Two Open Solutions for Industrial Robot Control: The Case of PUMA 560

In this paper we present two different, software and reconfigurable hardware, open architecture approaches to the PUMA 560 robot controller implementation, fully document them and provide the full design specification, software code and hardware description. Such solutions are necessary in today’s robotics and industry: deprecated old control units render robotic installations useless and allow no upgrades, advancements, or innovation in an inherently innovative ecosystem. For the sake of simplicity, just the first robot axis is considered. The first approach described is a PC solution with data acquisition I/O board (Humusoft MF634). This board is supported with Matlab Real-Time Windows Toolbox for real-time applications and thus whole controller was designed in Matlab environment. The second approach is a robot controller developed on field programmable gate arrays (FPGA) board. The complexity of FPGA design can be overcome by using a third party software package, such as self-developed Matlab FPGA Real Time Toolbox. In both cases, parameters of motion controller are calculated by using simulation of the PUMA 560 robot first axis motion. Simulations were conducted in Matlab/Simulink using Robotics Toolbox.