This paper presents the hardware and software design of the embedded control system for a highway crack sealing machine. A long-reach robotic manipulator has been specially designed for this application. In order to ensure the reliability and performance of the system, a unique distributed and multiprocessor architecture is used. The architecture is designed to employ the reliability of Windows NT and a graphical user interface while concurrently allowing real-time operation. By implementing embedded PC technologies, the software development process has benefited from the widely available off-the-shelf 32-bit software and programming tools. This paper discusses the use of both Visual C++ (MFC) and Visual Basic to realize a modern mechanical-electronic engineering system with minimum programming efforts. The communication between applications and over the network is also described with an emphasis on building an Internet-aware embedded system that has tremendous application potential.

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