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DMC-18x2 User Manual - Galil Motion Control

1. 96 Err Latin I 97 97 MOTION SMOOTHING 101 Using the IT and VT Commands S curve 101 Using the KS Command Step Motor Smoothing eese eren nee enne enne nennen nnne 102 T S 103 HIGH SPEED POSITION CAPTURE THE LATCH FUNCTION 106 FAST UPDATE RATE MODE too eie er ted eee eer pep ree ep nere He ene eee ree dene 106 CHAPTER 7 APPLICATION PROGRAMMTNG eeeee estne tn stent n netus sense toss 109 OVERVIEW eene ERRORI QE ERR RARO ERR OU I RAO RAE 109 USING THE DMC 18X2 EDITOR TO ENTER PROGRAMS 109 Edit Mode Commands E RNENE I ee ea vare ee ea ee a ava Ese ex eee 110 PROGRAM FORMAT nan a n ere ie dava eee eui itd avait aed E R A E 110 Using Labels 1n Programs eene e e te T teet dei sete tree te alee i e T 111 Special C Sina alg bien enh anal baa anh arti 111 Commenting Programs eee eU Ee dees was Haran ony Rae 112 EXECUTING PROGRAMS MULTITASKING cessere 113
2. 26 Example 13 Motion Programs with Trippoints esses eee enne enne trennen inneren 26 Exarmple 14 ControlL Y ariabl s eoo p Apa mc eo en ecd ep egi a o gie Pt s 26 Example 15 Line r Interpol ti n nitate pea UR ec Oe bec POR ER 27 Example I6 Circular Interpolation nisreen aien ponia e E EU eric petit a ev aia diga 2 CHAPTER 3 CONNECTING HARDWARE e esee ee ee eene enne tn senno ne seta seta 29 OVERVIEW M 29 USINGINPUTS 4 id deii ir eter tute e eere ue Pee e Y dne Cdp Rs 29 Limit S witch eto did a e eget nde e d nba ees 29 Switch eo See ua ics Avge ed at need i pte RO eto cens 30 Abort Inp t 2 se ut ee e ere ea te da et o ie ad etre Osee e tpe 30 Uncommitted Digital Inputs 32 2 au Ea ei tete e crie 31 AMPLIFIER INTERFACE a eee 31 TEL INPUTS ze eoe te tap ture reto ee e eee e eser tete ave n pee ueste tete A tote teme even tede bp eunte ries 32 TEL OUTPUTS oem eee ne e eee bee REP e dee RP exe ipu iE vie es 32 CHAPTER 4 SOFTWARE TOOLS AND COMMUNICATIONS ee eeeee eene eren setenta netos setas tons setas etn sese t
3. Motion Complete Trippoint 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 trippoint Motion Complete is generally more useful than the AM trippoint 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 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 outside of the application level DMC 18x2 Chapter 6 Programming Motion 95 Command Summary Stepper Motor Operation COMMAND DE Operand Summary Stepper Motor Operation 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 updat
4. The simplest method for determining 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 CO3 should be issued Note This calculation is identical to the formula n n 2 n 4 n 4 8 n5 16 ng 32 n 64 ng 128 no 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 is used all blocks are inputs 182 e Appendices DMC 18x2 Accessing extended I O When configured as an output each I O point may be defined 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 m a b c d where m is the decimal representation of the bits 1 8 va
5. Line 0 Col 4 C Testing dme Status connected with Galil DMC 18424 axis controller revision a CAP NUM 4 Filename Cursor Line and Column Info Display Area Controller Revision Info amp Serial Figure 4 2 Galil SmartTERM layout The following SmartTERM File menu items briefly describe some basic features of the application Download File Launches a file open dialog box that selects a file usually a DMC file to be downloaded to the controller This command uses the DL command to download the file clearing all programs in the controller s RAM Upload File Opens a file save as dialog that creates a file for saving the DMC program DMC 18x2 Chapter 4 Software Tools and Communications 37 Send File Download Array Upload Array Convert File ASCII to Binary Convert File Binary to ASCII Send Binary File that is in the controller s RAM This command uses the UL command to upload the file Launches a file open dialog box that selects a file usually a DMC file to be sent to the controller Each line of the file is sent to the controller as a command and is executed immediately Opens the Download Array dialog box that allows an array in the controller s RAM to be defined and populated with data The dialog box uses the DMC32 dll s DMCArrayDownload function to download the array The controller s firmware must be recent enough to support the QD command Array
6. 55 Explanation of Status Information and Axis Switch Information sees ener 58 CHAPTER 5 COMMAND BASICS roosie sorses re eea Ss ESN oR oE S STEES Soor Eoo s 61 INTRODUGCTION ierit eri EUR E ELLE 61 COMMAND SYNTAX ASCIL eet erede probet tede ed eerta Debe ce i rie Ue eere 61 Coordinated Motion with more than 1 axis nennen enne nne 62 COMMAND SYNTAX BINARY 4 ear t aerea rede aet a ari a 63 Binary Command Fortn t oae sei rei tae eter ire Letto ede eee ere io ep epe EE eee en 63 Binary commiand table gate eben t ga e eem re Ee ete dette qaem re ibat er 64 CONTROLLER RESPONSE TO DATA eeu eT epa ene E cera erp 65 INTERROGATING THE CONTROLLER ente sitne 65 Interrogation Commands iis uitae e bte en og e dece tte a ete ep Ae D eec en lp aa are 65 Summary of Interrogation Commands eese eene ener 65 Interrogating Current Commanded Values essent nennen eene enne enini enne eene nnne 66 Operands Raving ae ae ebbe memes tbe eain teens 66 Command Summaty 2 scele ode ida deeem eodem aedes 66 CHAPTER 6 PROGRAMMING MOTION
7. 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 DMC 18x2 Appendices 199 a b c time Figure A 4 Vector and Axes Velocities 200 e Appendices DMC 18x2 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 control 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
8. Axis Switches Coordinated Motion Status x v jz w L Latch Occurred Mowe in Progress Motion is Slewing ul a BBB State of Latch Input 2 of Forward Limit E Z Motion is Stopping ST or LimSwtch State of Reverse Limit state of Home Input segment Count SM Jumper Installed 0 OlDistance Traveled Axis Data Amplifier Status not configured Y Du WEE x v 2 w 0 OfReference Position 0 Motor Position 0 O Position Error Pf Auxiliary Position 9 o velecity Torque Hall Error 0 0 Figure 4 3 Data Record Display for a DMC 1842 The Data Record display is user customizable so that all or just parts of the record can be displayed To modify the display right click on an object to access the options For detailed information about the features of the Galil DMC SmartTERM including the Data Record please consult Help Topics under the Help menu Communication Settings for ISA and PCI DMC 18x2 Chapter 4 Software Tools and Communications 41 The Galil SmartTERM application installation as well as WSDK ActiveX and DMCWIN32 installations includes the necessary drivers and DLL files required to communicate with the Galil controller The drivers are automatically installed and default communications settings are applied to the device by the driver when a card is installed as per the installation
9. System Design and Compensation The closed loop control system can be stabilized by a digital filter which is preprogrammed in the DMC 18x2 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 cc 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 Nm A Torque constant J22404 kg m2 System moment of inertia R 2 Motor resistance K 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of the DMC 18x2 outputs 10V for a 14 bit command of 8192 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of oy 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 KyJs2 1000 s2 Amp K4 2 Amp V DAC Kg 10 32768 0003 Encoder DMC 18x2 Chapter 10 Theory of Operation 165 Kf 4 2 636 ZOH H s 2000 s 2000 Compensation Filter G s P sD 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 Kg
10. amp and see pg 7 127 For example using variables named V1 V2 V3 and V4 JP TEST V1 V2 amp V3 lt V4 In this example this statement will cause the program to jump to the label TEST 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 V1 lt V2 amp V3 lt V4 V5 lt V6 This statement will cause the program to jump to the label TEST under two conditions 1 If V1 is less than V2 AND is less than V4 2 If V5 is less than V6 Using the JP Command If the condition 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 Conditional Meaning JP Loop COUNT lt 10 Jump to Loop if the variable COUNT is less than 10 JS MOVE2 IN 1 1 Jump to subroutine MOVE2 if input 1 is logic level high After the subroutine MOVE 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 C V1 V7 lt 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 A DMC 18x2 Chapter 7 Application Programming 121 Example Using JP command
11. 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 is 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 18x2 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 Specifies deceleration rate Increments position instantly Time constant for independent motion smoothing DMC 18x2 Chapter 6 Programming Motion 71 JG x y z w Specifies jog speed and direction STXYZW Parameters can be set with individual axis specifiers such as JGY 2000 set jog speed for Y axis to 2000 or ACYH 400000 set acceleration for Y and H axes to 400000 Operand Summary Independent Axis _SPx _TVx Sx Returns the jog speed for the axis specified by x Returns the actual velocity of the axis specified by x averaged over 25 sec Example Jog in X only Jog X motor at 50000 count s After X motor is at its jog speed begin jogging Z in reverse direction at 25
12. DEBUGGING PROGRAMS arcte eo ttn ro vaste us 114 PROGRAM FLOW COMMANDS Un iem vam eet e geli ee vie tiet pee Miete iate e ae eode e Re RT eg 116 Event Triggers Toppoimits ettet EE eR Pete I E e elle EE os hee 116 Event Tigger Examples teet aie repe ee erede ipe Uer he ret eto eie te to ge aed 118 Conditional Jumps uou eel 120 Using If Else and Endif Commands rere 122 SUBTOULINES M 123 Stack Manipulation etiolated ek 124 Alito Start a cuetecaus ben ae axe verastatousub eee a E 124 DMC 18x2 eiii Automatic Subroutines for Monitoring Conditions eese nennen nennen enne trennen enr 124 MATHEMATICAL AND FUNCTIONAL EXPRESSIONS 127 Mathematical Operators e ee ep pretiu He aede ese 127 Bit Wase Operators voee oet tont er me qe tetti c meet estote tei iut tee iere bett te Creed 128 lares e eI oN REA FO PE CMM 129 MARTABLES 3 5 5t ienescodetonend eeiam nm n Staaten nail 130 Programmable Variables dE eem Dno rte i e DOR dE einai ents 130 OPERANDSzs 5c attese base un IB nemen eterne eee 131 S
13. INW INW GND MAW MAW MBW MBW Input Common For General Use Inputs e Abort Input Reset Input Signal Ground Analog Input 5 No Connection Analog Input 6 No Connection Analog Input 7 No Connection e Analog Input 8 No Connection Analog Input 1 No Connection Analog Input 2 No Connection Analog Input 3 No Connection Analog Input 4 No Connection 5Volts X Main encoder Index X Main encoder Index Signal Ground X Main encoder A X Main encoder A X Main encoder B X Main encoder B 5Volts X Main encoder Index X Main encoder Index Signal Ground X Main encoder A X Main encoder A X Main encoder B X Main encoder B 5Volts X Main encoder Index X Main encoder Index Signal Ground X Main encoder A X Main encoder A X Main encoder B X Main encoder B 5Volts X Main encoder Index X Main encoder Index Signal Ground X Main encoder A X Main encoder A X Main encoder B X Main encoder B DMC 18x2 No Connection The DMC 18X2 does not make full use of the functionality of the ICM 2900 These terminals refer to pins not used by the controller Opto Isolated Outputs on ICM 1900 ICM 2900 Opto option 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
14. Instruction Interpretation TE Tell error all axes TEX Tell error X axis only TEY Tell error Y axis only TEZ Tell error Z axis only TE W Tell error W axis only Example 6 Absolute Position Objective Command motion by specifying the absolute position Instruction Interpretation DP 0 2000 Define the current positions of X Y as 0 and 2000 DMC 18x2 Chapter 2 Getting Started 23 7000 4000 Sets the desired absolute positions BGX Start X motion BG Y Start Y motion After both motions are complete the X and Y axes can be command back to zero PA 0 0 Move to 0 0 BG XY Start both motions Example 7 Velocity Control Objective Drive the X and Y 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 XY Start motion after a few seconds command JG 40000 New X speed and Direction TVX Returns X speed and then JG 20000 New Y speed TV Y Returns Y speed These cause velocity changes including direction reversal The motion can be stopped with the instruction ST Stop Example 8 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 X axis to 0 2 volts JG 10000 Set X speed BGX Start X motion In this example the X motor will probably not move since the output
15. Move the X motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves BEGIN Begin Program COUNT 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec PAO Position absolute 0 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec COUNT COUNT 1 Decrement loop counter JP LOOP COUNT gt 0 Test for 10 times thru loop EN End Program Using If Else and Endif Commands The DMC 18x2 provides a structured approach to conditional statements using IF ELSE and ENDIF commands 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 it s 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 re direction of command execution In this case the command interpreter may not execute an ENDIF command U
16. USER MANUAL DMC 18x2 Manual Rev 1 0i By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet Address support galilmc com URL www galilmc com Rev 3 08 Using This Manual Ej 0 This user manual provides information for proper operation of the DMC 18x2 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller Your DMC 18x2 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 is shown below Attention Pertains to servo motor use Attention Pertains to stepper motor use Please note that many examples are written for the DMC 1842 four axes controller Users of the DMC 1832 3 axis controller DMC 1822 2 axes controller or DMC 1812 1 axis controller should note that the DMC 1832 uses the axes denoted as XYZ the DMC 1822 uses the axes denoted as XY and the DMC 1812 uses the X axis only WARNING Machinery in motion can be dangerous It is the resp
17. ee eeee esee eese tn seen sesta se tonat ta se tne seen se tone seta sess ese tones etos Des tnos ena 67 OVERVIEW ceee 67 INDEPENDENT AXIS POSITIONING siete tene epe n re EN E A E aa Ea USE 68 Command Summary Independent 5 69 iie DMC 18x2 Operand Summary Independent AXIS nonoi reote rote UG eee tees pe eda ecc ie aeons 69 INDEPENDENT JOGGING EE 71 Command Summary Jos ome e tem meo tete toute t e ne eet tee rese SR ee pd 71 Operand Sunmmary Independent AXIS tre aspe en note se oe ie eet ees 72 LINEAR INTERPOLATION MODE teer eit rere e re re er ge tree EaR ee A eerte Ae ve e eis eo eese SAER ee ipee dues 72 Specifying Linear Segments nars nra e reta te PER EORR REOR RO er ct ER ORE 72 Command Summary Linear Interpolation eese netten nennen 74 Operand Summary Linear Interpolation issenensis iep ras neret TEESE E trennen innen 75 Exampl Linear MOV e eei erae ie RR PD er n ORO DO e dee 75 Example Multiple Moves ss ni ort enr P e hl e i era e ce e te i i ei TI VECTOR MODE LINEAR AND CIRCULAR INTERPOLATION MOTION eeeeeeeeneene en enn enne nre nnne entere T Specifying Vector Segmerits aient n e EO
18. 1 063 1 062 1 061 1 060 1 059 1 058 I O57 OUTC57 64 I OC57 64 I O56 I O55 I O54 I O53 I O52 I O51 I O50 I O49 OUTC49 56 I OC49 56 I O48 I O47 I O46 I O45 I O44 I O43 I O42 I O41 OUTC41 48 I OC41 48 I O40 I O39 I O38 1 037 1 036 1 035 1 034 1 033 OUTC33 40 I OC33 40 I O32 I O31 I O30 I O29 1 028 I O bit 64 I O bit 63 I O bit 62 I O bit 61 I O bit 60 I O bit 59 I O bit 58 I O bit 57 Out common for I O 57 64 I O common for I O 57 64 I O bit 56 I O bit 55 I O bit 54 I O bit 53 I O bit 52 I O bit 51 I O bit 50 I O bit 49 Out common for I O 49 56 I O common for I O 49 56 I O bit 48 I O bit 47 I O bit 46 I O bit 45 I O bit 44 I O bit 43 I O bit 42 I O bit 41 Out common for I O 41 48 T O common for I O 41 48 I O bit 40 I O bit 39 I O bit 38 I O bit 37 I O bit 36 I O bit 35 I O bit 34 I O bit 33 Out common for I O 33 40 T O common for I O 33 40 I O bit 32 I O bit 31 I O bit 30 I O bit 29 I O bit 28 e e e mn P NY VY WWW WW WW WwW WH CO A HL HL d HR A Hh HR amp gt Uu tn tn tn tn tn tA nnn DMC 18x2 Appendices 195 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 70 69 72 71 74 73 76 75 78 77 80 79 82 81 84 83 86 85 88 87 90 89 92 91 94 93 96 95 98 97 100 99 102 101 104 103 1 027 1 026 1 025 OUT
19. 100 Y N 1048S ET N Y 1 LOOP N lt 100 EN Interpretation Label Select X as master Cam cycles Master position increments Index Loop to construct table from equation Note 3 6 0 18420 Define sine position Define slave position Define table Repeat the process 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 X 1000 and Y 500 This implies that Y must be driven to that point to avoid a jump This is done with the program Instruction RUN PA 500 SP 5000 BGY AM All EG 1000 AI 1 EQ 1000 EN Interpretation Label Enable cam starting position Y speed Move Y motor After Y moved Wait for start signal Engage slave Wait for stop signal Disengage slave End DMC 18x2 Chapter 6 Programming Motion 87 Command Summary Electronic CAM Specifies master axes for electronic cam where X Y Z or W or A B C D E F G H for main encoder as master ECAM counter sets the index into the ECAM table The following example illustrates a cam program with a master axis Z and two slaves X and Y Instruction Interpretation A V1 0 Label Initialize variable 0 0 BGXY AMXY Go to position 0 0 on X and Y axes EAZ Z axis as the Master for ECAM EM 0 0 4000 Change for Z is 4000 zero for X Y EP400 0 ECAM interval is 400 counts with zero
20. 162 e Chapter 10 Theory of Operation DMC 18x2 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 5 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 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 18x2 controller and the following parameters K 0 1 Nm A J 2 104 kg m R22 Q K 4 Amp Volt 12 5 KD 245 KI 0 N 500 Counts rev T 1 ms The transfer function of the system elements are Motor M s P I Kt Js2 500 s2 rad A Amp Ka 4 Amp V DAC Kg 0 0003 V count Encoder Kg 4N 2n 318 count rad ZOH 2000 s 2000 Digital Filter 12 5 KD 245 0 001 Therefore D z 1030 z 0 95 Z Torque constant System moment of inertia Motor resistance Current amplifier gain Digital filter gain Digital filter zero No integrator Encoder line density Sample period DMC 18x2 Chapter 10 Theory of Operation 163 Accordingly the coefficients
21. 91 93 109 114 120 128 141 170 Automatic Subroutine 124 CMDERR 111 125 126 127 LIMSWI 29 111 124 125 MCTIME 111 117 125 126 POSERR 111 124 125 Auxiliary Encoder 174 176 Dual Encoder 66 Begin Motion 111 113 118 119 125 126 Binary 1 49 61 64 Bit Wise 121 128 Burn EEPROM 3 Capture Data Record 91 93 Circular Interpolation 82 Clear Sequence 78 80 CMDERR 111 125 126 127 Code 49 125 131 Command Summary 69 80 Commanded Position 82 83 126 Communication 3 FIFO 3 54 55 Conditional jump 109 116 118 121 Contour Mode 89 94 Control Filter 204 e Index Damping 154 Coordinated Motion 62 Circular 82 Contour Mode 89 94 Ecam 84 85 88 Electronic Cam 84 86 Electronic Gearing 82 84 Gearing 82 84 Linear Interpolation 76 82 89 Cosine 128 129 DAC 165 Damping 154 Debugging 114 Differential Encoder 13 15 Digital Filter 61 Digital Input 129 Digital Output 129 Dip Switch Address 202 Download 61 109 Dual Encoder 66 Ecam 84 85 88 Electronic Cam 84 86 Echo 49 Edit Mode 109 110 115 125 Editor 109 110 EEPROM 3 Electronic Cam 84 86 Electronic Gearing 82 84 Ellipse Scale 80 Encoder Auxiliary Encoder 174 176 Differential 13 15 Dual Encoder 66 Index Pulse 13 30 103 Quadrature 4 150 161 Error Code 49 125 131 Error Handling 29 111 124 125 Error Limit 13 14 31 125 Off On Error 13 31 Feedrate 79 80 119 DMC 18
22. Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples DM SPEED 10 Dimension Speed Array SPEED 1 7650 2 Assigns the second element of the array SPEED the value 7650 2 SPEED 1 Returns array element value POSX 10 TPX Assigns the 11th element of the array POSX the returned value from the tell position command CON 2 2 G9 COS POS 2 Assigns the third element of the array CON the cosine of the variable POS multiplied by 2 TIMER 1 TIME Assigns the second element of the array timer the returned value of the TIME keyword 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 132 e Chapter 7 Application Programming DMC 18x2 For example A Begin Program COUNT 0 DM POS 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec POS COUNT _TPX 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 autom
23. Change speed of Y End program To start the program command XQ B Execute Program B Example 14 Control Variables Objective To show how control variables may be utilized Instruction A DPO PR 4000 26 e Chapter 2 Getting Started Interpretation Label Define current position as zero Initial position DMC 18x2 SP 2000 BGX AMX WT 500 B V1 _TPX 1 2 BGX AMX WT 500 1 JP 4C V1 0 JP B 8C EN Set speed Move X Wait until move is complete Wait 500 ms Determine distance to zero Command X move 1 2 the distance Start X motion After X moved Wait 500 ms Report the value of V1 Exit if position 0 Repeat otherwise Label 4C End of Program To start the program command XQ Execute Program A This program moves X to an initial position of 1000 and returns it to zero on increments of half the distance Note _TPX is an internal variable which returns the value of the X position Variables may be created by preceding a DMC 18x2 instruction with an underscore For example UI TPX Example 15 Linear Interpolation Objective Move X Y Z motors distance of 7000 3000 6000 respectively along linear trajectory Namely motors start and stop together Instruction LM XYZ LI 7000 3000 6000 LE VS 6000 VA 20000 VD 20000 BGS Interpretation Specify linear interpolation axes Relative distances for linear interpolation Linear End Vector speed Vector acceleratio
24. DA Command done DB Application program done FO thru FF User interrupt thru E8 Input interrupt CO Limit switch occurred C8 Excess position error D8 All axis motion complete D7 H axis motion complete D6 G axis motion complete D5 F axis motion complete D4 E axis motion complete D3 W axis motion complete D2 Z axis motion complete D1 Y axis motion complete DO X axis motion complete The recommended method to utilize the interrupts in a host application is to use a pre defined interrupt service routine Where the event routine on interrupt will automatically execute and return the Status Byte For example when using the ActiveX toolkit DMCShell control with VB the DMCShelll_DMCInterrupt event procedure shown below will automatically execute and return the StatusByte in the argument This StausByte can then be used in a case structure as the key to notify the host application of a specific event or condition In this VB example below the event procedure will display a message box every time the X axis motion is complete assuming the command was sent to the controller Note the argument is returned as 208 since the status byte is returned as an integer i e DO hex 208 decimal Private Sub DMCShelll DMCInterrupt StatusByte As Integer If StatusByte 208 Then MsgBox X axis complete End If End Sub Hardware Level Communications for PCI This section of the chapter describes in detail the structures used t
25. DIRECTION POSITION MOTION REVERSE TOWARD HOME DIRECTION lt POSITION MOTION TOWARD INDEX DIRECTION POSITION INDEX PULSES POSITION ci POSITION Figure 6 8 Motion intervals in the Home sequence DMC 18x2 Chapter 6 Programming Motion 105 High Speed Position Capture The Latch Function Often it is desirable to capture the position precisely for registration applications The DMC 18x2 provides a position latch feature This feature allows the position of the encoder of X Y Z or W to be captured upon the state change of an external input signal The general inputs 1 through 4 correspond to each axis through 4 INI X axis latch IN2 Y axis latch IN3 Z axis latch INA W axis latch Note The inputs are TTL Latch time is less than 1 usec high or low going The DMC 18x2 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 the AL XYZW command to arm the latch for the encoder 2 Test to see if the latch has occurred Input goes low by using the AL X or Y or Z or W command Example V1 _ALX returns the state of the X latch to the variable V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the RL XYZW command or _RLXYZW Note The latch must be re armed after each latching event Example Latch Latch program JG 5000 Jog Y BG Y
26. DMC 18x2 Chapter 10 Theory of Operation 155 The highest level of control is 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 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 BG X AD 2000 BG Y EN This program 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 156 e Chapter 10 Theory of Operation DMC 18x2 X VELOCITY Y VELOCITY X POSITION ee Y POSITION de TIME Figure 10 3 Velocity and Position Profiles Operation of Closed Loop Systems To understand the operation of a servo system we may compare it to a familiar closed loop operat
27. LI 4000 0 lt 4000 gt 1000 Specify first linear segment with a vector speed of 4000 and end speed 1000 LI 1000 1000 lt 4000 gt 1000 Specify second linear segment with a vector speed of 4000 and end speed 1000 LI 0 5000 lt 4000 gt 1000 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 Feedrate The command VR n allows the feedrate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS to be scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feedrate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided in half Command Summary Linear Interpolation COMMAND DESCRIPTION LM xyzw Specify axes for linear interpolation LM Returns number of available spaces for linear segments in DMC 18x2 sequence buffer Zero means buffer full 511 means buffer empty Specify incremental distances relative to current position and assign vector speed n Specify incremental distances relative to current position and assign vector speed Begin Linear Sequence on S or T coordinate system Linear End Required at end of LI command sequence BGS or BGT Begin Linear Sequence on S or T coordinate system LE Linear End Required at end of LI command
28. RA OUTC Electrical Specifications e T 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 High Power Digital Outputs e Maximum external power supply voltage 28 VDC e Minimum external power supply voltage 4 VDC e Maximum source current per output 500mA e Maximum sink current sinking circuit inoperative Standard Digital Outputs e Maximum external power supply voltage 28 VDC e Minimum external power supply voltage 4 VDC e Maximum source current limited by pull up resistor value e Maximum sink current 2mA DMC 18x2 Appendices 193 Relevant DMC Commands COn Configures the 64 bits of extended I O in 8 banks of 8 bits each n 2 n A n 4 8 ns5 16 ng 32 n 64 ng 128 no 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 extended I O banks amp 1 outputs 17 32 o extended I O banks 2 amp 3 outputs 33 48 extended I O banks 4 amp 5 outputs 49 64 q extended I O banks 6 amp 7 outputs 65 80 SBn Sets the output bit to a logic 1 n is the number of the output from 1 to 80 CBn Clears the output bit to a logic 0 n is the number of the output from 1 to 80 OB n m Sets the state of an output as 0 or 1 also able to use logical conditions TIn Returns the state of 8 digital inputs as bin
29. V1 ALPHA Assign string ALPHA to V1 V1 S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Fast Firmware Mode To allow faster servo update rates a minimized firmware mode is available where certain features are disabled When the fast firmware mode is activated the following functions are NOT available Gearing CAM PL Stepper Mode Trippoints in the main thread DMA TV DATARECORD The minimum sample times TM in the fast mode are as follows FAST MODE NORMAL MODE DMC 1812 1822 125 usec 250 usec DMC 1832 1842 250 usec 375 usec The FAST MODE firmware is available as part of the utilities disks shipped with the DMC 18x2 The FAST MODE firmware must be downloaded into the DMC 18x2 Run a terminal program through WSDK DMCWIN DMCDOS etc and select update controller firmare from the options menu Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM 140 e Chapter 7 Application Programming DMC 18x2 The DMC 18x2 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 sec2 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
30. line feed and colon An echo function is also provided to enable associating the DMC 18x2 response with the command sent The echo is enabled by sending the command EO 1 to the controller Binary Command Mode Some commands have an equivalent binary value for the controllers These values are listed in the Command Reference next to the command in parentheses in hexadecimal format Binary communication mode can be executed much faster than ASCII commands since the controller does not have to first decode the ASCII characters Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program DMC 18x2 Chapter 4 Software Tools and Communications 49 Binary Command Format All binary commands have a 4 byte header followed by data fields The 4 bytes are specified in hexadecimal format Binary Header Format Byte 1 specifies the hexadecimal command number between 80 to FF 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 coordinated motion on the or axis as follows Bit l T axis coordinated motion movement Bit 0 S axis coordinated motion movement For example the command STS commands motion t
31. lt RETURN gt 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 lt RETURN gt will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a lt return gt is given lt entrl 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 entrl D The lt cntrl 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 entrl Q The lt cntrl gt Q quits the editor mode In response the DMC 18x2 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 LS Lis
32. the motor off command MO is given or the OE1 command Enable Off On Error is given 12 e Chapter 2 Getting Started DMC 18x2 and the position error exceeds the error limit As shown in Figure 3 4 AEN can be used to disable the amplifier for these conditions The standard configuration of the AEN signal is TTL active high In other words the AEN 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 AMP 1900 or ICM 2900 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 AEN signal note the state of the resistor pack on the interconnect module 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 To do this pull the resistor pack Then connect the power supply 24V to the AEN connector on the ICM A resistor is placed in line to limit the current to 10mA Step C Connect the encoders For stepper motor operation an encoder is optional For servo motor operation if you have a pref
33. utilities The DMC 18x2 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode 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 ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN Note Another editor wiondow will not be opened in the 3 paned view of the SmartTerminal program DMC 18x2 Chapter 7 Application Programming 109 NOTE The ED command only accepts a parameter e g BEGIN in a DOS Window For general purposes the editing features described in this section are not applicable when not in DOS mode 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
34. where x y z w are the master positions at which the corresponding slave axes are disengaged SUDO Linien 2250 IA A a eats 0 2000 4000 6000 Master Figure 6 4 Electronic Cam Example This disengages the slave axis at a specified master position If the parameter is outside the master cycle the stopping is instantaneous To illustrate the complete process consider the cam relationship described by the equation Y 0 5 X 100 sin 0 18 X where X is 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 EAX defines X as the master axis The cycle of the master is 2000 Over that cycle Y varies by 1000 This leads to the instruction EM 2000 1000 86 e Chapter 6 Programming Motion DMC 18x2 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 18X and X varies in increments of 20 the phase varies by increments of 3 6 The program then computes the values of Y according to the equation and assigns the values to the table with the instruction ET N Y Instruction SETUP EAX EM 2000 1000 EP 20 0 N 0 LOOP P N 3 6 S SIN P
35. with TP The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a range between 0 5 and 16 where 16 implies the largest amount of smoothing See Command Reference regarding KS The DMC 18x2 profiler commands the step motor amplifier All DMC 18x2 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 is not generated To connect step motors with the DMC 18x2 you must follow this procedure Step A Install SM jumpers Each axis of the DMC 18x2 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 18x2 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 PWMX and SIGNX for the x axis on the ICM 2900 Consult the documentation for your step motor amplifier Step C Configure DMC 18x2 for motor type using MT command You can configure the DMC 18x2 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 9 Tune the Servo System Adjusting the tuning
36. with a 1 8 step motor and 4000 count rev encoder SETUP KS16 MT 2 2 2 2 YA64 YB200 YC4000 SHX WT50 YS1 MOTION SP16384 PR10000 BGX MCX JS CORRECT MOTION2 SP16384 PR 10000 BGX MCX JS CORRECT JP MOTION CORRECT 100 e Chapter 6 Programming Motion DMC 18x2 Spx SPX LOOP SP2048 WT100 JP END ABS _QSX lt 10 YRX _QSX MCX WT100 JP LOOP END 5 PX spx EN Motion Smoothing The DMC 18x2 controller allows the smoothing of the velocity profile to reduce mechanical vibrations in the system 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 we the IT and VT Commands S curve profiling When operating with servo motors motion smoothing can be accomplished with the IT and VT commands These commands filter the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile known as S curve has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following commands IT x y z w Independent time constant VTn Vector time constant The command IT is used for smooth
37. 10000 WT 300 BG XY RI Example Applications Wire Cutter Label A Enable input 1 for interrupt function Set speeds on X and Y axes Begin motion on X and Y axes Label B Report X and Y axes positions Wait 1000 milliseconds Jump to B End of program Interrupt subroutine Displays the message Stops motion on X and Y axes Loop until Interrupt cleared Specify new speeds Wait 300 milliseconds Begin motion on X and Y axes Return from Interrupt subroutine 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 revolution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 2n 637 count inch DMC 18x2 Chapter 7 Application Programming 143 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 input 1 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 A Here t
38. 16000 VE VS 200000 BGS AMS EN 146 e Chapter 7 Application Programming Speed X Start X Wait for X completion Lower Z Z second circle move Raise Z Return XY to start DMC 18x2 0 4 9 3 X Figure 7 2 Motor Velocity and the Associated Input Output signals DMC 18x2 Chapter 7 Application Programming 147 THIS PAGE LEFT BLANK INTENTIONALLY 148 e Chapter 7 Application Programming DMC 18x2 Chapter 8 Hardware amp Software Protection Introduction The DMC 18x2 provides several hardware and software features to check for error conditions and to inhibit the motor on error These features help protect the 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 18x2 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 18x2 Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 18x2 includes hardware input and output protection lines for 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 an off on error condi
39. 1L 3 MG WAITING FOR INPUT 1 INPUT 2 LOOP JP LOOP EN ININT IF IN 1 0 IF IN 2 0 MG INPUT 1 AND INPUT 2 ARE ACTIVE 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 Begin Main Program TEST Enable input interrupts on input 1 and input 2 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 IF conditional statement executed if 1 IF conditional true Message to be executed if 2 IF conditional is true ELSE command for 2 IF conditional statement Message to be executed if 2 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 1 IF conditional statement End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 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 mani
40. 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 are U03 and U04 bank 1 input IC s are labeled U13 and U14 and so on Also the resistor pack RPx4 must be inserted into the bank to finish the input configuration DMC 18x2 Appendices 189 Input Circuit 1 4 NEC2505 1 8 RPx4 To DMC 1748 I O X bank number 0 7 N n input number 17 80 P DMC 1748 GND e e 1 0 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 OC e e 5V OC e e GND O e GND IO e ems e 5V Current Current There is one I OC connection for each bank of eight inputs Whether the input is connected as sinking or sourcing 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 17x8 DB 14064 When the switch is closed in either circuit current flows This pulls the input on the DMC 17x8 DB 14064 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 are optically isolated and can accept a range of input voltages from 4 to 28 VDC Active outputs are connected t
41. BGX Start Motion DMC 18x2 Chapter 7 Application Programming 119 EN End 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 40 msec OUTPUT Program label ATO Initialize time reference 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 Set Output 1 JP LOOP Loop EN Conditional Jumps The DMC 18x2 provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition The 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 18x2 to make decisions without a host computer For example the DMC 18x2 can decide between two motion profiles based on the state of an input line 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
42. DMC 18x2 and DB 14064 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 0 188 e Appendices DMC 18x2 Resistor Pack for outputs RP03 OUT Resistor Pack for Input Buffer IC s inputs U03 U04 NI 0 Resistor Pack for outputs Output Buffer IC s U01 U02 c0duy OUT Indicator LED s Resistor Pack for DO LED s All of the banks have the same configuration pattern as diagrammed above For example all banks have Ux1 and Ux2 output optical isolator IC sockets labeled in bank 0 as 001 and U02 in bank 1 as U11 and U12 and so on Each bank is configured as inputs or outputs by inserting optical isolator IC s and resistor packs in the appropriate sockets A group of eight LED s indicates the status of each point The numbers above the Bank 0 label indicate the number of the I O point corresponding to the LED above it Digital Inputs 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
43. ICM 2900 interconnect module the ICM 2900 has an option to provide optoisolation on the outputs In this case the user provides an isolated power supply 5 volts to 24 volts and ground For more information consult Galil The output compare signal is TTL and is available on the ICM 2900 as CMP Output compare is controlled by the position of any of the main encoders on the controller The output can be programmed to produce an active low pulse 1usec based on 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 The error signal output is available on the interconnect module as ERROR This is a TTL signal which is low when the controller has an error Note When the error signal is low the LED on the controller will be on indicating one 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 The reset line on the controller is held low or is 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 DMC 18x2 Chapter 3 Connecting Hardware 33 THIS PAGE LEFT BLANK INTENTIONALLY 34 e Chapter 3 Connecting Hardware DMC 18x2 Chapter 4 Software Tools and Communications Introduction Galil software is a
44. Kg H s 3 17 109 s2 s 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 500 L j500 3 17 10 Gj500 2 j500 2000 This function has a magnitude of L j500 I 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 A j500 1 Arg A j500 135 However since A s L s G s then it follows that G s must have magnitude of 16 j500 l AG500 LG500 I 160 and a phase arg G j500 arg AG500 arg 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 c 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as IGG500 I IP G500D I 160 and arg G j500 tan 500D P 59 The solution of these equations leads to P 160cos 59 824 500D 160sin 59 137 166 e Chapter 10 Theory of Operation DMC 18x2 Therefore D 0 274 and 82 4 0 27445 The function is equivalent to a digital filter of the form D z 4 4KD 1 z7 where P 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 18x2 can be programmed with the instructio
45. POS N Print Y position XERR N Print X error YERR N Print Y error N N 1 Increment Counter DONE Done EN End Program 134 e Chapter 7 Application Programming Deallocating Array Space Array space may be deallocated using the DA command followed by the array name DA 0 deallocates all the arrays Input of 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 An Example for Inputting Numeric Data A IN Enter Length LENX 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 LENX Cut to Length Example 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 is variable and the operator is prompted to input it in inches Motion starts with a start button which is connected to input 1 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 counts inch The program below
46. SmartTERM and select the Properties command button The timeout property under the General Parameters tab shown in Fig 4 5 allows the user to select the timeout period that the Galil software waits for a response from the controller before generating an error If the controller does not reply with the data response and a colon or just a colon for commands that do not invoke responses then the Galil software API will generate the timeout error code 1 A 42 e Chapter 4 Software Tools and Communications DMC 18x2 time out occurred while waiting for a response from the Galil controller The default setting for the timeout is 5000ms which should be sufficient for most cases Controller Communications Parameters General Parameters PCI Bus Parameters Communication Method Controller DMC 1800 Timeout 5009 milliseconds Figure 4 5 General Communications Parameters Dialog Advanced communications settings are available under the Communication Method tab to allow different methods of communications to be utilized shown in Fig 4 6 The version 7 and higher drivers and DLL s allow for three different methods of communications Interrupt Stall and Delay Controller Communications Parameters XI General Parameters PCI Bus Parameters Communication Method Select the communication method that the device driver will use to send commands to the controller Vv Use Communication Interrupts This is the best overa
47. Started 13 At this point if TPX 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 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 Z axis are connected to inputs 6 7 and 8 use the instruction BI 6 or BIZ 6 Step 8a Connect Standard Servo Motors The following discussion applies t
48. W An equals sign is used to assign data to that axis For example PRX 1000 Specify a position relative movement for the X axis of 1000 ACY 200000 Specify acceleration for the Y axis as 200000 Instead of data some commands request action to occur on an axis or group of axes For example STXY stops motion on both the X and Y axes Commas are not required in this case since the particular axis is specified by the appropriate letter X Y Z or W If no parameters follow the instruction action will take place on all axes Here are some examples of syntax for requesting action BGX Begin X only BG Y Begin Y only BG XYZW Begin all axes BG YW Begin Y and W only BG Begin all axes Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S or T is used to specify the coordinated motion S and T refer to the two coordinate systems that can be used on the card To specify the desired coordinate system refer to the command CA in the Command Reference For example BGS Begin coordinated sequence on S coordinate system BG SW Begin coordinated sequence on S and motion on W axis BGT Begin coordinated sequence on T coordinate system 62 e Chapter 5 Command Basics DMC 18x2 Command Syntax Binary 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 a
49. Y Specify master axes as Y GR 5 5 10 Set gear ratios PR 10000 Specify Y position SP 100000 Specify Y speed BGY Begin motion 82 e Chapter 6 Programming Motion DMC 18x2 Example 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 1832 controller where the Z axis is the master and X and Y are the geared axes MOZ Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GR 1 132 045 Specify gear ratios Now suppose the gear ratio of the X axis is to change on the fly to 2 This can be achieved by commanding GR 2 Specify gear ratio for X axis to be 2 Example Gantry Mode In applications where both the master and the follower are controlled by the DMC 18x2 controller it may be desired to synchronize the follower with the commanded position of the master rather than the actual position This eliminates the possibility of an oscillation on the master passing the oscillation on to the slave For example assume that a gantry is driven by two axes X and Y one on each side This requires the gantry mode for strong coupling between the motors The X axis is the master and the Y axis is the follower To synchronize Y with the commanded position of X use the instructions GA CX Specify the commanded position of X as master for
50. Zoom Normal Command String iStart Collecting Contour Mode The DMC 18x2 also provides a contouring mode This mode allows any arbitrary position curve to be prescribed for 1 to 4 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 CMXZ specifies contouring on the X and Z 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 x y z w over a time interval DT n The parameter n specifies the time interval The time interval is defined n as2 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 5 The position X may be described by the points DMC 18x2 Chapter 6 Programming Motion 89 Point 1 X 0 at T 0ms Point 2 X 48 at T 4ms Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 DX 48 Time Increment 4 DT 2 Increment 2 DX 240 Time Increment 8 DT 3 Increment 3 DX 48 Time Increment 16 DT 4 When th
51. a string value the string must be in quotations String variables can contain up to six characters which must be in quotation Examples POSX _TPX Assigns returned value from TPX command to variable POSX 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 130 e Chapter 7 Application Programming DMC 18x2 Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as GN or PR PR VI Assign V1 to PR command SP P3 2000 Assign P3 2000 to SP command Displaying the value of variables at the terminal Variables may be sent to the screen using the format variable For example V1 returns the value of the variable V1 Operands Operands allow motion or status parameters of the DMC 18x2 to be incorporated into programmable variables and expressions Most DMC 18x2 commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 18x2 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 18x2 registers The axis designation is required following the command Examples of Internal Variables POSX TPX Assigns value from Tel
52. an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of Motion 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 seminar 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 18x2 Appendices 201 Contacting Us Galil Motion Control 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail address support galilmc com URL www galilmc com FTP www galilmc com ftp 202 e Appendices DMC 18x2 WARRANTY All 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
53. avoid this delay the command 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 Error Code Command When there is a program error the DMC 18x2 halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG ED The user can obtain information about the type of error condition that occurred by using the command TCI 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 memory the DMC 18x2 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 1812 will have a maximum of 8000 array elements in up t
54. 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 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 If Hall Sensors are Not Available 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 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 DMC 18x2 Chapter 2 Getting Started 19 suffic
55. 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 modification 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 DMC 18x2 Appendices 203 Index Abort 55 78 171 172 Off On Error 13 31 Stop Motion 78 126 152 Absolute Position 117 118 122 Absolute Value 84 121 129 150 Acceleration 119 198 199 Accessories 173 Address 202 AMP 1100 16 Ampflier Gain 4 Amplifier Gain 159 163 165 Analysis SDK 109 Arithmetic Functions 109 121 128 130 Arm Latch 106 Array 3 77
56. configuration information is necessary to determine the proper motor configuration Standard Servo Motor Operation The DMC 18x2 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 Sinusoidal Commutation Sinusoidal commutation is configured through a single software command BA This configuration causes the controller to reconfigure the number of available control axes Each sinusoidally commutated motor requires two DAC s In standard servo operation the DMC 18x2 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 DAC s and the controller must be a DMC 1842 Sinusoidal commutation is configured with the command BA For example BAX sets the X 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 1842 the command BAX will configure the X axis to be the main sinusoidal signal and the W axis to be the second sinusoidal signal The BA command also reconfigures the controller to indicate that the controller has one less axis of stan
57. 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 resulting 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 H MOTOR C P ENCODER Figure 10 4 Fun
58. controller Consult the amplifier documentation for proper instructions 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 is 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 ground and earth by a 10 KQ resistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal AEN is used by the controller to disable the motor This signal is labeled AMPENX for the X axis on the interconnect board 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
59. deceleration rates of 100 000 counts s In this example the motor turns and stops Instruction Interpretation PR10000 Distance SP20000 Speed AC100000 Acceleration DC100000 Deceleration BGX Start Motion Example 3 Multiple Axes Objective Move the four axes independently 22 e Chapter 2 Getting Started DMC 18x2 Instruction PR 500 1000 600 400 SP 10000 12000 20000 10000 AC 100000 10000 100000 100000 DC 80000 40000 30000 50000 BG XZ BG YW Example 4 Independent Moves Interpretation Distances of X Y Z W Slew speeds of X Y Z W Accelerations of X Y Z W Decelerations of X Y Z W Start X and Z motion Start Y and W motion The motion parameters may be specified independently as illustrated below Instruction Interpretation PR 300 600 Distances of Y and Z SP 2000 Slew speed of Y DC 80000 Deceleration of Y AC 100000 Acceleration of Y SP 40000 Slew speed of Z AC 100000 Acceleration of Z DC 150000 Deceleration of Z BGZ Start Z motion BGY Start Y motion Example 5 Position Interrogation The position of the four axes may be interrogated with the instruction TP Instruction Interpretation TP Tell position all four axes TPX Tell position X axis only TPY Tell position Y axis only TPZ Tell position Z axis only TP W Tell position W axis only The position error which is the difference between the commanded position and the actual position can be interrogated with the instruction TE
60. description of analog feedback in Chapter 2 under the section titled Test the encoder operation 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 to talk to one of our applications engineers about your particular system requirements Watch Dog Timer The DMC 18x2 provides an internal watch dog timer which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AEN which can be used to switch the amplifiers off in the event of a serious DMC 18x2 failure The AEN output is normally high During power up and if the microprocessor ceases to function properly the AEN output will go low The error light will also turn on at this stage A reset is required to restore the DMC 18x2 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 18x2 is damaged DMC 18x2 Chapter 1 Overview 5 THIS PAGE LEFT BLANK INTENTIONALLY 6 e Chapter 1 Overview DMC 18x2 Chapter 2 Getting Started The DMC 18x2 Motion Controller L5 2A JP2 2B 1 J2 JP6 DMC 18x2 L et Figure 2 1 Outline of the DMC 1812 thru DMC 1842 1 Flash EEPROM 2ADB RAM 3 Motorola 68331 microprocessor 4 GL 1800 custom gate array 5 Error LED J2 100 pin high density connector part numbe
61. desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion is CCW ending at 3000 0 Note that the 0 position in the XY plane is in the X direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First X Y and Z are driven to the starting point and later the cut is performed Assume that the knife is engaged with output bit 0 EXAMPLE Example program CAS Select coordinate system S VM XYZ XY coordinate with Z as tangent TN 2000 360 500 2000 360 counts degree position 500 is 0 degrees in XY plane CR 3000 0 180 3000 count radius start at 0 and go to 180 CCW VE End vector CBO Disengage knife PA 3000 0 _TN Move X and Y to starting position move Z to initial tangent position BG XYZ Start the move to get into position DMC 18x2 Chapter 6 Programming Motion 79 AM XYZ 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 Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION VM m n Specifies the axes for the planar motion where m and n represent the planar axes and p is the tangent axis Return coordinate of last point where m X Y Z or Specifies arc segment where r is the radius 0 is the starting angle and 6 is the travel angle Positive directi
62. drivers are contained on the COM DISK from Galil Advanced Communication Techniques Changing Full Flags The Full flag Bit 6 of the control register can be configured to change states at a different level from the default level of 16 characters The level m can be changed from 16 up to 256 in multiples of 16 as follows 1 Write a 5 to the control register at address N 1 2 Write the number m 16 to the control register where m is the desired Almost Full level between 16 and 256 For example to extend the Almost Full level to 256 bytes write a 5 to address N 1 Then write a 240 to address N 1 Clearing FIFO Buffer The FIFO buffer may be cleared by writing the following sequence Read N 1 address Send 01H to N 1 address Send 80H to N 1 address Send 01H to N 1 address Send 80H to N 1 address Read N 1 address Bit 7 will be 1 It is a good idea to clear any control data before attempting this procedure Send a no op instruction by reading N 1 address before you start All data including data from the DMC 18x2 will then be cleared Clearing the FIFO is useful for emergency resets or Abort For example to Reset the controller clear the FIFO then send the RS command Data Record DATA TYPE ITEM BLOCK UB 1 byte of header Header DMC 18x2 Chapter 4 Software Tools and Communications 55 UB 2 byte of header Header UB 3 byte of header Header UB 4 byte of header Header UW sample number I block UB gene
63. e Appendices DMC 18x2 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 ERROR RESET CMP MOCMDW SIGNW PWMW MOCMDZ SIGNZ PWMZ MOCMDY SIGNY PWMY MOCMDX SIGNX PWMX ISO VCC AMPENW AMPENZ AMPENY AMPENX LSCOM HOMEW RLSW FLSW HOMEZ RLSZ FLSZ HOMEY RLSY FLSY HOMEX RLSX FLSX VCC GND INCOM XLATCH YLATCH ZLATCH WLATCH INS IN6 IN7 Sa eR degunt He ce deb des arto OOo sO OF Or Qo Oo OQ m Hu option Error signal Reset Circular Compare output W axis motor command to amp input w respect to ground W axis sign output for input to stepper motor amp W axis pulse output for input to stepper motor amp Z axis motor command to amp input w respect to ground Z axis sign output for input to stepper motor amp Z axis pulse output for input to stepper motor amp Y axis motor command to amp input w respect to ground Y axis sign output for input to stepper motor amp Y axis pulse output for input to stepper motor amp X axis motor command to amp input w respect to ground X axis sign output for input to stepper motor amp X axis pulse output for input to stepper motor amp Isolated gnd used with opto isolation 5 Volts W axis amplifier enable Z axis amplifier enable Y axis amplifier enable X axis amplifier enable Limit Sw
64. e E peg 3 sss Ems 4 Amplifier Driver estetico dropped verre i i eit e p tp a e aeos 4 Encoder iier ee eei ERE TE EE EGER ERE REPE Gn ED bep 4 Watch Dog Timer eite ted reete De me ra ELO tp ie ce tto Sere ee tre irte bias 5 CHAPTER 2 GETTING STARTED Fe edes ve Da sepe Ue suas 7 THE DMC 18X2 MOTION CONTROLLER uten curses FRE ERE REPRE RF 7 ELEMENTS Y OU NEED terr REESE ERREUR PERS SR TAE ENEF SEN 8 INSTALLING THE DMC L8X2 i rettet E PERSIUS ER e Et BU tesvousegacesugets sve seus Saag RARE eee Y 8 Step 1 Determine Overall Motor Configuration 9 Step 2 Install Jumpers on the DMC 18x2 eese nennen nennen nennen trennen teen teen tentent eterne sees 10 Step 3 Install the Communications Software eese ener ener enne neen nennen nennen 10 Step 4 Install the DMCA 8x2 an the PC 4 s esee ottiene eee m ee Eee ip Rei e p Eras 10 Step 5 Establish Communication using Galil Software esee nennen ener 11 Step 6 Determine the Axes to be Used for Sinusoidal Commutation eese 11 Step 7 Make Connections to Amplifier and Encoder es
65. error B block SL y b axis auxiliary position B block SL y b axis velocity B block SW y b axis torque B block UW Z C axis status C block UB z c axis switches C block UB z c axis stopcode C block SL z c axis reference position C block SL Z c axis motor position C block SL Z c axis position error C block SL z c axis auxiliary position C block SL z c axis velocity C block SW Z c axis torque C block UW w d axis status D block UB w d axis switches D block UB w d axis stopcode D block SL w d axis reference position D block SL w d axis motor position D block SL w d axis position error D block SL w d axis auxiliary position D block SL w d axis velocity D block SW w d axis torque D block UW e axis status E block UB e axis switches E block UB e axis stopcode E block SL e axis reference position E block SL e axis motor position E block SL e axis position error E block SL e axis auxiliary position E block SL e axis velocity E block SW e axis torque E block UW f axis status F block UB f axis switches F block UB f axis stopcode F block SL f axis reference position F block SL f axis motor position F block SL f axis position error F block SL f axis auxiliary position F block SL f axis velocity F block SW f axis torque F block UW g axis status G block UB g axis switches G block UB g axis stopcode G block SL g axis reference position G block DMC 18x2 Chapter 4 Software Tools and Communications 57 SL SL SL SL SW UW UB UB SL SL
66. 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 10Volt to connect to a servo amplifier This connection is described in Chapter 2 Brushless Servo Motor with Sinusoidal Commutation The DMC 18x2 can provide sinusoidal commutation for brushless motors BLM In this configuration the controller generates two sinusoidal signals for connection with amplifiers specifically designed 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 For faster motors please contact the factory The controller provides a one time automatic set up procedure The parameters determined by this procedure can then be saved in non volatile memory to be used whenever the system is powered on The DMC 18x2 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 controller will estima
67. for input to stepper motor amp 1 PWMZ Z axis pulse output for input to stepper motor amp 1 GND Signal Ground 2 MOCMDW W axis motor command to amp input w respect to ground 2 SIGNW W axis sign output for input to stepper motor amp 2 PWMW W axis pulse output for input to stepper motor amp 2 GND Signal Ground 3 MOCMDX axis motor command to amp input w respect to ground 3 SIGNX X axis sign output for input to stepper motor amp 3 PWMX X axis pulse output for input to stepper motor amp 3 GND Signal Ground 4 MOCMDY axis motor command to amp input w respect to ground 4 SIGNY O Y axis sign output for input to stepper motor amp 4 PWMY Y axis pulse output for input to stepper motor amp 178 e Appendices DMC 18x2 NO NOD iO wi NI NINN OG OG OQ OG tn tan tA e e e e e e e e e e o a o i i i i a i d A A FW U WN NY NY NY RF e e KF O c c GND OUT PWR ERROR CMP OUT GND AMPENW AMPENZ AMPENY AMPENX OUTS OUT6 OUT7 OUT8 OUTI OUT2 OUT3 OUT4 45V HOMEZ RLSZ FLSZ LSCOM HOMEW RLSW FLSW HOMEX RLSX FLSX GND HOMEY RLSY FLSY GND INS IN6 IN7 IN8 XLATCH YLATCH ZLATCH WLATCH 45V 12V 12V ANA GND Signal Ground Isolated Power In for Opto Isolation Option Error output Circular Compare Output Isolated Ground for Opto I
68. for the DMC 18x2 controller and affect how the software waits for a response from the controller when a command is sent If a controller is configured with the Delay method the thread waiting for a command response gives up its time slice allowing other processes running on the operating system to proceed This method can slow communication but results in negligible CPU utilization The second method the Stall method uses the opposite strategy The thread that performs I O with the controller maintains ownership of the CPU and polls the controller until a response is received This approach is essentially the same method employed in previous versions lt V7 of the Galil communication DLLs and drivers While the Stall method does not have to wait for its thread to become eligible for execution it does result in 100 CPU utilization while communicating with the controller Windows Servo Design Kit WSDK The Galil Windows Servo Design Kit includes advanced tuning and diagnostic tools that allows the user to maximize the performance of their systems as well as aid in setup and configuration of Galil controllers WSDK is recommended for all first time users of Galil controllers WSDK has an automatic servo tuning function that adjusts the PID filter parameters for optimum performance and displays the resulting system step response A four channel storage scope provides a real time display of the actual position velocity error and to
69. from the PCI bus Order DMC 18x2 3VREG to have a regulator installed to allow 5V only supply DMC 18x2 Appendices 169 Performance Specifications Minimum Servo Loop Update Time DMC 1812 DMC 1822 DMC 1832 DMC 1842 Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Array Size Program Size Normal Fast Firmware 250 usec 125 usec 250 usec 125 usec 375 usec 250 usec 375 usec 250 usec 1 quadrature count 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 1 104 8000 elements 30 arrays 1000 lines x 80 characters Connectors for DMC 18x2 Main Board J1 DMC 1842 A D AXES MAIN 100 PIN HIGH DENSITY 1 Analog Ground 51 nc 2 Ground 52 Ground 3 5V 53 5V 4 Error Output 54 NC 5 Reset 55 Home W 6 Encoder Compare Output 56 Reverse limit W 7 Ground 57 Forward limit W 8 Ground 58 Home Z 9 Motor command W 59 Reverse limit Z 10 Sign W Dir W 60 Forward limit Z 11 PWM W Step W 61 Home Y 12 Motor command Z 62 Reverse limit Y 13 Sign Z Dir Z 63 Forward limit Y 170 e Appendices DMC 18x2 14 PWM Z Step Z 64 Home X 15 Motor command Y 65 Reverse limit X 16 Sign Y Dir Y 66 Forward Limit X 17 PWM Y S
70. full Label Specify coordinate system S Specify linear mode for XY 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 18x2 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the chosen vector speed even at transitions between linear and circular segments The DMC 18x2 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task 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 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 n 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 XWZ selects the XW axes for coordinated motion and the Z axis as the tangent Specifying Vector Segments The motion segments are described by two commands VP for linea
71. instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HMX return BGX return where X could be any axis on the controller X Y Z or W 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 HMX This command returns a 0 or 1 if the logic state is low or high dependent on the CN command 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 Motio
72. 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 Stepper Motor Jumpers For each axis that will be used for stepper motor operation the corresponding stepper mode SM jumper must be connected The stepper mode jumpers labeled JP2 are located directly beside the GL 1800 IC this is the largest IC on the board see the diagram of the DMC 18x2 The individual jumpers are labeled SMX SMY SMZ and SMW and configure the controller for Stepper Motors for the corresponding X Y Z and W axes when installed The jumper labeled OPT is for use by Galil technicians only Step 3 Install the Communications Software Before installing the DMC 18x2 controller in the PC Galil communications software and drivers should be loaded Installing the Galil software prior to installing the card will allow most operating system to automatically install the controller into both the Windows and Galil registries Using Win98SE ME NT4 0 2000 and XP Install the Galil Software Products CD ROM into your CD drive A Galil htm page should automatically appear with links to the software products Select DMC Smart Terminal and click Install Follow
73. position of that axis rather than the actual position The designation of the commanded position master is by the letter C For example GACX indicates that the gearing is the commanded position of X An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the X and Y motor form a circular motion the Z axis may move in proportion to the vector move Similarly if X Y and Z 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 JG VP or LI commands Command Summary Electronic Gearing Specifies master axes for gearing where X Y Z or W or A B C D for main encoder as master lt lt abide GR x y z w Sets gear ratio for slave axes 0 disables electronic gearing for specified axis n 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 Y is defined as the master X Z W are geared to master at ratios of 5 5 and 10 respectively GA Y Y
74. procedure outlined in Ch 2 However some advanced settings are available to modify the communications methods and data record access These settings are accessed through the Galil Registry Editor after the card is properly installed Galil Registry Editor The Edit Registry dialog box shown in Fig 4 4 can be accessed by selecting Controller Registration under the Tools menu or by selecting the toolbar icon with the magnifying glass within DMC SmartTERM The Edit Registry dialog shows the current controller models installed to the PC along with their associated I O addresses interrupt lines and controller serial numbers The Galil Registry is part of the DMCReg ocx ActiveX object refer to Fig 4 1 This ActiveX control is used to create maintain and modify the critical communication parameters which are discussed next Edit Registry 1 x Controller DMC 1800 PCI Address 41 76 Interrupt Level 16 Serial 8922 Controller2 DMC 1800 PCI Address 4160 Interrupt Level 16 Serial 2275 Controllers DMC 1740 ISA Address 824 SerialH 1 Properties Eres Non PnP Tools New Controller Find Ethernet Controller Plug and Play Device B Non Plug and Play Device Close Figure 4 4 Galil Registry Editor Setting Communications Parameters and Methods To access the Controller Communication Parameters dialog highlight the desired controller in the Galil Registry Editor accessed through
75. segment is being completed Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 18x2 computes the vector speed based on the axes specified in the LM mode For example LM XYZ designates linear interpolation for the X Y and Z axes The vector speed for this example would be computed using the equation vs xs vs zs where XS YS and ZS are the speed of the X Y and Z axes The controller computes the vector speed with the axis specifications from LM VT is used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trippoint which halts program execution until the vector distance of n has been reached An Example of Linear Interpolation Motion LMOVE label DP 0 0 Define position of X and Y axes to be 0 LMXY Define linear mode between X and Y axes LI 5000 0 Specify first linear segment LI 0 5000 Specify second linear segment LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector distance of 4000 is reached VS 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached VS 4000 Change vector speed EN Program end In this example the XY system is required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trippoint which slows the speed to 1000 count s Once
76. signal The second phase of the Y axis will be the motor command W 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 encoder counts For example if the X axis is a linear motor where the magnetic cycle length is 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 Z axis is 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 Test the Polarity of the DACs and Hall Sensor Configuration 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 The user must specify the value for V and T For example the command BSX 2 700 18 e Chapter 2 Getting Started DMC 18x2 will test the X axis with a voltage of 2 volts applying it for 700 millisecond for each phase In response this test indicates whether the DAC wiring is 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 bot
77. signal will not be sufficient to overcome the friction If the motion starts it can be stopped easily by a touch of a finger Note Response is determined by the gain of the amplifier Increase the torque level gradually by instructions such as Instruction Interpretation TL 1 0 Increase torque limit to 1 volt TL 9 98 Increase torque limit to maximum 9 98 Volts The maximum level of 9 998 volts provides the full output torque 24 e Chapter 2 Getting Started DMC 18x2 Example 9 Interrogation The values of the parameters may be interrogated Some examples Instruction Interpretation KP Return gain of X axis KP Return gain of Z 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 that can be interrogated Example 10 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 BGX Start the motion Example 11 Using the On Board Editor Motion programs may be edited and stored in the controller memory They may be executed at a later time If the Smart Terminal is opened in the 3 pane view then programs can be entered edited and downloaded from the window on the right side The editor window has a file and edit menu within the pane The upload or
78. 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 x y z w and n are numbers between 0 5 and 16 and determine the degree of filtering The minimum value of 0 5 implies no filtering 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 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 is connected to the Home input When the Find Edge command and Begin are used the motor will accelerate up to the slew speed and slew until a transition is 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 is shown in Fig 6 8 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 initializati
79. the installation procedure as outlined Using DOS Using the Galil Software CD ROM go to www galilmc com support download2 html and follow the instructions Note Galil software is also available for download at http www galilmc com support download html Step 4 Install the DMC 18x2 in the PC The DMC 18x2 is installed directly into the PCI expansion bus The procedure is outlined below Step A Make sure the PC is in the power off condition Step B Remove unit cover Step C Remove the metal plate covering the expansion bus slot where the DMC 18x2 will be inserted 10 e Chapter 2 Getting Started DMC 18x2 Step D Insert DMC 18x2 card in the expansion bus and secure with screw Step E Attach 100 pin cable to your controller card If you are using a Galil ICM 1900 19 0 or ICM 2900 this cable connects into the J2 connection on the interconnect module If you are not using a Galil interconnect module you will need to appropriately terminate the cable to your system components see the appendix for cable pin outs After turning on the power to the computer your computer should recognize the DMC 18x2 as a new device and will automatically install the device into the Windows and Galil registries Step 5 Establish Communication using Galil Software Using Win98SE ME NT4 0 2000 and XP When DMC Smart Terminal is executed it will automatically attempt communication if you have only 1 controller entry in the regis
80. the motors reach the corner the speed is increased back to 4000 cts s DMC 18x2 Chapter 6 Programming Motion 73 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 with two functions lt n and gt m For example LI x y z w lt n gt m 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 speed subject to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt 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 that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 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 As an example consider the following program ALT Label for alternative program DP 0 0 Define Position of X and Y axis to be 0 LMXY Define linear mode between X and Y axes
81. the output is on DMC 18x2 Chapter 7 Application Programming 141 For example Instruction Function OP6 Sets outputs 2 and 3 of output port to high AII other bits are 0 2 22 6 OPO Clears all bits of output port to zero OP 255 Sets all bits of output port to one 29 4 21422423 4244 25 426427 The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move OUTPUT Label PR 2000 Position Command BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec Clear Output 1 EN End Digital Inputs The DMC 18x2 has eight digital inputs for controlling motion by local switches The IN n function returns the logic level of the specified input 1 through 8 For example a Jump on Condition instruction can be used to execute a sequence if a high condition is noted on an input 3 To halt program execution the After Input AI instruction waits until the specified input has occurred Example 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 AI7 Wait until input 7 is high AI 6 Wait until input 6 is low Example Start Motion on Switch Motor X must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor X must stop turning Solution Connect panel switch to input 1 of DMC 18x2 High on input 1 means switch is in on posi
82. 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 ratio of the encoder resolutions For more information refer to ES in the Command Reference The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Tangent Motion Example Several applications such as cutting require a third axis i e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 18x2 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 VM m n p m n specifies coordinated axes p specifies the tangent axis such as X Y Z W p N 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 axis encoder position that corresponds to zero degrees The operand _TN can be used to return the initial position of the tangent axis Refer to TN in the Command Reference Assume an XY table that has the Z axis controlling a knife The Z 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 is
83. used to send data to the DMC 18x2 The CONTROL register may be read or written to and is used for controlling communication flags and interrupts Simplified Communication Procedure The simplest approach for communicating with the DMC 18x2 is to check bits 5 and 6 of the CONTROL register at address N 1 6 READ 0 Buffer not full to write up to 16 characters al READ Buffer full Do not send data Read Procedure To receive data from the DMC 18x2 read the control register at address N 1 and check bit 5 If bit 5 is zero the DMC 18x2 has data to be read in the READ register at address N Bit 5 must be checked 54 e Chapter 4 Software Tools and Communications DMC 18x2 for every character read and should be read until it signifies empty Reading data from the READ register when the register is empty will result in reading an FF hex Write Procedure To send data to the DMC 18x2 read the control register at address N 1 and check bit 6 If bit 6 is zero the DMC 18x2 FIFO buffer is not almost full and up to 16 characters may be written to the WRITE register at address N If bit 6 is one the buffer is almost full and no additional data should be sent The size of the buffer may be changed see Changing Full Flags below Any high level computer language such as C Basic Pascal or Assembly may be used to communicate with the DMC 18x2 as long as the READ WRITE procedure is followed as described above Example software
84. 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 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 BGX Begin motion to move material AMX Wait for motion done SB1 Set output to cut WT100 CB1 Wait 100 msec then turn off cutter JP CUT Repeat process EN End program DMC 18x2 Chapter 7 Application Programming 135 Inputting String Variables String variables with up to six characters may 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 X Y or Z V S specifies a string variable to be input Output of Data Numeric and String 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 values of variables and arrays as well as other information using the interrogation commands the interrogation commands are described in chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text
85. values specified in the data file must be comma separated or CRLF deliminated Opens the Upload Array dialog box that allows an array in the controller s RAM to be saved to a file on the hard disk The dialog box uses the DMC322 dll s DMCArrayUpload function to upload the array The controller s firmware must be recent enough to support the QU command Opens a dialog box that allows a file containing Galil ASCII language commands to be converted to Galil binary commands and saves the result to the specified file name Opens a dialog box that allows a file containing Galil binary language commands to be converted to Galil ASCII commands and saves the result to the specified file name Launches a file open dialog box that selects a file usually a DMC file to be sent to the controller This file can contain binary commands Each line of the file is sent to the controller as a command and executed immediately Additionally the Tools menu items described below provide some advanced tasks such as updating firmware diagnostics accessing the registry editor and resetting the controller 38 e Chapter 4 Software Tools and Communications DMC 18x2 Select Controller Disconnect from Controller Controller Registration DMC Program Editor Reset Controller Device Driver Diagnostics Opens the Select Controller dialog box that displays the currently registered Galil Motion Controllers Selecting a cont
86. voltage at the I O output is equal to the external supply voltage at I OC However when the output transistor is 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 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 Therefor a 10k ohm resistor pack will result in a low level voltage of 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 192 e Appendices DMC 18x2 Output Command Result CB Vou GNDigo SB Vout Viso The resistor pack RPx3 is removed to provide open collector outputs The same calculations for maximum source current and low level voltage applies as in the above circuit The maximum sink current is determined by the NEC2505 and is approximately 2mA Open Collector DMC 1748 5V 1 4 NEC2505 1 8 RPx2 Se ees e 10 DMC 1748 I O ee t
87. with the motor described by the previous example will have the transfer function P V 1000 52 rad V If the motor is a DC brushless motor it is driven by an 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 is fed back to the amplifier Such a system is illustrated in Fig 10 5 Note that the transfer function between the input voltage V and the velocity is V K K Js 1 K K Js VIKsGT4 1 where the velocity time constant T1 equals TI Ky Kg This leads to the transfer function P V I Kg s sT1 1 K 1 4 Kt Js Figure 10 5 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Fig 10 6 160 e Chapter 10 Theory of Operation DMC 18x2 VOLTAGE SOURCE V E W P o0 d ST 1 ST 41 S CURRENT SOURCE V K W d JS S VELOCITY LOOP d K ST 1 S Encoder Figure 10 6 Mathematical model of the motor and amplifier in three operational modes The encoder generates N pulses per revolution It outputs two signals Channel A and B which a
88. 0 Total 35708 counts In general the length of each linear segment is VRP Where Xk the changes in X and Y positions along the linear segment The length of the circular arc is Lx Ri A x 2 2 360 The total travel distance is given by D u k l The velocity profile may be specified independently in terms of the vector velocity and acceleration For example the velocity profile corresponding to the path of Fig A 2 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Fig A 3 Velocity 10000 time s T 0 05 T 0 357 T 0 407 a S a Figure A 3 Vector Velocity Profile 198 e Appendices DMC 18x2 The acceleration time T is given by VS _ 100000 0 055 VA 2000000 The slew time Ts is given by Ts E Ta 29 09 0 05 0 307s VS 100000 The total motion time Tt is given by D T Ta 0 4075 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 2 are given in Fig AA Fig A 4a shows the vector velocity It also indicates the position point along the path starting at A and ending at D Between the points A and B the motion is along the Y axis Therefore
89. 000 count s A AC 20000 20000 Specify X Z acceleration of 20000 cts sec DC 20000 20000 Specify X Z deceleration of 20000 cts sec JG 50000 25000 Specify jog speed and direction for X and Z axis BGX Begin X motion ASX Wait until X is at speed BGZ Begin Z motion EN Linear Interpolation Mode The DMC 18x2 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 described 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 is no limit to the total move length The LM command selects the Linear Interpolation mode and axes for interpolation For example LM YZ selects only the Y and Z 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 Linear Segments The command LI x y z w 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 or BGT command Once motion has begun additional LI segments may be sent to th
90. 1 cos 2x T 120 DMC 18x2 Chapter 6 Programming Motion 91 ACCELERATION VELOCITY POSITION Figure 6 6 Velocity Profile with Sinusoidal Acceleration The DMC 18x2 can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X 50T 955 sin 3T A complete program to generate the contour movement in this example is 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 is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example Instruction Interpretation POINTS Program defines X points DM POS 16 Allocate memory DM DIF 15 C 0 Set initial conditions C is index T 0 T is time in ms A V1 50 T V2 3 T Argument in degrees V3 955 SIN V2 V1 Compute position V4 INT V3 Integer value of V3 POS C V4 Store in array POS T T 8 C C 1 JP A C lt 16 92 e Chapter 6 Programming Motion DMC 18x2 B C 0 C D C 1 DIF C POS D POS C C C 1 JP C C lt 15 EN RUN CMX DT3 C20 E CD DIF C WC C C 1 JP E C lt 15 DTO CDO EN Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 18x2 automatic array capture feature to capture position data The captured data may then
91. 1 Drive motor to commutation phase zero and leave motor on Method 3 Use the command BC This command uses the hall 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 X axis motor upon power or reset the following commands may be given SHX Enable X axis motor BCX Enable the brushless calibration command PRX 50000 Command a relative position movement on X axis BGX Begin motion on X axis When the hall sensors detect a phase transition the commutation phase is re set nn Step 8C Connect Step Motors In Stepper Motor operation the pulse output signal has a 50 duty cycle Step motors operate open loop and do not require encoder feedback When a stepper is used the auxiliary encoder for the 20 e Chapter 2 Getting Started DMC 18x2 corresponding axis is 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 DE The encoder position can be interrogated
92. 119 Smoothing 78 80 Software SDK 109 Terminal 61 Special Label 111 Specification 79 Stack 123 126 Zero Stack 126 Status 54 61 66 114 116 131 Interrogation 81 Stop Code 66 Tell Code 65 Step Motor 102 103 KS Smoothing 78 80 Stop Abort 55 78 171 172 206 e Index Stop Code 49 66 125 131 Stop Motion 78 126 152 Subroutine 29 77 111 120 126 Automatic Subroutine 124 Synchronization 4 84 Tangent 77 79 80 Teach 93 Latch 66 Record 91 93 Tell Code 65 Tell Error 66 Position Error 15 51 53 111 124 125 131 Tell Position 66 Tell Torque 66 Terminal 29 61 109 131 Theory Damping 154 Digital Filter 61 PID 16 167 Time Interval 89 91 93 Timeout 111 117 125 126 MCTIME 111 117 125 126 Torque Limit 15 Trigger 109 116 118 119 157 Trippoint 79 80 91 117 118 123 124 TTL 5 Tuning SDK 109 Upload 109 Variable Internal 121 130 131 Vector Acceleration 80 145 Vector Deceleration 80 Vector Mode Circular Interpolation 82 Clear Sequence 78 80 Ellipse Scale 80 Feedrate 79 80 119 Tangent 77 79 80 Vector Speed 80 119 145 Zero Stack 126 DMC 18x2
93. 18x2 Controller The DMC 18x2 controller offers 64 extended I O points which can be interfaced to Grayhill and OPTO 22 I O mounting racks These I O points can be configured as inputs or outputs in 8 bit Appendices 181 increments through software The I O points are accessed through two 50 pin IDC connectors each with 32 I O points Configuring the I O of the DMC 18x2 with DB 14064 The 64 extended I O points of the DMC 18x2 w DB 14064 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 most significant bit represents block 9 The decimal value can be calculated by the following formula n 2 n3 4 n 8 n5 16 ng 32 n 64 ng 128 no 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 pg 49 4 1 o 72 4 e 73 80 7 128
94. 27 129 MCTIME 111 117 125 126 Memory 61 92 109 114 120 125 131 Array 3 77 91 93 109 114 120 128 141 170 Download 61 109 Upload 109 Message 77 103 104 114 125 126 128 151 152 Motion Complete MCTIME 111 117 125 126 Motion Smoothing 102 S Curve 102 Motor Command 15 163 Moving Acceleration 119 198 199 Begin Motion 111 113 118 119 125 126 Circular 82 Multitasking 113 Halt 113 117 118 120 Off On Error 13 31 Operand Internal Variable 121 130 131 Operators Bit Wise 121 128 Optoisolation Home Input 30 103 132 Output ICM 1100 13 31 Motor Command 15 163 PID 16 167 POSERR 111 124 125 Position Error 15 51 53 111 124 125 131 Position Capture Latch 66 Teach 93 Position Error 13 15 31 51 53 111 124 125 131 157 POSERR 111 124 125 Program Flow 110 116 Interrupt 51 Interrupt 111 113 Interrupt 118 Interrupt 124 126 Stack 123 126 Programmable 130 131 150 EEPROM 3 DMC 18x2 Index 205 Programming Halt 113 117 118 120 Protection Error Limit 13 14 31 125 Torque Limit 15 PWM 4 Quadrature 4 150 161 Quit Abort 55 78 171 172 Stop Motion 78 126 152 Record 91 93 Latch 66 Teach 93 Register 131 Reset 29 32 55 120 Scaling Ellipse Scale 80 S Curve 102 Motion Smoothing 102 SDK 109 Selecting Address 202 Servo Design Kit SDK 109 Sine 87 129 Single Ended 4 13 15 Slew 82 103 117
95. A version of the ICM 1900 is also available with servo amplifiers see AMP 19X0 below The ICM 1900 can be purchased with an option to provide opto isolation see OPTO option below on the digital outputs Features e Separates DMC 18x2 cable into individual screw type terminals Clearly identifies all terminals 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 is 42 178238 9 from AMP Terminal Label yo Description 1 AAX I X Auxiliary encoder A No Connection 2 AAX I X Auxiliary encoder A No Connection 3 ABX I X Auxiliary encoder B No Connection 4 ABX I X Auxiliary encoder B No Connection 5 Y Auxiliary encoder No Connection 6 AAY I Y Auxiliary encoder A No Connection 7 ABY I Y Auxiliary encoder B No Connection 8 ABY I Y Auxiliary encoder B No Connection 9 AAZ I Z Auxiliary encoder A No Connection 10 AAZ I Z Auxiliary encoder A No Connection 11 ABZ I Z Auxiliary encoder B No Connection 12 ABZ I Z Auxiliary encoder B No Connection 13 AAW I W Auxiliary encoder A No Connection 14 AAW I W Auxiliary encoder A No Connection 15 ABW I W Auxiliary encoder B No Connection 16 ABW I W Auxiliary encoder B No Connection 17 GND Signal Ground 18 VCC 5 Volts 19 OUTCOM Output Common for use with the opto isolated output 174
96. BIT 1 Off On Error Armed BIT 0 Echo On BIT O SM Jumper Installed BIT 8 Mode of Motion Coord Motion BIT 0 Motor off DMC 18x2 Coordinated Motion Status Information for S or T Plane 2 Byte BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in N A N A N A N A N A N A N A Progress BIT 7 BIT 6 5 4 BIT 3 BIT 2 BIT 1 BIT 0 N A N A Motion Motion Motion N A N A N A is is is slewing stopping making due to final ST or decel Limit Switch Notes Regarding Velocity Torque and Analog Input Data 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 32544 Maximum negative torque of 9 9982 V is represented by 32544 Maximum positive torque of 9 9982 V is represented by 32544 Torque information is then scaled linearly as 1v2 3255 The analog input is stored as a 16 bit value 32768 which represents an analog voltage range of 10V DMC 18x2 Chapter 4 Software Tools and Communications 59 THIS PAGE LEFT BLANK INTENTIONALLY 60 e Chapter 4 Software Tools and Communications DMC 18x2 Chapter 5 Command Basics Introduction The DMC 18x2 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interr
97. Begin motion on Y axis AL Y Arm Latch for Y axis Wait Wait label for loop JP Wait ALY 1 Jump to Wait label if latch has not occurred Result _RLY Set value of variable Result equal to the report position of y axis Result Print result EN End Fast Update Rate Mode The DMC 18x2 can operate with much faster servo update rates than default operation or standard operation This mode is known as fast mode and allows the controller to operate with the following update rates DMC 1812 125 usec DMC 1822 125 usec DMC 1832 250 usec DMC 1842 250 usec 106 e Chapter 6 Programming Motion DMC 18x2 In order to run the DMC 18x2 motion controller in fast mode 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 18x2 utilities or can be found on our website In order to set the desired update rate use the command TM When the controller is operating with the fast firmware the following functions are disabled Gearing mode Ecam mode Pole PL Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in threads 2 3 and 4 Tell Velocity TV Data Record Aux Encoders TD Dual Velocity DV Peak Torque Limit TK Notch Filter NB NF NZ Second Field of EI DMC 18x2 Chapter 6 Programming Motion 107 THIS PAGE LEFT BLANK INTENTIONALLY 108 e Chapter 6 Programming Motion DMC 18x2 Chapter 7 Applicat
98. C25 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 I O20 I O19 I O18 I O17 OUTC17 24 I OC17 24 OUTC17 24 I OC17 24 PWROUT24 PWROUT23 PWROUT22 PWROUT21 PWROUT20 PWROUT19 PWROUT18 PWROUT17 GND I O bit 27 I O bit 26 I O bit 25 Out common for I O 25 32 I O common for I O 25 32 Out common for I O 25 32 I O common for I O 25 32 Power output 32 Power output 31 Power output 30 Power output 29 Power output 28 Power output 27 Power output 26 Power output 25 I O bit 24 I O bit 23 I O bit 22 I O bit 21 I O bit 20 I O bit 19 I O bit 18 I O bit 17 Out common for I O 17 24 I O common for I O 17 24 Out common for I O 17 24 I O common for I O 17 24 Power output 24 Power output 23 Power output 22 Power output 21 Power output 20 Power output 19 Power output 18 Power output 17 Ground 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 196 e Appendices Q O O QUI OO lt gt DIO OG mieu DMC 18x2 Vs JVx vy The vector distance is the integral of Vs or the total distance traveled along the path To illust
99. D 28 GND 30 GND 32 GND DMC 18x2 Appendices 185 IOM 1964 Opto Isolation Module for Extended I O Controllers Description 186 e Appendices 34 36 38 40 42 44 46 48 50 GND GND 2 GND GND GND GND 3 GND GND GND Provides 64 optically isolated inputs and outputs each rated for 2mA at up to 28 VDC Configurable as inputs or outputs in groups of eight bits Provides 16 high power outputs capable of up to 500mA each Connects to controller via 100 pin shielded cable All I O points conveniently labeled Each of the 64 I O points has status LED Dimensions 6 8 x 11 4 Works with extended I O controllers DMC 18x2 High Current Buffer chips 16 Screw Terminals 0123 45 6 7 IOM 1964 REVA GALIL MOTION CONTROL MADE IN USA FOR INPUTS FOR OUTPUTS UX3 UX1 UX4 UX2 J5 RPX4 RPX2 RPX3 Banks 0 and 1 provide high power output capability 80 pin high density connector Banks 2 7 are standard banks Overview The IOM 1964 is an input output module that connects to the DMC 18x2 motion controller and DB 14064 extended I O daughter board cards from Galil providing optic
100. EED JG SPEED BGX JP BEGIN EN CMDERR JP DONE _ ED lt gt 2 JP DONE _TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN ZS1 JP BEGIN DONE ZSO EN 126 e Chapter 7 Application Programming Begin main program Prompt for speed Begin motion Repeat End main program Command error utility Check if error on line 2 Check if out of range Send message Send message Adjust stack Return to main program End program if other error Zero stack End program DMC 18x2 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 OPERAND FUNCTION 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 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 f
101. Example LIMSWI V1 _LFX V2 _LRX JP LF V 1 0 JP LR V2 0 JP END SLF MG FORWARD LIMIT STX AMX PR 1000 BGX AMX JP END LR MG REVERSE LIMIT STX AMX PR1000 BGX AMX END RE Dummy Program Limit Switch Utility Check state of forward limit Check state of reverse limit Jump to LF if forward limit low Jump to LR if reverse limit low Jump to end LF Send message Stop motion Move in reverse End LR Send message Stop motion Move forward End Return to main program NOTE An applications program must be executing for LIMSWI to function 152 e Chapter 8 Hardware amp Software Protection DMC 18x2 Chapter 9 Troubleshooting Overview The following discussion may help you get your system running if a problem is encountered 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 enc
102. Functions and Expressions Amplifier Interface The DMC 18x2 analog command voltage ACMD ranges between 10V This signal along with GND provides the input to the power amplifiers The power amplifiers must be sized to drive the motors and load For best performance the amplifiers should be configured for a 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 If the controller is operating in stepper mode the pulse and direction signals will be input into a stepper drive The DMC 18x2 also provides an amplifier enable signal AEN This signal is deactivated under the following conditions the watchdog timer activates the motor off command MO is given or the OElcommand Enable Off On Error is given and the position error exceeds the error limit As shown in Figure 3 1 AEN can be used to disable the amplifier for these conditions The standard configuration of the AEN signal is TTL active high In this configuration the AEN 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 vol
103. ICES M 169 ELECTRICAL SPECIFICATIONS dieu e Rea 169 Servo COMO IE UNTER 169 Stepper Controlo tote edet obe hdl emiten tea hehe aii ete 169 Input Output e Iter e eee D iy E etr ek eet utes 169 PO WOT NND MI RENE Ec BS kan a EE A is ha a eda LBB 169 PERF RMANCE SPECIFICATIONS thes eeclesie tx tees eua eeu 170 CONNECTORS FOR DMC 18X2 MAIN BOARD sasies ieres si disk eesosa e sek eesosa iisk so diens iS de 170 PIN QUT DESCRIPTION FOR DMC 18X2 i ee eter a ete exe do tons Ueda Gn Shee espe ee sare a a Ere d ev Eee bey ERE REY 171 JUMPER DESCRIPTION FOR DMC 18X2 cccc csccccsssssssscssvsssvusevscnsuvevesucusevscnsuesesssvusussessuvsvesveusevsenssesessevuseesevsvvevesbevseesess 173 ACCESSORIES AND OPTIONS tre eee odes aee doe Be te ero et aee dae be teet et e TRO 173 ICM 1900 INTERCONNECT MODULE eene n n n n 174 ICM 1900 DRAWING ette te teet ae ete Be tv eoe ame dade de te rid et ette te lee eue teed 177 AMP 19X0 MATING POWER AMPLIFIERS eene n n n n n n n n nnn nnn nnn n nnn e n n n n augu 177 ICM 2900 INTERCONNECT MODULE n n n 178 OPTO ISOLATED OUTPUTS ON ICM 1900 ICM 2900 OPTO OPTION esses enne enne rennen enn 181 Standard Opto Isolation and High Current Opto is
104. ICM 1900 has 2 forms ICM 1900 standard and ICM 1900hc 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 POWER ICM 1900 PIN 19 OUT POWER ICM 2900 RP4 on ICM 1900 10K OHMS RP2 on ICM 2900 OUT x 66 73 ISO POWER GND ICM 1900 PIN 35 OUT x TTL OUT GND ICM 2900 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 active high logic and care should be taken Using active low logic should avoid any problems associated with the outputs floating high 64 Extended I O of the DMC
105. LEN as fractional part of variable LEN Shift FLEN by 32 bits IE convert fraction FLEN to integer Mask top byte of FLEN and set this value to variable LEN Let variable LEN top byte of FLEN Let variable LEN3 bottom byte of LEN Let variable LEN4 second byte of LEN Let variable LENS third byte of LEN Let variable LEN6 fourth byte of LEN Display LENG as string message of up to 4 chars Display LENS as string message of up to 4 chars Display LEN4 as string message of up to 4 chars DMC 18x2 MG LEN3 S4 Display LEN3 as string message of up to 4 chars MG LEN2 S4 Display LEN2 as string message of up to 4 chars MG LENI S4 Display LEN1 as string message of up to 4 chars EN 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 T Response from command MG LEN6 54 Response from command MG LENS 54 Response from command MG LENA S4 Response from command MG LEN3 54 Response from command MG LEN S4 Response from command MG LENI 54 meuHn Functions FUNC
106. Motor and Encoder which uses a flat ribbon cable for connection to the AMP 1900 unit 16 e Chapter 2 Getting Started DMC 18x2 Unused with the DMC 18x2 Reset Switch Error LED 100 pin high density connector Controller AMP part 2 178238 9 1 A d 5 A L Motor Command buffer circuit Amp enable buffer circuit Encoder Wire Connections ee LSCOM VCC 99 INCOM x a Encoder ICM 1900 c a 3 z S Channel MAX a Z 5 Channel A MAX 2 E oce Channel B MBX EET Channel B MBX s gt Index Channel INX o 3 Index Channel INX lt DC Brush Servo Motor Jepoou3 Signal Gnd 2 Ref In 4 BRUSH TYPE PWM SERVO Inhibit 11 AMPLIFIER MSA 12 80 Motor 1 Motor 2 Power Gnd 3 4 5 DC Power Supply Power Gnd elslelsle High Volt Figure 2 3 System Connections with a separate amplifier MSA 12 80 This diagram shows the connections for a standard DC Servo Motor and encoder DMC 18x2 Chapter 2 Getting Started 17 Step 8b 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 servo can then be tuned as described in Step 9 Step A Disable the motor amplifier Use the command MO to disable the motor amplifiers For example MOX will turn t
107. Output Command Result CB Vowr Viso SB V oor 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 Ux 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 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 I OC or the RPx3 is removed resulting in an open collector output Here is a schematic of the digital output circuit Internal Pullup DMC 1748 5V e _ 1 8 RPx3 1 4 NEC2505 18RPx22 pee e 1 0 ye DMC 1748 I O e SET tanh wc OUTC 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
108. PR dtd e n ERR ea pe CREE 77 Additional Commands enit en eth oni b Dr RU P EO URDU RA RA 78 Command Summary Coordinated Motion Sequence eese 80 Operand Summary Coordinated Motion 80 ELECTRONIC GEARING a 82 Command Summary Electronic Gearing sees 82 BEECTRONICC AM erste cries it aaa tu 84 Command Summary Electronic CAM eese teen trennt trennt 88 CONTOURMODE 217 merear iere tiet n tea tcc ieri Dae Wee P PUE ITEM EE SRI EIU TUER 89 Specifying Contour Segments EE 89 Additional Commands 4 2 eee erede it eec e retia d eae Eiee eda tae eda kt eese e ree 91 Command Summary Contour Mod rna see rires eien an eene S PET EE rennen enneenne tenete EEEo rennen 91 STEPPER MOTOR OPERATION eere aeneo tete avene UO WR DO RE NEIN O 94 Specifying Stepper Motor Operation entente ennt 94 Using an Encoder with Stepper Motors eese 95 Command Summary Stepper Motor Operation sese nneteen enne ne enet trennen trennen 96 Operand Summary Stepper Motor Operation en enne treten eterne 96 STEPPER POSITION MAINTENANCE MODE
109. SL SL SL SW g axis motor position g axis position error g axis auxiliary position g axis velocity g axis torque h axis status h axis switches h axis stopcode h axis reference position h axis motor position h axis position error h axis auxiliary position h axis velocity h axis torque 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 Explanation of Status Information and Axis Switch Information General Status Information 1 Byte BIT 7 Program Running BIT7 Latch Occurred BIT 15 Move in Progress BIT7 Negative Direction Move BIT 6 N A BIT5 4 N A N A BIT 3 N A Axis Switch Information 1 Byte BIT 6 State of Latch Input BIT5 4 N A N A BIT 3 State of Forward Limit Axis Status Information 1 Word BIT 14 Mode of Motion PA or PR BIT 6 Mode of Motion Contour BIT 13 BIT 12 Mode of FE Motion Find PA only Edge in Progress 5 BIT 4 Motion Motion is is slewing stopping due to ST of Limit Switch 58 e Chapter 4 Software Tools and Communications BIT 11 Home HM in Progress BIT 3 Motion is making final decel BIT 2 N A BIT 2 State of Reverse Limit BIT 10 1 Phase of HM complete BIT 2 Latch is armed BIT 1 Trace on BIT 1 State of Home Input BIT 9 2 Phase of HM complete or FI command issued
110. Set the velocity gain so that an input signal of 10V runs the motor at the maximum required speed nn For step motors the amplifiers should accept step and direction signals For start up of a step motor system refer to Connecting Step Motors on page 20 The WSDK software is highly recommended for first time users of the DMC 18x2 It provides step by step instructions for system setup tuning and analysis Installing the DMC 18x2 Installation of a complete operational DMC 18x2 system consists of 9 steps Step 1 Determine overall motor configuration Step 2 Install Jumpers on the DMC 18x2 Step 3 Install the communications software Step 4 Install the DMC 18x2 in the PC Step 5 Establish communications with the Galil communication software Step 6 Determine the axes to be used for sinusoidal commutation Step 7 Make connections to amplifier and encoder Step 8a Connect standard servo motors Step 8b Connect sinusoidal commutation motors 8 e Chapter 2 Getting Started DMC 18x2 Step 8c Connect step motors Step 9 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 18x2 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
111. TION 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 AU zum en emma E esq ENS eom 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 Examples V1 ABS V7 The variable V1 is equal to the absolute value of variable 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 DMC 18x2 Chapter 7 Application Programming 129 Variables For applications that require a parameter that is variable the DMC 18x2 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 va
112. 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 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 1748 5V 1 4 NEC2505 1 8 RPx2 gt l IR6210 p I ye Ves VCC C IN OUT PWROUT DMC 1748 I O l GND 1 8 RPx3 e 1 0 e OUTC 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 1748 controller DB 14064 daughter board from the output circuit OC e Viso PWROUT External _ Isolated 1 Power Supply Current GND go OUTC DMC 18x2 Appendices 191 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
113. VECTOR MOTION ON X AND Y VS 10000 NO VECTOR SPEED IS 10000 VP 4000 0 NO BOTTOM LINE CR 1500 270 180 NO HALF CIRCLE MOTION VP 0 3000 NO TOP LINE CR 1500 90 180 NO HALF CIRCLE MOTION VE NO END VECTOR SEQUENCE BGS NO BEGIN SEQUENCE MOTION EN NO END OF PROGRAM Note The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Using REM Statements with the Galil Terminal Software If you are using Galil software to communicate with the DMC 18x2 controller you may also include REM remark statements REM statements begin with the word REM 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 VMXY REM VECTOR MOTION ON X AND Y VS 10000 REM VECTOR SPEED IS 10000 VP 4000 0 REM BOTTOM LINE CR 1500 270 180 REM HALF CIRCLE MOTION VP 0 3000 REM TOP LINE 112 e Chapter 7 Application Programming DMC 18x2 CR 1500 90 180 REM HALF CIRCLE MOTION VE REM END VECTOR SEQUENCE BGS REM BEGIN SEQUENCE MOTION EN REM END OF PROGRAM The REM statements will be removed when the program is downloaded to the controller Executing Programs Multitasking The DMC 18x2 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 thro
114. Y GR 1 Set gear ratio for Y as 1 1 GM 1 Set gantry mode PR 3000 Command X motion BGX Start motion on X axis 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 an incremental position movement of 10 on the Y axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on the Y axis BGY Begin motion on the Y axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity correction GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction DMC 18x2 Chapter 6 Programming Motion 83 Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 3 axes can be slaved to one master axis 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 To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis Y when t
115. a Galil controller The ActiveX Toolkit includes a collection of ready made ActiveX COM controls for use with Visual Basic Visual C Delphi LabVIEW and other ActiveX compatible programming tools The most common environment is Visual Basic 6 but Visual Basic NET Visual C Wonderware LabVIEW and HPVEE have all been tested by Galil to work with the OCX controls The ActiveX Toolkit can be purchased from Galil at http store yahoo com galilmc actoolsoffor html The ActiveX toolkit can save many hours of programming time Built in dialog boxes are provided for DMC 18x2 Chapter 4 Software Tools and Communications 45 quick parameter setup selection of color size location and text The toolkit controls are easy to use and provide context sensitive help making it ideal for even the novice programmer ActiveX Toolkit Includes e a terminal control for sending commands and editing programs e a polling window for displaying responses from the controller such as position and speed a storage scope control for plotting real time trajectories such as position versus time or X versus Y a send file control for sending contour data or vector DMC files a continuous array capture control for data collection and for teach and playback a graphical display control for monitoring a 2 D motion path a diagnostics control for capturing current configurations a display control for input and output status a vector motion control for tool
116. all axes either simultaneously or independently XYZ or W 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 AM when the profiler is finished not when the actual motor is in position The 68 e Chapter 6 Programming Motion DMC 18x2 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 is in the same direction Here the user specifies the desired position increment n The new target is 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 require a begin Note If the motor is not moving the IP command is equivalent to the PR and BG command combination Command Summary Independent Axis COMMAND BGXYZW STXYZN MCXYZW The lower case specifiers x y z w represent position values for each axis The DMC 18x2 also allows use of single axis specifiers such as PRY 2000 Operand Summary Independent Axis _PAx Returns current destination if x a
117. ally isolated buffers for the extended inputs and outputs of the controller The IOM 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 corresponding 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 The DMC 18x2 with DB 14064 however has an additional 64 digital input output points than the general 8 in and 8 out for a total of 80 input output points The 64 I O points on the DMC 18x2 model controllers are attached via two 50 pin ribbon cable header connectors on the DB 14064 A CB 50 80 adapter card is used to connect the two 50 pin ribbon cables to a 80 pin high density connector similar to the main axes connector A 80 pin shielded cable connects from the 80 pin connector of the CB 50 80 board to the 80 pin high density connector J5 on the IOM 1964 DMC 18x2 Appendices 187 Error LED CB 50 80 End bracket DMC 17x8 End bracket ee 80 pin high density connector used for extended I O 100 pin high density connector J1 used for motion I O Configuring Hardware Banks The extended I O on the
118. am For additional information about automatic array capture see Chapter 7 Arrays 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 pulse 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 fil
119. and at the end of the LIMSWI routine Auto Start Routine The DMC 18x2 has a special label for automatic program execution A program which has been saved into the controllers non volatile memory can be automatically executed upon power up or reset by beginning the program with the label AUTO The program must be saved into non volatile memory using the command BP If you include the AUTOERR routine in your program and you have a checksum error this program will execute For more information read the operand section of the RS command in your command reference Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 18x2 program sequences The DMC 18x2 can monitor several important conditions in the background These conditions include checking for the occurrence of a limit 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 SUBROUTINE DESCRIPTION LIMSWI Limit switch on any axis goes low ININT Input specified by II goes low 124 e Chapter 7 Application Programming DMC 18x2 POSERR Position error exceeds limit specified by ER MCTIME Motion Complete timeout occurred Timeout period set by TW command CMDERR Bad command given For example the POSERR subroutine will automatically be executed when any ax
120. and commanded position of the motor This limit can be set for any number between 1 and 32767 using the ER n command The default value for ER is 16384 Example ER 200 300 400 500 Set X axis error limit for 200 Y axis error limit to 300 Z axis error limit to 400 counts W axis error limit to 500 counts ER 1 10 Set Y axis error limit to 1 count set W 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 18x2 will generate 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 if included in program Error Light Turns on OE Function Shuts motor off if OE1 AEN Output Line Goes low The Jump if Condition statement is useful for branching within the program due to an error The position error of X Y Z and W can be monitored during execution using the TE command Programmable Position Limits The DMC 18x2 provides programmable forward and reverse position limits These are set by the BL Backwards Limit and FL Forward Limit software commands Once a position limit is specified the DMC 18x2 will not accept position commands beyond the limit Motion beyond the limit is also prevented 150 e Chapter 8 Hardware amp Software Pr
121. 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 The input is IN 1 MG The Position of X is TPX 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 S3 This statement returns 3 characters of the string variable named STR Numeric data may 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 is 00004 10 If the value of the variable RESULT is 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 stat
122. ary converted to decimal n is the bank number 2 _TIn Operand internal variable that holds the same value as that returned by TI n IN n Function that returns state of individual input bit n is number of the input from 1 to 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 5 5 3 1 GND Ground N A 4 4 5V SV DC out N A 5 3 1 080 I O bit 80 7 6 6 I O79 I O bit 79 7 7 5 1 078 I O bit 78 7 8 8 I O77 I O bit 77 7 9 7 I O76 I O bit 76 7 10 10 I O75 I O bit 75 T 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 I O bit 69 6 19 17 I O68 I O bit 68 6 20 20 1 067 I O bit 67 6 21 19 I O66 I O bit 66 6 22 22 1 065 I O bit 65 6 23 21 OUTC65 72 Out common for I O 65 72 6 24 24 I OC65 72 common for I O 65 72 6 194 e Appendices DMC 18x2 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 23 26 25 28 27 30 29 32 31 34 33 36 35 38 37 40 39 42 Al 44 43 46 45 48 47 50 49 52 51 54 53 56 55 58 57 60 59 62 61 64 63 66 65 68 67 1 064
123. at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called an overdamped response DMC 18x2 Chapter 10 Theory of Operation 157 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 pipes 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 is 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
124. atic 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 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 18x2 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 done as a one time event or as a circular continuous recording Command Summary Automatic Data Capture COMMAND DESCRIPTION RA n m o p 1 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 collec
125. be played back in the contour mode The following array commands are used DM C n RD TPX RC n m RC or RC Record and Playback Example RECORD DM XPOS 501 RA XPOS RD TPX MOX RC2 RC 1 COMPUTE DM DX 500 Program to find position differences Compute the difference and store End first program Program to run motor Contour Mode 4 millisecond intervals Contour Distance is in DIF Wait for completion Stop Contour End the program Dimension array Specify array for automatic record up to 4 Specify data for capturing such as TPX or _TPZ Specify capture time interval where n is 2n msec m is number of records to be captured Returns a 1 if recording Begin Program Dimension array with 501 elements Specify automatic record Specify X position to be captured Turn X motor off Begin recording 4 msec interval Continue until done recording Compute DX Dimension Array for DX DMC 18x2 Chapter 6 Programming Motion 93 C 0 L D C 1 DELTA XPOS D XPOS C DX C DELTA Initialize counter Label Compute the difference Store difference in array C C 1 Increment index JP L C lt 500 Repeat until done PLAYBCK Begin Playback CMX Specify contour mode DT2 Specify time increment I 0 Initialize array counter 8B Loop counter CD XPOS I WC Specify contour data I I 1 Increment array counter JP B I lt 500 Loop until done DT 0 CDO End contour mode EN End progr
126. casscescssescescesesssccesescescesoosascesesdescesesteccaseucoecescoseecssesseseasacceseesbocases 153 COVER VIE W AH Y R 153 INSTALLATION a ipe eee toe oe rie mu eter eve tte txs pv rece bte turre iis aie ree ee geo cue 153 COMMUNICATION recepte te e eie rie m enge eium lasts vist te tete eqno dee reete be REDE ey 153 EH ER e e reste Siva can erected EEN 154 OPERATION iie eren t reete RE iem e ege eet n Ie rien Hee ree qe deett Cate Ete reete p eas ate ee 154 CHAPTER 10 THEORY OF OPERATION ecce tees eee tees tn nonet eaae s sese tasse eee 155 OVERVIEW d 155 OPERATION OF CLOSED LOOP SYSTEMS ccssssssecessececesscecsesaeeecsesaeeecseeecsesaeeecsesaececsaeecsesaeeecseaaeeessneeecseaesecsesaeeeees 157 SYSTEM apodo 158 Motor Amphifier 45 ooo ee egt ri ertt m IC ERE E He Wawa e her rive 159 SYSTEM ANALYSIS ere cte aute enters Ds dec Reto Meee ds Morte dA d eu oe ed 163 SYSTEM DESIGN AND COMPENSATION ccssscecssssecesssececsessececsssaeceesceecsessececssseeceescsecsesaeeeceeseesecsessecsesaesecsenaeessnsaseeeens 165 iv e DMC 18x2 The Analytical Method rne eene acid ar eR eee tibt ire 165 APPEND
127. ch is activated during motion the controller will make a decelerated stop using the deceleration rate previously set with the DC command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position To set the activation state of the limit switches refer to the command CN configure in the Command Reference When a forward or reverse limit switch is activated the current application program that is 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 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 an 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 The operands _LFx and _LRx return the state of the forward and reverse limit switches respectively x represents the axis X Y Z or The value of the operand is either a 0 or 1 corresponding to the logic state of the limit switch active or inactive respectively If the limit switches are configured for active l
128. ctional Elements of a Motion Control System 158 e Chapter 10 Theory of Operation DMC 18x2 Motor Amplifier Voltage Drive Current Drive 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 The amplifier is 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 T RJ K 5 and T L R s and the motor parameters and units are K Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m 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 2Q0 J 0 0283 oz in s2 2 104 kg m2 L 0 004H Then the corresponding time constants are Tg 0 04 sec and Te 0 002 sec Assuming that the amplifier gain is Kv 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 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 DMC 18x2 Chapter 10 Theory of Operation 159 P V K K Js2 where Kt and J are as defined previously For example a current amplifier with K 2 A V
129. dard control for each axis of sinusoidal commutation For example if the command BAX is given to a DMC 1842 controller the controller will be re configured to a DMC 1832 controller By definition a DMC 1832 controls 3 axes X Y and Z The W axis is no longer available since the output DAC is being used for sinusoidal commutation Further instruction for sinusoidal commutation connections are discussed in Step 6 Stepper Motor Operation To configure the DMC 18x2 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 18x2 Further instructions for stepper motor connections are discussed in Step 8c DMC 18x2 Chapter 2 Getting Started 9 Step 2 Install Jumpers on the DMC 18x2 nn Master Reset and Upgrade Jumpers JP6 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 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 is not necessary for firmware updates when the controller is operating normally but may be
130. ded to move Example Position Error ED 000 LOOP 001 JP LOOP EN 002 POSERR 003 V12 TEX 004 MG EXCESS POSITION ERROR 005 MG ERROR V1 006 RE control Q LOOP JG 100000 BGX 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 DMC 18x2 Chapter 7 Application Programming 125 Now when excess position error occurs on the X axis the POSERR subroutine will be executed Example Input Interrupt A JG 30000 60000 BGXW LOOP JP LOOP EN ININT STXW AM TEST IN 1 0 JG 30000 6000 BGXW RIO Example Motion Complete Timeout BEGIN TW 1000 PA 10000 BGX MCX EN MCTIME MG X fell short EN 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 Begin main program Set the time out to 1000 ms Position Absolute command Begin motion Motion Complete trip point End main program Motion Complete Subroutine Send out a message End subroutine This simple program will issue the message X fell short if the X axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error BEGIN IN ENTER SPEED SP
131. des a hardware interrupt line that will when enabled interrupt the PC bus which will allow the controller to notify the host application of particular events occurring on the controller Interrupts free the host from having to poll for the occurrence of certain events such as motion complete or excess position error The DMC 18x2 uses only one of the PC s interrupts however it is possible to interrupt on multiple conditions For this reason the controller provides a status byte register that contains a byte designating each condition The DMC 18x2 provides an interrupt buffer that is 16 deep This allows for multiple interrupt conditions to be stored in sequence of occurrence without loss of data The DMC 18x2 provides two command forms of interrupt functionality EI and UI Specific interrupt conditions can be enabled using the EI command or explicit user defined interrupts can be sent using the UI command Enabling Event Interrupts EI command To enable certain conditions use the command EIm n Where the first field m represents a 16 bit value of conditions described in the table below For example to enable interrupts on X and Y motion complete and position error set EI515 i e 515 2 2 2 Once the EI command is enabled for a specific condition an interrupt will occur for every instance of that condition except for the items marked with an asterisk they must be re enabled after every occurrence DMC 18x2 C
132. download options are found in the file menu Instruction Interpretation A Define label PR 700 Distance SP 2000 Speed BGX Start X motion EN End program This program can be downloaded to the controller by selecting Download from the File menu Once this is done close the editor Now the program may be executed with the command XQ A Start the program running DMC 18x2 Chapter 2 Getting Started 25 Example 12 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction A V1 1000 LOOP VI BG X AM X WT 500 TPX 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 X motor V1 counts Start X motion After X motion is complete Wait 500 ms Tell position X Increase the value of V1 Repeat if V1 lt 10001 End After the above program is entered and downloaded to the controller start the motion with the command XQ A Execute Program A Example 13 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction B DP 0 0 PR 30000 60000 SP 5000 5000 BGX AD 4000 BGY AP 6000 SP 2000 50000 AP 50000 SP 10000 EN Interpretation Label Define initial positions Set targets Set speeds Start X motion Wait until X moved 4000 Start Y motion Wait until position X 6000 Change speeds Wait until position Y 50000
133. e controller 72 e Chapter 6 Programming Motion DMC 18x2 The clear sequence CS command can be used to remove LI segments stored in the buffer prior to the start of the motion To stop the motion use the instructions STS STT 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 is not given an Abort AB1 must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 18x2 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 or 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 number of the segment being processed As the segments processed CS increases starting at zero This function allows the host computer to determine which
134. e controller receives the command to generate a trajectory along these points it interpolates linearly between the points The resulting interpolated points include the position 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are A CMX Specifies X 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 4 Specifies the third time interval 2 ms CD 48 WC Specifies the third position increment Exits contour mode EN POSITION COUNTS ee ee ese 208 Pee pod e 240 192 96 48 B TIME ms J 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 5 The Required Trajectory 90 e Chapter 6 Programming Motion DMC 18x2 Additional Commands The command WC is used as a trippoint When Complete or Wait for Contour Data This allows the DMC 18x2 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 Command Summary Contour Mode COMMAND DESCRIPTION CM XYZW Specifies which axes for contourin
135. ed fab IL Controller Response to DATA The DMC 18x2 returns a for valid commands The DMC 18x2 returns a for invalid commands For example if the command BG is sent in lower case the DMC 18x2 will return a bg enter invalid command lower case DMC 18x2 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 TC1 For example TC1 enter Tell Code command 1 Unrecognized command 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 can be found in the Command Reference under TC Interrogating the Controller Interrogation Commands The DMC 18x2 has a set of commands that directly interrogate the controller When the command is entered the requested data is 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 7 and the Command Reference Summary of Interrogation Commands 18 2 Chapter 5 Com
136. ed 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 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 96 e Chapter 6 Programming Motion DMC 18x2 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 When a Galil controller is configured for step motor operation the step pulse output by the controller is 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 YS 1 executes an internal monitoring of the auxiliary and main encoder registers for that axis or axes Position error is
137. ement This is useful when a text string needs to surround a numeric value Example HA 136 e Chapter 7 Application Programming DMC 18x2 JG 50000 BGX ASX MG The Speed is TVX F5 1 N MG counts sec EN When A is executed the above example will appear on the screen as The speed is 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 Functions FUNCTION DESCRIPTION Fn m Formats numeric values in decimal n digits to the right of the decimal point and m digits to the left n m Formats numeric values in hexadecimal An Sends ASCII character specified by integer n N Suppresses carriage return line feed Sn Sends the first n characters of a string variable where n is 1 thru 6 Displaying Variables and Arrays Variables and arrays may be sent to the screen using the format variable or array x For example V returns the value of V1 Example Printing a Variable and an Array element DISPLAY Label DM POSX 7 Define Array POSX with 7 entries PR 1000 Position Command BGX Begin AMX After Motion 1 Assign Variable V1 POSX 1 _TPX Assign the first entry 1 Print V1 Interrogation Commands The DMC 18x2 has a se
138. encoder Note the necessary difference is with the YA command Full Stepping Drive X axis SETUP OE1 KS16 MT 2 200 YC4000 SHX WTS50 YS1 Half Stepping Drive X axis YA2 YB200 YC4000 SHX WT50 YSl 1 64 Step Microstepping Drive X axis SETUP OE1 KS16 MT 2 YA64 YB200 98 e Chapter 6 Programming Motion DMC 18x2 YC4000 SHX WT50 YS1 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 OE1 KS16 MTI 2 2 2 2 YA2 YB200 YC4000 SHX WT100 YS1 MOTION SP512 PR1000 BGX LOOP JP LOOP 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 WT100 spsave _SPX JP RETURN _YSX lt gt 2 SP64 MG ERROR QSX YRX _QSX DMC 18x2 Chapter 6 Programming Motion 99 MCX MG CORRECTED ERROR NOW QSX WT100 RETURN SPX spsave REO 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
139. entations respectively These can be found in the C ProgramFiles Galil DMCWIN CPP directory To link the application with the DLL s the DMC32 lib file must be included in the project and is located at C Program Files Galil DMCWIN LIB Example A simple console application that sends commands to the controller To initiate communication declare a variable of type HANDLEDMC a long integer and pass the address of that variable in the DMCOpen function If the 46 e Chapter 4 Software Tools and Communications DMC 18x2 DMCOpen function is successful the variable will contain the handle to the Galil controller which is required for all subsequent function calls The following simple example program written as a Visual C console application tells the controller to move the X axis 1000 encoder counts Remember to add DMC32 LIB to your project prior to compiling include windows h include lt dmccom h gt long rc HANDLEDMC hDmc HWND hWnd int main void Connect to controller number 1 rc DMCOpen 1 hWnd amp hDmc if rc DMCNOERROR char szBuffer 64 Move the X axis 1000 counts rc DMCCommand hDmc PR1000 BGX szBuffer sizeof szBuffer Disconnect from controller number 1 as the last action rc DMCClose hDmc return 0 Galil Communications API with Visual Basic Declare Functions To use the Galil communications API functions add
140. 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 Example 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 A1 Prompt for ACCEL AC A1 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program Programmable Hardware I O Digital Outputs The DMC 18x2 has an 8 bit uncommitted output port for controlling external events For example Instruction Function SB6 Sets bit 6 of output port CB4 Clears bit 4 of output port 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 Function OBI POS Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 OB 2 GIN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 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 2lis output 2 and so on A 1 designates that
141. erred definition of the forward and reverse directions make sure that the encoder wiring is consistent with that definition The DMC 18x2 accepts single ended or differential encoder feedback with or without an index pulse If you are not using the AMP 19x0 or the ICM 1900 you will need to consult the appendix for the encoder pinouts for connection to the motion controller The AMP 19x0 and the ICM 1900 can accept encoder feedback from 10 pin ribbon cable or individual signal leads For a 10 pin ribbon cable encoder connect the cable to the protected header connector labeled X ENCODER repeat for each axis necessary For individual wires simply match the leads from the encoder you are using to the encoder feedback inputs on the interconnect board The 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 command CE Step D Verify proper encoder operation Start with the X encoder first Once it is connected turn the motor shaft and interrogate the position with the instruction TPX return The controller response will vary as the motor is turned DMC 18x2 Chapter 2 Getting
142. es the feedback polarity is correct the motor does not attempt to run away but the direction of motion is reversed with respect to the desired commanded motion If this is the case reverse the motor leads AND the encoder signals DMC 18x2 Chapter 2 Getting Started 15 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 TTX CR Tell torque on X reports the level of the output signal It will show a non zero value that is 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 filter 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 nes enpace Reset Switch E LED 100 pin high density connectol input connector input connector eset AMD rt Aes 82 ad DB25 female 26 pin header partes P d VCC ee L SCOM VCC e INCOM MADE IN USA Filter Chokes slo ICM AMP 1900 GALIL MOTION CONTROL DC Power Supply Encoder Figure 2 2 System Connections with the AMP 1900 Amplifier Note this figure shows a Galil
143. esaececsesaececssssecsesaeeecsecaececsseecsesaeeecseaaecseaeeecseaeeecnesaeeeens 141 Digital Outputs iih enn aes eee oh ne heen le tio Nab aiden eed 141 Digital Inputs PE 142 Input Interrupt Function 5 ci enpROH a Ee sonet ir an beaten 143 EXAMPLE APPLICATIONS erase ESEE ETE KEE EER E EE KEER E EERSTE AAE ree dedu CE Tae e RU De pea e PUER DER 143 Ware a 143 XY Table Controller c ecrit ee P E RIEN TRUE soa Ee NE REDE QU ERE ete qe LEE WEE eee ees 144 CHAPTER 8 HARDWARE amp SOFTWARE PROTECT ION eee ee esee ee enne seen eset tn sese ta se setae seen 149 INTRODUGEION eei keine nime oth ede iste ae 149 HARDWARE PROTECTION 3 iio emiten nit atate nano eb mato Oeo tote es 149 Output Protection I3ne nie nU PO PI HERD re rod E E ET pa PO ta 149 Input Protection Lanes cet POPE ORO pole ere aO ER 150 SOETWARE PROTECTION enia ena PS nme onte me d te dese tete 150 Programmable Position Lirmts eie ode trece eee eet ea tede de oL eee ERR E Pe Eee gue Pee endo cet Peer e ruat 150 Off One KSI echten tam natn a mA E 151 Automatic Error rre het i e e I e ENTE TE Ee eR EY 151 Switch Routine ignea e WERE RV TRUE ia e EIU VEU 152 CHAPTER 9 TROUBLESHOOTIN Givisciesesss ccosessvects
144. esponseLength Text1 Text Val m_sResponse End Sub Private Sub Form_Load m_nResponseLength 256 m nController 1 m nRetCode DMCOpen m nController 0 m hDmc End Sub Private Sub Form Unload Cancel As Integer m nRetCode DMCClose m hDmc End Sub Where m_nController is the number for the controller in the Galil registry m hDmc is the DMC handle used to identify the controller It is returned by DMCOpen m nRetCode is the return code for the routine m_nResponseLength is the response string length which must be set to the size of the response string m_sResponse is the string containing the controller response to the command DOS Linux and QNX tools Galil offers unsupported code examples that demonstrate communications to the controller using the following operating systems DOS DOS based utilities amp Programming Libraries for Galil controllers which includes a terminal utilities to upload and download programs and source code for BASIC and C programs Download DMCDOS at http www galilmc com support download html dos 48 e Chapter 4 Software Tools and Communications DMC 18x2 Linux QNX Galil has developed code examples for the Linux operating system The installation includes sample drivers to establish communication with Galil PCI and ISA controllers The current version of the software has been tested under Redhat 6 X O S All source codes for the drivers and other util
145. f the torque limit is below the normal operating range See description of TL in the command reference 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 CR Position relative 1000 counts BGX lt CR gt Begin motion on X 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 be accomplished by several methods If you are driving a brush type DC motor the simplest way is to invert the two motor wires typically red and black For example switch the M1 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 respectively For more details on the MT command or the CE command see the Command Reference section Sometim
146. fterward SL DMC 18x2 Chapter 7 Application Programming 117 Event Trigger Examples Event Trigger Multiple Move Sequence The AM trippoint is 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 TWOMOVE Label PR 2000 Position Command BGX Begin Motion AMX Wait for Motion Complete PR 4000 Next Position Move BGX Begin 2nd move EN End program Event Trigger Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period SETBIT Label SP 10000 Speed is 10000 PA 20000 Specify Absolute position BGX Begin motion AD 1000 Wait until 1000 counts SB1 Set output bit 1 EN End program Event Trigger Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR trippoint is used as shown in the next example TRIP Label JG 50000 Specify Jog Speed BGX n 0 Begin Motion REPEAT Repeat Loop AR 10000 Wait 10000 counts TPX Tell Position Set output 1 WT50 Wait 50 msec Clear output 1 n n 1 Increment counter REPEAT n lt 5 Repeat 5 times STX Stop EN End Event Trigger Start Motion on Input This example waits for input to go low and then starts motion Note The AI command actually halts execution of the program until the input occurs If y
147. fy relative distances on X and Y axes BG XY 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 X and Y 10000 and 20000 units respectively 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 18x2 has special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines The following labels listed below are the automatic subroutines supported by the controller Sample programs for these subroutines can be found in Automatic Subroutines for Monitoring Conditions on page 124 AUTO Starts program on power up or reset ININT Label for Input Interrupt subroutine LIMSWI Label for Limit Switch subroutine POSERR Label for excess Position Error subroutine MCTIME Label for timeout on Motion Complete trip point CMDERR Label for incorrect command subroutine AUTOERR Label for checksum error DMC 18x2 Chapter 7 Application Programming 111 Commenting Programs Using the command NO The DMC 18x2 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 PATH NO 2 D CIRCULAR PATH VMXY NO
148. g mode Any non contouring axes may be operated in other modes CD x y z w Specifies position increment over time interval Range is 32 000 Zero ends contour mode 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 Waits for previous time interval to be complete before next data record is processed General Velocity Profiles The Contour Mode is ideal for generating an arbitrary velocity profile 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 Generating an Array An Example Consider the velocity and position profiles shown in Fig 6 6 The objective is 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 1 cos 2xT B X AT B 2 2x T B Note is the angular velocity X is the position and T is the variable time in milliseconds In the given example A 6000 and B 120 the position and velocity profiles are X 50T 6000 27 sin 2x T 120 Note that the velocity in count ms is 50
149. gn V4 the logical state of the Home input on the W axis Arrays For storing and collecting numerical data the DMC 18x2 provides array space for 8000 elements The arrays are one dimensional and up to 30 different arrays may be defined Each array element has a numeric range of 4 bytes of integer 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 Example DM 7 Defines an array names POSX with seven entries DM SPEED 100 Defines an array named speed with 100 entries DM POSX 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 POSX array defined with the DM command DM POSX 7 would be specified as POSX 0 Values are assigned to array entries using the equal sign
150. h 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 messages returned from the controller If Hall Sensors are Available 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 If Hall Sensors are Not Available 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
151. hapter 4 Software Tools and Communications 51 0 jXmotoncompee Z motion complete 3 Wmotion complete 4 Emotion complete S F motion complete 6G motion complete motion complete a Excess position error Limit switch TNot used when using new version 7 drivers The argument enables interrupts for the first 8 general inputs To enable interrupts for the desired inputs set bit 15 of the m argument then set the desired inputs using 8 bit mask for the argument For example to enable interrupt on inputs 1 4 set EI32768 15 Note that the input interrupts must be reset for all inputs after any input has caused an interrupt meme Ppt User Interrupts UI command The DMC 18x2 also provides 16 User Interrupts which can be sent by executing the command Uln to the DMC 18x2 where n is an integer between 0 and 15 The UI command does not require the EI command UI commands are useful in DMC programs to let the host application know that certain points within the DMC program have occurred 52 e Chapter 4 Software Tools and Communications DMC 18x2 Servicing Interrupts Once an interrupt occurs the host computer sends an associated Status Byte along with the interrupt vector The Status Byte returned denotes what condition has occurred as described in the table below Status Byte hex Condition 00 No interrupt D9 Watchdog timer activated
152. he X 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 the two sinusoidal signals generated by the controller The first signal is the axis specified with the command BA Step 6 The second signal is 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 2 phase of the highest sinusoidal commutation axis will be the highest command output and the 2 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 2 signals If this wiring is incorrect the setup procedure will alert the user Step D Example Sinusoidal Commutation Configuration using a DMC 1842 BAXY This command causes the controller to be reconfigured as a DMC 1822 controller The X and Y axes are configured for sinusoidal commutation The first phase of the X axis will be the motor command Z signal The second phase of the X axis will be the motor command Z signal The first phase of the axis will be the motor Y command Y
153. he controller waits for the input pulse on 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 Instruction Function A Label All Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AMX After motion is complete 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 ___ 78 _ _ output TIME INTERVALS move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals X Y Table Controller An X Y Z system must cut the pattern shown in Fig 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool 144 e Chapter 7 Application Programming DMC 18x2 The heavy solid curves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feedrate of 1 inch per second The light lines correspond 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 Z axis raised An X Y motion to point B is followed by lowering the Z axis and performing a cut along the circle Once the circular motion is completed the Z axis is raised and the motion continues to point C e
154. he interrogation is repeated at a point halfway between the points C and D The value of AV is 4000 15007t 2000 10 7 12 The value of CS is 2 _VPX _VPY contain the coordinates of the point C C 4000 3000 D 0 3000 B 4000 0 A 0 0 Figure 6 3 The Required Path DMC 18x2 Chapter 6 Programming Motion 81 Electronic Gearing This mode allows multiple 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 specifies the master axes GR x y z w 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 x y z w selects 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
155. he master is X 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 X Y Z W p is the selected master axis For the given example since the master is x we specify EAX Step 2 Specify the master cycle and the change in the slave axis es In the electronic cam mode the position of the master is always expressed within one cycle In this example the position of x is always expressed 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 is 1500 the positions of both x and y are redefined as zero To specify the master cycle and the slave cycle change we use the instruction EM EM x y z w where x y z w specify the cycle of the master and the total change of the slaves over one cycle 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 mas
156. ically executed if the error on any axis exceeds the error limit specified by ER The error routine should be closed with the RE command RE will cause the main program to be resumed where left off NOTE The Error Subroutine will be entered again unless the error condition is gone Example A JP Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor AMX After motor stops SHX Servo motor here to clear error RE Return to main program NOTE An applications program must be executing for the POSERR routine to function DMC 18x2 Chapter 8 Hardware amp Software Protection 151 Limit Switch Routine The DMC 18x2 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 LIMSWI 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 The RE command ends the subroutine and resumes the main program where it left off The state of the forward and reverse limit switches may also be interrogated or used in a conditional statement The _LR condition specifies the reverse limit and _LF specifies the forward limit X Y Z or W following LR or specifies the axis The CN command can be used to configure the polarity of the limit switches Limit Switch
157. ient 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 be decreased For example BZ 2 0 1 will drive both X and Z axes to zero will apply 2V and 1V respectively to X and Z and will end up with X in SH and Z in MO If Hall Sensors are Available 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 _BZx 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 X axis motor upon power or reset the following commands may be given SHX Enable X axis motor PRX 1 BZX Move X motor close to zero commutation phase BGX Begin motion on X axis AMX Wait for motion to complete on X axis BZX
158. ified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs MR X or Y or Z or W 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 MC X or Y or Z or W Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW x y z w sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stopcode will be set to 99 An application program will jump to label MCTIME AI Halts program execution until after 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 1812 1822 1832 1842 ASX YZWST Halts program execution until specified axis has reached its slew speed AT 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 A Halts program execution until specified distance along a coordinated path has occurred W Halts program execution until specified time in msec has elapsed Vn Tn Kn Halts the program at a specific line and allows single line step through a
159. ify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation ED Edit Mode 000 A Program Label 001 PR1000 Position Relative 1000 002 BGX Begin 003 PR5000 Position Relative 5000 004 EN End lt cntrl gt Q Quit Edit Mode XQ 8A Execute A 2003 PR5000 Error on Line 3 TCI Tell Error Code 7 Command not valid Command not valid while running while running ED 3 Edit Line 3 003 AMX PR5000 BGX Add After Motion Command lt cntrl gt Q Quit Edit Mode XQ 8A Execute A DMC 18x2 Chapter 7 Application Programming 115 Program Flow Commands The DMC 18x2 provides instructions to control program flow The DMC 18x2 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 18x2 can be programmed to make decisions based on the occurrence of an event Such 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 18x2 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically execu
160. ill load the diagnostics output file specified in the Tools Options menu to be loaded into the editor window for analysis The Test Controller command tests the current controller with a series of standard communication tests DMC 18x2 Chapter 4 Software Tools and Communications 39 Update Firmware The Update Firmware command allows new firmware to be downloaded to the currently connected controller Selecting this command will cause a file open dialog box to open allowing the user to specify a HEX file to be specified for download The latest firmware files can be downloaded from Galil s website Display Data Record Causes the Data Record dialog box to be displayed for the currently connected controller The dialog automatically configures itself to display the data record for each type of Galil Motion Controller Options The Options menu command causes the Options dialog to be displayed The Options dialog box allows several application options to be set These option settings are preserved between uses DMC Program Editor Window The Program Editor Window is used to create application programs DMC that are downloaded to the controller The editor window is also useful for uploading and editing programs already residing in the controller memory This window has basic text editing features such as copy cut paste etc Also the editor window File function allows an application program to be downloaded with com
161. ind Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX lt return gt BGX lt return gt where X could be any axis on the controller X Y Z or W The Find Edge routine will cause the motor to accelerate then slew at constant speed until a transition is detected in the logic state of the Home input The direction of the FE motion is dependent on the state of the home switch Refer to the CN command to set the correspondence between the Home Input voltage and motion direction The motor will decelerate to a stop when a transition is seen on the input 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 FIX return BGX return where X could be any axis on the controller X Y Z or W Find Index will cause the motor to accelerate to the user defined slew speed SP 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 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
162. ing 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 x y z w and n are numbers between 0 and 1 and determine the degree of filtering The maximum value of 1 implies no filtering 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 7 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing DMC 18x2 Chapter 6 Programming Motion 101 PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT 5 Filter for S curve BGX Begin ACCELERATION VELOCITY ACCELERATION VELOCITY E Figure 6 7 Trapezoidal velocity and smooth velocity profiles C 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 x y z w where x y z w is an integer from 0 5 to 16 and represents the amount of smoothing 102 e Chapter 6 Programming Motion DMC 18x2 Homing The command IT is used for
163. ion adjusting the water temperature in the shower One control objective is 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 is 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 want the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback is 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
164. ion Programming Overview The DMC 18x2 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 18x2 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 18x2 provides commands that allow the DMC 18x2 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 to the label LOOP if the variable n is less than 10 For greater programming flexibility the DMC 18x2 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 DMC 18x2 Editor to Enter Programs Application programs for the DMC 18x2 may be created and edited either locally using the DMC 18x2 editor or remotely using another editor and then downloading the program into the controller Galil s Smart Terminal and WSDK software provide an editor and UPLOAD and DOWNLOAD
165. ion on Z axis EN End Program 70 e Chapter 6 Programming Motion DMC 18x2 VELOCITY COUNTS SEC X axis velocity profile 20000 Y axis velocity profile 15000 Z axis velocity profile 10000 5000 TIME ms 0 20 40 60 80 100 Figure 6 1 Velocity Profiles of XYZ Notes on fig 6 1 The X and Y axis have a trapezoidal velocity profile while the Z axis has a triangular velocity profile The X and Y 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 Z axis accelerates but before the specified speed is achieved must begin deceleration such that the axis will stop at the commanded position All 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 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 acceleration AC and the deceleration DC rate for each axis The direction of motion is 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
166. ioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 1812 is a single axis controller and uses X axis motion only Likewise the DMC 1822 uses X and Y the DMC 1832 uses X Y and Z and the DMC 1842 uses X Y Z and W The example applications described below will help guide you to the appropriate mode of motion EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each axis 15 Independent Axis Positioning PA PR independent and follows prescribed velocity SP AC DC profile Velocity control where no final endpoint is Independent Jogging prescribed Motion stops on Stop command Motion Path described as incremental position Contour Mode points versus time 2 3 or 4 axis coordinated motion where path is Linear Interpolation described by linear segments 2 D motion path consisting of arc segments and Coordinated Motion linear segments such as engraving or quilting Third axis must remain tangent to 2 D motion path Coordinated motion with tangent axis VM such as knife cutting specified VP CR VS VA VD TN VE DMC 18x2 Chapter 6 Programming Motion 67 Electronic gearing where slave axes are scaled to Electronic Gearing GA master axis which can move in both directions GR GM gantry Master slave where slave axes must follow a Electronic Gearing master such as conveyer speed Mo
167. is 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 18x2 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 ED 000 LOOP 001 JP LOOP EN 002 LIMSWI 003 MG LIMIT OCCURRED 004 RE control Q XQ LOOP 5000 BGX Dummy Program Jump to Loop Limit Switch Label Print Message Return to main program Quit Edit Mode Execute Dummy Program Begin Motion Now when a forward limit switch occurs on the X axis the LIMSWI subroutine will be executed Notes regarding the ZLIMSWI Routine 1 The RE command is used to return from the LIMSWI 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 comman
168. itch Common W axis home input W axis reverse limit switch input W axis forward limit switch input Z axis home input Z axis reverse limit switch input Z axis forward limit switch input Y axis home input Y axis reverse limit switch input Y axis forward limit switch input X axis home input X axis reverse limit switch input X axis forward limit switch input 5 Volts Signal Ground Input common No Connection e Input 1 Used for X axis latch input Input 2 Used for Y axis latch input Input 3 Used for Z axis latch input Input 4 Used for W axis latch input Input 5 Input 6 Input 7 DMC 18x2 Appendices 175 176 e Appendices 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 IN8 ABORT OUTI OUT2 OUT3 OUT4 OUTS OUT6 OUT7 OUTS8 ND 1 2 N3 N4 5 6 7 gt gt gt gt gt AN8 MAX MAX MBX MBX INX INX ANALOG GND VCC MAY MAY MBY MBY INY INY MAZ MAZ MBZ MBZ INZ INZ GND VCC MAW MAW MBW gt gt Input 8 Abort Input Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Signal Ground Analog Input 1 No Connection Analog Input 2 No Connectio
169. ities developed for Linux are available to customers upon request Linux drivers are available for ISA and PCI cards under Kernel 2 2 Drivers are also available for the PCI card only for Kernel 2 4 For more information on downloading and installing the Linux drivers for Galil controllers download the Linux manual at http www galilmc com support manuals Inxmanual pdf Galil offers sample drivers for ISA and PCI cards for the QNX 4 24 operating system We also offer drivers and utilities for QNX 6 2 for PCI only Download at http www galilmc com support download html linux Command Format and Controller Response Instructions to the DMC 18x2 may be sent in Binary or ASCII format Binary communication allows for faster data processing since the controller does not have to first decode the ASCII characters ASCII Command mode In the ASCII mode instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon The DMC 18x2 decodes each ASCII character one byte one at a time It takes approximately 350 msec for the controller to decode each command and execute it After the instruction is decoded the DMC 18x2 returns a colon if the instruction was valid or a question mark if the instruction was not valid For instructions that return data such as Tell Position TP the DMC 18x2 will return the data followed by a carriage return
170. l Position X to the variable POSX VARI KPX 2 Assigns value from KPX multiplied by two to variable VARI JP LOOP _TEX gt 5 Jump to LOOP if the position error of X 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 they cannot be assigned a value For example _GNX 2 is invalid Special Operands Keywords The DMC 18x2 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 18x2 commands Pretas a ewemum he numberof available bels for programming Com he Pretas satus of Home Swier easaig Lum satus of Forwara Limit switch input ofans Lux Retr satus oF Reverse Limit switch input ofans ema Eur Retna he number of 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 _LF _LR and TIME do not have any associated commands keywords are listed in the Command Reference manual DMC 18x2 Chapter 7 Application Programming 131 Examples of Keywords V1 _LFX Assign V1 the logical state of the Forward Limit Switch on the X axis V3 TIME Assign V3 the current value of the time clock 4 HMW Assi
171. lifier the AMP 1920 2 amplifiers the AMP 1930 3 amplifiers and the AMP 1940 4 amplifiers Each amplifier is rated for 7 amps continuous 10 amps peak at up to 80 V The gain of the AMP 19X0 is 1 amp V The AMP 19X0 requires an external DC supply The AMP 19X0 connects directly to the DMC 18x2 and screwtype terminals are provided for connection to motors encoders and external switches DMC 18x2 Appendices 177 Features e 7 amps continuous 10 amps peak 20 to 80V e Available with 1 2 3 or 4 amplifiers Connects directly to DMC 18x2 series controllers Screw type terminals for easy connection to motors encoders and switches Steel mounting plate with 1 4 keyholes Specifications Minimum motor inductance 1 mH PWM frequency 30 Khz Ambient operating temperature 0 to 70 C Dimensions Same as ICM 1900 Mounting Keyholes 1 4 Gain 1 amp V ICM 2900 Interconnect Module The ICM 2900 interconnect module provides easy connections between the DMC 18x2 series controllers and other system elements such as amplifiers encoders and external switches The ICM 2900 accepts the 100 pin main cable and provides screw type terminals for connections Each screw terminal is labeled for quick connection of system elements A single ICM 2900 can be used for up to 4 axes Block 4 PIN Label Lo Description 1 MOCMDZ Z axis motor command to amp input w respect to ground 1 SIGNZ Z axis sign output
172. ll combination of speed and minimum CPU utilization c Stall Thread This method is fast but results in 100 CPU utilization if polling continuously Delay Thread This method in most cases is slower but is has negligible impact on GPU More Info utilization DMC 18x2 Chapter 4 Software Tools and Communications 43 Figure 4 6 Controller Communications Method Dialog Box Interrupt Communications Method The interrupt method overall is the most efficient of the three methods The software communications method uses a hardware interrupt to notify the application that a response or unsolicited data is available This allows for greater efficiency and response time since the drivers do not have to poll the buffers for the data Additionally the interrupt method allows for data record caching The interrupt method uses bus level interrupts IRQ from the controller to notify the PC that data is available This requires that the Controller be configured with a valid interrupt line For DMC 18x2 controllers the interrupt is configured automatically Firmware version 2 0m and greater is required for the communications interrupt method to be available For complete information on the different communications methods select the More Info button on the Communications parameters dialog box Stall Thread and Delay Thread Methods Users can also choose between Delay and Stall methods These two methods are available
173. lues 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 c 6 7 49 64 Extended I O d 8 9 65 80 Extended I O For example if block 8 is configured as an output the following command may be issued OP 7 7 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 All 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 n 0 2 3 4 5 6 7 8 or 9 The value returned will be a decimal representation of the corresponding bits Individual bits can be queried using the IN n function where n 1 through 8 or 17 through 80 If the following command is issued MG GIN 17 the controller will return the state of the least significant bit of block 2 assuming block 2 is configured as an input Connector Description The DB 14064 has two 50 Pin IDC header connectors The connectors are compatible with I O mounting racks such as Grayhill 70GRCM32 HL OPTO 22 G4PB24 Note for interfacing to OPTO 22 G4PB24 When using the OPTO 22 G4PB24 I O
174. lution 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 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 Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program 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 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 When active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command DMC 18x2 Home Switch Input 1 Input 8 Latch Input for Homing HM and Find Edge FE instructions U
175. ly KP should not be greater than KD 4 Only when the amplifier is configured in the 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 X CR 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 Y Z and W 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 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 Example 1 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 or X Y Z W axes KP 10 Alternate method for setting gain on all axes KPX 10 Alternate method for setting X or A axis gain KPA 10 Alternate method for setting A or X axis gain KP 20 Set Y axis gain only ER 1000 Set error limit for all axes to 1000 counts OEL 1 1 1 Enable automatic off on error function for all 4 axes Example 2 Profiled Move Objective Rotate the X axis a distance of 10 000 counts at a slew speed of 20 000 counts sec and acceleration and
176. mand Basics 65 For example the following example illustrates how to display the current position of the X axis TP X lt enter gt Tell position X 0000000000 Controllers Response TP XY lt enter gt Tell position X and Y 0000000000 0000000000 Controllers Response Interrogating Current Commanded Values Operands Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PR Request X Y Z W values PR Request Y value only The controller can also be interrogated with operands Most DMC 18x2 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 All of the command operands begin with the underscore character _ For example the value of the current position on the X axis can be assigned to the variable V with the command V _TPX 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 the Command Reference 66 e Chapter 5 Command Basics DMC 18x2 Chapter 6 Programming Motion Overview The DMC 18x2 provides several modes of motion including independent posit
177. mmanding 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 parameter gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt 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 that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 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 78 e Chapter 6 Programming Motion DMC 18x2 Changing Feedrate The command VR n allows the feedrate VS to be scaled from 0 and 10 times 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 feedrate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 act as VS 1000 Compensating for Differences in Encoder Resolution Trippoints By default the DMC 18x2 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If
178. 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 J6 50 PIN IDC Pin Signal Block IN n Bit OUT n No 1 I O 4 40 7 3 I O 4 39 6 3 I O 4 38 5 7 4 37 4 DMC 18x2 Appendices 183 184 e Appendices 5V I O I O GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND R2 b2 b2 02092 0202 02 0202 2 HH gt RAAN _ AURADAN OE DMC 18x2 J8 50 PIN IDC Pin Signal Block Bit IN n Bit OUT n No 1 8 72 7 3 I O 8 71 6 5 I O 8 70 5 f I O 8 69 4 9 I O 8 68 3 11 I O 8 67 2 13 8 66 1 Lx I O 8 65 0 17 7 64 7 19 7 63 6 21 I O 7 62 5 23 I O 7 61 4 25 I O 7 60 3 De 7 59 2 29 7 58 1 31 7 57 0 33 6 56 7 35 I O 6 55 6 3d I O 6 54 5 39 I O 6 53 4 4 6 52 3 43 I O 6 51 2 45 I O 6 50 1 47 6 49 0 49 5V 2 I O 9 73 0 4 I O 9 74 1 6 I O 9 75 2 8 I O 9 76 3 10 I O 9 77 4 12 9 78 5 14 9 79 6 16 I O 9 80 7 18 GND 20 GND 22 GND 24 GND 26 GN
179. n Analog Input 3 No Connection Analog Input 4 No Connection e Analog Input 5 No Connection Analog Input 6 No Connection Analog Input 7 No Connection Analog Input 8 No Connection X Main encoder A X Main encoder A X Main encoder B X Main encoder B X Main encoder Index X Main encoder Index Analog Ground 5 Volts Y Main encoder A4 Y Main encoder A Y Main encoder B Y Main encoder B Y Main encoder Index Y Main encoder Index Z Main encoder A4 Z Main encoder A Z Main encoder B Z Main encoder B Z Main encoder Index Z Main encoder Index Signal Ground 5 Volts W Main encoder A W Main encoder A W Main encoder B DMC 18x2 108 109 110 111 112 MBW INW INW 12V 12V W Main encoder B W Main encoder Index W Main encoder Index 12 Volts 12 Volts ISOLATED GND and ANALOG GND connections added to Rev D No Connection The DMC 18X2 does not make full use of the functionality of the ICM AMP 19X0 These terminals refer to pins not used by the controller J53 provides 4 additional screw terminals for Ground Connection on Revision D ICM 1900 Drawing 13 500 12 560 x 1 1 620 0 220 6 880 4 940 0 440 Dimensions 13 5 x 2 675 x 6 88 2 000 AMP 19X0 Mating Power Amplifiers The AMP 19X0O series are mating brush type servo amplifiers for the DMC 18x2 The AMP 1910 contains 1 amp
180. n 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 18x2 Digital D z K z A z Cz z 1 1 B Z B Digital D z 4 KP 4 KD zl KI 2 1 z7 1 B Z B KP KD KI PL KP KD 4 A KD KP KD C KI2 B PL Continuous G s P Ds I s a S a PID T P 4KP D 4T KD I KI 2T a B 2T DMC 18x2 Chapter 10 Theory of Operation 167 PAGE LEFT BLANK INTENTIONALLY 168 e Chapter 10 Theory of Operation DMC 18x2 Appendices Electrical Specifications Servo Control ACMD Amplifier Command A A B B IDX IDX Encoder Stepper Control Pulse Direction Input Output Uncommitted Inputs Limits Home Abort Inputs OUT 1 thru OUT 8 Outputs 10 Volts analog signal Resolution 16 bit DAC or 0003 Volts 3 mA maximum TTL compatible but can accept up to 12 Volts Quadrature phase on CHA CHB Can accept single ended A B only or differential A A B B Maximum A B edge rate 12 MHz Minimum IDX pulse width 80 nsec TTL 0 5 Volts level at 50 duty cycle 3MHz maximum step output frequency TTL 0 5 Volts TTL TTL Note The part number for the 100 pin connector is 2 178238 9 from AMP Power 3 3 100 Rev E 5V 750 mA 12V 20 mA 12V 20 mA DMC 18x2 revision E and higher require 3 3V
181. n Vector deceleration Start motion Example 16 Circular Interpolation Objective Move the XY axes in circular mode to form the path shown on Fig 2 4 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 XY VP 4000 0 CR 2000 270 180 VP 0 4000 CR 2000 90 180 VS 1000 Interpretation Select XY axes for circular interpolation Linear segment Circular segment Linear segment Circular segment Vector speed DMC 18x2 Chapter 2 Getting Started 27 VA 50000 Vector acceleration VD 50000 Vector deceleration VE End vector sequence BGS Start motion Y 4000 4000 0 4000 R 2000 O 4000 0 0 0 local zero Figure 2 4 Motion Path for Example 16 28 e Chapter 2 Getting Started DMC 18x2 Chapter 3 Connecting Hardware Overview The DMC 18x2 provides digital inputs for forward limit reverse limit home and abort signals The controller also has 8 uncommitted TTL inputs for general use as well as 8 TTL outputs This chapter describes the inputs and outputs and their proper connection Using Inputs 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 If a limit swit
182. n Chapter 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 is 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 30 e Chapter 3 Connecting Hardware DMC 18x2 NOTE The effect of an Abort input is dependent on the state of the off on error function OE 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 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 Uncommitted Digital Inputs The general use inputs are TTL and are accessible through the ICM 2900 as XLATCH WLATCH inputs 1 4 and IN5 IN8 These inputs can be interrogated with the use of the command TI Tell Inputs the operand _TI and the function IN n see Chapter 7 Mathematical
183. n Error function is further discussed in 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 to act as selective aborts for axes A B C D respectively Forward Limit Switch Low input inhibits motion in forward direction The CN command can be used to change the polarity of the limit switches 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 LIMSWI if such a routine has been written by the user Reverse Limit Switch Low input inhibits motion in reverse direction The CN command can be used to change the polarity of the limit switches If the motor is moving in the reverse direction when the limit switch is 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 Software Protection The DMC 18x2 provides a programmable error limit The error limit refers to a difference in the actual
184. n application program Binary Command Format All binary commands have a 4 byte header and are followed by data fields The 4 bytes are specified in hexadecimal format Header Format Byte 1 specifies the command number between 80 and 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 movement 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 8 data field Bit 6 7 data field Bit 5 6 data field Bit 4 5 data field Bit 3 D axis or 4 data field Bit 2 C axis or 3 data field 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 DMC 18x2 Chapter 5 Command Basics 63 Example 02 specifies 2 bytes for each data field 00 S is not active f
185. n sea 35 INTRODUCTION 5 ra er 35 GALIELSMARTEBRM uident ree eec te E xe e edens ee ER GE ER Eie RE ERE RR rer ERU CA 37 COMMUNICATION SETTINGS FOR ISA AND 41 WINDOWS SERVO DESIGN KIT 8 44 CREATING CUSTOM SOFTWARE INTERFACES ssccessceessecesececsscceseeecsseceeeeesaecesceecsaecesceeeaaeceseeeesaececeeesaeceeesenaeceseeeenaeees 45 Galil Communications API with Visual Basic esses ener nenne enn 47 DOS LINUX AND ONX TOOLS 5 ee aset tee PU re bere ED EU resorte E pii ee E REI 48 COMMAND FORMAT AND CONTROLLER RESPONSE 49 CONTROLLER EVENT INTERRUPTS AND USER INTERRUPTS 51 HARDWARE LEVEL COMMUNICATIONS FOR 53 Communication Registers aa enar a etie b Ea E HU Beet ce e bau 54 Simplified Communication Procedure eese ener nennen 54 Advanced Communication Techniques eese eene te 55
186. nctional Elements Microcomputer Section The main processing unit of the DMC 18x2 is a specialized 32 bit Motorola 68331 Series Microcomputer with 2 Meg RAM and 2 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 18x2 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 2 DACs to generate 2 10Volt analog signals For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the host PC contains a bi directional FIFO AM4701 and includes PC interrupt handling circuitry General I O The DMC 18x2 provides interface circuitry for 8 TTL inputs and 8 TTL outputs The general inputs can also be used for triggering a high speed positional latch for each axis System Elements As shown in Fig 1 2 the DMC 18x2 is part of a motion control system which includes amplifiers motors and encoders These elements are described below DMC 18x2 Chapter 1 Overview 3 Power Supply Computer DMC 18x2 Controller Amplifier Drive
187. nuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with multiple master axes as well as gantry mode operation For synchronization with outside events the DMC 18x2 provides uncommitted I O including 8 digital inputs and 8 digital outputs Committed digital 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 to autotune view trajectories on a PC screen translate CAD DXF files into motion and create powerful application specific operator interfaces with Visual Basic Labview and others Drivers for DOS Windows 3 1 95 98 98SE ME NT4 0 2000 XP QNX and Linux are available Overview of Motor Types DMC 18x2 The DMC 18x2 can provide the following types of motor control 1 Standard servo motors with 10 volt or PWM 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 Chapter 1 Overview e 1 Standard Servo Motors with 10 Volt Command Signal The DMC 18x2 achieves superior precision through use of a 16 bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration
188. o 30 arrays If an array of 100 elements is defined the command DM will return the value 7900 and the command DA will return 29 114 e Chapter 7 Application Programming DMC 18x2 To list the contents of the variable space use the interrogation command LV 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 _AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to spec
189. o communicate with the DMC 18x2 controller at the register interface level The information in this section is intended for advanced programmers with extensive knowledge of PCI bus operation DMC 18x2 Chapter 4 Software Tools and Communications 53 Communications with the DMC 18x2 For main bi directional communication the DMC 18x2 features a 512 character write FIFO buffer and a 512 character read buffer This permits sending commands at high speeds ahead of their actual processing by the DMC 18x2 Note This chapter provides an in depth look at how the controller communicates over the PCI bus at the register interface level For most users we recommend using the drivers supplied by Galil to provide the necessary tools for communicating with the controller Determining the Base Address The base address N is assigned its value by the BIOS and or Operating System The FIFO address N is referenced in the PCI configuration space at BAR2 offset 18H The following PCI information HEX can be used to identify the DMC 18x2 controller PCI Device Identification DEVICE ID VENDOR ID SUBSYSTEM ID SUBSYSTEM VENDOR ID 9050H 10B5H 1842 1079H Communication Registers The DMC 18x2 provides three registers used for communication The READ register and WRITE register occupy address N and the CONTROL register occupies address N 1 in the I O space The READ register is used for receiving data from the DMC 18x2 The WRITE register is
190. o connecting the DMC 18x2 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 controller read the following discussion on setting Error Limits and Torque Limits Note that this discussion only uses the X axis as an example 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 lt CR gt Sets error limit on the X axis to be 2000 encoder counts OE 1 lt CR gt Disables X axis amplifier when excess position error exists 14 e Chapter 2 Getting Started DMC 18x2 If the motor runs away and creates a
191. o stop on the S axis vector motion The third byte for the equivalent binary command would then be 01 Byte 4 specifies the axis or data field as follows Bit 7 H axis or 8 data field Bit 6 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 Bit 1 B axis or 2 data field Bit 0 A axis 1 data field Data Fields Format Data fields 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 coordinated motion is not active for PR 50 e Chapter 4 Software Tools and Communications DMC 18x2 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 22 5 03 E8 represents 1000 FE OC represents 500 Example The command to stop motion on just axis A B and C would be A1 00 00 07 where is the command number for ST 00 specifies 0 data fields 00 specifies the command does not apply to the coordinated motion 07 specifies stop A bit 0 bit 1 and C bit 2 224242 7 For more information and a complete list of all Galil binary commands please refer to the Optima Series Command Reference at http www galilmc com support manuals manc2000 pdf Controller Event Interrupts and User Interrupts The DMC 18x2 provi
192. o 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 Sinking Sourcing OC e e 5V e GND I O e e NPN IO e ere output output Current Current Whether connected in a sinking or sourcing circuit only two connections 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 190 e Appendices DMC 18x2 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 17x8 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
193. oder if necessary Same as above Bad controller Connect the encoder to different axis input If it works controller failure Repair or replace Communication SYMPTOM CAUSE REMEDY DMC 18x2 Chapter 9 Troubleshooting 153 Stability Using DMC Smart Terminal Plug and Play installation did not Check first that Dmc1802 INF was DMCDOS or WSDK cannot proceed properly used to install the controller Next communicate with the controller check the controller registry to see if the controller was automatically added and an address selected SYMPTOM CAUSE REMEDY Motor runs away when theloopis Wrong feedback polarity Invert the polarity of the loop by closed Positive Feedback inverting the motor leads brush type or the encoder channel A B if single ended channel A A if differential 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 start or completea Noise on limit switches stops the To check the cause interrogate the move motor Noise on the abort line stop code SC If caused by limit aborts the motion switch or abort line 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 differen
194. 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 FILTER ZOH DAC AMP MOTOR V 50 0 980s 2000 0 0003 4 208 5 2000 92 ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s is 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 co at which A j oc equals one This can be done by the Bode plot of AG o as shown in Fig 10 8 Magnitude 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 164 e Chapter 10 Theory of Operation DMC 18x2 Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 200 2 7200 2000 a Arg A j200 tan 1 200 51 180 tan 1 200 2000 a 76 180 6 110 Finally the phase margin equals 180 a 70 As long 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
195. offsets and corner speed control For more detailed information on the ActiveX Toolkit please refer to the user manual at http www galilmc com support manuals activex pdf DMCWin Programmers Toolkit DMCWin is a programmer s toolkit for C C and Visual Basic users The toolkit includes header files for the Galil communications API as well as source code and examples for developing Windows programs that communicate to Galil Controllers The Galil communications API includes functions to send commands download programs download upload arrays access the data record etc For a complete list of all the functions refer to the DMCWin user manual at http www galilmc com support manuals dmcwin pdf This software package is free for download and is available at http www galilmc com support download html Galil Communications API with C C When programming in C C the communications API can be used as included functions or through a class library All Galil communications programs written in C must include the DMCCOM H file and access the API functions through the declared routine calls C programs can use the DMCCOM H routines or use the class library defined in DMCWIN H After installing DMCWin into the default directory the DMCCOM H header file is located in C Program Files Galil DMCWIN INCLUDE C programs that use the class library need the files DMCWIN H and DMCWIN CPP which contain the class definitions and implem
196. ogate status and configure the digital filter These commands can be sent in ASCII or binary In ASCII the DMC 18x2 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 represented by a binary code ranging from 80 to FF ASCII commands can be sent live over the bus for immediate execution by the DMC 18x2 or an entire group of commands can be downloaded into the DMC 18x2 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 application programs This section describes the DMC 18x2 instruction set and syntax A summary of commands as well as a complete listing of all DMC 18x2 instructions is included in the Command Reference Command Syntax ASCII DMC 18x2 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 lt enter gt is used to terminate the instruction for processing by the DMC 18x2 command interpreter Note If you are using a Galil terminal program commands will not be processed until an lt enter gt command is given This allows the user to separate many commands on a
197. olation essere nennen nennen 181 64 EXTENDED I O OF THE DMC 18X2 CONTROLLER eee n 181 Configuring the I O of the DMC 18x2 with DB 14064 essen 182 Connector Descriptions oen eee beer tete ir tetto a teet belit t petite tt as edna ie Ub te bie Ere 183 IOM 1964 OPTO ISOLATION MODULE FOR EXTENDED I O CONTROLLERS eee e n n nen enhn nn nnn nnn nnn nean 186 Description ein pae ec epit S EL ee 186 B ORAL MERE DERE NE 187 Contisurins Hardware Banks bsp pe tan triste eludet etate ta estie nes bte iem dee 188 DiS tal DIRE E 189 High Power Digital ent eee eerie erae pa e a a ERS 191 Standard Digital Outputs iin eto eot e e xe eia Fee tret esu m eere tese deeem 192 Blectacal Specifications oontra on E c o ale aot m E eer trea 193 COORDINATED MOTION MATHEMATICAL ANALYSIS e n enn nnn nnn nnn nnn a unu 196 LIST OF OTHER PUBLICATIONS ccccccsccecscecececcrccececacececscacccececacecececesccevesacceecssarccesacacececasencceveracesecssencseveseeececeseresereseseses 201 TRAININGAOEMINARS enmt ame onse be OE 201 CONTACTING US E e e Pire o ey 202 hee t ce ath sie Shee d eer e M
198. oller include the argument c1802 For a complete list of command line arguments type the utility name with a as an argument Ex SEND2DMC Consult the factory if you need help Step 6 Determine the Axes to be Used for Sinusoidal Commutation This step is only required when the controller will be used to control brushless motors with sinusoidal commutation The command BA is used to select the axes of sinusoidal commutation For example BAXY sets X and Y as axes with sinusoidal commutation With the DMC 18X2 at most 2 axes can be set for sinusoidal commutation requiring a DMC 1842 DMC 18x2 Chapter 2 Getting Started 11 Notes on Configuring Sinusoidal Commutation The command BA reconfigures the controller such that it has one less axis of standard control for every axis using sinusoidal commutation For example if the command BAX is given to a DMC 1842 controller the controller will be re configured to be a DMC 1832 and will appear as such when interrogated In this case the highest axis is used for the 2 phase of the sinusoidal commutation and cannot be connected to control a separate motor Note that the highest axis on a controller can never be configured for sinusoidal commutation The DAC associated with the selected axis represents the first phase The second phase uses the highest available DAC When two axes are configured for sinusoidal commutation the controller will assign the X and Z axes DAC s fo
199. ollowing example shows an error correction routine which uses the operands Example Command Error w Multitasking TA Begin thread 0 continuous loop End of thread 0 B Begin thread 1 N 1 Create new variable KPN Set KP to value of N an invalid value TY Issue invalid command EN End of thread 1 CMDERR Begin command error subroutine IF __TC 6 If error is out of range KP 1 N21 Set N to a valid number XQ ED2 EDI Retry KP N command ENDIF _TC 1 If error is invalid command TY XQ_ED3 _ED1 1 Skip invalid command ENDIF EN End of command error routine Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 18x2 provides the use of the following mathematical operators DMC 18x2 Chapter 7 Application Programming 127 OPERATOR The numeric range for addition subtraction and multiplication operations is 2 147 483 647 9999 The precision for division is 1 65 000 Mathematical operations are executed from left to right Calculations within a parentheses have precedence Examples SPEED 7 5 V 1 2 COUNT COUNT 2 RESULT TPX GCOS 45 40 TEMP IN 1 amp IN 2 The variable SPEED is equal to 7 5 multiplied by V1 and divided by 2 The variable COUNT is equal to the current value plus 2 Puts the position of X 28 28 in RESULT 40 cosine of 45 is 28 28 TEMP is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators The ma
200. on The command sequence HM and BG causes the following sequence of events to occur 1 Upon begin the motor accelerates to the slew speed The direction of its motion is determined by the state of the homing input A zero GND will cause the motor to start in the forward direction 5V will cause it to start in the reverse direction The CN command is used to define the polarity of the home input 2 Upon detecting a change in state on the home input the motor begins decelerating to a stop The motor then traverses very slowly back until the home switch toggles again 4 The motor then traverses forward until the encoder index pulse is detected The DMC 18x2 defines the home position as the position at which the index was detected and sets the encoder reading at this position to zero NOTE For stepper motors only the edge is found as there is no index pulse Example HOME Label AC 1000000 DC 1000000 SP 5000 Acceleration Rate Deceleration Rate Speed for Home Search HM X BGX AM X MG AT HOME EN EDGE AC 2000000 DC 2000000 Home X Begin Motion After Complete Send Message End Label Acceleration rate Deceleration rate DMC 18x2 Chapter 6 Programming Motion 103 SP 8000 FEY BG Y AM Y MG FOUND HOME DP 0 EN 104 e Chapter 6 Programming Motion Speed Find edge command Begin motion After complete Send message Define position as 0 End DMC 18x2 MOTION BEGINS TOWARD HOME
201. on dey 203 IT 204 DMC 18x2 ev Chapter 1 Overview Introduction The DMC 18x2 series motion control cards install directly into the PCI bus This controller series offers many enhanced features including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction The DMC 18x2 provides a high speed FIFO for sending and receiving commands This PCI bus motion controller allows for high speed servo control up to 12 million encoder counts sec and step motor control up to 3 million steps per second Sample rates as low as 62 5 1sec per axis are available A 2 meg Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field without removing the controller from the PC The DMC 18x2 is available with up to four axes on a single PCI card The DMC 1812 1822 1832 and 1842 one thru four axes controllers are on a single 4 23 x 9 card Designed to solve complex motion problems the DMC 18x2 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences and contouring The controller eliminates jerk with programmable acceleration deceleration and profile smoothing For seamless following of complex contours the DMC 18x2 provides conti
202. on is CCW S LM Return number of available spaces for linear and circular segments in DMC 18x2 sequence buffer Zero means 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 Distance traveled Segment counter Number of the segment in the sequence starting at zero Vector length of coordinated move sequence buffer Zero means buffer is full 512 means buffer is empty VE When AV is used as an operand _AV returns the distance traveled along the sequence 80 e Chapter 6 Programming Motion DMC 18x2 The operands _VPX and _VPY can be used to return the coordinates of the last point specified along the path Example Traverse the path shown in Fig 6 3 Feedrate is 20000 counts sec Plane of motion is XY VM XY 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 CR 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 _VPX and _VPY contain the absolute coordinate of the point A Suppose that t
203. onsibility of the user to design effective error handling and safety protection as part of the machine Galil shall not be liable or responsible for any incidental or consequential damages Contents CONTENTS cccsessdstesstovdscsecostecsvecvesetesstscetesesesesucsedecscaccuse 1 CHAPTER T OVERVIENW ssnssssicsdintess lt ccssscaastutesossessestinsusscosunssatacadesesnsedsicessstseaseusduanutebsdeatesseseaussdusshsnesecseuautets e DES E DESEE DU 1 INTRODUCTION ri ib an e ERE eee e Hp ERE er te ee e 1 OVERVIEW OF MOTOR TYPES ep nit eee Ie eR EH rr ITO E EE pre e den e as 1 Standard Servo Motors with 10 Volt Command Signal eese eene enne enne 2 Brushless Servo Motor with Sinusoidal Commutation esee eene nennen nennen nein enne nein 2 Stepper Motor with Step and Direction Signals eescssescssecseeseceeesecsseeecaecaeesecseesecsaeeecsaecaseecsaecaeaecaeeatenaeseeegs 2 DMC 18X2 FUNCTIONAL ELEMENTS npese peere esee et E nee rrt terne eer repere rte rece ee ren 2 Microcomputer Section e ed dete c Prendas 3 Motor Interface c doge o Re dee it pP etek edet e eod s dh eee eet 3 COMMUNICATION vee ete nh dodo i Re ide m eR umb tecs teas eae etter eee 3 General I O 5 eo erm Ed re ree E ee PER Dre ee Pe pe FO tete e enit 3 System Blements nete pe ire ctt t i Ferre ORE RE pee
204. or PR 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 27 5 03 E8 represents 1000 FE OC represents 500 The command ST XYZS would be A1 00 01 07 where 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 2242 42 7 Binary command table COMMAND ee MEER RENS reserved 80 reserved 146 KP reserved fad reseved 107 KI 82 reserved fae RP KD 83 reserved TP b0 b6 eO VD S reserved fe vs reserved fe 8f VR ba reserved fet pC foi 16 se Mt Z Hy us 1 0p DEBA o OBR 9 FV 195 ET co SB jea EM cl Bt p 079 Jc fr pe 9 EG 1 teed o 99 EB cd Je GM EQ c5 reserved fee reserved 9b EC 6 reserved 0 reserved pomwmed __ e7__ _reserved MI reserved 190 c8 reserved R 64 e Chapter 5 Command Basics DMC 18x2 reserved f Bo e reserved 7 b cf do reserved fb PR JG WT d3 reserved Mo fa WC reserved SH resred d5 reserved reserv
205. or 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 switching frequency is 16 7 Khz 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 for 0 Voltage and 99 8 for full positive voltage 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 For stepmotors 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 Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER 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 The OP instruction is used to define the state of all the bits of the Output port Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any reso
206. ormat to 4 places TPX Tell position 0021 New format PF 4 Change to hexadecimal format TPX Tell Position 0015 Hexadecimal value PF2 Format 2 places TPX Tell Position 99 Returns 99 if position greater than 99 Removing Leading Zeros from Response to Interrogation Response The leading zeros on data returned as a response to interrogation commands can be removed by the use of the command LZ 138 e Chapter 7 Application Programming DMC 18x2 Local Formatting of Response of Interrogation Commands Formatting Variables and Array Elements Example Using the LZ command LZO TP 0000000009 0000000005 0000000000 0000000007 171 9 5 0 7 Disables the LZ function Tell Position Interrogation Command Response from Interrogation Command With Leading Zeros Enables the LZ function Tell Position Interrogation Command Response from Interrogation Command Without Leading Zeros 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 is the number of digits to the right of the decimal For example Examples TP 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 In
207. otection DMC 18x2 Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog BG XYZ Begin Execution of the above example will cause the motor to slew at the given jog speed until the forward position limit is reached Motion will stop once the limit is hit Off On Error The DMC 18x2 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 X Y Z and W axes To disable this function specify 0 for the axes When the function is enabled the corresponding 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 The abort command is given 3 The 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 Servo Here SH command The SH command will clear any position error and reset the commanded position to the actual position Examples OE 1 1 1 1 Enable off on error for X Y Z W OE 0 1 0 1 Enable off on error for Y and W axes and disable off on error for X and Z axes Automatic Error Routine The POSERR label causes the statements following to be automat
208. ou 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 4GO GIN 1 0 118 e Chapter 7 Application Programming DMC 18x2 INPUT Program Label AI 1 Wait for input 1 low PR 10000 Position command BGX Begin motion EN End program Event Trigger Set output when At speed ATSPEED Program Label JG 50000 Specify jog speed AC 10000 Acceleration rate BGX Begin motion ASX Wait for at slew speed 50000 SB1 Set output 1 EN End program Event Trigger Change Speed along Vector Path The following program changes the feedrate or vector speed at the specified distance along the vector The vector distance is measured from the start of the move or from the last AV command VECTOR CAS VMXY VS 5000 VP 10000 20000 Label Identify coordinate system Coordinated path Vector position VP 20000 30000 Vector position VE End vector BGS Begin sequence AV 5000 After vector distance VS 1000 Reduce speed EN End Event Trigger Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves MOVES Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration BGX Start Motion AD 10000 Wait a distance of 10 000 counts SP 5000 New Speed AMX Wait until motion is completed WT 200 Wait 200 ms PR 10000 New Position SP 30000 New Speed AC 150000 New Acceleration
209. ow no connection or a 5V input will be read as a 0 while grounding the switch will return a 1 If the limit switches are configured for active high the reading will be inverted and no connection or a 5V input will be read as a 1 while grounding the switch will return 0 See the CN command in the Command Reference for details Using a terminal program the state of a limit switch can be printed to the screen with the command MG _LFx or MG LRx This prints the value of the limit switch operands for the x axis The logic DMC 18x2 Chapter 3 Connecting Hardware 29 state of the limit switches can also be interrogated with the TS command For more details on TS _LFx _LRx or MG see the Command Reference 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 changes between logic states 0 and 1 corresponding to either or 5V depending on the configuration set by the user CN command The CN command can be used to customize the homing routine to the user s application There are three homing routines supported by the DMC 18x2 Find Edge FE F
210. parameters is required when using servo motors standard or sinusoidal commutation The system compensation provides fast 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 KIO CR Integrator gain and set the proportional gain to a low value such as KP 1 CR Proportional gain KD 100 CR Derivative gain 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 TE X CR 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 KP 10 CR Proportion gain DMC 18x2 Chapter 2 Getting Started 21 TE X CR 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 KP Typical
211. pecial Operands Keywords 5 pen ipo tee DO EE DR PR eee ape 131 ARRAYS oM enit I notnm tan eau want 132 Definins Array Mmm 132 Assignment of Array Entries uite Ete DR RE HO ODE EDO 132 Automatic Data Capture nto Arrays o PIE TREE HER rd Eie p ERR P REP E 133 Deallocating Array SpdCe UO PEARCE REG ORE asl bhawininaa una Rh 135 INPUT OF DATA NUMERIC AND STRING s cccssssecesssscecsessececssseececssaeecsesaeeecsesaececseceecsesaeeecseaaececseseecsesaeeecsenaeeesneaseeess 135 Input of Datars IEEE 135 OUTPUT OF DATA NUMERIC AND STRING cessescecesssececseseecessececseseececseeeecsssaeeecsesaececaaeeceesaeeecsecaeceseeeeseeaeeecsesaeeeees 136 Sending Messages oua tur rep ep dee eR e ee eve aa bet een Mae darte Beene Gn e eed n deve e Do ERR 136 Displaying Variables Arrays ecdesiae te rerit i Eie ise Peto ede taeda de Do ee ned ae Debe eie era rante 137 Interrogation Command Sisse ete ee centes ie LIP HE Pea Rea Hae Tete dudo Deu ds ER e cea K Lo oap 137 Formatting Variables and Array Elements eese 139 Fast Firmware Mode eret esata eee eins A e heec ere niens a e E er qe Tree re RR 140 Converting to User Units beer ael E HE erae re tio eee Ue debba eben ce eet AE TS 140 PROGRAMMABLE HARDWARE I O ecssccessssseceesscceceessececsecsecs
212. pon 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 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 X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W if the high speed position latch function is enabled High speed position latch to capture axis position in less than 1 micro second on occurrence of latch signal AL command arms latch Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W Jumper Description for DMC 18x2 JUMPER LABEL JP2 SMX SMY SMZ SMW OPT JP6 MRST FUNCTION IF JUMPERED For each axis the SM jumper selects the SM magnitude mode for servo motors or selects stepper motors If you are using stepper motors SM must always be jumpered The Analog command is not valid with SM jumpered Motor Off on power up Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated Accessories and Options DMC 1812 DMC 1822 DMC 1832 DMC 1842 Cable 100 1M Cable 100 2M Cable 100 4M ICM 2900 FL ICM 2900 LAEN ICM 2900 Opto ICM 1900 AMP 1910 AMP 1920 AMP 1930 AMP 1940 Utilities WSDK 16 1 axis motion controller 2 a
213. position error of 2000 counts the motor amplifier will be disabled Note This function requires the AEN 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 18x2 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 output torque of the motor 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 lt CR gt 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 i
214. pression 80 characters wide This allows the user to write an application program in the editor window that is longer than the normal line limitation 1000 lines and download it to the controller Additionally dynamic syntax help is available by activating the syntax help button A gt icon DMC Data Record Display The DMC SmartTERM utility program includes a Data Record display window that is useful for observing the current status of all the major functions of the controller including axis specific data I O status application program status and general status When using a DMC 18x2 controller the data record data is provided through the main FIFO To display the Data Record shown in Fig 4 3 select Display Data Record under the Tools menu of DMC SmartTERM 40 e Chapter 4 Software Tools and Communications DMC 18x2 Galil DMC 1842 Data Record and Galil Amplifier Status General Status Axis Status Program Running Ix v z _ Waiting for input from IN command Move in Progress Trace On 8 69 69 Mode of Motion PA or PR Mode of Motion Emor Code ist Phase HM Complete General I O 2nd Phase HM Complete or FI Issued Mode of Motion Coord Motion Direction Move a E iz E of Motion Contour L E m B pe eqs L Configured Input Bank 6 L Configured Input Bank 7 Configured Input Bank amp
215. pulated as described in the following section Chapter 7 Application Programming 123 Example An example of a subroutine to draw a square 500 counts per side is given below The square is drawn at vector position 1000 1000 M Begin Main Program Clear Output Bit 1 pick up pen VP 1000 1000 VE BGS Define vector position move pen AMS Wait for after motion trippoint SB1 Set Output Bit 1 put down pen JS Square CB 1 Jump to square subroutine EN End Main Program Square Square subroutine V1 500 JS L Define length of side V1 V1 JS L Switch direction EN End subroutine L PR V1 V1 BGX Define X Y Begin X AMX BGY AMY After motion on X Begin Y EN End subroutine Stack Manipulation Itis possible to manipulate the subroutine 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 ZS1 command clears 1 level of the stack This allows the program sequencer to continue to the next line The ZSO 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 comm
216. r Encoder e eee ee Motor Figure 1 2 Elements of Servo systems Motor 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 for more information The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step motors the controller is capable of controlling full step half step or microstep drives An encoder is not required when step motors are used Amplifier Driver Encoder For each axis the power amplifier converts a 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 peak motor current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers a 10 volt command
217. r Amp 2 178238 9 JP2 Jumpers used for configuring stepper motor operation JP6 Master Reset amp UPGRD jumpers Install JP2 OPT jumper for default MO Motor Off firmware 1 0e and higher DMC 18x2 Chapter 2 Getting Started 7 Elements You Need Before you start you must get all the necessary system elements These include 1 DMC 1812 1822 1832 or DMC 1842 Motion Controller 1 100 pin cable and 1 interconnect module either ICM AMP 1900 or ICM 2900 Servo Motors with Optical Encoder one per axis or Stepper Motors Power Amplifiers Power Supply for Amplifiers PC Personal Computer PCI bus Communications Software DMCTERM DMCWIN32 or WSDK32 On Galil Software CD or download at http www galilmc com support download html Qi pA o uBe per CR The motors may be servo brush type or brushless or steppers 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 S For servo motors in current mode the amplifiers should accept an analog signal in the 10 Volt range as a command The amplifier gain should be set such that a 10V command will generate the maximum required current For example if the peak motor current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers a command signal of 10 Volts should run the motor at the maximum required speed
218. r segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is Chapter 6 Programming Motion 77 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 coordinate system or subsequent coordinated motion sequences The command VP 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 r 0 6 define a circular arc with a radius starting angle of and a traversed angle 6 The notation for 0 is that zero corresponds to the positive horizontal direction and for both and 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 The motion can be initiated with a Begin Sequence BGS or BGT 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 decelera
219. r the first and second phase of the X axis commutation respectively and the Y and W axes DAC s for the first and second phase of the Y axis commutation respectively 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 Step 7 Make Connections to Amplifier and Encoder Once you have established communication between the software and the DMC 18x2 you are ready to connect the rest of the motion control system The motion control system typically consists of an interconnect module ICM 1900 or ICM 2900 an amplifier for each axis of motion and a motor to transform the current from the amplifier into torque for motion Galil also offers the AMP 19X0 which is an ICM 1900 equipped with X number servo amplifiers for brush type DC motors If you are using an ICM AMP 1900 or ICM 2900 connect the 100 pin cable to the DMC 18x2 and to the connector located on the interconnect board The interconnect provides screw terminals for access to the 100 pin connections System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 18x2 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 A Connect the motor to the amplifier with no connection to the
220. ral input 0 I block UB general input 1 I block UB general input 2 I block UB general input 3 I block UB general input 4 I block UB general input 5 I block UB general input 6 I block UB general input 7 I block UB general input 8 I block UB general input 9 I block UB general output 0 I block UB general output 1 I block UB general output 2 I block UB general output 3 I block UB general output 4 I block UB general output 5 I block UB general output 6 I block UB general output 7 I block UB general output 8 I block UB general output 9 I block UB error code Iblock UB general status Iblock UW segment count of coordinated move for S plane S block UW coordinated move status for S plane S block SL distance traveled in coordinated move for S plane S block UW segment count of coordinated move for T plane T block UW coordinated move status for T plane T block SL distance traveled in coordinated move for T plane T block UW X a axis status A block UB X a axis switches A block UB axis stopcode A block SL X a axis reference position A block SL X a axis motor position A block SL axis position error A block SL X a axis auxiliary position A block SL X a axis velocity A block SW X a axis torque A block UW y b axis status B block UB y b axis switches B block UB y b axis stopcode B block SL y b axis reference position B block 56 e Chapter 4 Software Tools and Communications DMC 18x2 SL y b axis motor position B block SL y b axis position
221. rate 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 is positive Angles are expressed in degrees and the resolution is 1 256th of a degree For example the path shown in Fig A 2 is specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 20000 10000 10000 20000 Figure A 2 X Y Motion Path The first line describes the straight line vector segment between points A and B 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 DMC 18x2 Appendices 197 427 Circular 15708 360 C D Linear 1000
222. re in quadrature Due to the quadrature relationship between the encoder channels the position resolution is increased to 4N quadrature counts rev The model of the encoder can be represented by a gain of Kg 4N 20 count rad For example a 1000 lines rev encoder is modeled as 638 DMC 18x2 Chapter 10 Theory of Operation 161 DAC Digital Filter 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 10 or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count The digital filter has a transfer function of D z K z A z Cz z 1 1 B Z B and a sampling time of T The filter parameters K A C and P are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are K KP KD 4 A KD KP KD C KI 2 B PL This filter includes a lead compensation an integrator and a low pass filter It is equivalent to a continuous PID filter with a transfer function G s G s P sD I s a S a P 4KP Dz4T KD I KI 2T a I BYT For example if the filter parameters of the DMC 18x2 are 4 KD 36 KI 2 PL 0 75 T 20 001 s the digital filter coefficients are K 160 0 9 1 250 rad s and the equivalent continuous filter G s is G s 16 0 144s 1000 s 250 s 250
223. rescribed 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 X 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 2 which corresponds to a time constant of 6 sample periods Fourth the output of the stepper smoothing filter is buffered and is 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 X axis to be zero Stepper Smoothing Filter Output Output Buffer Adds a Delay P gt To Stepper Driver Reference Position RP Step Count Register TD Motion Profiler
224. riables 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 Example PR POSX Assigns variable POSX to PR command JG RPMY 70 Assigns variable RPMY multiplied by 70 to JG command Programmable Variables The DMC 18x2 allows the user to create up to 254 variables Each variable is defined 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 names should not be the same as DMC 18x2 instructions For example PR is not a good choice for a variable name Examples of valid and invalid variable names are Valid Variable Names POSX POSI V3OS Invalid Variable Names REALLONGNAME Cannot have more than 8 characters 123 Cannot begin variable name with a number SPEED 7 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 equal sign Any valid DMC 18x2 function can be used to assign a value to a variable For example V1 ABS V2 or V2 IN 1 Arithmetic operations are also permitted To assign
225. roller from the list and clicking on the OK button or double clicking a controller will cause the application to close any current connections to a controller and open a new connection to the selected controller DMCTerminal only connects to a single controller at a time However multiple instances of the application can be open at once Causes the currently open connection to a Galil Motion Controller to be closed Opens the Edit Registry dialog box which allows the Galil Registry entries to be edited or new entries for non bus based controllers to be created or deleted Causes the terminal to enter Smart Terminal with Editor mode This is the same as clicking on the Smart Terminal with Editor mode button on the terminal window s toolbar Offers three reset options Reset Controller sends an RS command to the controller The RS command does not clear any saved variables programs or parameters Master Reset performs a master reset on the controller A Master Reset does clear any saved variables programs or parameters Clear Controller s FIFO causes the controller s output FIFO to be cleared of data The Device Driver menu selection is available to operating systems and or controllers that have device drivers that can be stopped and started This includes drivers on NT4 0 and serial and Ethernet controllers on all operating systems The Diagnostics menu allows diagnostics to be stopped and started It also w
226. rque WSDK also includes impulse step and frequency response tests which are useful for analyzing system stability bandwidth and resonances WSDK can be purchased from Galil via the web at http store yahoo com galilmc wsdk32 html Features Include Automatic tuning for optimizing controller PID filter parameters Provides impulse step and frequency response tests of actual hardware Four channel storage scope for displaying real time position velocity error and torque Displays X versus Y position for viewing actual 2 D motion path Terminal editor and program editor for easy communication with the controller 44 e Chapter 4 Software Tools and Communications DMC 18x2 Galil Motion Control Servo Design Kit o Terminal Help Select pun amp Storage Scopes System Evaluation C System Information 6 Galil Motion Control Inc Set up and Configuration OG Servo Design Kit Diagnostics Motion Profile Builder s Getting Started Status Connected with Galil DMC 1840 4 axis controller revision 2 0ndev Figure 4 7 WSDK Main Screen Creating Custom Software Interfaces Galil provides programming tools so that users can develop their own custom software interfaces to a Galil controller These tools include the ActiveX Toolkit and DMCWin ActiveX Toolkit Galil s ActiveX Toolkit is useful for the programmer who wants to easily create a custom operator interface to
227. sequence 74 e Chapter 6 Programming Motion DMC 18x2 LE Returns the length of the vector resets after 2147483647 AMS or AMT Trippoint for After Sequence complete on S or T coordinate system AVn Trippoint for After Relative Vector distance n VT Motion smoothing constant for vector moves Operand Summary Linear Interpolation OPERAND DESCRIPTION _AV Return distance traveled _CS Segment counter returns number of the segment in the sequence being processed starting at zero _LE Returns length of vector resets after 2147483647 _LM Returns number of available spaces for linear segments in DMC 18x2 sequence buffer Zero means buffer full 511 means buffer empty Return the absolute coordinate of the last data point along the trajectory x X Y Z W To illustrate the ability to interrogate the motion status consider the first motion segment of our example LMOVE where the X axis moves toward the point X 5000 Suppose that when X 3000 the controller is interrogated using the command MG AV The returned value will be 3000 The value of CS VPX and VPY will be zero Now suppose that the interrogation is repeated at the second segment when Y 2000 The value of _AV at this point is 7000 CS equals 1 VPXz5000 and __VPY 0 Example Linear Move Make a coordinated linear move in the ZW plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 coun
228. sere nene nennen enne 12 Step 8a Connect Standard Servo Motors sese enne ennt nene tentent trennen teen ener enne 14 Step 8b Connect Sinusoidal Commutation Motors eese enint nrennete ene tnen nre 18 Step 5C Connect Step MOItOTS sess cse o et e ER eere P re eee e e 20 Step 9 Tune the Servo System nte ene nte e ERE SEPO EEEo EO Rep RE er UEa ESER TERAS EEEo aE EEES Erden 21 DESIGN EXAMPLES C M 22 Example T System set up tbe ee ii ete mae dde e oti ee e o est 22 Example 2 Profiled MO y s etate en reme pietas eb ed itte e NP 22 Example 3 Multiple Axes ogiutdep Ene RH DR Rn rei pd beo OO 22 Example 4 Independent teet eee tp te e ER E e Pe e ETE RR TTR bET ESSES 23 Exampl 5 Position Interrogation isit opener RU TR ERR e ERE HD te re RO ERU re pc pes 23 Ex mple 6 Absolute Position per RUD e TP REDE DH ED RT PERO ERE Cer pe a c EORR 23 Example 7 Velocity Control iiiter et pd OE n RP a D ue pe rU RE 24 Example 8 Operation Under Torque Limit 24 DMC 18x2 ei Example 9 Interros ation su e e tree diet aan ae Rae eee aie ee oem e estere nts 25 Example 10 Operation in the Buffer Modes ienee aee nera a i EA RRE ASR EE i RE 25 Example 11 Usmg the On Board EdItor ue nere e Re ree rete AA De e nee E e ESR ER pe 25 Example 12 Motion Programs with
229. series with the 24V supply by removing Interconnect cover External 24V PS DMC 18x2 ICM 1900 ICM 2900 SES SERVO MOTOR 100 PIN tae HIGH DENSITY CABLE 31 MOCMDX 7407 Open Collector Buffer The Enable signal can be inverted by using a 7406 Accessed by removing Interconnect cover Analog Switch Figure 3 1 Connecting AEN to the motor amplifier TTL Inputs As previously mentioned the DMC 18x2 has 8 uncommitted TTL level inputs The command IN or TI will read the state of the inputs For more information on these commands refer to the Command Reference The reset input is also a TTL level non isolated signal and is used to locally reset the DMC 18x2 without resetting the PC TTL Outputs The DMC 18x2 provides eight general use outputs an output compare and an error signal output The general use outputs TTL and are accessible through the ICM 2900 as OUTI thru OUTS These outputs can be turned On and Off with the commands SB Set Bit CB Clear Bit OB Output Bit and OP Output Port The outputs can sink or source up to 24 mA For more information about these commands see the Command Reference The value of the outputs can be checked with the operand _OP and the function OUT see Chapter 7 Mathematical Functions and Expressions 32 e Chapter 3 Connecting Hardware DMC 18x2 NOTE For systems using the
230. should run the motor at the maximum speed An encoder translates motion into electrical pulses which are fed back into the controller The DMC 18x2 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 CHB or differential CHA CHA CHB CHB The DMC 18x2 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 18x2 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 if the encoder line density is 10000 cycles per inch the maximum speed is 300 inches second If higher encoder frequency is required please consult the factory 4 e Chapter 1 Overview DMC 18x2 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 18x2 Single ended 12 Volt signals require a 5 7V bias voltage input to the complementary inputs The DMC 18x2 can accept analog feedback instead of an encoder for any axis For more information see
231. sing 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 18x2 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 18x2 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 122 e Chapter 7 Application Programming DMC 18x2 Command Format IF ELSE and ENDIF FORMAT DESCRIPTION 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 Example using IF ELSE and ENDIF Subroutines TEST
232. single line and not begin execution until the user gives the lt enter gt command IMPORTANT All DMC 18x2 commands are sent in upper case DMC 18x2 For example the command PR 4000 lt enter gt Position relative PR is the two character instruction for position relative 4000 is the argument which represents the length of the move in counts The lt enter gt terminates the instruction The space between PR and 4000 is optional When specifying data for the X Y Z and W axes commas are used to separate the axis parameters If no data is specified for an axis a comma is still needed as a place holder see below If no data is specified for an axis the previous value is maintained The space between the data and instruction is optional Chapter 5 Command Basics e 61 To view the current values for each command type the command followed by a for each axis requested This is interrogation Not all commands can be interrogated Refer to the Command Reference to determine whether or not a command can be interrogated PR 1000 Specify X only as 1000 PR 2000 Specify Y only as 2000 PR 3000 Specify Z only as 3000 PR 4000 Specify W only as 4000 PR 2000 4000 6000 8000 Specify X Y Z and W PR 8000 9000 Specify Y and W only PR 2 2 Request X Y Z W values PR Request Y value only The DMC 18x2 provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as X Y Z or
233. solation Option W axis amplifier enable Z axis amplifier enable Y axis amplifier enable X axis amplifier enable General Output 5 General Output 6 General Output 7 General Output 8 General Output 1 General Output 2 General Output 3 General Output 4 5 Volts Z axis home input Z axis reverse limit switch input Z axis forward limit switch input Limit Switch Common Input No Connection W axis home input W axis reverse limit switch input W axis forward limit switch input X axis home input X axis reverse limit switch input X axis forward limit switch input Signal Ground Y axis home input Y axis reverse limit switch input Y axis forward limit switch input Signal Ground Input 5 Input 6 Input 7 Input 8 Input 1 Used for X axis latch input Input 2 Used for Y axis latch input Input 3 Used for Z axis latch input Input 4 Used for W axis latch input 5 Volts 12 Volts 12 Volts Isolated Analog Ground for Use with Analog Inputs DMC 18x2 Appendices 179 180 e Appendices 16 16 16 16 17 17 17 17 18 18 18 18 19 19 19 19 20 20 20 20 21 21 21 21 22 22 22 22 23 23 23 23 24 24 24 24 25 25 25 25 26 26 26 26 INCOM ABORT RESET GND ANALOGS ANALOG6 ANALOG7 ANALOG8 ANALOGI ANALOG2 ANALOG3 ANALOG4 45V INX INX GND MAX MAX MBX MBX 5V INY INY GND MAY MAY MBY MBY 45V INZ INZ GND MAZ MAZ MBZ MBZ 45V
234. start 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 point in the ECAM table ET 3 2240 120 4th point in the ECAM table ET 4 2280 140 5th point in the ECAM table ET 5 2280 140 6th 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 10 0 0 Starting point for next cycle EB 1 Enable ECAM mode JGZ 4000 Set Z to jog at 4000 EG 0 0 Engage both X and Y when Master 0 BGZ Begin jog on Z axis LOOP JP LOOP V 1 0 Loop until the variable is set EQ2000 2000 Disengage X and Y when Master 2000 MF 2000 Wait until the Master goes to 2000 STZ Stop the Z axis motion EB 0 Exit the ECAM mode EN End of the program 88 e Chapter 6 Programming Motion DMC 18x2 The above example shows how the ECAM program is structured and how the commands can be given to the controller The next page 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 X axis the second graph shows the cycle on the Y axis and the third graph shows the cycle of the Z axis Three Storage Scopes en File Collection Graph First Scope x Actual Position Zoom Normal Second Scope v Position Zoom Normal Third Scope z Actuat Position
235. t entire program 158 5 Begin listing at line 5 LS 5 9 List lines 5 thru 9 15 9 List line label A thru line 9 15 A A 5 List line label A and additional 5 lines Program Format A DMC 18x2 program consists of DMC 18x2 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 18x2 instruction 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 110 e Chapter 7 Application Programming DMC 18x2 program line where the maximum number of characters on a line is 80 including semicolons A carriage return enters the final command on a program line Using Labels in Programs All DMC 18x2 programs must begin with a label and end with an End EN statement Labels start with the pound 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 254 Valid labels BEGIN SQUARE X1 begin1 Invalid labels 1 Square 123 A Simple Example Program START Beginning of the Program PR 10000 20000 Speci
236. t locations it implies encoder noise Also use a scope to see the noise Reduce noise Use differential encoder inputs Same as above Programming error Avoid resetting position error at end of move with SH command 154 e Chapter 9 Troubleshooting DMC 18x2 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 CONTROLLER DRIVER ENCODER Figure 10 1 Elements of Servo Systems The operation of such a system can be divided into three levels as illustrated in 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 is 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 is 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
237. t of commands that directly interrogate the controller When these commands are entered the requested data is 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 chapter 5 DMC 18x2 Chapter 7 Application Programming 137 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 EM TN FL VE IP TE TP The numeric 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 Examples DP21 Define position TPX Tell position 0000000021 Default format PF4 Change f
238. tage level of the AEN signal note the state of the resistor pack on the ICM AMP 1900 or 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 To connect an external 24V supply remove the resistor pack RP1 from the interconnect board Connect a 2 2kQ resistor in series between the 24V of the supply and the amplifier enable terminal on the interconnect AMPEN Then wire the AMPEN to the enable pin on the amplifier Connect the 24V to the ground GND of the interconnect and connect the GND of the interconnect to the GND of the amplifier NOTE Before connecting the GND of the interconnect to the GND of the amplifier check for continuity between the two points If continuity exists do not connect the two points If continuity does not exist then you must connect the points to create a reference for the motor command signal DMC 18x2 Chapter 3 Connecting Hardware 31 Connection to 5V or 12V made through An external 24V supply is only necessary if a Resistor pack RP1 Removing the resistor pack 24V AEN signal is necessary Remove the allows the user to connect their own resistor to resistor pack from RP1 and connect a resistor in the desired voltage level Up to24V Accessed
239. tc 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 1 inch 40 000 counts and the speeds of 1 in sec 40 000 count sec 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 0 1g 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 Z must move 2 at a linear speed of 2 per second The required motion is performed by the following instructions Instruction A VM XY VP 160000 160000 VE VS 200000 VA 1544000 BGS AMS PR 80000 SP 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ PR 21600 Function Label Circular interpolation for XY Positions End Vector Motion Vector Speed Vector Acceleration Start Motion When motion is complete Move Z down Z speed Start Z motion Wait for completion of Z motion Circle Feedrate Start circular move Wait for completion Move Z up Start Z move Wait for Z completion Move X DMC 18x2 Chapter 7 Application Programming 145 SP 20000 BGX AMX PR 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ VP 37600
240. te the commutation phase 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 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec default rate Stepper Motor with Step and Direction Signals The DMC 18x2 can control 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 Chapter 2 describes the proper connection and procedure for using stepper motors DMC 18x2 Functional Elements The DMC 18x2 circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed below 2 e Chapter 1 Overview DMC 18x2 WATCHDOG TIMER TTL LIMITS AND HOME INPUTS 68331 HIGH SPEED MICROCOMPUTER MOTOR ENCODER MAIN ENCODERS WITH INTERFACE 10 VOLT OUTPUT FOR Primary e A FOR SERVO MOTORS FIFOS eg X Y Z W PULSE DIRECTION OUTPUT FOR STEP MOTORS PLUG amp PLAY HIGH SPEED ENCODER VO INTERFACE COMPARE OUTPUT 8 PROGRAMMABLE INTERRUPTS HIGH SPEED 8 PROGRAMMABLE UTPUT PCI BUS LATCH FOR EACH TTL AXIS INPUTS Figure 1 1 DMC 18x2 Fu
241. ted 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 18x2 can make decisions based on its own status or external events without intervention from a host computer 116 e Chapter 7 Application Programming DMC 18x2 DMC 18x2 Event Triggers Command MXYZWS or T 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 AD X or Y or Z or W 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 AR X or Y or Z or W 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 AP X or Y or Z or W Halts program execution until after absolute position occurs Only one axis may be specified at a time MF X or Y or Zor W Halt program execution until after forward motion reached absolute position Only one axis may be spec
242. tep Y 68 5V 18 Motor command X 69 NC 19 Sign X Dir X 70 Latch X 20 PWM X Step X 71 Latch Y 21 Amp enable W 72 Latch Z 22 Amp enable Z 73 Latch W 23 Amp enable Y 74 Input 5 24 Amp enable X 75 Input 6 25 A X 76 Input 7 26 A X 77 Input 8 27 B X 78 Abort 28 B X 79 Output 1 29 I X 80 Output 2 30 I X 81 Output 3 31 A Y 82 Output 4 32 A Y 83 Output 5 33 B Y 84 Output 6 34 B Y 85 Output 7 35 I Y 86 Output 8 36 I Y 87 45V 37 A Z 88 Ground 38 A Z 89 Ground 39 B Z 90 Ground 40 B Z 91 NC 411 7 92 NC 42 IL Z 93 NC 43 A W 94 NC 44 A W 95 NC 45 B W 96 NC 46 B W 97 NC 47 I W 98 NC 48 I W 99 12V 49 12V 100 12V 50 12V Notes X Y Z W are interchangeable designations for A B C D axes Pin Out Description for DMC 18x2 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 is held at the OF command level Amp Enable Signal to disable and enable an amplifier Amp Enable goes low on Abort and OE1 DMC 18x2 Appendices 171 PWM STEP OUT PWM STEP OUT Sign Direction Error Output 1 Output 8 Inputs Encoder A B Encoder Index I Encoder A B I Abort Reset Forward Limit Switch Reverse Limit Switch 172 e Appendices PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers F
243. ter 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 84 e Chapter 6 Programming Motion DMC 18x2 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 x y z w where n indicates the order of the point The value n starts at zero and may go up to 256 The parameters x y z w indicate the corresponding slave position For this example the table may be specified by 0 0 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 x y z w where x y z w are the master positions at which the corresponding slaves must be engaged DMC 18x2 Chapter 6 Programming Motion 85 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 x y z w
244. tering 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 94 e Chapter 6 Programming Motion DMC 18x2 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 forth For example when operating with servo motors the trippoint 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 First the controller generates a motion profile in accordance with the motion commands Second the profiler generates pulses as p
245. terrogation Command Tell Position in hexadecimal format 4 2 Response from Interrogation Command The Variable Format VF command is used to format variables and array elements The VF command is specified by VF 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 The default format for VF is VF 10 4 Hex values are returned preceded by a and in 2 s complement V1 10 Assign V1 Vl Return V1 0000000010 0000 Default format VF2 2 Change format WI Return V1 10 00 New format VF 2 2 Specify hex format Vl Return V1 0A 00 Hex value VF1 Change format Vl Return V1 9 Overflow DMC 18x2 Chapter 7 Application Programming 139 Local Formatting of Variables PF and VF commands are global format commands that effect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m or n m following the variable name and the symbol F 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 For example Examples V1 10 Assign V1 Vl Return V1 0000000010 0000 Default Format V1 F4 2 Specify local format 0010 00 New format V1 4 2 Specify hex format 000A 00 Hex value
246. the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 18x2 provides commands and operands which are useful in debugging application programs These commands include breakpoint single line step through and 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 The trace command causes the controller to send each line in a program to the host computer immediately prior to execution Tracing is 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 an output FIFO buffer The output FIFO buffer can store up to 512 characters of information In normal operation the controller places output into the FIFO buffer The software on the host computer monitors this buffer and reads information as needed When the trace mode is enabled the controller will send information to the FIFO buffer at a very high rate In general the FIFO will become full since the software is unable to read the information fast enough When the FIFO becomes full program execution will be delayed until itis cleared If the user wants to
247. 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 DESCRIPTION Conditional Statements The conditional statement is satisfied if it evaluates to any value other than zero The conditional statement can be any valid DMC 18x2 numeric operand including variables array elements numeric 120 e Chapter 7 Application Programming DMC 18x2 values functions keywords and arithmetic expressions If no conditional statement is given the jump will always occur Examples Number V1 6 Numeric Expression V1 V7 6 ABS V1 gt 10 Array Element V1 lt Count 2 Variable 1 lt 2 Internal Variable _TPX 0 _TVX gt 500 VO V1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 18x2 will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and I The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The I 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 18x2 executes operations from left to right For further information on Mathematical Expressions and the bit wise operators
248. the module file included in the C ProgramFiles Galil DMCWIN VB directory named DMCCOMAO BAS This module declares the routines making them available for the VB project To add this file select Add Module from the Project menu in VB5 6 Sending Commands in VB Most commands are sent to the controller with the DMCCommand function This function allows any Galil command to be sent from VB to the controller The DMCCommand function will return the response from the controller as a string Before sending any commands the DMCCOpen function must be called This function establishes communication with the controller and is called only once This example code illustrates the use of DMCOpen and DMCCommand A connection is made to controller 1 in the Galil registry upon launching the application Then the controller is sent the command TPX whenever a command button is pressed The response is then placed in a text box When the application is closed the controller is disconnected To use this example start a new Visual Basic project place a Text Box and a Command Button on a Form add the DMCCOMAO BAS module and type the following code Dim m nController As Integer Dim m hDmc As Long Dim m nRetCode As Long DMC 18x2 Chapter 4 Software Tools and Communications 47 Dim m_nResponseLength As Long Dim m_sResponse As String 256 Private Sub Command1 Click m nRetCode DMCCommand m hDmc TPX m_sResponse m nR
249. thematical operators amp and are bit wise operators The operator amp is a Logical And The operator is a Logical Or These operators allow for bit wise operations on any valid DMC 18x2 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 TEST IN ENTER LEN S6 FLEN FRAC LEN FLEN 10000 FLEN LEN1 FLEN amp 00FF LEN2 FLEN amp FF00 100 LEN3 LEN amp 000000FF LEN4 LEN amp 0000FF00 100 LEN5 LEN amp 00FF0000 10000 LEN6 LEN amp FF000000 1000000 MG LENG 54 MG LENS 54 MG LEN4 S4 128 e Chapter 7 Application Programming Begin main program Input character string of up to 6 characters into variable LEN Define variable F
250. then tracked in step pulses between these two registers QS command YB QS TD Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally YA 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 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 YS is set to 2 which causes the automatic subroutine labeled POSERR to be executed Correction A 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 is automatically reset back to 1 indicating a cleared error DMC 18x2 Chapter 6 Programming Motion 97 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 64th microstepping drive for an axis with a 1 80 step motor and 4000 count rev
251. tion Instruction Function S JG 4000 Set speed AI 1 BGX Begin after input 1 goes high AI 1 STX Stop after input 1 goes low AMX JP S After motion repeat EN 142 e Chapter 7 Application Programming DMC 18x2 Input Interrupt Function The DMC 18x2 provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the II 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 20 is bit 1 2 is bit 2 and so on For example IL 5 enables inputs 1 and 3 20 22 5 A low input on any of 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 after the execution of the ININT subroutine the Zero Stack ZS command is used followed by unconditional jump statements IMPORTANT Use the RI instruction not EN to return from the ININT subroutine Examples Input Interrupt A JG 30000 20000 BG WT 1000 ININT MG Interrupt has occurred ST XY LOOP JP LOOP IN 1 0 JG 15000
252. tion ABI aborts the motion instantaneously The Vector End VE command must be used to specify the end of the coordinated motion This command tells the controller to decelerate to a stop following the last motion in the sequence If a VE command is not given an Abort AB1 must be used to abort the coordinated motion sequence The user must keep enough motion segments in the DMC 18x2 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or 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 the PCI bus speed The operand _CS can 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 is the motion smoothing constant used for 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 xy n m CR r 0 6 lt n gt m The first parameter lt n is equivalent to co
253. tion Sets data capture time interval where n is 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 number 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 n 0 stops recording Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress DMC 18x2 Chapter 7 Application Programming 133 Data Types for Recording DATA TYPE DESCRIPTION Torque reports digital value 8097 Note X may be replaced by Y Z or W for capturing data on other axes pop Operand Summary Automatic Data Capture Example Recording into An Array During a position move store the X and Y positions and position error every 2 msec RECORD DM XPOS 300 YPOS 300 DM XERR 300 YERR 300 RA XPOS XERR YPOS YERR RD TPX TEX TPY TEY PR 10000 20000 Begin program Define X Y position arrays Define X Y error arrays Select arrays for capture Select data types Specify move distance RCI Start recording now at rate of 2 msec BG XY Begin motion A JP A RC 1 Loop until done MG DONE Print message EN End program PLAY Play back N 0 Initial Counter JP DONE N gt 300 Exit if done N Print Counter X POS N Print X position Y
254. tion is enabled OE1 and the abort command is given Each axis amplifier has a separate enable line This signal also goes low when the watch dog timer is activated 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 1900 interface board To make these changes see section entitled Amplifier Interface in Chapter 3 Error Output The error output is a TTL signal which indicates an error condition in the controller This signal is available on the interconnect module as ERROR When the error signal is low this indicates one 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 The reset line on the controller is held low or is 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 DMC 18x2 Chapter 8 Hardware amp Software Protection 149 Input Protection Lines 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 O
255. try If more than one controller is installed or registered a prompt will appear where you can select the controller by highlighting it Once the entry has been selected click on the OK button If communication is established with the controller the terminal window will open and a colon prompt will be displayed From the top line of the terminal you can send commands to the controller Command syntax is described in later sections and the Command Reference If you are not properly communicating with the controller the program will pause for 3 15 seconds The top of the screen will display the message Status not connected with Galil motion controller and the following error will appear STOP Unable to establish communication with the Galil controller A time out occurred while waiting for a response from the Galil controller If this message appears you must click OK Contact Galil if you are unable to communicate with your controller Dos Users The installation of DMCDOS from the Galil software CD will install the program DMCTERM an interactive communication program When running DMCTERM you will have to provide 1 The communication address 2 The IRQ number if one is used After providing the setup information the terminal display should show a colon If you do not receive a colon the computer does not recognize your 18x2 controller Our DOS utilities accept command line arguments To use these utilities with the 1802 contr
256. ts sec2 LM ZW Specify axes for linear interpolation LL 40000 30000 Specify ZW distances LE Specify end move VS 100000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration BGS Begin sequence Note that the above program specifies the vector speed VS and not the actual axis speeds VZ and VW The axis speeds are determined by the DMC 18x2 from VS JVZ VW The resulting profile is shown in Figure 6 2 DMC 18x2 Chapter 6 Programming Motion 75 30000 27000 POSITION W 3000 0 4000 36000 40000 POSITION Z FEEDRATE 0 0 1 0 5 0 6 TIME sec VELOCITY Z AXIS TIME sec VELOCITY W AXIS TIME sec Figure 6 2 Linear Interpolation 76 e Chapter 6 Programming Motion DMC 18x2 Example Multiple Moves This example makes a coordinated linear move in the XY plane The Arrays VX and VY are used to store 750 incremental distances which are filled by the program LOAD LOAD DM VX 750 VY 750 COUNT 0 N 10 LOOP VX COUNT N VY COUNT N N N 10 COUNT COUNT 1 JP LOOP COUNT lt 750 A CAS LM XY COUNT 0 LOOP2 JP LOOP2 LM 0 JS C COUNT 500 LI VX COUNT VY COUNT COUNT COUNT 1 JP LOOP2 COUNT lt 750 LE AMS MG DONE EN C BGS EN Load Program Define Array Initialize Counter Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not
257. ugh 7 where 0 is 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 1 Only the main thread thread 0 may use the input command IN 2 When input interrupts are implemented for limit switches position errors or command errors the subroutines are executed as thread 0 To begin execution of the various programs use the following instruction XQ fA n Where n indicates the thread number To halt the execution of any thread use the instruction n 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 Task1 label ATO Initialize reference time Clear Output 1 LOOPI Loop label AT 10 Wait 10 msec from reference time Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference 1 1 1 JP LOOP1 Repeat Loop1 TASK2 Task2 label XQ 1 Execute Task1 LOOP2 Loop2 label PR 1000 Define relative distance BGX Begin motion AMX After motion done WT 10 Wait 10 msec DMC 18x2 Chapter 7 Application Programming 113 JP LOOP2 IN 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
258. vailable for PC computers running Microsoft Windows to communicate with the DMC 18x2 controller via the PCI bus Standard Galil communications software utilities are available for Windows operating systems which includes SmartTERM and WSDK These software packages are developed to operate under Windows 98SE ME NT4 0 2000 and XP and include all the necessary drivers to communicate with the PCI card In addition Galil offers software development tools CToolkit and ActiveX Toolkit to allow users to create their own application interfaces using programming environments such as C C Visual Basic and LabVIEW Galil also offers some basic software drivers and utilities for non Windows environments such as DOS Linux and QNX For users who prefer to develop there own drivers details are provided in this chapter describing the PCI communication registers used on the DMC 18x2 controller The following sections in this chapter are a brief introduction to the software tools and communication techniques used by Galil Figure 1 illustrates the software hierarchy that Galil communications software employs At the application level SmartTERM and WSDK are the basic programs that the majority of users will need to communicate with the controller to perform basic setup and to develop application code DMC programs that is downloaded to the controller At the Galil API level Galil provides software tools ActiveX and API functions for advanced users
259. ving 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 is independent and each axis follows its own profile The user specifies the desired absolute position PA or relative position PR slew speed SP acceleration ramp AC and deceleration ramp DC for each axis On begin BG the DMC 18x2 profiler 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 18x2 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
260. who wish to develop their own custom application programs to communicate with the controller Custom application programs can utilize API function calls directly to our DLL s or use our ActiveX COM objects which simplifies programming At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers DMC 18x2 Chapter 4 Software Tools and Communications 35 Application Level Galil API Level Hardware Interface SmartTERM WSDK Galil ActiveX Controls DMCShell ocx DMCReg ocx DMCTerm ocx etc te iar EP d DMC32 dll 4 dd ur ae JL DMCBUS342 dll DMC 18x2 FIFO IRQ Figure 4 1 Software Communications Hierarchy 36 e Chapter 4 Software Tools and Communications DMC 18x2 Galil SmartTERM SmartTERM is Galil s basic communications utility that allows the user to perform basic tasks such as sending commands directly to the controller editing downloading and executing DMC programs uploading and downloading arrays and updating controller firmware The latest version of SmartTERM can be downloaded from the Galil website at http www galilmc com support download html omc Terminal oT File Edit Tools View Help SE TE File Edit Type Commands Here COUNT COUNT 1 JP LOOP COUNT 10 EN Program Editor Window
261. x2 FIFO 3 54 55 Filter Parameter Damping 154 PID 16 167 Find Edge 30 103 Frequency 4 102 Function 30 31 49 61 73 91 92 109 113 117 118 121 125 127 132 145 Functions Arithmetic 109 121 128 130 Gear Ratio 82 83 Gearing 82 84 Halt 113 117 118 120 Abort 55 78 171 172 Off On Error 13 31 Stop Motion 78 126 152 Hardware 51 Address 202 TTL 5 Home Input 30 103 132 Homing 30 103 Find Edge 30 103 VO Digital Input 129 Digital Output 129 Home Input 30 103 132 TTL 5 ICM 1100 13 31 Independent Motion Jog 82 88 106 118 119 125 127 151 Index Pulse 13 30 103 ININT 111 124 126 Input Interrupt 53 111 118 125 126 ININT 111 124 126 Input of Data 135 Interconnect Module ICM 1100 13 31 Interface Terminal 61 Internal Variable 121 130 131 Interrogation 81 Interrupt 51 111 113 118 124 126 Invert 154 Jog 82 88 106 118 119 125 127 151 Keyword 121 128 130 Label 77 87 88 94 103 106 109 115 117 126 137 145 Special Label 111 Latch 66 Arm Latch 106 Record 91 93 Teach 93 Limit Torque Limit 15 Limit Switch 52 53 111 113 124 125 131 LIMSWI 29 111 124 125 Linear Interpolation 76 82 89 Clear Sequence 78 80 Logical Operator 120 Masking Bit Wise 121 128 Math Function Absolute Value 84 121 129 150 Bit Wise 121 128 Cosine 128 129 Logical Operator 120 Sine 87 129 Mathematical Expression 121 1
262. xes motion controller 3 axes motion controller 4 axes motion controller 100 pin high density cable 1 meter 100 pin high density cable 2 meter 100 pin high density cable 4 meter Interconnect module with flange for mounting Interconnect module with Low Amp Enable Interconnect module with Optoisolated digital outputs Interconnect module Interconnect module with 1 axis power amplifier Interconnect module with 2 axes power amplifier Interconnect module with 3 axes power amplifier Interconnect module with 4 axes power amplifier Utilities for Plug amp Play DMCWIN firmware Servo Design Kit for Windows 3 X DMC 18x2 Appendices 173 WSDK 32 Servo Design Kit for Windows NT or higher ActiveX Tool Kit Visual Basic Tool Kit includes OCXs Setup 16 Set up software for Windows 3 X Setup 32 Set up software for Windows NT or higher CAD to DMC AutoCAD DXF translator HPGL HPGL translator The ICM 2900 or AMP 19X0 are the preferred interconnect method for a DMC 18X2 ICM 1900 Interconnect Module The ICM 1900 interconnect module provides easy connections between the DMC 18x2 series controllers and other system elements such as amplifiers encoders and external switches The ICM 1900 accepts the 100 pin main cable and breaks it into screw type terminals Each screw terminal is labeled for quick connection of system elements A single ICM 1900 can be used for up to 4 axes The ICM 1900 is contained in a metal enclosure
263. xis is moving otherwise returns the current commanded position if in a move _PRx Returns current incremental distance specified for the x axis DMC 18x2 Chapter 6 Programming Motion 69 Example Absolute Position Movement PA 10000 20000 Specify absolute X Y position AC 1000000 1000000 Acceleration for X Y DC 1000000 1000000 Deceleration for X Y SP 50000 30000 Speeds for X Y BG XY Begin motion Example Multiple Move Sequence Required Motion Profiles X Axis 2000 counts Position 15000 count sec Speed 500000 counts sec2 Acceleration amp Deceleration Y Axis 500 counts Position 10000 count sec Speed 500000 counts sec2 Acceleration amp Deceleration Z Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration amp Deceleration This example will specify a relative position movement on X Y and Z axes The movement on each axis will be separated by 20 msec Fig 6 1 shows the velocity profiles for the X Y and Z axis A Begin Program PR 2000 500 100 Specify relative position movement of 2000 500 and 100 counts for X Y and Z axes SP 20000 10000 5000 Specify speed of 20000 10000 and 5000 counts sec AC 500000 500000 500000 Specify acceleration of 500000 counts sec for all axes DC 500000 500000 500000 Specify deceleration of 500000 counts sec for all axes BGX Begin motion on the X axis WT 20 Wait 20 msec BG Y Begin motion on the Y axis WT 20 Wait 20 msec BGZ Begin mot

DMC-18x2 User Manual - Galil Motion Control

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