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Open-Source Robotics and Process Control Cookbook

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Open-Source Robotics and Process Control Cookbook Open-Source Robotics and Process Control Cookbook Open-Source Robotics and Process Control Cookbook Designing and Building Robust, Dependable Real-Time Systems by Lewin A.R.W. Edwards AMSTERDAM • BOSTON • HEIDELBERG • LONDON NEW YORK • OXFORD • PARIS • SAN DIEGO SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO Newnes is an imprint of Elsevier Newnes is an imprint of Elsevier 30 Corporate Drive, Suite 400, Burlington, MA 01803, USA Linacre House, Jordan Hill, Oxford OX2 8DP, UK Copyright © 2005, Elsevier Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Permissions may be sought directly from Elsevier’s Science & Technology Rights De- partment in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, e-mail: [email protected]. You may also complete your request on-line via the Elsevier homepage (http://elsevier.com), by selecting “Customer Support” and then “Obtaining Permissions.” Recognizing the importance of preserving what has been written, Elsevier prints its books on acid-free paper whenever possible. Library of Congress Cataloging-in-Publication Data (Application submitted.) British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. ISBN: 0-7506-7778-3 For information on all Newnes publications, visit our Web site at www.books.elsevier.com 04 05 06 07 08 09 10 9 8 7 6 5 4 3 2 1 Printed in the United States of America. Dedication This book is dedicated to my wife Cristen, in recognition of her uncomplaining acceptance of yards of PVC conduit in hallways, pounds of gel-cells in the living room, and never-ending snarls of wire and motors throughout the house. v Contents About the Author ........................................................................... xi What’s on the CD-ROM? ...............................................................xii Chapter 1: Introduction ...................................................................1 1.1 History of this Book and What You’ll Get From Reading It .........................1 1.2 Target Readership and Required Skills and Tools .........................................5 1.3 Conventions Used in the Text .......................................................................7 Chapter 2: Microcontrollers, Single-Board Computers and Development Tools ..................................................................9 2.1 The Division of Labor ....................................................................................9 2.2 Candidate Microcontrollers for ‘Hard’ Tasks ...............................................13 2.3 The Atmel AVR and its Development Hardware Up Close .......................17 2.4 Candidate x86-based SBCs for ‘Soft’ Tasks .................................................21 2.5 The Advantech PCM-5820 Single-Board Computer Up Close .................27 2.6 Selecting an Inter-Module Communications Protocol ...............................32 Chapter 3: Some Example Sensor, Actuator and Control Applications and Circuits (Hard Tasks) ......................41 3.1 Introduction .................................................................................................41 3.2 E2BUS PC-Host Interface ...........................................................................44 3.3 Host-to-Module Communications Protocol ................................................49 vii Contents 3.4 Stepper Motor Controller ............................................................................52 3.5 Speed-Controlled DC Motor with Tach Feedback and Thermal Cutoff .......70 3.6 Two-Axis Attitude Sensor using MEMS Accelerometer ............................79 3.7 RS-422—Compatible Indicator Panel .........................................................90 Chapter 4: The Linux-Based Controller (A Soft Task) ...................115 4.1 A Brief Introduction to Embedding Linux on PC Hardware ....................115 4.2 Configuring the Development System and Creating Our Custom Kernel ..117 4.3 The Linux Boot Process—Creating a Bootable CompactFlash Card .......123 4.4 Creating a Root Filesystem for our Embedded System ..............................128 4.5 Creating a Bootable Linux System-Restore CD-ROM Disc .....................136 4.6 Using the Parallel Port as a General-Purpose I/O Interface in Linux .......142 4.7 Implementing Graphical Control Interfaces .............................................149 4.8 Infra-Red Remote Control in Linux Using LIRC .....................................175 4.9 Introduction to Machine Vision Using Video4Linux ...............................189 4.10 Customizing Your BIOS—The Structure of a Modern BIOS .................201 Chapter 5: Encryption and Data Security Primer ..........................209 5.1 Introduction ...............................................................................................209 5.2 Classes of Algorithm ..................................................................................214 5.3 Protecting One-Way Control Data Streams ..............................................217 5.4 Protecting One-Way Telemetry .................................................................218 5.5 Protecting Bidirectional Control/Data Streams ........................................220 5.6 Protecting Logged Data ..............................................................................222 5.7 Where to Obtain Encryption Algorithms .................................................224 viii Contents Chapter 6: Expecting the Unexpected ...........................................227 6.1 Introduction ...............................................................................................227 6.2 Dangerous Exception Conditions and Recovering From Them ...............228 6.3 On-Chip vs. Off-Chip Watchdog Hardware .............................................230 6.4 Good Power-On Reset Practices ................................................................232 6.5 A Few Additional Considerations for Battery-Powered Applications ......235 Chapter 7: Contents of the Enclosed CD-ROM ............................237 Index ...........................................................................................237 ix About the Author Lewin A.R.W. Edwards was born in Adelaide, Australia. He worked for five years in Melbourne, Australia on government-approved encryption, desktop protection and data security products for DOS, Windows and OS/2. For the next five years, he worked in Port Chester, New York for Digi-Frame, Inc., where he designed both the hardware and firmware of a range of multimedia digital picture frame appliances. These devices ranged in complexity from small pocket-size still-image viewers up to fully networked wall-mounted devices with audio and full-motion video support. He currently lives in New York City and works as a short-range radio digital design engineer for a well-known manufacturer of wireless security and fire safety products. His earlier works include Embedded Systems Design on a Shoestring, (a book about low- cost embedded systems development, principally targeted at ARM7 platforms), as well as articles on specialized design considerations for the microcontrollers used in electronic toys, commentary on Universal Plug’N’Play, reverse-engineering Internet appliances, and other topics of interest. xi What’s on the CD-ROM? Included on the accompanying CD-ROM: ■ A free version of the schematic capture and PCB CAD software used to pre- pare this book. (Refer to the license agreement included with the software for usage restrictions and limitations.) ■ Atmel AVR Studio® 4.08. ■ Full schematics and sourcecode for the projects described in this book. ■ Ready-made disk images for the miniature Linux distribution used as a basis for the book’s PC-side software. ■ Distribution archives of the sourcecode for all GNU software used, along with application-specific patches, where appropriate. xii CHAPTER 1 Introduction 1.1 History of this Book and What You’ll Get From Reading It Over the course of roughly a year, after completing my first book, I resurrected an old pet project of building an autonomous submarine (referred to as the E-2 project) with certain fairly challenging functionality requirements. In the course of developing this idea, I spent many hours on the Internet and elsewhere, researching techniques for rapid development of various electromechanical control systems and platforms to run fairly complex signal-processing algorithms. Although there are, of course, thousands of useful projects and snippets of information to be obtained from the Internet and books on hobbyist robotics, I found that nobody else seemed to have my exact priori- ties. In particular, there is apparently no single reference that gathers together at least introductory solutions to all the embedded design issues that affected my proj- ect: a need to use low-cost (open-source) tools and operating systems, a requirement for several features with fairly hard real-time requirements, and a desire to use cheap, off-the-shelf consumer grade components wherever possible. Available resources on many topics concentrate either on very expensive off-the-shelf industrial compo- nents, or on tightly constrained systems built around a single microcontroller, with delicately optimized, nonportable code to control peripherals—and a very limited range of peripheral
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