Energy efficiency is one of the most important parameters in transportation electrification. It allows to improve the production rate due to longer operation without charging or decrease the cost related to transportation. To provide collision-free operation in unknown or various environment, the local path planning algorithm should be considered. An Artificial Potential Field (APF) algorithm is commonly used for this task, however it provides unsmooth and oscillating motion of autonomous ground vehicle (AGV), and is prone to being trapped in a local minimum, e.g, dead-end. In such a case, the energy used to achieve the goal position is higher than necessary. In this paper, the energy-efficient local path planning algorithm is proposed. Future movement prediction has been introduced to APF to allow AGV to bypass obstacles in advance. A novel method for local minimum avoidance is introduced. It is based on placement of virtual obstacles called top quarks in critical areas. These obstacles provide additional repulsive force for the APF based path planner. Considering the predicted stagnation-free path of the AGV, the new temporary goal for APF is selected. Such a combination allows to reduce traveled route length, improve its smoothness, and bypass local minima. The proposed Predictive Artificial Potential Field (PAPF) algorithm has been examined using Husarion ROSbot 2.0 PRO mobile robot, and the obtained results in form of videos are also attached as supplementary files. In comparison to original APF, the proposed path planning algorithm allows to reduce the used electric power by 21.4 %. PAPF provided a shorter path by up to 8.73 % and shorter time to reach the goal position by up to 40.23 %. The movement of the AGV is also much smoother in a case of usage of the proposed algorithm, and the proposed top quarks -based local minimum avoidance mechanism allows to bypass the local minima.

In computerized numerical control (CNC) systems, the communication bus between the controller and axis servo drives must offer high bandwidth, noise immunity, and time determinism. More and more CNC systems use real-time Ethernet protocols such as Ethernet Powerlink (EPL). Many modern controllers are closed costly hardware-based solutions. In this paper, the implementation of EPL communication bus in a PC-based CNC system is presented. The CNC system includes a PC, a software CNC controller running under Linux Real-Time Application Interface real-time operating system and servo drives communicating via EPL. The EPL stack was implemented as a real-time kernel module. Due to software-only implementation, this system is a cost-effective solution for a broad range of applications in machine control. All software systems are based on GNU General Public License or Berkeley Software Distribution licenses. Necessary modifications to the EPL stack, Linux configurations, computer basic input/output system, and motherboard configurations were presented. Experimental results of EPL communication cycle jitter on three different PCs were presented. The results confirm good performance of the presented system.

A high-performance electrical drive with a permanent magnet synchronous motor (PMSM) should ensure superior dynamic properties, reasonable load torque compensation, and robustness against parameter variations. The performance investigation related to the dynamic properties is usually made using the step response indicators and integral performance indexes. The robustness evaluation is more complex than performance analysis since there are no simple tools for this purpose, especially if it is done experimentally to consider nonlinearities and unmodeled dynamics of the plant. In this article, sensitivity functions suitable for investigating the closed-loop control systems in the time and the frequency domain are proposed, explained, and experimentally verified. Three control schemes designed for the speed control of PMSM are analyzed: a cascade control structure, robust two-degrees-of freedom speed controller, and a cascade-free constrained state feedback controller. Studies are conducted for experimental responses of the drive in the time and the frequency domain to investigate the sensitivity of the PMSM drive against the moment of inertia and load variations. Analysis of nonlinearities influence on the developed sensitivity functions is also presented.

Synchronization between devices (in particular drive systems) is paramount for multi-axis motion control systems used in Computerized Numerical Control (CNC) machines, robots, and specialized technology machines used in many areas of the manufacturing industry. EtherCAT is an Ethernet-based network that is one of the most popular industrial networks for multi-axis motion control systems. EtherCAT is standardized in the IEC 61158 and IEC 61784 standards. In the article, an EtherCAT communication network for electrical drives is presented. The article focuses on the synchronization in the EtherCAT network consisting of one master device and slave servo drive devices. Special attention is given to synchronization mechanisms in EtherCAT, such as distributed clocks in slave servo drives devices. For this purpose, a laboratory stand was built consisting of two prototype servo drive devices with BLDC motors equipped with EtherCAT communication modules. A description of the working developed EtherCAT communication modules is given. Authors in communication modules ware used an EtherCAT Slave Controller (ESC) chip (AX58100) to implement lower EtherCAT layers. EtherCAT application layer was implemented in software form on a 32-bit microcontroller, based on CANopen over EtherCAT (CoE) CAN in Automation 402 (CiA402) profile. This research’s main contribution was to show the time dependencies regarding synchronization in terms of data flow in the EtherCAT communication stack in slave servo drive devices. The research results showed that the synchronous operation of drives is mainly influenced not by the mechanism of distributed clocks that ensures synchronization in the EtherCAT network but the implementation of the highest layer of the communication stack in slave servo drive devices. Experimental results are presented that prove the modules’ adequacy for use in high-performance motion control systems.

In this article, a NURBS toolpath feedrate profile generation algorithm for a biaxial linear motor control system is presented. High achievable velocities and accelerations of linear motor machines present new computational challenges in implementing feedrate generation and toolpath interpolation algorithms in real-time controllers. The proposed algorithm is capable of online generation of the feedrate profile with axial acceleration and jerk constraints. Each stage of the feedrate profiling algorithm is described with attention being given to both performance and implementation aspects. Furthermore, an alternative to the commonly used Taylor series interpolation method is also tested to ensure minimal interpolation errors. The feedrate profiling and interpolation algorithms’ implementation in a PC-based controller with real-time Linux kernel is described. Experimental results are presented that confirm that the algorithm is capable of limiting acceleration and jerk in the machine’s axes and it is low computation time enables real-time on-line operation in a PC-based CNC controller.