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DMC-2x00 User Manual - Galil Motion Control

1. ion f Extended OM 126 80 provides Connection to Signals for Axes E H 100 10 BASE T 1 0121314156 7 Provides Connection to All Auxiliary Serial Port Auxiliary Encoder Signals Connection System Dependent Cable ICM 2900 2900 Connection to s E Signals for Axes A D acd CABLE ex 1Meter Ug Eu lt Cm CABLE 80 4M 4Meter 1 1 Cable 9 PinD jme 1 Main Serial Port to CABLE I00 1M 1 Computer oR d 1 CABLE 100 4M 1 1 EN 1 1 2 aa li 1 24 1 4 ap C Up DMC 2000 V CABLE 36 1M 1METER Power Cable Included on with the controller CABLE 36 4M 4 Figure 2 5 Recommended System Element
2. 1964 80 Provides Opto Isolation and Interconnection for Extended 1OM 1964 80 Cond Signals for Axes E H Auxiliary Serial Port ICM 2908 Connection 0 1 2 5 6 7 Provides Connection to All System Dependent Auxiliary Encoder Signals Cable IB 1 2900 2900 Connection to H Signals for Axes A D 1 2908 casio 1Meter CABLE 60 4M 4Met mm Main Serial Port to O M 1 3n JD f 0 M CABLE 100 1M E B 1 ELE 1 4 CABLE 100 AM Wl 1 4 1 CABLE USB 2M CABLE USB 3M DMC 2000 CABLE 36 1M 1METER Power Cable Included OR with the controller CABLE 36 4M 4METER Figure 2 4 Recommended System Elements of DMC 2000 12 e Chapter 2 Getting Started DMC 2X00 IOM 1964 80 Provides Opto Isolation
3. 158 Variable 5 15 36 67 113 121 126 127 133 142 144 145 146 153 154 155 158 167 193 Internal Variable 36 145 146 227 Vector Acceleration 37 83 89 Vector Deceleration 37 83 84 89 Vector MOde n nenatis teet 81 86 Circular Interpolation s 37 86 166 Clear 81 83 87 89 EllipseScale suite oae 82 89 Beedrate t 88 166 Linear Interpolation36 37 69 70 81 82 83 86 91 70 86 88 89 144 Vector Speed 37 81 82 83 84 87 88 131 248 Wire Culte dea Ratten o PRISE Pes 164 206 193 99 24 19 14 Zero Stack es 139 161 Index e 257
4. ener nennen 172 Software Prot cu n teet lette E it e SETS 172 Programmable Position Limits essere 173 26 do fh tette ret ied eH tri rrr CE TUS 173 eene nennen enne 173 nnne nnne 174 Chapter 9 Troubleshooting 175 OVerVie wv coins rt apt reb ebur d 175 erue ate bti eot teta tei Beto tee Dr Nie n 175 Communication n 176 M c RE 176 sale Ma ottenere a bile Ores te Fat 176 Chapter 10 Theory of Operation 177 177 Operation of Closed Loop 11 enne 179 System ec tt te eet A Modes aee de NE 180 181 oet ra 7 183 DYN S utt coo i Di I e pisos Eel Ne DM oT OR ore 184 Digital Filter cedente esee eei ice tede eee ee Re Enna 184 15 System Analysis eoe etie eet erret e edd ede ice det eec fete e ERG 186 System Design and Compensation sss ennemis 188 Analytical Method cete ce ere 188 Appendices 191 Electrical Specifications aime een RR EG ed RO IER Reis 191 Servo Control 191 Stepper Control tec Ati ee BIET s 191 Input gt
5. U9 2 94 CMB 2001 REV C USB DAUGHTER CARD RS 232 buffer 7 GALIL MOTION CONTROL IC s On Y 5 2 1 4 rd A1 B1 D O Ne V v USB Communications 100 pin connector Status LED attaches to DMC 2000 Main board Figure 2 2 Outline of the DMC 2000 Daughter Board 10 e Chapter 2 Getting Started The DMC 2200 Daughter Board 10 BASE F TRANSMITTER 100 BASE T MAIN SERIAL PORT 80 PIN HIGH DENSITY DB 9 MALE CONNECTOR FOR EXTENDED AUX SERIAL PORT JO BASE DB 9 FEMALE CONFIGURATION DIP SWITCHES COMMUNICATIONS 10 BASE F STATUS LED RECEIVER J2D1 02 p CMB 21002 REV J GALIL MOTION CONTROL 2 9 8558 L Vv O 100 PIN CONNECTOR ATTACHES TO DMC 2000 MAIN BOARD 9 5 Figure 2 38 Outline of the DMC 2200 Daughter Board DMC 2X00 Chapter 2 Getting Started 11 Elements You Need
6. 191 POWEE cerea e e RUNE CU HII 192 Performance Specifications iisdem 192 Minimum Servo Loop Update Time essere 192 Fast Update Rate Mode isses eene e eee e RE 193 enne enne 194 vi Contents DMC 2X00 DMC 2x00 Axes A D High Density Connector eene 194 DMC 2x00 Axes E H High Density Connector 195 DMC 2x00 Auxiliary Encoder 36 Pin High Density 196 DMC 2x00 Extended 80 Pin High Density 196 RS 232 Main Port br E Roper e ee ede 198 RS 232 Auxiliary ener ener enne enne 198 USB In QUE iecit impe ttr tU impetu tbt iut 198 Ethethet 22 554 se 199 Cable Connections for 2 00 ener ener 199 199 DMC 2x00 Serial Cable Specifications esses 200 Pin Out Description for 2 00 222 2 22 20 0 2 1 000000000000 202 7 204 205 0000707000 83 206 ICM 2900 Interconnect Module 0 207 207 207 Equipment Maintenance sene etes dete deter dee e deed 207 Description sitet eee ee deer ie edn da ee ewan P deve 207 2900 Drawing nite
7. Enable input 1 for interrupt function JG 30000 20000 Set speeds on A and B axes BG AB Begin motion on A and B axes B Label TP AB Report A and B axes positions WT 1000 Wait 1000 milliseconds JP 2B Jump to 4B EN End of program ZININT Interrupt subroutine MG Interrupt has occurred Displays the message ST AB Stops motion on and B axes LOOP JP LOOP IN 1 0 Loop until Interrupt cleared JG 15000 10000 Specify new speeds WT 300 Wait 300 milliseconds BG AB Begin motion on A and B axes RI Return from Interrupt subroutine Analog Inputs The DMC 2x00 provides eight analog inputs The value of these inputs in volts may be read using the function where n is the analog input 1 through 8 The resolution of the Analog to Digital conversion is 12 bits 16 bit ADC is available as an option Analog inputs are useful for reading special sensors such as temperature tension or pressure The following examples show programs which cause the motor to follow an analog signal The first example is a point to point move The second example shows a continuous move Example Position Follower Point to Point Objective The motor must follow an analog signal When the analog signal varies by 10V motor must move 10000 counts Method Read the analog input and command A to move to that point Instruction Interpretation POINTS Label SP 7000 Speed AC 80000 DC 80000 Acceleration LOOP VP ANT 1 1000 Read and a
8. VS 100000 0 05 0 3075 The total motion time Tt is given by Ge 410 407 VS The velocities along the X and Y axes are such that the direction of motion follows the specified path yet the vector velocity fits the vector speed and acceleration requirements For example the velocities along the X and Y axes for the path shown in Fig A 21 are given in Fig 23 Fig 23 shows the vector velocity It also indicates the position point along the path starting at and ending at D Between the points A and B the motion is along the Y axis Therefore Vy Vs and Vx 0 Between the points B and C the velocities vary gradually and finally between the points C and D the motion is in the X direction Fig A 23b shows X axis velocity Fig A 23c shows Y axis velocity 248 Appendices DMC 2X00 time Figure A 23 Vector and Axes Velocities Example Communicating with OPTO 22 SNAP B3000 ENET Controller is connected to OPTO 22 via handle F The OPTO 22 s IP address is 131 29 50 30 The Rack has the following configuration Digital Inputs Module 1 Digital Outputs Module 2 Analog Outputs 10V Module 3 Analog Inputs 10V Module 4 Instruction Interpretation CONFIG Label 131 29 50 30 lt 502 gt 2 Establish connection WT10 Wait 10 milliseconds JP CFGERR IHF2 0 Jump to subroutine JS 4CFGDOUT Configure digital outputs JS CFGAOUT Configure analog outputs JS CFGAIN Configure an
9. sse 108 oi cc ade idi Ace 109 WOTTECHON odi cns etes fter de 109 Dual Loop 0 2 112 Additional Commands for the Auxiliary Encoder sss 113 Backlash Compensation sess enne nnne nnne 113 113 Motion Smoothing dO aue ut dais 114 Using the IT and VT Commands 115 EXAMPLE annees entities rte ive ut ciii i tn 115 Using the KS Command Step Motor Smoothing sss 116 117 i 117 7 119 Operand Summary Homing Operation 119 High Speed Position Capture The Latch 119 Example et dee 120 DMC 2X00 DMC 2x00 Chapter 7 Application Programming 121 OVVIE W sR eae Ae cue ep ERE TEE ug o 121 Using the DOS Editor to Enter Programs DMC 2000 121 Edit Mode Corimands 4 nen oett de erri ene etn 122 RU An NS 122 Program P 123 Using Labels in Programs eo RW A HS 123 Special aae teet E eee ECC 123 Commenting Pfograms ee a REOR ae NERIS 124 Executing 125 Debugging PrOgrairns aed Sete p Ra EA esI 126 Trace Commands DMC 2100 2200 only sse 126 Error Code Comm
10. 81 87 Subroutine 39 105 121 123 124 125 132 133 134 136 137 138 139 140 152 160 172 174 203 DMC 2X00 MES 61 62 63 144 89 88 86 70 Tan 70 104 148 Data Captures mre 148 149 203 149 120 119 66 6 80 1 Play Back esee 104 70 104 147 148 149 252 Tell Error 65 66 128 Tell Position 32 60 66 108 146 156 Gell 25 66 Terminal 15 18 19 21 22 24 34 35 39 43 48 49 51 61 121 122 125 146 193 206 ie cedet 177 Daimping ense 30 176 180 185 Digital Filter 61 184 186 188 Modeling eere 177 181 185 184 180 31 30 25 3 Stability 113 114 169 175 176 180 147 ore tee E ECRIRE 19 5 124 129 137 139 Torque Limit eee 24 34 Trigger iussi 121 128 129 130 132 202 203 Trippoint 35 71 83 88 89 101 106 107 128 129 130 193 serere 175 TTL 6 7 22 39 44 45 171 191 202 220 222 t 1 14 25 31 113 Stability nee 113 114 169 175 176 180 eed 14 19 24 99 193 206 te 35 148 193
11. Kg Js I Kg sT 1 where the velocity time constant T1 equals TI J K Ky Kg This leads to the transfer function P V I Kg s sT1 1 K 5 Figure 10 5 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Fig 10 6 182 gt Chapter 10 Theory of Operation DMC 2X00 VOLTAGE SOURCE V E W P tcu _ e b suh ST 1 ST 1 S CURRENT SOURCE V W P VELOCITY LOOP V W P K ST 1 S Figure 10 6 Mathematical model of the motor and amplifier in three operational modes Encoder The encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the position resolution 5 increased to 4N quadrature counts rev The model of the encoder can be represented by a gain of 4 2 count rad For example 1000 lines rev encoder is modeled as 638 DMC 2X00 Chapter 10 Theory of Operation 3 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65536 and the output voltage range is 10V or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count Digital Filter The digital filter h
12. FOR 12 VOLT AMPLIFIER ENABLE PLACE PIN 1 OF RP1 ON PIN LABELED 12V OPTIONAL OPTO ISOLATION CIRCUIT 100PIN HIGH DENSITY CONNECTOR part 2 178238 9 ICM 2900 BOARD LAYOUT 214 e Appendices DMC 2X00 ICM 1900 Interconnect Module DMC 2X00 The ICM 1900 interconnect module provides easy connections between the DMC 2x00 series controllers and other system elements such as amplifiers encoders and external switches The ICM 1900 accepts the 100 pin main cable and 25 pin auxiliary cable and breaks them into screw type terminals Each screw terminal 15 labeled for quick connection of system elements An ICM 1900 is required for each set of 4 axes Two required for DMC 2x50 thru DMC 2x80 The ICM 1900 is contained in a metal enclosure A version of the ICM 1900 is also available with servo amplifiers see AMP 19x0 Features e Separate DMC 2x00 cables into individual screw type terminals Clearly identifies all terminals e Provides jumper for connecting limit and input supplies to 5 V supply from PC Available with on board servo drives see AMP 19X0 e Can be configured for AEN high or low NOTE The part number for the 100 pin connector 15 2 178238 9 from Terminal Label Description W Auxiliary encoder W Auxiliary encoder A I W Auxiliary encoder COEN esis ISO OUT Isolated Output Power for use with the opto isol
13. n input number 17 80 ho Figure A 8 Connections to this optically isolated input circuit are done in a sinking or sourcing configuration referring to the direction of current Some example circuits are shown below Sinking Sourcing e e 5V OC e e GND O dt GND lO e e 45V Current Current Figure A 9 There is one I OC connection for each bank of eight inputs Whether the input 1 connected as sinking or souring when the switch is open no current flows and the digital input function IN n returns 1 This is because of an internal pull up resistor on the DMC 2x40 When the switch is closed in either circuit current flows This pulls the input on the DMC 2x40 to ground and the digital input function IN n returns 0 Note that the external 5V in the circuits above is for example only The inputs optically isolated and can accept a range of input voltages from 4 to 28 VDC Active outputs are connected to the optically isolated inputs in a similar fashion with respect to current An NPN output is connected in a sinking configuration and a PNP output is connected in the sourcing configuration Appendices e 223 Sinking Sourcing OC e e 45V e GND I O e e NPN lO e OCurrent output gt Current are Figure A 10 Whether connected in a sinking or sourcing circuit only two connections
14. 100 PIN HIGH DENSITY CABLE MOCMDX 7407 Open Collector Buffer The Enable can be inverted Analog Switch by using a 7406 Accessed by removing ICM 2900 cover Figure 3 3 Connecting AMPEN to the motor amplifier TTL Inputs The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 44 e Chapter 3 Connecting Hardware DMC 2X00 Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is of the full voltage range for example connect the input to 6 volts if the signal 15 a 0 12 volt logic Example DMC 2x10 has one auxiliary encoder This encoder has two inputs channel and channel Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal will be connected to AA and the second to AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The
15. a 9 zo fe mem s ao i Dem 5 O Controller Response to DATA DMC 2X00 The DMC 2x00 returns a for valid commands and a for invalid commands For example if the command BG is sent in lower case the DMC 2x00 will return a return invalid command lower case DMC 2x00 returns a When the controller receives an invalid command the user can request the error code The error code will specify the reason for the invalid command response To request the error code type the command TCI For example TC1 return Tell Code command 1 Unrecognized Returned response There are many reasons for receiving an invalid command response The most common reasons are unrecognized command such as typographical entry or lower case command given at improper time such as during motion or a command out of range such as exceeding maximum speed A complete listing of all codes is listed in the TC command in the Command Reference section Chapter 5 Command Basics 65 Interrogating the Controller Interrogation Commands The DMC 2x00 has a set of commands that directly interrogate the controller When the command is entered the requested data 1s returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and Leading Zeros LZ command See Chapter
16. Use the New Controller button to add a new entry to the Registry You will need to supply the Galil Controller model eg DMC 2000 Pressing the down arrow to the right of this field will reveal a menu of valid controller types You then need to choose serial or Ethernet connection Remember a DMC 2000 connected via USB is plug and play and should be automatically added to the registry upon connection The registry information will show a default Comm Port of 1 and a default Comm Speed of 19200 appears This information can be changed as necessary to reflect the computers Comm Port and the baud rate set by the dip switches on the front of the controller default is 19200 with HSHK on The registry entry also displays timeout and delay information These are advanced parameters which should only be modified by advanced users see software documentation for more information Once you have set the appropriate Registry information for your controller Select OK and close the registry window You will now be able to communicate with the controller If you are not properly communicating with the controller the program will pause for 3 15 seconds and an error message will be displayed In this case there is most likely an incorrect setting of the serial communications port or the serial cable is not connected properly The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the contro
17. bit 69 6 19 17 1 068 bit 68 6 20 20 1 067 bit 67 6 21 19 1 066 bit 66 6 22 22 1 065 bit 65 6 23 21 OUTC65 72 Out common for I O 65 72 6 24 24 I OC65 72 I O common for I O 65 72 6 25 23 1 064 bit 64 5 26 26 1 063 bit 63 5 27 25 1 062 bit 62 5 28 28 I O61 I O bit 61 5 29 27 1 060 I O bit 60 5 30 30 1 059 I O bit 59 31 29 1 058 bit 58 5 32 32 I O57 I O bit 57 33 3l OUTC57 64 Out common for I O 57 64 5 34 34 I OC57 64 I O common for I O 57 64 5 35 33 1 056 bit 56 4 36 36 I O55 I O bit 55 4 37 35 1 054 bit 54 4 38 38 1 053 I O bit 53 4 39 37 1 052 bit 52 4 40 40 V051 I O bit 51 4 41 39 1 050 bit 0 4 42 42 1 049 bit 49 4 43 41 OUTC49 56 Out common for I O 49 56 4 44 44 I OC49 56 I O common for I O 49 56 4 45 43 1 048 I O bit 48 3 46 46 I O47 I O bit 47 3 47 45 1 046 bit 46 3 48 48 1 045 bit 45 3 49 47 1 044 bit 44 3 50 50 1 043 I O bit 43 3 51 49 1 042 bit 42 3 52 52 1 041 I O bit 41 3 228 Appendices DMC 2X00 DMC 2X00 REV A B TERMINAL 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 7 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 REV C TERMINAL 51 54 53 56 55 58 57 60 59 62 61 64 63 66 65 68 67 70 69 72 71 74 73 76 75 78 TI 80 79 82 81 84 83 86 85 88 87 90 89 92 91 94 93 LABEL OUTC
18. CI2 MG 2 Type 0 to stop motion MG P2 Type 1 to pause motion MG P2 Type 2 to resume motion rate 2000 SPA rate LOOP PAA 10000 BGA AMA PAA 0 BGA AMA JP LOOP 140 e Chapier 7 Application Programming Interpretation Label for beginning of program Setup communication configuration for auxiliary serial port Setup communication interrupt for auxiliary serial port Message out of auxiliary port Message out of auxiliary port Message out of auxiliary port Variable to remember speed Set speed of A axis motion Label for Loop Move to absolute position 10000 Begin Motion on A axis Wait for motion to be complete Move to absolute position 0 Begin Motion on A axis Wait for motion to be complete Continually loop to make back and forth motion DMC 2X00 DMC 2X00 For additional information see section on page EN COMINT JP STOP P2CH 0 JP PAUSE P2CH 1 JP RESUME P2CH 2 STOP STA ZS EN PAUSE rate SPA SPA 0 EN1 1 RESUME SPA rate EN1 1 End main program Interrupt Routine Check for S stop motion Check for P pause motion Check for R resume motion Do nothing Routine for stopping motion Stop motion on A axis Zero program stack End Program Routine for pausing motion Save current speed setting of A axis motion Set speed of A axis to zero allows for pause Re enable trip point and communication interrupt Routine for resuming motion Set speed on A axis
19. Error Output The controller provides a TTL signal ERROR to indicate a controller error condition When an error condition occurs the ERROR signal will go low and the controller LED will go on An error occurs because of one of the following conditions 1 Atleast one axis has a position error greater than the error limit The error limit is set by using the command ER 2 Thereset line on the controller 1 held low or 1s being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal Extended of the DMC 2x00 Controller The DMC 2x00 controller offers 64 extended TTL I O points which can be configured as inputs or outputs in 8 bit increments Configuration 18 accomplished with command CO see Chapter 7 The I O points are accessed through the 80 pin high density connector labeled EXTENDED I O Interfacing to Grayhill or OPTO 22 G4PB24 The DMC 2x00 controller uses one 80 Pin high density connector to access the extended I O This connector is accessed via the Galil CABLE 80 The Galil CABLE 80 can be converted to 2 50 pin ribbon cables which are compatible with I O mounting racks such as Grayhill 70GRCM32 HL and OPTO 22 G4PB24 To convert the 80 pin cable use the CB 50 80 adapter from Galil The 50 pin ribbon cables which connect to the CB 50 80 connect directly into the I O mounting racks The CB 50 80 adapter boar
20. OB 3 IN 1 amp IN 2 Set Output 3 only if Input 1 and Input 2 are high OB 4 COUNT 1 Set Output 4 if element 1 in the array COUNT is non zero The output port can be set by specifying an 8 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 8 bit output port where 20 is output 1 2l is output 2 and so on A 1 designates that the output 1s on Example Output Port Instruction Interpretation 06 Sets outputs 2 and 3 of output port to high other bits are 0 21 22 6 OPO Clears all bits of output port to zero OP 255 Sets all bits of output port to one Q2 21 22 23 25 4 25 26 27 The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move Instruction Interpretation ZOUTPUT Label PR 2000 Position Command BG Begin AM After move SBI Set Output 1 WT 1000 Wait 1000 msec Clear Output 1 EN End Digital Inputs The general digital inputs for are accessed by using the IN n function or the TI command The IN n function returns the logic level of the specified input n where n is a number through 96 DMC 2X00 Chapter 7 Application Programming 159 Example Using Inputs to control program flow Instruction Interpretation JP A IN 1 0 Jump to A if input 1 is low JP B IN 2 1 Jump to B if input 2 is high AIT Wait until
21. gt 4 5 ps pia 8 2 2 pis 0 pis 0 6 2 pis 2 02 cn E NN pis pis pig 8 2 8 0 pig 19 0 IN8 XLATCH YLATCH ZLATCH WLATCH 5 2 12V 12V ANA GND INCOM ABORT n 4 4 55 lt 2 2 0 lt Llalla 2 gt o o E Er o o pr 3 o o EN Isolated Analog Ground for Use with Analog Inputs Appendices 9 Main encoder Index Main encoder Index Signal Ground Main encoder Main encoder A Main encoder Main encoder B 210 Appendices DMC 2X00 ICM 2900 Drawing 2 40 2 75 2 40 00 00 sianw exp LL eno Holes for 00 mounting to DMC sianx 2000 2 holes ewwx Pwmy GND our ew error 00 2 100 high
22. 124 136 172 173 0510 0 137 TCPERR A iint a 124 137 141 Auxiliary 22 93 70 112 113 114 168 169 Dual Loop seen 70 112 113 114 17 18 19 48 49 176 Begin 202 25 29 50 82 89 Binary 1 53 61 63 64 162 227 252 5 133 142 153 Burn 28 47 EEPROM 0 1 5 163 204 Capture Data 70 104 147 148 149 252 124 165 166 Circular Interpolation esses 37 86 45 158 159 202 225 Clear 2 81 83 87 89 CMDERR 124 137 139 140 DMC 2X00 Coordinated Motion Linear Interpolation36 37 69 70 81 82 83 85 86 9 Data Record 57 59 101 102 252 Echo49 58 60 244 ien RS ew 34 122 137 cete One RE 34 35 121 122 EEPROM ec 1 5 15 16 17 163 204 Electronic 69 70 95 98 99 105 Electronic Gearing 1 69 70 91 94 95 Ellipse Scale E erret 89 Enable Amplifier Enable 7 22 43 171 206 220 Encoder Auxiliary Encoderl 6 13 23 30 39 44 45 93 107 112 113 114 160 191 192 196 203 212 D
23. DMC 2X00 The position error which is the difference between the commanded position and the actual position can be interrogated with the instruction TE Instruction Interpretation TE Tell error all axes TEA Tell error A axis only TEB Tell error B axis only TEC Tell error C axis only TED Tell error D axis only Absolute Position Objective Command motion by specifying the absolute position Instruction Interpretation DP 0 2000 Define the current positions of A B as 0 and 2000 PA 7000 4000 Sets the desired absolute positions BGA Start A motion BGB Start B motion After both motions are complete the A and B axes can be command back to zero PA 0 0 Move to 0 0 BG AB Start both motions Velocity Control Objective Drive the A and B motors at specified speeds Instruction Interpretation JG 10000 20000 Set Jog Speeds and Directions AC 100000 40000 Set accelerations DC 50000 50000 Set decelerations BG AB Start motion after a few seconds command JG 40000 New A speed and Direction TVA Returns A speed and then JG 20000 New B speed B Returns B speed These cause velocity changes including direction reversal The motion can be stopped with the instruction ST Stop DMC 2X00 Chapter 2 Getting Started 3 Operation Under Torque Limit The magnitude of the motor command may be limited independently by the instruction TL Instruction Interpretation TL 0 2 Set output limit of A axis to 0
24. Halts program execution until motion is complete on the specified axes or motion sequence s AM with no parameter tests for motion complete on all axes This command is useful for separating motion sequences in a program Halts program execution until position command has reached the specified relative distance from the start of the move Only one axis may be specified at a time Halts program execution until after specified distance from the last AR or AD command has elapsed Only one axis may be specified at a time Halts program execution until after absolute position occurs Only one axis may be specified at a time Halt program execution until after forward motion reached absolute position Only one axis may be specified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs Halt program execution until after reverse motion reached absolute position Only one axis may be specified If position is already past the point then MR will trip immediately Will function on geared axis or aux inputs Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW A B C D sets timeout to declare an error if not in position If timeout occurs then the trip point will clear and the stop code will be set to 99 An application program will jump to label Halts program execution until aft
25. LR LR MG REVERSE LIMIT Send message STX AMA Stop motion PR1000 BGA AMA Move forward END End RE Return to main program NOTE An applications program must be executing for LIMSWI to function 174 e Chapter 8 Hardware amp Software Protection DMC 2X00 Chapter 9 Troubleshooting Overview The following discussion may help you get your system to work Potential problems have been divided into groups as follows 1 Installation 2 Communication 3 Stability and Compensation 4 Operation The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM CAUSE REMEDY Motor runs away when connected to amplifier with Amplifier offset too Adjust amplifier offset no additional inputs large Same as above but offset adjustment does not stop Damaged amplifier Replace amplifier the motor Controller does not read changes in encoder position Wrong encoder Check encoder wiring connections Same as above Bad encoder Check the encoder signals Replace encoder if necessary Same as above Bad controller Connect the encoder to different axis input If it works controller failure Repair or replace DMC 2X00 Chapter 9 Troubleshooting 175 Communication SYMPTOM CAUSE REMEDY Using terminal emulator cannot Selected comm port incorrect Try another comport communicate with controller Same as above Selected baud rate incorrect Check to be sure that baud
26. OPERAND FUNCTION EDI Returns the number of the thread that generated an error _ED2 Retry failed command operand contains the location of the failed command _ED3 Skip failed command operand contains the location of the command after the failed command The operands are used with the XQ command in the following format XQ ED2 or ED3 ED1 1 DMC 2X00 Chapter 7 Application Programming 139 Where the 1 at the end of the command line indicates a restart therefore the existing program stack will not be removed when the above format executes The following example shows an error correction routine which uses the operands Example Command Error w Multitasking Instruction EN ZCMDERR IF 6 N 1 XQ ED2 ED1 1 ENDIF IF TC 1 ED3 1 ENDIF EN Interpretation Begin thread 0 continuous loop End of thread 0 Begin thread 1 Create new variable Set KP to value of N an invalid value Issue invalid command End of thread 1 Begin command error subroutine If error is out of range KP 1 Set N to a valid number Retry KP N command If error is invalid command TY Skip invalid command End of command error routine Example Communication Interrupt DMC 2x10 is used to move the A axis back and forth from 0 to 10000 This motion can be paused resumed and stopped via input from an auxiliary port terminal Instruction ZBEGIN CC 9600 0 0 0
27. Start is the first element of array default 0 End is the last element of array default last element Delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 The file is terminated using lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 2x00 provides a special feature for automatic capture of data such as position position error inputs or torque This is useful for teaching motion trajectories or observing system performance Up to four types of data can be captured and stored in four arrays The capture rate or time interval may be specified Recording can be done as a one time event or as a circular continuous recording 148 e Chapter 7 Application Programming DMC 2X00 DMC 2X00 Command Summary Automatic Data Capture RA n m o p Selects up to four arrays for data capture The arrays must be defined with the DM command RD typel type2 type3 type4 Selects the type of data to be recorded where typel type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command The RC command begins data collection Sets data capture time interval where nis an integer between 1 and 8 and designates 2 msec between data m is optional and specifies the number of elements to be captured If m is not defined the numbe
28. Step 9b Step 9c Step 10 Determine overall motor configuration Install Jumpers on the DMC 2x00 Configure the DIP switches on the DMC 2000 Configure the DIP switches on the DMC 2100 Configure the DIP switches on the DMC 2200 Install the communications software Connect AC power to controller Establish communications with the Galil Communication Software Determine the Axes to be used for sinusoidal commutation Make connections to amplifier and encoder Connect standard servo motors Connect sinusoidal commutation motors Connect step motors Tune the servo system Step 1 Determine Overall Motor Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 2x00 can control any combination of standard servo motors sinusoidally commutated brushless motors and stepper motors Other types of actuators such as hydraulics can also be controlled please consult Galil The following configuration information 1s necessary to determine the proper motor configuration Standard Servo Motor Operation The DMC 2x00 has been setup by the factory for standard servo motor operation providing an analog command signal of 10V No hardware or software configuration is required for standard servo motor operation 14 e Chapter 2 Getting Started DMC 2X00 DMC 2X00 Sinusoidal Commutation Sinusoidal commutation is configured through a single software command BA T
29. USER MANUAL DMC 2x00 Manual Rev 2 1 By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Rev 03 2011 Using This Manual This user manual provides information for proper operation of the DMC 2x00 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller Your DMC 2x00 motion controller has been designed to work with both servo and stepper type motors Installation and system setup will vary depending upon whether the controller will be used with stepper motors or servo motors To make finding the appropriate instructions faster and easier icons will be next to any information that applies exclusively to one type of system Otherwise assume that the instructions apply to all types of systems The icon legend 1s shown below Attention Pertains to servo motor use Attention Pertains to stepper motor use Attention Pertains to controllers with more than 4 axes Please note that many examples are written for the DMC 2x40 four axes controller or the DMC 2x80 eight axes controller Users of the DMC 2x30 3 axis controller DMC 2x20 2 axes controller or 2 10 1 axis controller should note that the DMC 2x30 uses the axes denoted as XYZ the DMC 2x20 uses the axes denoted as XY and the
30. 1000 and 500 This implies that B must be driven to that point to avoid a jump This is done with the program Instruction Interpretation RUN Label EBI Enable cam PA 500 starting position SP 5000 B speed BGB Move B motor AM After B moved Wait for start signal EG 1000 Engage slave AI 1 Wait for stop signal EQ 1000 Disengage slave EN End Command Summary Electronic CAM Command Descripion gt gt S O EA p EB n ECn EG a b c d EM a b c d EP m n EQ m n ET n EW Specifies master axes for electronic cam where Enables the ECAM ECAM counter sets the index into the ECAM table Engages ECAM Defines CAM table entry size and offset Disengages ECAM at specified position Defines the ECAM table entries Widen segment see Application Note 2444 98 Chapter 6 Programming Motion DMC 2X00 DMC 2X00 Operand Summary Electronic CAM Contains State of ECAM Contains current ECAM index E Example Electronic CAM The following example illustrates a cam program with a master axis C and two slaves A and B Instruction Interpretation A vl 0 Label Initialize variable 0 0 BGAB AMAB Go to position 0 0 on A and B axes C axis as the Master for ECAM EM 0 0 4000 Change for C is 4000 zero for A B EP400 0 ECAM interval is 400 counts with zero start ET 0 0 0 When master is at 0 position 1st point ET 1 40 20 2nd point in the ECAM table ET 2 120 60 3rd p
31. GND will cause the motor to start in the forward direction 5 will cause it to start in the reverse direction The CN command is used to define the polarity of the home input CN e oom Example Instruction 4HOME AC 1000000 DC 1000000 SP 5000 HM A BGA AMA MG AT HOME EN EDGE AC 2000000 DC 2000000 SP 8000 FEB BGB AMB MG FOUND HOME DP 0 EN DMC 2X00 Upon detecting the home switch changing state the motor begins decelerating to a stop The motor then traverses very slowly back until the home switch toggles again The motor then traverses forward until the encoder index pulse is detected The DMC 2x00 defines the home position 0 as the position at which the index was detected Interpretation Label Acceleration Rate Deceleration Rate Speed for Home Search Home A Begin Motion After Complete Send Message End Label Acceleration rate Deceleration rate Speed Find edge command Begin motion After complete Send message Define position as 0 End Chapter 6 Programming Motion 117 HOME SENSOR HOME SWITCH POSITION VELOCITY 1 MOTION BEGINS TOWARD HOME DIRECTION gt POSITION VELOCITY MOTION REVERSE TOWARD HOME DIRECTION POSITION VELOCITY 8 MOTION TOWARD INDEX DIRECTION gt POSITION INDEX PULSES POSITION Figure 6 10 Motion intervals in the Home sequence 118 gt Chapter 6 Programming Motion DMC 2X00
32. L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to MKS units For example consider a motor with the parameters 14 16 oz 0 1 Nm A R 2 0 J 0 0283 oz in s2 2 1074 m L 0 004 H Then the corresponding time constants are Tm 0 04 sec and 0 002 sec Assuming that the amplifier gain is Kv 4 the resulting transfer function 1s P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of Ka The resulting transfer function in this case is P V K K Js Chapter 10 Theory of Operation 1 where Kt and J are as defined previously For example a current amplifier with K4 2 A V with the motor described by the previous example will have the transfer function P V 1000 52 rad V If the motor is DC brushless motor it 15 driven by amplifier that performs the commutation The combined transfer function of motor amplifier combination is the same as that of a similar brush motor as described by the previous equations Velocity Loop The motor driver system may include a velocity loop where the motor velocity is sensed by a tachometer and 15 fed back to the amplifier Such a system 15 illustrated in Fig 10 5 Note that the transfer function between the input voltage V and the velocity o is Kg 15 1
33. Out and in are referenced to the terminal Ordering Information TERM 1500H P2 Hand held terminal with female adapter TERM 1500P P2 Panel Mount terminal with female adapter DMC 2X00 Appendices 5 Coordinated Motion Mathematical Analysis The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which is also known as the feed rate is the vector sum of the velocities along the X and Y axes Vx and Vy Vs Vx Vy The vector distance 1 the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle corresponds to the positive direction of the X axis and the CCW direction of rotation 1 positive Angles are expressed in degrees and the resolution is 1 256 of a degree For example the path shown in Fig A 21 is specified
34. Speed 20000 x vin The corresponding velocity for the motor is assigned to the VEL variable Instruction ZA 760 BGA B vin AN 1 vel vin 20000 JG vel JP B EN Position Control by Joystick This system requires the position of the motor to be proportional to the joystick angle Furthermore the ratio between the two positions must be programmable For example if the control ratio is 5 1 it implies that when the joystick voltage is 5 volts corresponding to 1024 counts the required motor position must be 5120 counts The variable V3 changes the position ratio Instruction Interpretation Label 3 1024 Initial position ratio DPO Define the starting position JGO Set motor in jog mode as zero BGA Start 4B 1 1 Read analog input 2 1 3 Compute the desired position 4 2 TEA Find the following error 5 4 20 Compute a proportional speed JG v5 Change the speed JP B Repeat the process EN End Backlash Compensation by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective way to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method described below This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The
35. Systems with or without Hall Sensors Set Zero Commutation Phase When an axis has been defined as sinusoidally commutated the controller must have an estimate for commutation phase When Hall sensors are used the controller automatically estimates this value upon reset of the controller If no Hall sensors are used the controller will not be able to make this estimate and the commutation phase must be set before enabling the motor To initialize the commutation without Hall effect sensor use the command BZ This function drives the motor to a position where the commutation phase is zero and sets the phase to zero The BZ command is followed by real numbers in the fields corresponding to the driven axes The number represents the voltage to be applied to the amplifier during the initialization When the voltage is specified by a positive number the initialization process ends up in the motor off MO state A negative number causes the process to end in the Servo Here SH state 28 e Chapter 2 Getting Started DMC 2X00 WARNING This command must move the motor to find the zero commutation phase This movement is instantaneous and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The applied voltage will typically be sufficient for proper operation of the BZ command For systems with significant friction this voltage may need to be increased and for systems with very small motors this value should
36. ZOH H s 2000 s 2000 Compensation Filter G s P sD 188 gt Chapter 10 Theory of Operation DMC 2X00 DMC 2X00 The next step is to combine all the system elements with the exception of G s into one function L s L s M s Ka Kg Kr H s 3 17 106 52 5 2000 Then the open loop transfer function A s is A s L s G s Now determine the magnitude and phase of L s at the frequency c 0 L j500 3 17 106 1500 2 j500 2000 This function has a magnitude of L j500 0 00625 and a phase Arg L j500 180 tan 1 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that 0500 1 Arg AG500 135 However since A s L s G s then it follows that G s must have magnitude of GG500 AG500 LG500 160 and a phase arg G j500 arg AG500 LG500 135 194 59 In other words we need to select a filter function G s of the form G s P sD so that at the frequency o 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as GG500 15000 0 and arg G j500 tan 500D P 59 The solution of these equations leads to P 160008 59 4 500D 160sin 59 7 Therefore 0 274 G 82 4 0 27445 Chapter 10 Theory of Operation 9 The function G is equivalent to a digital filter
37. full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WT100 Allow slight settle time Perform motion 110 Chapter 6 Programming Motion DMC 2X00 DMC 2X00 SP512 Set the speed PR1000 Prepare mode of motion BGX Begin motion LOOP JP LOOP Keep thread zero alive for POSERR to run in REM When error occurs the axis will stop due to OE1 In REM POSERR query the status YS and the error QS correct REM and return to the main code POSERR Automatic subroutine is called when YS 2 WT100 Wait helps user see the correction spsave _SPX Save current speed setting JP RETURN YSX lt gt 2 Return to thread zero if invalid error SP 64 Set slow speed setting for correction MG ERROR QSX YRX QSX Else error is valid use QS for correction MCX Wait for motion to complete MG CORRECTED ERROR NOW QSX WT100 Wait helps user see the correction RETURN SPX spsave Return the speed to previous setting REO Return from POSERR Example Friction Correction The following example illustrates how the SPM mode can be useful in correcting for X axis friction after each move when conducting a reciprocating motion The drive is a 1 64 microstepping drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to continue upon error KS16 Set step smoothing MT 2 2 2 2 Motor type set to stepper Y A64 Step resolution of the microstepping drive Y
38. null modem cable RS232 Port P1 DATATERM CTS output 6 CTS output 2 Transmit Data output 7 RTS input 3 Receive Data input 8 CTS output 4 RTS input 9 No connect Can connect to 5V or sample clock 5 Ground RS232 Auxiliary Port P2 DATASET 1 CTS input 6 CTS input 2 Transmit Data input 7 RTS output 3 Receive Data output 8 CTS input 4 RTS output 9 5V Can be connected to sample clock with jumpers 5 Ground Chapter 4 Communication e 47 RS422 Main Port P1 CTS output 6 CTS output 2 Transmit Data output 7 Transmit output 3 Receive Data input 8 Receive input 4 RTS input 9 RTS input 5 Ground RS422 Auxiliary Port P2 1 CTS input 6 CTS input 2 Receive Data input 7 Receive input 3 Transmit Data output 8 Transmit output 4 RTS output 9 RTS output 5 Ground Default configuration is 115232 RS422 configuration available from factory RS 232 Configuration Configure your PC for 8 bit data one start bit one stop bit full duplex and no parity The baud rate for the RS232 communication can be selected by setting the proper switch configuration on the front panel according to the table below Baud Rate Selection SWITCH SETTINGS _ so 102 300 BAUD RATE Handshaking Modes The RS232 main port can be configured for hardware and software handshaking For Hardware Handshaking set the HSHK switch to ON In this mode the
39. 1 significantly different from the response of an activated limit switch When the abort input is activated the controller stops generating motion commands immediately whereas the limit switch response causes the controller to make a decelerated stop NOTE The effect of an Abort input is dependent on the state of the Off On Error function for each axis If the Off On Error function is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no 40 e Chapter 3 Connecting Hardware DMC 2X00 longer under servo control If the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running are terminated when a transition in the Abort input is detected For information on setting the Off On Error function see the Command Reference OE Reset Input When this input 15 pulled low to 0 volts the controller will reset This is equivalent to pushing the reset button on the front of the DMC 2x00 Uncommitted Digital Inputs The DMC 2x00 has 8 opto isolated inputs These inputs can be read individually using the function IN x where x specifies the input number 1 thru 8 These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller Fo
40. 2X00 C 4000 3000 B 4000 0 A 0 0 Figure 6 3 The Required Path Electronic Gearing This mode allows up to 8 axes to be electronically geared to some master axes The masters may rotate in both directions and the geared axes will follow at the specified gear ratio The gear ratio may be different for each axis and changed during motion The command GA ABCDEFGH specifies the master axes GR a b c d specifies the gear ratios for the slaves where the ratio may be a number between 127 9999 with a fractional resolution of 0001 There are two modes standard gearing and gantry mode The gantry mode is enabled with the command GM GR 0 0 0 0 turns off gearing in both modes A limit switch or ST command disables gearing in the standard mode but not in the gantry mode The command GM a b c d select the axes to be controlled under the gantry mode The parameter 1 enables gantry mode and 0 disables it GR causes the specified axes to be geared to the actual position of the master The master axis is commanded with motion commands such as PR PA or JG When the master axis is driven by the controller in the jog mode or an independent motion mode it is possible to define the master as the command position of that axis rather than the actual position The designation of the commanded position master is by the letter C For example GACA indicates that the gearing is the commanded position of A An alternative gearing method is t
41. 36 pin high density cable CABLE 36 from the controller and provides terminal blocks for easy access Each terminal is labeled for quick connection One ICM 1908 provides access to all of the auxiliary encoders on a DMC 2x00 up to 8 axes 212 Appendices DMC 2X00 ICM 2908 Drawing gt 2 40 2 75 gt 2 40 2908 Holes for mounting to DMC 2000 2 holes 36 pin high density connector 2 178238 5 Solderless 10236 55 G3VC connections insert screwdriver to open contacts for insertion removal of lead 00 aax Bib AAY 00 aax Ds 00 00 AAW 00 aaz AAW aaz ABW asz ABW 2 GND 00 sv 12 GND 5v GND 00 sv GND 00 00 00 00 amp 00 e 00 00 0 Front Side Back Figure A 2 DMC 2X00 Appendices 213 PCB Layout of the ICM 2900 U1 U2 RP2 c ANALOG ceeXxvN SWITCH AMPLIFIER ENABLE 2072 c o RP3 BUFFER FOR 5 VOLT AMPLIFIER ENABLE PLACE PIN 1 OF RP1 ON PIN LABELED
42. 40000 BGS AMS 80000 BGC AMC PR 21600 SP 20000 BGA AMA PR 80000 BGC AMC CR 80000 270 360 VE VS 40000 BGS AMS 166 gt Chapter 7 Application Programming Interpretation Label Circular interpolation for AB Positions End Vector Motion Vector Speed Vector Acceleration Start Motion When motion is complete Move C down C speed Start C motion Wait for completion of C motion Circle Feed rate Start circular move Wait for completion Move C up Start C move Wait for C completion Move A Speed A Start A Wait for A completion Lower C C second circle move DMC 2X00 DMC 2X00 80000 Raise BGC AMC VP 37600 16000 Return AB to start VE VS 200000 BGS AMS EN 4 9 3 A Figure 7 2 Motor Velocity and the Associated Input Output signals Speed Control by Joystick The speed of a motor is controlled by a joystick The joystick produces a signal in the range between 10V and 10 The objective is to drive the motor at a speed proportional to the input voltage Assume that a full voltage of 10 volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec Chapter 7 Application Programming 167 The program reads the input voltage periodically and assigns its value to the variable vin To get a speed of 200 000 ct sec for 10 volts we select the speed as
43. 99 PWROUT20 Power output 20 0 102 102 PWROUT19 Power output 19 0 103 101 PWROUT18 Power output 18 0 104 104 PWROUT17 Power output 17 0 103 GND Ground e Silkscreen on Rev A board is incorrect for these terminals NOTE The part number for the 100 pin connector is 2 178238 9 from AMP CB 50 100 Adapter Board The CB 50 100 adapter board can be used to convert the CABLE 100 to 2 50 Pin Ribbon Cables The 50 Pin Ribbon Cables provide a versatile method of accessing the controller signals without the use of a Galil Interconnect Module Connectors JC8 50 PIN IDC J9 100 PIN HIGH DENSITY CONNECTOR 230 Appendices DMC 2X00 DMC 2X00 Appendices 231 JC6 50 PIN IDC J9 100 PIN HIGH DENSITY CONNECTOR 232 Appendices DMC 2X00 CB 50 100 Drawing 15 16 ue 1 8 50 100 REVA GALIL MOTION CONTROL MADE IN USA J9 JC8 JC6 1 51 41 2 21 71 41 91 Y 1 2 n 9 16 1 m Figure A 15 DMC 2X00 _ 1 8 D 4 places Mounting bracket 4 for attaching _ inside PC JC6 JC8 50 pin shrouded headers w center key JC8 pins 1 50 of J9 JC6 pins 51 100 of J9 J9 100 pin connector part 9 Appendices e 233 JC8 IDC 50 Pin Pini 2 975 0 6125 JC6 IDC 50 Pin 1 2 975 0 9875 JC6 JC8
44. As with any automatic subroutine a program must be running in thread 0 at all times for it to be enabled Example DMC 2x00 is used to jog the A and B axis This program automatically begins upon power up and allows the user to input values from the main serial port terminal The speed of either axis may be changed during motion by specifying the axis letter followed by the new speed value An S stops motion on both axes Instruction Interpretation AUTO speedA 10000 speedB 10000 CI 2 JG speedA speedB BGXY PRINT MG P2 TO CHANGE SPEEDS MG P2 TYPE OR B MG 2 TO STOP JOGLOOP JG speedA speedB JP JOGLOOP EN 152 e Chapter 7 Application Programming Label for Auto Execute Initial A speed Initial B speed Set Port 2 for Character Interrupt Specify jog mode speed for A and B axis Begin motion Routine to print message to terminal Print message Loop to change Jog speeds Set new jog speed End of main program DMC 2X00 Interrupt routine JP A P2CH A Check for A JP 2 Check for B JP 2C P2CH S Check for S ZSL CD JPZJOGLOOP Jump if not X Y S A JSHNUM speedX val New X speed ZS1 CI2 JP PRINT Jump to Print B JS4NUM speed Y val New Y speed ZS1 CI2 JP PRINT C ST AMX CI 1 8 THE END Jump to Print Stop motion on S ZS EN 1 End Re enable interrupt NUM Routine for entering new jog speed MG ENTER P2CH S AXIS SPEE
45. Clear Display and Home lt Ctrl gt Space lt Shift gt 5 6 Function Keys lt CNTRL gt lt SHIFT gt F3 Allows function keys to be configured Follow prompts on display to change function keys Default Function Keys Fl 22 decimal F2 23 decimal F3 24 decimal F4 25 decimal F5 26 decimal Input Output of Data DMC 2x00 Commands Refer to Chapter 7 in this manual for Data Communication commands When using Port 2 use CC command to configure P2 Example CC 9600 0 0 1 Configures P2 MG P2 Hello There V1 F2 1 Send message to P2 IN P2 Enter Value NUM Prompts operator for value Example 0 00 0 1 Interrupt on any key Configure 2 MG P2 press to start X Print Message to P2 MG P2 Press F2 to start Y Print Message to P2 244 Appendices DMC 2X00 ZB JP B EN End Program COMINT Interrupt Routine JS XMOVE P2CH F 1 Jump to X move if F1 JS Y MOVE P2CH F2 Jump to Y move if F2 EN1 1 End Re enable comm interrupt amp restore trip point ZXMOVE PR1000 BGX EN Move X routine ZYMOVE PR 1000 BGY EN Move Y routine NOTE F1 through F5 are used as dedicated keywords for testing function keys Do not use these as variables 6 Pin Modular Connector Handshake in Handshake out 9 Pin D Adaptor Male For P2 CTS input Transmit Data input Receive Data output RTS output CTS input RTS output CTS input 5V or no connect or sample clock with jumpers NOTE
46. Command Homing Operation FE ABCD Find Edge Routine This routine monitors the Home Input FI ABCD Find Index Routine This routine monitors the Index Input HM ABCD Home Routine This routine combines FE and FI as Described Above SC ABCD Stop Code TS ABCD Tell Status of Switches and Inputs Operand summer Homing Operation High Speed Position Capture The Latch Function DMC 2X00 Often it 1s desirable to capture the position precisely for registration applications The DMC 2x00 provides a position latch feature This feature allows the position of the main or auxiliary encoders of A B C or D to be captured when the latch input changes state This function can be setup such that the position 15 captured when the latch input goes high or low When the latch function is enabled for active low operation the position will be captured within 12 microseconds When the latch function is enabled for active high operation the position will be captured within 35 microseconds Each axis has one general input associated to the axis for position capture B Axis Latch 0 F Axis Latch C Axis Latch INII G Axis Latch D Axis Latch IN12 H Axis Latch The DMC 2x00 software commands AL and RL are used to arm the latch and report the latched position The steps to use the latch are as follows 1 Give AL ABCD command to arm the latch for the main encoder and ALSASBSCSD for the auxiliary encoders 2 Test to see if the latc
47. Communications Port Connect the DMC 2x00 MAIN serial port to your computer via the Galil CABLE 9PIN D RS 232 Cable Using Galil Software for DOS serial communication only To communicate with the DMC 2000 type TALK2DMC at the prompt Once you have established communication the terminal display should show a colon If you do not receive a colon press the carriage return If a colon prompt is not returned there is most likely an incorrect setting of the serial communications port The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software The user must also insure that the proper serial cable is being used see appendix for pin out of serial cable Using Galil Software for Windows In order for the windows software to communicate with a Galil controller the controller must be registered in the Windows Registry To register a controller you must specify the model of the controller the communication parameters and other information The registry is accessed through the Galil software under the File menu in WSDK or under the Tools menu in the Galil Smart Terminal The registry window 1s equipped with buttons to Add a New Controller change the Properties of an existing controller Delete a controller or Find an Ethernet Controller
48. DMC 2x00 motion controller Its numeric keypad allows easy data entry from an operator The TERM 1500 is available with a male adapter for connection to P2 Dataset NOTE Since the TERM 1500 requires 5 on pin 9 of RS 232 it can only work with port 2 of the DMC 2x00 Specifications Hand Held Keypad Key Tactile 4 row x 5character Display LCD with 5 by 7 character font Power 5 volts 30mA from DMC 2x00 240 Appendices DMC 2X00 DMC 2X00 Specifications Panel Mount Keypad 30 Key 5 rows x 6 columns 5x7 font Display 4 row x 20 character LCD Power 5 volts 30mA Keypad Maps Hand Held 30 Keys 5 keys across 6 down Single Key Output NOTE Values in parentheses are ASCII decimal values Key locations are represented by m n where m is element column n is element row Example U is lt Shift gt 1 2 Appendices 1 is lt Cntrl gt 5 1 Keypad Map Panel Mount 6 columns 5 rows Single Key Output 16 3 9 2 4 NOTE Values in parentheses are ASCII decimal values Key locations are represented by m n where m is element column n is element row Escape Commands Escape codes can be used to control the TERM 1500 display cursor style and position and sound settings NOTE The escape character hex 1B can be sent through port 2 of the DMC 2x00 with special syntax 27 Example MG P2 27 H Sends escape H to the terminal from port 2 Cursor Mo
49. DMC 2x10 uses the X axis only Examples for the DMC 2x80 denote the axes as A B C D E F G H Users of the DMC 2x50 5 axes controller DMC 2x60 6 axes controller or DMC 2x70 7 axes controller should note that the DMC 2x50 denotes the axes as A B C D E DMC 2x60 denotes the axes as A B C D E F and the DMC 2x70 denotes the axes as A B C D E F G The axes A B C D may be used interchangeably with A B C D WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machinery Galil shall not be liable or responsible for any incidental or consequential damages Contents DMC 2x00 Using This Marual 5 5224 2224 1 Contents i Chapter 1 Overview 1 Introductio ie a E 1 ec 2 11030 6 DMC 2000 Family Part 2 Electrical Specifications o Rocco e bitu p Ee 2 Mechanical 2 3 3 7 nennen 3 Standard Servo Motor with 10 Volt Command 3 Brushless Servo Motor with Sinusoidal Commutation sess 3 Stepper Motor with Step and Direction Signals sese 4 Overview of Amplifiers 2 52 224 4 Amplifiers in Current nennen 4 ener enne 4 Stepper Motor Amplifi
50. Fig 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming The first level the closing of the loop assures that the motor follows the commanded position This 8 done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling 18 the generation of the desired position function This function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the loop forces the motor to follow the commanded position Chapter 10 Theory of Operation 177 The highest level of control 15 the motion program This can be stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000 SP 20000 20000 AC 200000 00000 BGA AD 2000 BGB EN This progra
51. Figure 5 plots velocity vs time and Figure 6 demonstrates the use of motion smoothing IT on the velocity profile in this mode The jerk in the system is also affected by the values set for AC and DC 76 e Chapter 6 Programming Motion DMC 2X00 Figure 4 Position vs Time msec Motion 4 Figure 5 Velocity vs Time Motion 4 DMC 2X00 Chapter 6 Programming Motion 77 Figure 6 Velocity cts sec vs Time msec with IT Motion 4 Note the controller treats the point where the velocity passes through zero as the end of one move and the beginning of another move IT 18 allowed however it will introduce some time delay Trip Points Most trip points are valid for use while in the position tracking mode There are a few exceptions to this the AM and MC commands may not be used while in this mode It is recommended that MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position 78 Chapter 6 Programming Motion DMC 2X00 Command Summary Position Tracking Mode n n n n n n n n point to hold up program execution until n number of counts have passed in the forward direction Only one axis at a time may be specified reverse direction Only one axis at a time may be specified Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion The user specifies the Jog speed JG ac
52. Functions 000 Fn m Formats numeric values in decimal n digits to the left of the decimal point and m digits to the right P1 P2 U or E Send message to Main Serial Port Auxiliary Serial Port USB Port or Ethernet Port Sends the first n characters of a string variable where n is 1 thru 6 Displaying Variables and Arrays Variables and arrays be sent to the screen using the format variable or array x For example v1 returns the value of v1 Example Printing a Variable and an Array element Instruction Interpretation DISPLAY Label DM posA 7 Define Array POSA with 7 entries PR 1000 Position Command BGX Begin AMX After Motion Assign Variable v1 posA 1 TPA Assign the first entry vl Print v1 Interrogation Commands The DMC 2x00 has a set of commands that directly interrogate the controller When these command are entered the requested data 15 returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF and Leading Zeros LZ command For a complete description of interrogation commands see Ch 5 Chapter 7 Application Programming 155 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by theses interrogation commands BL LE DE PA DP PR TN FL VE IP TE TP The num
53. Galil Software esses 19 Step 7 Determine the Axes to be Used for Sinusoidal Commutation 21 Step 8 Make Connections to Amplifier and Encoder sss 22 Step 9a Connect Standard Servo Motors 24 Step 9b Connect Sinusoidal Commutation Motors sse 27 Step 9c Connect Step Motors 30 20 Design Examples 31 SUNSET ELM 31 Profiled MOoye 32 Uie ites 32 Objective Move the four axes independently sss 32 Independent Moves insiste e a eee d e 32 The motion parameters may be specified independently as illustrated below 32 Position Interrogation 32 The position error which is the difference between the commanded position and the actual position can be interrogated with the instruction TE sss 33 Absolute Position zn eae Re REA TER tt R 33 33 Operation Under Torque 34 Interrogation nee Re eed e ERR T dee e 34 Operation in the Buffer Mode 34 Using the On Board 34 35 Motion Programs with Trippoints 35 Control Variabl s E 36
54. In general the UART will become full because the hardware handshake line will halt serial data until the correct data 15 read When the UART becomes full program execution will be delayed until it is cleared If the user wants to avoid this delay the command CW 1 can be given This command causes the controller to throw away the data which can not be placed into the FIFO In this case the controller does not delay program execution 126 e Chapter 7 Application Programming DMC 2X00 DMC 2X00 Error Code Command When there is a program error the DMC 2x00 halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG The user can obtain information about the type of error condition that occurred by using the command This command reports back a number and a text message which describes the error condition The command TCO or TC will return the error code without the text message For more information about the command TC see the Command Reference Stop Code Command The status of motion for each axis can be determined by using the stop code command SC This can be useful when motion on an axis has stopped unexpectedly The command SC will return a number representing the motion status See the command reference for further information RAM Memory Interrogation Commands For debugging the status of the program memory array memory or variable me
55. X W 50 1 2 M Roy Analog to Digital Converter IC xc 7806 12 bit i 7807 16 bit GL 1800 GL 1800 SMD W ee 6 1 ee JP5 SRAM DMC 2000 REVA 5 80 GALIL MOTION CONTROL t Jumper to connect 52 optoisolators to onboard 5V supply JP1 SRAM Motorola MASTER RESET 68331 e UPGRADE EX 4 4 EEPROM 5 00000 J2 MADE IN USA AH 9999 x DOES Power connector Microprocessor Communications Daughterboard connector Jumper Master Reset to clear EEPROM Serial number label 6 pin Molex Figure 2 1 Outline of the main board of the DMC 2x00 DMC 2X00 Chapter 2 Getting Started 9 9 The DMC 2000 Daughter Board USB type A port Configuration DIP AUX Serial port USB type B Switches connector x2 80 pin high DB 9 connector density connector SITAS for extended t 7 85 gt 7 Y AUX 6 5 SEER 8 i 5 E J3 EXTENDED lt S eeeeeee JI USBIN OP 5 USBOUT 5852555 c c cc 02 U6 ss zE zE 2 53
56. Z axis 1s the master and X and Y are the geared axes We will implement the gearing change over 6000 counts 3 revolutions of the master axis MOZ Turn Z off for external master GAZ Z Specify Z as the master axis for both X and Y GD6000 6000 Specify ramped gearing over 6000 counts of the master axis GR 1 132 045 Specify gear ratios Question What is the effect of the ramped gearing Answer Below in the example titled Electronic Gearing gearing would take effect immediately From the start of gearing 1f the master traveled 6000 counts the slaves would travel 6792 counts and 270 counts Using the ramped gearing the slave will engage gearing gradually Since the gearing is engaged over the interval of 6000 counts of the master the slave will only travel 3396 counts and 135 counts respectively The difference between these two values is stored in the GPn operand If exact position synchronization is required the IP command is used to adjust for the difference Command Summary Electronic Gearing COMMAND DESCRIPTION GAn Specifies master axes for gearing where X Y Z or W or A B C D E F G H for main encoder as master CX CY CZ CW or CA CB CC CD CE CF CG CH for commanded position n DX DY DZ or DW or DA DB DC DD DE DF DG DH for auxiliary encoders n S or T for gearing to coordinated motion GD a b c d e f g h Sets the distance the master will travel for the gearing change to take full effect _GPn
57. amplifier has separate amplifier enable lines This signal also goes low when the watch dog timer is activated or upon reset NOTE The standard configuration of the AEN signal is TTL active low Both the polarity and the amplitude can be changed if you are using the ICM 2900 interface board To make these changes see section entitled Amplifier Interface pg 3 25 Error Output The error output is a TTL signal which indicates on error condition in the controller This signal is available on the interconnect module as ERROR When the error signal is low this indicates on of the following error conditions 1 At least one axis has a position error greater than the error limit The error limit is set by using the command ER 2 Thereset on the controller 1 held low or 1s being affected by noise DMC 2X00 Chapter 8 Hardware amp Software Protection e 171 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal Input Protection Lines General Abort A low input stops commanded motion instantly without a controlled deceleration For any axis in which the Off On Error function is enabled the amplifiers will be disabled This could cause the motor to coast to a stop If the Off On Error function is not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in
58. and deceleration The DMC 2x00 computes the vector speed based on the axes specified in the LM mode For example LM ABC designates linear interpolation for the A B and C axes The vector speed for this example would be computed using the equation 2 452 852 82 where AS BS and CS are the speed of A B and axes The controller always uses the axis specifications from LM not LI to compute the speed is used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trip point which halts program execution until the vector distance of n has been reached Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications such as CNC it is necessary to attach various speeds to different motion segments This can be done by two functions n and gt For example LI a b c d gt n gt m The first command gt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function lt m requires the vector speed to reach the value m at the end of the segment Note that the function lt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however
59. as PM is positive the system is stable However for a well damped system PM should be between 30 degrees and 45 degrees The phase margin of 70 degrees given above indicated overdamped response Next we discuss the design of control systems System Design and Compensation closed loop control system can be stabilized by a digital filter which 1 preprogrammed in the DMC 2x00 controller The filter parameters can be selected by the user for the best compensation The following discussion presents an analytical design method The Analytical Method The analytical design method is aimed at closing the loop at a crossover frequency o with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Consider a system with the following parameters Kt Nm A Torque constant J 2404 kg m System moment of inertia R22 Q Motor resistance 2 Current amplifier gain N 0 Counts rev Encoder line density The DAC of the DMC 2x00 outputs 10 for 14 bit command of 8192 counts The design objective 15 to select the filter parameters in order to close a position loop with a crossover frequency of 500 rad s and a phase margin of 45 degrees The first step is to develop a mathematical model of the system as discussed in the previous system Motor M s P I Kj Js2 2 Amp K 2 Amp V DAC 10 32768 0003 Encoder 4 2 636
60. first level allows the user to create a raw packet and receive raw data It uses the MBh command with a function code of 1 The format of the command is Chapter 4 Communication e 3 MBh 1 len array where lenis the number of bytes is the array with the data The second level incorporates the Modbus structure This is necessary for sending configuration and special commands to an I O device The formats vary depending on the function code that 15 called For more information refer to the Command Reference The third level of Modbus communication uses standard Galil commands Once the slave has been configured the commands that may be used are IN AN SB CB OB and AO For example AO 2020 8 2 would tell I O number 2020 to output 8 2 volts If a specific slave address is not necessary the I O number to be used can be calculated with the following I O Number HandleNum 1000 Module 1 4 BitNum 1 Where HandleNum 15 the handle number from 1 A to 6 F Module is the position of the module in the rack from 1 to 16 BitNum is the I O point in the module from 1 to 4 If an explicit slave address 1s to be used the equation becomes Number SlaveAddress 10000 HandleNum 1000 Module 1 4 Bitnum 1 To view an example procedure for communicating with an OPTO 22 rack refer to the appendix Which devices receive what information from the controller depends a number of things Ifa device
61. forth For example when operating with servo motors the trip point AM After Motion is used to determine when the motion profiler is complete and is prepared to execute a new motion command However when operating in stepper mode the controller may still be generating step pulses when the motion profiler is complete This is caused by the stepper motor smoothing filter KS To understand this consider the steps the controller executes to generate step pulses 106 Chapter 6 Programming Motion DMC 2X00 DMC 2X00 First the controller generates a motion profile in accordance with the motion commands Second the profiler generates pulses as prescribed by the motion profile The pulses that are generated by the motion profiler can be monitored by the command RP Reference Position RP gives the absolute value of the position as determined by the motion profiler The command DP can be used to set the value of the reference position For example DP 0 defines the reference position of the A axis to be zero Third the output of the motion profiler is filtered by the stepper smoothing filter This filter adds a delay in the output of the stepper motor pulses The amount of delay depends on the parameter which Is specified by the command KS As mentioned earlier there will always be some amount of stepper motor smoothing The default value for KS is 1 313 which corresponds to a time constant of 3 939 sample periods Fourth the output of t
62. has a special label for automatic program execution A program which has been saved into the controller s non volatile memory can be automatically executed upon power up or reset by Chapter 7 Application Programming 123 beginning the program with the label AUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions on page 136 ININT Label for Input Interrupt subroutine LIMSWI Label for Limit Switch subroutine POSERR Label for excess Position Error subroutine Label for timeout on Motion Complete trip point CMDERR Label for incorrect command subroutine COMINT Label for communication interrupt on the aux serial port TCPERR Label for TCP IP communication error 2100 and 2200 only Commenting Programs There are two methods for commenting programs The first method uses the NO command and allows for comments to be embedded into Galil programs The second method used the REM statement and requires the use of Galil software NO Command The DMC 2x00 provides a command NO for commenting programs This command allows the user to include up to 78 characters on a single line after the NO command and can be used to include comments from the programmer as in the following example Instruction Interpretation PATH Label NO 2 D CIRCULAR PATH Comment No Operation VMAB Vector Mode NO VECTOR MOTION ON A AND B Comment No Operation VS 1000
63. high when the controller expects the amplifier to be enabled The polarity can be changed when using 8 Galil Interconnect Module To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the socketed IC 7407 with a 7406 These IC s are labeled U6 on the ICM 1900 and U2 on the ICM 2900 and can be accessed by removing the cover This option can be requested when ordering the unit by specifying the LAEN option Changing the Amplifier Enable Voltage Level To change the voltage level of the AEN signal note the state of the resistor pack labeled RP1 on the ICM 1900 ICM 2900 When Pin 1 is on the 5V mark the output voltage is 0 5V To change to 12 volts pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side If you remove the resistor pack the output signal is an open collector allowing the user to connect an external supply with voltages up to 24V DMC 2000 ICM 1900 ICM 2900 Connection to 5V or 12V made through Resistor pack RP1 Removing the resistor pack allows the user to connect their own resistor to the desired voltage level Up to24V Accessed by removing ICM cover AMPENX SERVO MOTOR AMPLIFIER 100 PIN CENE HIGH DENSITY CABLE 7407 Open Collector Buffer The Enable signal can be inverted by using a 7406 Accessed by removing ICM 2900 cover F
64. input 7 is high AI 6 Wait until input 6 is low Example Start Motion on Switch Motor A must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor A must stop turning Solution Connect panel switch to input of DMC 2x00 High on input 1 means switch is in on position Instruction Interpretation S JG 4000 Set speed AI 1 BGA Begin after input 1 goes high AI 1 STA Stop after input 1 goes low AMA JP S After motion repeat EN The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is of the full voltage range for example connect the input to 6 volts if the signal is a 0 12 volt logic Example DMC 2x10 has one auxiliary encoder This encoder has two inputs channel and channel Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for
65. is slowly engaged over 30 000 cts of the master axis greatly diminishing the initial shock to the slave axis Figure 1 below shows the velocity vs time profile for instantaneous gearing Figure 2 shows the velocity vs time profile for the gradual gearing engagement Figure 1 Velocity cts sec vs Time msec Instantaneous Gearing Engagement Figure 2 Velocity cts sec vs Time msec Ramped Gearing 92 e Chapter 6 Programming Motion DMC 2X00 DMC 2X00 The slave axis for each figure is shown in the bottom portion of the figure the master axis is shown in the top portion The shock to the slave axis will be significantly less in figure 2 than in figurel The ramped gearing does have one consequence There isn t a true synchronization of the two axes until the gearing ramp is complete The slave will lag behind the true ratio during the ramp period If exact position synchronization is required from the point gearing is initiated then the position must be commanded in addition to the gearing The controller keeps track of this position phase lag with the GP operand The following example will demonstrate how the command is used Example Electronic Gearing Over a Specified Interval Objective Run two geared motors at speeds of 1 132 and 045 times the speed of an external master Because the master is traveling at high speeds it is desirable for the speeds to change slowly Solution Use a DMC 1730 or DMC 1830 controller where the
66. of the form D z 4 4KD 1 z7 where 4 D 4 KD T and 4 KD D T Assuming a sampling period of T 1ms the parameters of the digital filter are KP 20 6 KD 68 6 The DMC 2x00 can be programmed with the instruction KP 20 6 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters Equivalent Filter Form DMC 2x00 Digital D z K z A z Cz z 1 1 B Z B Digital D z 4 KP 4 KD 1 z P 2 1 2 1 1 7 KP KD KI PL K KP KD 4 A KD KP KD C KI2 B PL Continuous G s P Ds I s 48 PID T 4 D 4T KD I KI2T a In 1 PL 190 gt Chapter 10 Theory of Operation DMC 2X00 Appendices Electrical Specifications Servo Control ACMD Amplifier Command A A B B IDX IDX Encoder and Auxiliary Stepper Control Pulse Direction Input Output Limit Switch Inputs Home Inputs IN 1 thru IN 8 Uncommitted Inputs and Abort Input IN 9 thru IN 16 Uncommitted Inputs DMC 2x50 through DMC 2x80 only AN 1 thru AN 8 Analog Inputs thru OUT 8 Outputs OUT 9 thru OUT 16 Outputs DMC 2x50 through DMC 2x80 only IN 81 IN 82 DMC 2X00 10 volt analog signal Resolution 16 bit DAC or 0 0003 volts 3 mA maximum TTL compatible but can accept up to 12 volts Quadrature phase on CHA CHB Can accept
67. queries the controller it will receive the response unless it explicitly tells the controller to send It to another device If the command that generates a response is part of a downloaded program the response will route to whichever port is specified as the default unless explicitly told to go to another port with the ENET switch ON designates Ethernet in which case it goes to the last handle to communicate with the controller OFF designates main RS232 To designate a specific destination for the information add Eh to the end of the command Ex MG EC Hello will send the message Hello to handle 3 TP EF will send the z axis position to handle 6 Multicasting A multicast may only be used in UDP IP and is similar to a broadcast where everyone on the network gets the information but specific to a group In other words all devices within a specified group will receive the information that is sent in a multicast There can be many multicast groups on a network and are differentiated by their multicast IP address To communicate with all the devices in a specific multicast group the information can be sent to the multicast IP address rather than to each individual device IP address Galil controllers belong to a default multicast address of 239 255 19 56 The controller s multicast IP address can be changed by using the IA u command Using Third Party Software Galil supports ARP BOOT P and Ping which are utilities fo
68. raises and lowers the cutting tool The solid curves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate is 0 1 g The motion starts at point A with the C axis raised An A B motion to point B is followed by lowering the and performing a cut along the circle Once the circular motion 18 completed the C axis is raised and the motion continues to point C etc Assume that all of the 3 axes are driven by lead screws with 10 turns per inch pitch Also assume encoder resolution of 1000 lines per revolution This results in the relationship Chapter 7 Application Programming 165 1 inch 40 000 counts and the speeds of 1 in sec 40 000 0 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 0 18 38 6 in s2 1 544 000 count s2 Note that the circular path has a radius of 2 or 80000 counts and the motion starts at the angle of 270 and traverses 360 in the CW negative direction Such a path is specified with the instruction CR 80000 270 360 Further assume that the C must move 2 at a linear speed of 2 per second The required motion is performed by the following instructions Instruction HA VM AB VP 160000 160000 VE VS 200000 VA 1544000 BGS AMS PR 80000 5 80000 BGC AMC CR 80000 270 360 VE VS
69. resistor pack RPx4 is removed Each bank of eight outputs shares one I OC connection which is connected to a DC power supply between 4 and 28 VDC The resistor pack RPx3 is optional used either as a pull up resistor from the output transistor s collector to the external supply connected to or the RPx3 15 removed resulting in an open collector output Here is a schematic of the digital output circuit Internal Pullup e OC To DMC 2x40 45V e 1 8 RPx3 1 4 NEC2505 1 8 RPx2 mere e p v bc 4 2 40 I O OUTC Figure 13 DMC 2X00 Appendices 5 The resistor pack RPx3 limits the amount of current available to source as well as affecting the low level voltage at the I O output The maximum sink current is 2mA regardless of RPx3 or I OC voltage determined by the NEC2505 optical isolator IC The maximum source current is determined by dividing the external power supply voltage by the resistor value of RPx3 The high level voltage at the I O output is equal to the external supply voltage at I OC However when the output transistor 1s on and conducting current the low level output voltage is determined by three factors The external supply voltage the resistor pack RPx3 value and the current sinking limit of the NEC2505 all determine the low level voltage The sink current available from the NEC2505 is between 0 and 2mA Therefore
70. s non volatile memory NOTE Galil strongly recommends that the IP address selected 1s not one that can be accessed across the Gateway The Gateway 15 an application that controls communication between an internal network and the outside world The third level of Ethernet addressing is the UDP or TCP port number The Galil controller does not require a specific port number The port number is established by the client or master each time it connects to the controller 52 e Chapter 4 Communication DMC 2X00 Communicating with Multiple Devices The DMC 2100 2200 is capable of supporting multiple masters and slaves The masters may be multiple PC s that send commands to the controller The slaves are typically peripheral I O devices that receive commands from the controller NOTE The term Master is equivalent to the internet client The term Slave is equivalent to the internet server An Ethernet handle is a communication resource within a device The DMC 2100 2200 can have a maximum of 6 Ethernet handles open at any time When using each master or slave uses individual Ethernet handle In UDP IP one handle may be used for all the masters but each slave uses one Pings and ARPs do not occupy handles If all 6 handles are in use and a 7 master tries to connect it will be sent a reset packet that generates the appropriate error in its windows application NOTE There are a number of ways to reset the controller H
71. signals resulting in a resolution of quadrature counts 4 x encoder cycles NOTE Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses into CHA and direction into Channel B and using the CE command to configure this mode 202 Appendices DMC 2X00 Encoder Index I Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Encoder A B I Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Auxiliary Encoder Aux Inputs for additional encoder Used when an encoder on both the Aux Aux I Aux A motor and the load is required Not available on axes configured Aux B Aux I for step motors Abort A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program Reset A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored Forward Limit Switch When active inhibits motion in forward direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Reverse Limit Switch When active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The
72. such as in DOS Window For general purposes the editing features this section are not applicable when not in DOS mode Instruction Interpretation Chapter 7 Application Programming 121 ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED ZBEGIN Puts Editor at label Line numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 80 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below Edit Mode Commands RETURN Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of RETURN will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a return is given lt cntrl gt P The lt cntrl gt P command moves the editor to the previous line lt entrl gt I The lt cntrl gt I command inserts a line above the current line For example if the editor is at line number 2 and lt cntrl gt I is applied a new line will be inserted between lines 1 and 2 This new line will be labeled line 2 The old line number 2 is renumbered as line 3 lt cntr1 gt D The lt c
73. that the controller works with one lt m command at a time As a consequence one function may be masked by another For example if the function 72100000 is followed by 75000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point As an example consider the following program Instruction Interpretation ALT Label for alternative program DP 0 0 Define Position of A and B axis to be 0 LMAB Define linear mode between A and B axes LI 4000 0 4000 gt 1000 Specify first linear segment with a vector speed of 4000 and end speed 1000 LI 1000 1000 gt 4000 71000 Specify second linear segment with a vector speed of 4000 and end speed 1000 LI 0 5000 lt 4000 21000 Specify third linear segment with a vector speed of 4000 and end speed 1000 LE End linear segments BGS Begin motion sequence EN Program end Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0 0001 This command takes effect immediately and causes VS to be scaled VR also applies when the vector speed is specified with the operator This 1s a useful feature for feed rate override VR does not ratio the accelerations For example VR 0 5 results in the specification VS 2000 to be divided in half 82 Chapter 6 Programming Motion DMC 2X00 DMC 2X00 Command Summary Linear In
74. the ICM 2900 When Pin 1 is on the 5V mark the output voltage is 0 5V To change to 12 volts pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side If you remove the resistor pack the output signal is an open collector allowing the user to connect an external supply with voltages up to 24V Step C Connect the encoders 22 e Chapter 2 Getting Started DMC 2X00 DMC 2X00 For stepper motor operation an encoder 1 optional For servo motor operation if you have a preferred definition of the forward and reverse directions make sure that the encoder wiring is consistent with that definition The DMC 2x00 accepts single ended or differential encoder feedback with or without an index pulse If you are not using the ICM 2900 you will need to consult the appendix for the encoder pinouts for connection to the motion controller The ICM 2900 accepts encoder feedback via individual signal leads Simply match the leads from the encoder you are using to the encoder feedback inputs on the interconnect board signal leads are labeled CHA channel A CHB channel B and INDEX For differential encoders the complement signals are labeled CHA CHB and INDEX NOTE When using pulse and direction encoders the pulse signal is connected to CHA and the direction signal is connected to CHB The controller must be configured for pulse and direction with the command CE See the command summary for further information on the comma
75. the X axis NOTE As stated in Chapter 2 the wiring is simplified when using a Galil Interconnect module such as the ICM 1900 or ICM 2900 These boards accept the cables of the DMC 2x00 and provide terminals for easy access Refer to figure 2 2 Bypassing the Opto Isolation If no isolation is needed the internal 5 volt supply may be used to power the switches This can be done by connecting a jumper between the pins LSCOM or INCOM and 5V labeled JP3 on the main board The Galil interconnect modules provide jumpers and the DMC 2x00 also provides a jumper for making this connection Analog Inputs The DMC 2x00 has eight analog inputs configured for the range between 10V and 10V The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 005 A 16 bit ADC is available as an option The impedance of these inputs is 10 KQ The analog inputs are specified as AN x where x is a number thru 8 Amplifier Interface The DMC 2x00 command voltage ranges between 10V This signal along with GND provides the input to the motor amplifiers The amplifiers must be sized to drive the motors and load For best performance the amplifiers should be configured for a torque current mode of operation with no additional compensation The gain should be set such that a 10 volt input results in the maximum required current The DMC 2x00 also provides an amplifier enable signal AMPEN This signal changes under the f
76. the maximum voltage drop across RPx3 is calculated by multiplying the 2mA maximum current times the resistor value of RPx3 For example if a 10k ohm resistor pack is used for RPx3 then the maximum voltage drop is 20 volts The digital output will never drop below the voltage at OUTC however Therefore a 10 resistor pack will result in a low level voltage of 0 7 to 1 0 volts at the I O output for an external supply voltage between 4 and 21 VDC If a supply voltage greater than 21 VDC is used a higher value resistor pack will be required Output Command Result CB Vout SB Vout Viso The resistor pack RPx3 is removed to provide open collector outputs The same calculation for maximum source current and low level voltage applies as in the above circuit The maximum sink current is determined by the 2505 and 15 approximately 2mA Open Collector To DMC 2x40 5 6 1 4 NEC2505 1 8 RPx2 gt e 10 DMC 2x40 I O 9 OUTC Figure A 14 Electrical Specifications e O points configurable as inputs or outputs in groups of 8 Digital Inputs e Maximum voltage 28 VDC e Minimum input voltage 4 VDC e Maximum input current 3 mA 226 Appendices DMC 2X00 High Power Digital Outputs Maximum external power supply voltage 28 VDC e Minimum external power supply voltage 4 VDC Maximum source current per output 500mA e Maximum sink current s
77. this chapter Selective Abort The controller can be configured to provide an individual abort for each axis Activation of the selective abort signal will act the same as the Abort Input but only on the specific axis To configure the controller for selective abort issue the command CN 1 This configures the inputs 5 6 7 8 13 14 15 16 to act as selective aborts for axes A B C D E F G H respectively Forward Limit Switch Low input inhibits motion in forward direction If the motor is moving in the forward direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMS WI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch 1s activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Software Protection The DMC 2x00 provides a programmable error limit The error limit can be set for any number between 1 and 32767 using the ER n co
78. to the label LOOP if the variable n 18 less than 10 For greater programming flexibility the DMC 2x00 provides user defined variables arrays and arithmetic functions For example with a cut to length operation the length can be specified as a variable in a program which the operator can change as necessary The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 80 characters x 1000 lines Using the DOS Editor to Enter Programs DMC 2000 only DMC 2X00 The DMC 2000 has an internal editor which may be used to create and edit programs in the controller s memory The internal editor is opened by the command ED Note that the command ED will not open the internal editor if issued from Galil s Window based software in this case a Windows based editor will be automatically opened The Windows based editor provides much more functionality and ease of use therefore the internal editor is most useful when using a simple terminal with the controller and a Windows based editor is not available Once the ED command has been given each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number or label by specifying a line number or label following ED NOTE ED command only accepts a parameter
79. transitions to determine the commutation phase Ideally the Hall sensor transitions will be separated by exactly 60 and any deviation from 60 will affect the accuracy of this method If the Hall sensors are accurate this method is recommended The BC command monitors the Hall sensors during a move and monitors the Hall sensors for a transition point When that occurs the controller computes the commutation phase and sets it For example to initialize the A axis motor upon power or reset the following commands may be given SHA Enable A axis motor BCA Enable the brushless calibration command 50000 Command a relative position movement A axis BGA Begin motion on A axis When the Hall sensors detect a phase transition the commutation phase is re set DMC 2X00 Chapter 2 Getting Started 9 Step 9c Connect Step Motors In Stepper Motor operation the pulse output signal has a 5096 duty cycle Step motors operate open loop and do not require encoder feedback When a stepper 1s used the auxiliary encoder for the corresponding axis 1s unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input corresponding to that axis The commanded position of the stepper can be interrogated with RP or TD The encoder position can be interrogated with TP The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a r
80. where 1 the master with a cycle of 2000 counts The cam table can be constructed manually point by point or automatically by a program The following program includes the set up The instruction EAA defines A as the master axis The cycle of the master is 2000 Over that cycle B varies by 1000 This leads to the instruction EM 2000 1000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18A and A varies in increments of 20 the phase varies by increments of 3 6 The program then computes the values of B according to the equation and assigns the values to the table with the instruction ET N Chapter 6 Programming Motion e 97 Instruction Interpretation SETUP Label EAA Select A as master EM 2000 1000 Cam cycles EP 20 0 Master position increments n 0 Index LOOP Loop to construct table from equation p n 3 6 Note 3 6 0 18 20 s Q SIN P 100 Define sine position 58 Define slave position ET n b Define table Update Counter 1 JP LOOP lt 100 Repeat the process EN End Program Step 9 Create program to run ECAM mode Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center of the cycle A
81. z density connector our eno 00 Solderless connections 2 178238 9 use screwdriver to ours our open contacts for oure oure insertion removal of our 00 ours lead wires part outs 00 jours replacement PCD part E Tm 0 v OO LSCOM 00 Howe 82 F sw Homey rsx 1 00 Jacsy risx IU UL INS D 00 12 25 me 00 1 IN8 LL v 00 ben viv 00 12v ANA GND 5 OQ ANALOGe6 00 ANALoce ANALOG7 anatoes 00 sv 00 0 00 max nx 0 00 00 5v OO may AN 00 OO may ny 00 0 eno 1 00 sv OQ 00 maz amz 1 00 maz INZ 00 2 00 2 sv maw 00 ww ano 0 0 mew Front Side Back Figure A 1 DMC 2X00 Appendices 1 ICM 2908 Interconnect Module The ICM 2908 interconnect module provides easy connections between the auxiliary encoder connections of the DMC 2x00 series controller and other system elements The ICM 2908 accepts the
82. 0 3 amplifiers and the AMP 1940 4 amplifiers Each amplifier 1 rated for 7 amps continuous 10 amps peak at up to 80 V The gain of the 19 0 is 1 amp V The 19 0 requires an external DC supply The AMP 19x0 connects directly to the DMC 2x00 and screw type terminals are provided for connection to motors encoders and external switches Features e 7 amps continuous 10 amps peak 20 to 80V e Available with 1 2 3 or 4 amplifiers e Connects directly to DMC 2x00 series controllers 218 Appendices DMC 2X00 Screw type terminals for easy connection to motors encoders and switches e Steel mounting plate with 4 keyholes Specifications Minimum motor inductance mH PWM frequency 30 kHz Ambient operating temperature 0 to 70 C Dimensions Weight Mounting Keyholes Gain amp V Opto lsolated Outputs for ICM 2900 ICM 1900 AMP 19x0 DMC 2X00 The ICM AMP 1900 and ICM 2900 modules from Galil have an option for opto isolated outputs Standard Opto Isolation and High Current Opto isolation The Opto isolation option on the ICM 1900 has 2 forms opto standard and optohc high current The standard version provides outputs with 4ma drive current output with approximately 2 usec response time The high current version provides 25ma drive current output with approximately 400 usec response time FROM ICM 1900 ICM 2900 CONTROLLER CONNECTIONS 5V ISO OUT PO
83. 0 500 800 Figure 1 Position vs Time msec Motion 1 Example Motion 2 The previous step showed the plot if the motion continued all the way to 5000 however partway through the motion the object that was being tracked changed direction so the host program determined that the actual target position should be 2000 cts at that time Figure 2 shows what the position profile would look like if the move was allowed to complete to 2000 cts The position was modified when the robot was at a position of 4200 cts Note that the robot actually travels to a distance of almost 5000 cts before it turns around This is a function of the deceleration rate set by the DC command When a direction change is commanded the controller decelerates at the rate specified by the DC command The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position In figure 3 the velocity profile is triangular because the controller doesn t have sufficient time to reach the set speed of 50000 cts sec before it is commanded to change direction Chapter 6 Programming Motion 5 Figure 2 Position vs Time msec Motion 2 Figure 3 Velocity vs Time msec Motion 2 Example Motion 4 In this motion the host program commands the controller to begin motion towards position 5000 changes the target to 2000 and then changes it again to 8000 Figure 4 shows the plot of position vs time
84. 0 6000 LE VS 6000 VA 20000 VD 20000 BGS Interpretation Specify linear interpolation axes Relative distances for linear interpolation Linear End Vector speed Vector acceleration Vector deceleration Start motion Circular Interpolation Objective Move the AB axes in circular mode to form the path shown on Fig 2 7 Note that the vector motion starts at a local position 0 0 which is defined at the beginning of any vector motion sequence See application programming for further information Instruction VM AB VP 4000 0 CR 2000 270 180 VP 0 4000 CR 2000 90 180 VS 1000 VA 50000 VD 50000 VE BGS 4000 4000 2000 4000 0 Interpretation Select AB axes for circular interpolation Linear segment Circular segment Linear segment Circular segment Vector speed Vector acceleration Vector deceleration End vector sequence Start motion 0 4000 Q 0 0 local zero Figure 2 7 Motion Path for Circular Interpolation Example DMC 2X00 Chapter 2 Getting Started 37 THIS PAGE LEFT BLANK INTENTIONALLY 38 e Chapter 2 Getting Started DMC 2X00 Chapter 3 Connecting Hardware Overview The DMC 2x00 provides opto isolated digital inputs for forward limit reverse limit home and abort signals The controller also has 8 opto isolated uncommitted inputs for general use as well as 8 TTL outputs and 8 analog inputs configured for voltages between 10 volts Controllers with 5
85. 0 Vector Speed NO VECTOR SPEED IS 10000 Comment No Operation VP 4000 0 Vector Position NO BOTTOM LINE Comment No Operation CR 1500 270 180 Circle Motion NO HALF CIRCLE MOTION Comment No Operation VP 0 3000 Vector Position NO TOP LINE Comment No Operation CR 1500 90 180 Circle NO HALF CIRCLE MOTION Comment No Operation VE Vector End NO END VECTOR SEQUENCE Comment No Operation BGS Begin Sequence NO BEGIN SEQUENCE MOTION Comment No Operation EN End of Program NO END OF PROGRAM Comment No Operation NOTE The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller HINT Some users annotate their programs using the word NOTE everything after the NO isa comment 124 e Chapter 7 Application Programming DMC 2X00 REM Command If you are using Galil software to communicate with the DMC 2x00 controller you may also include REM statements statements begin with the word and may be followed by any comments which are on the same line The Galil terminal software will remove these statements when the program is downloaded to the controller For example PATH REM 2 D CIRCULAR PATH VMAB REM VECTOR MOTION ON A AND B VS 10000 REM VECTOR SPEED IS 10000 VP 4000 0 REM BOTTOM LINE CR 1500 270 180 REM HALF CIRCLE MOTION 0 3000 REM TOP LINE CR 1500 90 180 REM HALF CIRCLE MOTION VE REM END VECTOR SEQUENCE
86. 00 000 0009 2009 o 060 060 XO 05 0 50 000 000 o 000 o9 00 00 29 0 0 Figure 18 238 Appendices DMC 2X00 TERM 1500 Operator Terminal Two types of terminals are offered from Galil the hand held unit and the panel mount unit Both have the same programming characteristics Hand held unit is shown below Figure A 19 DMC 2X00 Appendices e 239 The panel mount terminal is shown below 78 52 X 25 8 PLACES 9 4 LOT 4 500 9 E 2 8535 E EA S 5 667 dum dae Figure A 20 Features For easy data entry to DMC 2x00 motion controller 4 line x 20 character Liquid Crystal Display Full numeric keypad Five programmable function keys Available in Hand held or Panel Mount No external power supply required Connects directly to RS232 port P2 via coiled cable Description The TERM 2000 is a compact ASCII terminal for use with the
87. 00000 MG len6 54 MG 1 5 54 MG len4 S4 MG len3 S4 MG len2 54 MG len1 S4 EN Shift flen by 32 bits IE convert fraction flen to integer Mask top byte of flen and set this value to variable 1 Let variable len2 top byte of flen Let variable len3 bottom byte of len Let variable len4 second byte of len Let variable len5 third byte of len Let variable len6 fourth byte of len Display 6 as string message of up to 4 chars Display 5 as string message of up to 4 chars Display 4 as string message of up to 4 chars Display 3 as string message of up to 4 chars Display 2 as string message of up to 4 chars Display lenl as string message of up to 4 chars This program will accept a string input of up to 6 characters parse each character and then display each character Notice also that the values used for masking are represented in hexadecimal as denoted by the preceding For more information see section Sending Messages To illustrate further if the user types in the string at the input prompt the controller will respond with the following Response from command MG len6 54 Response from command MG 1 5 54 Response from command MG len4 54 Response from command MG len3 454 Response from command MG len2 54 Response from command MG len1 454 Chapter 7 App
88. 2 byte of header Header 3 byte of header Header 4 byte of header Header sample number I block general input 0 I block general input 1 I block general input 2 I block general input 3 I block general input 4 I block general input 5 I block general input 6 I block general input 7 I block general input 8 I block general input 9 I block general output 0 I block general output 1 I block general output 2 I block general output 3 I block general output 4 I block general output 5 I block general output 6 I block general output 7 I block general output 8 I block general output 9 I block error code I block general status I block segment count of coordinated move for S plane S block coordinated move status for S plane S block distance traveled in coordinated move for S plane S block segment count of coordinated move for T plane T block coordinated move status for T plane T block Chapter 4 Communication 55 SL UW UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL SL SL SW SW UW UB UB SL 56 e Chapter 4 Communication distance traveled in coordinated move for T plane a axis status a axis switches a axis stop code a axis reference position a axis motor position a axis position error a axis auxiliary position a axis velocity a axis torque a axis analog b axis status b axis switches b axis stop code b axis reference position
89. 2 TTL signals the first signal will be connected to AA and the second to AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Input Interrupt Function The DMC 2x00 provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the m n o command The m specifies the beginning input and n specifies the final input in the range The parameter o is an interrupt mask If m and n are unused o contains a number with the mask A 1 designates that input to be enabled for an interrupt where 2 is bit 1 2 is bit 2 and so on For example IL 5 enables inputs 1 and 3 2 2 5 A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RI command is used to return from this subroutine to the place in the program where the interrupt had occurred If it is desired to return to somewhere else in the program 160 gt Chapter 7 Application Programming DMC 2X00 after the execution of the ININT subroutine the Zero Stack ZS command is used followed by unconditional jump statements Important Use the RI command not EN to return from the ININT subroutine Example Input Interrupt Instruction Interpretation Label
90. 2 volts JG 10000 Set A speed BGA Start A motion In this example the A motor will probably not move since the output signal will not be sufficient to overcome the friction If the motion starts it can be stopped easily by a touch of a finger Increase the torque level gradually by instructions such as Instruction Interpretation TL 1 0 Increase torque limit to 1 volt TL 9 998 Increase torque limit to maximum 9 998 volts The maximum level of 9 998 volts provides the full output torque Interrogation The values of the parameters may be interrogated Some examples Instruction Interpretation KP Return gain of A axis Return gain of C axis KP Return gains of all axes Many other parameters such as KI KD FA can also be interrogated The command reference denotes all commands which can be interrogated Operation in the Buffer Mode The instructions may be buffered before execution as shown below Instruction Interpretation PR 600000 Distance SP 10000 Speed WT 10000 Wait 10000 milliseconds before reading the next instruction BGA Start the motion Using the On Board Editor Motion programs may be edited and stored in the controller s on board memory When the command ED is given from the Galil DOS terminal such as DMCTERM the controllers editor will be started The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited The editor provides th
91. 2100 2200 only sse 50 Communication Protocols ssnin aie iin 50 1 51 Communicating with Multiple Devices sss 53 Multicastttig espere tie OR 54 54 Data Record ea erp re Dim et ee best ENSE Ore ag REED PRENNE tee to o e 55 Data Record ARRA Re EE an sete AUT Rund 55 Explanation of Status Information and Axis Switch Information 57 Notes Regarding Velocity and Torque Information sese 59 OZ Commande oet tede 59 7 59 Unsolicited Messages Generated by Controller 60 Tools and Libraries nu oa Sept ea pp DU bacon Ra 60 Chapter 5 Command Basics 61 Introduction oseta ek eee Aa ee es Dto e ei 61 Command Syntax ASC eei ttr a e a 61 Coordinated Motion with more than 1 62 Command Syntax ios eee beue danke ens 63 Binary Command Format sees ener 63 Binary Command Table sse 64 Controller Response to 22 65 Interrogating the Controller sess 66 Interrogation Commands 66 Summary of Interrogation Commands essere 66 Interrogating Current Commanded Values sse 66 Operands e eet eed t OR REQUE 66 Command Summary esee eene enne nenne
92. 3 oe DPA EE 254 254 255 DMC 2X00 Chapter 1 Overview Introduction The DMC 2x00 Series are Galil s highest performance stand alone controller The controller series offers many enhanced features including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 2x00 provides two communication channels high speed RS 232 2 channels up to 115K Baud and Universal Serial Bus 12Mb s for the DMC 2000 or 10BaseT Ethernet for the DMC 2100 and 100BaseT Ethernet for the DMC 2200 A 4Meg Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field The DMC 2x00 is available with up to eight axes in a single stand alone unit The DMC 2x10 2x20 2x30 2x40 are one thru four axes controllers and the DMC 2x50 2x60 2x70 2x80 are five thru eight axes controllers Designed to solve complex motion problems the DMC 2x00 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences and contouring The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 2x00 provides continuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with multiple ma
93. 41 48 I OC41 48 I O40 1 039 1 038 1 037 1 036 1 035 1 034 1 033 OUTC33 40 I OC33 40 1 032 1 031 1 030 1 029 1 028 1 027 1 026 1 025 OUTC25 32 I OC25 32 OUTC25 32 I OC25 32 PWROUT32 PWROUT31 PWROUT30 PWROUT29 PWROUT28 PWROUT27 PWROUT26 PWROUT25 1 024 1 023 1 022 I O21 1 020 I O19 I O18 I O17 OUTC17 24 I OC17 24 OUTC17 24 DESCRIPTION BANK Out common for I O 41 48 3 I O common for I O 41 48 3 I O bit 40 2 I O bit 39 2 I O bit 38 2 I O bit 37 2 I O bit 36 2 I O bit 35 2 I O bit 34 2 I O bit 33 2 Out common for I O 33 40 2 I O common for I O 33 40 2 I O bit 32 1 I O bit 1 1 I O bit 0 1 I O bit 29 1 I O bit 8 1 I O bit 27 1 I O bit 6 1 I O bit 25 1 Out common for I O 25 32 1 I O common for I O 25 32 1 Out common for I O 25 32 1 I O common for I O 25 32 1 Power output 32 1 Power output 1 1 Power output 0 1 Power output 9 1 Power output 8 1 Power output 7 1 Power output 6 1 Power output 25 1 I O bit 4 0 I O bit 23 0 I O bit 22 0 I O bit 21 0 I O bit 20 0 I O bit 19 0 I O bit 18 0 I O bit 17 0 Out common for I O 17 24 0 I O common for I O 17 24 0 Out common for I O 17 24 0 Appendices 9 REV A B REV C LABEL DESCRIPTION BANK TERMINAL TERMINAL 96 96 I OC17 24 I O common for I O 17 24 0 97 95 PWROUT24 Power output 24 0 98 98 PWROUT23 Power output 23 0 99 97 PWROUT22 Power output 22 0 100 100 PWROUT21 Power output 21 0 101
94. 50 pin shrouded headers w center key JC8 pins 1 50 of J9 JC6 pins 51 100 of J9 CB 50 80 Adapter Board 0 CB 50 100 REVA GALIL MOTION CONTROL MADE IN USA JC8 JC6 4 OO 319 joo d loo N X joo a QUO loo loo 0 joo Noo DO loo Da 70 DO loo DO OO joo loo loo ool ool loo ool loo 0 9 2000000000 0 OO mU 35 ORs ee 200 0 0 0 0 o o IO 0 0 0 0 0 2000000 2000000000000 Cy OC o Figure A 16 1 8 D 4 places J9 100 pin connector part 9 Pin 1 DETAIL 2 J d c o _ 53 X7 4 eu DEC E NEM Nd fe gt 21 Ww The CB 50 80 adapter board can be used to convert the CABLE 80 to 2 50 Pin Ribbon Cables The 50 Pin Ribbon Cables provide a versatile method of accessing the extended I O signals without the use of the Galil IOM 1964 The ribbon cables provided by the CB 50 80 are compatible with I O mounting racks such as Grayhill 70GRCM32 HL and OPTO 22 G4PB24 When using the OPTO 22 G4P
95. 60 12 Specification DMC 2X00 Environmental Specifications Description Unit Specification Storage Temperature C 25 to 70 Operating Temperature C 0 to 0 Operating Altitude feet 10 000 Equipment Maintenance The DMC 2000 does not require maintenance Overview of Motor Types DMC 2X00 The DMC 2x00 can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Brushless servo motors with sinusoidal commutation 3 Step motors with step and direction signals 4 Other actuators such as hydraulics For more information contact Galil The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 2x00 achieves superior precision through use of a 16 Bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feedforward an extra pole filter and integration limits The controller is configured by the factory for standard servo motor operation In this configuration the controller provides an analog signal 10 volts to connect to a servo amplifier This connection is described in Chapter 2 Brushless Servo Motor with Sinusoidal Commutation The DMC 2x00 can provide sinusoidal commutation for brushless motors BLM In this configuration the controller generates two sinusoidal signals for connection with amplifiers specifically desi
96. 7 and the Command Reference Summary of Interrogation Commands For example the following example illustrates how to display the current position of the X axis TP A return Tell position A 0000000000 Controllers Response TP AB return Tell position A and B 0000000000 0000000000 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested 2 2 2 2 Request A B C D values Request value only The controller can also be interrogated with operands Operands Most DMC 2x00 commands have corresponding operands that can be used for interrogation Operands must be used inside of valid DMC expressions For example to display the value of an operand the user could use the command MG operand where operand is a valid DMC operand 66 Chapter 5 Command Basics DMC 2X00 All of the command operands begin with the underscore character For example the value of the current position on the A axis can be assigned to the variable with the command V TPA The Command Reference denotes all commands which have an equivalent operand as Used as an Operand Also see description of operands in Chapter 7 Command Summary For a complete command summary see Command Reference manual DMC 2X00 Chapter 5 Command Basics 67 THIS PAGE LEFT BLANK INTENTION
97. 88 3 5 10 BASE 2 AMP 227161 7 10 BASE F HP HFBR 1414 TX Transmitter HP HFBR 2416 RX Receiver LED Status F Uses Fiber Link C 1 On solid when using full duplex plugged into a switch 2 Off when using half duplex plugged into a hub 3 Blinks in the case of a collision L Ethernet link established will blink for any activity 100 Uses 100Base T speed Ethernet Cable Connections for DMC 2x00 The DMC 2x00 requires the transmit receive and ground for slow communication rates 1 e 1200 baud For faster rates the handshake lines are required The connection tables below contain the handshake lines These descriptions and tables are for RS 232 only RS 422 is available on request Standard RS 232 Specifications 25 pin Serial Connector Male D type This table describes the pinout for standard serial ports found on most computers Request to Send Clear to Send DMC 2X00 Appendices 9 NC Transmit Current Loop Data Receive Current Loop Data 0 ata Terminal Ready 0 ing Indicator 0 Receive Current Loop Return DENN Bp 9 Pin Serial Connector Male D type Standard serial port connections found on most computers 7 2 00 Serial Cable Specifications Cable to Connect Computer 25 pin to Main Serial Port 200 Appendices 25 Pin Male computer 9 Pin female contro
98. ALLY 68 Chapter 5 Command Basics DMC 2X00 Overview Chapter 6 Programming Motion The DMC 2x00 provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 2x10 is a single axis controller and uses A axis motion only Likewise the DMC 2x20 uses A and B the DMC 2x30 uses A B and C and the DMC 2x40 uses A B C and D The DMC 2x50 uses A B C D and E The DMC 2x60 uses A B C D E and The DMC 2x70 uses A B C D E F and The DMC 2x80 uses the axes A B C D E F G and The example applications described below will help guide you to the appropriate mode of motion Example Application Absolute or relative positioning where each axis is independent and follows prescribed velocity profile Velocity control where no final endpoint is prescribed Motion stops on Stop command Absolute positioning mode where absolute position targets may be sent to the controller while the axis is in motion Motion Path described as incremental position points versus time 2 3 or 4 axis coordinated motion where path is described by linear segments Independent Axis Positioning PA PR SP AC DC Independent Jogging Position Tracking Contour Mode Linear Interpolation Chapter 6 Programming Motion 69 2 D motion path consisting of arc segments and Coordinated Motion linea
99. B contains the state of the Abort Input _LFa contains the state of the forward limit switch for the a axis _LRa contains the state of the reverse limit switch for the a axis Example The following program has an error It attempts to specify a relative movement while the A axis 1s already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command The controller responds with the corresponding explanation Chapter 7 Application Programming 127 Instruction ED 000 001 PR1000 002 BGA 003 PR5000 004 EN lt cntrl gt Q XQ 2003 PR5000 1 97 Command not valid while running ED 3 003 AMX PR5000 BGA lt cntrl gt Q XQ A Program Flow Commands Interpretation Edit Mode Program Label Position Relative 1000 Begin Position Relative 5000 End Quit Edit Mode Execute Error on Line 3 Tell Error Code Command not valid while running Edit Line 3 Add After Motion Done Quit Edit Mode Execute The DMC 2x00 provides instructions to control program flow The DMC 2x00 program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements Event Triggers amp Trippoints To function independently from the host computer the DMC 2x00 can be programmed to make decisions based on the occurrence of an event Such
100. B200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis 50 Allow slight settle time YSI Enable SPM mode MOTION Perform motion Chapter 6 Programming Motion 111 SP16384 Set the speed PR10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction MOTION2 SP16384 Set the speed PR 10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction JPZMOTION ZCORRECT Correction code spx SPX ZLOOP Save speed value SP2048 Set a new slow correction speed WT100 Stabilize JP HEND ABS _ QSX lt 10 End correction if error is within defined tolerance YRX QSX Correction move MCX WT100 Stabilize JP LOOP Keep correcting until error is within tolerance END End CORRECT subroutine returning to code SPX spx EN Dual Loop Auxiliary Encoder The DMC 2x00 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation and any axis used in circular compare When used the second encoder is typically mounted on the motor or the load but may be mounted in any position The most common use for the second encoder is backlash compensation described below The second encoder may be a standard quadrature type or it may provide pulse and direction The controller also offers the provision for inverting the direction of the encoder rotation The main and the a
101. B24 I O mounting rack the user will only have access to 48 of the 64 I O points available on the controller Block 5 and Block 9 must be configured as inputs and will be grounded by the I O rack 234 Appendices DMC 2X00 Connectors 1028 and JC6 50 Pin Male IDC 19 80 Pin High Density Connector PART 3 178238 0 DMC 2X00 Appendices e 235 o 9 c c d o DMC 2X00 236 Appendices DMC 2X00 CB 50 80 Drawing 1 8 4 1 2 Figure A 17 CB 50 80 Outline 1 8 15 16 cBsos REV A1 GALIL MOTION CONTROL MADE IN USA Jg ue 1 8 D 4 places Mounting bracket for attaching inside PC JC6 JC8 50 pin shrouded headers w center key JC8 pins 1 50 of J9 JC6 pins 51 100 of J9 J9 80 pin connector part N10280 52E2VC part 0 Appendices e 237 CB 50 80 Layout JC6 IDC 50 Pin 1 8 D 4 places Pint 0 J9 80 pin connector O CB 50 80 AME part 3 178238 0 JC8 IDC 50 Pin SAN GON Pin 1 Pini CONTROL MADE IN USA DETAIL 1 one O Os O JC6 JC8 50 pin shrouded headers w center key o 9o 08 9009 00 08 09 0 95 9p 95 90 95 90 09 9009 9o 09 9009 8005 9009 0099 0009 960 96 9 G0 020 000 0
102. BGS REM BEGIN SEQUENCE MOTION EN REM END OF PROGRAM These REM statements will be removed when this program is downloaded to the controller Executing Programs Multitasking DMC 2X00 The DMC 2x00 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 through 7 where 0 1 the main thread Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The main thread differs from the others in the following ways Only the main thread thread 0 may use the input command IN 2 When automatic subroutines are implemented for limit switches position errors or command errors they are executed in thread 0 To begin execution of the various programs use the following instruction XQ A n Where n indicates the thread number To halt the execution of any thread use the instruction HXn where n is the thread number Note that both the XQ and HX commands can be performed by an executing program The example below produces a waveform on Output 1 independent of a move Chapter 7 Application Programming 125 Instruction Interpretation 5 Task1 label ATO Initialize reference time Clear Output 1 1 Loop label AT 10 Wait 10 msec from reference time SBI Set Output 1 AT 40 Wait 40 msec from reference then initialize reference Clear Output 1 JP LOOP1 Repeat Loopl 5 2 Tas
103. BS V1 gt 10 Array Element V1 lt Count 2 Variable V1 lt V2 Internal Variable _TPA 0 TVA 500 V1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 2x00 will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The operand between any two conditions requires that only one statement be true for the combined statement to be true NOTE Each condition must be placed in parentheses for proper evaluation by the controller In addition the DMC 2x00 executes operations from left to right For further information on Mathematical Expressions and the bit wise operators amp and see pg 142 For example using variables named V1 V2 V3 and V4 JP TEST V1 lt V2 amp V3 lt V4 DMC 2X00 Chapter 7 Application Programming 133 In this example this statement will cause the program to jump to the label ZTEST if V1 is less than V2 and V3 is less than V4 To illustrate this further consider this same example with an additional condition JP 1 lt 2 amp V3 lt V4 5 lt 6 This statement will cause the program to jump to the label TEST under two conditions 1 If V1 is less than V2 and V3 15 less than V4 OR 2 If V5 is less than V6 Examples If the co
104. D Prompt for value ZNUMLOOP CI 1 Check for enter NMLP Routine to check input from terminal JP ZNMLP P2CD 2 Jump to error if string JP ZERROR P2CD 2 Read value val P2NM EN End subroutine ZERROR CI 1 Error Routine MG INVALID TRY AGAIN Error message JP NMLP EN End Inputting String Variables String variables with up to six characters may be input using the specifier Sn where n represents the number of string characters to be input If n is not specified six characters will be accepted For example IN Enter A B or C V S specifies a string variable to be input The DMC 2x00 stores all variables as 6 bytes of information When a variable is specified as a number the value of the variable 15 represented as 4 bytes of integer and 2 bytes of fraction When a variable is specified as a string the variable can hold up to 6 characters each ASCII character is 1 byte When using the IN command for string input the first input character will be placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The characters can be individually separated by using bit wise operations see section Bit wise Operators Output of Data Numeric and String DMC 2X00 Numerical and string data can be output from the controller using several methods The message command MG can output string and numerical data Also the controller can be commanded to return the valu
105. ERR Start error routine on error MG error Send message SB 1 Fire relay STA Stop motor AMA After motor stops Chapter 8 Hardware amp Software Protection e 173 SHA Servo motor here to clear error RE Return to main program NOTE An applications program must be executing for the ZPOSERR routine to function Limit Switch Routine The DMC 2x00 provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automatic execution of a limit switch subroutine The ZLIMSWI label specifies the start of the limit switch subroutine This label causes the statements following to be automatically executed if any limit switch is activated and that axis motor 1 moving in that direction The RE command ends the subroutine The state of the forward and reverse limit switches may also be tested during the jump on condition statement The LR condition specifies the reverse limit LF specifies the forward limit or D following LR or LF specifies the axis The CN command can be used to configure the polarity of the limit switches Example Instruction Interpretation A JP Dummy Program LIMSWI Limit Switch Utility vl LFA Check if forward limit v2 LRA Check if reverse limit JP LF v1 0 Jump to LF if forward JP LR v2 0 Jump to LR if reverse JP END Jump to end LF LF MG FORWARD LIMIT Send message STX AMA Stop motion PR 1000 BGA AMA Move in reverse JP END End
106. Ethernet Using Galil Software for Windows The controller must be registered in the Windows registry for the host computer to communicate with it The registry may be accessed via Galil software such as WSDK or SmartTERM From WSDK the registry is accessed under the FILE menu From Smart TERM it is accessed under the TOOLS menu Use the NEW CONTROLLER button to add a new entry in the registry Choose DMC 2100 or DMC 2200 as the controller type Enter the IP address obtained from your system administrator Select the button corresponding to the UDP or TCP protocol in which you wish to communicate with the controller If the IP address has not been already assigned to the controller click on ASSIGN IP ADDRESS ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do not have an IP address The program will then ask you whether you would like to assign the IP 20 e Chapter 2 Getting Started DMC 2X00 DMC 2X00 address you entered to the controller with the specified serial number Click on YES to assign it NO to move to next controller or CANCEL to not save the changes If there are no controllers on the network that do not have an IP address assigned the program will state this When done registering click on OK If you do not wish to save the changes click on CANCEL Once the controller has been register select the correct controller from the list and click on OK If the software successfully est
107. Figure 6 7 Velocity Profile with Sinusoidal Acceleration The DMC 2x00 can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for is written as 501 955 sin 3T A complete program to generate the contour movement in this example 15 given below To generate an array we compute the position value at intervals of 8 ms This is stored at the array pos Then the difference between the positions is computed and 18 stored in the array dir Finally the motors are run in the contour mode Contour Mode Instruction POINTS DM pos 16 DM dir 15 c 0 d 0 d 0 t 0 A vl 50 t 2 3 v3 955 g SIN v2 v1 v4 INT v3 pos c v4 t t 8 1 JP A c lt 16 0 d c 1 dir c pos d pos c 1 Interpretation Program defines A points Allocate memory Set initial conditions c is index tis time in ms Argument in degrees Compute position Integer value of v3 Store in array pos Program to find position differences Compute the difference and store Chapter 6 Programming Motion 103 JP lt 15 EN End first program RUN Program to run motor CMA Contour Mode DT3 4 millisecond intervals c 0 HE CD dif c Contour Distance is in dif WC Wait for completion c ctl JP E c lt 15 DTO CDO Stop Contour EN End the program Teach Record and Play Back Several applications require teaching the machine a m
108. G TIMER ISOLATED LIMITS AND HOME INPUTS MAIN ENCODERS AUXILIARY ENCODERS HIGH SPEED WITH INTERFACE 10 VOLT OUTPUT FOR RS 232 A Mee RAM FOR SERVO MOTORS 4 Meg FLASH EEPROM RS 422 eg ABCD PULSE DIRECTION OUTPUT FOR STEP MOTORS HIGH SPEED ENCODER COMPARE OUTPUT I O INTERFACE 8 PROGRAMMABLE 8 PROGRAMMABLE OPTOISOLATED OUTPUTS INPUTS 8 UNCOMMITTED ANALOG INPUTS HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 2x00 Functional Elements Microcomputer Section The main processing unit of the DMC 2x00 is a specialized 32 Bit Motorola 68331 Series Microcomputer with 4 Meg RAM and 4 Meg Flash EEPROM The RAM provides memory for variables array elements and application programs The flash EEPROM provides non volatile storage of variables programs and arrays It also contains the DMC 2x00 firmware Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 12 MHz For standard servo operation the controller generates a 10 volt analog signal 16 Bit DAC For sinusoidal commutation operation the controller uses two DACs to generate two 10 volt analog signals For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the DMC 2x00 consists of high speed RS 232 and USB or high speed RS 232 and Ethernet The USB channel accep
109. HA and CHB CHB The DMC 2x00 decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization For stepper motors the DMC 2x00 can also interface to encoders with pulse and direction signals There is no limit on encoder line density however the input frequency to the controller must not exceed 3 000 000 full encoder cycles second 12 000 000 quadrature counts sec For example 1f the encoder line density 15 10000 cycles per inch the maximum speed is 300 inches second If higher encoder frequency 15 required please consult the factory The standard voltage level is TTL zero to five volts however voltage levels up to 12 volts are acceptable If using differential signals 12 volts can be input directly to the DMC 2x00 Single ended 12 volt signals require a bias voltage input to the complementary inputs The DMC 2x00 can accept analog feedback instead of an encoder for any axis To interface with other types of position sensors such as resolvers or absolute encoders Galil can customize the controller and command set Please contact Galil and talk to one of our applications engineers about your particular system requirements Watch Dog Timer The DMC 2x00 provides an internal watch dog timer which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AMPEN which can be used to switch the amplifiers off in the e
110. IC s I A gt zh IN Resistor Pack for outputs Output Buffer IC s 2 001 002 RS e OUT Indicator LED s r4 Resistor Pack for pp LED s ad C6 L2 OQ LOI QNI QN RP010 Bank 0 Figure A 7 All of the banks have the same configuration pattern as diagrammed above For example all banks have and Ux2 output optical isolator IC sockets labeled in bank 0 as 1101 and 002 in bank 1 as and U12 and so on Each bank is configured as inputs or outputs by inserting optical isolator 222 Appendices DMC 2X00 and resistor packs in the appropriate sockets A group of eight LED s indicates the status of each I O point The numbers above the Bank 0 label indicate the number of the I O point corresponding to the LED above it Digital Inputs To DMC 1748 DMC 2X00 DMC 1748 GND e Configuring a bank for inputs requires that the Ux3 and Ux4 sockets be populated with NEC2505 optical isolation integrated circuits The IOM 1964 is shipped with a default configuration of banks 2 7 configured as inputs The output IC sockets Ux1 and Ux2 must be empty The input IC s are labeled Ux3 and Ux4 For example in bank 0 the IC s U03 and U04 bank 1 input IC s are labeled 3 and U14 and so on Also the resistor pack RPx4 must be inserted into the bank to finish the input configuration nput Circuit VOC 1 4 NEC2505 1 8 RPx4 bank number 0 7
111. Instruction BEGIN 138 e Chapter 7 Application Programming Interpretation Begin main program DMC 2X00 TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command BGA Begin motion MCA Motion Complete trip point EN End main program ZMCTIME Motion Complete Subroutine MG fell short Send out a message EN End subroutine This simple program will issue the message fell short if the A axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error Instruction Interpretation BEGIN Begin main program IN ENTER SPEED speed Prompt for speed JG speed BGA Begin motion JP BEGIN Repeat EN End main program CMDERR Command error utility JP DONE ED lt gt 2 Check if error on line 2 JP DONE lt gt 6 Check if out of range MG SPEED TOO HIGH Send message MG TRY AGAIN Send message ZS1 Adjust stack JP BEGIN Return to main program DONE End program if other error ZSO Zero stack EN End program The above program prompts the operator to enter a jog speed If the operator enters a number out of range greater than 8 million the CMDERR routine will be executed prompting the operator to enter a new number In multitasking applications there is an alternate method for handling command errors from different threads Using the XQ command along with the special operands described below allows the controller to either skip or retry invalid commands
112. LE RLE HOMEE FLF RLF HOMEF FLD RLD HOMED FLG RLG HOMEG FLH RLH HOMEH Chapter 3 Connecting Hardware 41 LSCOM Additional Limit Switches Dependent on Number of Axes FLSA RLSA HOMEA FLSB RLSB HOMEB IN1 IN2 IN3 INA IN5 IN6 IN7 IN8 ALATCH BLATCH CLATCH DLATCH Figure 3 1 The Optoisolated Inputs NOTE Controllers with 5 or more axes have IN 9 through IN 16 also connected to INCOM Using an Isolated Power Supply To take full advantage of opto isolation an isolated power supply should be connected to the input common When using an isolated power supply do not connect the ground of the isolated power to the ground of the controller A power supply in the voltage range between 5 to 24 volts may be applied directly see Figure 3 2 For voltages greater than 24 volts a resistor R 15 needed in series with the input such that 1 mA gt V supply R 2 2K 2 gt 11 mA 42 Chapter 3 Connecting Hardware DMC 2X00 External Resistor Needed for Voltages gt 24V LSCOM O 2 2K X FLSA Configuration to source current at LSCOM terminal and sink switch External Resistor Needed for Voltages gt 24V LSCOM O 2 2K E x ee FLSA Configuration to sink current at LSCOM terminal and source switch Figure 3 2 Connecting a single Limit or Home Switch to an Isolated Supply This diagram only shows the connection for the forward limit switch of
113. LOAD Instruction LOAD DM VA 750 VB 750 count 0 n 10 LOOP VA count n VB count n n n 10 count count 1 JP LOOP count lt 750 count 0 LOOP2 JP LOOP2 LM 0 JS C count 500 LI VA count VB count count count 1 JP LOOP2 count 750 LE AMS MG DONE EN C BGS EN Interpretation Load Program Define Array Initialize Counter Initialize position increment LOOP Fill Array VA Fill Array VB Increment position Increment counter Loop if array not full Label Specify linear mode for AB Initialize array counter If sequence buffer full wait Begin motion on 500th segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Motion Subroutine Vector Mode Linear and Circular Interpolation Motion The DMC 2x00 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments The DMC 2x00 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task 86 e Chapter 6 Programming Motion The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third
114. Linear Interpolation 36 Circular Interpolation R R REN NE 37 Chapter 3 Connecting Hardware 39 2 39 Using Optoisolated Inputs 39 39 Home Switch Input ert 0 te be eee ts 40 Abort Input ne ER RR DATA Rs 40 hog 41 Uncommitted Digital Inputs i E enne 41 Wiring the Opto Isolated Inputs 41 The Opto Isolation Common Point 41 Using an Isolated Power 002 200 04 0000000 00000010000000000000000000000004000 1 42 Bypassing 43 Analog Inputs ee ee ed 43 Amplifier Interface o oe re ite ette ate 43 TEE Inputsc acoso erret EO 0 OE tee 44 enne 44 eee he RAE etn NO ere RUE RE Db EE Pe 45 General Use Outputs ede eed 45 Output Compare au or e tete ee de ace HO te DA teet beste ee qe 45 poste Eee ge 46 Extended I O of the DMC 2x00 Controller eese 46 ii e Contents DMC 2X00 Chapter 4 Communication 47 Introductions ea eo Ret ETE e Le ein doh 47 RAPTUM EE 47 RS232 Main Port P1 47 RS232 Auxiliary Port P2 DATASET 47 RS422 Matim Pott tee De 5 Rue 48 RS422 Auxili ty Pott P2Y ie Sou Ste ae irte pie Rus 48 RS 232 Configuration sen td aye RE C eie Ie ee 48 Ethernet Configuration DMC
115. NOTE The CC command must be specified to configure the port P2 of each unit Chapter 4 Communication e 9 Example Daisy Chain Objective Control a 7 axis motion system using two controllers a DMC 2040 4 axis controller and a DMC 2030 3 axis controller Address 0 18 the DMC 2040 and address 1 18 the DMC 2030 Desired motion profile Address 0 DMC 2040 A Axis is 500 counts B Axis is 1000 counts C Axis is 2000 counts D Axis is 1500 counts Address 1 DMC 2030 A Axis is 700 counts B Axis is 1500 counts C Axis is 2500 counts Command Interpretation 0 Talk only to controller 0 DMC 2040 PR 500 1000 2000 1500 Specify A B C D distances 1 Talk only to controller board 1 DMC 2030 PR 700 1500 2500 Specify distances Begin motion on both controllers Synchronizing Sample Clocks in Daisy Chain It is possible to synchronize the sample clocks of all DMC 2000 s in the daisy chain The first controller connected to the computer should have a jumper placed on the jumper JP3 to connect the pins labeled S and 8 Note that this connection requires a jumper to be placed sideways The subsequent controllers should have jumpers placed on the jumper JP3 JP4 to connect the pins labeled S and 8 on both jumpers Note that these connections require the jumpers to be placed sideways Ethernet Configuration DMC 2100 2200 only Communication Protocols The Ethernet is a local area network through which information is transferred i
116. O esses 222 Hardware eene enne eene enn 39 I O 158 Hardware Handshake 16 17 48 60 Home eren 40 117 119 191 emen 40 117 119 203 Uo 256 e Index Amplifier Enable 7 22 23 43 171 206 220 Digital Inputl 41 144 159 222 223 224 226 227 Digital Output 1 144 158 206 219 222 224 225 227 Home Input sess 40 117 119 191 Limit Switch 39 123 127 136 137 138 146 172 174 176 203 1900 43 206 215 218 219 220 ICM 290013 18 22 23 43 44 45 171 206 207 211 214 219 220 23 40 117 124 135 137 160 161 Input Interrupt 124 135 137 160 161 Integratori eee etos 30 31 180 186 Interconnect Module 19 0 206 215 218 219 1 1900 43 206 215 218 219 220 ICM 2900 13 18 22 23 43 44 45 171 206 207 211 214 219 220 Internal Variable 36 145 146 227 Interrogation 31 32 34 66 83 126 127 155 156 193 iiem nne pe 25 112 176 202 219 Jog 1 69 79 80 91 152 Jumper 14 15 16 19 30 43 50 106 202 204 215 e tete emer a 16 22 30 Program Label sssse 127 128 132 Special abel tac epe 123 136 6 66 119 203 Arm Late eet 120 Positi
117. ON Return acceleration rate for the axis specified by x DMC 2X00 Chapter 6 Programming Motion 79 Return deceleration rate for the axis specified by x Returns the jog speed for the axis specified by Returns the actual velocity of the axis specified by x averaged over 25 sec Examples Jog in X only Jog A motor at 50000 count s After A motor is at its jog speed begin jogging C in reverse direction at 25000 count s Instruction Interpretation Label AC 20000 20000 Specify A C acceleration of 20000 cts sec DC 20000 20000 Specify A C deceleration of 20000 cts sec JG 50000 25000 Specify jog speed and direction for A and C axis BGA Begin motion ASA Wait until A is at speed BGC Begin C motion EN Joystick Jogging The jog speed can also be changed using an analog input such as a joystick Assume that for a 10 volt input the speed must be 50000 counts sec Instruction Interpretation JOY Label JGO Set in Jog Mode BGA Begin motion 4B Label for loop vl AN 1 Read analog input vel v1 50000 10 Compute speed JG vel Change JG speed JP B Loop 80 Chapter 6 Programming Motion DMC 2X00 Linear Interpolation Mode DMC 2X00 The DMC 2x00 provides a linear interpolation mode for 2 or more axes In linear interpolation mode motion between the axes is coordinated to maintain the prescribed vector speed acceleration and deceleration along the specified path The motion path is descri
118. RTS and CTS lines are used The CTS line will go high whenever the DMC 2x00 is not ready to receive additional characters The RTS line will inhibit the DMC 2x00 from sending additional characters Note the RTS line goes high for inhibit The handshake should be turned on to ensure proper communication especially at higher baud rates Software handshaking can be enabled by setting the XON switch to ON In this mode the controller will generate accept XON and XOFF characters to control the flow of characters to from the terminal The controller uses the hex value 13 for the XOFF character and the hex value 11 for the XON character The auxiliary port of the DMC 2x00 can be configured either as a general port or for the daisy chain DMC 2000 only When configured as a general port the port can be commanded to send ASCII messages to another DMC 2x00 controller or to a display terminal or panel 48 e Chapter 4 Communication DMC 2X00 DMC 2X00 Configure Communication at port 2 The command is in the format of CC m n 1 p where m sets the baud rate n sets for either handshake or non handshake mode r sets for general port or the auxiliary port and p turns echo on or off m Baud Rate 300 1200 4800 9600 19200 38400 Handshake 0 No 1 Y es r Mode 0 General Port 1 Daisy chain p Echo 0 Off 1 On Valid only if r 0 Note for the handshake of the auxiliary port the roles for the RTS and CTS lines are reversed Exampl
119. SX X axis forward limit switch input s wc INCOM Input common Common for general inputs and Abort input XLATCH Input 1 Used for X axis latch input YLATCH Input 2 Used for Y axis latch input ZLATCH Input 3 Used for Z axis latch input 60 WLATCH Input 4 Used for W axis latch input 216 Appendices DMC 2X00 DMC 2X00 mM H 4 06 gt N 88 82 4 N 100 101 102 103 104 105 106 107 lt 2 2 2 gt lt lt Y ANA GND MBZ HNZ ND M Main encoder Main encoder A X X X Main encoder X Main encoder B X X Main encoder Index Main encoder Index Main encoder Index Main encoder Index Y Y Y W Main encoder A3 W Main encoder A Appendices 217 W Main encoder B W Main encoder Index W Main encoder Index ICM 1900 Drawing 13 500 12 560 1 1 620 0 220 6 880 4 940 2 000 Figure A 3 AMP 19x0 Mating Power Amplifiers The AMP 19x0 series are mating brush type servo amplifiers for the DMC 2x00 The AMP 1910 contains 1 amplifier the AMP 1920 2 amplifiers the AMP 193
120. Step resolution of the full step drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WTS50 Allow slight settle time YSI Enable SPM mode Chapter 6 Programming Motion 109 Half Stepping Drive X axis 5 OEI Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA2 Step resolution of the half step drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WTS50 Allow slight settle time YSI Enable SPM mode 1 642 Step Microstepping Drive X axis SETUP Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA64 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WTS50 Allow slight settle time YSI Enable SPM mode Example Error Correction The following code demonstrates what is necessary to set up SPM mode for the X axis detect error stop the motor correct the error and return to the main code The drive is a full step drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 2 2 2 Motor type set to stepper YA2 Step resolution of the drive YB200 Motor resolution
121. Switch Label 003 MG LIMIT OCCURRED Print Message 004 RE Return to main program lt control gt Quit Edit Mode XQ LOOP Execute Dummy Program JG 5000 Jog BGA Begin Motion Chapter 7 Application Programming 137 Now when a forward limit switch occurs on the A axis ZLIMSWI subroutine will be executed Notes regarding the LIMSWI Routine 1 The RE command is used to return from the ZLIMSWI subroutine 2 The LIMSWI subroutine will be re executed if the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error Instruction ED 000 LOOP 001 JP ZLOOP EN 002 POSERR 003 1 004 MG EXCESS POSITION ERROR 005 MG ERROR v1 006 RE lt control gt XQ 4LOOP JG 100000 Example Input Interrupt Instruction HA JG 30000 60000 BGAD LOOP JP LOOP EN ININT STAD AM TEST JP TEST IN 1 0 JG 30000 6000 BGAD RIO Interpretation Edit Mode Dummy Program Loop Position Error Routine Read Position Error Print Message Print Error Return from Error Quit Edit Mode Execute Dummy Program Jog at High Speed Begin Motion Interpretation Label Input Interrupt on 1 Jog Begin Motion Loop Input Interrupt Stop Motion Test for Input 1 still low Restore Velocities Begin motion Return from interrupt routine to Main Program and do not re enable trippoints Example Motion Complete Timeout
122. T 11 BIT BIT 9 BIT 8 10 N A N A N A N A BIT 3 BIT2 BIT 1 BIT 0 Motionis N A N A N A making final decel Notes Regarding Velocity and Torque Information The velocity information that is returned in the data record is 64 times larger than the value returned when using the command TV Tell Velocity See command reference for more information about TV The Torque information is represented as a number in the range of 32767 Maximum negative torque is 32767 Maximum positive torque is 32767 Zero torque is 0 QZ Command The QZ command can be very useful when using the QR command since it provides information about the controller and the data record The QZ command returns the following 4 bytes of information BYTE INFORMATION number of bytes in general block of data record number of bytes in coordinate plane block of data record Number of Bytes in each axis block of data record Most DMC 2x00 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon Instructions are sent in ASCII and the DMC 2x00 decodes each ASCII character one byte one at a time It takes approximately 0 5 msec for the controller to decode each command However the PC can send data to the controller at a much faster rate because of the FIFO buffer After the instruction 15 decoded the DMC 2x00 returns a response to the port from whic
123. This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately and the distance traveled since gearing changes take effect over a specified interval Chapter 6 Programming Motion 93 GR a b c d e f g h Sets gear ratio for slave axes 0 disables electronic gearing for specified axis GM a b c d e f g h X 1 sets gantry mode 0 disables gantry mode Trippoint for reverse motion past specified value Only one field may be used Trippoint for forward motion past specified value Only one field may be used Example Simple Master Slave Master axis moves 10000 counts at slew speed of 100000 counts sec B is defined as the master A C D are geared to master at ratios of 5 5 and 10 respectively Instruction Interpretation GA B B B Specify master axes as B GR 5 5 10 Set gear ratios PR 10000 Specify B position SP 100000 Specify B speed BGB Begin motion Electronic Gearing Objective Run two geared motors at speeds of 1 132 and 0 045 times the speed of an external master The master is driven at speeds between 0 and 1800 RPM 2000 counts rev encoder Solution Use a DMC 2x30 controller where the C axis is the master and A and B are the geared axes Instruction Interpretation MOC Turn C off for external master GA Specify C as the master axis for both A and B GR 1 132 045 Specify gear ratios Now suppose the gear ratio of the A axis is to chan
124. VD Note however that the controller works with one lt m command at a time As a consequence one function may be masked by another For example if the function 7100000 is followed by 75000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point Changing Feed rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed Is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided by two Compensating for Differences in Encoder Resolution By default the DMC 2x00 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in Chapter 11 Command Summary Trippoints The AV n command is the After Vector which waits for the vector relative distance of n to occur before executing the next comma
125. WER ICM 1900 PIN 19 OUT POWER ICM 2900 RP4 on ICM 1900 10K OHMS RP3 RP2 on ICM 2900 OUT x 66 73 OUTI TTL ISO POWER GND ICM 1900 PIN 35 OUT GND ICM 2900 Figure A 4 The ISO OUT POWER OUT POWER ON ICM 2900 and ISO POWER GND OUT GND ON ICM 2900 signals should be connected to an isolated power supply This power supply should be used only to power the outputs in order to obtain isolation from the controller The signal OUT x is one of the isolated digital outputs where X stands for the digital output terminals The default configuration is for active high outputs If active low outputs are desired reverse RP3 in it s socket This will tie RP3 to GND instead of VCC inverting the sense of the outputs NOTE If power is applied to the outputs with an isolated power supply but power is not applied to the controller the outputs will float high unable to sink current This may present a problem when using Appendices 219 active high logic and care should be taken Using active low logic should avoid any problems associated with the outputs floating high Configuring the Amplifier Enable for ICM 2900 ICM 1900 The ICM 1900 and ICM 2900 modules can be configured to provide an active low signal to enable external amplifiers These modules can also be configured for voltage levels other than TTL LAEN Option The standard configuration of the AEN signal is TTL active high In other words the AEN signal will be
126. ablished communications with the controller the registry entry will be displayed at the top of the screen NOTE The controller must be registered via an Ethernet connection Sending Test Commands to the Terminal After you connect your terminal press return or the lt enter gt key on your keyboard In response to carriage return return the controller responds with a colon Now type TPA lt return gt This command directs the controller to return the current position of the A axis The controller should respond with a number such as 0000000 Step 7 Determine the Axes to be Used for Sinusoidal Commutation This step is only required when the controller will be used to control a brushless motor s with sinusoidal commutation The command BA is used to select the axes of sinusoidal commutation For example BAAC sets A and C as axes with sinusoidal commutation Notes on Configuring Sinusoidal Commutation The command BA reconfigures the controller such that it has one less axis 01 standard control for each axis of sinusoidal commutation For example if the command BAA is given to a DMC 2x40 controller the controller will be re configured to be a DMC 2x30 controller In this case the highest axis is no longer available except to be used for 274 phase of the sinusoidal commutation Note that the highest axis on a controller can never be configured for sinusoidal commutation The DAC associated with the selecte
127. ailable to newer revision controllers Please consult Galil for adding this functionality to older revision controllers Communications Jumpers for DMC 2000 The Main and Auxiliary Serial Communication Ports are normally connected for RS 232 connection The jumpers JP3 and JP4 on the DMC 2001 daughter board allows the DMC 2000 to be configured for RS 422 This can be specified as an option when the unit is purchased or the DMC 2000 may be re configured by the user please consult Galil for instructions Other serial communication protocols such as RS 485 can be implemented as a special consult Galil Communications Jumpers for DMC 2100 DMC 2200 The main and Auxiliary Serial Commutations Ports are normally connected for RS 232 connection The jumpers JP4 and JP5 on the DMC 21001 daughter board allows the controller to be configured for RS 422 This can be specified as an option when the unit is purchased or the controller may be re configured by the user please consult Galil for instructions Other serial communications protocols such as RS 485 can be implemented as a special consult Galil Step 3a Configure DIP switches on the DMC 2000 Located on the outside of the controller box 15 a set of 5 switches When the controller is powered on or reset the state of the dip switches are read Switch 1 Master Reset When this switch 1 on the controller will perform a master reset upon PC power up Whenever the controller has a ma
128. aking XON XOFF through the main serial port Switch 3 Hardware Handshake Mode When on this switch will enable hardware handshaking through the main serial port Step 3c Configure DIP switches on the DMC 2200 Switch 1 Master Reset When this switch 15 on the controller will perform a master reset upon PC power up Whenever the controller has a master reset all programs and motion control parameters stored in EEPROM will be ERASED During normal operation this switch should be off Switch 2 XON XOFF When on this switch will enable software handshaking XON XOFF through the main serial port Switch 3 Hardware Handshake Mode When on this switch will enable hardware handshaking through the main serial port Chapter 2 Getting Started 17 Switch 4 5 and 6 Main Serial Port Baud Rate The following table describes the baud rate settings 9600 192 3800 BAUD RATE OFF 19200 OFF 38400 Switch 7 Option When OFF the controller will use the auto negotiate function to set the Ethernet connection speed When the switch is ON the controller defaults to 10BaseT Switch 8 Ethernet When ON the controller will use the Ethernet port as the default port for unsolicited messages When OFF the controller will use the RS 232 port as the default When the firmware 15 updated the controller will send the response a colon to the default port setting If this is not the same port that was used to download t
129. alog in 6 47 W 97 analog in 7 48 I W 98 analog in 8 9 49 12V 50 12 100 12v DMC 2x00 Axes E H High Density Connector 4 emorouput 7 54 limit common 9 motor command H 39 reverse limit G 12 motorcommandG 62 reverse limit F 15 sign G dirG 63 16 signF dirF 66 forward limit E 19 signE dirE 7 69 input common 24 amp enable E 74 input 13 7 25 5 input 4 6 input 15 7 input 16 8 abort 9 output 9 0 output 0 1 output 1 2 output 2 3 output 13 75 inptl4d 5 output 5 6 output 16 Appendices 5 17 abW 18 abW 196 gt Appendices aaH 35 abH 36 abH Bit IN n OUTIn Bit No N N CA ON 1 4 1 gt 0 gt gt ane G DMC 2X00 Appendices 197 DMC 2X00 1 N gt N 076 10 SR 3 RS 232 Main Port Standard connector and cable 9Pin 1 CTS OUTPUT RTS input RS 232 Auxiliary Port Standard connector and cable 9Pin Gnd CTS input USB In USB Out Series B 4 pos Series A 8 pos Connector Amp 787780 1 Connector Amp 787617 1 198 Appendices DMC 2X00 Ethernet 100 BASE T 10 BASE T Kycon GS NS
130. alog inputs MBF 6 6 1025 1 Save configuration to OPTO 22 DMC 2X00 Appendices 249 EN End CFGDOUT Label MODULE 2 Set variable CFGV ALUE 180 Set variable NUMOFIO 4 Set variable JP CFGJOIN Jump to subroutine CFGAOUT Label MODULE 3 Set variable CFGVALUE A7 Set variable NUMOFIO 2 Set variable JP CFGJOIN Jump to subroutine CFGAIN Label MODULE 5 Set variable CFGVALUE 12 Set variable NUMOFIO 2 Set variable JP CFGJOIN Jump to subroutine CFGJOIN Label DM A 8 Dimension array I 0 Set variable CFGLOOP Loop subroutine A I 0 Set array element Increment Set array element Increment JP CFGLOOP I lt 2 NUMOFIO Conditional statement MBF 6 16 632 MODULE 8 NU_ Configure I O using Modbus function code 16 where the starting MOFIO 2 A register is 6322 MODULE 8 number of registers is NUMOFIO 2 and contains the data EN end CFERR Label MG UNABLE TO ESTABLISH Message CONNECTION EN End Using the equation I O number Handlenum 1000 Module 1 4 Bitnum 1 MG IN 6001 display level of input at handle 6 module 1 bit 2 250 Appendices DMC 2X00 SB 6006set bit of output at handle 6 module 2 bit 3 or to one OB 6006 1 AO 608 3 6 set analog output at handle 6 module 53 bit 1 to 3 6 volts MG AN 6017 display voltage value of analog input at handle6 module 5 bit 2 DMC 2X00 Appendices 1 DMC 2x00 DMC 1500 Comparison Access to parameters
131. ample PAN 2000 BGN will cause the AB axes to move to the corresponding points on the motion cycle Sinusoidal Motion Example The x axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a frequency of 20 Hz This can be performed by commanding the A and N axes to perform circular motion Note that the value of VS must be VS 2n R F where R is the radius amplitude and F is the frequency in Hz Set VA and VD to maximum values for the fastest acceleration Chapter 6 Programming Motion 105 Instruction Interpretation VMAN Select Axes VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten Cycles VE BGS Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation In order to command stepper motor operation the appropriate stepper mode jumpers must be installed See chapter 2 for this installation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step output pulses 2 5 specifies a stepper motor with active low step output pulses and reversed direction 2 5 specifies a stepper motor with active high step output pul
132. and accurate response and the following presentation suggests a simple and easy way for compensation More advanced design methods are available with software design tools from Galil such as the Servo Design Kit SDK software The filter has three parameters the damping KD the proportional gain KP and the integrator KI The parameters should be selected in this order To start set the integrator to zero with the instruction return Integrator gain and set the proportional gain to a low value such as 1 return Proportional gain KD 100 return Derivative gain 30 e Chapter 2 Getting Started DMC 2X00 For more damping you can increase KD maximum is 4095 Increase gradually and stop after the motor vibrates A vibration is noticed by audible sound or by interrogation If you send the command TEA return Tell error a few times and get varying responses especially with reversing polarity it indicates system vibration When this happens simply reduce KD Next you need to increase the value of KP gradually maximum allowed is 1023 You can monitor the improvement in the response with the Tell Error instruction 10 return Proportion gain return Tell error As the proportional gain is increased the error decreases Again the system may vibrate if the gain is too high In this case reduce Typically KP should not be greater than KD 4 only when the amplifier is configured in t
133. andes un np oda eS e UE a exte net 127 E e edem 127 127 127 Example E 127 Program Flow Commands e neue Re b e e RR ee 128 128 Conditional 132 If Else and 134 SUDTOULINES e EE 136 Stack Manipulation se eene ener enne 136 ROUDE OR 136 Automatic Subroutines for Monitoring Conditions sss 137 Mathematical and Functional 142 142 Bite Wise Operators ys tip e e T a 142 Eunctlotis EN UR IB RED RU 144 144 Programmable Variables 0000 00000 145 146 Special Operands 45 146 147 Defining Arrays ice ee e 147 nennen nennen enne 147 Uploading and Downloading Arrays to On Board 148 Automatic Data Capture into Arrays ssssssssseeeeeeenee eene 148 Deallocating Array Sp ace esee desees ie ede e edel 150 150 Inputiof ee IRR 150 Operator Data Entry Mode sse 151 152 153 Sending Messages ssi ecce pedet tie a eee redes 154 Displaying Variables and Arrays sse 155 Interrogation Comman
134. ange between 0 5 and 8 where 8 implies the largest amount of smoothing See Command Reference regarding KS The DMC 2x00 profiler commands the step motor amplifier All DMC 2x00 motion commands apply such as PR PA VP CR and JG The acceleration deceleration slew speed and smoothing are also used Since step motors run open loop the PID filter does not function and the position error 15 not generated To connect step motors with the DMC 2x00 you must follow this procedure Step Install SM jumpers Each axis of the DMC 2x00 that will operate a stepper motor must have the corresponding stepper motor jumper installed For a discussion of SM jumpers see section Step 2 Install Jumpers on the DMC 2x00 Step B Connect step and direction signals from controller to motor amplifier From the controller to respective signals on your step motor amplifier These signals are labeled PULSX and DIRX for the A axis on the ICM 2900 Consult the documentation for your step motor amplifier Step C Configure DMC 2x00 for motor type using MT command You can configure the DMC 2x00 for active high or active low pulses Use the command MT 2 for active low step motor pulses and MT 2 for active high step motor pulses See description of the MT command in the Command Reference Step 10 Tune the Servo System Adjusting the tuning parameters is required when using servo motors standard or sinusoidal commutation The system compensation provides fast
135. ant the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback 15 sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction 15 called overdamped response Chapter 10 Theory of Operation 179 The results may be worse if we turn the faucet too fast The overreaction results in temperature oscillations When the response of the system oscillates we say that the system is unstable Clearly unstable responses are bad when we want a constant level What causes the oscillations The basic cause for the instability is a combination of delayed reaction and high gain In the case of the temperature control the delay is due to the water flowing in the pi
136. ardware reset push reset button or power down controller and software resets through Ethernet or RS232 by entering RS The only reset that will not cause the controller to disconnect 15 a software reset via the Ethernet When the Galil controller acts as the master the IH command is used to assign handles and connect to its slaves The IP address may be entered as a 4 byte number separated with commas industry standard uses periods or as a signed 32 bit number port number may also be specified but if it is not it will default to 1000 The protocol TCP IP or UDP IP to use must also be designated at this time Otherwise the controller will not connect to the slave Ex 151 25 255 9 lt 179 gt 2 This will open handle 2 and connect to the IP address 151 25 255 9 port 179 using An additional protocol layer is available for speaking to I O devices Modbus is an RS 485 protocol that packages information in binary packets that are sent as part of a TCP IP packet In this protocol each slave has a 1 byte slave address The DMC 2100 2200 can use a specific slave address or default to the handle number The port number for Modbus is 502 The Modbus protocol has a set of commands called function codes The DMC 2100 2200 supports the 10 major function codes Function Code Definition 01 02 03 04 05 06 07 15 16 17 DMC 2X00 Report Slave ID The DMC 2100 2200 provides three levels of Modbus communication The
137. are needed in each case When the NPN output is 5 volts then no current flows and the input reads 1 When the NPN output goes to 0 volts then it sinks current and the input reads 0 The PNP output works in a similar fashion but the voltages are reversed i e 5 volts on the PNP output sources current into the digital input and the input reads 0 As before the 5 volt is an example the I OC can accept between 4 28 volts DC Note that the current through the digital input should be kept below 3 mA in order to minimize the power dissipated in the resistor pack This will help prevent circuit failures The resistor pack RPx4 is standard 1 5k ohm which is suitable for power supply voltages up to 5 5 VDC However use of 24 VDC for example would require a higher resistance such as a 10k ohm resistor pack The 1 4 axis models of the DMC 2x00 all work with the IOM 1964 all have identical extended I O features High Power Digital Outputs The first two banks on the IOM 1964 banks 0 and 1 have high current output drive capability The IOM 1964 is shipped with banks 0 and 1 configured as outputs Each output can drive up to 500mA of continuous current Configuring a bank of I O as outputs is done by inserting the optical isolator NEC2505 IC s into the Ux1 and Ux2 sockets The digital input IC s Ux3 and Ux4 are removed The resistor packs RPx2 and RPx3 are inserted and the input resistor pack RPx4 is removed Each bank of eight outputs shares one I OC
138. ariables may be sent to the screen using the format variable For example v1 returns the value of the variable v1 Example Using Variables for Joystick The example below reads the voltage of an A B joystick and assigns it to variables VA and VB to drive the motors at proportional velocities where 10 volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 Instruction Interpretation JOYSTIK Label JG 0 0 Set in Jog mode BGAB Begin Motion LOOP Loop va AN 1 20000 Read joystick A vb AN 2 20000 Read joystick B JG va vb Jog at variable va vb JP LOOP Repeat EN End Operands Operands allow motion or status parameters of the DMC 2x00 to be incorporated into programmable variables and expressions Most DMC 2x00 commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 2x00 command The command reference indicates which commands have an associated operand Status commands such as Tell Position return actual values whereas action commands such as KP or SP return the values in the DMC 2x00 registers The axis designation is required following the command Instruction Interpretation posA _TPA Assigns value from Tell Position A to the variable posA JP LOOP TEA gt 5 Jump to LOOP if the position error of A is greater than 5 JP ERROR TC 1 Jump to ERROR if the error code equals 1 Operands can be used in an expression and assigned to a programmable variable but t
139. as three elements in series PID low pass and a notch filter The transfer function of the filter The transfer function of the filter elements are PID D z Ed rem Z Z 1 1 B Low pass L z 2 Notch N z gt 2 Z pXZ The filter parameters K A C and B are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are 4 KD KP KD C KI2 B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD 1 8 a S a P 4KP D 4T KD I KI 2T a 1 T In 1 B where T 1 the sampling period 184 gt Chapter 10 Theory of Operation DMC 2X00 For example if the filter parameters of the DMC 2x00 are 4 KD 36 2 PL 0 75 T 8 the digital filter coefficients are 160 9 1 250 rad s and the equivalent continuous filter G s 15 G s 16 0 1445 1000 s 250 250 The notch filter has two complex zeros Z and z and two complex poles P and p The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of the resonance poles The notch poles P and p are programmable and are selected to have sufficient damping It is best to select the notch parameters by the frequency terms The poles and zeros have a frequency in Hz selected by the command NF The real part of the poles is se
140. ated output POWER option Perron mm ow Lm 1 2 3 4 5 7 10 1 12 13 14 15 16 17 18 19 20 21 22 3 Appendices 215 SIGNW W axis sign output for input to stepper motor amp PWMW EX W axis pulse output for input to stepper motor amp MOCMDZ EX Z axis motor command to amp input w respect to ground SIGNZ Z axis sign output for input to stepper motor amp PWMZ o Z axis pulse output for input to stepper motor amp MOCMDY Y axis motor command to amp input w respect to ground SIGNY EN Y axis sign output for input to stepper motor amp PWMY o Y axis pulse output for input to stepper motor amp MOCMDX X axis motor command to amp input w respect to ground SIGNX o X axis sign output for input to stepper motor amp PWMX o X axis pulse output for input to stepper motor amp ISOOUTGND Isolated Output Ground xw we e AMPENW ED W axis amplifier enable AMPENZ 7 axis amplifier enable AMPENY Y axis amplifier enable AMPENX o X axis amplifier enable LSCOM Limit Switch Common HOMEN RLSW W axis reverse limit switch input FLSW W axis forward limit switch input HOMEZ RLSZ Z axis reverse limit switch input FLSZ Z axis forward limit switch input HOMEY RLSY Y axis reverse limit switch input FLSY Y axis forward limit switch input HOMES RLSX X axis reverse limit switch input FL
141. auxiliary encoder inputs are not available for any axis that is configured for stepper motor TTL Outputs DMC 2X00 The DMC 2x00 provides dedicated and general use outputs General Use Outputs The DMC 2x00 provides eight general use outputs an output compare and an error signal output The general use outputs are TTL and are accessible through the ICM 2900 as OUTI thru OUT8 These outputs can be turned On and Off with the commands SB Set Bit CB Clear Bit OB Output Bit and OP Output Port For more information about these commands see the Command Summary The value of the outputs can be checked with the operand and the function see Chapter 7 Mathematical Functions and Expressions Controllers with 5 or more axes have an additional eight general use TTL outputs NOTE The ICM 2900 has an option to provide opto isolation on the outputs In this case the user provides an isolated power supply 5volts to 24volts and ground For more information consult Galil Output Compare The output compare signal is TTL and 15 available on the ICM 2900 as CMP Output compare 18 controlled by the position of any of the main encoders on the controller The output can be programmed to produce an active low pulse lusec based an incremental encoder value or to activate once when an axis position has been passed For further information see the command OC in the Command Reference Chapter 3 Connecting Hardware 45
142. axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specified for coordinated motion at any given time The command VM m n p where m and are the coordinated pair and p is the tangent axis NOTE the commas which separate m n and p are not necessary For example VM ABC selects the AD axes for coordinated motion and the C axis as the tangent Specifying the Coordinate Plane The DMC 2x00 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T DMC 2X00 To specify vector commands the coordinate plane must first be identified This 1s done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applied to the active coordinate system until changed with the CA command Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence 15 ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence NOTE This local definition of zero does not affect the absolute coordinat
143. ays must be defined using the command DM before assigning entry values DM speed 10 Dimension Speed Array speed 1 7650 2 Assigns the first element of the array the value 7650 2 800060 1 Returns array element value posXA 10 TPA Assigns the 10th element the position of A Chapter 7 Application Programming 147 con 2 2 COS POS 2 Assigns the 2 element of array the cosine of POS 2 timer 1 TIME Assigns the 1 element of the array TIME Using a Variable to Address Array Elements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter Instruction Interpretation Begin Program count 0 DM POS 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec POS count _TPA Record position into array element POS count Report position count count 1 Increment counter JP LOOP count lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named POS The variable COUNT is used to increment the array element counter The above example can also be executed with the automatic data capture feature described below Uploading and Downloading Arrays to On Board Memory Arrays may be uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A
144. b axis motor position b axis position error b axis auxiliary position b axis velocity b axis torque b axis analog c axis status c axis switches c axis stop code c axis reference position c axis motor position axis position error c axis auxiliary position c axis velocity 0 axis torque c axis analog d axis status d axis switches d axis stop code d axis reference position d axis motor position d axis position error d axis auxiliary position d axis velocity d axis torque d axis analog e axis status e axis switches e axis stop code e axis reference position T block A block A block A block A block A block A block A block A block A block A block B block B block B block B block B block B block B block B block B block B block C block C block C block C block C block C block C block C block C block C block D block D block D block D block D block D block D block D block D block D block E block E block E block E block DMC 2X00 DMC 2X00 SL e axis motor position SL e axis position error SL e axis auxiliary position SL e axis velocity SW e axis torque SW e axis analog UW f axis status UB f axis switches UB f axis stop code SL f axis reference position SL f axis motor position SL f axis position error SL f axis auxiliary position SL f axis velocity SW f axis torque SW f axis analog UW g axis status UB g axis switches UB g axis stop code SL g axis re
145. be accomplished by several methods If you are driving a brush type DC motor the simplest way 15 to invert the two motor wires typically red and black For example switch the and M2 connections going from your amplifier to the motor When driving a brushless motor the polarity reversal may be done with the encoder If you are using a single ended encoder interchange the signal CHA and CHB If on the other hand you are using a differential encoder interchange only CHA and CHA The loop polarity and encoder polarity can also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section Sometimes the feedback polarity 1s correct the motor does not attempt to run away but the direction of motion 15 reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals If the motor moves in the required direction but stops short of the target it is most likely due to insufficient torque output from the motor command signal ACMD This can be alleviated by reducing system friction on the motors The instruction TTA return Tell torque on A reports the level of the output signal It will show a non zero value that 15 below the friction level Once you have established that you have closed the loop with the correct polarity you can move on to the compensation phase servo system tuning to adjust the PID f
146. be decreased For example 2 0 1 ill drive both A and C axes to zero will apply 2V and 1V respectively to A and C and will end up ith A in SH and C in MO Step F part 2 Systems with Hall Sensors Only Set Zero Commutation Phase With Hall sensors the estimated value of the commutation phase is good to within 30 This estimate can be used to drive the motor but a more accurate estimate is needed for efficient motor operation There are 3 possible methods for commutation phase initialization Method 1 Use the BZ command as described above Method 2 Drive the motor close to commutation phase of zero and then use BZ command This method decreases the amount of system jerk by moving the motor close to zero commutation phase before executing the BZ command The controller makes an estimate for the number of encoder counts between the current position and the position of zero commutation phase This value is stored in the operand 32 Using this operand the controller can be commanded to move the motor The BZ command is then issued as described above For example to initialize the A axis motor upon power or reset the following commands may be given SHA Enable A axis motor 1 BZA Move A motor close to zero commutation phase BGA Begin motion on A axis AMA Wait for motion to complete on A axis BZA 1 Drive motor to commutation phase zero and leave motor on Method 3 Use the command BC This command uses the Hall
147. be formatted using the Fn m expression following the completed MG statement n m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is result F5 2 If the value of the variable result is equal to 4 1 this statement returns the following The Final Value 15 00004 10 If the value of the variable result 15 equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppressed by sending N at the end of the statement This is useful when a text string needs to surround a numeric value Example JG 50000 ASA MG The Speed is TVA 75 1 N MG counts sec 154 gt Chapter 7 Application Programming DMC 2X00 DMC 2X00 EN When is executed the above example will appear on the screen as The speed 1s 50000 counts sec Using the MG Command to Configure Terminals The MG command can be used to configure a terminal Any ASCII character can be sent by using the format n where n is any integer between 1 and 255 Example MG 407 4255 sends the ASCII characters represented by 7 and 255 to the bus Summary of Message
148. be placed in the position tracking mode to support changing the target of an absolute position move on the fly New targets may be given in the same direction or the opposite direction of the current position target The controller will then calculate a new trajectory based upon the new target and the acceleration deceleration and speed parameters that have been set The motion profile in this mode is trapezoidal There is not a set limit governing the rate at which the end point may be changed however at the standard TM rate the controller updates the position information at the rate of Imsec The controller generates a profiled point every other sample and linearly interpolates one sample between each profiled point Some examples of applications that may use this mode are satellite tracking missile tracking random pattern polishing of mirrors or lenses or any application that requires the ability to change the endpoint without completing the previous move The PA command is typically used to command an axis or multiple axes to a specific absolute position For some applications such as tracking an object the controller must proceed towards a target and have the ability to change the target during the move In a tracking application this could occur at any time during the move or at regularly scheduled intervals For example if a robot was designed to follow a moving object at a specified distance and the path of the object wasn t known the robot w
149. bed in terms of incremental distances for each axis An unlimited number of incremental segments may be given in a continuous move sequence making the linear interpolation mode ideal for following a piece wise linear path There 18 no limit to the total move length The LM command selects the Linear Interpolation mode and axes for interpolation For example LM BC selects only the B and C axes for linear interpolation When using the linear interpolation mode the LM command only needs to be specified once unless the axes for linear interpolation change Specifying the Coordinate Plane The DMC 2x00 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T To specify vector commands the coordinate plane must first be identified This 1s done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applied to the active coordinate system until changed with the CA command Specifying Linear Segments The command LI a b c d e f g h specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis position Up to 511 incremental move segments may be given prior to the Begin Sequence BGS command Once motion has begun additional LI segments may be sent to the controller The clear sequence CS command can be used to remove LI segments stored in the bu
150. ber NOTE The value of P2CD returns to zero after the corresponding string or number is read Chapter 7 Application Programming 151 These keywords may be used in an applications program to decode data and they may also be used in conditional statements with logical operators Example Instruction Interpretation JP LOOP P2CD lt gt 3 Checks to see if status code is 3 number received JP P P1CH V Checks if last character received was a V PR P2NM Assigns received number to position JS XAXIS PIST X Checks to see if received string is X Using Communication Interrupt The DMC 2x00 provides a special interrupt for communication allowing the application program to be interrupted by input from the user The interrupt is enabled using the CI command The syntax for the command is CI n n 0 Don t interrupt Port 2 n l Interrupt on lt enter gt Port 2 n 2 Interrupt on any character Port 2 n l Clear any characters in buffer The COMINT label is used for the communication interrupt For example the DMC 2x00 can be configured to interrupt on any character received on Port 2 The COMINT subroutine is entered when a character is received and the subroutine can decode the characters At the end of the routine the EN command is used EN 1 will re enable the interrupt and return to the line of the program where the interrupt was called EN will just return to the line of the program where it was called without re enabling the interrupt
151. ble v7 v2 5 SIN pos The variable v2 is equal to five times the sine of the variable pos v3 IN 1 The variable v3 is equal to the digital value of input 1 v4 2 5 ANJ 5 The variable v4 is equal to the value of analog input 5 plus 5 then multiplied by 2 Variables For applications that require a parameter that is variable the DMC 2x00 provides 254 variables These variables can be numbers or strings A program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by program calculations For example a cut to length application may require that a cut length be variable Instruction Interpretation PR posa Assigns variable posa to PR command JG rpmb 70 Assigns variable rpmb multiplied by 70 to JG command 144 e Chapter 7 Application Programming DMC 2X00 Programmable Variables The DMC 2x00 allows the user to create up to 254 variables Each variable is defines by a name which can be up to eight characters The name must start with an alphabetic character however numbers are permitted in the rest of the name Spaces are not permitted Variable can be upper or lowercase or any combination Variables are case sensitive SPEEDC speedC Variable names should not be the same as DMC 2x00 instructions For example PR is not a good choice for a variable name Examples of valid and invalid variable names are Valid Var
152. broutine stack by using the ZS command Every time a JS instruction interrupt or automatic routine such as POSERR or LIMSWI is executed the subroutine stack is incremented by 1 Normally the stack is restored with an EN instruction Occasionally it is desirable not to return back to the program line where the subroutine or interrupt was called The 751 command clears 1 level of the stack This allows the program sequencer to continue to the next line 250 command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is often desirable to restart the program sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of the LIMSWI routine Auto Start Routine The DMC 2x00 has a special label for automatic program execution A program which has been saved into the controller s non volatile memory can be automatically executed upon power up or reset by 136 gt Chapter 7 Application Programming DMC 2X00 DMC 2X00 beginning the program with the label AUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 2x00 program sequences The DMC 2x00 can monitor several important conditions in the background These conditions include checking for the occurrence of a l
153. buffer is full 512 means buffer is empty Operand Summary Coordinated Motion Sequence operand Description _ The absolute coordinate of the axes at the last intersection along the sequence Number of available spaces for linear and circular segments in DMC 2x00 sequence buffer Zero means buffer is full 512 means buffer is empty Segment counter Number of the segment in the sequence starting at zero Vector length of coordinated move sequence When AV is used as an operand returns the distance traveled along the sequence The operands and can be used to return the coordinates of the last point specified along the path Example Tangent Axis Assume an AB table with the C axis controlling a knife The C axis has a 2000 quad counts rev encoder and has been initialized after power up to point the knife in the direction A 180 circular cut 18 desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion 5 CCW ending at 3000 0 Note that the 0 position in the AB plane is in the direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First A B and C are driven to the starting point and later the cut is performed Assume that the knife 18 engaged with output bit 0 Instruction Interpretation Example program VM ABC AB coordinate with C as tangent TN 2000 360 500 2000 360
154. by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 246 e Appendices DMC 2X00 DMC 2X00 20000 10000 10000 20000 Figure A 21 X Y Motion Path The first line describes the straight line vector segment between points and The next segment is a circular arc which starts at an angle of 180 and traverses 90 Finally the third line describes the linear segment between points C and D Note that the total length of the motion consists of the segments A B Linear 10000 units R A d2 B C Circular 15708 C D Linear 10000 Total 35708 counts In general the length of each linear segment is Le Where Xk and Yk are the changes in X and Y positions along the linear segment The length of the circular arc is Lx Ri A x 2 0 The total travel distance is given by D S fs k l The velocity profile may be specified independently in terms of the vector velocity and acceleration Appendices 247 For example the velocity profile corresponding to the path of Fig A 21 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Fig A 22 Velocity 10000 time s T 0 05 T 0 357 T 0 407 a 5 8 Figure 4 22 Vector Velocity Profile The acceleration time is given by Los 100909 0 055 VA 2000000 The slew time Ts is given by D 35708 Ts
155. celeration AC and the deceleration DC rate for each axis The direction of motion 15 specified by the sign of the JG parameters When the begin command is given BG the motor accelerates up to speed and continues to jog at that speed until a new speed or stop ST command is issued If the jog speed is changed during motion the controller will make an accelerated or decelerated change to the new speed An instant change to the motor position can be made with the use of the IP command Upon receiving this command the controller commands the motor to a position which 1 equal to the specified increment plus the current position This command is useful when trying to synchronize the position of two motors while they are moving Note that the controller operates as a closed loop position controller while in the jog mode The DMC 2x00 converts the velocity profile into a position trajectory and a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging COMMAND DESCRIPTION Specifies acceleration rate Begins motion Specifies deceleration rate Increments position instantl Time constant for independent motion smoothing Specifies jog speed and direction Stops motion Parameters can be set with individual axes specifiers such as JGB 2000 set jog speed for B axis to 2000 Operand Summary Independent Axis OPERAND DESCRIPTI
156. click on the ASSIGN IP ADDRESS The Galil Terminal Software will respond with a list of all controllers on the network that do not currently have IP addresses The user selects the controller and the software will assign the controller the specified IP address Then enter the terminal and type in BN to save the IP address to the controller s non volatile memory CAUTION Be sure that there is only one BOOT P server running If your network has DHCP or BOOT P running it may automatically assign an IP address to the controller upon linking it to the network In order to ensure that the IP address is correct please contact your system administrator before connecting the controller to the Ethernet network DMC 2X00 Chapter 4 Communication e 51 Ethernet Parameters IP Address 1 24 51 29 31 Assign IP Address Do Not Open Multi cast Handle Ethernet Protocol Unsolicited Messages TCP Use current CF Setting C Ns Receive Through Second Handle is sent to redirect messages Receive Through Same Handle sent to redirect messages lt Back Cancel The second method for setting an IP address is to send the 1 command through the DMC 2100 2200 main RS 232 port The IP address you want to assign may be entered as a 4 byte number delimited by commas industry standard uses periods or a signed 32 bit number Ex IA 124 51 29 31 or IA 2083724575 Type in BN to save the IP address to the controller
157. connection which is connected to a DC power supply between 4 and 28 VDC A 10k ohm resistor pack should be used for RPx3 Here is a circuit diagram e To DMC 2x40 45V e 1 4 NEC2505 1 8 RPx2 gt eee 1 186210 pt uisi PWROUT DMC 2x40 I O 1 8 RPx3 e 1 0 e OUTC Figure A 11 The load is connected between the power output and output common The I O connection is for test purposes and would not normally be connected An external power supply is connected to the I OC and OUTC terminals which isolates the circuitry of the DMC 2x40 controller from the output circuit 224 e Appendices DMC 2X00 e Viso PWROUT our External 5 Isolated 8 1 Power i Supply GND OUTC Iso Figure A 12 The power outputs must be connected in a driving configuration as shown on the previous page Here are the voltage outputs to expect after the Clear Bit and Set Bit commands are given Output Command Result CB Vowr Viso SB Vowr Standard Digital Outputs The I O banks 2 7 can be configured as optically isolated digital outputs however these banks do not have the high power capacity as in banks 0 1 In order to configure a bank as outputs the optical isolator chips Ux1 and Ux2 are inserted and the digital input isolator chips Ux3 and Ux4 are removed The resistor packs RPx2 and RPx3 are inserted and the input
158. control at the application program level SPM mode can be used with Galil and non Galil step drives SPM mode is configured executed and managed with seven commands This mode also utilizes the POSERR automatic subroutine allowing for automatic user defined handling of an error event Internal Controller Commands user can query QS Error Magnitude pulses User Configurable Commands user can query amp change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status A pulse is defined by the resolution of the step drive being used Therefore one pulse could be a full step a half step or a microstep 108 gt Chapter 6 Programming Motion DMC 2X00 DMC 2X00 When a Galil controller is configured for step motor operation the step pulse output by the controller 18 internally fed back to the auxiliary encoder register For SPM the feedback encoder on the stepper will connect to the main encoder port Enabling the SPM mode on a controller with 1 executes internal monitoring of the auxiliary and main encoder registers for that axis or axes Position error 15 then tracked in step pulses between these two registers QS command TPxYAxYB YC QS TD Where TD is the auxiliary encoder register step pulses and TP 15 the mai
159. count per revolution results in a rotary resolution of 0 25 micron This results in equal resolution on both linear and rotary sensors To illustrate the control method assume that the rotary encoder is used as a feedback for the X axis and that the linear sensor is read and stored in the variable LINPOS Further assume that at the start both the position of X and the value of LINPOS are equal to zero Now assume that the objective 1s to move the linear load to the position of 1000 The first step is to command the X motor to move to the rotary position of 1000 Once it arrives we check the position of the load If for example the load position is 980 counts it implies that a correction of 20 counts must be made However when the X axis is commanded to be at the position of 1000 suppose that the actual position is only 995 implying that X has a position error of 5 counts which will be eliminated once the motor settles This implies that the correction needs to be only 15 counts since 5 counts out of the 20 would be corrected by the X axis Accordingly the motion correction should be Correction Load Position Error Rotary Position Error The correction can be performed a few times until the error drops below 2 counts Often this 8 performed in one correction cycle Instruction Interpretation Label DPO Define starting positions as zero linpos 0 PR 1000 Required distance BGA Start motion B AMA Wait for completio
160. counts degree position 500 is 0 degrees in AB plane CR 3000 0 180 3000 count radius start at 0 and go to 180 CCW VE End vector 0 Disengage knife Chapter 6 Programming Motion 9 PA 3000 0 TN Move A and B to starting position move C to initial tangent position BG ABC Start the move to get into position AM ABC When the move is complete SBO Engage knife WT50 Wait 50 msec for the knife to engage BGS Do the circular cut AMS After the coordinated move is complete CBO Disengage knife MG ALL DONE EN End program Coordinated Motion Traverse the path shown in Fig 6 3 Feed rate is 20000 counts sec Plane of motion is AB Instruction Interpretation VM AB Specify motion plane VS 20000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration VP 4000 0 Segment AB CR 1500 270 180 Segment BC VP 0 3000 Segment CD 1500 90 180 Segment DA VE End of sequence BGS Begin Sequence The resulting motion starts at the point A and moves toward points B C D A Suppose that we interrogate the controller when the motion is halfway between the points A and B The value of AV is 2000 The value of CS is 0 VPAand VPB contain the absolute coordinate of the point A Suppose that the interrogation 1s repeated at a point halfway between the points C and D The value of AV 185 2 The value of CS is 2 _ VPB contain the coordinates of the point C 90 e Chapter 6 Programming Motion DMC
161. crement Counter DONE Done EN End Program Deallocating Array Space Array space may be deallocated using the DA command followed by the array name DA 0 deallocates all the arrays Data Numeric and String Input of Data The command IN is used to prompt the user to input numeric or string data Using the IN command the user may specify a message prompt by placing a message in quotations When the controller executes an IN command the controller will wait for the input of data The input data is assigned to the specified variable or array element Example Inputting Numeric Data IN Enter Length lenA EN In this example the message Enter Length is displayed on the computer screen The controller waits for the operator to enter a value The operator enters the numeric value which is assigned to the variable lenA NOTE Do not include a space between the comma at the end of the input message and the variable name Example Cut to Length In this example a length of material is to be advanced a specified distance When the motion is complete a cutting head is activated to cut the material The length 1s variable and the operator is prompted to input it in inches Motion starts with a start button which is connected to input 1 150 gt Chapter 7 Application Programming DMC 2X00 DMC 2X00 The load is coupled with a 2 pitch lead screw A 2000 count rev encoder is on the motor resulting in a resolution of 4000 co
162. ction Tell Position Interrogation Command Response Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrogation commands may be formatted locally To format locally use the command Fn m or n m on the same line as the interrogation command The symbol F specifies that the response should be returned in decimal format and specifies hexadecimal n is the number of digits to the left of the decimal and m 15 the number of digits to the right of the decimal F2 2 05 00 05 00 00 00 07 00 TP 4 2 FFFB 00 0005 00 0000 00 0007 00 Tell Position in decimal format 2 2 Response from Interrogation Command Tell Position in hexadecimal format 4 2 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by VF mn where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format The default format for VF is VF 10 4 Hex values are returned preceded by a and in 2 s complement Instruction 1 10 vl 0000000010 0000 VF2 2 vl 10 00 vF 2 2 vl 0A 00 VFI vl 19 Local Formatting of Variables Interpretation Assign v1 Return v1 Response Default format Change format Return v1 Res
163. d axis represents the first phase The second phase uses the highest available DAC When more than one axis 18 configured for sinusoidal commutation the controller will assign the second phases to the DACs which have been made available through the axes reconfiguration The highest sinusoidal commutation axis will be assigned to the highest available DAC and the lowest sinusoidal commutation axis will be assigned to the lowest available DAC Note that the lowest axis 1s the A axis and the highest axis 18 the highest available axis for which the controller has been configured Example Sinusoidal Commutation Configuration using a DMC 2x70 BAAC This command causes the controller to be reconfigured as a DMC 2x50 controller The A and C axes are configured for sinusoidal commutation The first phase of the A axis will be the motor command A signal The second phase of the A axis will be F signal The first phase of the C axis will be the motor command C signal The second phase of the C axis will be the motor command G signal Chapter 2 Getting Started 21 Step 8 Make Connections to Amplifier and Encoder Once you have established communications between the software and the DMC 2x00 you are ready to connect the rest of the motion control system The motion control system typically consists of an ICM 2900 Interface Module an amplifier for each axis of motion and a motor to transform the current from the amplifier into torque for motion If
164. d is described in the appendix When using the OPTO 22 G4PB24 I O mounting rack the user will only have access to 48 of the 64 I O points available on the controller Block 5 and Block 9 must be configured as inputs and will be grounded by the I O rack 46 e Chapter 3 Connecting Hardware DMC 2X00 Chapter 4 Communication Introduction The DMC 2x00 has two RS232 ports and either one USB input port and 2 USB output ports or Ethernet ports The main RS 232 port is the data set and can be configured through the switches on the front panel The auxiliary RS 232 port is the data term and can be configured with the software command CC The auxiliary RS 232 port can be configured either for daisy chain operation DMC 2000 only or as a general port This configuration can be saved using the Burn BN instruction The RS232 ports also have a clock synchronizing line that allows synchronization of motion on more than one controller RS232 Ports DMC 2X00 The RS232 pin out description for the main and auxiliary port is given below Note that the auxiliary port 1s essentially the same as the main port except inputs and outputs are reversed The DMC 2x00 may also be configured by the factory for RS422 These pin outs are also listed below NOTE If you are connecting the RS232 auxiliary port to a terminal or any device which is a DATASET it is necessary to use a connector adapter which changes a dataset to a dataterm This cable is also known as a
165. d with the SBn and CBn commands where n 1 through 8 and 17 through 80 Outputs may also be defined with the conditional command OBn where n 1 through 8 and 17 through 80 The command OP may also be used to set output bits specified as blocks of data The OP command accepts 5 parameters The first parameter sets the values of the main output port of the controller Outputs 1 8 block 0 The additional parameters set the value of the extended I O as outlined OP m a b c d where m is the decimal representation of the bits 1 8 values from 0 to 255 and a b c d represent the extended I O in consecutive groups of 16 bits values from 0 to 65535 Arguments which are given for I O points which are configured as inputs will be ignored The following table describes the arguments used to set the state of outputs Argument Blocks Bits Description m 0 1 8 General Outputs a 2 3 17 32 Extended I O b 4 5 33 48 Extended I O 6 6 7 49 64 Extended I O d 8 9 65 80 Extended I O DMC 2X00 Chapter 7 Application Programming 163 For example if block 8 is configured as an output the following command may be issued 07 This command will set bits 1 2 3 block 0 and bits 65 66 67 block 8 to 1 Bits 4 through 8 and bits 68 through 80 will be set to 0 other bits are unaffected When accessing I O blocks configured as inputs use the TIn command The argument n refers to the block to be read 0 2 3 4 5 6 7 8 or 9 The value returned w
166. dard Digital Outputs essere enne nnne 225 Electrical Specifications nette n e HU 226 Relevant DMC Commands 6 2 hti e b bt tabs 227 Screw Tertmmnal Listing disset ede RD ERU ERU ined 227 CB 50 100 Adapter Board eene nennen nnne nennen nnns 230 God c a 230 CB 50 100 Dra Wing ioci pea e a oe 233 50 80 eene nennen enne 234 oou d c 235 CB 50 80 Drawing io ete ege ie 237 TERM 1500 Operator Terminal 7 209 egeo eie RENE LI E eee 240 Description 240 Specifications Hand Held sse 240 ennemis 221 DMC 2x00 Contentse vii viii e Contents Index 221 Keypad Map Panel Mount 6 columns 5 rows 3 3 3 3232 7 242 Config ration sa adeo e ete OR ee s E been E b ee RU ERR CH QUU 243 Function Keys aueh nte Bd ORNS ein ee Ration 244 Input Output of Data DMC 2x00 Commands sese 244 Ordering Information essere 000 245 Coordinated Motion Mathematical Analysis sese 246 Example Communicating with OPTO 22 3000 249 7 222 List of Other Publications 2 2 23 Tr mite Seminars oer e iEn is eru 25
167. de on A axis DT2 Set contour data rate to be 2 msec i 0 Set array index to 0 LOOP3 Subroutine to execute contour points Contour data command Wait for next contour point 1 Update index JP LOOP3 i lt 500 Continue until all array elements have been executed DTO Set contour update rate to 0 CDO Disable the contour mode combination of and EN End program For additional information about automatic array capture see Chapter 7 Arrays Virtual Axis DMC 2X00 The DMC 2x00 controller has an additional virtual axis designated as the N axis This axis has no encoder and no DAC However it can be commanded by the commands AC DC JG SP PR PA BG IT GA VM VP CR ST DP RP EA The main use of the virtual axis is to serve as a virtual master in ECAM modes and to perform an unnecessary part of a vector mode These applications are illustrated by the following examples Ecam master example Suppose that the motion of the AB axes 15 constrained along path that can be described by an electronic cam table Further assume that the ecam master is not an external encoder but has to be a controlled variable This can be achieved by defining the N axis as the master with the command EAN and setting the modulo of the master with a command such as EMN 4000 Next the table is constructed To move the constrained axes simply command the N axis in the jog mode or with the PR and PA commands For ex
168. der ANALOGe 00 ANALOG7 00 ANALOGS 00 aNALoG4 5 00 max INX 0 0 D GND n 5 00 vv AN 0 may 00 0 0 0 sv D0 2 inz 0 00 maz nz 00 vez 2 5 00 00 maw Nw 0 00 maw 00 ew 00 mew Figure 2 6 System Connections with a separate amplifier MSA 12 80 This diagram shows the connections for a standard DC Servo Motor and encoder 26 e Chapter 2 Getting Started DMC 2X00 Step 9b Connect Sinusoidal Commutation Motors When using sinusoidal commutation the parameters for the commutation must be determined and saved in the controller s non volatile memory The setup for sinusoidal commutation is different when using Hall Sensors Each step which is affected by Hall Sensor Operation is divided into two parts part 1 and part 2 After connecting sinusoidal commutation motors the servos must be tuned as described in Step 10 Step A Disable the motor amplifier Use the command MO to disable the motor amplifiers For example MOA will turn the A axis motor off Step B Connect the motor amplifier to the controller The sinusoidal commutation amplifier requires 2 signals usually denoted as Phase A amp Phase B These inputs should be connected to
169. der counts For example if the X axis is a linear motor where the magnetic cycle length 18 62 mm and the encoder resolution is 1 micron the cycle equals 62 000 counts This can be commanded with the command BM 62000 On the other hand if the C axis 15 a rotary motor with 4000 counts per revolution and 3 magnetic cycles per revolution three pole pairs the command is BM 1333 333 Step D part 1 Systems with or without Hall Sensors Test the Polarity of the DACs Use the brushless motor setup command BS to test the polarity of the output DACs This command applies a certain voltage V to each phase for some time T and checks to see if the motion is in the correct direction DMC 2X00 Chapter 2 Getting Started e 27 The user must specify the value for V and T For example the command BSA 0 will test the A axis with a voltage of 2 volts applying it for 700 millisecond for each phase In response this test indicates whether the DAC wiring 1s correct and will indicate an approximate value of BM If the wiring is correct the approximate value for BM will agree with the value used in the previous step NOTE In order to properly conduct the brushless setup the motor must be allowed to move a minimum of one magnetic cycle in both directions NOTE When using Galil Windows software the timeout must be set to a minimum of 10 seconds time out 10000 when executing the BS command This allows the software to retrieve all me
170. ds eere t ve Rest e Deep te esee eva 155 157 Converting to User Units E RENI eee 158 Hardware VO pe 158 Digital Outputs RR Tee ae 158 Digital Inputs eerie eet tete tse eee ees 159 The Auxiliary Encoder Hee ee 160 Input Interrupt FUNCIO 160 Analoe Inputs 2 ccce RR Re abutere ei end 161 Contentse v Extended I O of the DMC 2x00 20000 0011 00081 1 nennen 162 Configuring the I O of the 2 00 162 Saving the State of the Outputs in 1 163 Accessing Extended 163 Interfacing to Grayhill or OPTO 22 6 24 000 164 Example ener nnne nr enne n reinen 40 164 Wire Cutlery o unte ET 0 7 164 A B Table Controller ede e Re dre 165 Speed Control by Joystick 167 Position Control by Joystick essere enne 168 Backlash Compensation by Sampled Dual Loop sess 168 Chapter 8 Hardware amp Software Protection 171 Introduction et ce DOR o e D P ne 171 Hardware Protectioti eH du eai e tr DOES 171 Output Protection ener nenne nnne 171 Input Protection Lines
171. e CC 1200 0 0 1 Configure auxiliary communication port for 1200 baud no handshake general port mode and echo turned on Daisy Chaining DMC 2000 only Up to eight DMC 2000 controllers may be connected in a daisy chain allowing for multiple controllers to be commanded from a single serial port One DMC 2000 is connected to the host terminal via the RS232 at port 1 or the main port Port 2 or the auxiliary port of that DMC 2000 is then brought into port 1 of the next DMC 2000 and so on The address of each DMC 2000 is configured by setting the three address dipswitches A0 A1 A2 located on the front of the controller When connecting multiple controllers in a daisy chain the cable between controllers should be female on both ends with all wires connected straight through ADRI represents the 2 bit ADR2 represents 2 bit and ADR4 represents 2 bit of the address The eight possible addresses 0 through 7 are set as follows To communicate with any one of the DMC 2000 units give the command A where A is the address of the board instructions following this command will be sent only to the board with that address Only when a new command is given will the instruction be sent to another board The only exception is command To talk to all the DMC 2000 boards in the daisy chain at one time insert the character before the software command boards receive the command but only address 0 will echo
172. e instruction The space between PR and 4000 15 optional For specifying data for the A B C and D axes commas are used to separate the axes If no data 1s specified for an axis a comma is still needed as shown in the examples below If no data is specified for an axis the previous value is maintained DMC 2X00 Chapter 5 Command Basics 61 To view the current values for each command type the command followed by a for each axis requested PR 1000 Specify A only as 1000 PR 2000 Specify B only as 2000 3000 Specify C only as 3000 4000 Specify D only as 4000 PR 2000 4000 6000 8000 Specify A B C and D 8000 9000 Specify B and D only 2 2 2 2 Request A B C D values PR Request B value only The DMC 2x00 provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as A B C or D An equals sign is used to assign data to that axis For example PRA 1000 Specify a position relative movement for the A axis of 1000 ACB 200000 Specify acceleration for the B axis as 200000 Instead of data some commands request action to occur on an axis or group of axes For example ST AB stops motion on both the A and B axes Commas are not required in this case since the particular axis is specified by the appropriate letter A B C or D If no parameters follow the instruction action will take place on all axes Here are some examples of syntax for requesting actio
173. e line number For example in response to the first ED command the first line is zero 34 e Chapter 2 Getting Started DMC 2X00 DMC 2X00 Line 000 001 002 003 004 Instruction HA PR 700 SP 2000 BGA EN Interpretation Define label Distance Start A motion End program To exit the editor mode input lt gt The program may be executed with the command XQ Start the program running If the ED command is issued from the Galil Windows terminal software such as SmartTERM the software will open a Windows based editor From this editor a program can be entered edited downloaded and uploaded to the controller Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction HA DP 0 V1 1000 LOOP PA Vl BGA AMA WT 500 TPA V1 V1 1000 JP LOOP V1 lt 10001 EN Interpretation Label Define current position as zero Set initial value of V1 Label for loop Move A motor V1 counts Start A motion After A motion is complete Wait 500 ms Tell position A Increase the value of V1 Repeat if V1 lt 10001 End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ A Execute Program Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction zB DP 0 0 PR 30000 60000 SP 5000 5000 BGA AD 4000 BGB AP 6000 SP 2000 50000 Interpr
174. e system or subsequent coordinated motion sequences The command VP xy specifies the coordinates of the end points of the vector movement with respect to the starting point Non sequential axes do not require comma delimitation The command CR 6 define a circular arc with a radius r starting angle of q and a traversed angle d The convention for q 18 that zero corresponds to the positive horizontal direction and for both q and d the counter clockwise CCW rotation is positive Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE motion can be initiated with a Begin Sequence BGS command Once motion starts additional segments may be added The Clear Sequence CS command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or ABI ST stops motion at the specified deceleration ABI aborts the motion instantaneously The Vector End VE command must be used to specify the end of the coordinated motion This command requires the controller to decelerate to a stop following the last motion requirement If a VE command is not given an Abort ABI must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 2x00 sequence buffer to ensure continuous motion If the controller receives no additional motion seg
175. eite 211 ICM 2908 Interconnect Module essere nne 212 ICM 2908 213 Layout of the 2900 1 2 4 220 02000000000 nere 214 1900 Interconnect Module essere enne i 215 Feat res ies dee een mte etin E EE RE e 215 ICM 1900 218 AMP 19x0 Mating Power Amplifiers 218 Dv MD 218 Specifica ons EE Y 219 Opto Isolated Outputs for ICM 2900 ICM 1900 19 0 219 Standard Opto Isolation and High Current 1 219 Configuring the Amplifier Enable for ICM 2900 1900 220 tv eode e isti etate ge EIER EIS 220 Changing the Amplifier Enable Voltage 220 IOM 1964 Opto Isolation Module for Extended 2 221 DeSCHDptOt ssepe Imo natiuitatis 221 oh 221 Configuring Hardware Banks sss enne nnne 222 Digat l 223 224 Stan
176. ement 01 Coordinated motion movement For example the command STS designates motion to stop on a vector motion The third byte for the equivalent binary command would be 01 Byte 4 Specifies the axis or data field as follows Bit 7 axis or 8 data field Bit 6 G axis or 7 data field Bit 5 F axis or 6 data field Bit 4 E axis or 5 data field Bit 3 D axis or 4 data field Bit 2 C axis or 3 data field Chapter 5 Command Basics 63 Bit 1 B axis or 2 data field Bit 0 A axis or 1 data field Datafields Format Datafields must be consistent with the format byte and the axes byte For example the command PR 1000 500 would be A7 02 00 05 03 E8 FE 0C where A7 is the command number for PR 02 specifies 2 bytes for each data field 00 S is not active for PR 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 27 5 03 8 represents 1000 FE OE represents 500 Example The command ST ABCS would be 00 01 07 where A1 is the command number for ST 00 specifies 0 data fields 01 specifies stop the coordinated axes S 07 specifies stop X bit 0 Y bit 1 and Z bit 2 2 2 23 7 Binary Command Table mea s mee 8 e eee a fe fe m e ux s n m e w s sw we Em e s Pei ve if 64 Chapter 5 Command Basics DMC 2X00 GR DE or m e mes
177. eminar and students can test their application on actual hardware and review it with Galil specialists Attendees must have a current application and recently purchased a Galil controller to attend this course TIME Two days 8 30 4 30pm DMC 2X00 Appendices 3 Contacting Us Galil Motion Control 270 Technology Way Rocklin CA 95765 Phone 916 626 0101 Fax 916 626 0102 E Mail Address support galilmc com URL www galilmc com FTP www galilmc com ftp WARRANTY controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship for a period of 18 months after shipment Motors and Power supplies are warranted for 1 year Extended warranties are available In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship at our expense only to destinations in the United States and for products within warranty Call Galil to receive a Return Materials Authorization RMA number prior to returning product to Galil Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer alteration modif
178. ented by a binary code ranging from 80 to FF ASCII commands can be sent live over the bus for immediate execution by the DMC 2x00 or an entire group of commands can be downloaded into the DMC 2x00 memory for execution at a later time Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter Binary commands cannot be used in Applications programming This section describes the DMC 2x00 instruction set and syntax A summary of commands as well as a complete listing of all DMC 2x00 instructions is included in the Command Reference chapter Command Syntax ASCII DMC 2x00 instructions are represented by two ASCII upper case characters followed by applicable arguments A space may be inserted between the instruction and arguments A semicolon or return Is used to terminate the instruction for processing by the DMC 2x00 command interpreter NOTE If you are using a Galil terminal program commands will not be processed until an return command is given This allows the user to separate many commands on a single line and not begin execution until the user gives the return command IMPORTANT All DMC 2x00 commands are sent in upper case For example the command PR 4000 return Position relative PR is the two character instruction for position relative 4000 15 the argument which represents the required position value in counts The return terminates th
179. epresents the Number of bytes in the data record including the header Byte 2 is the low byte and byte 3 is the high byte NOTE The header information of the data records is formatted in little endian General Status Information 1 Byte 7 BIT BIT BIT BIT BIT 2 BIT 1 BIT 0 6 5 4 3 Program N A N A N A N A Waiting for TraceOn Echo On Running input from IN command Axis Switch Information 1 Byte BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Latch Stateof N A N A State of Stateof Stateof SM Occurred Latch Forward Reverse Home Jumper Input Limit Limit Input Installed Axis Status Information 2 Byte BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 8 Modeof Modeof FE Home Ist Phase 2 Phase Mode of Progress Motion Motion Find HM in of HM of Motion complete PA only 2222 Progress complete or FI Coord PR 5 command Motion issued BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Negative Modeof Motion Motionis Motionis Latchis Off On Motor Direction Motion is stopping making armed Error Off Move slewing due toST final armed Contour or Limit decel 58 e Chapter 4 Communication DMC 2X00 Controller Response to Commands DMC 2X00 Switch Coordinated Motion Status Information for S or T plane 2 Byte BIT 15 BIT BIT 13 14 Movein N A N A Progress BIT 7 BIT 6 BIT 5 N A N A Motion is slewing BIT 12 N A BIT 4 Motion is stopping due to ST or Limit Switch BI
180. er IF conditional statements This technique is known as nesting and the DMC 2x00 allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to specify a variety of different cases for branching Command Format IF ELSE and ENDIF Execute commands proceeding IF command up to ELSE command if conditional statement s is true otherwise continue executing at ENDIF command or optional ELSE command IF conditional statement s ELSE Optional command Allows for commands to be executed when argument of IF command evaluates not true Can only be used with IF command ENDIF Command to end IF conditional statement Program must have an ENDIF command for every IF command Instruction Interpretation TEST Begin Main Program TEST 3 Enable interrupts on input 1 and input 2 MG WAITING FOR INPUT 1 INPUT 2 LOOP JP LOOP EN ININT IF 1 0 IF GIN 2 0 MG INPUT 1 AND INPUT 2 ARE ACTIVE Output message Label to be used for endless loop Endless loop End of main program Input Interrupt Subroutine IF conditional statement based on input 1 2 executed if 1 IF conditional true Message executed if 2 IF is true Chapter 7 Application Programming 135 ELSE MG ONLY INPUT 1 IS ACTIVE ENDIF ELSE MG ONLY INPUT 2 IS ACTIVE ENDIF WAIT JP WAIT IN 1 0 IN 2 0 RIO Subroutines ELSE command for 2 IF statement Message executed if 2 IF is
181. er in revolutions A program could be used such that the input number is converted into counts by multiplying it by the number of counts revolution Instruction Interpretation RUN Label IN ENTER OF REVOLUTIONS n1 Prompt for revs PR n1 2000 Convert to counts IN ENTER SPEED IN RPM s1 Prompt for RPMs SP s1 2000 60 Convert to counts sec IN ENTER ACCEL IN RAD SEC2 al Prompt for ACCEL AC a1 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program Hardware Digital Outputs The DMC 2x00 has an 8 bit uncommitted output port and an additional 64 I O which may be configured as inputs or outputs with the CO command for controlling external events The DMC 2x50 through DMC 2x80 has an additional 8 outputs Each bit on the output port may be set and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit 158 e Chapter 7 Application Programming DMC 2X00 Example Set Bit and Clear Bit Instruction Interpretation SB6 Sets bit 6 of output port 4 Clears bit 4 of output port Example Output Bit The Output Bit OB instruction is useful for setting or clearing outputs depending on the value of a variable array input or expression Any non zero value results in a set bit Instruction Interpretation OBI POS Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 OB 2 IN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2
182. er motor amp GND lo Signal Ground MOCMDW W axis motor command to amp input w respect to ground SIGNW lo W axis sign output for input to stepper motor amp PWMW W axis pulse output for input to stepper motor amp GND lo Signal Ground MOCMDX X axis motor command to amp input w respect to ground SIGNX EX X axis sign output for input to stepper motor amp DMC 2X00 Appendices 207 PWMX GND MOCMDY X axis pulse output for input to stepper motor amp Signal Ground Y axis motor command to amp input w respect to ground ENG X sis pulse output for input t0 stepper moram Po o o Compare pr saei o Wmsamiersdle Fo same Fo xis ampli male Fo Genel was o Genel puts Fo o Genel puts o o Genet pie E i o Genet Opies i Egg SIGNY PWMY GND OUT PWR 55 lt C es et Gyre 3 3 3 3 00 4 lt 2 ran pe S pe pe ee oUm pee __ Ex NEN 9 pu pu pu 208 e Appendices DMC 2X00 DMC 2X00 Re 5 3
183. er specified input is at specified logic level n specifies input line Positive is high logic level negative is low level n 1 through 8 for DMC 2x10 2x20 2x30 2x40 1 through 16 for DMC 2x50 2x60 2x70 2x80 17 through 80 for DMC 2xx0 Halts program execution until specified axis has reached its slew speed Halts program execution until n msec from reference time AT 0 sets reference AT n waits n msec from reference AT n waits n msec from reference and sets new reference after elapsed time Halts program execution until specified distance along a coordinated path has occurred Halts program execution until specified time in msec has elapsed Chapter 7 Application Programming 129 Example Multiple Move Sequence The AM trip point 18 used to separate the two PR moves If AM is not used the controller returns a for the second PR command because a new PR cannot be given until motion is complete Instruction Interpretation TWOMOVE Label PR 2000 Position Command BGA Begin Motion AMA Wait for Motion Complete PR 4000 Next Position Move BGA Begin 2nd move EN End program Example Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trip point is the speed multiplied by the sample period Instruction Interpretation SETBIT Label SP 10000 Speed is 10000 PA 20000 Specify Absolute position BGA Begin motion AD 1000 Wait until 1000 co
184. eration To configure the DMC 2x00 for stepper motor operation the controller requires a jumper for each stepper motor and the command MT must be given The installation of the stepper motor jumper is discussed in the following section entitled Installing Jumpers on the DMC 2x00 Further instruction for stepper motor connections are discussed in Step 9 Step 2 Install Jumpers on the DMC 2x00 Master Reset and Upgrade Jumpers JP1 on the main board contains two jumpers MRST and UPGRD The MRST jumper is the Master Reset jumper When MRST is connected the controller will perform a master reset upon PC power up or upon the reset input going low The MRST can also be set with the DIP switches on the outside of the controller Whenever the controller has a master reset all programs arrays variables and motion control parameters stored in EEPROM will be ERASED The UPGRD jumper enables the user to unconditionally update the controller s firmware This jumper 18 not necessary for firmware updates when the controller 15 operating normally but may be necessary in cases of corrupted EEPROM EEPROM corruption should never occur however it is possible if there is a power fault during a firmware update If EEPROM corruption occurs your controller may not operate properly In this case install the UPGRD Jumper and use the update firmware function on the Galil Terminal to re load the system firmware Opto Isolation Jumpers The inputs and limit
185. eric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the decimal point using the PF command Position Format is specified by PF m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format Hex values are returned preceded by a and in 2 s complement Hex values should be input as signed 2 s complement where negative numbers have a negative sign The default format is PF 10 0 If the number of decimal places specified by PF is less than the actual value a nine appears in all the decimal places Example Instruction Interpretation DP21 Define position TPA Tell position 0000000021 Default format PF4 Change format to 4 places TPA Tell position 0021 New format PF 4 Change to hexadecimal format TPA Tell Position 0015 Hexadecimal value PF2 Format 2 places TPA Tell Position 99 Returns 99 if position greater than 99 Removing Leading Zeros from Response to Interrogation Commands The leading zeros on data returned as a response to interrogation commands can be removed by the use of the command LZ 120 Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 Response With Leading Zeros 156 gt Chapter 7 Application Programming DMC 2X00 DMC 2X00 11 TP 9 5 Enables the LZ fun
186. ers ient n e eie etr 4 DMC 2x00 Functional 7 5 Microcomputer 2000 5 Motor Interface ci dE Ee e ROI UE RR DE REI e EP ERE 5 Communication 2 5 General VO pet toa dha dU eed ase vote 6 System ete rece D RR ER E E e ERR edge 6 e eni t NIE e e eit Be ee re 6 Amplifier Driver Eie e ire irte eee egisti ete 6 DE 7 Watch Dog Timers 7 Chapter 2 Getting Started 9 The DMC 2x00 Main Board 9 The DMC 2000 Daughter 10 The DMC 2200 Daughter 4 11 Elements You Nedi ehe een ere er dre oe eens 12 Installing the DM 2X00 secs its ise Seah adr kc iere 14 Step 1 Determine Overall Motor Configuration seen 14 Step 2 Install Jumpers the 2 00 nennen 15 Step Configure switches on 11 sse 16 Contentse i Step 3b Configure DIP switches on 12 17 Step Configure switches on 11 0 sse 17 Step 4 Install the Communications Software sse 18 Step 5 Connect AC Power to the Controller 18 Step 6 Establish Communications with
187. es of variables and arrays as well as other information using the interrogation commands the interrogation commands are described in chapter 5 Chapter 7 Application Programming 153 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is result In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Position of A is TPA Specifying the Port for Messages By default messages will be sent through the port specified by the USB Ethernet Dip Switch the state of this switch upon power up will determine if messages will be sent to USB port DMC 2000 or Ethernet DMC 2100 2200 the Main Serial Port However the port can be specified with the specifier for the main serial port P2 for auxiliary serial port 0 for the USB port or for the Ethernet port MG P2 Hello World Sends message to Auxiliary Port Formatting Messages String variables can be formatted using the specifier Sn where n is the number of characters 1 thru 6 For example MG STR 53 This statement returns 3 characters of the string variable named STR Numeric data may
188. etation Label Define initial positions Set targets Set speeds Start A motion Wait until A moved 4000 Start B motion Wait until position A 6000 Change speeds Chapter 2 Getting Started 35 AP 50000 Wait until position 50000 SP 10000 Change speed of B EN End program To start the program command XQ B Execute Program Control Variables Objective To show how control variables may be utilized Instruction Interpretation ZA DPO Label Define current position as zero PR 4000 Initial position SP 2000 Set speed BGA Move A AMA Wait until move is complete WT 500 Wait 500 ms B Determine distance to zero V1 2 Command A move 1 2 the distance BGA Start A motion AMA After A moved WT 500 Wait 500 ms Report the value of V1 JP 4C V1 0 Exit if position 0 JP 4B Repeat otherwise C Label C EN End of Program To start the program command XQ Execute Program A This program moves to an initial position of 1000 and returns it to zero on increments of half the distance Note is an internal variable which returns the value of the A position Internal variables may be created by preceding a DMC 2x00 instruction with an underscore Linear Interpolation Objective Move A B C motors distance of 7000 3000 6000 respectively along linear trajectory Namely motors start and stop together 36 e Chapter 2 Getting Started DMC 2X00 Instruction LM ABC LI 7000 300
189. events include waiting for motion to be complete waiting for a specified amount of time to elapse or waiting for an input to change logic levels The DMC 2x00 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the DMC 2x00 can make decisions based on its own status or external events without intervention from a host computer NOTE It is not recommended to send trip point commands e g AM from the PC to a DMC 2100 2200 The buffer becomes filled easily when using event triggers which would halt communications between the host and the controller 128 gt Chapter 7 Application Programming DMC 2X00 DMC 2X00 DMC 2x00 Event Triggers Command AMABCDEFGHorS ADAorBorCorDorE or For or H ARAorBorCorDorEorFor Gor H APAorBorCorDorEorForGorH MFAorBorCorDorEorF or GorH or For Gor H or For or H ASABCDEFGH AT
190. false End of 2 conditional statement ELSE command for 1 IF statement Message executed if 1 IF statement End of 1 conditional statement Label to be used for a loop Loop until Input 1 amp 2 are not active End Input Interrupt Routine without restoring trippoints A subroutine is a group of instructions beginning with a label and ending with an End command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program location where the subroutine was called unless the subroutine stack is manipulated as described in the following section An example of a subroutine to draw a square of 500 counts per side is given below The square is drawn at vector position 1000 1000 Instruction M VP 1000 1000 LE BGS AMS SBI JS SQUARE CB1 EN SQUARE 1 500 75 vl v1 JS L EN ZL PR vl v1 BGA AMA BGB AMB EN Stack Manipulation Interpretation Begin Main Program Clear Output Bit 1 pick up pen Define vector position move pen Wait for after motion trip point Set Output Bit 1 put down pen Jump to SQUARE subroutine End Main Program SQUARE subroutine Define length of side Switch direction End subroutine Define Begin After motion on A Begin B End subroutine It is possible to manipulate the su
191. ference position SL g axis motor position SL g axis position error SL g axis auxiliary position SL g axis velocity SW g axis torque SW g axis analog UW h axis status UB h axis switches UB h axis stop code SL h axis reference position SL h axis motor position SL h axis position error SL h axis auxiliary position SL h axis velocity SW h axis torque SW h axis analog NOTE UB Unsigned Byte UW Unsigned Word SW Signed Word SL Signed Explanation of Status Information and Axis Switch Information Header Information Byte 0 1 of Header BIT15 BIT14 BIT13 BIT12 BIT11 BIT10 BIT9 1 N A N A N A N A I Block T Block Present Present E block E block E block E block E block E block F block F block F block F block F block F block F block F block F block F block G block G block G block G block G block G block G block G block G block G block H block H block H block H block H block H block H block H block H block H block Long Word BIT 8 S Block Present Chapter 4 Communication e 57 in Data in Data in Data Record Record Record BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 H Block G Block F Block E Block D Block C Block Block A Block Present Present Present Present Present Present Present Present in Data in Data in Data in Data in Data in Data in Data in Data Record Record Record Record Record Record Record Record Bytes 2 3 of Header Bytes 2 and 3 make a word which r
192. ffer prior to the start of the motion To stop the motion use the instructions STS or AB The command ST causes a decelerated stop The command AB causes an instantaneous stop and aborts the program and the command ABI aborts the motion only The Linear End LE command must be used to specify the end of a linear move sequence This command tells the controller to decelerate to a stop following the last LI command If an LE command 18 not given an Abort ABI must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 2x00 sequence buffer to ensure continuous motion If the controller receives no additional LI segments and no LE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM LM returns the available spaces for LI segments that can be sent to the buffer 511 returned means the buffer is empty and 511 LI segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent at PC bus speeds The instruction CS returns the segment counter As the segments are processed CS increases starting at zero This function allows the host computer to determine which segment is being processed Chapter 6 Programming Motion 81 Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration
193. filer generates the corresponding trapezoidal or triangular velocity profile and position trajectory The controller determines a new command position along the trajectory every sample period until the specified profile is complete Motion is complete when the last position command is sent by the DMC 2x00 profiler NOTE The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified The Begin BG command can be issued for all axes either simultaneously or independently ABC or D axis specifiers are required to select the axes for motion When no axes are specified this causes motion to begin on all axes The speed SP and the acceleration AC can be changed at any time during motion however the deceleration DC and position PR or PA cannot be changed until motion is complete Remember motion is complete when the profiler is finished not when the actual motor is in position The Stop command ST can be issued at any time to decelerate the motor to a stop before it reaches its final position An incremental position movement IP may be specified during motion as long as the additional move 18 in the same direction Here the user specifies the desired position increment n The new target 1s equal to the old target plus the increment n Upon receiving the IP command a revised profile will be generated for motion towards the new end position The IP command does not requi
194. g resulting in trapezoidal velocity profiles Larger values of the smoothing parameters imply heavier filtering and smoother moves Note that KS is valid only for step motors 116 gt Chapter 6 Programming Motion DMC 2X00 Homing The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference This reference is connected to the Home input line The HM command initializes the motor to the encoder index pulse in addition to the Home input The configure command CN is used to define the polarity of the home input The Find Edge FE instruction is useful for initializing the motor to a home switch The home switch 18 connected to the Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew speed and slew until a transition 15 detected on the Homing line The motor will then decelerate to a stop A high deceleration value must be input before the find edge command Is issued for the motor to decelerate rapidly after sensing the home switch The velocity profile generated 1 shown in Fig 6 10 The Home HM command can be used to position the motor on the index pulse after the home switch Is detected This allows for finer positioning on initialization The command sequence HM and BG causes the following sequence of events to occur 1 Upon begin motor accelerates to the slew speed The direction of its motion is determined by the state of the homing input A zero
195. g output signal in the range between 10 and 10 volts is then applied to the amplifier and the motor The motor position whether rotary or linear is measured by a sensor The resulting signal called position feedback is returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Fig 10 4 The mathematical model of the various components is given below CONTROLLER R X DIGITAL Y V E FILTER ZOH DAC MOTOR 6 P ENCODER Figure 10 4 Functional Elements of a Motion Control System 180 gt Chapter 10 Theory of Operation DMC 2X00 DMC 2X00 Motor Amplifier The motor amplifier may be configured in three modes 1 Voltage Drive 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Drive The amplifier 15 a voltage source with a gain of Kv V V The transfer function relating the input voltage V to the motor position P is P V K K S ST 1 ST 1 where 2 T RJ K Is and 1 5 and the motor parameters and units Ky Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m
196. g to the eight banks of extended I O on the controller Each bank is individually configured as an input or output bank by inserting the appropriate integrated circuits and resistor packs The hardware configuration of the IOM 1964 must match the software configuration of the controller card DMC 2x00 series controllers have general purpose I O connections On a DMC 2x10 2x20 2x30 and 2x40 the standard uncommitted I O consists of eight optically isolated digital inputs eight TTL digital outputs and eight analog inputs The DMC 2x00 however has an additional 64 digital input output points than the 16 described above for a total of 80 input output points An 80 pin shielded cable connects from the 80 pin connector of the DMC 2x00 to the 80 pin high density connector on the IOM 1964 J5 Illustrations for this connection can be found on pages 10 and 11 Configuring Hardware Banks The extended I O on the DMC 2x00 is configured using the CO command The banks of buffers on the IOM 1964 are configured to match by inserting the appropriate IC s and resistor packs The layout of each of the I O banks is identical For example here is the layout of bank 0 Resistor Pack for outputs RP03 OUT Resistor Pack for inputs x U03 004 Input Buffer
197. ge on the fly to 2 This can be achieved by commanding GR2 Specify gear ratio for A axis to be 2 Gantry Mode In applications where both the master and the follower are controlled by the DMC 2x00 controller it may be desired to synchronize the follower with the commanded position of the master rather than the actual position This eliminates the coupling between the axes which may lead to oscillations For example assume that a gantry is driven by two axes A and B on both sides This requires the gantry mode for strong coupling between the motors The A axis is the master and the B axis is the follower To synchronize B with the commanded position of A use the instructions Instruction Interpretation GA CA Specify the commanded position of A as master for B GR 1 Set gear ratio for Y as 1 1 Set gantry mode PR 3000 Command A motion BGA Start motion on A axis 94 Chapter 6 Programming Motion DMC 2X00 You may also perform profiled position corrections in the electronic gearing mode Suppose for example that you need to advance the slave 10 counts Simply command 10 Specify incremental position movement of 10 on B axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on B axis BGB Begin motion on B axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Synchronize two conveyor belts w
198. given unsolicited messages will be sent to the default port The default port 15 determined by the state of the USB Ethernet dip switch when the system 1 reset The controller has a special command CW which can affect the format of unsolicited messages This command is used by Galil Software to differentiate response from the command line and unsolicited messages The command CW1 causes the controller to set the high bit of ASCII characters to 1 of all unsolicited characters This may cause characters to appear garbled to some terminals This function can be disabled by issuing the command CW2 For more information see the CW command in the Command Reference When handshaking is used hardware and or software handshaking characters which are generated by the controller are placed in a FIFO buffer before they are sent out of the controller This size of the USB buffer is 64 bytes and the size of the RS 232 buffer 15 128 bytes When this buffer becomes full the controller must either stop executing commands or ignore additional characters generated for output The command CW 1 causes the controller to ignore all output from the controller while the FIFO is full The command CW 0 causes the controller to stop executing new commands until more room is made available in the FIFO This command can be very useful when hardware handshaking is being used and the communication line between controller and terminal will be disconnected In this case cha
199. gned for this purpose Note The task of generating sinusoidal commutation may be accomplished in the brushless motor amplifier If the amplifier generates the sinusoidal commutation signals only a single command signal is required and the controller should be configured for a standard servo motor described above Sinusoidal commutation in the controller can be used with linear and rotary BLMs However the motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds with a standard update rate of 1 millisecond For faster motors please contact the factory To simplify the wiring the controller provides a one time automatic set up procedure When the controller has been properly configured the brushless motor parameters may be saved in non volatile memory The DMC 2x00 can control BLMs equipped with Hall sensors as well as without Hall sensors If Hall sensors are available once the controller has been setup the brushless motor parameters may be saved in non volatile memory In this case the controller will automatically estimate the commutation phase Chapter 1 Overview 9 3 upon reset This allows the motor to function immediately upon power up The Hall effect sensors also provide a method for setting the precise commutation phase Chapter 2 describes the proper connection and procedure for using sinusoidal commutation of brushless motors Stepper Motor with Step and Direction Signals The DMC 2x00 can c
200. h compensation using the auxiliary encoders 1 Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Example Continuous Dual Loop The motor aux encoder needs a finer resolution than load main encoder Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop Chapter 6 Programming Motion 113 method splits the filter function between the two encoders It applies the KP proportional and KI integral terms to the position error based on the load encoder and applies the KD derivative term to the motor encoder This method results in a stable system The dual loop method is activated with the instruction DV Dual Velocity where DV 1 1 1 ac
201. h has occurred Input goes low by using the AL A or or C or D command Example 1 returns the state of the A latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the RL ABCD command or RL ABCD NOTE The latch must be re armed after each latching event Chapter 6 Programming Motion 119 Example Instruction LATCH JG 5000 BGB ALB WAIT JP WAIT ALB 1 Result _RLB Result EN 120 gt Chapter 6 Programming Motion Interpretation Latch program Jog B Begin motion on B axis Arm Latch for B axis Wait label for loop Jump to Wait label if latch has not occurred Set Result equal to the reported position of y axis Print result End DMC 2X00 Chapter 7 Application Programming Overview The DMC 2x00 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 2x00 memory freeing the host computer for other tasks However the host computer can send commands to the controller at any time even while a program is being executed Only ASCII commands can be used for application programming In addition to standard motion commands the DMC 2x00 provides commands that allow the DMC 2x00 to make its own decisions These commands include conditional jumps event triggers and subroutines For example the command JP LOOP n 10 causes a jump
202. h the command was generated If the instruction was valid the controller returns a colon or a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the USB port back through the USB port to commands which are sent via the main RS 232 port back through the RS 232 port and to commands which are sent via the Ethernet port back through the Ethernet port Chapter 4 Communication e 59 For instructions that return data such as Tell Position TP the DMC 2x00 will return the data followed by a carriage return line feed and It is good practice to check for after each command is sent to prevent errors An echo function is provided to enable associating the DMC 2x00 response with the data sent The echo 15 enabled by sending the command EO 1 to the controller Unsolicited Messages Generated by Controller When the controller is executing a program it may generate responses which will be sent via the USB port DMC 2000 main RS 232 port or Ethernet ports DMC 2100 2200 This response could be generated as a result of messages using the MG or IN command OR as a result of a command error These responses are known as unsolicited messages since they are not generated as the direct response to a command Messages can be directed to a specific port using the specific Port arguments see MG and IN commands described in the Command Reference If the port is not explicitly
203. he DMC 2x00 provides array space for 8000 elements The arrays are one dimensional and up to 30 different arrays may be defined Each array element has numeric range of 4 bytes of integer Ay followed by two bytes of fraction 2 147 483 647 9999 Arrays can be used to capture real time data such as position torque and analog input values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Defining Arrays An array is defined with the command DM The user must specify a name and the number of entries to be held in the array An array name can contain up to eight characters starting with an uppercase alphabetic character The number of entries in the defined array is enclosed in DM posA 7 Defines an array names posA with seven entries DM speed 100 Defines an array named speed with 100 entries DM posA 0 Frees array space Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the posA array defined with the DM command DM posA 7 would be specified as posA 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arr
204. he conditional jump determines if a condition is satisfied and then branches to a new location or subroutine Unlike event triggers the conditional jump instruction does not halt the program sequence Conditional jumps are useful for testing events in real time They allow the DMC 2x00 to make decisions without a host computer For example the DMC 2x00 can decide between two motion profiles based on the state of an input line 132 gt Chapter 7 Application Programming DMC 2X00 Command Format JP and JS FORMAT DESCRIPTION JS destination logical condition Jump to subroutine if logical condition is satisfied JP destination logical condition Jump to location if logical condition is satisfied The destination is a program line number or label where the program sequencer will jump if the specified condition is satisfied Note that the line number of the first line of program memory is 0 The comma designates IF The logical condition tests two operands with logical operators Logical operators less than or equal to greater than or equal to Conditional Statements The conditional statement is satisfied 1f it evaluates to any value other than zero The conditional statement can be any valid DMC 2x00 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions If no conditional statement is given the jump will always occur Number V1 6 Numeric Expression V1 V7 6 A
205. he current mode Finally to select KI start with zero value and increase it gradually The integrator eliminates the position error resulting in improved accuracy Therefore the response to the instruction TE A lt return gt becomes zero As KI is increased its effect is amplified and it may lead to vibrations If this occurs simply reduce KI Repeat tuning for the B C and D axes For a more detailed description of the operation of the PID filter and or servo system theory see Chapter 10 Theory of Operation Design Examples DMC 2X00 Here are a few examples for tuning and using your controller These examples have remarks next to each command these remarks must not be included in the actual program System Set up This example assigns the system filter parameters error limits and enables the automatic error shut off Instruction Interpretation KP10 10 10 10 Set gains for a b c d A B C D axes 10 Alternate method setting gain on all axes KPA 10 Method for setting only A axis gain KP 20 Set B axis gain only Instruction Interpretation 0 Enable automatic Off on Error function for all axes ER 1000 Set error limit for all axes to 1000 counts KP10 10 10 10 10 10 10 10 Set gains for a b c d e f g and h axes KP 10 Alternate method for setting gain on all axes KPA 10 Alternate method for setting A axis gain KP 10 Set C axis gain only KPD 10 Alternate method for setting D axis gain KPH 10 Alternate met
206. he firmware the Galil software will not return control to the user In this case the software will have to be re started Step 4 Install the Communications Software After applying power to the computer you should install the Galil software that enables communication between the controller and PC Using Windows 98SE NT ME 2000 or XP The Galil Software CD ROM will automatically begin the installation procedure when the CD ROM is installed To install the basic communications software run the Galil Software CD ROM and choose DMC Smart Term This will install the Galil Smart Terminal which can be used for communication Step 5 Connect AC Power to the Controller Before applying power connect the 100 pin cable between the DMC 2x00 and ICM 2900 interconnect module The DMC 2x00 requires a single AC supply voltage single phase 50 Hz or 60 Hz from 90 volts to 260 volts WARNING Dangerous voltages current temperatures and energy levels exist in this product and the associated amplifiers and servo motor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install set up and operate this equipment Never open the controller box when AC power is applied to it The green power light indicator should go on when power 15 applied 18 e Chapter 2 Getting Started DMC 2X00 Step 6 Establish Communications with Galil Software Communicating through the Main Serial
207. he order of the point The value n starts at zero and may go up to 256 The parameters A B C D indicate the corresponding slave position For this example the table may be specified by ET 0 0 ET 1 3000 ET 2 2250 ET 3 1500 This specifies the ECAM table Step 5 Enable the ECAM To enable the ECAM mode use the command EBn where n 1 enables ECAM mode and n 0 disables ECAM mode Step 6 Engage the slave motion To engage the slave motion use the instruction EG a b c d where a b c d are the master positions at which the corresponding slaves must be engaged If the value of any parameter is outside the range of one cycle the cam engages immediately When the cam is engaged the slave position is redefined modulo one cycle Step 7 Disengage the slave motion To disengage the cam use the command EQ a b c d where a b c d are the master positions at which the corresponding slave axes are disengaged 96 e Chapter 6 Programming Motion DMC 2X00 DMC 2X00 f B 2250 beo seco oe 1500 Pera 500 7 1 4 0 2000 4000 Figure 6 4 Electronic Cam Example 6000 Master A This disengages the slave axis at a specified master position If the parameter 1s outside the master cycle the stopping is instantaneous Step 8 Create program to generate ECAM table To illustrate the complete process consider the cam relationship described by the equation 0 5 A 100 sin 0 18 4
208. he stepper smoothing filter is buffered and 1s available for input to the stepper motor driver The pulses which are generated by the smoothing filter can be monitored by the command TD Tell Dual TD gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position For example DP 0 defines the reference position of the A axis to be zero Stepper Smoothing Filter Motion Profiler Adds a Delay Output Buffer Output To Stepper Driver Reference Position RP Step Count Register TD Figure 6 8 Velocity Profiles of ABC Motion Complete Trip point When used in stepper mode the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position The MC trip point Motion Complete is generally more useful than AM trip point After Motion since the step pulses can be delayed from the commanded position due to stepper motor smoothing Using an Encoder with Stepper Motors An encoder may be used on a stepper motor to check the actual motor position with the commanded position If an encoder is used it must be connected to the main encoder input NOTE The auxiliary encoder 15 not available while operating with step
209. hey cannot be assigned a value For example TPA 2 is invalid Special Operands Keywords The DMC 2x00 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 2x00 commands Keyword Function BGn Returns a 1 if motion on axis is complete otherwise returns 0 BN Returns serial of the board Returns the number of arrays available DL Returns the number of available labels for programming Returns the available array memo HMn Returns status of Home Switch equals 0 or 1 Returns status of Forward Limit switch input of axis n equals 0 or 1 BGn BN DA DL DM HMn LFn 146 gt Chapter 7 Application Programming DMC 2X00 Arrays DMC 2X00 Returns status of Reverse Limit switch input of axis equals 0 or 1 Returns the number of available variables Free Running Real Time Clock off by 2 4 Resets with power on NOTE TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords LR and TIME do not have any associated commands All keywords are listed in the Command Summary vl LFA Assign v1 the state of the Forward Limit Switch on the A axis v3 TIME Assign v3 the current value of the time clock 4 HMD Assign v4 the logical state of the Home input on the D axis For storing and collecting numerical data t
210. his configuration causes the controller to reconfigure the number of available control axes Each sinusoidally commutated motor requires two DACs In standard servo operation the DMC 2x00 has one DAC per axis In order to have the additional DAC for sinusoidal commutation the controller must be designated as having one additional axis for each sinusoidal commutation axis For example to control two standard servo axes and one axis of sinusoidal commutation the controller will require a total of four DACs and the controller must be a DMC 2x40 Sinusoidal commutation is configured with the command BA For example BAA sets the A axis to be sinusoidally commutated The second DAC for the sinusoidal signal will be the highest available DAC on the controller For example Using a DMC 2x40 the command BAA will configure the A axis to be the main sinusoidal signal and the D axis to be the second sinusoidal signal The BA command also reconfigures the controller to indicate that the controller has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAA is given to a DMC 2x40 controller the controller will be re configured to a DMC 2x30 controller By definition a DMC 2x30 controls 3 axes A B and C The D axis is no longer available since the output DAC 15 being used for sinusoidal commutation Further instruction for sinusoidal commutation connections are discussed in Step 6 Stepper Motor Op
211. hod for setting H axis gain Chapter 2 Getting Started 9 31 Profiled Move Rotate the A axis a distance of 10 000 counts at a slew speed of 20 000 counts sec and an acceleration and deceleration rates of 100 000 counts s2 In this example the motor turns and stops Instruction PR1000 SP20000 DC 100000 AC 100000 BGA Multiple Axes Interpretation Distance Speed Deceleration Acceleration Start Motion Objective Move the four axes independently Instruction PR 500 1000 600 400 SP 10000 12000 20000 10000 10000 10000 10000 10000 DC 80000 40000 30000 50000 BG AC BG BD Independent Moves Interpretation Distances of A B C D Slew speeds of A B C D Accelerations of A B C D Decelerations of A B C D Start A and C motion Start B and D motion The motion parameters may be specified independently as illustrated below Instruction PR 300 600 SP 2000 DC 80000 AC 100000 AC 100000 DC 150000 BGC BGB Position Interrogation Interpretation Distances of B and C Slew speed of B Deceleration of B Acceleration of B Acceleration of C Deceleration of C Start C motion Start B motion The position of the four axes may be interrogated with the instruction TP Instruction TP TPA TPB TPC TPD 32 gt Chapter 2 Getting Started Interpretation Tell position all four axes Tell position axis only Tell position B axis only Tell position C axis only Tell position D axis only
212. iable Names POSA posl speedC Invalid Variable Names REALLONGNAME Cannot have more than 8 characters 123 Cannot begin variable name with a number SPEED C Cannot have spaces in the name Assigning Values to Variables Assigned values can be numbers internal variables and keywords functions controller parameters and strings The range for numeric variable values is 4 bytes of integer 2 followed by two bytes of fraction 2 147 483 647 9999 Numeric values can be assigned to programmable variables using the equal sign Any valid DMC 2x00 function can be used to assign a value to a variable For example vl ABS v2 or v2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters which must be in quotation Instruction Interpretation posA TPA Assigns returned value from TPA command to variable posA SPEED 5 75 Assigns value 5 75 to variable SPEED input IN 2 Assigns logical value of input 2 to variable input v2 v1 v3 v4 Assigns the value of v1 plus v3 times v4 to the variable v2 Var CAT Assign the string CAT to Var Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as GN or PR PR vl Assign v1 to PR command SP VSS 2000 Assign VSS 2000 to SP command DMC 2X00 Chapter 7 Application Programming 145 Displaying the value of variables at the terminal V
213. ication negligence or misuse is not covered by this warranty EXCEPT AS SET FORTH ABOVE GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES COPYRIGHT 3 97 The software code contained in this Galil product is protected by copyright and must not be reproduced or disassembled in any form without prior written consent of Galil Motion Control Inc 254 Appendices DMC 2X00 Index Abort 1 40 41 81 87 127 171 172 173 191 202 203 0 0 40 172 173 Stop Motion isisa einen sene 81 87 Absolute 33 70 71 72 129 Absolute Value 96 107 144 172 1 3 30 71 79 83 158 247 206 19 0 206 215 218 219 Amplifier Enable 7 22 43 171 206 220 Amplifier 10 4 6 24 186 188 Analog Input 1 6 39 43 80 144 146 147 149 161 168 191 206 209 249 252 Analysis 14 19 24 99 193 206 0 120 1 15 70 102 103 104 127 142 146 147 Automatic Subroutine CMDERR 124 137 139 140 INN 5 erecto eee 124 135 137 160 161 LIMSWI 39 124 136 137 138 172 174 203 MCTIME eere 124 129 137 139 POSERR
214. ifferential 7 23 25 45 160 176 191 192 203 Dual 4 66 113 149 Index Pulse teret 23 40 117 Quadrature 5 7 112 158 164 183 191 192 202 Error Code secet 53 65 66 127 128 Error Handling sss 1 123 171 Error Limit 22 24 31 44 46 137 171 172 202 Off On Error 22 40 44 171 172 173 Example BINAN 64 Change Speed along Vector Path 131 139 Command Error w Multitasking 140 Communication 140 152 Continuous Dual Loop eee 113 COD LOUE reis teg emet en 101 Cut to Length sse 150 Daisy essen 50 Define Output Waveform Using AT 132 Design Example sese 31 Electronic 99 Ethernet Communication Error 141 Example 164 eos 94 Generating an sss 102 Index 255 Independent 72 138 161 Inputting Numeric 150 Jog80 starent eis ing 120 Limit Switch sese 137 174 Linear 6 83 Motion Complete sse 138 Motion Smoothing sse 115 Multiple Move Sequence 8 130 Mu
215. igure A 5 220 Appendices DMC 2X00 1964 Opto Isolation Module for Extended Obsolete Description e Provides 64 optically isolated inputs and outputs each rated for 2mA at up to 28 VDC e Configurable as inputs or outputs in groups of eight bits e Provides 16 high power outputs capable of up to 500mA each e Connects to controller via 80 pin shielded cable e All I O points conveniently labeled e Each of the 64 I O points has status LED e Dimensions 6 8 x 11 4 High Current Buffer chips 16 Screw Terminals 01123 4 5 6 7 1964 GALIL MOTION CONTROL MADE IN USA FOR INPUTS FOR OUTPUTS 5 RPX4 RPX2 RPX3 Banks 0 and 1 80 pin high Banks 2 7 are standard banks provide high density connector power output capability Figure A 6 Overview The IOM 1964 is an input output module that connects to the motion controller cards from Galil providing optically isolated buffers for the extended inputs and outputs of the controller The IOM DMC 2X00 Appendices 1 1964 also provides 16 high power outputs capable of 500mA of current per output point The IOM 1964 splits the 64 I O points into eight banks of eight I O points each correspondin
216. ill be a decimal representation of the corresponding bits Individual bits can be queried using the IN n function where 1 through 8 or 17 through 80 If the following command is issued MG IN 17 the controller will return the state of the least significant bit of block 2 assuming block 2 1 configured as an input Interfacing to Grayhill or OPTO 22 G4PB24 The DMC 2x00 controller uses one 80 Pin high density connector which requires connection to a 80 pin high density cable Galil CABLE 80 This cable can be converted to 2 50 pin IDC connectors which are compatible with I O mounting racks such as Grayhill 70GRCM32 HL OPTO 22 G4PB24 To convert the 80 pin cable use the CB 50 80 adapter from Galil The 50 pin ribbon cables which connect to the CB 50 80 connect directly into the mounting racks When using the OPTO 22 G4PB24 I O mounting rack the user will only have access to 48 of the 64 I O points available on the controller Block 5 and Block 9 must be configured as inputs and will be grounded by the I O rack Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal which activates the cutter Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per rev
217. ilter parameters KP KD and KI It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section Chapter 2 Getting Started 5 ICM 2900 0 00 sieuz sianw ewwz UU PWMW SignalGnd 2 62 0 Il GND Ref In 4 L 5 E U o SIGNY PSU 4 gt 5 m Dr 4 Motor 1 our 00 00 2 error IU AMPENZ o cue 00 Q Power Gnd 4 High Volt 5 OUTS 0 0 OUTI 00 our 00 jours outs J 00 ours 5v 00 00 uscom I RLsz 00 82 Jl r sw Homey acsx RLSY UL UL GND 0 0 ine 0 00 5 Hl zeaten ine 1 UU o 5V 0 0 0 INCOM i pm 32v 0 00 GND ANALOGS Enco
218. iltering resulting in trapezoidal velocity profiles Smaller values of the smoothing parameters imply heavier filtering and smoother moves The following example illustrates the effect of smoothing Fig 6 9 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Instruction Interpretation PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT 5 Filter for smoothing BGA Begin Chapter 6 Programming Motion 115 ACCELERATION TIME VELOCITY TIME ACCELERATION WITH SMOOTHING TIME VELOCITY WITH SMOOTHING TIME Figure 6 9 Trapezoidal velocity and smooth velocity profiles Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command smoothes the frequency of step motor pulses Similar to the commands IT and VT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS a b c d where a b c d is an integer from 0 5 to 8 and represents the amount of smoothing The command IT is used for smoothing independent moves of the type JG PR PA and the command VT is used to smooth vector moves of the type VM and LM The smoothing parameters a b c d and n are numbers between 0 5 and 8 and determine the degree of filtering The minimum value of 0 5 implies no filterin
219. imit 22 24 31 44 46 137 171 172 202 Torque Limit etse 24 34 ERE 6 202 219 Quadrature 5 7 112 158 164 183 191 192 202 Quit 40 41 81 87 127 171 172 173 191 202 203 Stop Motion 81 87 R cotd 70 104 147 148 149 252 6 66 119 120 203 70 104 Register e RH 19 20 21 Reset 4 15 16 17 23 28 29 39 41 46 53 60 171 173 176 202 203 204 Scale 89 Serial Port 16 17 18 19 20 49 124 140 141 152 154 155 199 200 201 204 Set Bit ie ceteris 45 158 159 202 225 Sine 70 98 144 Single Ended 7 23 25 191 Slew 30 32 70 71 117 129 164 203 Smoothing 1 30 70 71 79 82 83 87 89 106 107 114 115 116 Software Terminall5 18 19 21 22 24 34 35 39 43 48 49 51 61 121 122 125 146 193 206 14 19 20 24 99 193 206 Special 1 22 123 136 174 Stability 113 114 169 175 176 180 LACK 136 139 141 161 Zero Stack E S 139 161 Step 007 3 4 6 14 30 116 202 203 KS Smoothing 30 70 106 107 108 114 115 116 Stepper Position Maintenance 108 Stop 66 119 127 149 176 Stop
220. imit switch a defined input position error or a command error Automatic monitoring is enabled by inserting a special predefined label in the applications program The pre defined labels are ANINT MCTIME Motion Complete timeout occurred Timeout period set by TW command COMINT DMC 2000 only Communication Interrupt Routine TCPERR TCP IP communication error 2100 and 2200 only CMDERR Bad command given For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the POSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt subroutine When the specified input occurs the program will be executed automatically NOTE An application program must be running for automatic monitoring to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the LIMSWI routine to function the DMC 2x00 must be executing an applications program from memory This can be a very simple program that does nothing but loop on a statement such as LOOP JP LOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed Instruction Interpretation ED Edit Mode 000 LOOP Dummy Program 001 JP ZLOOP EN Jump to Loop 002 LIMSWI Limit
221. ing DMC 2X00 DMC 2X00 Using the IF and ENDIF Commands An IF conditional statement is formed by the combination of an IF and ENDIF command The IF command has as its arguments one or more conditional statements If the conditional statement s evaluates true the command interpreter will continue executing commands which follow the IF command If the conditional statement evaluates false the controller will ignore commands until the associated ENDIF command is executed OR an ELSE command occurs in the program see discussion of ELSE command below NOTE An ENDIF command must always be executed for every IF command that has been executed It is recommended that the user not include jump commands inside IF conditional statements since this causes redirection of command execution In this case the command interpreter may not execute an ENDIF command Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command and has no arguments If the argument of the IF command evaluates false the controller will skip commands until the ELSE command If the argument for the IF command evaluates true the controller will execute the commands between the IF and ELSE command Nesting IF Conditional Statements The DMC 2x00 allows for IF conditional statements to be included within oth
222. inking circuit inoperative Standard Digital Outputs Maximum external power supply voltage 28 VDC e Minimum external power supply voltage 4 VDC Maximum source current limited by pull up resistor value e Maximum sink current 2mA Relevant DMC Commands COn Configures the 64 bits of extended I O in 8 banks of 8 bits each N Ny 2 n 4 n t 8 n t 16 ng 32 n 64 ng t 128 where n is a 1 or 0 1 for outputs and 0 for inputs The x is the bank number OP m 8 standard digital outputs m n 0 p q n extended I O banks 0 amp 1 outputs 17 32 o extended I O banks 2 amp 3 outputs 33 48 p extended I O banks 4 amp 5 outputs 49 64 q extended I O banks 6 amp 7 outputs 65 80 Screw Terminal Listing Rev A B boards orange and Rev C boards black have the pinouts listed below REV A B REV C LABEL DESCRIPTION BANK TERMINAL TERMINAL 1 GND Ground N A 2 2 5V 5V DC out N A 3 1 GND Ground N A 4 4 5V 5V DC out N A 5 3 80 bit 80 7 6 6 1 079 I O bit 79 7 7 5 1 078 I O bit 78 7 8 8 1077 T O bit 77 7 9 7 1 076 I O bit 76 7 DMC 2X00 Appendices 227 REV REV C LABEL DESCRIPTION BANK TERMINAL TERMINAL 10 10 I O75 I O bit 75 7 11 9 1 074 I O bit 74 7 12 12 1 073 I O bit 73 7 13 11 OUTC73 80 Out common for I O 73 80 7 14 14 I OC73 80 I O common for I O 73 80 7 15 13 I O72 I O bit 72 6 16 16 I O71 I O bit 71 6 17 15 1 070 I O bit 70 6 18 18 1 069
223. ith trapezoidal velocity correction Instruction Interpretation GA A Define A as the master axis for B GR 2 Set gear ratio 2 1 for B PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGB Start correction Electronic Cam DMC 2X00 The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 7 axes can be slaved to one master axis The master axis encoder must be input through a main encoder port The electronic cam is a more general type of electronic gearing which allows a table based relationship between the axes It allows synchronizing all the controller axes For example the DMC 2x80 controller may have one master and up to seven slaves To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis B when the master is A Such a graphic relationship is shown in Figure 6 4 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master axis This is done with the instruction EAp where p A B C D p is the selected master axis For the given example since the master 1s x we specify EAA Step 2 Specify the master cycle and the change in the slave axes In the electronic cam mode the position of the master is always expressed modulo one cycle In this example the position of x 18 always ex
224. k2 label XQ 1 1 Execute Task1 LOOP2 Loop2 label PR 1000 Define relative distance BGX Begin motion AMX After motion done WT 10 Wait 10 msec JP ZLOOP2 QIN 2 1 Repeat motion unless Input 2 is low HX Halt all tasks The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 2x00 provides commands and operands which are useful in debugging application programs These commands include interrogation commands to monitor program execution determine the state of the controller and the contents of the controllers program array and variable space Operands also contain important status information which can help to debug a program Trace Commands DMC 2100 2200 only The trace command causes the controller to send each line in a program to the host computer immediately prior to execution Tracing 15 enabled with the command TR1 TRO turns the trace function off NOTE When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed Data which is output from the controller is stored in the output UART The UART buffer can store up to 128 characters of information In normal operation the controller places output into the FIFO buffer When the trace mode is enabled the controller will send information to the UART buffer at a very high rate
225. known as fast mode and allows the controller to operate with the following update rates DMC 2X00 DMC 2x10 DMC 2x20 DMC 2x30 DMC 2x40 DMC 2x50 DMC 2x60 DMC 2x70 DMC 2x80 Phase locked better than 005 System dependent 2147483647 counts per move Up to 12 000 000 counts sec Servo 3 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1 10 4 8000 elements 30 arrays 1000 lines x 80 characters 125 usec 250 usec 375 usec 500 usec In order to run the DMC 2x00 motion controller in fast mode the fast firmware must be uploaded This can be done through the Galil terminal software such as DMCTERM and WSDK The fast firmware is included with the original DMC 2x00 utilities To set the update rate use command TM When the controller 18 operating with the fast firmware the following functions are disabled Gearing mode Ecam mode Pole PL Analog Feedback AF Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in thread 2 8 DMA channel Tell Velocity Interrogation Command TV Appendices 3 Connectors for DMC 2x00 Main Board DMC 2x00 Axes A D High Density Connector 25 2 2 2 2 0 25 AYX 8 B4 By 6 55 LY 8 9 1 1 1 1 1 1 1 1 1 1 3 3 3 3 3 3 3 3 6 7 56 LY 56 7A 58 A Z 8 9 B X X X 2 3 3 5 194 Appendices DMC 2X00 DMC 2X00 46 B W 96 an
226. l with over 500 000 controllers working worldwide has a proud reputation for anticipating and setting the trends in motion control Galil understands your need to keep abreast with these trends in order to remain resourceful and competitive Through a series of seminars and workshops held over the past 20 years Galil has actively shared their market insights in a no nonsense way for a world of engineers on the move In fact over 10 000 engineers have attended Galil seminars The tradition continues with three different seminars each designed for your particular skill set from beginner to the most advanced MOTION CONTROL MADE EASY WHO SHOULD ATTEND Those who need a basic introduction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30pm ADVANCED MOTION CONTROL WHO SHOULD ATTEND Those who consider themselves a servo specialist and require an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of Control Made Easy or equivalent is required Analysis and design tools as well as several design examples will be provided TIME 8 hours 8 5pm PRODUCT WORKSHOP WHO SHOULD ATTEND Current users of Galil motion controllers Conducted at Galil s headquarters in Rocklin CA students will gain detailed understanding about connecting systems elements system tuning and motion programming This is a hands on s
227. lication Programming 143 Functions FUNCTION DESCRIPTION SIN n Sine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution COS n Cosine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution TAN n Tangent of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution ASIN n Arc Sine of n between 90 and 90 Angle resolution in 1 64000 degrees ACOS n Arc Cosine of n between 0 and 180 Angle resolution in 1 64000 degrees ATAN n Arc Tangent of n between 90 and 90 Angle resolution in 1 64000 degrees COM n 175 Complement of n ABS n Absolute value of n FRAC n Fraction portion of n INT n Integer portion of n RND n Round of n Rounds up if the fractional part of n is 5 or greater SQR n Square root of n Accuracy is 0001 IN n Return digital input at general input n where n starts at 1 OUT n Return digital output at general output n where n starts at 1 AN n Return analog input at general analog in n where n starts at 1 Note that these functions are multi valued An application program may be used to find the correct band Functions may be combined with mathematical expressions The order of execution of mathematical expressions is from left to right and can be over ridden by using parentheses Instruction Interpretation vl ABS v7 The variable v1 is equal to the absolute value of varia
228. ller 1 8 Carrier Detect 2 Transmit Data DMC 2X00 20 Data Terminal Ready Cable to Connect Computer 9 pin to Main Serial Port Cable 9 pin 9 Pin FEMALE Computer 9 Pin FEMALE Controller 1 Carrier Detect Cable to Connect Computer 25 pin to Auxiliary Serial Port Cable 9 pin gt Cable to Connect Computer 9 pin to Auxiliary Serial Port Cable 9 pin 9 Pin FEMALE terminal 9 Pin MALE Controller Deew 5 DMC 2X00 Appendices 1 Pin Out Description for DMC 2x00 Outputs Analog Motor Command 10 volt range signal for driving amplifier In servo mode motor command output is updated at the controller sample rate In the motor off mode this output 15 held at the OF command level Amp Enable Sin to disable and enable an amplifier Amp Enable goes to disable and enable an amplifier Amp Enable goes low on Signal to disable and enable an amplifier Amp Enable goes low and 1 PWM STEP OUT PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a conventional amplifier that accepts a 10 volt analog signal this pin is not used and should be left open The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM signal is 2 duty cycle for full negative voltage 50 fo
229. ller Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software The user must also insure that a straight through serial cable is being used NOT a Null Modem cable see appendix for pin out of serial cable Once you establish communications open up the Terminal and hit the Enter key You should receive a colon prompt Communicating with the controller 15 described in later sections DMC 2X00 Chapter 2 Getting Started 19 Using Non Galil Communication Software The DMC 2x00 main serial port is configured as DATASET Your computer or terminal must be configured as a DATATERM for full duplex no parity 8 data bits one start bit and one stop bit Check to insure that the baud rate switches have been set to the desired baud rate as described above Your computer needs to be configured as a dumb terminal which sends ASCII characters as they are typed to the DMC 2x00 Communicating through the Universal Serial Bus USB NOTE Galil Software only supports the use of the USB port under Windows 98SE ME 2000 and XP Connect the USB cable from the computer to the USB IN port on the controller Since the controller has been powered on in the previous step the computer will recognize the first connection to a Galil USB controller The computer will identify the USB controller and add it to the Windows Registry as a plug and play device Communicating through the
230. ller to be in this mode but for the sake of discussion it is assumed that the robot is tracking only in the X dimension The controller must be placed in the position tracking mode to allow on the fly absolute position changes This is performed with the PT command To place the X axis in this mode the host would issue to the controller if both X and Y axes were desired the command would be PT 1 1 The next step is to begin issuing PA command to the controller The BG command isn t required in this mode the SP AC and DC commands determine the shape of the trapezoidal velocity profile that the controller will use Example Motion 1 The host program determines that the first target for the controller to move to 1s located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 cts sec and the velocity is set to 50 000 cts sec The command sequence to perform this is listed below COMMAND DESCRIPTION PTI Place the X axis in Position tracking mode 150000 Set the X axis acceleration to 150000 cts sec DC150000 Set the X axis deceleration to 150000 cts sec SP50000 Set the X axis speed to 50000 cts sec 5000 Command the X axis to absolute position 5000 encoder counts 74 e Chapter 6 Programming Motion DMC 2X00 DMC 2X00 1 D i i D 4 i D E D 0 1 4 40
231. ltiple Move with 132 Opto 22 ute tet utei P ed ERO 249 Output sese 159 Output Porterin nienean nie tree egg 159 Position 1701100 eene 161 155 Record and Playback 104 Recording into 149 Repetitive Position 10 130 Set Bit and Clear 159 Set Output when 4 8 131 Sinusoidal Commutation esse 2127 Sinusoidal 105 Start Motion on 130 Start Motion on Switch 160 Tangent Axis secrete TEC 89 Turn on output after move 159 Using Inputs 160 Using Variables for 101810 8 146 Wite 164 Eeedrate eee ete 82 88 166 FIFO 59 60 126 Filter Parameter 30 176 180 5 Galil cicuta re 30 31 34 176 180 Integrator nette rer 30 31 180 186 PID re 3 25 30 31 180 184 Proportional 30 31 114 180 sss 113 114 175 176 180 40 58 117 119 203 Formattihg 154 157 Frequency 7 30 105 116 185 187 188 191 202 219 Function 10 121 133 142 145 158 Gain 4 6 24 30 31 34 176 180 91 94 Gearitig esos 1 69 70 91 94 95 193 252 Halt 82 125 126 128 129 131 132 hardware Extended I
232. m corresponds to the velocity profiles shown in Fig 10 3 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The following section explains the operation of the servo system First it is explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined 178 e Chapter 10 Theory of Operation DMC 2X00 X VELOCITY Y VELOCITY X POSITION Y POSITION 0 TIME Figure 10 3 Velocity and Position Profiles Operation of Closed Loop Systems DMC 2X00 To understand the operation of a servo system we may compare it to a familiar closed loop operation adjusting the water temperature in the shower One control objective 18 to keep the temperature at a comfortable level say 90 degrees F To achieve that our skin serves as a temperature sensor and reports to the brain controller The brain compares the actual temperature which 1 called the feedback signal with the desired level of 90 degrees F The difference between the two levels is called the error signal If the feedback temperature is too low the error is positive and it triggers an action which raises the water temperature until the temperature error is reduced sufficiently The closing of the servo loop is very similar Suppose that we w
233. ments and no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM LM returns the available spaces for motion segments that can be sent to the buffer 511 returned means the buffer is empty and 511 segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional segments can be sent at PC bus speeds The operand CS be used to determine the value of the segment counter Additional commands The commands VS n VA n and VD n are used for specifying the vector speed acceleration and deceleration VT 1s the s curve smoothing constant used with coordinated motion Specifying Vector Speed for Each Segment The vector speed may be specified by the immediate command VS It can also be attached to a motion segment with the instructions VP ab lt n gt m CR r 0 8 lt n gt m DMC 2X00 Chapter 6 Programming Motion 87 The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function lt m requires the vector speed to reach the value m at the end of the segment Note that the function lt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and
234. mmand The default value for ER is 16384 ER 200 300 400 500 Set A axis error limit for 200 B axis error limit to 300 C axis error limit to 400 counts D axis error limit to 500 counts ER 1 10 Set B axis error limit to 1 count set D axis error limit to 10 counts The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position If the absolute value of the error exceeds the value specified by ER the DMC 2x00 will generate several signals to warn the host system of the error condition These signals include SIGNAL OR FUNCTION STATE IF ERROR OCCURS POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 AEN Output Line Goes low The Jump on Condition statement is useful for branching on a given error within a program The position error of A B C and D can be monitored during execution using the TE command 172 Chapter 8 Hardware amp Software Protection DMC 2X00 DMC 2X00 Programmable Position Limits The DMC 2x00 provides programmable forward and reverse position limits These are set by the BL and FL software commands Once a position limit is specified the DMC 2x00 will not accept position commands beyond the limit Motion beyond the limit is also prevented Example Instruction Interpretation DP0 0 0 Define Position BL 2000 4000 8000 FL 2000 4000 8000 JG 2000 2000 2000 Set Reverse
235. mory the DMC 2x00 has several useful commands The command DM will return the number of array elements currently available The command DA will return the number of arrays which can be currently defined For example a standard DMC 2x10 will have a maximum of 8000 array elements in up to 30 arrays If an array of 100 elements is defined the command DM will return the value 7900 and the command DA will return 29 To list the contents of the variable space use the interrogation command List Variables To list the contents of array space use the interrogation command LA List Arrays To list the contents of the Program space use the interrogation command LS List To list the application program labels only use the interrogation command LL List Labels Operands In general all operands provide information which may be useful in debugging an application program Below is a list of operands which are particularly valuable for program debugging To display the value of an operand the message command may be used For example since the operand ED contains the last line of program execution the command MG ED will display this line number _ ED contains the last line of program execution Useful to determine where program stopped DL contains the number of available labels _ UL contains the number of available variables DA contains the number of available arrays DM contains the number of available array elements _A
236. most significant bit represents block 9 The decimal value can be calculated by the following formula n n 2 n 4 n 8 5 16 ng 32 n 64 ng 128 where n represents the block If the n value is a one then the block of 8 I O points is to be configured as an output If the n value is a zero then the block of 8 I O points will be configured as an input For example if block 4 and 5 is to be configured as an output CO 12 is issued 162 e Chapter 7 Application Programming DMC 2X00 8 Bit Block Binary Decimal Value for Representation Block The simplest method for determining n Step 1 Determine which 8 bit I O blocks to be configured as outputs Step 2 From the table determine the decimal value for each I O block to be set as an output Step 3 Add up all of the values determined in step 2 This is the value to be used for n For example if blocks 2 and 3 are to be outputs then n is 3 and the command should be issued NOTE This calculation is identical to the formula n n 2 4 n 8 16 ng 32 n 64 ng 128 where n represents the block Saving the State of the Outputs in Non Volatile Memory The configuration of the extended I O and the state of the outputs can be stored in the EEPROM with the BN command If no value has been set the default of CO 0 1 used all blocks are inputs Accessing Extended I O When configured as an output each I O point may be define
237. n BGA Begin A only BGB Begin B only BG ABCD Begin all axes BG BD Begin B and D only BG Begin all axes For controllers with 5 or more axes the axes are referred to as A B C D E F G H BG ABCDEFGH Begin all axes BGD Begin D only Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S and T are used to specify coordinated motion planes For example BGS Begin coordinated sequence S BGTW Begin coordinated sequence T and D axis 62 Chapter 5 Command Basics DMC 2X00 Command Syntax Binary DMC 2X00 Some commands have an equivalent binary value Binary communication mode can be executed much faster than ASCII commands Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format binary commands have 4 byte header and is followed by data fields The 4 bytes are specified in hexadecimal format Header Format Byte 1 Specifies the command number between 80 to FF The complete binary command number table is listed below Byte 2 Specifies the of bytes in each field as 0 1 2 4 or 6 as follows 00 No datafields i e SH or BG 01 One byte per field 02 One word 2 bytes per field 04 One long word 4 bytes per field 06 Galil real format 4 bytes integer and 2 bytes fraction Byte 3 Specifies whether the command applies to a coordinated move as follows 00 No coordinated motion mov
238. n WT 50 Wait 50 msec linpos Read linear position er 1000 linpos TEA JP C ABS er lt 2 Find the correction Exit if error is small PR er Command correction BGA JP 4B Repeat the process Chapter 7 Application Programming 169 THIS PAGE LEFT BLANK INTENTIONALLY 170 gt Chapter 7 Application Programming DMC 2X00 Chapter 8 Hardware amp Software Protection Introduction The DMC 2x00 provides several hardware and software features to check for error conditions and to inhibit the motor on error These features help protect the various system components from damage WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machine Since the dmc 2x00 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the dmc 2x00 Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 2x00 includes hardware input and output protection lines for various error and mechanical limit conditions These include Output Protection Lines Amp Enable This signal goes low when the motor off command is given when the position error exceeds the value specified by the Error Limit ER command or when off on error condition is enabled OE1 and the abort command is given Each axis
239. n encoder register feedback encoder Additionally Y A defines the step drive resolution where YA 1 for full stepping or YA 2 for half stepping The full range of YA is up to YA 9999 for microstepping drives Error Limit The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor steps Once the value of QS exceeds this limit the controller then performs the following actions 1 The motion is maintained or is stopped depending on the setting of the OE command If OE 0 the axis stays in motion if OE 1 the axis is stopped 2 is set to 2 which causes the automatic subroutine labeled ZPOSERR to be executed Correction correction move can be commanded by assigning the value of QS to the YR correction move command The correction move is issued only after the axis has been stopped After an error correction move has completed and QS is less than three full motor steps the YS error status bit 1s automatically reset back to 1 indicating a cleared error Example SPM Mode Setup The following code demonstrates what is necessary to set up SPM mode for a full step drive a half step drive and a 1 64 microstepping drive for an axis with a 1 8 step motor and 4000 count rev encoder Note the necessary difference is with the YA command Full Stepping Drive X axis SETUP Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper 1
240. n inactive state This usually involves physically opening the tripped switch Any attempt at further motion before the logic state has been reset will result in the following error 022 Begin not possible due to limit switch error operands LFx LRx contain the state of the forward and reverse limit switches respectively x represents the axis A B C D etc The value of the operand is either a 0 or 1 corresponding to the logic state of the limit switch Using a terminal program the state of a limit switch can be printed to the screen with the command LFx or MG LFx This prints the value of the limit switch operands for the x axis The logic state of the limit switches can also be interrogated with the TS command For more details on TS see the Command Reference Chapter 3 Connecting Hardware 9 Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user There are th
241. n nennen 67 Chapter 6 Programming Motion 69 7 69 Independent Axis 70 Command Summary Independent 1 71 71 72 Position A eeu itti iet 73 ther 75 76 78 Command Summary Position Tracking Mode sse 79 Independent Jogging cidem eter e e e desee des 79 Command Summary 089110 eene 79 79 Operand Summary Independent Axis Examples 2 Ede advan dede de 80 Linear 0 0 7 81 DMC 2x00 Contentse iii iv e Contents Specifying the Coordinate Plane sess 81 Specifying Linear Segments e gt e etre 81 Additional Commands a vo DC tee aUe Re a 82 83 5 83 83 Vector Mode Linear and Circular Interpolation Motion sess 86 Specifying the Coordinate Plane 86 ener 87 Additional commandis eese eene nre ener 87 Command Summary Coordinated Motion Seq
242. n units known as packets Communication protocols are necessary to dictate how these packets are sent and received The DMC 2100 supports two industry standard protocols TCP IP and UDP IP The controller will automatically respond in the format in which it is contacted TCP IP is a connection protocol The master must be connected to the slave in order to begin communicating Each packet sent is acknowledged when received If no acknowledgement is received the information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connection This protocol 1 similar to communicating via RS232 If information is lost the controller does not return a colon or question mark Because the protocol does not provide for lost information the sender must re send the packet 50 e Chapter 4 Communication DMC 2X00 Although UDP IP is more efficient and simple Galil recommends using the TCP IP protocol TCP IP insures that if a packet is lost or destroyed while in transit it will be resent Ethernet communication transfers information in packets The packets must be limited to 470 data bytes orless Larger packets could cause the controller to lose communication NOTE In order not to lose information in transit Galil recommends that the user wait for an acknowledgement of receipt of a packet before sending the next packet There are four LEDs provided for the status of Ethernet connection The representation of LED status 18 gi
243. nalog input compute position DMC 2X00 Chapter 7 Application Programming 161 PA VP Command position BGA Start motion AMA After completion JP LOOP Repeat EN End Example Position Follower Continuous Move Method Read the analog input compute the commanded position and the position error Command the motor to run at a speed in proportions to the position error Instruction Interpretation CONT Label AC 80000 DC 80000 Acceleration rate JG 0 Start job mode BGX Start motion LOOP vp AN 1 1000 Compute desired position ve vp _TPA Find position error vel ve 20 Compute velocity JG vel Change velocity JP LOOP Change velocity EN End Extended I O of the DMC 2x00 Controller The DMC 2x00 controller offers 64 extended I O points which can be configured as inputs or outputs in 8 bit increments through software The I O points are accessed through 1 80 pin high density connector Configuring the I O of the DMC 2x00 The 64 extended I O points of the DMC 2x00 series controller can be configured in blocks of 8 The extended I O is denoted as blocks 2 9 or bits 17 80 The command CO is used to configure the extended I O as inputs or outputs The CO command has one field COn where n is a decimal value which represents a binary number Each bit of the binary number represents one block of extended I O When set to 1 the corresponding block is configured as an output The least significant bit represents block 2 and the
244. nd CE Step D Verify proper encoder operation Start with the A encoder first Once it 1s connected turn the motor shaft and interrogate the position with the instruction TPA return The controller response will vary as the motor is turned At this point if TPA does not vary with encoder rotation there are three possibilities 1 The encoder connections are incorrect check the wiring as necessary 2 The encoder has failed using an oscilloscope observe the encoder signals Verify that both channels A and B have a peak magnitude between 5 and 12 volts Note that if only one encoder channel fails the position reporting varies by one count only If the encoder failed replace the encoder If you cannot observe the encoder signals try a different encoder 3 There is a hardware failure in the controller connect the same encoder to a different axis If the problem disappears you probably have a hardware failure Consult the factory for help Step E Connect Hall Sensors if available Hall sensors are only used with sinusoidal commutation and are not necessary for proper operation The use of Hall sensors allows the controller to automatically estimate the commutation phase upon reset and also provides the controller the ability to set a more precise commutation phase Without Hall sensors the commutation phase must be determined manually The Hall effect sensors are connected to the digital inputs of the controller These inp
245. nd in a program Tangent Motion Several applications such as cutting require third axis i e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 2x00 allows one axis to be specified as the tangent axis The VM command provides parameter specifications for describing the coordinated axes and the tangent axis m n specifies coordinated axes specifies tangent axis such as A B C or D turns off tangent axis Before the tangent mode can operate it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m n command m defines the scale factor in counts degree and n defines the tangent position that equals zero degrees in the coordinated motion plane The operand _ can be used to return the initial position of the tangent axis Command Summary Coordinated Motion Sequence Command Description m n Specifies the axes for the planar motion where m and n represent the planar axes and is the tangent axis Return coordinate of last point where m A B C or D CR r O Specifies arc segment where r is the radius O is the starting angle and AO is the travel angle Positive direction is CCW Specify vector speed or feed rate of sequence 88 e Chapter 6 Programming Motion DMC 2X00 DMC 2X00 AMS LM Return number of available spaces for linear and circular segments in DMC 2x00 sequence buffer Zero means
246. ndition for the JP command is satisfied the controller branches to the specified label or line number and continues executing commands from this point If the condition is not satisfied the controller continues to execute the next commands in sequence Instruction Interpretation ZLOOP count 10 Jump to LOOP if the variable count is less than 10 JS MOVE2 IN 1 1 Jump to subroutine ZMOVE2 if input 1 is logic level high After the subroutine MOVE2 is executed the program sequencer returns to the main program location where the subroutine was called JP BLUE ABS v2 gt 2 Jump to BLUE if the absolute value of variable v2 is greater than 2 JP ZC v1 v7 v8 v2 Jump to C if the value of v1 times v7 is less than or equal to the value of v8 v2 Jump to ZA Move the A motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves Instruction Interpretation BEGIN Begin Program count 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGA Begin move AMA Wait for motion complete WT 100 Wait 100 msec 0 Position absolute 0 BGA Begin move AMA Wait for motion complete WT 100 Wait 100 msec count count 1 Decrement loop counter JP LOOP count 70 Test for 10 times thru loop EN End Program If Else and Endif The DMC 2x00 provides a structured approach to conditional statements using IF ELSE and ENDIF commands 134 e Chapter 7 Application Programm
247. nitiated by the sequence of commands HMA return BGA retur Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detecting the transition in the logic state on the Home Input the motor will decelerate to a stop at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of 256 counts sec When the logic state changes again the motor moves forward in the direction of increasing encoder count at the same speed until the controller senses the index pulse After detection it decelerates to a stop and defines this position as 0 The logic state of the Home input can be interrogated with the command MG _ This command returns a 0 or 1 if the logic state is low or high respectively The state of the Home input can also be interrogated indirectly with the TS command For examples and further information about Homing see command HM FI FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state NOTE The response of the abort input
248. nstruction HA PR 2000 500 100 SP 15000 10000 5000 AC 500000 500000 500000 DC 500000 500000 500000 BGA WT 20 BGB WT 20 BGC EN Interpretation Begin Program Specify relative position movement of 2000 500 and 100 counts for A B and C axes Specify speed of 10000 15000 and 5000 counts sec Specify acceleration of 500000 counts sec for all axes Specify deceleration of 500000 counts sec for all axes Begin motion on the A axis Wait 20 msec Begin motion on the B axis Wait 20 msec Begin motion on C axis End Program 72 Chapter 6 Programming Motion DMC 2X00 VELOCITY COUNTS SEC A axis velocity profile 20000 B axis velocity profile 15000 C axis velocity profile 10000 5000 TIME ms 0 20 40 60 80 100 Figure 6 1 Velocity Profiles of ABC Notes on fig 6 1 The and B axis have a trapezoidal velocity profile while the C axis has triangular velocity profile The A and B axes accelerate to the specified speed move at this constant speed and then decelerate such that the final position agrees with the command position PR The C axis accelerates but before the specified speed 15 achieved must begin deceleration such that the axis will stop at the commanded position 3 axes have the same acceleration and deceleration rate hence the slope of the rising and falling edges of all 3 velocity profiles are the same Position Tracking DMC 2X00 The Galil controller may
249. ntrl gt D command deletes the line currently being edited For example if the editor is at line number 2 and lt cntrl gt D is applied line 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q The lt cntrl gt Q quits the editor mode In response the DMC 2000 will return a colon After the Edit session is over the user may list the entered program using the LS command If no operand follows the LS command the entire program will be listed The user can start listing at a specific line or label using the operand n A command and new line number or label following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation 18 List entire program 18 5 Begin listing at line 5 LS 5 9 List lines 5 thru 9 1 5 A 9 List line label thru line 9 15 ZA A 5 List line label and additional 5 lines NOTE Editor is not available for DMC 2100 however any terminal may be used 1 e Telnet 122 e Chapter 7 Application Programming DMC 2X00 Program Format DMC 2X00 A DMC program consists of DMC 2x00 instructions combined to solve a machine control application Action instructions such as starting and stopping motion are combined with Program Flow instructions to form the complete program Program Flow instructions evaluate real time conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 2x00 inst
250. nts include the position 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are Instruction Interpretation Label CMA Specifies A axis for contour mode DT2 Specifies first time interval 2 ms CD 48 WC Specifies first position increment DT3 Specifies second time interval 2 ms CD 240 WC Specifies second position increment DT4 Specifies the third time interval 2 ms CD 48 WC Specifies the third position increment DT0 CDO Exits contour mode EN POSITION COUNTS 240 192 96 48 gt TIME ms 0 4 8 12 16 20 24 28 1 2 3 Figure 6 6 The Required Trajectory Additional Commands The command WC is used as a trip point When Complete This allows the DMC 2x00 to use the next increment only when it is finished with the previous one Zero parameters for DT followed by zero parameters for CD exit the contour mode If no new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a DMC 2X00 Chapter 6 Programming Motion 1 Command Summary Contour Mode COMMAND DESCRIPTION CM ABCDEFGH Specifies which axes for contouring mode Any non contouring axes may be operated in other modes CD a b c d e f g h Specifies position increment
251. o synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the A and B motor form a circular motion the C axis may move in proportion to the vector move Similarly if A B and C perform a linear interpolation move W can be geared to the vector move Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced an additional distance with PR or JG commands or VP or LI Ramped Gearing DMC 2X00 In some applications especially when the master 1s traveling at high speeds it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing 1s engaged For example if the master axis 1s already traveling at 1 000 000 cts sec and the slave will be geared at a ratio of 1 1 when the gearing is engaged the slave will instantly develop following error Chapter 6 Programming Motion 91 and command maximum current to the motor This can be a large shock to the system For many applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame Galil allows the user to specify an interval of the master axis over which the gearing will be engaged For example the same master X axis in this case travels at 1 000 000 counts sec and the gear ratio 15 1 1 but the gearing
252. oint in the ECAM table ET 3 240 120 4th point in the ECAM table ET 4 280 140 5 point in the ECAM table ET 5 280 140 6 point in the ECAM table ET 6 280 140 7th point in the ECAM table ET 7 240 120 8th point in the ECAM table ET 8 120 60 9th point in the ECAM table ET 9 40 20 10th point in the ECAM table ET 10 0 0 Starting point for next cycle EB 1 Enable ECAM mode JGC 4000 Set C to jog at 4000 EG 0 0 Engage both A and B when Master 0 BGC Begin jog on C axis LOOP JP LOOP v1 0 Loop until the variable is set EQ2000 2000 Disengage A and B when Master 2000 MF 2000 Wait until the Master goes to 2000 STC Stop the C axis motion EB 0 Exit the ECAM mode EN End of the program The above example shows how the ECAM program is structured and how the commands can be given to the controller Figure 6 5 provides the results captured by the WSDK program This shows how the motion will be seen during the ECAM cycles The first graph is for the A axis the second graph shows the cycle on the B axis and the third graph shows the cycle of the C axis Chapter 6 Programming Motion 9 99 Three Storage Scopes en File Collection Graph First Scope x Position Zoom Normal Second Scope v Position Zoom Normal Third Scope z Position Zoom Normal Command String iStart Collecting Figure 6 5 Position Profiles of XYZ Contour Mode The DMC 2x00 also provide
253. ollowing conditions the motor off command MO is given the watchdog timer activates or the OEI DMC 2X00 Chapter 3 Connecting Hardware 3 command Enable Off On Error is given and the position error exceeds the error limit As shown in Figure 3 4 AMPEN can be used to disable the amplifier for these conditions The standard configuration of the AMPEN signal is TTL active high In other words the AMPEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed if you are using the ICM 2900 interface board To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AMPEN signal note the state of the resistor pack on the ICM 2900 When Pin 1 is on the 5V mark the output voltage is 0 5V To change to 12 volts pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side If you remove the resistor pack the output signal is an open collector allowing the user to connect an external supply with voltages up to 24V DMC 2x00 ICM 2900 Connection to 5V or 12V made resistor pack RP1 Removing the resistor allows the user to connect their own resistor the desired voltage level Up to 24V by removing ICM 2900 cover SERVO MOTOR AMPLIFIER
254. olution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 2 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Fig 7 1 The program starts at a state that we define as Here the controller waits for the input pulse on I1 As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle 164 gt Chapter 7 Application Programming DMC 2X00 Instruction Interpretation HA Label Wait for input 1 PR 6370 Distance SP 3185 Speed BGA Start Motion AMA After motion is complete SBI Set output bit 1 WT 20 Wait 20 ms Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process START PULSE 11 MOTOR VELOCITY OUTPUT PULSE output TIME INTERVALS DMC 2X00 move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals A B Table Controller An A B C system must cut the pattern shown in Fig 7 2 The A B table moves the plate while the C axis
255. on Capture 119 Limit Switch 39 124 136 137 138 172 174 203 Linear Interpolation 36 37 69 70 81 82 83 85 86 9 Logical 0 133 152 Masking see ERES 133 142 153 Memory 1 3 5 27 28 34 52 61 121 123 127 133 136 137 148 163 252 Message 17 18 48 54 60 127 137 143 154 155 Modelling eS 180 Motion Complete 07 124 129 137 139 Motion Smoothing 70 71 79 106 114 115 116 Motor Command 3 21 25 27 185 193 202 Multitasking 22 125 139 140 22 40 44 58 171 172 173 Operand Internal Variable 36 145 146 227 Operator Bit WISQ NL M AE 133 142 Output Amplifier Enable 7 22 43 171 206 220 Digital Output 1 144 158 206 219 222 224 225 227 Error 46 171 Motor Command 3 21 25 27 185 193 202 DMC 2X00 Output Compare x wit RR needs 45 Step and 3 4 Position Error POSERR 124 136 137 172 173 Position Limit 173 Program 123 128 160 Interrupt 1 123 124 131 135 136 138 140 141 152 153 160 161 203 245 cn 136 139 141 161 40 61 69 146 176 177 Proportional 30 Protection Error L
256. onfiguration for RS 232 RS 422 JP 5 for DMC 2100 2200 MAIN Main Serial Port configuration for RS 232 RS 422 NOTE MB denotes motherboard DB denotes daughter board JP7 MB 204 Appendices DMC 2X00 Dimensions for DMC 2x00 0 100 2 PLACES DMC 2080 MOUNTING DIMENSIONS Overall Dimensions 12 0 x 2 3 x 6 25 180 PLACES R0 100 9 000 5 j a i 8 3 i B 9 em p 4 l 1 105 2 940 70 9 810 10 75 Im DMC 2X00 6 250 Appendices 5 Accessories and Options CABLE USB 3M USB cable 3 meter CB 50 100 50 pin to 100 pin converter board includes two 50 pin ribbon cables CABLE 36 4M 36 pin high density cable 4 meter CB 50 80 50 pin to 80 pin converter board includes two 50 pin ribbon cables CABLE USB 2M USB cable 2 meter ICM 1900 LAEN Option for ICM 1900 OPTO Option for ICM 1900 CIEN Provides High Current Opto isolation for digital outputs of amplifiers Provides Opto0isolation for digital outputs Option for 19 0 Perte Opine digi outputs ICM 2900 LAEN Option for ICM 2900 Provides Active Low Amplifier Enable Signal OPTO Option for AMP 19x0 Provides Opto isolation for digital outputs Option for 19 0 Provides High Current Opto isolation fo
257. ontrol stepper motors In this mode the controller provides two signals to connect to the stepper motor Step and Direction For stepper motor operation the controller does not require an encoder and operates the stepper motor in an open loop fashion Chapter 2 describes the proper connection and procedure for using stepper motors Overview of Amplifiers The amplifiers should be suitable for the motor and may be linear or pulse width modulated An amplifier may have current feedback voltage feedback or velocity feedback Amplifiers in Current Mode Amplifiers in current mode should accept an analog command signal in the 10 volt range The amplifier gain should be set such that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V Amplifiers in Velocity Mode For velocity mode amplifiers a command signal of 10 volts should run the motor at the maximum required speed The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed Stepper Motor Amplifiers For step motors the amplifiers should accept step and direction signals 4 eChapter 1 Overview DMC 2X00 DMC 2x00 Functional Elements USB ETHERNET 68331 MICROCOMPUTER MOTOR ENCODER 64 Configurable I O DMC 2X00 The DMC 2x00 circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed below WATCHDO
258. or more axes have an additional 8 opto isolated inputs and an additional 8 TTL outputs This chapter describes the inputs and outputs and their proper connection If you plan to use the auxiliary encoder feature of the DMC 2x00 you will require a separate encoder cable and breakout contact Galil Motion control Using Optoisolated Inputs DMC 2X00 Limit Switch Input The forward limit switch FLSx inhibits motion in the forward direction immediately upon activation of the switch The reverse limit switch RLSx inhibits motion in the reverse direction immediately upon activation of the switch limit switch is activated during motion the controller will make decelerated stop using the deceleration rate previously set with the DC command The motor will remain in a servo state after the limit switch has been activated and will hold motor position When a forward or reverse limit switch is activated the current application program that 1 running will be interrupted and the controller will automatically jump to the LIMSWI subroutine if one exists This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch Automatic Subroutines are discussed in Chapter 6 After a limit switch has been activated further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to a
259. ors the controller can be configured to control full step half step or microstep drives An encoder 18 not required when step motors are used Amplifier Driver For each axis the power amplifier converts 10 volt signal from the controller into current to drive the motor For stepper motors the amplifier converts step and direction signals into current The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation is required or the controller must be configured to provide sinusoidal commutation The amplifiers may be either pulse width modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 volts should run the motor at the maximum speed 6 eChapter 1 Overview DMC 2X00 DMC 2X00 Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 2x00 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as CHA and CHB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended CHA and or differential CHA C
260. otion trajectory Teaching can be accomplished using the DMC 2x00 automatic array capture feature to capture position data The captured data may then be played back in the contour mode The following array commands are used DM C n Dimension array RA Specify array for automatic record up to 4 for DMC 2x40 RD TPA Specify data for capturing such as_TPA TPC RC n m Specify capture time interval where n is 2 samples m is number of records to be captured RC or RC Returns a 1 if recording Record and Playback Example Instruction Interpretation RECORD Begin Program DPO Define position for A axis to be 0 DA De allocate all arrays DM xpos 501 Dimension 501 element array called xpos RA xpos Record Elements into xpos array RD TPA Element to be recorded is encoder position of A axis MOA Motor off for A axis RC2 Begin Recording with a sample rate of 2 msec LOOP1 JP LOOP1 RC 1 Loop until all elements have been recorded COMPUTE Routine to determine the difference between consecutive points DM dx 500 Dimension a 500 element array to hold contour points i 0 Set loop counter LOOP2 Loop to calculate the difference DX I xpos i 1 xpos i Calculate difference 1 1 1 Update loop counter JP LOOP2 i lt 500 Continue looping until dx is full PLAYBK Routine to play back motion that was recorded 104 Chapter 6 Programming Motion DMC 2X00 SHA Servo Here WT1000 Wait 1 sec 1000 msec CMA Specify contour mo
261. ould be required to constantly monitor the motion of the object that it was following To remain within a specified distance it would also need to constantly update the position target it is moving towards Galil motion controllers support this type of motion with the position tracking mode This mode will allow scheduled or random updates to the current position target on the fly Based on the new target the controller will either continue in the direction it is heading change the direction it is moving or decelerate to a stop Chapter 6 Programming Motion 73 The position tracking mode shouldn t be confused with the contour mode The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate In this mode the position can be updated randomly or at a fixed time rate but the velocity profile will always be trapezoidal with the parameters specified by AC DC and SP Updating the position target at a specific rate will not allow the user to create a custom profile The following example will demonstrate the possible different motions that may be commanded by the controller in the position tracking mode In this example there is a host program that will generate the absolute position targets The absolute target is determined based on the current information the host program has gathered on the object that it is tracking The position tracking mode does allow for all of the axes on the contro
262. over time interval Range is 32 000 Zero ends contour mode when issued following DTO DTn Specifies time interval 2 msec for position increment where n is an integer between 1 and 8 Zero ends contour mode If n does not change it does not need to be specified with each CD WC Waits for previous time interval to be complete before next data record is processed General Velocity Profiles The Contour Mode is ideal for generating any arbitrary velocity profiles The velocity profile can be specified as a mathematical function or as a collection of points The design includes two parts Generating an array with data points and running the program Example Generating an Array Consider the velocity and position profiles shown in Fig 6 7 The objective 15 to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe the position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner 0 s cos 2zT B X A sin 22T B B 2 NOTE is the angular velocity A is the position and T is the variable time in milliseconds In the given example A 6000 and 120 the position and velocity profiles are 501 6000 27 sin 27 T 120 Note that the velocity 02 in count ms is 6 50 1 cos 27 T 120 102 e Chapter 6 Programming Motion DMC 2X00 DMC 2X00
263. per motors The position of the encoder can be interrogated by using the command TP The position value can be defined by using the command DE NOTE Closed loop operation with a stepper motor is not possible without special firmware Contact Galil for more information Command Summary Stepper Motor Operation Define Encoder Position When using an encoder Define Reference Position and Step Count Register Motion Profile Smoothing Independent Time Constant Stepper Motor Smoothing Chapter 6 Programming Motion 107 Motor Type 2 2 2 5 or 2 5 for stepper motors Report Commanded Position Report number of step pulses generated by controller Tell Position of Encoder Operand Summary Stepper Motor Operation Lom Contains te valne ofthe main encoder orte wai wn Stepper Position Maintenance Mode SPM The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle the event of stepper motor position error The mode looks at position feedback from the main encoder and compares it to the commanded step pulses The position information is used to determine if there is any significant difference between the commanded and the actual motor positions If such error is detected it is updated into a command value for operator use In addition the SPM mode can be used as a method to correct for friction at the end of a microstepping move This capability provides closed loop
264. pes When the human reaction is too strong the response becomes unstable Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which 1 designed to help the stability and accuracy Typically such a filter produces in addition to the proportional gain damping and integrator The combination of the three functions is referred to as a PID filter The filter parameters are represented by the three constants KP KI and KD which correspond to the proportional integral and derivative term respectively The damping element of the filter acts as a predictor thereby reducing the delay associated with the motor response The integrator function represented by the parameter KI improves the system accuracy With the KI parameter the motor does not stop until it reaches the desired position exactly regardless of the level of friction or opposing torque The integrator also reduces the system stability Therefore it can be used only when the loop is stable and has a high gain The output of the filter is applied to a digital to analog converter DAC The resultin
265. polarity of the limit switch may be set with the CN command Home Switch Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Input 1 Input 8 isolated Uncommitted inputs May be defined by the user to trigger events Inputs are checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input 1 is latch A Input 2 is latch B Input 3 is latch C and Input 4 is latch D if the high speed position latch function is enabled Input 9 Input 16 isolated High speed position latch to capture axis position on occurrence 1 latch signal AL command arms latch Input 1 is latch A Input 2 18 latch B Input 3 is latch C and Input 4 is latch D Input 9 1 latch E input 10 18 latch F input 11 1s latch G input 12 1s latch H DMC 2X00 Appendices 3 Jumper Description for DMC 2x00 Psi made or sro mon orses psi tors fywaewmpseme Lee motors SM must always be jumpered The Analog command is not valid with SM jumpered we SSCS C ma 2 2 sa LS er mm MRST Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated JP4 DB for DMC 2100 2200 18 corrupt JP4 DB for DMC 2000 AUX Serial Port C
266. ponse New format Specify hex format Return v1 Response Hex value Change format Return v1 Response Overflow PF and VF commands are global format commands that affect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command or n m following the variable name and the symbol specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal Chapter 7 Application Programming 157 Instruction Interpretation 1 10 Assign v1 vl Return v1 0000000010 0000 Default Format 1 4 2 Specify local format 0010 00 New format 1 4 2 Specify hex format 000A 00 Hex value vl ALPHA Assign string ALPHA to v1 vl S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 2x00 position parameters such as PR PA and VP have units of quadrature counts Speed parameters such as SP JG and VS have units of counts sec Acceleration parameters such as AC DC VA and VD have units of counts sec The controller interprets time in milliseconds All input parameters must be converted into these units For example an operator can be prompted to input a numb
267. position limit Set Forward position limit Jog BG ABC Begin motion stops at forward limits Off On Error The DMC 2x00 controller has a built in function which can turn off the motors under certain error conditions This function is know as Off On Error To activate the OE function for each axis specify 1 for A B C and D axis To disable this function specify 0 for the axes When this function is enabled the specified motor will be disabled under the following 3 conditions 1 The position error for the specified axis exceeds the limit set with the command ER 2 abort command is given 3 abort input is activated with a low signal NOTE If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Example OE 1 1 1 1 Enable off on error for A B C and D OE 0 1 0 1 Enable off on error for B and D axes Disable off on error for A and C Automatic Error Routine The POSERR label causes the statements following to be automatically executed if error on any axis exceeds the error limit specified by ER The error routine must be closed with the RE command The RE command returns from the error subroutine to the main program NOTE The Error Subroutine will be entered again unless the error condition is gone Example Instruction Interpretation A EN Dummy program POS
268. pressed in the range between 0 and 6000 Similarly the slave position is also redefined such that it starts at zero and ends at 1500 At the end of a cycle when the master is 6000 and the slave 1s 1500 the positions of both A and B are redefined as zero To specify the master cycle and the slave cycle change we use the instruction EM EM a b c d where a b c d specify the cycle of the master and the total change of the slaves over one cycle Chapter 6 Programming Motion 95 The cycle of the master is limited to 8 388 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 Step 3 Specify the master interval and starting point Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are specified by the instruction EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0 Step 4 Specify the slave positions Next we specify the slave positions with the instruction ET n a b c d where n indicates t
269. que When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to the velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt on the X axis TL 1 CR NOTE Once the correct polarity of the feedback loop has been determined the torque limit should in general be increased to the default value of 9 99 The servo will not operate properly if the torque limit is below the normal operating range See description of TL in the command reference 24 e Chapter 2 Getting Started DMC 2X00 DMC 2X00 Step D Connect the Motor Once the parameters have been set connect the analog motor command signal ACMD to the amplifier input To test the polarity of the feedback command a move with the instruction PR 1000 lt CR gt Position relative 1000 counts CR Begin motion on A axis When the polarity of the feedback is wrong the motor will attempt to run away The controller should disable the motor when the position error exceeds 2000 counts If the motor runs away the polarity of the loop must be inverted Inverting the Loop Polarity When the polarity of the feedback is incorrect the user must invert the loop polarity and this may
270. r 0 voltage and 99 8 for full positive voltage 25kHz switching frequency In the Sign Magnitude Mode Jumper SM the PWM signal is 0 for 0 voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output 50kHz switching frequency PWM STEP OUT For step motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Upon Reset the output will be low if the SM jumper is on If the SM jumper is not on the output will be tristate Sign Direction Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors Error The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER Output 1 Output 8 These 8 TTL outputs are uncommitted and may be designated by the user to toggle relays and trigger external events The output lines are toggled by Set Bit SB and Clear Bit CB instructions DMC 2x50 thru 2x80 The OP instruction is used to define the state of all the bits of the Output port Inputs Encoder B Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximum frequency does not exceed 12 000 000 quadrature states sec The controller performs quadrature decoding of the encoder
271. r digital outputs CABLE 36 1M 36 pin high density cable 1 meter Galil CD ROM Utilities Includes the following DMCWINI6 Windows 3 x Terminal DMCWIN32 Windows 95 98 NT Terminal SETUP16 Setup Utility for Window 3 x SETUP32 Setup Utility for Windows 95 98 NT CKIT C Programmers Kit Servo Design Kit for Windows 95 98 NT Visual Basic Tool Kit includes VBXs and OCXs CAD to DMC 206 e Appendices DMC 2X00 ICM 2900 Interconnect Module Mechanical Specifications Description Unit Specification Weight Ib 2 3 Length in 12 25 Width in 2 61 Height in 2 37 Environmental Specifications Description Unit Specification Storage Temperature C 25 to 70 Operating Temperature C 0 to 0 Operating Altitude feet 10 000 Equipment Maintenance The ICM 2900 does not require maintenance Description The ICM 2900 interconnect module provides easy connections between the Optima series controllers and other system elements such as amplifiers encoders and external switches The ICM 2900 accepts the 100 pin main cable and provides terminal blocks for connections Each terminal 15 labeled for quick connection of system elements The ICM 2900 provides access to the signals for up to 4 axes Two required for 5 or more axes Label Description MOCMDZ Z axis motor command to amp input w respect to ground SIGNZ Z axis sign output for input to stepper motor amp PWMZ lo Z axis pulse output for input to stepp
272. r establishing Ethernet connections ARP Is an application that determines the Ethernet hardware address of a device at a specific IP address BOOT P is an application that determines which devices on the network do not have an IP address and assigns the IP address you have chosen to it Ping 1 used to check the communication between the device at a specific IP address and the host computer The DMC 2100 can communicate with a host computer through any application that can send TCP IP or UDP IP packets A good example of this is Telnet a utility that comes with most Windows systems 54 e Chapter 4 Communication DMC 2X00 Data Record The DMC 2x00 can provide a block of status information with the use of a single command QR This command along with the QZ command can be very useful for accessing complete controller status The QR command will return 4 bytes of header information and specific blocks of information as specified by the command arguments QR ABCDEFGHST Each argument corresponds to a block of information according to the Data Record Map below If no argument is given the entire data record map will be returned Note that the data record size will depend on the number of axes Data Record Map DMC 2X00 DATA TYPE Qc wuguddauscuddacddzdcdcdcdcdccocdcdccctucdgcdua zdgceccd t z U z z U uU u ou ou c t t z Uu uw oc ITEM BLOCK 1 byte of header Header
273. r example the user may wish to have the x axis motor move 1000 counts in the positive direction when the logic state of IN1 goes high Controllers with more than 4 axes have 16 optoisolated inputs which are denoted as Inputs 1 thru 16 Wiring the Opto Isolated Inputs DMC 2X00 The Opto isolation inputs have a bi directional capability To activate an input at least of current must flow from the input common through the input see figure 3 1 This can be accomplished by 2 methods Method 1 Connect a positive voltage in the range of 5V to 24V with respect to the input at the input common point Each input is connected to ground to activate the input Method 2 Connect ground to the input common point Each input is activated by connecting a positive voltage between 5 and 24 volts The Opto Isolation Common Point The opto isolated inputs are configured into 2 groups The general inputs IN 1 IN 8 and the ABORT input are in one group The signal INCOM is a common connection for all inputs in this group The limit switches and home switches are in the second group The signal LSCOM is a common connection for all inputs in this group Figure 3 1 illustrates the internal circuitry Group Controllers with 1 4 Group Controllers with 5 9 Common Axes Axes Signal IN 1 IN 8 ABORT IN 1 IN 16 ABORT INCOM FLA RLA HOMEA FLA RLA HOMEA FLB RLB HOMEB LSCOM FLB RLB HOMEB FLC RLC HOMEC FLD RLD HOMED FLC RLC HOMEC F
274. r of elements defaults to the smallest array defined by DM When m is a negative number the recording is done continuously in a circular manner RD is the recording pointer and indicates the address of the next array element 0 stops recording Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Recorder pee For Analog Input Letter corresponds to input e g AFA 1 Analog In AFB 2 Analog In NOTE A may be replaced by B C D E F G or for capturing data on other axes Operand Summary Automatic Data Capture Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress RD Returns address of next array element Example Recording into an Array Instruction Interpretation RECORD Begin program DM apos 300 bpos 300 Define A B position arrays DM aerr 300 berr 300 Define A B error arrays RA apos aerr bpos berr Select arrays for capture RD TPA TEA TPB TEB Select data types Chapter 7 Application Programming 149 Input of PR 10000 20000 Specify move distance 1 Start recording now at rate of 2 msec BG AB Begin motion ZA RC 1 Loop until done MG DONE Print message EN End program PLAY Play back 0 Initial Counter JP DONE N gt 300 Exit if done n Print Counter apos n Print X position bpos n Print Y position aerr n Print X error berr n Print Y error n n 1 In
275. r segments such as engraving or quilting Third axis must remain tangent to 2 D motion path Coordinated motion with tangent such as knife cutting axis specified Electronic gearing where slave axes are scaled to Electronic Gearing GA GD master axis which can move in both directions GP GR GM if gantry Master slave where slave axes must follow a Electronic Gearing GA GD master such as conveyer speed _GP GR Moving along arbitrary profiles or mathematically Contour Mode prescribed profiles such as sine or cosine trajectories Teaching or Record and Play Back Contour Mode with Automatic Array Capture Backlash Correction Dual Loop Following a trajectory based on a master encoder Electronic Cam position EQ Smooth motion while operating in independent axis Independent Motion Smoothing IT positioning Smooth motion while operating in vector orlinear Vector Smoothing VT interpolation positioning Smooth motion while operating with stepper Stepper Motor Smoothing KS motors Gantry two axes are coupled by gantry Gantry Mode GM Independent Axis Positioning In this mode motion between the specified axes 1s independent and each axis follows its own profile The user specifies the desired absolute position PA or relative position PR slew speed SP 70 gt Chapter 6 Programming Motion DMC 2X00 DMC 2X00 acceleration ramp AC and deceleration ramp DC for each axis On begin BG the DMC 2x00 pro
276. racters will continue to build up in the controller until the FIFO is full For more information see the CW command in the Command Reference Galil Software Tools and Libraries API Application Programming Interface software 15 available from The software is written in C and is included in the Galil CD ROM They can be used for development under Windows environments With the API s the user can incorporate already existing library functions directly into a C program Galil has also developed a Visual Basic Toolkit This provides 32 bit OCXs for handling all of the DMC 2x00 communications including support of interrupts These objects install directly into Visual Basic and are part of the run time environment Galil also has an Active X Tool Kit to allow developers to rapidly develop their own user applications For more information contact Galil 60 Chapter 4 Communication DMC 2X00 Chapter 5 Command Basics Introduction The DMC 2x00 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands can be sent in ASCII or binary In ASCII the DMC 2x00 instruction set is BASIC like and easy to use Instructions consist of two uppercase letters that correspond phonetically with the appropriate function For example the instruction BG begins motion and ST stops the motion In binary commands are repres
277. rate same as dip switch settings on controller change as necessary Stability Motor runs away when the loop is Wrong feedback polarity Invert the polarity of the loop by closed inverting the motor leads brush type or the encoder Motor oscillates Too high gain or too little Decrease KI and KP Increase KD damping Operation SYMPTOM CAUSE REMEDY Controller rejects command Anything Interrogate the cause with TC or Responded with a TCI Motor does not complete move Noise on limit switches stops the To verify cause check the stop motor code SC If caused by limit switch noise reduce noise During a periodic operation motor Encoder noise Interrogate the position drifts slowly periodically If controller states that the position is the same at different locations it implies encoder noise Reduce noise Use differential encoder inputs Same as above Programming error Avoid resetting position error at end of move with SH command 176 gt Chapter 9 Troubleshooting DMC 2X00 Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Fig 10 1 COMPUTER DMC 2X00 CONTROLLER DRIVER ENCODER am Figure 10 1 Elements of Servo Systems The operation of such a system can be divided into three levels as illustrated in
278. rator amp is a Logical And The operator is a Logical Or These operators allow for bit wise operations on any valid DMC 2x00 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The characters can be individually separated by using bit wise operations as illustrated in the following example Instruction Interpretation TEST Begin main program IN ENTER len S6 Input character string of up to 6 characters into variable len flen FRAC len Define variable flen as fractional part of variable len 142 e Chapter 7 Application Programming DMC 2X00 DMC 2X00 flen 10000 len1 flen amp 00FF len2 flen amp 00 100 len3 len amp 000000FF len4 len amp 0000FF00 100 len5 len amp 00FF0000 10000 len6 len amp FF000000 10
279. re a BG NOTE If the motor is not moving the IP command is equivalent to the PR and BG command combination Command Summary Independent Axis AM MC ABCD The DMC 2x00 also allows use of single axis specifiers such 88 0 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the speed for the axis specified by x Chapter 6 Programming Motion 71 Returns current destination if x axis is moving otherwise returns the current commanded position if in a move Returns current incremental distance specified for the axis Examples Absolute Position Movement Instruction PA 10000 20000 AC 1000000 1000000 DC 1000000 1000000 Deceleration for A B SP 50000 30000 Speeds for A B BG AB Begin motion Interpretation Specify absolute A B position Acceleration for A B Multiple Move Sequence Required Motion Profiles A Axis 500 counts Position 10000 count sec Speed 500000 counts sec Acceleration B Axis 1000 counts Position 15000 count sec Speed 500000 counts sec Acceleration C Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on A B and C axes The movement on each axis will be separated by 20 msec Fig 6 1 shows the velocity profiles for the A B and C axis I
280. real time data Data Record Block Data Transfer No DMA channel processing amp recording Easy to install USB is self configuring Plug and Play USB not available Can capture and save array data Variable storage Firmware can be upgraded in field Flash memory for firmware EPROM for firmware which without removing controller from PC must be installed on controller Faster servo operation good for very 12 MHz encoder speed for servos 8 MHz high resolution sensors Faster stepper operation 3 MHz stepper rate Higher servo bandwidth 62 usec axis sample time 125 usec axis Higher resolution for analog inputs 8 analog inputs with 16 bit ADC option 7 inputs with 16 Bit option Improved EMI 100 pin high density connector 60 pin IDC 26 pin IDC 20 pin IDC x2 For precise registration applications Output Position Compare Available as a special More flexible gearing Multiple masters allowed in gearing One master for gearing mode Binary command mode Binary and ASCII communication ASCII only modes Multiple Gearing Masters Accepted Single Gearing Master Accepted Coordinated Motion 2 Sets of Coordinated Motion Accepted Single set of coordinated motion only 252 Appendices DMC 2X00 List of Other Publications Step by Step Design of Motion Control Systems by Dr Jacob Tal Motion Control Applications by Dr Jacob Tal Motion Control by Microprocessors by Dr Jacob Tal Training Seminars Galil a leader in motion contro
281. ree homing routines supported by the DMC 2x00 Find Edge FE Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEA return BGA return The Find Edge routine will cause the motor to accelerate then slew at constant speed until a transition 1s detected in the logic state of the Home input The direction of the FE motion is dependent on the state of the home switch The motor will then decelerate to a stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP It is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine is initiated by the command sequence FIA return BGA return Find Index will cause the motor to accelerate to the user defined slew speed at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The slew speed and direction in which the motor will move is designated by the JG command The motor then decelerates to a stop at the rate previously specified by the user with the DC command Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is i
282. ruction in a program must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 80 characters A carriage return enters the final command on a program line Using Labels in Programs DMC 2x00 programs must begin with a label and end with an End EN statement Labels start with the pound 7 sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted The maximum number of labels which may be defined is 510 for firmware 1 0c and higher Valid labels ZBEGIN SQUARE X1 ZBEGINI Invalid labels 1 123 Example Instruction Interpretation 5 Beginning of the Program PR 10000 20000 Specify relative distances on A and B axes BG AB Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves A and B 10000 and 20000 units After the motion is complete the motors rest for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 2x00 has some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines See section on Auto Start Routine The DMC 2x00
283. s a contouring mode This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes This is ideal for following computer generated paths such as parabolic spherical or user defined profiles The path is not limited to straight line and arc segments and the path length may be infinite Specifying Contour Segments The Contour Mode is specified with the command CM For example CMAC specifies contouring on the A and C axes Any axes that are not being used in the contouring mode may be operated in other modes A contour is described by position increments which are described with the command CD a b c d over atime interval DT n The parameter n specifies the time interval The time interval is defined as 2 ms where n is a number between 1 and 8 The controller performs linear interpolation between the specified increments where one point is generated for each millisecond Consider for example the trajectory shown in Fig 6 6 The position A may be described by the points Point 1 A 0 at T 0ms Point 2 A 48 at T 4ms Point 3 A 288 at T 12ms Point 4 A 336 at T 28ms The same trajectory may be represented by the increments 100 Chapter 6 Programming Motion DMC 2X00 Increment 1 DA 48 Time 4 DT 2 Increment 2 DA 240 Time 8 DT 3 Increment 3 DA 48 Time 16 DT 4 When the controller receives the command to generate a trajectory along these points it interpolates linearly between the points The resulting interpolated poi
284. s of DMC 2100 DMC 2200 For a complete system Galil recommends the following elements 18 DMC 2x10 2x20 2x30 or DMC 2x40 Motion Controller 15 DMC 2x50 2x60 2x70 or DMC 2x80 2a 1 ICM 2900 and 1 CABLE 100 for controllers DMC 2x10 through DMC 2x40 2b 2 ICM 2900 s and 2 CABLE 100 s for controllers DMC 2x50 through DMC 2x80 2c interconnect board provided by the user 3 1 IOM 1964 and 1 CABLE 80 for access to the extended I O Only required if extended I O will be used The CABLE 80 can also be converted for use with OPTO 22 or Grayhill I O modules consult Galil 4 1 ICM 2908 and 1 CABLE 36 for access to auxiliary encoders Only required if auxiliary encoders are needed DMC 2X00 Chapter 2 Getting Started 13 Go Gh GO MA Motor Amplifiers Power Supply for Amplifiers Brush or Brushless Servo motors with Optical Encoders or stepper motors PC Personal Computer RS232 or USB for DMC 2000 or Ethernet for DMC 2100 9a WSDK 16 or WSDK 32 recommend for first time users or 9b DMCWINI6 DMCWIN32 or DMCDOS communication software The WSDK software is highly recommended for first time users of the DMC 2x00 It provides step by step instructions for system connection tuning and analysis Installing the DMC 2x00 Installation of a complete operational DMC 2x00 system consists of 9 steps Step 1 Step 2 Step 3a Step 3b Step 3c Step 4 Step 5 Step 6 Step 7 Step 8 Step 9a
285. se and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought of as a simple Resistor Capacitor single pole filter The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor Use of KS is most applicable when operating in full step or half step operation KS will cause the step pulses to be delayed in accordance with the time constant specified When operating with stepper motors you will always have some amount of stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving back and
286. single ended A B only or differential A A B B Maximum edge rate 12 MHz Minimum IDX pulse width 80 nsec TTL 0 5 volts level at 50 duty cycle 3 000 000 pulses sec maximum frequency TTL 0 5 volts 2 2K ohm in series with opto isolator Active high or low requires at least ImA to activate Once activated the input requires the current to go below 0 5ma Limit Switch and Home inputs use one common voltage LSCOM which can accept up to 24 volts Voltages above 24 volts require an additional resistor 2 mA ON lt 0 5 OFF Standard configuration is 10 volts 12 Bit Analog to Digital converter 16 bit optional TTL TTL Auxiliary Encoder Inputs for A X axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Appendices 1 IN 83 IN 84 DMC 2x20 through DMC 2x80 only IN 85 IN 86 DMC 2x30 through DMC 2x80 only IN 87 IN 88 DMC 2x40 through DMC 2x80 only IN 89 IN 90 DMC 2x50 through DMC 2x80 only IN 91 IN 92 DMC 2x60 through DMC 2x80 only IN 93 IN 94 DMC 2x70 through DMC 2x80 only IN 95 IN 96 DMC 2x80 only Power T5V LIA 12V 40 mA 12V 40 mA Performance Specifications Auxiliary Encoder Inputs for B Y axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for C Z axis Line Receiver Inputs accep
287. slide is to be controlled by a rotary motor which is coupled to the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy is for 0 5 micron 168 gt Chapter 7 Application Programming DMC 2X00 DMC 2X00 The basic dilemma is where to mount the sensor If you use a rotary sensor you get a 4 micron backlash error On the other hand if you use a linear encoder the backlash in the feedback loop will cause oscillations due to instability An alternative approach 15 the dual loop where we use two sensors rotary and linear The rotary sensor assures stability because the position loop is closed before the backlash whereas the linear sensor provides accurate load position information The operation principle is to drive the motor to a given rotary position near the final point Once there the load position is read to find the position error and the controller commands the motor to move to a new rotary position which eliminates the position error Since the required accuracy 18 0 5 micron the resolution of the linear sensor should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000
288. ssages returned from the controller Step D part 2 Systems with Hall Sensors Only Test the Hall Sensor Configuration Since the Hall sensors are connected randomly it is very likely that they are wired in the incorrect order The brushless setup command indicates the correct wiring of the Hall sensors The Hall sensor wires should be re configured to reflect the results of this test The setup command also reports the position offset of the Hall transition point and the zero phase of the motor commutation The zero transition of the Hall sensors typically occur at 0 30 or 90 of the phase commutation It is necessary to inform the controller about the offset of the Hall sensor and this is done with the instruction BB Step E Save Brushless Motor Configuration Itis very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configured the burn command BN should be given NOTE Without Hall sensors the controller will not be able to estimate the commutation phase of the brushless motor In this case the controller could become unstable until the commutation phase has been set using the BZ command see next step It is highly recommended that the motor off command be given before executing the BN command In this case the motor will be disabled upon power up or reset and the commutation phase can be set before enabling the motor Step F part 1
289. ster axes as well as gantry mode operation For synchronization with outside events the DMC 2x00 provides uncommitted I O including 8 opto isolated digital inputs 16 inputs for DMC 2x50 thru DMC 2x80 8 digital outputs 16 outputs for DMC 2x50 thru DMC 2x80 and 8 analog inputs for interface to Joysticks sensors and pressure transducers The DMC 2x00 also has an additional 64 I O Further I O is available if the auxiliary encoders are not being used 2 inputs each axis Dedicated optoisolated inputs are provided for forward and reverse limits abort home and definable input interrupts Commands can be sent in either Binary or ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen CAD translation and program development using many environments such as Visual Basic C etc Drivers for DOS Linux Windows 3 1 95 98 2000 ME and NT are available DMC 2X00 Chapter 1 Overview 9 1 Specifications DMC 2000 Family Part Number Definition DMC 200 0 Communication Options 0 USB 2 Ethernet Number of Axis One Axes WO Axes Three Axes Four Axes Six Axes 1 2 3 4 5 Five Axes 6 7 Seven Axes 8 Eight Axes Electrical Specifications Description AC Input Line Voltage AC Input Line Frequency Power Dissipation Unit VAC Mechanical Specifications Description 2 eChapter 1 Overview Unit Specification 100 240 50
290. ster reset all programs and motion control parameters stored in EEPROM will be ERASED During normal operation this switch should be off Switch 2 XON XOFF When on this switch will enable software handshaking XON XOFF through the main serial port Switch 3 Hardware Handshake Mode When on this switch will enable hardware handshaking through the main serial port 16 gt Chapter 2 Getting Started DMC 2X00 DMC 2X00 Switch 4 5 and 6 Main Serial Port Baud Rate The following table describes the baud rate settings 192 9900 OFF OFF 19200 OFF OFF 38400 Switch 10 USB When on the controller will use the USB port as a default port for messages When off the controller will use the RS 232 port as default When the firmware 15 updated the controller will send the response a colon to the default port setting If this 1 not the same port that was used to download the firmware the Galil software will not return control to the user In this case the software will have to be re started Step 3b Configure DIP switches on the DMC 2100 Switch 1 Master Reset When this switch 15 on the controller will perform a master reset upon PC power up Whenever the controller has a master reset all programs and motion control parameters stored in EEPROM will be ERASED During normal operation this switch should be off Switch 2 XON XOFF When on this switch will enable software handsh
291. switches are opto isolated If you are not using an isolated supply the internal 5 supply from the PC may be used to power the opto isolators This is done by installing jumpers on JP3 on main board Chapter 2 Getting Started 15 Stepper Motor Jumpers For each axis that will used for stepper motor operation the corresponding stepper mode SM jumper nn must be connected The stepper mode jumpers labeled JP5 and JP7 are located directly beside the GL 1800 IC s on the main board see the diagram of the DMC 2x00 The individual jumpers are labeled SMA thru SMH and configure the controller for Stepper Motors for the corresponding axes A H when installed Note that the daughter board must be removed to access these jumpers Contact the Galil factory if stepper motor jumpers should be placed on your controller with each order for a special part number Optional Motor Off Jumpers The state of the motor upon power up may be selected with the placement of a hardware jumper on the controller With a jumper installed at the MO location the controller will be powered up in the motor off state The SH command will need to be issued in order for the motor to be enabled With no jumper installed the controller will immediately enable the motor upon power up The MO command will need to be issued to turn the motor off The MO jumper is always located on the same block of jumpers as the stepper motor jumpers SM This feature is only av
292. t by NB and the real part of the zeros 18 set by NZ The simplest procedure for setting the notch filter is to identify the resonance frequency and set NF to the same value Set NB to about one half of NF and set NZ to a low value between zero and 5 ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 81 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis DMC 2X00 Chapter 10 Theory of Operation 185 System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 2x00 controller and the following parameters 0 1 Nm A Torque constant 1 14 kg m2 System moment of inertia R 2 Q Motor resistance 4 Current amplifier gain 12 5 Digital filter gain KD 245 Digital filter zero 0 No integrator 500 Counts rev Encoder line density ms Sample period 1 The transfer function of the system elements are Motor M s P I Kt Js2 500 52 rad A Amp 4 Amp V DAC Kg 0 0003 V co
293. t initial value Main move Start motion Correction loop Wait for motion completion Find linear encoder error Compensate for motor error Exit if error is small Correction move Start correction Repeat The DMC 2x00 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system 114 e Chapter 6 Programming Motion DMC 2X00 DMC 2X00 Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value The discontinuous acceleration results in jerk which causes vibration The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration Using the IT and VT Commands When operating with servo motors motion smoothing can be accomplished with the IT and VT command These commands filter the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile has continuous acceleration and results in reduced mechanical vibrations The smoothing function 18 specified by the following commands IT a b c d Independent time constant VTn Vector time constant The command IT is used for smoothing independent moves of the type JG PR PA and the command VT is used to smooth vector moves of the type VM and LM The smoothing parameters a b c d and n are numbers between 0 and 1 and determine the degree of filtering The maximum value of 1 implies no f
294. t linear segment Specify second linear segment End linear segments Specify vector speed Begin motion sequence Set trip point to wait until vector distance of 4000 is reached Change vector speed Set trip point to wait until vector distance of 5000 is reached Change vector speed Program end Make a coordinated linear move in the CD plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 counts sec Instruction LM CD LI 40000 30000 LE VS 100000 VA 1000000 VD 1000000 BGS Interpretation Specify axes for linear interpolation Specify CD distances Specify end move Specify vector speed Specify vector acceleration Specify vector deceleration Begin sequence Note that the above program specifies the vector speed VS and not the actual axis speeds VC and VD The axis speeds are determined by the DMC 2x00 from VS JVC vD The resulting profile is shown in Figure 6 2 84 e Chapter 6 Programming Motion DMC 2X00 30000 27000 POSITION D 3000 0 4000 36000 40000 POSITION C FEEDRATE 0 0 1 0 5 0 6 TIME sec VELOCITY C AXIS TIME sec VELOCITY D AXIS TIME sec Figure 6 2 Linear Interpolation DMC 2X00 Chapter 6 Programming Motion 85 Multiple Moves This example makes a coordinated linear move in the AB plane The Arrays VA and VB are used to store 750 incremental distances which are filled by the program
295. terpolation COMMAND buffer Zero means buffer full 512 means buffer empty ANS Operand Summary Linear Interpolation OPERAND _LM Returns number of available spaces for linear segments in DMC 2x00 sequence buffer Zero means buffer full 512 means buffer empty _VPm Return the absolute coordinate of the last data point along the trajectory m A B C D E F G or H To illustrate the ability to interrogate the motion status consider the first motion segment of our example ZLMOVE where the A axis moves toward the point A 5000 Suppose that when A 3000 the controller is interrogated using the command The returned value will be 3000 The valueof CS VPAand VPB will be zero Now suppose that the interrogation is repeated at the second segment when 2000 The value of AV at this point is 7000 CS equals 1 5000 0 Example Linear Interpolation Motion In this example the AB system is required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trip point which slows the speed to 1000 count s Once the motors reach the corner the speed 18 increased back to 4000 cts s Instruction Interpretation LMOVE Label Chapter 6 Programming Motion 83 DP 0 0 LMAB LI 5000 0 LI 0 5000 LE VS 4000 BGS AV 4000 VS 1000 AV 5000 VS 4000 EN Linear Move Define position of A and B axes to be 0 Define linear mode between A and B axes Specify firs
296. the start of the move or from the last AV command Instruction VECTOR VMAB VS 5000 VP 10000 20000 VP 20000 30000 VE BGS AV 5000 VS 1000 EN DMC 2X00 Interpretation Label Coordinated path Vector position Vector position End vector Begin sequence After vector distance Reduce speed End Chapter 7 Application Programming 131 Example Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves Instruction Interpretation MOVES Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration BGA Start Motion AD 10000 Wait a distance of 10 000 counts SP 5000 New Speed AMA Wait until motion is completed WT 200 Wait 200 ms PR 10000 New Position SP 30000 New Speed AC 150000 New Acceleration BGA Start Motion EN End Example Define Output Waveform Using AT The following program causes Output to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec Instruction Interpretation ZOUTPUT Program label ATO Initialize time reference SBI Set Output 1 LOOP Loop AT 10 After 10 msec from reference Clear Output 1 AT 40 Wait 40 msec from reference and reset reference SBI Set Output 1 JP LOOP Loop EN Conditional Jumps The DMC 2x00 provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition T
297. the two sinusoidal signals generated by the controller The first signal is the axis specified with the command BA Step 6 The second signal 5 associated with the highest analog command signal available on the controller note that this axis was made unavailable for standard servo operation by the command BA When more than one axis is configured for sinusoidal commutation the controller will assign the second phase to the command output which has been made available through the axes reconfiguration The 274 phase of the highest sinusoidal commutation axis will be the highest command output and the 2M phase of the lowest sinusoidal commutation axis will be the lowest command output It is not necessary to be concerned with cross wiring the 1 and 274 signals If this wiring is incorrect the setup procedure will alert the user Step D Example Sinusoidal Commutation Configuration using a DMC 2x70 BAAC This command causes the controller to be reconfigured as a DMC 2x50 controller The A and C axes are configured for sinusoidal commutation The first phase of the A axis will be the motor command A signal The second phase of the A axis will be the motor command F signal The first phase of the C axis will be the motor command C signal The second phase of the C axis will be the motor command G signal Step C Specify the Size of the Magnetic Cycle Use the command BM to specify the size of the brushless motors magnetic cycle in enco
298. tivates the dual loop for the four axes and DV 0 0 0 0 disables the dual loop Note that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI 1f necessary Sampled Dual Loop In this example we consider a linear slide which is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it is best to use a rotary encoder on the motor Connect the rotary encoder to the A axis and connect the linear encoder to the auxiliary encoder of A Assume that the required motion distance is one inch and that this corresponds to 40 000 counts of the rotary encoder and 10 000 counts of the linear encoder The design approach 15 to drive the motor 8 distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program Instruction DUALOOP CE 0 DEO PR 40000 BGA CORRECT AMA 1 10000 DEA v2 _TEA 4 v1 JP END ABS v2 lt 2 PR v2 4 BGA JP CORRECT END EN Motion Smoothing Interpretation Label Configure encoder Se
299. to original speed Re enable trip point and communication interrupt Example Ethernet Communication Error This simple program executes in the DMC 2100 2200 and indicates via the serial port when a communication handle fails By monitoring the serial port the user can re establish communication if needed Instruction LOOP JP LOOP EN TCPERR MG IA4 RE Interpretation Simple program loop Ethernet communication error auto routine Send message to serial port indicating which handle did not receive proper acknowledgment Chapter 7 Application Programming 141 Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 2x00 provides the use of the following mathematical operators Multiplication The numeric range for addition subtraction and multiplication operations 15 9 The precision for division is 1 65 000 Mathematical operations are executed from left to right Calculations within parentheses have precedence speed 7 5 v1 2 The variable speed is equal to 7 5 multiplied by v1 and divided by 2 count count 2 The variable count is equal to the current value plus 2 result _TPA COS 45 40 Puts the position of A 28 28 in result 40 cosine of 45 is 28 28 temp IN 1 amp IN 2 temp is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators The mathematical operators amp and are bit wise operators The ope
300. troller read the following discussion on setting Error Limits and Torque Limits Note that this discussion only uses the A axis as an examples Step B Set the Error Limit as a Safety Precaution Usually there is uncertainty about the correct polarity of the feedback The wrong polarity causes the motor to run away from the starting position Using a terminal program such as DMCTERM the following parameters can be given to avoid system damage Input the commands ER 2000 CR Sets error limit on the A axis to be 2000 encoder counts OE 1 CR Disables A axis amplifier when excess position error exists If the motor runs away and creates a position error of 2000 counts the motor amplifier will be disabled NOTE This function requires the AMPEN signal to be connected from the controller to the amplifier Step C Set Torque Limit as a Safety Precaution To limit the maximum voltage signal to your amplifier the DMC 2x00 controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output tor
301. ts based rates up to 12Mb sec and the two RS 232 channels can generate up to 115K Chapter 1 Overview gt 5 General I O The DMC 2x00 provides interface circuitry for 8 bi directional optoisolated inputs 8 TTL outputs and 8 analog inputs with 12 Bit ADC 16 Bit optional The DMC 2x00 also has an additional 64 I O and unused auxiliary encoder inputs may also be used as additional inputs 2 inputs each axis The general inputs can also be used as high speed latches for each axis A high speed encoder compare output is also provided The DMC 2x50 through DMC 2x80 controller provides an additional 8 optoisolated inputs and 8 TTL outputs System Elements As shown in Fig 1 2 the DMC 2x00 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Computer Power Supply DMC 2x00 Controller Encoder Figure 1 2 Elements of Servo systems Motor Amplifier Driver A motor converts current into torque which produces motion Each axis of motion requires a motor sized properly to move the load at the required speed and acceleration Galil s Motion Component Selector software can help you with motor sizing Contact Galil at 800 377 6329 if you would like this product The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step mot
302. ts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for D W axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for E axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for F axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for G axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for H axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Minimum Servo Loop Update Time DMC 2x10 DMC 2x20 DMC 2x30 DMC 2x40 DMC 2x50 DMC 2x60 DMC 2x70 DMC 2x80 Position Accuracy 192 e Appendices Normal Fast Firmware 250 usec 125 psec 250 usec 125 usec 375 usec 250 psec 375 psec 250 psec 500 usec 375 usec 500 psec 375 usec 625 usec 500 usec 625 usec 500 usec 1 quadrature count DMC 2X00 Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Array Size Program Size Fast Update Rate Mode The DMC 2x00 can operate with much faster servo update rates This mode 1
303. uence sss 88 Operand Summary Coordinated Motion 89 oiov een iles 89 Electronic ede pne e 91 91 Example ede 93 7 93 Electronic ee dde indi alanis OE 95 Command Summary Electronic 98 Operand Summary Electronic 99 99 Contour Mode nds lon ebrei ner tei Rr De 100 Specifying Contour Segment 100 7 101 7 102 General Velocity Profiles 22 102 Examples a snae ese ne ide e RU Te 102 AXIS ER 105 Ecam master example esee ee 105 22 5 15 Stepper Motor io aie VERE IR RENE TEN NERA E EI dots 106 106 Stepper Motor E E ARRE R 106 Monitoring Generated Pulses vs Commanded 4 106 0 107 Using an Encoder with Stepper Motors sse 107 Command Summary Stepper Motor Operation seen 107 108 Stepper Position Maintenance Mode SPM
304. und and earth by a 10 resistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal 15 used by the controller to disable the motor This signal is labeled AMPENA for the A axis on the ICM 2900 and should be connected to the enable signal on the amplifier Note that many amplifiers designate this signal as the INHIBIT signal Use the command MO to disable the motor amplifiers check to insure that the motor amplifiers have been disabled often this is indicated by an LED on the amplifier This signal changes under the following conditions the watchdog timer activates the motor off command is given or the OE1 command Enable Off On Error is given and the position error exceeds the error limit AMPEN can be used to disable the amplifier for these conditions The standard configuration of the AMPEN signal is TTL active high In other words the AMPEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed if you are using the ICM 2900 interface board change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AMPEN signal note the state of the resistor pack on
305. unt Encoder 2 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 T 0 001 Therefore D z 1030 z 0 95 Z Accordingly the coefficients of the continuous filter are P 50 D 0 98 The filter equation may be written in the continuous equivalent form G s 50 0 985 098 5 51 The system elements are shown in Fig 10 7 186 gt Chapter 10 Theory of Operation DMC 2X00 FILTER ZOH DAC AMP MOTOR V 2000 500 0 0003 4 50 0 980s 62000 ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s 18 the product of all the elements in the loop A 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency o at which A j c equals one This can be done by the Bode plot of AG as shown in Fig 10 8 Magnitude 50 200 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 200 2 200 2000 a Arg A j200 tan 200 51 180 tan 200 2000 a 76 180 6 110 DMC 2X00 Chapter 10 Theory of Operation 187 Finally the phase margin PM equals 180 a 70 As long
306. unts SBI Set output bit 1 EN End program Example Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR is used as shown in the next example Instruction Interpretation TRIP Label JG 50000 Specify Jog Speed BGA n 0 Begin Motion Repeat Loop AR 10000 Wait 10000 counts TPA Tell Position SBI Set output 1 WT50 Wait 50 msec Clear output 1 1 Increment counter JP REPEAT n lt 5 Repeat 5 times STA Stop EN End Example Start Motion on Input This example waits for input 1 to go low and then starts motion 130 gt Chapter 7 Application Programming DMC 2X00 NOTE The AI command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Input Interrupt function II or use a conditional jump on an input such as JP GO IN 1 71 Instruction 1 1 10000 BGA EN Example Set Output when At Speed Instruction ATSPEED JG 50000 AC 10000 BGA ASA SBI EN Interpretation Program Label Wait for input 1 low Position command Begin motion End program Interpretation Program Label Specify jog speed Acceleration rate Begin motion Wait for at slew speed 50000 Set output 1 End program Example Change Speed along Vector Path The following program changes the or vector speed at the specified distance along the vector The vector distance is measured from
307. unts inch The program below uses the variable len to length The IN command is used to prompt the operator to enter the length and the entered value is assigned to the variable LEN Instruction Interpretation BEGIN LABEL AC 800000 Acceleration DC 800000 Deceleration SP 5000 Speed len 3 4 Initial length in inches CUT Cut routine All Wait for start signal IN enter Length IN len PR LEN 4000 Prompt operator for length in inches Specify position in counts BGA Begin motion to move material AMA Wait for motion done SBI Set output to cut WT100 CBl Wait 100 msec then turn off cutter JP ZCUT Repeat process EN End program Operator Data Entry Mode The Operator Data Entry Mode provides for un buffered data entry through the auxiliary RS 232 port In this mode the DMC 2x00 provides a buffer for receiving characters This mode may only be used when executing an applications program The Operator Data Entry Mode may be specified for Port 2 only This mode may be exited with the or escape key NOTE Operator Data Entry Mode cannot be used for high rate data transfer Set the third field of the CC command to zero to set the Operator Data Entry Mode To capture and decode characters in the Operator Data Mode the DMC 2x00 provides special the following keywords P2CD Contains the status code mode disabled 0 nothing received 1 received character but not lt enter gt 2 received string not a number 3 received num
308. uts can be used with the general use inputs bits 1 8 the auxiliary encoder inputs bits 81 96 or the extended I O inputs of the DMC 2x00 controller bits 17 80 NOTE The general use inputs are optoisolated and require a voltage connection at the INCOM point for more information regarding the digital inputs see Chapter 3 Connecting Hardware Each set of sensors must use inputs that are in consecutive order The input lines are specified with the command BI For example if the Hall sensors of the C axis are connected to inputs 6 7 and 8 use the instruction BI 6 or BIC 6 Chapter 2 Getting Started 23 Step 9a Connect Standard Servo Motors The following discussion applies to connecting the DMC 2x00 controller to standard servo motor amplifiers The motor and the amplifier may be configured in the torque or the velocity mode In the torque mode the amplifier gain should be such that a 10 volt signal generates the maximum required current In the velocity mode a command signal of 10 volts should run the motor at the maximum required speed Step by step directions on servo system setup are also included on the WSDK Windows Servo Design Kit software offered by Galil See section on WSDK for more details Step A Check the Polarity of the Feedback Loop It is assumed that the motor and amplifier are connected together and that the encoder is operating correctly Step B Before connecting the motor amplifiers to the con
309. uxiliary encoders are configured with the CE command The command form is CE a b c d or a b c d e f g h for controllers with more than 4 axes where the parameters a b c d each equal the sum of two integers m and n m configures the main encoder and n configures the auxiliary encoder NOTE This operation is not available for axes configured for stepper motors 112 Chapter 6 Programming Motion DMC 2X00 DMC 2X00 Using the CE Command m Main Encoder Second Encoder Normal quadrature Normal quadrature Pulse amp direction Reverse pulse amp direction 12 Reversed pulse amp direction For example to configure the main encoder for reversed quadrature m 2 and a second encoder of pulse and direction n 4 the total is 6 and the command for the A axis is CE 6 Additional Commands for the Auxiliary Encoder The command DE a b c d can be used to define the position of the auxiliary encoders For example DE 0 500 30 300 sets their initial values The positions of the auxiliary encoders may be interrogated with the command DE For example DE returns the value of the A and C auxiliary encoders The auxiliary encoder position may be assigned to variables with the instructions 1 The command TD a b c d returns the current position of the auxiliary encoder The command DV a b c d configures the auxiliary encoder to be used for backlash compensation Backlash Compensation There are two methods for backlas
310. vement Commands ESCA Cursor Up ESC Cursor Down ESC Cursor Right ESC D Cursor Left 242 e Appendices DMC 2X00 Erasing Display ESC E ESC I ESC J ESC K ESC M Sounds ESC T ESC L ESC P ESC Cursor Style ESC F ESC G ESCR ESC S Clear Display and Home Clear Display Cursor to End of Display Cursor to End of Line Line Containing Cursor Short Bell Long Bell Click Alert Underscore Cursor On Underscore Cursor Off Blinking Cursor On Blinking Cursor Off Key Clicks audible sounds from terminal ESC U ESC V Key Click Enable Key Click Disable Identify sends TT then terminal firmware version ESC Z Cursor Position ESC Y Send Terminal ID Pr Pc In the above sequence Pr is the row number and Pc is the column number of the target cursor location These parameters are formed by adding hexadecimal 1F to the row and column numbers Row and column numbers are absolute with row 1 column 1 Pr H20 Pc H20 representing the upper left corner of the display Configuration lt CNTRL gt lt SHIFT gt F1 configuration DMC 2X00 Allows user to configure terminal Follow prompts on display to change Appendices e 243 Default Configuration Baud Rate 9600 Data bits 7 Parity Ignore PE Display enabled Repeat Fast Echo Disabled Handshake Disabled Self Test Disabled Key Click Disabled lt Ctrl gt Space Shift 2 2 Key Click Enabled lt Ctrl gt Space Shift 1 2
311. ven below LED Status F Uses Fiber Link C Uses Full Duplex will blink when a collision Uses Full Duplex will blink when a collision occurs with half duplex L Ethernet link established will blink for any activity 100 Uses 100 T speed Ethernet Addressing There are three levels of addresses that define Ethernet devices The first is the Ethernet or hardware address This is a unique and permanent 6 byte number No other device will have the same Ethernet address The DMC 2100 2200 Ethernet address is set by the factory and the last two bytes of the address are the serial number of the controller The second level of addressing 15 the IP address This is a 32 bit or 4 byte number IP address is constrained by each local network and must be assigned locally Assigning an IP address to the controller can be done in a number of ways The first method 1s to use the BOOT P utility via the Ethernet connection the DMC 2100 2200 must be connected to network and powered For a brief explanation of BOOT P see the section Third Party Software Either a BOOT P server on the internal network or the Galil terminal software may be used To use the Galil BOOT P utility select the registry in the terminal emulator Select the DMC 2100 2200 and then the Ethernet Parameters tab Enter the IP address at the prompt and select either TCP IP or UDP IP as the protocol When done
312. vent of a serious DMC 2x00 failure The AMPEN output is normally high During power up and if the microprocessor ceases to function properly the AMPEN output will go low The error light will also turn on at this stage A reset is required to restore the DMC 2x00 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 2x00 is damaged Chapter 1 Overview gt 7 THIS PAGE LEFT BLANK INTENTIONALLY 8 eChapter 1 Overview DMC 2X00 Chapter 2 Getting Started The DMC 2x00 Main Board AXES A D Error 100 pin high density connector Power LED s AMP part 2 178238 9 AXES E H 100 pin high density connector AUX Encoder inputs AMP part 2 178238 9 36 pin high density connector B3 X Reset N Switch gt 9 50 Ne 24 Stepper motor 4 configuration header Stepper Motor configuration JQ 1 AXES E H Ms AUX ENCODERS J1 AXES A D
313. you are using an ICM 2900 connect it to the DMC 2x00 via the 100 pin high density cable The ICM 2900 provides screw terminals for access to the connections described in the following discussion Motion Controllers with more than 4 axes require a second ICM 2900 and 100 pin cable System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 2x00 If sinusoidal commutation is to be used special attention must be paid to the reconfiguration of axes Here are the first steps for connecting a motion control system Step Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are operating properly the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller you need to verify that the ground level of the amplifier 15 either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier gro

DMC-2x00 User Manual - Galil Motion Control

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