Design of Embedded Control System Using Super- Scalar ARM Cortex-A8 for Nano-Positioning Stages in Micro-Manufacturing

Signal & Image Processing : An International Journal (SIPIJ) Vol.4, No.4, August 2013
DOI : 10.5121/sipij.2013.4406 71
Design of Embedded Control System Using Super-
Scalar ARM Cortex-A8 for Nano-Positioning
Stages in Micro-Manufacturing
Niharika Jha1
, Gaurav Singh Naruka1
and Himanshu Dutt Sharma2
1
International Institute of Information Technology (I2IT), Pune-411057(Mah.)India
niharikajha2509@gmail.com, gauravnaruka3322@gmail.com
2
CSIR-Central Electronics Engineering Research Institute (CEERI),
Pilani-333031(Raj.)India
hdsharma@gmail.com, hdsharma@ceeri.ernet.in
ABSTRACT
A superscalar microcontroller based system is used to control the Physik Instrumente (PI) piezo-electric
ultrasonic nano-positioning (PUN) stage for a micro-factory has been proposed by the author. A Linux
based development board i.e. BeagleBone containing TI AM3358/9 SoC based on an ARM Cortex-A8
processor core, is suggested to provide visual servo control to the nano-positioning stage. The stages are
driven at the tuning parameters which have been identified, tested and validated for robustness under
uncertainties. The microcontroller i.e. LPC2478 provides the user with the choices of operations on the
3.2” QVGA LCD screen and the choice can be made by a 5-key joystick. The PUN stage moves in different
geometrical patterns as chosen by the user. The stage is placed in the workspace of a femto-second laser.
Different patterns are made on the material in question. A camera interfaced to the BeagleBone traces the
movements of the nano-positioning stage with the help of image processing routines which can be
communicated to enable further control of actions .As compared to the previous works in this area, the user
is given the power for position control, real time tracking, and trajectory planning of the actuator. The user
interface has been made very easy to comprehend. The repeatability of tasks, portability of the assembly,
the reduction in the size of the system, power con-sumption and the human involvement are the major
achievements after the inclusion of an embedded platform.
1. INTRODUCTION
Micro-systems are now an essential element in fields from every walk of life; bio-technology,
aviation, energy harvesting to name a few. However as the dimensions of these parts are on the
decline the man-ufacturing, characterization and maintenance constraints increase exponentially.
The classic mechanical theories also do not hold well after the paradigm shift from micro to nano
scale. Problems such as scal-ing effects, incompatibility of various materials and their processing
technologies and their assembly into one functional microstructure arise. Hence many versatile
manufacturing and assembly technologies were proposed to meet the requirement. These systems
over the years became more specific to material types, component geometries, and types of
mechanical motions that can be realized and cost. The technique of MEMS eventually became
slow, sequential and hence not suitable to mass production [10, 12].High speed and positional
accuracy can also be achieved by using PUN actuators which have an excellent operating

72
bandwidth, can generate large forces from a compact size and achieve a positional accuracy of
under several nano-meters [1].Most of the works in this area have dealt with the development of
control ap-proaches to perform tasks such as positioning, orientation, picking, placing, and
insertion of the different
Figure 1: Femtosecond Laser Micromanufacturing Setup
micro objects in grids or in between plates[13]. Enabling a 2 DOF through a Piezo actuator can
foray its use in Characterization of micro-devices, Manufacturing and assembly of micro devices,
High resolution industrial applications such as optical fibre alignment, biological cell
manipulation, and scanning probe microscopy (SPM) [2, 3, 4, 13].The inclusion of embedded
systems enables the automation of the micro-manufacturing tasks along with the achieving
portability, flexibility and real time control. A personal computer has been used for the purpose of
providing automation. However the use of micro-controllers to achieve communication with
manipualtors and positioning stages is yet to be seen. Authors propose the use of a 32 bit ARM
microcontroller to establish a serial connection with the PILine Controller C867 which essentially
uses the PID servo control to drive the PI stage M663. A joystick (interfaced with the
microcontroller) is used to choose the controls displayed on an LCD screen (also interfaced to the
same micro controller).Another 32 bit ARM Cortex A8 based SoC operated by Ubuntu is
interfaced with a camera to track the position of the nano-positioning stages via image processing
algorithms. Necessary control actions can then be communicated to the PI Line Controller. Thus
the system features a piezo-electric ultrasonic standing wave motor taking commands from the
user through a microcontroller and a feedback in the form of position error is provided using an
intelligent USB camera system. Paper is divided into nine sections; Section 2 is the description of
the hardware involved in the micromanufactur-ing workcell. Section 3 discusses the flow of
signal to analyse the control elements of the system and explains graphically the conclusions of
the experiments conducted by tuning the PID controller .Section 4 is the description how the
communication between the components of the automatic control system was designed. Section 5
includes the process of realizing different geometries. Section 6 explains the execution of the
tasks in the micromanufacturing system. Section 7 gives information about the future scope of the
experiments conducted and the last section concludes the work.
2. DESCRIPTION OF THE MICROMANUFACTURING WORKCELL
The Fig.1 shows the entire set up of the micromanufacturing system, employed by the author, at
work

Signal & Image Processing : An
The Fig. 2 shows briefly the structure and the main blocks of
2.1 LPC2478
It is a 16/32 bit RISC microcontroller that has 512 kB of on
develop-ment board named Embedded Artists’ LPC2478
includes: 3.2 inch QVGA TFT colour LCD with touch
joystick, Ethernet
Figure 2: Block Daigram of the Micromanufacturing System
Figure 3: Control Architecture of the Ultrasonic Motor
connector (RJ45), MMC/SD interface & connector, CAN
useful features.[5]
2.2 PILine R
Controller
The C-867 controller is a compact case enclosing both, the driver electronics for the PUN motors
and components for controlling and communication. The controller can be
either via a USB port or a RS
connected in daisy chain topology have been used to drive 2 Piezo
2.3 PI Stage
The advantages of using Piezo-actua
M-663 is a Precision-class micropositioning stage with a non
measuring the distance travelled by the stage. The minimum incremental motion is 300
nanometer and sensor resolution is 100 nanometer. The maximum velocity it can obtain is 400
The Fig. 2 shows briefly the structure and the main blocks of this system .
It is a 16/32 bit RISC microcontroller that has 512 kB of on-chip high-speed flash memory. A
ment board named Embedded Artists’ LPC2478-32 OEM Board v1.3 is used. The board
includes: 3.2 inch QVGA TFT colour LCD with touch screen panel, RS232 male terminal, 5
Figure 2: Block Daigram of the Micromanufacturing System
Figure 3: Control Architecture of the Ultrasonic Motor
connector (RJ45), MMC/SD interface & connector, CAN interface & connector and many other
867 controller is a compact case enclosing both, the driver electronics for the PUN motors
and components for controlling and communication. The controller can be operated by a host PC
either via a USB port or a RS-232 interface or manually by a joy-stick [6]. Two controllers
connected in daisy chain topology have been used to drive 2 Piezo-motors which enable a 2 DOF.
actuators have already been discussed in the introduction. The PI
class micropositioning stage with a non-contact optical linear encoder for
sensor resolution is 100 nanometer. The maximum velocity it can obtain is 400
International Journal (SIPIJ) Vol.4, No.4, August 2013
73
speed flash memory. A
32 OEM Board v1.3 is used. The board
screen panel, RS232 male terminal, 5-key
interface & connector and many other
867 controller is a compact case enclosing both, the driver electronics for the PUN motors
operated by a host PC
stick [6]. Two controllers
motors which enable a 2 DOF.
tors have already been discussed in the introduction. The PI
contact optical linear encoder for
sensor resolution is 100 nanometer. The maximum velocity it can obtain is 400

74
mm/sec. Its travel range is 19mm [7]. Two PI stages have been placed on top of each other to
ascertain a 2 DOF. The movement of each stage can be individually controlled.
2.4 BeagleBone
This development board is based on a 720 MHz superscalar ARM Cortex-A8 AM3358/9
processor. It contains 256 MB RAM which is its unique selling point. Its various peripherals
include an Ethernet RJ45 socket, MicroSD slot, Dual USB hub on USB 2.0 type mini-A OTG
device port, USB 2.0 type A host port, I2C, UART, SPI and CAN. It is preloaded with Angstrom
ARM Linux Distribution however Ubuntu , Debian and Android kernels can also be loaded.
2.5 USB camera
Any USB compatible VGA camera can be used for this work cell. A resolution of 1.2 Megapixels
or more and a frame rate of 30 frames per second are considered to be effective for providing the
necessary vision feedback.
2.6 Control Strategy
To devise the control strategy of this assembly, the time domain data of the system is recorded
and further used to determine or estimate the transfer functions of the plant and the controller is
then designed.
2.7 Working of the Plant
The PUN actuator used here is entirely defined as a Standing Wave Ultrasonic Piezoelectric
Linear Mo-tor.The working of this rare class of motors can be briefly described as follows. Two
orthogonal vibration components, when coupled, create a 2-D standing wave in the piezo-ceramic
(PIC181) electrodes. [16], An alumina tip placed on top of these electrodes follows an elliptical
trajectory, as a result of these vi-brations, The aluminium plate which is in contact with the tip
receives micro-impulses from it during the course of the tip’s trajectory, which causes it to move
forward or backward according to the angles which these impulses are given.[15] If seen in
analogy with any motor, the peizoceramic electrodes play the role of the stator, where as the
moving aluminium plate becomes the rotor. Researchers have generated mathematical models for
this motor considering it as a spring-mass-damper system [14]. This trajectory is generally
trapezoidal, meaning there is acceleration till the desired velocity is reached, the velocity remains
constant till a certain position, and then there is a deceleration as controlled by the closed loop
servo control.
2.8 Study of Controller Dynamics
There are traditional methods of extracting the plant dynamics ,if the transfer function of the
controller is estimated . However, few of these can be applied to the system in consideration due
to the constraints in the type of input signal applied, adjustments in fundamental frequency, and
non availability of cer-tain piezo-electric constants necessary for mathematical modelling. The
Proportional(P), Integral(I) and Derivative(D) constants are changed using the PI Tuning Tool in
the PI Mikromove application. The graphs below are plotted using MATLAB. They show the
time-domain response of the moving stage using three different sets of P, I, D terms. The Graph

4(a) shows the behaviour of the stage using P
unacceptably long and there is a noticeable overshoot making the system under
4(b) is plotted using P-30, I-100,D
with damping factor greater than 1. However there is a
re-sponse. Graph 4(c) is the behaviour of the stage using a combination of the sets mentioned
above.The time domain response of this combination shows an overdamped system with a rise
time better than in Fig. 4(b) and a settling time lesser than in Fig. 4(a).This implies that 2 or more
than 2 P,I,D sets should be used for the actuator to ensure no vibrations and optimized rise time
and settling time. The analysis of the Fig. 4(a) and (b) provides a solution for
time and the settling time. A combination of these 2 sets in a manner such that when the target
position is relatively far the P,I,D values in the set 1 are used and when the target position close
the P,I,D values in the set 2 are used
2.9 Control Architecture
The signal flow from the microcontroller to the actuator is described in steps below and in Fig. 3.
The user uses the joystick to make choices maximum velocity, acceleration and the geometry to
be traced. The microcontroller converts these decisions into m
coupled stages and se-lects the appropriate stage to be moved according to the geometry, The
target position, maximum velocity and the maximum acceleration of each of the stages will be
sent to their individual PILine controllers, According to the target position the stage is moved.
The encoder obtains the actual position is obtained at 0.2 ms. The difference between the actual
position and the target position is the error signal e (t), which can also be provided by the
BeagleBone. This error signal is fed to the PID controller according to which the control signal u
(t) is generated, The control signal is a voltage in the range of
excitation voltage to the piezoceramic plates. This br
the geometry chosen is completely realised, an acknowledgement signal is generated and sent to
the user. Thus the user will be able to continue with his next task.
4(a) shows the behaviour of the stage using P-10, I-15, D-15. Here the settling time was
y long and there is a noticeable overshoot making the system under-damped. Graph
100,D-90. It shows an overdamped system
Figure 4: Responses of PID
with damping factor greater than 1. However there is a slight increase in the rise time of this time
sponse. Graph 4(c) is the behaviour of the stage using a combination of the sets mentioned
(b) and a settling time lesser than in Fig. 4(a).This implies that 2 or more
and settling time. The analysis of the Fig. 4(a) and (b) provides a solution for optimizing the rise
the P,I,D values in the set 2 are used .
be traced. The microcontroller converts these decisions into macros. It plans the trajectory of the
lects the appropriate stage to be moved according to the geometry, The
controllers, According to the target position the stage is moved.
(t) is generated, The control signal is a voltage in the range of -10 to +10 V which is applied as an
excitation voltage to the piezoceramic plates. This brings about the movement in the stage, When
the user. Thus the user will be able to continue with his next task.
75
15. Here the settling time was
damped. Graph
slight increase in the rise time of this time
sponse. Graph 4(c) is the behaviour of the stage using a combination of the sets mentioned
(b) and a settling time lesser than in Fig. 4(a).This implies that 2 or more
optimizing the rise
acros. It plans the trajectory of the
lects the appropriate stage to be moved according to the geometry, The
controllers, According to the target position the stage is moved.
10 to +10 V which is applied as an
ings about the movement in the stage, When

Figure 5: Setup for the Embedded Control Syste
Figure 6: Embedded Control System
2.10 Study of Controller Dynamics
The approach used by the authors for model identification is to study the transient response by
using the step response which is derived iteratively using various sets of tuning
step sizes. As suggested by Mamat and Fleming, the controller is almost brought to redundancy
for closed loop system identification. The overshoot produced by the step should be
approximately more than 60% for reliable use in transient respo
parameters where the oscillations necessary for studying the dynamics were visible are observed
to be P=5, I=5, D=0(normalized values). It was observed that increasing the values of P and I any
further would dampen the visible osci
performed with P=5(normalized), I=5(normalized) and D incrementing in steps of ten from 0 to
30(normalized). An elaborate description of these results is seen in the previous works. The
instrumental variable method is used for model identification. The Robust Response time and
Internal Model Control methods are used for controller design. The procedure for model
identification, validation and controller design has been discussed intricately in [17, 18].
2.11 Design of the Automatic Control System
The Fig. 5 highlights the flow of data from the microcontroller to the actuator.
Figure 5: Setup for the Embedded Control System
Figure 6: Embedded Control System
Study of Controller Dynamics
using the step response which is derived iteratively using various sets of tuning parameters and
approximately more than 60% for reliable use in transient response analysis. The tuning
further would dampen the visible oscillations. Therefore the next set of experiments were
able method is used for model identification. The Robust Response time and
Design of the Automatic Control System
The Fig. 5 highlights the flow of data from the microcontroller to the actuator.
76
parameters and
nse analysis. The tuning
llations. Therefore the next set of experiments were
able method is used for model identification. The Robust Response time and

77
The automatic control system is an amalgamation of optimal tuning of the PI R
Line controller
and the transfer of commands through the microcontroller. The knowledge of UART is essential
for this design.
(a) Initial Algorithm (b) Algorithm for linear Geometries
(b) Algorithm for Polygonal Geometry (D) Algorithm for Circular Geometry
Figure 7: Flowcharts for Different Geometries
A few points were kept in mind while communicating through LPC2478. The PILine R
Controller
recog-nizes text based commands sent in a specific format as specified by the PI R
General
Command Set, One or more sets of these commands can be stored in a file and/or transmitted
over RS-232 with the baud rate set the same as that of the PI R
Line controller, Each controller in
a daisy chain topology has a unique address. While in daisy chain topology the addresses of the
target controller and the sender are required in every command line. [6], The number of data bits,
parity bit and stop bit settings are also made con-sidering mode switches in the front panel of the

Line Controller (in our case 8 data bits, n
sequence ”nn” for a new line has to be sent after every command line.
Figure 8: Pattern Made by the Movement of the Stages
Figure 9: Different Windows of the User Interface
2.12 Realization of Different Geometries
The Fig. 7(a), 7(b), 7(c) and 7(d) display the basic algorithms adopted by the user interface
routine to realize different geometrical patterns. As seen, the user can make the stages move in
different geometries and set individual velocities for each task without switching the servo motor
on/off, till he decides to exit. The pattern that wil be made by the laser on the work piece is
plotted roughly in the Fig. 8. The USB camera attached to the Beagle Bone uses colour
recognition and separation theory to track the red spot made by the laser beam when the 2 stages
are in movement.
2.13 Software Design of the User Interface
The choice of realizing different geometrical patterns using the 5 position joystick is displayed on
the LCD provided on the board. The current co
and hence tracking of the stage is assured. Assigning the ve
acceleration with which the stage is moving is also facilitated. Fig. 9 shows the different windows
created for the user interface. Window (A) is the first screen informing the user that the XY
stages have been initialized and the instruction for moving to the exit screen has been displayed at
Line Controller (in our case 8 data bits, no parity and one stop bit), The ASCII character of the
sequence ”nn” for a new line has to be sent after every command line.
(c) Circle
Figure 8: Pattern Made by the Movement of the Stages
Figure 9: Different Windows of the User Interface
Realization of Different Geometries
t individual velocities for each task without switching the servo motor
cognition and separation theory to track the red spot made by the laser beam when the 2 stages
Software Design of the User Interface
the LCD provided on the board. The current co-ordinates of the stage are also shown on the LCD
and hence tracking of the stage is assured. Assigning the velocity(max 400mm/sec)and the
the instruction for moving to the exit screen has been displayed at
78
o parity and one stop bit), The ASCII character of the
t individual velocities for each task without switching the servo motor
cognition and separation theory to track the red spot made by the laser beam when the 2 stages
ordinates of the stage are also shown on the LCD
locity(max 400mm/sec)and the
the instruction for moving to the exit screen has been displayed at

the bottom. Window (B) is the home screen where the user can make choices for diferent
geometrical patterns and also choose the velocity at which the stages must move. Window (C)
displays the tracking co-ordinates of the stages when the stages were moving in circular
geometry. Window (D) shows the exit window after the user decides that he has executed all of
his tasks. As is seen at every stage except for window (D) the user can go back to
Figure 10: Manufactured Silicon Workpiece
home screen increasing repeatability.
2.14 Software Design of the Feedback Visual Servo Control
The BeagleBone is initially loaded with Angstrom operating system. However due to flexibility
in terms of interfacing the USB camera, Ubuntu 12.0 especially designed for usage in
BeagleBone has been used. Python programming language has been used to write the routine to
capture frames and track the position of the positioning stages. A separate terminal on a r
PC has been created to monitor the nano
Since the BeagleBone has an operating system handling its booting as well as other operations,
any screen interfaced to the BeagleBone will suffice. For
use the Ethernet over USB feature to SSH into the BeagleBone. The Fig. 11 shows the set up used
to capture the video of the nano-
of micro-vision setup is shown.
2.15 Excecution of tasks in Micro
The program was first run on a very raw set up where the 2 stages were not yet placed on top of
each other. The movement of the 2 stages was verified to be correct. The stages were then
assembled as shown in Fig. 3. The routine was run to verify the joint movement of the stages.
Once verified ,the set up was placed below the femtosecond laser and the material on which the
pattern had to be made was placed on top of the stage, as shown in the Fig.1
laser is acting on the material in short bursts and hence can be co
movement of the stages. The stages move to expose a different portion of the material to the laser
each time which subsequently leads to the creat
photographs of the manufactured material taken inside the light microscope. The line as shown in
part (a) was burnt on the material whilst the stages were moving from one extreme end to the
other. The part (b) is the cicle with a radius of approximately 90 micron.
ordinates of the stages when the stages were moving in circular
his tasks. As is seen at every stage except for window (D) the user can go back to the
Figure 10: Manufactured Silicon Workpiece
home screen increasing repeatability.
Software Design of the Feedback Visual Servo Control
interfacing the USB camera, Ubuntu 12.0 especially designed for usage in
capture frames and track the position of the positioning stages. A separate terminal on a r
PC has been created to monitor the nano-positioning stages. The usage of a PC is not mandatory.
any screen interfaced to the BeagleBone will suffice. For this micro-manufacturing workcell we
-positioning stages in movement and in the Fig. 12 block diagram
Excecution of tasks in Micro-Manufacturing System
as shown in Fig. 3. The routine was run to verify the joint movement of the stages.
pattern had to be made was placed on top of the stage, as shown in the Fig.1 . The femtosecond
laser is acting on the material in short bursts and hence can be co-ordinated well with the
each time which subsequently leads to the creation of the pattern on the materials.Fig. 10 are the
t (b) is the cicle with a radius of approximately 90 micron.
79
ordinates of the stages when the stages were moving in circular
the
interfacing the USB camera, Ubuntu 12.0 especially designed for usage in
capture frames and track the position of the positioning stages. A separate terminal on a regular
positioning stages. The usage of a PC is not mandatory.
manufacturing workcell we
positioning stages in movement and in the Fig. 12 block diagram
as shown in Fig. 3. The routine was run to verify the joint movement of the stages.
. The femtosecond
ordinated well with the
ion of the pattern on the materials.Fig. 10 are the

2.16 Future Scope
The kinematics of the micro parts see to it that surface interaction and friction force become more
promi-nent .Also there is a significant problem of spring back characterist
geometries are needed for the tools for increased tolerances and good surface quality [11]. The
creation of patterns in three dimensions made by a powerful femtosecond laser pulse, allows us to
delve deeper and create
Figure 11: Cont
further advancements in the fields of fabrication of integrated circuits, Micro electromechanical
systems (MEMS), biosensors, Power MEMS and energy harvesters/scavengers[8,13]. The use of
BeagleBone for communication with the PILine Controller as well as for providing the vision
feedback is envisioned. The model identification and controller design has been achieved and
hence the digital implementation of the PID controller can also be implemented. Thus a
BeagleBone can be made the sole processor used to provide automation to the micro
manufacturing workcell.
nent .Also there is a significant problem of spring back characteristics. Hence complex
Figure 11: Control of Micro-Vision through Linux Based Board
communication with the PILine Controller as well as for providing the vision
BeagleBone can be made the sole processor used to provide automation to the micro
80
ics. Hence complex
communication with the PILine Controller as well as for providing the vision
BeagleBone can be made the sole processor used to provide automation to the micro-

81
3. CONCLUSION
Automation is achieved in the aspect of geometry selection, assigning velocity and acceleration.
Vision feedback to enable further control of position errors has been provided. The software
necessary to com-municate with 2 controllers is not more than 40 kB in size. The user interface
was self- explanatory and had the option of returning to the home screen after every task.
Tracking of the position of the actuator was achieved as shown in Fig. 9 Window (C). The
assembly was highly portable. The repeatability was marginally increased along with saving a
precious amount of time.
ACKNOWLEDGEMENT
Authors thank CSIR-Central Electronics Engineering Research Institute (CSIR-CEERI), Pilani
for fund-ing the research program and creating supporting facilities for the project. Authors also
wish to thank Dr. P. Bhanu Prasad and S Mohan Mahalaxmi Naidu & Amit Patwardhan
professors at International Institute of Information Technology, Pune for their valuable discussion
and support towards this project.
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[3] Yung-Tien Liu, Y. Yamagata, T. Higuchi, ”Micropositioning device using impact force of
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