Industrial Control Computer Research Articles

Design and testing of a low-cost mobile platform for contactless building surveying

After the completion of building construction, evaluating the accuracy of the distance between the lower edge of electrical switches and the one-meter line of the building is a crucial metric for assessing construction quality. Currently, the traditional measurement method basically uses manual measurement and is inefficient. To overcome this problem, we present a low-cost, non-contact mobile platform for building measurement, based on a 2D laser rangefinder and RGB camera. The system mainly consists of six key components: a mobile chassis, dual-axis gimbal, laser rangefinder, RGB camera, industrial control computer, and an automatic one-meter line calibration device, which can achieve high-precision distance measurement. Firstly, a sensorless control method for brushless DC motors (BLDCM) based on the Extended Kalman Filter (EKF) algorithm is proposed, which effectively improves the accuracy and robustness of rotor position estimation. Secondly, an automatic calibration device is developed to ensure the laser line consistently remains at a height of one meter from the ground. Finally, by combining image processing technology and 2D laser range data, the distance between the lower edge of the electrical switch and the building’s one-meter line is precisely measured using a triangulation algorithm. Experimental results show that the system’s measurements, compared to manual measurements, have a relative error percentage of 0.57 %, while the automatic calibration device has a maximum error of only 0.2 centimeter. Therefore, the system shows great potential for widespread application in the field of building measurement.

Update of high voltage isolation control and monitoring system for HVE-400 ion implanter

HVE-400 ion implanter is special ion implantation equipment for semiconductor materials boron and phosphorus doping. The ion source and extraction deflection system are at high voltage platform, while the corresponding control system is at ground voltage position. The control signals and measurement signals of various parameters at the high-voltage end need to be transmitted between ground voltage and high voltage through optical fibers to isolate high voltage. Upgrading is carried out due to the aging of the optical fiber transmission control and monitoring system, which cannot work stably. The transformation replaces the original distributed single-point control method with an advanced distributed centralized control method, and integrates all control and monitoring functions into an industrial control computer for digital operation and display. In the computer software, two kinds of automatic calculation of ion mass number are designed. After upgrading, the implanter high-voltage platform control and monitoring system features digitalization, centralized control, high reliability, strong anti-interference, fast communication speed, and easy operation.

Algorithm for automatic optimizing cross-cut saw based on computer vision techniques

The optimization of timber classification by grades and defect detection plays an important role in the production of timbers. Traditionally, a timber is manually cut by a worker according to his experience. Defect detection and classification of a timber are with great subjectivity. Meanwhile, the action is not safe enough. In this case, an automatic optimizing cross-cut saw to finish these tasks of timber classification by grades and defect detection is built significantly. Related algorithms and detailed procedures for optimizing cross-cut saws are proposed in this paper. Additionally, a vision system is used to capture images of a timber. Captured images are analyzed and processed. First, defects in these images are detected. Then the serviceable part (defect-free) of a timber can be determined. Based on the pretrained network, the timber can be classified. As the homography matrix has been known, the physical position can be confirmed. In our proposed system, the cutting list is transmitted from the industrial control computer to a motion control system, then the timber can be cut according to the cutting list automatically. In this paper, related algorithms and detailed procedures are given. Moreover, a new optimizing cross-cut saw is built. Experiments show that the processing time for each image is about 0.026s and the minimum mean average precision is 94.15%. In this case, it can make the optimizing cross-cut saw efficient, labor-saving and safe. Furthermore, related algorithms are suitable to improve a traditional automatic optimizing cross-cut saw.

Research on Road Sign Detection and Visual Depth Perception Technology for Mobile Robots

To accomplish the task of detecting and avoiding road signs by mobile robots for autonomous running, in this paper, we propose a method of road sign detection and visual depth perception based on improved Yolov5 and improved centroid depth value filtering. First, the Yolov5 model has a large number of parameters, a large computational volume, and a large model size, which is difficult to deploy to the CPU side (industrial control computer) of the robot mobile platform. To solve this problem, the study proposes a lightweight Yolov5-SC3FB model. Compared with the original Yolov5n model, the Yolov5-SC3FB model only loses lower detection accuracy, the parameter volume is reduced to 0.19 M, the computational volume is reduced to 0.5 GFLOPS, and the model size is only 0.72 MB, making it easy to deploy on mobile robot platforms. Secondly, the obtained depth value of the center point of the bounding box is 0 due to the influence of noise. To solve this problem, we proposed an improved filtering method for the depth value of the center point in the study, and the relative error of its depth measurement is only 2%. Finally, the improved Yolov5-SC3FB model is fused with the improved filtering method for acquiring centroid depth values and the fused algorithm is deployed to the mobile robot platform. We verified the effectiveness of this fusion algorithm for the detection and avoidance of road signs of the robot. Thus, it can enable the mobile robot to correctly perceive the environment and achieve autonomous running.

Parking Robot Path-Tracking System Based on Discrete PID Algorithm

To improve the space utilization rates of intelligent stereo garages, their key execution equipment—parking robots—must be highly flexible; therefore, the chassis of parking robots use steering wheel systems. However, this design increases the complexity of robot motion control and path-tracking systems. Because of the large sizes of parking robots, large position and angle deviations can lead to derailment events, posing significant risk to users. Thus, in this study, based on the characteristics required for parking robots, a diagonally arranged parking robot with double steering wheels was developed and its kinematic model was established using the velocity–geometry method. For the positioning of the robot in a garage, a fusion positioning algorithm based on quick response (QR) codes and track calculation was used, considering the requirements of real-time response and accuracy. A discrete proportional-integral-derivative (PID) path-tracking algorithm for the synchronous compensation of the position and angle deviations was also devised. Using the Visual C++ platform, a path-tracking system that uses an industrial computer and motion control card was developed. Experiments on the path-tracking capability of the parking robot showed that, using the discrete PID path-tracking algorithm, it can track a planned path well. On Z- and U-type paths, its maximum tracking deviations were reduced by 84.8% and 64.0%, compared with the unused path-tracking system, reaching 10.4 mm and 10.9 mm, respectively. Thus, the tracking accuracy was significantly improved, proving that the developed robot well satisfies the path-tracking requirements of parking robots.

DESIGN OF PLC BASED TEMPERATURE CONTROL SYSTEM FOR FOOD STABILITY TEST CHAMBER

A stability test chamber simulates specific environmental conditions and tests a product or material in the manufacturing stage. The tested product or material is then analyzed about its shelf-life estimation related to the state and durability of the product for a certain period. The main parameter that must control accurately is temperature. Programmable Logic Controller (PLC) as an industrial computer control system has been widely used. In this paper, the temperature control system was designed based on PLC and supervisory control and data acquisition (SCADA). The PLC and SCADA would indirectly control the heater. The PLC was feeded from the temperature sensor for real-time temperature inside the test chamber. Received temperature value, compared to the temperature set point. The validation and verification of controlled temperature inside the chamber were also investigated. The system was designed on a miniaturized chamber using commercial PLC and SCADA, Stepper motor, slide regulator, heater, and the temperature sensor PT100. The temperature test point for validation and verification was performed at 35 °C, 45 °C, and 55 °C. The result showed that The PT100 successfully had an excellent response to the temperature test point. The correction value for temperature is as high as 0.6 °C with a deviation of 1 %.

The Overall Design of the Comber Drive Control System

Objective: The cotton textile industry, as a competitive industry in China's international competition, is confronting new opportunities and challenges brought by the growing process of mechatronics. To further improve the traditional drive control of combing machines made in China and the automatic level of machines as a whole, some of our cotton textile enterprises have undertaken necessary technical transformations on the combing machines so as to raise the operational efficiency and production technology of domestic textile equipments. Methods: This paper focuses on the basic status and dynamic characteristics of the drive part of the domestic new comber, and analyzes the operation process of the comber and the prominent problems from the production practice. Results: The technically improved drive control system uses an industrial control computer (IPC) as the core of the system, which effectively improves the overall working efficiency of the comber, and improves the production accuracy and production efficiency. Conclusion: The combers that are textile machinery equipments with comprehensive application of machines, electricity, gases and instruments, play a vital role in enhancing product quality and production efficiency. Highly intelligent and integrated process control, real-time monitoring and accurate data acquisition and data analysis have become the mainstreams in the development of auto-control. Therefore, the commitment of high technology to transform the traditional production mode has also been an important research.

Research and development of weld tracking system based on laser vision

Aiming at the shortcomings of low real-time, low applicability, and low welding precision of automatic welding system, a seam tracking system based on laser vision is designed. Use the laser vision sensor to collect the weld image and transmits it to the industrial control computer for processing. Using a median filter to eliminate noise impacts such as arc and splash. Then, this paper focuses on the combination of an improved image threshold segmentation algorithm is used to solve the optimal threshold to obtain the binary image. And the information of laser stripe and the background are separated, overcomes the problems that the researchers have encountered before, such as the unrecognized global optimal solution, and the inaccuracy of the segmentation caused by system jitter. Finally, combined with the improved upper and lower average method, least square method, and Hough transform, the weld feature points are identified and more ideal real-time weld tracking is realized. The experimental results show that the method can accurately track the weld feature points, and improve the detection speed.

Design and Motion Analysis of a Magnetic Climbing Robot Applied to Ship Shell Plate

The manufacture, maintenance and inspection of a ship involve a series of works on the ship shell plate, which were always seen as harmful for human operators and time-consuming work. The shipping industry is looking to replace manual work with automation equipment. A magnetic climbing robot that can omnidirectionally move on ship shell plate was presented in this paper. This article summarized the mechanical structure, control system, kinematic model, and autonomy of robot. The mechanical structure of the robot was inspired by bionics and adopted a wheel-leg hybrid locomotion system. In the control system of this robot, industrial control computer (IPC) was adopted as the core controller and brushless direct current servomotor was chosen as the actuating station. Finally, the motion analysis of the designed robot was performed. The results of the analysis show that the magnetic climbing robot adapted to the ship curved shell plate and crossed obstacles.

Design and Performance Simulation of Computer Control System for Automatic Monitoring of Upper Computer Communication Operation State

The upper computer communication operation state automatic monitoring system is mainly used to remotely monitor the equipment, obtain various parameter indexes in the operation process of remote equipment, realize remote monitoring and fault diagnosis, and improve the management efficiency of decentralized equipment. This paper completes the design of communication, data storage, query, and other subsystems of upper and lower computers. The lower computer establishes a data channel with the OPC server through the MPI protocol and uploads the collected data to the OPC server in real time. The upper computer reads the data through the OPC server and displays the changes of monitored parameters in real time through the monitoring interface, so as to give an alarm under abnormal conditions. In addition, since the default database of Kingview is access, considering that the Microsoft Access database can store up to 2G of content, in order to upgrade and expand the subsequent system, SQL Server database is selected for data query, backup, and saving. The parameter setting method of communication control system is analyzed, the simulation model of industrial boiler control system is established by using Matlab/Simulink, and the interface between host computer software (IBCCS-e) and the model is provided. This paper analyzes the results of communication parameter adjustment. The simulation results show that the industrial boiler computer control system (IBCCS) has stable performance, low cost, convenient operation, and good maintainability. After further improvement, it has certain application value in the operation transformation of new small- and medium-sized boilers and original boilers.

Research on Face Recognition Sports Intelligence Training Platform Based on Artificial Intelligence

With the application of artificial intelligence in many social fields, the research of human behavior recognition and non-contact detection of human physiological parameters based on face recognition and other technologies has developed rapidly, and the application of artificial intelligence in culture, sports and entertainment has also begun to rise. How to apply the existing mature technology to the sports intelligence training system taking table tennis as an example is a hot issue worthy of study. In this paper, a comprehensive intelligent table tennis training system and platform based on Convolutional Neural Network face recognition and face heart rate detection is designed, which is mainly used to solve the philosophical training problem in table tennis. In the system place, an identification cameras is set at the entrance of table tennis training places, which is used for table tennis players’ sign-in and training table number allocation, and an intelligent analysis cameras is set above each intelligent training table, which is used for detecting the face and heart rate of table tennis players. Each intelligent training platform consists of intelligent voice control unit, server, camera, industrial control computer, monitor and other terminal modules. The member data center constitutes the platform of intelligent table tennis training system.

Electroplating solution concentration detection based on interference principle and balanced detector

In this research work a noble approach towards measurement of solution concentration in electroplating process has been exercised by inducting laser interferometer and balanced detector. The research design of this study has been fragmented into three parts. In the first part, an experimental set up constituting of DFB laser, Michelson interferometer, reflector, balanced detector, oscilloscope and high performance industrial control computer was established for detection of electroplating solution concentration. In the second part, by taking the quantitative observations of solution concentration, light intensity, refractive index and voltage, a mathematical model was established. The model parameters were identified and verified by the common liquids. In the third part of the study, experiments were carried out on single solution and mixed solution during nickel plating of punched steel strip. The experiment revealed that the concentration detection of single solution, the error found was within 1.32%. In the concentration detection of mixed electroplating solution, the error was within 2.03%. The error is less than the detection error of chemical titration method (3%), which meets the requirements of the enterprise. It is indicated that the proposed method can detect the refractive index and liquid concentration quickly and accurately, which lays the foundation for the optimization control of the solution concentration in the process of nickel plating in punched steel strip.

Design of Ackerman Mobile Robot System Based on ROS and Lidar

An ackerman mobile robot system based on ROS and lidar was developed in this research. The i5 industrial control computer was taken as the core controller, and the Ubuntu system was installed inside, the control core of the driving part was the STM32 microcontroller. Using the external environment information obtained by lidar and IMU sensors, the corresponding SLAM algorithm was developed and designed under the Linux system based on the distributed framework of ROS operating system. Through establishing the feature map of environment, the system can locate position and posture of vehicle body in real time, and generate optimal path according to the given target point automatically identify and avoid surrounding obstacles. According to the state of the robot and the commands of the user, it can realize the functions of human-computer interaction, SLAM map scanning and drawing, Wi-fi remote control, real-time positioning, autonomous navigation, etc. efficiently and quickly.

Design and analysis of field test of surface unmanned boat radio

Communication distance and real-time monitoring are important performances of surface USV radio stations, which can better play the role of smooth communication information between surface USV and shore-based platform and real-time monitoring of USV dynamics, usually in the field. Test verification. This article analyzes the main problems in the field communication distance and real-time monitoring test of the surface unmanned boat radio station, introduces the evaluation method of the field wireless electromagnetic environment monitoring, designs the network environment of the shore-based computer and the surface unmanned boat industrial control computer, and designs the surface Field test plan for man- ship radio station. The test analysis shows that the design scheme is feasible and the communication between the surface unmanned boat and the shore-based platform is smooth, which can better monitor the dynamics of the surface unmanned boat, thereby improving the operation quality of the surface unmanned boat.

Design and Application of Monitoring Station of Black and Odorous Water Body Based on Industrial Computer and Remote Computer

Monitoring station of black and odorous water body (BOWD) based on industrial computer and remote computer control was designed and built to resolve the time-consuming problem about manual monitoring in the course of supervise of BOWD. Hardware configuration, technological process and software design were researched according to the demand analysis of monitoring station of BOWD. The results indicate that the monitoring station of BOWD can get real-time monitoring data of classification evaluation indexes of BOWD with a good stability, the relative error is below 7.14% between real-time monitoring data and manual monitoring date.

Defect detection method for rail surface based on line-structured light

• A novel rail defect detection scheme before welding is designed. • A registration algorithm based on feature points is presented to align data. • A dynamic defect detection algorithm is proposed for real-time detection. • Results show that the proposed method has higher accuracy and practicability. Based on intensive study on rail surface defect, a rail surface defect inspection scheme is proposed in this paper. With high-precession structured laser sensors, the original data are collected by industrial control computer and transformed into dimensional point cloud pattern. According to analysis of the specific feature of rail surface, a registration method is proposed to re-construct the digital rail surface. To achieve a high-precision detection result, a novel curve fitting model is established and accordingly a dynamic defect detection algorithm is improved to adapt to the successive production process based on the former study. Within the detailed study process, for each single frame data, a judge method is developed for noise elimination and specific feature defect detection. Finally, by studying successive frames of data points (actually cloud points), multiple frames data are dynamically computed to judge if there is a defect area on rail surface. In this paper, to avoid the random influence of minor factors, a probability threshold is introduced to judge defect points in the algorithm, which increases the anti-interference and decreases instability in the defect detection process. To verify the effect of proposed method, an experimental bench is developed in research process. Experimental results show that the detection method has reliable stability and anti-interference possibly influenced by minor factors like oxygen layer detection and characters area detection on rail surface. Compared with traditional two dimensional defect detection methods, the algorithm proposed in this paper is less computationally intensive and more suitable for online detection on rail surface.

Design of Industrial Computer Control System in Grease Production

Abstract In the actual production of grease, the design and application of industrial computer control systems can help to achieve intelligent management of various processes in grease production, thereby improving grease production efficiency and exerting positive impact. This paper will introduce the problems of industrial computer control systems design in grease production, analyze industrial computer control systems, and optimize the design plan and implement the system.

Embedded Control System for Six-DOF Electro-hydraulic Motion Platform

Six-degree-of-freedom electro-hydraulic motion platform (SEMP), which is an integration of a mechanical system, a hydraulic system and a control system, is kind of a high performance equipment. The control system is the core component of SEMP. But controllers for SEMP now are commonly motion controllers or industrial control computers, which are expensive, large and inconvenient. In this paper, a SEMP is established and the main parameters of the SEMP are shown. Based on a real-time operating system μC/OS-III, an embedded control system, which has advantages of cheap to buy, easy to manufacture and, small and convenient to move, is designed. And the main design schemes of hardware and software are shown in allusion to functional modules of the control system. The whole system including the test rig of the SEMP, the embedded control system and an upper computer is established. System trajectory experiments are carried out. The results show that the embedded control system designed can totally meet the control demands. This embedded control system designed has good interactivity, flexibility and performance.

Design of a Miniature Testing Equipment

During the long-term use of a certain type of equipment in the army, it is necessary to carry out regular technical inspection and testing. The traditional inspection and testing equipment usually uses a larger industrial control computer for measurement and control, which is inconvenient to operate. In order to detect the equipment more quickly and easily, a new type of testing device based on Arduino integrated development environment is designed. Using Arduino as the main control system, the communication control between Arduino board and the terminal of programmable intelligent liquid crystal touch display is realized. Combining with the fault diagnosis system, the equipment performance inspection and fault diagnosis are realized. The testing equipment is simple and convenient to operate, which a certain reference value for products developed has based on Arduino integrated development environment.

Automated Machine Vision System for Liquid Particle Inspection of Pharmaceutical Injection

The particle matter inspection for pharmaceutical injection is inevitable in the field of pharmaceutical manufacturing, as it has the direct impact on the quality of the drugs. It is a challenge to inspect the contaminated injection online using an imaging system. This paper introduces a novel and effective inspection machine consisting of three modules, a mechanical system with 120 carousel grips, an image acquisition system with multihigh resolution cameras and a multilight sources station, and a distributed industrial electrical computer control system. Particle visual inspection machine first acquires image sequence using the high-speed image acquisition system. The image capture process at each camera module is alternately synchronized with different LED illumination techniques (light transmission method and light reflection method), enabling independent capture of particle images from the same container. Then, a set of novel algorithms for image registration and fast segmentation are proposed to minimize false rejections even in sensitive conditions, which enable the identification of all the tiny potential defects. Finally, a particle tracking and classification algorithm based on an adaptive local weighted-collaborative sparse model is also presented. The experiments demonstrate that the proposed inspection system can effectively detect the particles in the pharmaceutical infusion solution online, and achieve a performance rate of above 97% average accuracy.