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USER`S MANUAL - Pro-Dex

1. Table 4 2 IOMAXnet Terminal Block Pin Out Pin Signal Pin Signal Pin Signal Pin Signal 52 Y Phase A 51 Y Phase A 2 X Phase A 1 X Phase A 54 Y Phase B 53 Y Phase B 4 X Phase B 3 X Phase B 56 Y Index 55 Y Index 6 X Index 5 X Index 58 GROUND GROUND 8 Z Phase A 7 Z Phase A 60 T Phase A 59 T Phase A 10 Z Phase B 9 Z Phase B 62 T Phase B 61 T Phase B 12 Z Index 11 Z Index 64 T Index 63 T Index 14 U Phase A 13 U Phase A 66 U Index 65 U Index 16 U Phase B 15 U Phase B o5 i JAG 67 x Positive Limit Bee 70 ZNegative 69 eee 20 Positive Limit 9 ME Limit Limit 72 U Negative 71 T Negative 22 U Positive 21 T Positive Limit Limit Limit Limit 74 XDirection 73 24 X Home 23 76 Z Direction 75 Y Direction 26 Z Home 25 Y Home 78 T Direction 77 GROUND 28 T Home 27 GROUND 80 GROUND 79 U Direction 30 GROUND 29 U Home 82 Y Step 81 X Step 32 Y Aux 31 X Aux 84 83 Z Step 34 5 Volts 33 Z Aux 86 U Step 85 T Step 36 U Aux 35 T Aux 88 IO1 87 90 105 89 103 102 107 106 ADC 1 ADC 0 Y Servo X Servo T Servo Z Servo DAC 0 U Servo 4 10 For a black and white version of this table click Table 6 2 MAXk User s Manual HOST SOFTWARE INTRODUCTION TO MAXk SOFTWARE SUPPORT 5 HOST SOFTWARE 5 1 INTRODUCTION TO MAXk SOFTWARE SUPPORT A disk containing device drivers application
2. Encoder slip will be signaled by setting the appropriate bit in the door bell register The Host will respond to the door bell interrupt by reading the door bell register and capturing the encoder slip status data The slip bits will be cleared when the host writes ONES to set the bits 3 4 MAXk User s Manual COMMUNICATION INTERFACE DYNAMIC LINK LIBRARY 3 4 4 COMMAND ERROR The command error bit is ODBR bit 24 and it is cleared when the host writes a ONE to it 3 4 5 AXES NOTIFICATION FLAGS Bit 26 Bit 25 Axis K Axis W The axis nofication flags for the axes W and K in the ODBR indicate a done overtravel slip set bit in its axis status flag register This keeps the MAXk backward compatible to the MAXp driver 3 4 6 ASCII COMMAND RING BUFFER Command characters strings from the host are transferred to the controller by placing it in the ASCII Command Ring Buffer and updating the buffer insert pointer 3 4 7 ASCII RESPONSE RING BUFFER This ring buffer is resident in the Common Memory area region and the Message Unit s Outbound Message Register 0 OMR Data is sent from the controller to the host by placing data into the ring buffer and then using OMR to notify the host that data is available 3 5 DYNAMIC LINK LIBRARY OMS provides a Motion Control DLL for Windows NT Windows 2000 Windows XP amp Windows 7 32 bit operating systems These DLL s function with the drivers to provide a
3. Figure 2 3 MAXk connector and jumper locations 2 4 CONFIGURING THE CARD FOR USE WITH ENCODERS Quadrature encoder with TTL level outputs can be connected directly to the appropriate axis on IOMAXnet connected to J1 and or J2 connector resp The MAXk has built in biasing to allow single ended encoders for each axis on board Single ended operation may be limited by cable length and encoder velocity 2 2 MAXk User s Manual GETTING STARTED HARDWARE INSTALLATION 2 5 HARDWARE INSTALLATION e Turn off power to the PCI computer and disconnect its power cord from the wall socket e Note Some PC s have power on the board even if the power switch is turned off e Remove the cover of the computer to gain access to the PCI bus Caution ESD Warning The MAXk as well as most computers are sensitive to Electro Static Discharge ESD and may be damaged if proper precautions are not taken to avoid ESD Use properly grounded ESD mats wrist straps and other ESD techniques to prevent damage to the controller and or computer e On the MAXk board configure board number selection jumper J5 as needed e For controllers with more than 5 axes attach the ribbon cable to the J3 and J4 Figure 2 3 connector on the board Make sure to align pin 1 correctly at the connector on MAXk e Align the MAXk with the PCI slot of the computer and insert the MAXk fully into the slot Remember the MAXk will require a full length slot e Doub
4. 4 4 MAXk User s Manual CONTROL SIGNAL INTERFACE ENCODER FEEDBACK 4 7 ENCODER FEEDBACK Incremental encoder feedback is provided for all axes Encoder feedback is required for each servo axis Its use is optional for stepper axes The MAXk encoder feedback accepts quadrature pulse inputs from high resolution encoders at rates up to 16 MHz after quadrature detection When used with stepper motors the encoder monitors the actual position through the encoder pulse train On servo axes it continuously provides input to calculate the position error adjust for it through the PID filter and change the output accordingly The stepper axes can monitor the error and correct and maintain the position after the move is finished The encoder input can also be used as an independent feedback source or in the encoder tracking mode to mimic an activity All modes are capable of slip or stall detection and encoder tracking with electronic gearing These options are selectable by the user through software commands The MAXk is compatible with virtually any incremental encoder which provides quadrature outputs Times four quadrature detection is used to increase resolution This means that an encoder rated for 1000 counts or lines per revolution will result in 4000 counts of quadrature encoded input for each encoder shaft revolution The inputs are compatible with encoders that have single ended or differential TTL outputs The MAXk has differential line r
5. KO150 iv Continue adjusting and resending the KO command until the motor comes to rest Write down the final KO value for later reference as your zero setting 4 Maximize your system s usage of the MAXk s DAC this method works only with incremental encoders skip it if you use absolute encoder only on that axis a Connect the servo encoder to the MAXk See section 4 4 on incremental encoder feedback Set the signal command gain of your amplifier to its minimum setting Send the KQ3277 command to the MAXk and observe the velocity of the motor The output of MAXk will be near 1VDC If the motor does not move at all your amplifier does not work well at a low velocity In this case adjust the signal command gain of the amplifier to approximately 20 of maximum or until the motor begins to move Using a frequency meter measure the pulse rate of Phase A of the encoder The frequency measured is of the actual pulse rate Adjust the signal command gain of the amplifier until the pulse rate of Phase A is approximately 10 of your desired peak operational velocity If the pulse rate is already greater than 10 of peak your amplifier is not designed for low velocity motion and you will likely have some difficulty tuning your motors Send the KO 3277 command to the MAXk and recheck the velocity You may need to readjust your amplifier If so do not reduce the signal command gain only increase the s
6. MAXk User s Manual APPENDIX C Analog inputs Four analog inputs 10V 16 bit resolution Analog outputs 10V or 0 to 10V max mA each 16 bit resolution One per axis plus one general purpose output per 5 axes Step pulse output Pulse width 50 duty cycle Actively driven TTL level signal max 12mA Direction output Actively driven TTL level signal max 12mA Encoder Feedback Maximum 16 MHz after 4x quadrature detection Differential TTL level signal Single ended TTL level signal require external bias for reliable operation Absolute Encoders SSI Technology X and Y axes up to 12 bits resolution default Upon request absolute encoders up to 32 bits resolution for each axis Reference PCI Bus Specification Revision 2 2 PCB mechanical specification IEEE 1101 1 1101 10 and P1101 11 Software High level expertise not required Over 200 ASCII character commands expanded from current OMS command set Software drivers and DLLs for Windows provided at no additional cost User Manual included Servo Tuning Assistant software tools included at no additional cost Support software available for download at our web site http www pro dexoms com FEATURES PID Update Rate of 122 us on All 10 Axes Delivers exceptional servo control on multi axis applications Identical outcomes when utilizing one or all axes of motion Configurable PID filter with feedforward coefficients 266 MH
7. 2 14 MAXk User s Manual GETTING STARTED SETTING THE USER DEFAULT CONFIGURATION The block diagram below describes the feedback loop that is taking place in the servo system PID Algorithm Motor and Encoder Amplifier Error i e Position Figure 2 13 Feedback Loop To verify that your motor is tuned properly send the commands LPO CL1 and check the shaft of the motor to make sure it is stiff If there is play in the motor shaft when you turn it then you may have to re adjust your PID filter Once you are satisfied with the static holding torque you could check for position error Send the command AC100000 VL5000 MR64000 GO With a 2000 line encoder this move would be equivalent to 8 revolutions of the motor After the move is complete check the position error by sending the RE and RP commands for the specific axis you are moving Compare the difference in the two responses If they are the same then you are on the right track if the error is greater than 32768 the controller will disable the PID so that you don t have a runaway motor In this case major changes to the PID parameters may be required For minor differences in the encoder and the motor position readings you can fine tune your PID filter according to the earlier steps You may want to save the values for KP Kl KD etc for future reference These values can be saved in the board s flash memory so they can be accessed easily on reset or power up This can be don
8. ABS LUTE ENGODER rettet ete rete ra dee REM EA MR RR P ERU SEMEN RAE TU teta ote coud sant ua 4 7 CURRENT MODE ite e d estre asikusqa pika basa sepes e dc eu passa 2 10 MAXk HOME SWITCH STATUS WORD WORD ACCESS OFFSET 4 3 10 MAXk LIMIT SWITCH STATUS WORD WORD ACCESS OFFSET 0X40 3 9 MAXk PCI SHARED ADDRESS SPACE MAPPING L a 3 6 MAXk CONTROLLER FIRMWARE STATUS FLAGS WORD ACCESS OFFSET 0 48 3 11 ODBR E R P 3 4 OUT BOUND DOOR BELL REGISTER rnrvvvnnvennvvenrnrennvvenrnrennvvenrsrennvvenrsrennvvenrnrennnvrenssrennrreessrensrrenssrennrvene 3 4 PCI CONFIGURATION REGISTERS uiii a asian a a a sensn tren 3 1 QUADRATURE ENCODER WITH TTL LEVEL OUTPUTS sessi nennen enne nennen 2 2 REAL TIME POSITION CAPTURE ENTRY nennen nenehnnret tret terret enters etn sn tenia 3 12 REAL TIME POSITION CAPTURE PCI SHARED MEMORY WORD ACCESS OFFSET 0X1540 3 12 SERVOUPDATE RATE umet khunan 2 h uitiis RA LIN Ed NL 2 10 VOLTAGE MODE qc PK 2 10 MAXk User s Manual
9. Telephone 8 00 a m 5 00 p m Pacific Standard Time 503 629 8081 or 800 707 8111 4 Facsimile 24 Hours 503 629 0688 5 USPS PRO DEX INC OREGON MICRO SYSTEMS INC 15201 NW Greenbrier Parkway B 1 Ridgeview Beaverton OR 97006 RETURN FOR REPAIRS Call Pro Dex Inc Oregon Micro Systems Customer Service at 503 629 8081 or 800 707 8111 or E Mail to mailto salesor pro dex com Explain the problem and we may be able to solve it on the phone If not we will give you a Return Materials Authorization RMA number Mark the RMA number on the shipping label packing slip and other paper work accompanying the return We cannot accept returns without an RMA number Please be sure to enclose a packing slip with the RMA number serial number of the equipment reason for return and the name and telephone number of the person we should contact if we have further questions Pack the equipment in a solid cardboard box secured with packing material Ship prepaid and insured to PRO DEX INC OREGON MICRO SYSTEMS INC 15201 NW Greenbrier Parkway B 1 Ridgeview Beaverton OR 97006 MAXk User s Manual APPENDIX B RETURN FOR REPAIRS This page is intentionally left blank MAXk User s Manual DESCRIPTION The MAXk is a full length PCI bus motion controller that conforms to the PCI Bus Specification Revision 2 2 It is capable of up to 10 axis of control of which each axis can be configured as an open loop steppe
10. The system s maximum acceleration is determined several different ways The best method is to determine the system time constant which includes hitting or bumping the motor under system load and measuring the time from 0 rpm to maximum rpm and divide this value by 5 The maximum acceleration is either 2 5 times this value or is based on the system requirements for handling the load as defined in the operating specifications of the system This value is always lower than the calculated value and if this acceleration value is not high enough then a different motor amplifier with more power or bandwidth should be utilized The MAXk can control either current mode or voltage mode amplifiers The HUR command sets the servo update rate of the MAXk to one of the following rates 976 6us 488 3us 244 1us 122 1us This affects the responsiveness of the system High Following Error can be compensated for using the feedforward coefficients KV and KA commands explained later in this section There are some general formulas that have been developed to determine acceptable Following Error for both current and velocity mode systems Current mode KP Following Error 3 360 x counts per revolution Voltage mode KP Following Error 90 360 x counts per revolution It is obvious that the voltage mode allows for much greater Following Errors than the current mode This value is the Following Error when the motor is at
11. ensure that the outputs of the MAXk are as described and ensure that the encoder is operating correctly 2 10 TUNE THE SYSTEM 2 11 INTRODUCTION The following is an introduction to tuning a servo motor and the basics of the process of doing it Tuning a servo system is the process of balancing three primary gain values Proportional Integral and Derivative in order to achieve optimum system performance In a closed loop system an error signal is derived from the command position and actual position amplified and then supplied to the motor to correct any error If a system is to compensate for infinitely small errors the gain of the amplifier needs to be infinite Real world amplifiers do not possess infinite gain therefore there is some minimal error which cannot be corrected The three primary gain values used in servo systems are P proportional I integral and D derivative The P term is used as a straight gain factor to get the system response in the ballpark The I term defines how quickly the system will respond to change The D term is a dampening term This term defines how quickly the system settles at its desired position without oscillating The effects of these parameters can be seen when looking at the system s response to a step change at the input The shape of the step response falls into one of three categories under damped critically damped or over damped Over damped systems are slow to reach their final
12. offset 0x00 contains MSBs offset 0x03 0x00 4 contains LSBs 0x04 1 Axis X 0 Y 1 etc Home event bits 0x01 Positive edge home switch 0x02 Encoder home event 0x04 Negative edge home switch 0x05 Positive edge I O bits offset 0x06 contains MSBs and 0x06 offset 0x07 contains LSBs Negative edge I O bits offset 0x08 contains MSBs and offset 0x09 contains LSBs 0x08 3 12 MAXk User s Manual COMMUNICATION INTERFACE REAL TIME POSITION CAPTURE A value of 1 for a given bit indicates that it triggered the capture event A value of 0 for a given bit means it did not trigger the capture event The motion controller contains a PowerPC processor which writes the data in the shared memory in big endian format If the host processor is not a big endian processor then appropriate byte swapping to correct for endian differences must be performed by the host processor when accessing the shared memory data MAXk User s Manual 3 13 REAL TIME POSITION CAPTURE COMMUNICATION INTERFACE This page is intentionally left blank 3 14 MAXk User s Manual CONTROL SIGNAL INTERFACE INTRODUCTION 4 CONTROL SIGNAL INTERFACE 4 1 INTRODUCTION The MAXk family of motion controllers is available in configurations from one to ten axes to manage combinations of servo and step motor systems Each MAXk 100 pin connector incorporates half of the overall possible I O The first 5 axes and half of the digita
13. MAXk Example MR6000 GO Adjust the KP term while repeating the above move command until the Following Error at the flat spot of the profile is acceptable If the motor becomes unstable prior to obtaining the optimum KP term then increase the KD term until the motor stabilizes Example LPO KP1 CL1 MR6000 GO LPO KP2 CL1 MR6000 GO LPO The values in the above example are totally arbitrary and may vary drastically with different systems The LPO command is used to set the position error to O The values for KP range from 0 00 to 32767 00 Once the KP term has been obtained it can be used to determine the initial value for the KI term Set the KI and KU variables to 4 times the KP value The KI term is a gain applied to the accumulated position error over time The KU variable limits the amount the KI term can contribute to MAXk User s Manual 2 11 MANUAL TUNING GETTING STARTED the PID Continue executing the motion profile and raising the KU term until the long term Following Error is acceptable This error can be measured at the two knees of the motion profile Increasing the KI term will increase the response time of your system The motion profile should also have a steeper slope as KI increases see figures 2 9 and 2 10 below However as KI increases the system can also become unstable When the increased KI values cause unacceptable instability increase the KD parameter This will increase the d
14. a power failure simply run MAXKUPG again Examples Description MAXkupg upgrades flash of controller 1 with file MAXk bin MAXkupg f newMAXk bin upgrades flash of controller 1 with file newMAXk bin MAXkupg c 3 upgrades flash of controller 3 with file MAXk bin MAXkupg e 3 c 2 upgrades flash of controller 2 with file MAXk bin first erasing 3 flash blocks instead of the default of 2 MAXkupg h will display a help message Error Messages Unknown operating system type The operating system was not one that is valid for MAXKUPG Operating version detection error MAXKUPG could not successfully detect the operating system Invalid controller selection The parameter supplied with the C command line option was not valid The valid range is 1 8 Invalid erase blocks selection The parameter supplied with the E command line option was not valid The valid range is 1 4 Invalid command line option The character following a character on the command line was not one of the valid command line options Valid options are C E F Device OmsMAXkn not found A handle could not be opened for a MAXk controller number n Flash upgrade failed Some failure occurred during the erasing of the flash or the writing of the upgrade file to the flash Firmwarezxxxxxxxx Unknown Status Exiting MAXKUPG could not determine the state of the firmware executing on the MAXk controller Cannot get file handle filename A problem occurred trying t
15. and verifying that the board responds with its model type and revision levels i e MAXk 4000 ver 1 00 S N 0001 NOTE Reference section 2 6 SOFTWARE INSTALLATION Once communication has been established with the controller shut down the system and turn power off to the controller board NOTE It is not recommended to continue with the hardware connection if communication has not been established Connect the motor phase signals from the motor to the stepper driver output signals Use the motor and stepper driver manufacturer s manuals for instructions Now connect the controller signals from J1 of the MAXk or from IOMAXnet if it is used to the stepper driver Short cable lengths and shielded cables are recommended for improved signal integrity and reduction in signal noise NOTE Using the IOMAXnet interface module is strongly recommended as it provides an easy way to connect to the 100 pin connectors J1 and J2 on the MAXk Use a shielded 100 pin cable to connect the IOMAXnet to the MAXk From the terminal block on the IOMAXnet connect the appropriate wires to your motor drivers and system I O Attach the STEP outputs from the controller to the STEP inputs on the stepper driver Do the same for DIR signals Next connect an external power supply which is OFF to the stepper driver Again refer to the manufacturer s manual for instructions Note that power supply requirements differ from driver to driver Once all wire co
16. peak velocity and will be used when determining the proportional gain KP The Following Error for the integral term KI or long term gain value will follow the guidelines below Current Mode KI Following Error 0 counts Voltage Mode KI Following Error 805 360 x counts per revolution While still in open loop mode CLO use the KO command to zero the motor This variable is used to provide a constant output that will compensate for torque offset from the load So when the system should be stationary the necessary voltage will be sent to the amplifier to cause the motor to maintain position With the correct KO value the motor should successfully maintain a zero position 2 10 MAXK User s Manual GETTING STARTED MANUAL TUNING KO is the offset coefficient used while in closed loop or open loop mode hold on HN You should have determined the correct value the KO variable before beginning to tune the PID filter The values for KO range from 32767 00 to 32767 00 Set the previously determined values for maximum velocity maximum acceleration and the move distance for a trapezoidal profile with at least a 20 flat spot at peak velocity Use the following formula to determine the move distance Profile distance peak velocity 2 2xacceleration x2 4 Example 50 000 2 2x500 000 x2 4 6 000 Set the KD and KI variables to 0 and the KP variable to 1 and execute the move by sending the move commands to the
17. purpose analog output available per connector For every available axis that is not being used as a servo motor there is a general purpose analog output available Each DAC has a 15mA maximum output current 4 6 CONTROL OUTPUT The MAXk is configured at the factory to control open loop stepper motors Upon installation each axis can be configured for servo motors open loop steppers stepper motors with encoder feedback or a combination thereof The servo output may be either unipolar analog 0 10V or bipolar analog 10 10 V Each axis configured as a servo motor uses one analog output Step pulse and direction outputs are active drive TTL level output signals which will wire directly into most driver inputs Auxiliary outputs are active drive TTL outputs Each step direction and auxiliary output has a 20mA maximum output current 4 2 MAXk User s Manual CONTROL SIGNAL INTERFACE CONTROL OUTPUT Step Step Clock Direction Direction Opto 5V Supply Ground Opto Figure 4 1CONNECTION TO STEP DRIVES Enable Step Step Clock Direction Direction 5V Opto 5VDC Direction Step Clock Opto Ground Figure 4 2 CONNECTION TO STEP DRIVES WITH DIFFERENTIAL DRIVE INPUTS MAXk User s Manual 4 3 CONTROL OUTPUT CONTROL SIGNAL INTERFACE Home Limit Limit Switch Input Figure 4 3 HOME AND LIMIT INPUT WIRING DIAGRAM Digital Input Output TTL input Figure 4 4 GENERAL PURPOSE I O WIRING DIAGRAM
18. software and demonstration code for Pro Dex Oregon Micro Systems MAXk family controllers is supplied with the purchase of a MAXk controller Refer to the text files on the disk for installation instructions and other information Some programs on the demo disk that include source code may be adapted for use in application programs that use OMS motion controls No license is required The software is also available on the Pro Dex Oregon Micro Systems web page http www pro dexoms com MAXk User s Manual 5 1 INTRODUCTION TO MAXk SOFTWARE SUPPORT HOST SOFTWARE This page intentionally left blank 5 2 MAXk User s Manual SERVICE USER SERVICE 6 SERVICE 6 1 USER SERVICE The MAXk family of controllers contain no user serviceable parts 6 2 THEORY OF OPERATION The MAXk controller uses a PowerPC microprocessor for the core of its design The highest priority process calculates the desired velocity at the selected update rate with a proprietary algorithm patent number 4 734 847 This frequency is written to logic on board which generates the pulses for stepper motor control and or the appropriate voltage levels for Servo Control The velocity profile and synchronization of each axis is also handled by the PowerPC The commands from the PCI computer are temporarily stored in a character buffer until the MAXk can parse them The command is then executed immediately or routed to separate command queues for each axis The co
19. the program vector velocity MAXk User s Manual SPECIFICATIONS Velocity 0 to 4 176 000 pulses per second simultaneous on each axis Acceleration 0 to 8 000 000 pulses per second per second Position range 4 294 967 295 pulses 2 147 487 647 Accuracy Position accuracy and repeatability 0 counts for point to point moves Environmental Operating temperature range 0 to 50 degrees centigrade Storage temperature range 20 to 85 degrees centigrade Humidity 0 to 90 non condensing Power 5VDC 5 at 1 amp typical 3 3VDC 0 3 at 0 6 amps typical 12VDC at 0 1 amp typical 5 12VDC at 0 1 amp typical 10 Dimensions 12 283 x 4 200 x 0 475 312 mm x 106mm x 12 06 mm Communication Interface Meets all signal specifications PCI Bus Specification Revision 2 2 Is backward compatible with MAXp Limit switch inputs TTL input levels Input sense low or high true selectable by command input for each axis Connector Two 100 Pin SCSI type connectors for all control and I O signals shielded Controller models with 5 or less axes provide only half of the possible I Os on one connector Home switch inputs TTL input levels Input sense low or high true selectable by command input for each axis Accuracy to 1 encoder count User definable I O Up to 16 bits of user definable Digital I O The 16 bits are user configurable that are configured as 8 inputs and 8 outputs from the factory
20. 1 J2 Each digital I O bit can be set as an input or output and is controlled by firmware commands so there are no jumper to set MAXk User s Manual 1 1 INSTALLATION GENERAL DESCRIPTION Data communication is performed by sending and receiving strings of data ASCII characters through the DLL or driver The device driver provides handshaking information for writing to the shared memory registers Requests by and responses to the driver handle some status information like error conditions motion complete and so on See also Fig 3 1 Functional Communications Flow The MAXk bus interface uses PCI memory technology to provide a fast communication channel for the commands from the Host PC as well as feedback of motion parameters such as encoder positions Commands may be written to this RAM by the host thus eliminating the bottlenecks of I O and port based communications Critical motion parameters such as position and velocity are available allowing the host to interrogate these parameters in real time while the motion is in progress All of the data can be captured within the same update cycle Interrupt control and other data are available through blocks of dedicated registers These registers report status on controller flags over travel limit done flag and encoder slip for each axis The device driver processes and interrogates these registers then initiates the appropriate action Some commands may be passed to the MAXk while bypass
21. 76 Z Direction 26 S Home 76 S Direction 27 ROUND 77 ROUND 27 ROUND 77 elt 28 T Home 78 T Direction 28 W Home 78 W Direction 29 U Home 79 U Direction 29 K Home 79 K Direction 30 ROUND 80 ROUND 30 ROUND 80 ROUND 31 X Aux 81 X Step 31 V Aux 81 V Step 32 Y Aux 82 Y Step 32 R Aux 82 R Step 33 Z Aux 83 Z Step 33 S Aux 83 S Step 34 5 Volts 84 ROUND 34 5 Volts 84 ROUND 35 T Aux 85 T Step 35 W Aux 85 W Step 36 U Aux 86 U Step 36 K Aux K Step 38 100 88 101 108 109 39 102 89 103 1010 89 1011 40 104 90 105 1012 90 1013 41 106 91 IO7 1014 91 1015 43 ADCO 93 ADC 1 ADC 2 ADC 3 eo EEE BONE gt EON 45 X Servo Y Servo V Servo R Servo 47 Z Servo 97 T Servo S Servo W Servo 49 U Servo 99 DAC 0 K Servo DAC 1 50 FR GROUND Table 6 2 IOMAXnet Terminal Block Pin Out Pin Signal Pin Signal Pin Signal Pin Signal 52 Y Phase A 51 Y Phase A 2 X Phase A 1 X Phase A 54 Y Phase B 53 Y Phase B 4 X Phase B 3 X Phase B 56 Y Index 55 Y Index 6 X Index 5 X Index 58 GROUND 57 GROUND 8 Z Phase 7 Z Phase A 60 T Phase A 59 T Phase A 10 Z Phase B 9 Z Phase B 62 T Phase B 61 T Phase B 12 Z Index 11 Z Index 64 T Index 63 T Index 14
22. DE This message indicates that the boot code is still performing the hardware initialization functions This message will be displayed continuously until the boot code completes initialization Waiting for Controller to enter Upgrade Mode This message indicates that MAXKUPG has requested that the controller enter upgrade mode but the controller has not yet indicated that is in upgrade mode Firmware Status xxxx Waiting for microupg application to start This message indicates that the microupg bin application that has been successfully uploaded to the MAXk controller s RAM but has not yet indicated that it has started execution INFO messages MAXKUPG Version n nn Displays the current version of the MAXk firmware upgrade utility Firmware Required MAXKUPG has determined that there is no application running on the MAXk controller It will attempt to upload the microupg bin application to the controllers RAM Application Running MAXKUPG has determined that an application is running on the MAXk controller The application could either be a previously existing motion control firmware or it could be the microupg bin that MAXKUPG has just uploaded to the controllers RAM Upgrading flash with filename MAXKUPG has determined that the controller is ready to start the upgrade Signature packet re sent successfully This message indicates the last packet with a valid firmware signature has been successfully sent to the controller fla
23. E MEMORY REGISTER MAP COMMUNICATION INTERFACE Table 3 1 MAXk PCI SHARED ADDRESS SPACE MAPPING CON T 0 2 0 2 0 2 4 Ox2eb8 Ox2ebc Ox2ec0 Ox2ec4 Ox2ec8 Ox2ecc Coherent T axis servo DAC output Coherent U axis servo DAC output Coherent V axis servo DAC output Coherent R axis servo DAC output Coherent S axis servo DAC output Coherent W axis servo DAC output Coherent K axis servo DAC output W axis DAC output K axis DAC output AA lA A A AA A Ox2ed0 1616 Reserved The following memory region contains absolute encoder data 0x3520 4 X axis absolute encoder position 0x3524 4 Y axis absolute encoder position 0x3528 Z axis absolute encoder position 0x352c T axis absolute encoder position 0x3530 U axis absolute encoder position 0x3534 V axis absolute encoder position 0x3538 R axis absolute encoder position 0x353c S axis absolute encoder position 0x3540 W axis absolute encoder position 0x3544 K axis absolute encoder position 0x3548 Reserved 3 8 MAXk User s Manual COMMUNICATION INTERFACE MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP Table 3 2 MAXk Limit switch status word word access offset 0X40 Function Byte access offset 0x43 X axis negative limit sensor Y axis negative limit sensor Z axis negative limit sensor T axis negative limit sensor U axis negative limit sensor V axis negative limit sensor R axis negative lim
24. ERFACE 4 1 INTRODUCTION 4 2 LIMIT INPUTS 4 3 HOME INPUTS 4 4 GENERAL PURPOSE DIGITAL I O 4 5 ANALOG I O 4 5 1 ANALOG INPUTS 4 5 2 ANALOG OUTPUTS 4 6 CONTROL OUTPUT 4 7 ENCODER FEEDBACK 4 8 HOME PROCEDURES 4 9 ABSOLUTE ENCODERS WITH SSI 4 9 1 CONFIGURATION EXAMPLES 4 10 IOMAXnet ADAPTER MODULE 5 HOST SOFTWARE 5 1 INTRODUCTION TO MAXk SOFTWARE SUPPORT 6 SERVICE 6 1 USER SERVICE 6 2 THEORY OF OPERATION 6 3 FIRMWARE UPGRADE A LIMITED WARRANTY B TECHNICAL INFORMATION RETURN FOR REPAIR PROCEDURES C SPECIFICATIONS INDEX 3 5 3 6 3 12 4 1 4 1 4 1 4 1 4 2 4 2 4 2 4 2 4 5 4 5 4 7 4 10 5 1 5 1 6 1 6 1 6 1 6 2 MAXk User s Manual GENERAL DESCRIPTION INSTALLATION 1 GENERAL DESCRIPTION 1 1 INTRODUCTION The Pro Dex Oregon Micro Systems MAXk family of motion controllers are high performance PCI bus based products and are in compliance with the standard length universal PCI Bus Specification Revision 2 2 The MAXk motion controller can manage up to 10 axes of open loop stepper closed loop stepper or servo systems in any combination The Pro Dex Oregon Micro Systems MAXk controller synchronizes all independent or coordinated motion of up to 10 axes while incorporating other critical signals such as hard or soft limits home and other digital and or analog I O signals to provide the motion solutions to perform virtually any task With high level fun
25. F0 0000 to access this address space Table 3 1 MAXK PCI SHARED ADDRESS SPACE MAPPING Byte Offset Byte Offset Hex Byte Description length The following 8 words contain axis motor positions It is updated each motor update cycle motor position 0x4 Y axis motor position 0x8 Z axis motor position Oxc T axis motor position 0x10 U axis motor position 0x14 V axis motor position 0x18 R axis motor position Ox1c S axis motor position The following 8 words contain the axis encoder positions It is updated each update cycle 0x20 X axis encoder position 0x24 Y axis encoder position 0x28 Z axis encoder position 2 axis encoder position 0x30 U axis encoder position 0x34 V axis encoder position 0x38 R axis encoder position Ox3c S axis encoder position The following word contains the axis limit status bits It is updated each update cycle 64 0x40 4 Limit Switch status word The following word contains the axis home sensor status bits It is updated each update cycle 68 0x44 4 Home Switch status word The following word contains the controller firmware status flags It is updated as events occur 72 0x48 4 Firmware State flags The following word is a direct command mechanism that bypasses the text command buffer 76 Ox4c 4 Direct Command Mail Box The following 17 words contain a memory region used to capture coherent snapshots of axis position 0x50 Position Request Mail Box 0x54 X axis motor position 0x58 Y axis motor pos
26. GNAL INTERFACE Encoder Data Data Figure 4 7 SSI ENCODER WIRE DIAGRAM 4 8 MAXk User s Manual CONTROL SIGNAL INTERFACE ABSOLUTE ENCODERS WITH SSI Table 4 1 OUTPUT CONNECTORs PIN LIST J1 J2 J2 100 pin connector J1 100 pin connector 50 User s Manual GROUND 50 GROUND Pin Signal Pin Signal Pin Signal Pin 1 X Phase A 51 Y Phase A 1 V Phase A 51 2 X Phase A 52 Y Phase A 2 V Phase A 52 3 X Phase B 53 Y Phase B 3 V Phase B 53 4 X Phase B 54 Y Phase B 4 V Phase B 54 5 X Index 55 Y Index 5 V Index 55 6 X Index 56 Y Index 6 V Index 7 Z Phase A 57 fee 7 57 8 Z Phase A 58 8 GROUND 9 Z Phase B 59 T Phase A 10 Z Phase B 60 T Phase A 10 11 Z Index 61 T Phase B 11 12 Z Index 62 T Phase B 12 13 U Phase A 63 T Index 13 K Phase A 14 U Phase A 64 T Index 14 K Phase A 64 15 U Phase B 65 U Index 15 K Phase B 16 U Phase B U Index K Phase B 17 GROUND 18 X Positive Limit X Negative Limit V Positive Limit 19 Y Positive Limit 69 Y Negative
27. Limit 19 20 Z Positive Limit 70 Z Negative Limit 20 21 T Positive Limit 71 T Negative Limit 21 22 U Positive Limit 72 U Negative Limit GROUND 24 X Home 74 X Direction 25 Y Home 75 Y Direction 26 Z Home 76 Z Direction GROUND 28 T Home 78 T Direction 29 U Home 79 U Direction 31 X Aux 81 X Step 32 Y Aux 82 Y Step 33 Z Aux 83 Z Step 34 5 Volts 84 5 Volts 35 T Aux 85 T Step 36 U Aux 86 U Step 38 100 88 101 39 102 89 103 39 1010 40 104 90 105 40 1012 41 106 91 107 43 ADC 0 3 ADC 1 GROUND 45 X Servo 5 Y Servo 95 96 Nene 47 Z Servo 97 T Servo 49 U Servo 99 DACO DAC 1 GROUND IOMAXnet ADAPTER MODULE CONTROL SIGNAL INTERFACE 4 10 IOMAXnet ADAPTER MODULE The optional IOMAXnet is an adapter module designed to provide easy connection for each signal of the MAXk and MAXnet It incorporates two row terminal blocks It is used with a 10 foot shielded cable to connect to the MAXk via the 100 pin connector The 5VDC on the IOMAXnet is supplied by the MAXk This supply voltage is intended to be utilized with accessories used in conjunction with the MAXk such as sensors motor driver modules etc and supports a maximum current of 0 5 amps for these purposes For controller models with 6 or more axes a second IOMAXnet provides the connectivity for the second 100 pin connector
28. M Pro Dex II AN Accelerating Possibilities sus OREGON MICRO SYSTEMS USER S MANUAL INTELLIGENT MOTION CONTROLLERS FOR PCI BUS MAXk PRO DEX INC OREGON MICRO SYSTEMS 15201 NW GREENBRIER PARKWAY B 1 RIDGEVIEW BEAVERTON OR 97006 PHONE 503 629 8081 FAX 503 629 0688 mailto csr pro dex com WEB SITE http www pro dexOMS com COPYRIGHT NOTICE O 2013 Pro Dex Inc Oregon Micro Systems ALL RIGHTS RESERVED This document is copyrighted by Pro Dex Inc Oregon Micro Systems Inc You may not reproduce transmit transcribe store in a retrieval system or translate into any language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise any part of this publication without the express written permission of Pro Dex Inc Oregon Micro Systems Inc TRADEMARKS IBM IBM PC IBM PC XT IBM PC AT IBM PS 2 and IBM PC DOS are registered trademarks of International Business Machines Corporation CompactPCl PICMG PCI PICMG are registered trademarks of the PCI Special Interest Group LabView is a registered trademark of National Instruments Windows XP 2000 Win NT amp Vista Windows 7 are registered trademarks of Microsoft Corporation DISCLAIMER Pro Dex Inc Oregon Micro Systems makes no representations or warranties regarding the contents of this document We reserve the right to revise this document or make changes to the specifications of the product described within
29. O 0 KV 0 KAO Servo zero value KO Factory Default 0 2 15 POWER SUPPLY REQUIREMENTS The MAXk Motion Controller Card plugs into the PCI Bus The MAXk is designed to fit into a standard full size card PCI slot and draws 0 6 Amps from the 5V and 3 3V power supplies of the PC in addition to the possible 1 Amp of 5V provided on the J1 J2 connectors For servo models only 12V at 0 1 Amp and 12V at 0 1 Amp are also taken from the PC 2 16 MAXk User s Manual COMMUNICATION INTERFACE INTRODUCTION 3 COMMUNICATION INTERFACE 3 1 INTRODUCTION The MAXk is 100 compatible with standard PCs and complies with the PCI Bus Specification Revision 2 2 The MAXk can be considered a motion co processor in the PCI computer where it can execute the motion process independent of the host CPU The application software issues DLL function calls and receives requested data from the driver support DLL All communication is done between the motion controller and the host PC via the device driver and the DLL See also Functional and Data Flow Info Diagrams Figure 3 1 3 2 PCI INTERFACE The PCI interface to the controller consists of a 32 bit register and 64 Kbytes of shared memory After the host system BIOS has executed its PCI resource allocation functions the controller s PCI configuration registers will contain the following information PCI Register Offset HEX Register Contents 32 bits 0x000 The Device ID and Vendor ID 0006 1057 Thi
30. Phase A 2 V Phase A 52 R Phase A 3 X Phase B 53 Y Phase B 3 V Phase B 53 R Phase B 4 X Phase B 54 Y Phase B 4 V Phase B 54 R Phase B 5 X Index 55 Y Index 5 V Index 55 R Index 6 X Index 56 Y Index 6 V Index 56 R Index 7 Z Phase A 57 GROUND 7 S Phase A 57 ROUND 8 Z Phase A 58 GROUND 8 S Phase A 58 ROUND 9 Z Phase B 59 T Phase A 9 S Phase B 59 W Phase A 10 Z Phase B 60 T Phase A 10 S Phase B 60 W Phase A 11 Z Index 61 T Phase B 11 S Index 61 W Phase B 12 Z Index 62 T Phase B 12 S Index 62 W Phase B 13 U Phase A 63 T Index 13 K Phase A 63 W Index 14 U Phase A 64 T Index 14 K Phase A 64 W Index 15 U Phase B 65 U Index 15 K Phase B 65 K Index 16 U Phase B 66 U Index 16 K Phase B 66 K Index 17 ROUND 67 ROUND 17 ROUND 67 elt 18 X Positive Limit 68 X Negative Limit 18 V Positive Limit 68 V Negative Limit 19 Y Positive Limit 69 Y Negative Limit 19 R Positive Limit 69 R Negative Limit 20 Z Positive Limit 70 Z Negative Limit 20 S Positive Limit 70 S Negative Limit 21 T Positive Limit 71 T Negative Limit 21 W Positive Limit 71 W Negative Limit 22 U Positive Limit 72 U Negative Limit 22 K Positive Limit 72 K Negative Limit 23 ROUND 73 ROUND 23 ROUND 73 ROUND 24 X Home 74 X Direction 24 V Home 74 V Direction 25 Y Home 75 Y Direction 25 R Home 75 R Direction 26 Z Home
31. TXT or README DOC The instructions will show you how to properly install the device driver and appropriate DLL To begin communicating with the MAXk run the OMSSuite EXE utility and select the MAXk controller number you selected with the Board Number Select jumpers You can begin interactively sending commands and receiving responses immediately if all has been properly installed For backward compatibility with MAXp installed MAXp drivers work properly with MAXk although without the added features of the MAXk Type WY and observe the response from the MAXk If you are communicating to the MAXk it would return its version number number of axes FPGA version number etc You should receive a reply similar to MAXk 8000 Ver x xx S N 000001 FPGA 20 from the MAXk If you receive nothing double check that the MAXk is fully seated in the chassis and the device drivers are installed properly For technical support refer to Appendix B for contact information 2 4 MAXk User s Manual GETTING STARTED CONNECT TO STEPPER MOTOR SYSTEM 2 7 CONNECT TO STEPPER MOTOR SYSTEM The MAXk control signals are located on the J1 connector and J2 connector where applicable This section will explain how to connect a stepper motor driver to the controller board Begin this procedure with a MAXk controller board installed in your system Be sure that communication to the board has been established This can be checked by issuing a WY command to the board
32. U Phase A 13 U Phase A 66 U Index 65 U Index 16 U Phase B 15 U Phase B 68 XNegative 67 GROUND 18 x Positive Limit 17 70 ZNegative 69 Y Negative 20 positive Limit 19 Y Positive Limit Limit Limit 72 U Negative 71 T Negative 22 U Positive 21 T Positive Limit Limit Limit Limit 74 XDirection 73 GROUND 24 X Home 23 76 Z Direction 75 Y Direction 26 Z Home 25 Y Home 78 TDirection 77 GROUND 28 T Home 27 80 GROUND 79 U Direction 30 GROUND 29 U Home 82 Y Step 81 X Step 32 Y Aux 31 X Aux 84 GROUND 83 Z Step 34 5 Volts 33 Z Aux 86 U Step 85 T Step 36 U Aux 35 T Aux 88 IO1 87 38 IO0 37 90 105 89 103 40 104 39 102 92 GROUND 91 IO7 42 GROUND 41 106 94 GROUND 93 ADC 1 44 GROUND 43 ADC 0 96 GROUND 95 Y Servo 46 GROUND 45 X Servo 98 GROUND 97 T Servo 48 GROUND 47 Z Servo 100 GROUND 99 DAC 0 50 GROUND 49 U Servo ORDERING INFORMATION Model oe Axes Servo Stepper Digital nterface General Auxiliary Home Purpose MAXk 1000 1 User Definable 1 1 2 MAXk 2000 2 User Definable 2 2 2 MAXk 3000 3 User Definable 3 3 2 MAXk 4000 4 User Definable 4 4 2 MAXk 5000 Universal 5 User Definable 5 5 2 MAXk 6000 PCI 6 User Definable 6 6 4 MAXk 7000 7 User Definable 7 7 4 MAXk 8000 8 User Definable 8 8 4 MAXk 9000 9 User Definable 9 9 4 MAXk A000 10 User Definable 10 10 4 CBL58 3M 100 Pin 12 ft cable one per 5 axes IOMAXnet 100 Pin Connector Breakout Module one per 5 axes MAXk User s Manual INDEX
33. accomplish these functions Bits in the 32 bit Out Bound Door Bell Register ODBR are used to pass status and flag data to the Host Bits in the ODBR register are defined as follows 3 4 1 STATUS DONE FLAG DATA Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Axis S Axis R Axis V Axis U Axis T Axis Z Axis Y Axis X Done is signaled by setting the appropriate done bits in the Out Bound Door Bell Register ODBR The host responds to the door bell interrupt by reading the Door Bell register and capturing the done flag data The done flags are cleared when the host writes ONES to set the bits 3 4 2 OVERTRAVEL Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8 Axis S Axis R Axis V Axis U Axis T Axis Z Axis Y Axis X An Over Travel condition is signaled by setting the appropriate bit in the ODBR register and the host will respond to the Door Bell interrupt by reading the ODBR and capturing the over travel status The over travel bits will be cleared when the host writes ONES to set the bits Note that the over travel bits in the door bell register are used to notify the host that an over travel axis has been detected The actual LIMIT switch status is obtained by reading the current limit switch status from the common memory area 3 4 3 SLIP FLAG Bit 23 Bit 22 Bit 21 Bit 20 Bit 19 Bit 18 Bit 17 Bit 16 Axis S Axis R Axis V Axis U Axis T Axis Z Axis Y Axis X
34. ad packet When MAXKUPG detects that no firmware exists on the MAXk controller it attempts to write a short program to the controller RAM using a write and read back verification This error occurs when the MAXk controller did not accept the packet being written to the controllers RAM MAXKUPG will retry continuously until the write packet is successful NAK on packet verification When MAXKUPG detects that no firmware exists on the MAXk controller it attempts to write a short program to the controller RAM using a write and read back verification This error occurs when the read back of the packet was unsuccessful MAXKUPG will retry continuously until the read back is successful Data verification failure retry When MAXKUPG detects that no firmware exists on the MAXk controller it attempts to write a short program to the controller RAM using a write and read back verification This error occurs when the data packet read back from the controller did not compare equally to the data packet written to the controller MAXKUPG will attempt to re send the packet until it is successfully verified or the user aborts MAXKUPG Erasing code block n FAILURE An error occurred attempting to erase a block of flash WAIT messages NOTE messages preceded with WAIT will be displayed continuously until the condition indicated is met Waiting for boot code to complete initialization 6 4 MAXk User s Manual SERVICE MAXk FIRMWARE UPGRA
35. ampening on the system s motion profile therefore reducing oscillation or ringing Continue adjusting the KI KU and KD terms until the proper response time is obtained The values for KI range from 0 00 to 32767 00 The values for KU range from 0 00 to 32767 00 FIGURE 2 7 FIGURE 2 8 If you are getting too much ringing in the motion profile then increase KD to help dampen the system s response If instead the system is over damped and is reaching the final velocity too slowly then reduce the KD parameter Optimally the system s motion profile should show the motor reaching the desired velocity as quickly as possible without overshoot and oscillation ringing The values for KD range from 0 00 to 32767 00 2 12 MAXk User s Manual GETTING STARTED MANUAL TUNING Desired Step Response Too Much KD FIGURE 2 9 Desired Step Response Too Little KD FIGURE 2 10 KP KI and KD are the primary parameters of concern when tuning a servo system Once the optimum values for these variables have been determined you can adjust some of the secondary parameters that will help fine tune your system s performance These other variables are described in the subsequent steps The KV variable is the velocity feedforward coefficient and compensates for friction that is proportional to velocity Unlike KP KI and KD which have to wait for system error before responding the KV variable has an immediate eff
36. back as feedback for the stepper axes or as independent position feedback Encoder feedback is also used to provide slip and or stall detection SSI Absolute encoder feedback with resolution of up to 32 bit are available for each axis upon request The MAXk has many user definable parameter that can customize the controllers behavior These parameters can be conveniently stored in Flash so that the user defined behavior will be automatically preset at each power up MAXk User s Manual APPENDIX C APPENDIX C SPECIFICATIONS PROGRAMMING MAXk motion controllers are easily programmed with ASCII character commands through an extensive command structure These commands are combined into character strings to create sophisticated motion profiles with features of I O and other functionality A separate FIFO command queue for each axis is used to store the commands once they are parsed by the The commands executed sequentially allowing the host to send complex command sequence and attend to other tasks while the MAXk manages the motion process These command queues store 2559 command values and include a command loop counter which allows multiple executions of any queued commands All commands are sent to the controller as two or three character ASCII strings Some of these commands expect one or more numerical operands to follow These commands are identified with a after the command The 7 indicates a signe
37. ctionality such as circular and linear interpolation multi tasking custom profiling etc the MAXk can satisfy the needs of most any motion control application See Appendix C Ordering Information for specific MAXk family models The MAXk communicates as a slave only device and functions as a motion co processor to the PCI host It utilizes patented proprietary technology to control the trajectory profile acceleration velocity deceleration and direction of selected axes In response to commands from the host computer the MAXK controller will calculate the optimum velocity profile to reach the desired destination in the minimum time while conforming to the programmed acceleration and velocity parameters In addition the MAXk can provide motion control information such as axis and encoder position as well as the state of over travel limits home switch inputs and done interrupt flags The MAXk motion controllers utilize a Power PC processor configured to operate as an efficient and powerful co processor with the PC host via the PCI Bus at 33 MHz The stepper control of the MAXk produces a 50 duty cycle square wave step pulse at velocities of 0 to 4 000 000 pulses per second and an acceleration of 0 to 8 000 000 pulses per second per second The servo control utilizes a 16 bit DAC and outputs either 10V or 0 to 10V The encoder feedback control can be used as feedback for the servo PID position maintenance for the stepper axes or a
38. d integer input parameter or a signed fixed point number of the format when user units are enabled User Units define distances velocity and acceleration parameters and may be inputted in inches millimeters revolutions etc Synchronized moves may be made by entering the AA or AM command mode This form of the command performs a context switch that allows entering commands of the format MR H HHHH HEHH The order of axes is always X Y Z T U V R S W Numbers are entered for each axis commanded to move An axis may be skipped by entering the comma with no parameter The command may be prematurely terminated with a i e a move requiring only the X and Y axes would use the command MR followed by the GO command Each axis programmed to move will start together upon executing the GO command The MAXk can be switched back to the single axis mode by entering the desired single axis command such as AX APPENDIX C PROGRAMMING EXAMPLES In a typical move requirement where it is desired to home the stage then move to a specified position the following will demonstrate the programming for a single axis e Initialize the velocity and acceleration parameters to a suitable value Set a PID filter gain values Enable the PID hold mode Perform the home operation initializing the position counter to Zero Perform a motion to an absolute position of 10 000 and set the done flag for that axis when the move is f
39. e by using the APP command These saved parameters will then be used as the power up default set of values 2 14 SETTING THE USER DEFAULT CONFIGURATION There are several parameters that can be defined by the user as default These parameter values can supersede the factory default values and be stored in flash memory for power up configuration Most of these parameters consist of axis specific values i e velocity acceleration limit switch logic sense etc The MAXk comes from the factory with default values for all parameters For instance the default value for the velocity of all axes is 200 000 counts per second A count is equivalent to a step pulse or one count of an encoder In a typical application when the system is powered up the main host computer would initialize all of the peripherals such as the MAXk sending each of the axes the peak velocity When the User Definable Default Parameter value is defined then the velocities of the defined axes will be set accordingly This feature can greatly simplify the software and initialization process Once the values for all of the associated parameters are defined i e velocity acceleration PID values etc then the APP command is executed to place the values into flash memory From this point forward these defined values will be used after reset or power up The individual parameters can be over written at anytime by using the associated command i e VL AC etc To restore the fact
40. e process in order to minimize the chance of an irrecoverable error that would require the board to be sent back to the factory Files Required MAXKUPG EXE Host executable that does the firmware upgrade via PCI bus MAXK BIN The default new controller firmware file MICROUPG BIN Controller firmware for assisting MAXKUPG This file is only required if no firmware is running on controller when MAXKUPG is executed This can occur when an attempt to do a firmware upgrade has failed or has been interrupted before completion MAXKUPG command line parameters c n n specifies controller number default is 1 valid is 1 8 f n n specifies controller firmware filename default is MAXk bin le n n specifies number of blocks to erase default is 2 valid is 1 4 h for help display a usage line no default Description of operation MAXKUPG will first verify the existence and the validity of the firmware upgrade file prior to sending any commands to the controller to erase or program flash Next MAXKUPG determines whether there is firmware currently executing on the MAXk controller If firmware is currently executing then MAXkupg proceeds to the next step of the upgrade process Otherwise MAXKUPG will upload the microupg bin file to the controllers RAM and start the controller execution of the microupg firmware Once MAXKUPG determines that the microupg firmware is executing MAXKUPG proceeds to the next step of the upgrade process Next t
41. eceivers to accommodate encoders with differential outputs Encoders with single ended outputs can wire the signals to the plus side of the differential line receiver and 1 5V bias the minus side 4 8 HOME PROCEDURES Two logical input functionalities are provided to synchronize the physical hardware with the MAXk controller i e put the controlled motor in the home position The home switch input is a TTL input signal If current limiting is required it should be done externally to the board Contact Pro Dex Inc Oregon Micro Systems technical support for assistance The MAXk home switch input can be used to physically home a mechanical stage When this functionality is used the axis position counter will be reset to a selected value when the switch is activated At this point the MAXk can either ramp the axis to a stop or stop the axis immediately The control of the direction of travel the logic active state and the response to the active switch are controlled through commands The other homing method on the MAXk uses the home switch and the encoder signals to home a motor When using the Home Encoder HI mode the homing logic is used with these input signals The home position consists of the logical AND of the encoder index pulse the home switch input and a single quadrant from the encoder logic The home switch and encoder should be positioned relative to each other in such a way that there is only a single location in the enti
42. ect on the commanded move and is a gain applied to the current velocity KV makes the system more responsive and by increasing this term the Following Error of the system s response can be minimized However too large of a value may result in unstable behavior after command velocity changes The values for KV range from 0 00 to 32767 00 MAXk User s Manual 2 13 MANUAL TUNING GETTING STARTED Desired Step Response Actual Step Response Velocity Following Error FIGURE 2 11 The KA variable is the acceleration feedforward coefficient and compensates for inertia Like KV the KA variable does not operate on system error and is applied as a gain to the current acceleration and deceleration KA determines how closely the system follows the desired acceleration and deceleration portions of the motion profile Increasing this term reduces the following error occurring during acceleration and deceleration of the system but if KA is too large instability may occur The values for KA range from 0 00 to 32767 00 Desired Step Response Actual Step Response Acceleration Deceleration Following Error FIGURE 2 12 The KF variable is the friction offset coefficient and compensates for static friction The KF variable does not operate on system error and is applied to all commanded moves KF increases all portions of the motion profile If KF is too large instability may occur The values for KF range from 0 00 to 32767 00
43. ed memory for the capture data is implemented as a ring buffer with an insert index that the controller uses to insert data into the shared memory region and a removal index that the host uses to remove data from shared memory region The controller places the capture data into the ring buffer at the location specified by the insert index and advances the insert index If after being advanced the insert index equals the removal index then the controller also advances the removal index If the controller has to advance the removal index this means that the host is not removing data fast enough and capture data was lost by the host The capture data is available in the shared PCI memory at offset addresses 0x1540 through 0x1767 The format of the capture table data in shared PCI memory is defined in table 3 5 below Table 3 5 REAL TIME POSITION CAPTURE PCI SHARED MEMORY WORD ACCESS OFFSET 0X1540 Byte Offset Hex Byte length Description 0x1540 1 Controller insert index 0x1541 1 Host removal index 0x1542 550 Table entries 10 bytes per entry and 55 entries The number of entries can be greater than one for each axis if capture events occur on back to back motor update cycles and if the host does not collect the data fast enough The format of each table entry is defined in table 3 6 below Table 3 6 REAL TIME POSITION CAPTURE TABLE ENTRY Byte Offset Byte Offset Hex Byte length Description Encoder position
44. etting as needed Increasing the gain will not impair the forward peak velocity but reduction will Send the KO command with the zero value to the MAXk MAXk User s Manual GETTING STARTED TUNE THE SYSTEM 5 Verify the direction of your servo encoder a Send the LPO KO2000 command to the MAXk b Send the RE command to the MAXk and observe the response c Ifthe response is positive no further action need be taken go to step 6 d If the response is negative your encoder or analog output must be reversed use one of the methods below i Use EDI EDN to invert normalize encoder direction or ii Use SVP SVP to invert normalize PID analog output inverts values of KO and KOD or iii if your incremental encoder produces a differential signal swap Phase B with Phase B and repeat from step a above iv If your incremental encoder produces a single ended or TTL signal swap Phase A with Phase B and repeat from step a above e If the RE response is still negative contact OMS Technical Support for assistance 6 Repeat from step 1 for the other servo axes 7 Remember to set KO for each axis at every power up unless you store the values in Flash NOTE Most encoder problems are caused by lack of power or incorrect connections If the encoder position changes by only 1 count this is an indication that one of the phases is not connected Do not proceed until you perform all the steps in this procedure
45. factory Though the MAXk is a low power device there should be ventilation including forced air around the circuit board The MAXk will draw all of its power from the PCI bus so no external power supply is needed 1 01 S 1 83 054 le Figure 2 1 Board dimensions 2 2 TO PREPARE FOR INSTALLATION Note The Board Number Select Jumper J5 must be set BEFORE power up See Figure 2 3 for MAXk component locations CAUTION The MAXk is a static sensitive device and standard Electro Static Discharge ESD techniques are required when handling and installing the MAXk MAXk User s Manual 2 1 BASIC CARD CONFIGURATION GETTING STARTED 2 3 BASIC CARD CONFIGURATION If the MAXk is to be installed with other MAXk boards the Board Number Select Jumper J5 must be set to a different value on each board The Board Number Select Jumper block is located near the bottom center of the board and is labeled J5 See Figure 2 2 Set the first MAXk board identification number to 1 the second MAXK to 2 and so forth The default value is all jumpers off which identifies the board as controller 1 The jumper block represents the board number in binary form 4 bit See Figure 2 2 BOARD SELECT Jumper J5 J5 J5 J5 J5 Default Board 2 Board 3 Board 4 Figure 2 2 BOARD SELECT Jumper J5 ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 000000000000000000000 000000000000000000000
46. gs Text Event Responses Notification Text Direct Commands Commands MAXk Motion Controller Figure 3 1 FUNCTIONAL COMMUNICATIONS FLOW 3 2 MAXk User s Manual COMMUNICATION INTERFACE PCI COMMUNICATION THEORY Simplified Data Dictionary of Figure 3 1 Event Notification New status flag data available Query command text response available Direct Commands Kill all motion Text Commands ASCII controller command strings Status Flags I Axis done flags IX Y Z T U V R S Axis over travel flags X Y Z T U V R S Axis encoder slip flags X Y Z T U V R S Command error flag Axis notification flags W K Text Responses Query command RP RE ASCII response strings Shared Memory Data Axis motor position data axis encoder position data velocity profile data and servo tuning data axis status flags W amp K Requested Data Null terminated ASCII text response string velocity profile data servo tuning data axis done flags axis over travel flags axis encoder slip flags command error status MAXk User s Manual 3 3 COMPARISON OF PREVIOUS OMS ARCHITECTURE TO MAXkCOMMUNICATION INTERFACE 3 4 COMPARISON OF PREVIOUS OMS ARCHITECTURE TO MAXk OMS motion controllers previously used hardware registers for status slip done and over travel limits The MAXk uses the Power PC s Message unit in combination with reserved storage regions in the common memory area to
47. he flash code blocks are erased If a failure occurs erasing flash the program is aborted Next the firmware file is sent to the controller and the controller programs the flash to the flash code blocks The firmware is sent in packets If any single packet has a transmission error it will be resent until the transmission is successful or the user aborts the upgrade program Next the first code block is re written with a valid MAXk signature so that the boot block will recognize that valid firmware is loaded in the flash Finally a restart command is sent to the controller causing the controller to re boot with the new firmware Verify that the controller is running the new firmware by running the MAXKCOMM utility and sending a WY command to the controller The WY response should indicate the version number of the upgraded firmware 6 2 MAXk User s Manual SERVICE MAXk FIRMWARE UPGRADE If the WY response does not reflect the version number of the new firmware then power cycle the PC and run MAXKCOMM after the PC is re booted The new firmware version should now be reflected in the WY response If MAXKUPG encounters an error that will not allow it continue it will either abort the program or continuously retry until the error no longer occurs In the case of a continuous error that does not clear the user can abort by entering Control C holding down the Ctrl key and pressing C If an upgrade is interrupted by the user or
48. ing the communications channel These direct commands cause an immediate interrupt and may be used for critical commands such as an abort Each axis may perform individual unrelated moves or the controller can be coordinated as required by the application DLLs are provided to allow applications written in high level languages to communicate with the controller Software provided by Pro Dex Inc Oregon Micro Systems directly supports the use of Microsoft C C or Visual Basic In addition any language that has a mechanism for utilizing a standard Microsoft DLL Library can be used for application development The MAXk I O Breakout Modules the IOMAXnet provide an efficient means of connecting the MAXk signals to external devices More details on the functionality of the controller are included in the following chapters 1 2 MAXk User s Manual GETTING STARTED INSTALLATION 2 GETTING STARTED 2 1 INSTALLATION For installation of MAXk you will need a computer with a PCI bus that is compliant to the PCI Bus Specification Revision 2 2 The MAXk is a universal PCI board and can be installed in either a 5VDC PCI slot or a 3 3VDC PCI slot Read through the following two sections before beginning the installation Do not turn on the power to the PC until you have properly configured the controller per the following instructions Note that the header J5 is used to choose the controller number The MAXk is set for controller number 1 from the
49. inished The following would be input from the host computer AX VL5000 AC50000 KP20 KI1 KD45 CL1 HMO MA10000 GO ID In a move requiring a three axis coordinated move to a select position the following commands could be used AM VL5000 5000 5000 AC50000 50000 50000 MT1000 2000 3000 GO ID The controller would calculate the relative velocities required to perform a straight line move from the current position to the desired absolute position so that all axes arrive at their destinations at the same time The following demonstrates cutting a hole with a 10 000 count radius using variable velocity contouring with circular interpolation e The vector velocity is set to 1000 counts per second A contour is defined beginning at coordinates 0 0 on the X and Y axes e General purpose l O7 is turned on which could turn on the cutting torch or laser starting the cut at the center of the circle e A half circle is cut from the center to the outside of the hole positioning the cutting tool at the start of the hole The hole is then cut the torch turned off the stage stopped and the contour definition completed The following would be input from the host computer AA VOAO0 5 VV1000 1000 VP0 0 V100100 0100 VC0 5000 180 VC0 0 360 V100 0100 VV1000 0 VP 1000 0 VE During this sequence the VO command or an analog input may be used to vary the vector velocity from 0 200 of
50. is encoder positions It is updated each update cycle 180 0xb4 4 W axis encoder position 184 0xb8 4 K axis encoder position The following 4 words contain a memory region used to capture coherent snapshots of axis position 188 Oxbc 4 W axis motor position 192 OxcO 4 K axis motor position 196 Oxc4 4 W axis encoder position 200 Oxc8 4 K axis encoder position 204 Oxcc 4 W axis status flags 208 0xd0 4 K axis status flags 212 0xd4 28 Reserved The following memory region contains various data transfer buffers 240 0xf0 4 ASCII Command Buffer insert index 244 0xf4 4 ASCII Command Buffer process index 248 Oxf8 4 ASCII Response Buffer insert index 252 Oxfc 4 ASCII Response Buffer process index 256 0x100 1024 ASCII Command Ring Buffer 1280 0x500 1024 ASCII Response Ring Buffer 2304 0x900 2048 Utility transfer buffer 4352 0x1100 1088 Reserved 5440 0x1540 552 Real Time Position Capture Data 5992 0x1768 5912 Reserved The following memory region contains analog I O data 11904 0x2e80 4 X axis DAC output 11908 0 2 84 4 Y axis DAC output 11912 0x2e88 4 Z axis DAC output 11916 Ox2e8c 4 T axis DAC output 11920 0x2e90 4 U axis DAC output 11924 0 2 94 4 V DAC output 11928 0 2 98 4 axis DAC output 11932 2 9 4 S DAC output 11936 0x2ea0 4 Coherent X axis servo DAC output 11940 0x2ea4 4 Coherent Y axis servo DAC output 11944 0x2ea8 4 Coherent Z axis servo DAC output MAXk User s Manual 3 7 MAXk PCI ADDRESS SPAC
51. it at any time without notice and without obligation to notify any person of such revision or change 3301 1900000 Rev B TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS 1 GENERAL DESCRIPTION 1 1 1 2 INTRODUCTION SYSTEM OVERVIEW 2 GETTING STARTED 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 10 1 2 11 2 12 2 13 2 14 INSTALLATION TO PREPARE FOR INSTALLATION BASIC CARD CONFIGURATION CONFIGURING THE CARD FOR USE WITH ENCODERS HARDWARE INSTALLATION SOFTWARE INSTALLATION CONNECT TO STEPPER MOTOR SYSTEM CONNECT AND CHECKOUT THE SERVO SYSTEM CONNECT AND CONFIGURE THE MOTOR AMPLIFIER TUNE THE SYSTEM INTRODUCTION TUNING ASSISTANT MANUAL TUNING SETTING THE USER DEFAULT CONFIGURATION POWER SUPPLY REQUIREMENTS 3 COMMUNICATION INTERFACE 3 1 3 2 3 3 3 4 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 3 4 7 INTRODUCTION PCI INTERFACE PCI COMMUNICATION THEORY COMPARISON OF PREVIOUS OMS ARCHITECTURE TO MAXk STATUS DONE FLAG DATA OVERTRAVEL SLIP FLAG COMMAND ERROR AXES NOTIFICATION FLAGS ASCII COMMAND RING BUFFER ASCII RESPONSE RING BUFFER MAXk User s Manual 1 1 1 1 1 1 1 1 2 1 2 1 2 1 2 2 2 2 2 3 2 5 2 7 2 8 2 9 2 9 2 10 2 10 2 15 2 16 3 1 3 1 3 1 3 2 3 4 3 4 3 4 3 4 3 5 3 5 3 5 TABLE OF CONTENTS 3 5 DYNAMIC LINK LIBRARY 3 6 MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP 3 7 REAL TIME POSITION CAPTURE 4 CONTROL SIGNAL INT
52. it sensor S axis negative limit sensor Byte access offset 0x42 X axis positive limit sensor Y axis positive limit sensor Z axis positive limit sensor T axis positive limit sensor U axis positive limit sensor V axis positive limit sensor R axis positive limit sensor S axis positive limit sensor Byte access offset 0x41 W axis negative limit sensor K axis negative limit sensor Not used Not used Not used Not used Not used Not used Byte access offset 0x40 W axis positive limit sensor K axis positive limit sensor Not used Not used Not used Not used Not used Not used MAXk User s Manual 3 9 MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP COMMUNICATION INTERFACE Table 3 3 MAXk Home Switch Status Word Word Access Offset 0X44 Function B yte access offset 0x47 X axis home sensor Y axis home sensor Z axis home sensor T axis home sensor U axis home sensor V axis home sensor R axis home sensor S axis home sensor e access offset 0x46 W axis home sensor K axis home sensor Not used Not used Not used Not used Not used Not used B yte access offset 0x45 Not used Not used Not used Not used Not used Not used Not used Not used e access offset 0x44 Not used N
53. ition Ox5c Z axis motor position 0x60 T axis motor position 0x64 U axis motor position 0x68 V axis motor position Ox6c R axis motor position 0x70 S axis motor position 0x74 X axis encoder position 0x78 Y axis encoder position Ox7c Z axis encoder position 0x80 T axis encoder position 0x84 U axis encoder position BARBARA HIB T RPAH 3 6 MAXk User s Manual COMMUNICATION INTERFACE MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP Table 3 1 MAXk PCI SHARED ADDRESS SPACE MAPPING CON T Byte Offset Byte Offset Hex Byte Description length 136 0x88 4 V axis encoder position 140 4 encoder position 144 0 90 4 S encoder position The following word is used to coordinate the sending of text responses from the controller to the host 148 0x94 4 Message semaphore 152 0x98 4 Reserved The following word contains the state of the 16 general purpose I O bits updated each update cycle 156 9 4 General Purpose I O bits status 160 0xa0 12 Reserved The following 2 words contain axis motor positions It is updated each motor update cycle 172 Oxac 4 W axis motor position 176 0xb0 4 K axis motor position The following 2 words contain the ax
54. l and analog I Os are accessable on connector J1 Models with 6 or more axes provide the remaining axes and I Os on connector J2 which is wired to J3 and J4 The MAXk default configuration is as an open loop stepper controller for the number of axes ordered The MAXk controller fully meets the PCI Bus Specification Revision 2 2 and plugs directly into a PCI slot in a computer motherboard 4 2 LIMIT INPUTS To facilitate system safety TTL inputs for limit conditions are provided for each axis Limits may be activated by mechanical switches using contact closures or other suitable active switches such as a Hall Effect switch or opto isolator that connects to ground If the motor travels beyond its allowable limits and trips the switch the limit condition removes any further excitation in the limit direction from the affected axis Servo Motor systems should be designed for safety i e to have electrical braking to stop them The limit switch active signal state can be selected with the LT command on an axis by axis basis The behavior of the limit functionality can be set for the axis to decelerate to a stop or to stop without deceleration when a limit condition occurs Reference MAX Command Manual http www pro dexOMS com LM and LT commands 4 3 HOME INPUTS To facilitate positioning of an axis to a known reference position a TTL home input is provided for each axis For axes using an encoder the home input can be used in conju
55. le check the board to ensure it is properly seated in the connector e Use a screw to fix the bracket on the MAXk to the computer s chassis e For controllers with more than 5 axes e Position the J2 Bracket with the connector so that it can be accessed from outside the PC e Screw down the J2 Bracket to the computer s chassis e Double check that the MAXk is correctly installed and that the ribbon cables are correct e Once you are sure everything is installed and configured correctly replace the cover to the PC e Replace the power cord and turn on the computer e Allow the computer to boot up MAXk User s Manual 2 3 SOFTWARE INSTALLATION GETTING STARTED Establish communication with the controller board before wiring external components to the board i e drivers and motors This can be done by using the MAXkComm exe utility DO NOT make wiring connections to the controller board with power applied to the board Caution 2 6 SOFTWARE INSTALLATION OMS provides drivers for Windows NT 2k XP Vista 32 bit and Win7 32 bit for other operating systems please contact Pro Dex Inc Oregon Micro Systems refer to Appendix B For Windows NT XP 2k Vista amp Win7 After installing the MAXk in the chassis apply power to the host PC and insert the software support disk or CD ROM supplied by OMS or download the software from the OMS website http www pro dexoms com Follow the installation instructions found in README
56. mmand queue contains a list of addresses to execute The argument queue stores the parameters as applicable supplied with each command for the axis A command from the host may be expanded into several commands to the appropriate axis The GO command for example will expand into start ramp up constant velocity and ramp down commands The LS command will save its parameter in the argument queue the loop count on a loop stack along with the address of the LS command to be used by the next LE command as a target for a jump command are stored in the command queue The LE command will decrement the loop count and jump to the most recent LS command providing the loop count has not reached zero If the loop count has reached zero and it is not nested inside another loop the queue space will be flagged as available and the next instruction in the queue will be executed The communication interface is performed by the MAXk microprocessor Interrupts from the MAXk to the PCI host are generated by this component Status of the interrupts and error flags may be read by the host in the status register MAXk User s Manual 6 1 MAXk FIRMWARE UPGRADE SERVICE 6 3 MAXk FIRMWARE UPGRADE CAUTION The firmware upgrade utility erases the flash memory of the controller during the upgrade process While every precaution has been taken to recover from any failures the customer should also take every precaution to provide a stable environment for the upgrad
57. n request The MAXk provides a differential clock output through the encoder index port to deliver clocking to an absolute encoder The data signal is wired to encoder phase A The data clocking can be configured for the frequencies 31 250Hz 62 500Hz 125 000Hz 250 000HGz 500 000Hz 1MHz 2MHz and 4MHz 4 9 1 CONFIGURATION EXAMPLES The following are two examples on how to configure the MAXk for absolute encoding The first case is the standard MAXk with two absolute encoders with up to 12 bits resolution For this example the X axis is 12 bits resolution with a clock frequency at 125 000HZz and the Y axis is 9 bits resolution with a clock frequency of 250 000Hz AX PSE ECA12 125000 AY PSE ECA9 250000 The second example calls for five absolute encoders two axes at 16 bits resolution with a clock frequency of 125 000Hz one axis at 24 bits resolution with a clock frequency of 500 000Hz and two axes at 32 bits resolution at 250000Hz This example also shows the use of clock sharing with other absolute encoders with the same clock frequency and bits resolution AX PSE ECA16 125000 AY PSE ECA16 125000 AZ PSE ECA24 500000 AT PSE ECA32 250000 AU PSE ECA32 250000 Below is an example of how the absolute encoder can be connected to the MAXk This utilizes the IOMAXnet breakout board for easier connectivity to the absolute encoder environment MAXk User s Manual 4 7 ABSOLUTE ENCODERS WITH SSI CONTROL SI
58. nction with the index signal of the encoder The logic of the encoder signals Phase A Phase B Index that constitutes a true home condition is programmable Reference MAX Command Manual http www pro dexOMS com EH HM HR HT KM and KR commands MAXk User s Manual 4 4 GENERAL PURPOSE DIGITAL I O CONTROL SIGNAL INTERFACE 4 4 GENERAL PURPOSE DIGITAL I O There are 16 general purpose digital lines that can be individually configured as either a TTL input or an active drive TTL output Commands are provided for setting the I O direction of the lines setting the state of the outputs and reading the current state of the I O lines Inputs can be used to control loops qualify motion or signal an event Reference MAX Command Manual http www pro dexOMS com BD BH BL BW BX IOK and SW commands 4 5 ANALOG I O 4 5 1 ANALOG INPUTS The 4 general purpose analog inputs are available to read 10V values via 16 bit analog to digital converters These can be used to provide input from analog sensors to application software Analog inputs can also be configured to provide a velocity override input Reference MAX Command Manual http www pro dexOMS com Al AO and VOA commands 4 5 2 ANALOG OUTPUTS The 12 analog outputs provide 10V outputs via the 16 bit digital to analog converters DAC Each servo axis requires a dedicated DAC There are twelfe DACs and a maximum of ten axes So there is always at least one general
59. nnections have been made power can be restored to your system It is recommended that you bring the controller board up first So it is in a known state and then apply power to the stepper driver Refer to Figure 2 5 for an example wiring diagram of OMS MAXk connected to the OMS PMD4 m stepper driver on the X axis MAXk User s Manual 2 5 CONNECT TO STEPPER MOTOR SYSTEM GETTING STARTED 24 DRIVER SV Vi GROUND w SIEE PULSE DIRECTION DIRECTION AUXILIARY AUXILIARY INPUT Figure 2 4 Example Wiring Diagram of MAXk Controller 24 DRIVER Vi GROUND GROUND STEP PULSE DIRECTION DIRECTION AUXIGIARY AUXILIARY INPUT TERMINAL BLOCK Figure 2 5 Example Wiring Diagram of MAXk Controller via the IOMAXNET Interface Module 2 6 MAXk User s Manual GETTING STARTED CONNECT AND CHECKOUT THE SERVO SYSTEM 2 8 CONNECT AND CHECKOUT THE SERVO SYSTEM Servo systems tend not to respond gracefully to connection errors You can reduce the chance of making connection errors by following a step by step procedure DC SERVO AMPLIFIER Analog Input IOMAXnet TN SERVO MOTOR 5V X PHASE A TERMINAL BLOCK ENCODER Figure 2 6 EXAMPLE OF WIRING DIAGRAM OF MAXK CONTROLLER VIA THE IOMAXNET INTERFACE MODULE TO SERVO MOTOR Caution The servo motor may jump or spin at a very high velocity during connection and configuration The motor should be restrained by some means before beginning this p
60. o open the upgrade file named filename Cannot open file filename A problem occurred opening the upgrade file named filename Invalid upgrade file signature The upgrade file did not have the required signature of a valid upgrade file MAXk User s Manual 6 3 MAXk FIRMWARE UPGRADE SERVICE Upgrade File Seek Error An error occurred trying to access the upgrade file Could not read serial number An error occurred trying to read the serial number from the upgrade file Invalid upgrade file for MAXk serial number nnnnnn An upgrade file with a serial number lock installed did not match the MAXk controller found Flash write failure on packet ppp The controller did not accept the upgrade packet number ppp due to a flash write failure Flash verify failure on packet ppp The controller did not accept the upgrade packet number ppp due toa flash verify failure If the controller successfully wrote the packet to flash then it attempts to read it back from flash and compare it to the packet data This error occurs when the packet data is not equal to the flash data CRC failure on packet ppp The controller did not accept the upgrade packet number ppp due to a failure to pass the crc checksum test The controller does not attempt to write to flash until the crc checksum is successful for the packet Unknown failure on packet ppp The controller did not accept the upgrade packet number ppp due to some unknown failure NAK on ram uplo
61. oller has not completed power up initialization MAXk User s Manual 3 11 REAL TIME POSITION CAPTURE COMMUNICATION INTERFACE 3 7 REAL TIME POSITION CAPTURE The position capture commands control the real time recording of axis position data and the management of the captured position data The captured position data includes the axis the positive edge I O bits the negative edge I O bits the home and encoder home events and the encoder position of the axis The position data is captured when the conditions specified for the input bit are met The capture conditions for the home switch and general purpose input bits can be a rising positive edge a falling negative edge or the event can be both the rising positive and the falling negative edge so data is captured on any transition of the input bit The real time position capture feature is only available on an axis with incremental encoders See the MAX family command reference manual for more details on the real time position capture feature The MAXk controller has a ring buffer in PCI shared memory which is used to transfer the real time position capture data to the host When a capture event is recorded by the motor update cycle routine it transfers the capture table entry to the shared PCI memory The host is signaled that the data is available via bit number 1 or hexadecimal value 0x00000002 in the out bound message register 1 which causes INTA to be asserted on the PCI bus The shar
62. ory defaults the command RDF is executed To restore the User Defined Default Parameters the command RDP is executed The following is a list of parameters that can be defined as part of the User Definable Power Up Default Parameters Over travel limit soft limit or hard limit Factory Default Hard limit Over travel limit enabled or disabled Factory Default Enabled MAXk User s Manual 2 15 POWER SUPPLY REQUIREMENTS GETTING STARTED Over travel limit polarity active high or active low Factory Default active low Software based over travel for each axis Factory Default disabled Direction Bit polarity Acceleration value for each axis Factory Default 2 000 000 Trajectory profile for each axis linear parabolic S curve custom Factory Default Linear Velocity Peak Factory Default 200 000 Velocity Base Factory Default 0 User Unit values for each axis Factory Default Off Auxiliary output settle time for each axis Factory Default 0 Automatic auxiliary control axis by axis Factory Default Off Encoder Ratio for each axis Factory Default 1 1 Encoder Slip tolerance for each axis Used for stepper motors Factory Default 0 Home Active Low Position Maintenance Dead Band Hold Gain and Hold Velocity Used for stepper systems Factory Default 0 0 0 Servo axis unipolar bipolar output Factory Default bipolar Servo PID values KP KD KI KO KV KA Factory Default KP 10 KD 160 KI 1 00 K
63. ot used Not used Not used Not used Not used Not used 3 10 Not used MAXk User s Manual COMMUNICATION INTERFACE MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP Table 3 4 MAXk CONTROLLER FIRMWARE STATUS FLAGS WORD ACCESS OFFSET 0x48 Function Controller application code not downloaded to RAM Controller application code is initializing Controller application code is running Not used Not used Not used Not used Not used Application stored in flash memory has a check sum error A programming error occurred while storing the application code in flash memory Not used Not used A checksum error was detected in the power up default parameter archive A programming error occurred while storing parameters in the power up default parameter archive A checksum error was detected in the alternate parameter archive A programming error occurred while storing parameters in the alternate parameter archive The power up default parameter set has been loaded into working memory The alternate parameter set has been loaded into working memory The factory default parameter set has been loaded into working memory Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used Not used NOTE If the firmware state register contains OxFFFF_FFFF then the contr
64. r a closed loop stepper or a servo axis The MAXk is powered by a PowerPC processor This high performance processor provides a 64 bit Floating Point processor and is clocked at 266MHz This provides the MAX with the pure processing power to update every signal of the controller i e I O bits direction limits etc at rates up to 122us Every axis includes dedicated over travel limit inputs a home input and an auxiliary output The home and over travel limit inputs are TTL level inputs The MAXk supports 16 general purpose digital I O signals In addition it has 4 general purpose analog inputs that can be used to sense Pressure Transducers Dial Switches etc Analog inputs can also be used to control velocity override These analog inputs have 16 bit of resolution with 10 VDC input There are two general purpose analog output that use a 16 bit resolution DAC with 10 VDC output Each axis has servo output signal capability configured as a 10V or 0 10V signal and is driven by a 16 bit DAC The servo control loop is a PID filter with feedforward coefficients and an update rate up to 122us The servo output of axes not configured as a servo axis is available as a general purpose analog output The step pulse is a TTL level 50 duty cycle square wave that supports velocities of O through 4 176 00 pulses per second Encoder feedback functionality supports quadrature encoders up to 16 MHz and is used as the servo feed
65. r from date of shipment This warranty is in lieu of any other warranty express or implied In no event will Seller be liable for incidental or consequential damages as a result of an alleged breach of the warranty The liability of Seller hereunder shall be limited to replacing or repairing at its option any defective units which are returned f o b Seller s plant Equipment or parts which have been subject to abuse misuse accident alteration neglect or unauthorized repair are not covered by warranty Seller shall have the right of final determination as to the existence and cause of defect As to items repaired or replaced the warranty shall continue in effect for the remainder of the warranty period or for 90 days following date of shipment by Seller of the repaired or replaced part whichever period is longer No liability is assumed for expendable items such as lamps and fuses No warranty is made with respect to custom equipment or products produced to Buyer s specifications except as specifically stated in writing by Seller and contained in the contract MAXk User s Manual APPENDIX A LIMITED WARRANTY This page is intentionally left blank MAXk User s Manual TECHNICAL SUPPORT APPENDIX B APPENDIX B TECHNICAL SUPPORT Pro Dex Inc Oregon Micro Systems Inc can be reached for technical support by any of the following methods 1 Internet E Mail mailto support pro dex com 2 World Wide Web http www pro dexoms com 3
66. re travel of the axis that creates a true condition for the defined home logic The HT and EH commands can be used to create different patterns for the home logic including the option to ignore an encoder phase signal The default home logic expressed in Boolean terms is Home Phase A Phase B Index Home Switch Default It is necessary that the configured quadrant occurs within the index pulse as provided by the encoder for this logic to function properly The encoder counter read by a RE RI commands must increase for positive moves or the system will oscillate due to positive feedback For other options please contact Technical Support MAXk User s Manual 4 5 HOME PROCEDURES CONTROL SIGNAL INTERFACE Home Switch Phase A x Phase B u Index Figure 4 5 ENCODER HOMING STATE DETECTION Figure 4 6 ENCODER WIRE DIAGRAM FOR SINGLE ENDED INPUT SIGNALS NOTE The differential receiver has an internal bias on the negative input and may not need the external bias For better reliability external bias is recommended MAXKk User s Manual CONTROL SIGNAL INTERFACE ABSOLUTE ENCODERS WITH SSI 4 9 ABSOLUTE ENCODERS WITH SSI The MAXk comes with two axes of configurable absolute encoders with SSI Synchronous Serial Interface technology By default the X and Y axes will have up to 12 bits of resolution of absolute encoding SSI encoder feedback for each axis with resolution up to 32 bit is available opo
67. rich set of commands for use in various motion control environments The latest versions of the DLL s are included on a CD ROM with the shipment of the MAXk Controller card Also included on a separate CD is a PDF version of the User Manual The PDF version of the MAXk User manual and the support software is also available from the Pro Dex Inc Oregon Micro Systems Web site http www pro dexoms com The omsMAXkmoc dll is the Motion Control Dynamic Link Library that provides a means for C and Visual Basic applications running under Windows NT to communicate with Oregon Micro Systems PCI motion controllers The DLL supplies a set of functions that provide single function call solutions to some of the more common motion control problems For added flexibility other functions are also provided to allow the application to interact with the controller at its most basic text command string and text response string level The document omsMAXkmc txt or omsMAXkmc doc supplies a description of each function function calling conventions and code samples These are available on the support software CD ROM or on our web site MAXk User s Manual 3 5 MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP COMMUNICATION INTERFACE 3 6 MAXk PCI ADDRESS SPACE MEMORY REGISTER MAP The MAXKk family of motion controllers utilizes 0xe010 57360 bytes in the PCI Controller Host shared memory address space The MAXk controller uses a base address of 0x01
68. rocedure Keep hands and clothing clear of the motor and any mechanical assemblies while performing this procedure It is recommended that the motor shaft not be connected to the physical system until you are sure you have control over the motor MAXk User s Manual 2 7 CONNECT AND CONFIGURE THE MOTOR AMPLIFIER GETTING STARTED 2 8 2 9 CONNECT AND CONFIGURE THE MOTOR AMPLIFIER 1 Connect and configure your amplifier per the manufacturer s instructions for Torque or Open Loop mode 2 With the motor and amplifier power turned off connect the MAXk to the amplifier 3 Balance your motor a Configure the axis as a servo axis by sending the PSM command Using a voltage meter verify that the command signal from the MAXk is less than 500mV If it is not send the command KO0 to the MAXk and recheck the voltage If the voltage is still too high contact Pro Dex Oregon Micro Systems Technical Support department for guidance Turn on power to the amplifier and then to the motor Adjust the balance setting of your amplifier if equipped until the motor stops moving If the motor continues to revolve or your amplifier has no balance adjustment i Send the command KO100 to the MAXk ii If the motor spins faster reduce the command parameter and resend the command e g KO50 iii If the motor spins slower but does not stop increase the command parameter and resend the command e g
69. s register identifies the vendor that supplies the PCI bridge chip 0x018 The base address of the controller s dual port RAM 0x020 The base address of the controller s memory mapped I O registers 0x02C The controller s Subsystem ID and Subsystem Vendor ID 0010 NNNN 160C This register identifies the PCI card as an Oregon Micro System controller with NNNN see also Figure 2 1 being the board number set on the card 0x03C Bits 0 through 3 contain the controller s IRQ assignment The shared RAM also called dual port RAM is used to pass data from the controller to the host computer The 32 bit word at offset zero in dual port RAM contains a binary image of the controller s configuration dip switches Bits 0 thru 2 contain the controller number selection The shared RAM is used extensively in the MAXk including status flags text commands interrupt notification and various registers The remainder of the RAM is used for axis and encoder position data velocity profile and servo tuning information to the host MAXk User s Manual 3 1 PCI COMMUNICATION THEORY COMMUNICATION INTERFACE 3 3 PCI COMMUNICATION THEORY As shown in the simplified diagram below Figure 3 1 communication between the MAXk controller and the application is via the device driver and its associated driver support DLL Application Software Requested Data DLL Function call Driver Support DLL Device Driver Shared Memory Status Data Fla
70. s strictly a position feedback of any axis The encoder input supports differential or single ended quadrature TTL signals at a rate of up to 16 MHz The MAXk motion controller has 4 general purpose analog inputs that utilize a 16 bit ADC with a DC range of 10 to 10 VDC Complete specifications for MAXk can be found in Appendix C The MAXk command set employs two or three ASCII character commands which can be combined into character strings Using virtually any programming language these ASCII command strings can be sent to the MAXk Motion Controller over the PCI bus 1 2 SYSTEM OVERVIEW The MAXKk is a standard length PCI module 12 83 x 4 20 x 0 475 The communication interface is accessed through the PCI bus and is compliant with the PCI Bus Specifications Revision 2 2 see Figure 2 1 The MAXk receives power 3 3V 5V 12VDC from the host computer by the PCI bus The MAXK utilizes an optimally configured Power PC RISC based 32 bit micro controller and FPGA technology for extensive logic integration and flexibility The firmware which resides in flash memory can be upgraded through the communication interface without having to remove the controller from the system 32MB of system RAM is used for firmware and data storage There is a jumper block J5 on the MAXK that allows for setting the board number All general purpose digital and analog I O signals and all motor control signals are available on the two 100 pin connectors J
71. sh memory RESTARTING with new firmware This message indicates that the firmware upgrade was successful and MAXKUPG has sent a command to the controller to restart This will start the controller running with the new upgraded firmware Sending nnn packets This message indicates how many packets are going to be sent to the controller flash when sending the new firmware to the controller Uploading nnn packets This message indicates how many packets are going to be sent to the controller RAM when uploading the microupg bin to the controller JUMPING TO Application Start Address This message indicates that the microupg bin has been successfully uploaded to the controller RAM and MAXKUPG is now sending a command to the controller to start execution of the microupg bin program Erasing flash block n success This message indicates that flash block n has successfully been erased Serial Number verified MAXk User s Manual 6 5 MAXk FIRMWARE UPGRADE SERVICE This message indicates that the upgrade file had a Serial Number lock installed and it was successfully verified that the specified upgrade file was valid for the MAXk controller specified 6 6 MAXk User s Manual APPENDIX A LIMITED WARRANTY APPENDIX A LIMITED WARRANTY The Seller warrants that the articles furnished are free from defect in material and workmanship and perform to applicable published Pro Dex Inc Oregon Micro Systems Inc specifications for one yea
72. value and produce little or no oscillation Critically damped systems reach final value quickly without overshoot Under damped systems reach final value quickly but have various degrees of ringing or oscillation that decay to zero over time Ideally a system should be critically damped allowing for the fastest response time with the least amount of oscillation MAXk User s Manual 2 9 TUNING ASSISTANT GETTING STARTED 2 12 TUNING ASSISTANT OMS Tuning Assistant utility is provided to assist the user in finding the right combination of parameters This utility plots the motor s response The user can analyze this data to arrive at the right servo parameters for their servo system 2 13 MANUAL TUNING In most motion control applications the optimum tuning of the servo system is achieved through a manual tuning process Auto tuning algorithms typically can only get the system parameters close and require manual steps to fine tune the parameters An empirical trial and error approach will be discussed first There are some system parameters that need to be determined before attempting to tune a motor The encoder resolution counts per revolution is one element to be determined Another is the system s maximum velocity Note that a motor should never exceed 90 of the motor s maximum rate rpm If the system requirement is for a velocity higher than 90 of the motors top rpm then another motor with higher rpm capability should be used
73. z 32 bit RISC Processor Updates all signals and data points providing superior application control 64K Shared Memory Permits rapid data transfer to amp from controller Large size accommodates expandability to unique and custom applications PCI Universal Bus 3 3 or 5 0 volts PCI Bus Specification Revision 2 2 compliant Compatible with current and future PCI bus computers Memory 32 Mb System Memory Controller I O Capabilities 4 Channels of general purpose Analog Input with 16 bit 10 VDC input Support Quadrature Encoder Feedback up to 16 MHz Support for SSI Absolute encoder up to 32 bit resolution 16 bit DAC analog resolution Step pulses from 0 to 4 176 000 steps per second 0 steps Backlash compensation Custom Parabolic S curve amp Linear trajectory profiles Real time encoder position capture S Curve with 4 quadrant jerk parameters Control signals TTL level Digital SCSI type 100 pin connector MAXk User s Manual APPENDIX C Table 6 1 OUTPUT CONNECTOR PIN LISTs J1 J2 APPENDIX C MAXk User s Manual J1 100 pin connector J2 100 pin connector Pin Signal Pin Signal Pin Signal Pin Signal 1 X Phase A 51 Y Phase A 1 V Phase A 51 R Phase A 2 X Phase A 52 Y

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