Team Name
Rewired & ReARMed
Timeline
Spring 2025 – Summer 2025
Students
- Angelina Abuhilal – Computer Engineering
- Xander Addington – Computer Engineering
- Rachel Garcia – Computer Engineering
- Travis Parker – Computer Engineering
- AnMinh Vuong – Computer Engineering
Sponsor
Dr. Chris McMurrough
Abstract
Rewired & ReARMed aims to retrofit and modernize the control system of the IBM 7535 SCARA robotic arm using a programmable industrial microcontroller, the Arduino OPTA. The original system, built with legacy hardware from forty years in the past, lacked flexibility and modernity. To resolve this, the team designed a control interface that integrates Yaskawa CPCR servopacks with OPTA’s industrial capabilities. The OPTA handles digital and analog signal routing, interprets positional feedback from the servopacks and sensors, and generates control voltages for precise movement. The project also includes the stepper motor, allowing finer movements for the Z-axis. This retrofit revitalizes legacy robotics but also shows the potential of modern automation with the legacy hardware.
Background
The IBM 7535 SCARA arm is a valuable but underutilized industrial automation technology. However, its control system is outdated, relying on 40-year-old hardware and software that is no longer practical for modern applications. The current system is bulky, inefficient, and incompatible with current interfaces, making it difficult for future Senior Design teams to integrate and experiment with. Without modernization, the arm remains obsolete. This project presents an opportunity to join legacy and modern robotics. By redesigning the control system with microcontrollers and a compact, streamlined form factor, we aim to restore the arm’s functionality while making it more accessible and practical for students and researchers. This modernization extends the lifespan of the equipment and transforms it into a useful learning platform for robotics, embedded systems, and industrial automation.
Project Requirements
- Control system’s PCB needs to be replaced by a microcontroller
- Must be efficiently replaced, meaning replacing only parts that need to be replaced, and keeping as much of the original legacy system as possible, like the motors and motor drivers
- The SCARA needs to be able to be used by future students
- The SCARA must be operational and functioning
Design Constraints
- Must utilize cost-effective microcontrollers that support C++ programming
- Must be intuitive enough for students to use
- The system should be upgradable so future teams can enhance its functionality without requiring a full redesign
- Must operate on available lab power sources
- Must be able to output power signals strong enough for the motor controllers to respond
- Minimum radius of three feet of clearance for safe operation
Engineering Standards
- IEC 60204-1: Electrical, electronic and programmable electronic equipment safety
- IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related systems
- ISO 13850: Functional requirements and design principles for the emergency stop function on machinery
- UL 991: Testing of solid-state safety controls
- NFPA 70: Safe electrical design, installation, and inspection
System Overview
The robot control system is designed to modernize and replace a legacy motor control platform with a modular, layered architecture. At the heart of the system is an Arduino Opta microcontroller, which serves as the new programmable controller for all motor and actuator functions. The layers can be separated into: Application, Power Supply, and the Hardware Abstraction layer.
- The Application Layer: Executes the core logic and control algorithms for the robot system. It runs on the Arduino Opta microcontroller, replacing the legacy CPU/motor controller. This layer generates all commands necessary to operate the motors and gripper according to programmed behavior. A computer will be used to program the OPTA for functionality and control of the IBM 7535.
- The Power Supply Layer: Responsible for delivering all required voltage levels to the robot control system. It consists of a PS1101 power supply and a relay board for power distribution. The PS1101 outputs five regulated voltages: +5V, -5V, +12V, -12V, and +24V. These voltages are routed through the relay board, which manages the power distribution to the Arduino Opta, Yaskawa servo packs, and any auxiliary control hardware. A bypass of the manipulator power was required to connect and test the SCARA, which also allows the OPTA to be powered and control the robot. DIN rails were also added to allow power to other components that the team had installed.
- The Hardware Abstraction Layer: Responsible for translating control signals into mechanical motion via the servo packs and motors. It interfaces directly with actuators, providing low-level execution of motor and gripper commands. This layer includes an operational amplifier circuit to control the theta motors as well as the solenoids used to give control to the Z-axis and gripper attachment. Sensors can also provide input to the OPTA for PID.
Results
We were able to install the OPTA and find a way to restore the SCARA’s functionality. We’ve managed to set up the control system with its basic operations again while retrofitting the control board. However, we have only been able to minimally restore it.
Future Work
In the future, we would like the project to be well-organized and clean. We would like the OPTA, PCB, and rails to be more securely set up and to be set up inside the chassis. The project is still open and set up for any new installations and improvements, such as restoring functionality to the controller or implementing a new controller.
Project Files
Project Charter
System Requirements Specification
Architectural Design Specification
Detailed Design Specification
Poster
References
International Organization for Standardization, Robotics & Safety Requirements: Part 1: Industrial Robots. ISO, 2025.
IBM 7535/7540 Manufacturing System: Hardware Library, 2nd ed. IBM.
