4.jpg
8. Iwata Spray Gun - http://www.anest-iwata.co.jp/english/products/paint/prd/fog/auto/images/ceramic_ph01.jpg
9. Personal Computer - http://www.ubergizmo.com/photos/2008/12/dell-xps-13.jpg
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Further Examples and Information
541028:PICARSO Samuel Oosterholt
Hardware
HardwarePainting System
Image Processing
Control Software
PICARSO
Mechanical &Electrical
Software
Sven Paschburg 551028:PICARSO
End-Effector
561028:PICARSO Joyce Phan
Higher Level Software Flow Diagram
571028:PICARSO Joyce Phan
Raster Functionality
581028:PICARSO Joyce Phan
Vector Functionality
Ian Hooi 591028:PICARSO
Vector Algorithm Demonstration
Joyce Phan 601028:PICARSO
PICARSO Analog Communication
PC MasterEPOS2 Slave (Node 1)
EPOS2 Slave (Node 2)
EPOS2 Slave (Node 3)
NI PCI-6221 card(Analogue Inputs)
NI SB 68-LPBreakout Board
61
Click icon to add picture
1028:PICARSO Joyce Phan
Control Software: Main Menu GUI
62
Click icon to add picture
1028:PICARSO Joyce Phan
Control Software: Paint Raster Image GUI
63
Click icon to add picture
1028:PICARSO Joyce Phan
Control Software: Paint Vector Image GUI
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100mm Pixel Spacing
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50mm Pixel Spacing
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25 mm Pixel Spacing
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10 mm Pixel Spacings
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Testing and Results
Raster processing functionalityProcess an image in less than 60sVector processing functionality
Image Processing Software
Processing Settings Options
Image Input JPEG, PNG, GIF, BMP, TIFF
Image Resolution 10 – 500 pixels
Image Threshold 0 – 1
Conversion Type Fills, Edges
Palette Type Binary (Black & White)
Sizing Square, Original Aspect Ratio
Image Processing Time < 3 s
Sven Paschburg 691028:PICARSO
Testing and Results
Raster functionalityHuman Machine Interface (HMI)Vector functionalityTouch screen interface
High Level Control Software
Specifications Options
Control Mode Raster Painting, Vector Painting, Manual Positioning, Spray Control
Platform Mathworks MATLAB 2007 +
Operating System Windows XP, Vista, 7
Interface Type Graphical (Touch Screen)
Sven Paschburg 701028:PICARSO
Testing and Results
Position the motorsControl the motor velocity and accelerationRead back the current positionActuate the spray gun solenoid
Low Level Control Software
Specifications Options
Control Functions Position Control, Set Max. Velocity & Acceleration, Read Current Position, Activate Digital Output
Platform Mathworks MATLAB 2007 +
Operating System Windows XP, Vista, 7
Positioning Accuracy (theoretical) 2.11 × 10-3 mm
Sven Paschburg 711028:PICARSO
Testing and ResultsComplete a picture in 1 hour
Parameter Specification
Speed 2 – 250 mms-1
Acceleration 2 – 150 mms-2
Picture Time (av.) 2.5 hrs (edge image)
A 1.8 × 1.8m painted ‘fills’ image of the Mona Lisa
A 1 × 1m painted ‘edge’ image of the University of Adelaide logo