Home

DMC-1415/1416/1425 USER MANUAL

1. OO 0 Figure A 13 CB 50 80 Layout Coordinated Motion Mathematical Analysis DMC 14x5 6 The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which is also known as the feed rate is the vector sum of the velocities along the X and Y axes Vx and Vy Vs Vx Vy The vector distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified Appendices 179 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 th
2. V 2000 500 50 0 980 0 0003 4 2000 52 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 606 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 50 200 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 j200 2 0200 2000 Arg A j200 tan 1 200 51 180 tan 1 200 2000 a 76 180 6 110 Finally the phase margin PM equals PM 180 70 146 Chapter 10 Theory of Operation DMC 14x5 6 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 System Design and Compensation The closed loop control system can be stabilized by a digital filter which is preprogrammed in the DMC 14XX controller The filter parameters can be selected by the user for the be
3. x LNO OUT Indicator LED s X Resistor Pack for LED s Figure A 4 Bank 0 Layout 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 U01 and 002 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 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 166 Appendices DMC 14x5 6 and U14 and so on Also the resistor pack RPx4 must be inserted into the bank to finish the input configuration gt 1 4 NEC2505_______ 1 8 RPx4 To DMC 14XX I O bank number 0 7 input number 17 80 s RG DMC 14xX GND l
4. 60 Command Summary Linear Interpolation esee 62 Operand Summary Linear Interpolation eese 62 o tonem n AR a RUP HE PRISE Ee ds 63 Example Multiple Moves 65 Vector Mode Linear and Circular Interpolation Motion seen 65 Specifying Vector Segments 65 Additional commands ntt eher e ri nO PI RR 66 Command Summary Coordinated Motion 67 Operand Summary Coordinated Motion Sequence sse 67 Blectror c Gearing e ue eg alia al n Cre iR re ERR Eden 68 Command Summary Electronic Gearing eene 69 Electronic Cat ou eese hod a nian e ed att he oie entes 70 Contour Mode etn a ate 75 Specifying Contour Segments eese 75 Additional Commandis eese ene enne neenon enne nennen nenne nene 76 Command Summary 76 Operand Summary Contour Mode serrer TI Stepper Motor Opera tlon 4 eet tnter tette eee DE Ee pde se POE see esa eee epu 80 Specifying Stepper Motor Operation essere rennen 81 Using an Encoder with Stepper Motors 0000 82 Command Summary Stepper Motor Operation 82 Operand Summary Stepper Motor Operation sese 82 Aux
5. EA 1 Overview of Motor Types Ase ie E sein Hebe pied este ree RU estne aegis 2 Standard Servo Motors with 10 Volt Command Signal sss 2 Brushless Servo Motor with Sinusoidal Commutation esee 2 Stepper Motor with Step and Direction Signals eee 2 DMC 14XX Functional Elements ninrita ep aro e a n S E A 3 Microcomputer Section serere ip EE Een ER UO HR herbes idea ese Rh 3 Motor Interface OREL a eee 3 CommCat OD 6 0 3 General I O inei EORR OPE E EUR EC CHER E E s 4 System Elements rto e tr teret e anne eee ERR Cer RE ep eod 4 lf M M 4 Amplifier Driver 4 Encoder ia aite cadet eig eco de Oo medie 5 Watch Dog cine ERU ER ee pe p Da eben 3 Chapter 2 Getting Started 7 The DMC 141X Motion Controller nete 0 7 Elements You Need eerte ee Ori RO rte i ete mean 8 Installing the DMC 14XX Controller eese eene nennen ener nenne 9 Step 1 Determine Overall Motor Configuration eeeeeeeereen een 9 Step 2 Configuring Jumpers on the DMC 14XX sese 10 Step 3 Connecting DC power and the Serial Cable to the DMC 14XX 11 Step 4 Installing the Communications Software eee 12 Step 5 Establishing Communication between the DMC 14XX and the host PC 12 Step 6 Set u
6. Input Interrupt Function The DMC 14XX 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 p command The m specifies the beginning input and n specifies the final input in the range The parameter o is an integer that represents a binary range of inputs For example if inputs 1 and 3 want to be used for the input interrupt function then the corresponding value of o is 20 2 or 5 The parameter p is similar to o except the inputs that are specified will activate the input interrupt routine when they go high instead of low See the II command DMC 1400 Series command reference for details A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RT 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 Instruction Interpretation A Label A Enable input 1 for interrupt function JG 30000 20000 Set speeds on X and Y axes BG XY Begin motion on X and Y axes B Label B TP XY Report X and Y axes posi
7. Event Triggers amp Trippoints To function independently from the host computer the DMC 14XX 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 14XX provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the DMC 14XX can make decisions based on its own status or external events without intervention from a host computer 98 Chapter 7 Application Programming DMC 14x5 6 DMC 14x5 6 DMC 14XX Event Triggers Command AM XY orS 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 Halts program execution until position command has reached the specified relative
8. 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 80 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 14x5 6 High Current Buffer chips 16 Screw Terminals 0123456 7 IOM 1964 REV 8 GALIL MOTION CONTROL MADE IN USA FOR INPUTS FOR OUTPUTS UX3 UX1 UX4 Ux2 J5 RPX4 RPX2 RPX3 DMC 14x5 6 Banks 0 and 1 provide high power output capability 80 pin high density connector Banks 2 7 are standard banks Figure A 3 IOM 1964 Overview The IOM 1964 is an input output module that connects to the DB 14064 extended I O daughter board cards from Galil providing optically 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 i
9. Q 2 Q 2 Q 2 5 2 N 2 2 Q 2 N Q 2 LIQ Z 4 176 DMC 14x5 6 o S Q gt Appendices 177 DMC 14x5 6 CB 50 80 Drawing 41 1 8 2 1 8 CB 50 80 Outline 1 8 15 16 cB50 80 REV 1 MOTION CONTROL USA jg E 1 1 4 Figure A 12 CB 50 80 Outline 178 Appendices 1 8 D 4 places Mounting bracket for attaching inside PC JC6 JC8 50 pin shrouded headers w center key JC8 pins 1 50 of J9 JC6 pins 51 100 of J9 J9 80 pin connector part N10280 52E2VC AMP part 3 178238 0 DMC 14x5 6 CB 50 80 Layout JC6 IDC 50 Pin 1 8 D 4 places Pint J9 80 pin connector O CB 50 80 Ol AMP part 3 178238 0 JC8 IDC 50 Pin ENT Pin 1 Pint CONTROL MADE IN USA DETAIL 2 406 008 50 pin C8 C6 w shrouded headers w 3 center V
10. The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motors with 10 Volt Command Signal The DMC 14XX achieves superior precision through use of a 16 bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feedforward an extra notch 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 In the case of the DMC 1416 a brush or brushless servo amplifier is connected to the analog signal internally Brushless Servo Motor with Sinusoidal Commutation The DMC 1415 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 millisecond
11. USER MANUAL DMC 14x5 6 Manual Rev 2 7 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 8 2011 Using This Manual E 0 This user manual provides information for proper operation of the DMC 1415 DMC 1416 and DMC 1425 controllers A separate supplemental manual the Command Reference contains a description of the commands available for use with these controllers Your DMC 14XX 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 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 Galil shall not be liable or responsible for any incidental or consequential damages Contents Using This Mantal o e eec ee teas i e e tege 1 Chapter 1 Overview 1 Hiis ester
12. 59 62 61 64 63 66 65 68 67 1 064 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 1 039 1 038 1 037 1 036 1 035 1 034 1 033 OUTC33 40 I OC33 40 1 032 1 031 1 030 1 029 1 028 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 I 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 I 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 n r2 NY WW WWW WW WH fF A HR HR H 5 HP d t Un tA tUa Un tn tA tA tA DMC 14x5 6 DMC 14x5 6 70 71 72 73 74 75 76 7j 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 70 69 72 71 74 73 76 75 78 TI 80 79 82 81 84 83 86 85 88 87 90 89 92 91 94 93 96 95 98 97 100 99 102 101 104 103 I
13. CMDERR TCPERR DMC 14x5 6 Starts program on power up or reset Starts program on power up error Label for input interrupt subroutine Label for limit switch subroutine Label for excess position error subroutine Label for timeout on motion complete trip point Label for incorrect command subroutine Ethernet communication error Chapter 7 Application Programming 93 Commenting Programs Using the command NO The DMC 14XX 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 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 1 The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Note 2 On the DMC 1415 1416 1425 controllers an apostrophe may be used instead of the NO command to document a program Using REM Statements with the Galil Terminal Software If you are using Galil software to communicate with the DMC 14XX controller you may also include REM remark st
14. MA Channel B MB Index l Index l Gnd GND 5V 5V p S VAMP ower ou Motor 1 PPY AMPGND L Motor 3 Motor 2 Figure 2 4 System Connections with the AMP 1460 Amplifier 22 Chapter 2 Getting Started DMC 14x5 6 ICM 1460 a Description Connection lt Channel A MA Channel B MB Channel A MA Channel B MB Index l Index l Gnd GND 5V Red Connector CPS Power Supply Black Wire Motor 1 Black Connector S high volt 4 power gna 2 motor 1 motor MSA 12 80 11 INHIBIT 4 REF IN 2 SIGNALGND Figure 2 5 System Connections with a separate amplifier MSA 12 80 This diagram shows the connections for a standard DC Servo Motor and encoder Step 8b Connect brushless motor for sinusoidal commutation DMC 1415 only DMC 14x5 6 Please consult the factory before operating with sinusoidal commutation The sinusoidal commutation option is available only on the DMC 1415 When using sinusoidal commutation the parameters for the commutation must be determined and saved in the controllers 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 Step B Connect the motor amplifier to the controller The sinusoidal commutation amplifier requires 2 signals usually denoted as Phase A amp P
15. NT 4 2000 ME and XP The controller must be registered in the Windows registry for the host computer to communicate with it The registry may be accessed via Galil software such as WSDK DMC Terminal or DTERM DMCWIN From WSDK and DMC Terminal the registry is accessed under the FILE menu From DTERM it is accessed under the REGISTRY menu Use the New Controller button under Non PnP tools to add a new entry in the registry Choose DMC 1415 DMC 1416 or DMC 1425 as the controller type Select Ethernet under the Connection Type and then Next The following screen will allow the user to enter an IP address for the controller This is a 4 byte number each byte separated by periods Also select the Ethernet Protocol as either TCP or UDP Galil recommends TCP because if information is lost during communication it will be resent using this protocol UDP is a more efficient protocol but does not resend lost information Enter the IP address obtained from your system administrator Select the button corresponding to the UDP or TCP protocol in which you wish to communicate with the controller Ethernet Parameters x IP Address 10 865 120 75 Assign IP Address Do Not Open Multi cast Handle r Ethernet Protocol r Unsolicited Messages OTe Use current CF Setting UDP c Receive Through Second Handle CF is sentto redirect messages Receive Through Same Handle CF is sentto redirect messa
16. Reference Position RP Step Count Register TD 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 Command Summary Stepper Motor Operation DE Operand Summary Stepper Motor Operation 82 Chapter 6 Programming Motion DMC 14x5 6 Aux Encoder Dual Loop DMC 1415 and DMC 1416 only The DMC 141X provides an interface for a second encoder except when the controller is configured for stepper motor operation When used the second encoder is typically mounted on the motor or the load but may be mounted in any position The most common use for the second encoder is backlash compensation described below The second encoder may be of the standard quadrature
17. 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 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 or Y 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
18. The program will then ask you whether you would like to assign the IP address you entered to the controller with the specified serial number Click on YES to assign it NO to move to next controller or CANCEL to not save the changes If there are no controllers on the network that do not have an IP address assigned the program will state this When done registering click on OK If you do not wish to save the changes click on CANCEL Once the controller has been register select the correct controller from the list and click on OK If the software successfully established communications with the controller the registry entry will be displayed at the top of the screen If the above method is unsuccessful in assigning an IP address to a controller the second option is connecting to the controller serially and using the IA command to assign the IP address See the controller command reference for information on the command Although the IP address can be assigned serially the user must still register the controller as an Ethernet controller in order to Chapter 2 Getting Started 15 communicate it over Ethernet Follow the steps above for registering an Ethernet controller but do not click the ASSIGN IP ADDRESS button Just click OK once the IP address has been entered in the text box and the controller will be entered into the Galil registry Connect to the controller through the Terminal utility Using Galil Software for Windows 98 SE
19. WT50 n n 1 JP REPEAT n lt 5 STX EN 100 Chapter 7 Application Programming Interpretation Label Specify Jog Speed Begin Motion Repeat Loop Wait 10000 counts Tell Position Set output 1 Wait 50 msec Clear output 1 Increment counter Repeat 5 times Stop End DMC 14x5 6 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 you do not want to halt the program sequences you can use the Input Interrupt function II or use a conditional jump on an input such as JP GO IN 1 0 Instruction Interpretation INPUT Program Label 1 Wait for input 1 low PR 10000 Position command BGX Begin motion EN End program Event Trigger Set output when At speed Instruction Interpretation ATSPEED Program Label JG 50000 Specify jog speed AC 10000 Acceleration rate BGX Begin motion ASX Wait for at slew speed 50000 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 Instruction Interpretation VECTOR Label VMXY VS 5000 Coordinated path VP 10000 20000 Vector position VP 20000 30000 Vector position VE End vector BGS Begin sequence AV 5000 After v
20. event triggers and subroutines For example the command JPZ LOOP n 10 causes a jump to the label 41 OOP if the variable n is less than 10 For greater programming flexibility the DMC 14XX 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 500 lines Using the DMC 14XX Editor to Enter Programs DMC 14x5 6 The DMC 14XX has an internal editor which may be used to create and edit programs in the controller s memory The internal editor is opened by the command ED Note that the command ED will not open the internal editor if issued from Galil s Window based software in this case Windows based editor will be automatically opened The Windows based editor provides much more functionality and ease of use therefore the internal editor is most useful when using a simple terminal with the controller and a Windows based editor is not available 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
21. label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label Line numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 80 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below Chapter 7 Application Programming 91 Edit Mode Commands 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 cntrl gt P The lt cntrl gt P command moves the editor to the previous line cntrl 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 cntrl 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
22. seminar and students can test their application on actual hardware and review it with Galil specialists TIME Two days 8 30 am 5 00 pm Appendices 183 Contacting Us Galil Motion Control 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet address support galilmc com URL www galilmc com FTP galilmc com 184 Appendices DMC 14x5 6 WARRANTY DMC 14x5 6 All products manufactured by Galil Motion Control are warranted against defects in materials and workmanship The warranty period for controller boards is 1 year The warranty period for all other products is 180 days In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship at our expense only to destinations in the United States 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 RESPO
23. 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 By default the DMC 14XX uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the ratio of the encoder resolutions For more information refer to ES in the Command Reference Trippoints 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 Command Summary Coordinated Motion Sequence Command Description Specifies the axes for the planar motion where m and n represent the planar axes Return coordinate of last point where m X Y Z or W Specifies arc segment where is the radius is the starting angle and 6 is the travel angle Positive direction is CCW LM Return number of available spaces for linear and circular segments in DMC 14XX sequence buffer Zero means buffer is full 255 means buffer is empty Operand Summary Coordinated Motion Sequence DMC 14x5 6 Operand Description The absolute coordinate of the axes at the last intersection along the sequence Segment counter Number of the segment in th
24. 11 BIT BIT 9 BIT 8 14 10 Movein N A N A N A N A N A N A N A Progress BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 N A N A Motion is Motion is Motionis N A N A N A slewing stopping due making to ST or final Limit decel Switch Notes Regarding Velocity and Torque Information The velocity information that is returned in the data record is 64 times larger than the value returned when using the command TV Tell Velocity See command reference for more information about TV The Torque information is represented as a number in the range of 32767 Maximum negative torque is 32767 Maximum positive torque is 32767 Zero torque is 0 46 Chapter 4 Communication DMC 14x5 6 QZ Command The QZ command can be very useful when using the QR command since it provides information about the controller and the data record The QZ command returns the following 4 bytes of information BYTE INFORMATION number of bytes in general block of data record number of bytes in coordinate plane block of data record Number of Bytes in each axis block of data record Controller Response to Commands Most DMC 14x5 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon Instructions are sent in ASCII and the DMC 14x5 decodes each ASCII character one byte one at a time It takes approximately 0 5 msec for the controller to decode each
25. 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q The lt cntrl gt Q quits the editor mode In response the DMC 14XX 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 List entire program LS 5 Begin listing at line 5 LS 5 9 List lines 5 thru 9 15 A 9 List line label A thru line 9 15 A A 5 List line label A and additional 5 lines Program Format A DMC 14XX program consists of DMC 14XX 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 14XX 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 program line where the maximum number of characters on a line is 80 including semicolons A carriage return en
26. 6 Motor Amplifier DMC 14x5 6 The motor amplifier may be configured in three modes 1 Voltage Drive 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Drive The amplifier 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 2 T RJ K Is and T L R s and the motor parameters and units are 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 s 4 kg m2 L 0 004H Then the corresponding time constants are Tm 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 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of Ka The resulting transfer function in this case is P V K Js2 Chapter 10 Theory of Operation 141 where Kt and J are as defined previously For example a current amplifier with K 2 A V with the motor described by the previous example will have the transfer function P V 1000 s2
27. 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 Limit Switch Routine The DMC 14XX 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 DMC 14x5 6 Chapter 8 Hardware amp Software Protection 133 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 or Y following _LR or _LF specifies the axis The CN command can be used to configure the polarity of the limit switches Limit Switch Example Instruction A EN 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 Interpretation 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 Sen
28. AXIS TIME sec VELOCITY Y AXIS TIME sec Figure 6 2 Linear Interpolation 64 Chapter 6 Programming Motion DMC 14x5 6 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 Instruction 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 HA LM XY COUNT 0 LOOP2 JP LOOP2 _LM 0 JS C COUNT 250 LI VX COUNT VY COUNT COUNT COUNT 1 JP LOOP2 COUNT lt 750 LE AMS MG DONE EN C BGS EN Interpretation Load Program Define Array Initialize Counter Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full wait Begin motion on 250th 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 14XX 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 14XX performs all the complex computations of linear and
29. DMC 14XX 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 SPEEDZ Invalid Variable Names REALLONGNAME Cannot have more than 8 characters 123 Cannot begin variable name with a number SPEEDZ 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 14XX 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 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 Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as PR or SP PR VI Assign V1 to PR command SP VS 2000 Assign VS 2000
30. Encoder Dual Loop DMC 1415 and DMC 1416 only eee 83 Backlash Corpensation odere rtr ete b ei eie iine egeta 83 Motion Smoothing 2 apr Re ce Pee Ee Pt Ene erbe deren eu Rees 85 Using the IT and VT Commands eese enne nre 85 Using the KS Command Step Motor Smoothing eee 86 OMS a D 87 High Speed Position Capture 90 Chapter 7 Application Programming 91 OVEeIVIEW ER ERR ns bie oes STARS itr aca rite baie tea epe 91 Using the DMC 14XX Editor to Enter Programs 07 91 Edit Mode Comimarnds onda baie doin aera Eno A n ete 92 Program Format o te be ete ne dite epit i ater t 92 Using Labels in Programs in eere t t oA I eter 92 Special Labels 4 dtt e roe e e a OR aao e eet t 93 Commenting Programs oh teet mm aat aoo Dit d asma tiat 94 Executing Programs Multitasking 95 Debugging Programs p A a Ee erect iie S 96 Program Flow Cormasnds uere ere etes E E E E EE 98 Event Triggers amp TrIppolnts c nde detti erp ee debeat 98 Event Trigger BXaniples J oi cn cete emp Het Moana ka 100 Conditional ee hte coer nei pi Gh eats 102 Using If Else and Endif Commands sse 104 SUDIOULIeS sostiene eet rios 106 Stack Manipulation een ert etie p bee teen sto R qs 106 Contents iii 0 0 106 Automatic Subroutines for Monito
31. Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec Chapter 7 Application Programming 115 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 automatic data capture feature described below Uploading and Downloading Arrays to On Board Memory Arrays may be uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A 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 14XX 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 spec
32. Installation 9 135 Integrator 27 140 144 45 Interconnect Board 8 Interconnect Module 157 ICM 1100 19 35 Interface Terminal 49 Internal Variable 103 113 114 Interrogation 27 53 54 62 68 119 120 153 Interrupt 93 101 106 8 125 157 Invert 136 J Jog 59 69 75 100 101 107 9 133 Jumpers 39 K Keyword 103 111 113 114 15 TIME 114 15 L Label 65 73 74 80 91 97 100 108 118 120 123 25 128 133 LIMSWI 132 34 POSERR 132 33 Special Label 93 133 Latch 53 Data Capture 116 17 Record 56 76 80 115 117 Teach 80 Limit Torque Limit 21 Limit Switch 33 34 107 114 132 34 136 LIMSWI 33 106 7 132 34 Linear Interpolation 55 60 62 75 Clear Sequence 60 62 66 67 Logical Operator 103 188 Index Masking Bit Wise 103 111 Math Function Absolute Value 71 104 112 132 Bit Wise 103 111 Cosine 56 111 12 115 Logical Operator 103 Sine 56 74 112 Mathematical Expression 103 110 112 MCTIME 99 107 108 Memory 30 49 79 91 96 103 107 114 116 Array 3 56 65 77 80 91 96 103 111 114 22 123 152 Download 49 91 116 Message 47 65 96 107 8 111 117 19 125 133 34 Modelling 137 140 41 144 Motion Complete MCTIME 99 107 108 Motion Smoothing 56 85 86 S Curve 85 Motor Command 21 22 4 Moving Acceleration 101 2 118 123 181 Begin Motion 93 96 100 101 107 8 117 19 123 125 Circular 65 67 116 127 Home Inputs 87 Slew Speed 157 Multitasking 95 Halt
33. LEN3 LEN amp 000000FF Let variable LEN3 bottom byte of LEN LEN4 LEN amp 0000FF00 100 Let variable LEN4 second byte of LEN LEN5 LEN amp 00FF0000 10000 Let variable LENS third byte of LEN LEN6 LEN amp FF000000 1000000 Let variable LEN6 fourth byte of LEN MG LEN6 S4 Display LENG as string message of up to 4 chars MG LENS S4 Display LENS as string message of up to 4 chars MG LEN4 S4 Display LEN4 as string message of up to 4 chars 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 LEN S4 Display LEN1 as string message of up to 4 chars EN Chapter 7 Application Programming 111 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 TESTME at the input prompt the controller will respond with the following T Response from command MG LEN6 54 E Response from command MG LENS 54 S Response from command MG LENA S4 T Response from command MG LEN3 54 M Response from command MG LEN2 S4 E Response from command MG LENI 54 Functions Function Description O T mm UN E
34. 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 sufficient for proper operation of the BZ command For systems with significant friction this voltage may need to be increased and for systems with very small motors this value should be decreased For example BZ 2 lt CR gt will drive the axis to zero using a 2V signal The controller will then leave the motor enabled For systems that have external forces working against the motor such as gravity the BZ argument must provide a torque 10x the external force If the torque is not sufficient the commutation zero may not be accurate 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 n
35. Modbus structure This is necessary for sending configuration and special commands to an I O device The formats vary depending on the function code that is called For more information refer to the Command Reference The third level of Modbus communication uses standard Galil commands Once the slave has been configured the commands that may be used are IN AN SB CB OB and AO For example AO 2020 8 2 would tell I O number 2020 to output 8 2 volts If a specific slave address is not necessary the I O number to be used can be calculated with the following I O Number HandleNum 1000 Module 1 4 BitNum 1 Where HandleNum is the handle number from 1 A to 6 F Module is the position of the module in the rack from 1 to 16 BitNum is the I O point in the module from 1 to 4 If an explicit slave address is to be used the equation becomes I O Number SlaveAddress 10000 HandleNum 1000 Module 1 4 Bitnum 1 To view an example procedure for communicating with an OPTO 22 rack refer to the appendix Which devices receive what information from the controller depends on a number of things If a device queries the controller it will receive the response unless it explicitly tells the controller to send it to another device If the command that generates a response is part of a downloaded program the response will route to whichever port is specified as the default by the CF command To designate a specific destinatio
36. 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 1460 interface board To make these changes see section entitled Amplifier Interface Note There is only one amplifier enable signal for the DMC 1425 Therefore both amplifiers will be controlled by the same enable output 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 Chapter 8 Hardware amp Software Protection 131 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
37. OPTO COMMON to the GND side of the power supply the inputs will be activated by sourcing current The opto isolation circuit requires 1 ma drive current with approximately 400 usec response time The voltage should not exceed 24V without placing additional resistance to limit the current to 11 ma DMC 14x5 6 Appendices 159 CONTROLLER ICM 1460 CONNECTIONS vcc RP5 2 2K OPTO COMMON OUTPUT our x Figure A 2 Opto isolated Outputs The signal OUT x is one of the isolated digital outputs where x stands for the digital output terminals The OPTO COMMON needs to be connected to an isolated power supply The OUT x can be used to source current from the power supply The maximum sourcing current for the OUT x is 25 ma Sinking configuration can also be specified Please contact Galil for detail When opto isolated outputs are used either a pull up or pull down resistor needs to be provided by the user depending upon whether the signal is sinking or sourcing 64 Extended I O of the DMC 1415 1416 1425 Controller The DMC 1415 1416 1425 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 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 1415 1416 1425 with DB 14064 The 64 extended I O points of the DMC 14
38. The communication interface with the DMC 14XX consists of one RS 232 port 19 2 kbaud and one 10base T Ethernet port DMC 14x5 6 Chapter 1 Overview 3 General I O The DMC 1415 and DMC 1416 provide interface circuitry for 7 TTL inputs and 3 TTL outputs In addition the controller provides two 12 bit analog inputs The general inputs can also be used for triggering a high speed positional latch for each axis NOTE In order to accommodate 2 axes on the DMC 1425 many of the general I O features become dedicated I O for the second axis The standard DMC 1425 will have 3 TTL inputs 3 TTL outputs and 2 analog inputs System Elements As shown in Fig 1 2 the DMC 14XX is part of a motion control system which includes amplifiers motors and encoders These elements are described below Power Supply Computer DMC 141X Controller Amplifier Driver Encoder 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 d
39. Y axes Instruction SA PR 2000 100 SP 15000 5000 AC 500000 500000 DC 500000 500000 BGX WT 40 BG Y EN VELOCITY COUNTS SEC 20000 15000 10000 5000 0 20 Interpretation Begin Program Specify relative position movement of 2000 and 100 counts for the X and Y axes Specify speed of 15000 and 5000 counts sec Specify acceleration of 500000 counts sec for all axes Specify deceleration of 500000 counts sec for all axes Begin motion on the X axis Wait 40 msec Begin motion on the Y axis End Program X axis velocity profile Y axis velocity profile TIME ms 40 60 80 100 Figure 6 1 Velocity Profiles of XY Notes on fig 6 1 The X axis has a trapezoidal velocity profile while the Y axis has a triangular velocity profile The X axis accelerates to the specified speed moves at this constant speed and then decelerates such that the final position agrees with the commanded position PR The Y axis accelerates but before the specified speed is achieved must begin deceleration such that the axis will stop at the commanded position Both axes have the same acceleration and deceleration rate hence the slope of the rising and falling edges of both velocity profiles are the same 58 Chapter 6 Programming Motion DMC 14x5 6 Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion The user specifies th
40. 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 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 OP m a b c d where m is the decimal representation of the bits 1 8 values from 0 to 255 and a b c d represent the extended I O in consecutive groups of 16 bits values from 0 to 65535 Arguments which are given for I O points which are configured as inputs will be ignored The following table describes the arguments used to set the state of outputs Appendices 161 Argument Blocks Bits Description m 0 1 8 General Outputs a 2 3 17 32 Extended I
41. 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 are processed CS increases starting at zero This function allows the host computer to determine which 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 14XX computes the vector speed based on the axes specified in the LM mode For example LM XY designates linear interpolation for the X and Y axes The vector speed for this example would be computed using the equation vs xs vs where XS and YS are the speed of the X and Y axes The controller computes the vector speed with the axis specifications from LM 60 Chapter 6 Programming Motion DMC 14x5 6 DMC 14x5 6 VT is used to set the 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 Instruction Interpretation 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 dista
42. command in the Command Reference Galil Software Tools and Libraries API Application Programming Interface software is available from Galil The API software is written in C and is included in the Galil CD ROM They can be used for development under Windows environments With the API s the user can incorporate already existing library functions directly into a C program Galil has also developed an Axtive X Toolkit This provides 32 bit OCXs for handling all of the DMC 14x5 communications These objects install directly into Visual Basic and are part of the run time environment 48 Chapter 4 Communication DMC 14x5 6 Chapter 5 Command Basics Introduction The DMC 14XX provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands can be sent in ASCII or binary In ASCII the DMC 14XX 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 14XX or an entire group of commands can be downloaded into the DMC 14XX memory for execution at a later time Combining commands into groups for later execut
43. 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 104 Chapter 7 Application Programming DMC 14x5 6 DMC 14x5 6 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 Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command and has no arguments If the argument of the IF command evaluates false the controller will skip commands until the ELSE command If the argument for the IF command evaluates true the controller will execute the commands between the IF and ELSE command Nesting IF Conditional Statements The DMC 14XX allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 14XX allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to spec
44. command or Pulse Output for Stepper Analog Input 1 Analog Input 2 Signal Ground 6 DMC 14x5 6 Appendices 157 RESET I Reset 8 Bo i WP Wl NUT _ 1 Signal Ground X Axis Main Encoder A X Axis Main Encoder A gt X Axis Main Encoder B gt peo 81 A AB B V ND X Axis Main Encoder Index X Axis Main Encoder Index I X Axis Auxiliary Encoder A Y Axis Main Encoder A for DMC 1425 E A I X Axis Auxiliary Encoder A Y Axis Main Encoder A for DMC 1425 I X Axis Auxiliary Encoder B Y Axis Main Encoder B for DMC 1425 X Axis Auxiliary Encoder B Y Axis Main Encoder B for DMC 1425 A ACMD2 SIGNX 4 The screw terminals for 12V can be configured as opto input output common See next section for detail 2nd Motor command Signal for Sine Amplifier or SIGNX for stepper Signal Ground AB 5 The screw terminal for amplifier enable output can be configured as the stepper motor direction output for Y axis for DMC1425 controller 6 The error ouput is the pulse Y when Y is configured for stepper output Note Red LED will always be on when Y is in stepper mode 158 Appendices DMC 14x5 6 7 The screw terminal for CMP can be configured as input output common for opto isolated I O Please see next section for detail Opto Isolation Opt
45. connector for 20 60V DC supply and motor connections DMC 1416 Error LED s for active Ethernet Master reset upgrade and baud rate selection connection transmit receive on Ethernet jumpers Y step error output and power Controller RAM JP2 Motor off as default jumper Stepper motor jumper DMC 1415 DMC 1425 Fuse for DC to DC converter JP3 Jumper for selecting analog motor command or step and direction pin out configuration RS232 Serial connection Elements You Need Before you start you must get all the necessary system elements These include 1l DMC 1415 DMC 1425 or DMC 1416 Controller and 37 pin cable order Cable 37 Servo motor s with Encoder or stepper motor Appropriate motor drive servo amp Power Amplifier or AMP 1460 or stepper drive Power Supply for Amplifier 5V 12V supply for DMC 1415 or DMC 1425 card level 20V to 60V DC supply for DMC 1416 Communication CD from Galil WSDK Servo Design Software not necessary but strongly recommended TS exe oA BO 00 Interface Module ICM 1460 with screw type terminals or integrated Interface Module Amplifier AMP 1460 Note An interconnect module is not necessary but strongly recommended The motors may be servo brush or brushless type or steppers The driver amplifier should be suitable for the motor and may be linear or pulse width modulated and it may have current feedback or voltage feedback For servo motors
46. e i 1 0 NT DMC 14x5 6 Figure A 5 Input Circuit Connections to this optically isolated input circuit are done in a sinking or sourcing configuration referring to the direction of current Some example circuits are shown below Sinking Sourcing e e 5V OC e e GND y o GND e e 45V Ourrent OCurrent Figure A 6 Optically Isolated Inputs Connected to Switches 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 14XX DB 14064 When the switch is closed in either circuit current flows This pulls the input on the DMC 14XX 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 to the optically isolated inputs in a similar fashion with respect to current An NPN output is connected in a sinking configuration and a PNP output is connected in the sourcing configuration IOC e e 45V OC e e GND lO e e NPN VO e D i Curren gt output Current Figure 7 Optically Isolated Inputs Connected to Transistor Outp
47. is indicated by an LED on the amplifier This signal changes under the following conditions the watchdog timer activates the motor off command MO is given or the OE1 command 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 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 1460 interface board To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AEN signal note the state of jumper at location JP1 on the ICM 1460 When a jumper is placed across AEN and 5V the output voltage is 0 5V To change to 12 volts pull the jumper and rotate it so that AEN is connected to 12V If you remove the jumper the output signal is an open collector allowing the user to connect an external supply with voltages up to 24V Connect the encoders For stepper motor operation an encoder is optional For servo motor operation if you have a preferred definition of the forward and reverse directions make sure that the encoder wiring is consistent
48. jog speed for the axis specified by x _TVx 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 25000 count s Instruction Interpretation A Label AC 20000 20000 Specify X Y acceleration of 20000 cts sec DC 20000 20000 Specify X Y deceleration of 20000 cts sec JG 50000 25000 Specify jog speed and direction for X and Y axis Chapter 6 Programming Motion 59 BGX Begin X motion AS X Wait until X is at speed BG Y Begin Y motion EN Linear Interpolation Mode The DMC 14XX provides a linear interpolation mode for 2 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 XY selects the X and Y 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 Spec
49. motion path consisting of arc segments and Coordinated Motion linear segments such as engraving or quilting DMC 14x5 6 Chapter 6 Programming Motion 55 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 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 Moving along arbitrary profiles or mathematically Contour Mode prescribed profiles such as sine or cosine trajectories Teaching or Record and Play Back Contour Mode with Automatic Array Capture Backlash Correction Dual Loop Following a trajectory based on a master encoder Electronic Cam position EQ Smooth motion while operating in independent axis Independent Motion Smoothing IT positioning Smooth motion while operating in vector orlinear Vector Smoothing VT interpolation positioning Smooth motion while operating with stepper Stepper Motor Smoothing KS motors Gantry two axes are coupled by gantry Gantry Mode GM Independent Axis Positioning In this mode motion between the specified axes 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 decelera
50. network and powered For a brief explanation of BOOT P see the section Third Party Software Either a BOOT P server on the internal network or the Galil terminal software may be used To use the Galil BOOT P utility select the registry in the terminal emulator NOTE Select the DMC 1415 controller Once the controller has been selected enter the IP address and select either TCP IP or UDP IP as the protocol When done click on the ASSIGN IP ADDRESS The Galil Terminal Software will respond with a list of all controllers on the network that do not currently have IP addresses The user selects the controller and the software will assign the controller the specified IP address Then enter the terminal and type in BN to save the IP address to the controller s non volatile memory CAUTION Be sure that there is only one BOOT P server running If your network has DHCP or BOOT P running it may automatically assign an IP address to the controller upon linking it to the network In order to ensure that the IP address is correct please contact your system administrator before connecting the controller to the Ethernet network 40 Chapter 4 Communication DMC 14x5 6 Controller Communications Parameters General Parameters ISA Bus Parameters PCI Bus Parameters Serial Parameters Ethernet Parameters IP Address f124 51129 31 m Ethernet Protocol TCP UDP Assign IP Address _ Cancel Appi Ethernet Parameters Tab
51. not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in this chapter 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 LIMS WI if such a routine has been written by the user Software Protection The DMC 14XX provides a programmable error limit The error limit refers to a difference in the actual 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 Set X axis error limit for 200 Y axis error limit to 300 ER 1 Set Y axis error limit to 1 count The unit
52. 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 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 Interpretation SETUP Label EAX Select X as master EM 2000 1000 Cam cycles DMC 14x5 6 Chapter 6 Programming Motion 73 EP 20 0 Master position increments N 0 Index LOOP Loop to construct table from equation P N 3 6 Note 3 6 0 18 20 S SIN P 100 Define sine position Y N 8 Define slave position ET N Y Define table N N 1 JP LOOP N lt 100 Repeat the process EN 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 Interpretation RUN Label EB1 Enable
53. 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 Kp 8 DMC 14x5 6 Chapter 10 Theory of Operation 143 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65536 and the output voltage range is 10 or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count Digital Filter ZOH The digital filter has a transfer function of D z K z A z Cz z 1 and a sampling time of T The filter parameters K A and C are selected by the instructions KP KD and KI respectively The relationship between the filter coefficients and the instructions are K KP KD 4 KD C KI 2 This filter includes a lead compensation and an integrator It is equivalent to a continuous PID filter with a transfer function G s G s P sD I s P 4KP D 4T KD I KI 2T For example if the filter parameters of the DMC 14XX are 4 KD 36 KI 2 T 0 001 s the digital filter coefficients are 160 0 9 1 and the equivalent continuous filter G s is G s 16 0 1445 1000 5 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 fun
54. press the carriage return If a colon prompt is not returned there is most likely an incorrect setting of the serial communications port The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software The user must also insure that the proper serial cable is being used see appendix for pin out of serial cable 12 Chapter 2 Getting Started DMC 14x5 6 Using Galil Software for Windows 3 x 95 and 98 SE In order for the windows software to communicate with a Galil controller the controller must be registered in the Windows Registry To register a controller you must specify the model of the controller the communication parameters and other information The registry is accessed through the Galil software such as WSDK and DTERM DTERM is installed with DMCWIN and installed as the icon Galil Terminal From WSDK the registry is accessed under the FILE menu From the DTERM program the registry is accessed from the REGISTRY menu The registry window is equipped with buttons to Add Change or Delete a controller Pressing any of these buttons will bring up the Set Registry Information window Use the Add button to add a new entry to the Registry You will need to supply the Galil Controller type The controller model number must be entered and
55. previous value is maintained The space between the data and instruction is optional DMC 14x5 6 TTChapter 5 Command Basics 49 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 2000 4000 Specify X and Y PR Request X and Y values PR Request Y value only The DMC 14XX provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as X or Y 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 or Y 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 XY Begin all axes BG Begin all axes Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S is used to specify the coor
56. program Chapter 6 Programming Motion 79 Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 14XX automatic array capture feature to capture position data The captured data may then be played back in the contour mode The following array commands are used DM C n Dimension array Specify array for automatic record up to 4 RD TPX Specify data for capturing such as TPX or TPY RC n m Specify capture time interval where n is 2n msec m is number of records to be captured RC or RC Returns a 1 if recording Record and Playback Example Instruction Interpretation RECORD Begin Program DM XPOS 501 Dimension array with 501 elements RA XPOS Specify automatic record RD TPX Specify X position to be captured MOX Turn X motor off RC2 Begin recording 4 msec interval A JP A RC 1 Continue until done recording COMPUTE Compute DX DM DX 500 Dimension Array for DX C 0 Initialize counter L Label 1 DELTA XPOS D XPOS C Compute the difference DX C DELTA 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 1 lt 500 Loop until done DT 0 CDO End contour mode EN End program For addit
57. se S MEE I M I VP R N E VE VT VA VD VS VR 9 9 9 9 9 9 AM 9 MC 9 TW MF MR AD AP AR AS gt o n rj ri pn en eni li gt gt e F5 8 9 F F E gt 84 87 8A 8B 8C 8E 8F 1 4 5 7 1 A4 5 7 52 TTChapter 5 Command Basics DMC 14x5 6 Controller Response to DATA The DMC 14XX returns for valid commands The DMC 14XX returns a for invalid commands For example if the command BG is sent in lower case the DMC 14XX will return a bg enter invalid command lower case DMC 14XX 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 14XX has a s
58. serial port the user can re establish communication if needed Instruction Interpretation LOOP Simple program loop JP LOOP EN TCPERR Ethernet communication error auto routine MG P1 _IA4 Send message to serial port indicating which handle did not receive proper acknowledgement RE Return to main program Note The TCPERR routine only detects the loss of TCP IP Ethernet handles not UDP Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 14XX provides the use of the following mathematical operators Operator Function Subtraction Multiplication 110 Chapter 7 Application Programming DMC 14x5 6 Logical And Bit wise Te Logical Or On some computers a solid vertical line appears as a broken line 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 parentheses have precedence Examples SPEED 7 5 V 2 The variable SPEED is equal to 7 5 multiplied by V1 and divided by 2 COUNT COUNT 2 The variable COUNT is equal to the current value plus 2 RESULT _TPX COS 45 40 Puts the position of X 28 28 in RESULT 40 cosine of 45 is 28 28 TEMP IN 1 amp IN 2 TEMP is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators DMC 14x5 6 The mathematical operators amp and are bit wise ope
59. status for S plane BLOCK Header Header Header Header I block I block I block I block Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock Iblock I block I block Iblock I block S block S block DMC 14x5 6 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 a axis status A block UB a axis switches A block UB axis stop code A block SL a axis reference position A block SL a axis motor position A block SL a axis position error A block SL axis auxiliary position A block SL a axis velocity A block SW a axis torque A block SW a axis analog A block UW b axis status B block UB b axis switches B block UB b axis stop code B block SL b axis reference position B block SL b axis motor position B block SL b axis position error B block SL b axis auxiliary position B block SL b axis velocity B block SW b axis torque B block SW b axis analog B block NOTE UB Unsigned Byte UW Unsigned Word SW Signed Word SL Signed Long Word Explanation of Status Information and Axis Switch Information Header Information Byte 0 1 of Header BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 1 N A N A N A N A I Block T Block S Block Present Present Present in Data in Data in Data Record Reco
60. stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving back and 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 pr
61. that send commands to the controller The slaves are typically peripheral I O devices that receive commands from the controller NOTE The term Master is equivalent to the internet client The term Slave is equivalent to the internet server An Ethernet handle is a communication resource within a device The DMC 14XX can have a maximum of 6 Ethernet handles open at any time When using TCP IP each master or slave uses an individual Ethernet handle In UDP IP one handle may be used for all the masters but each slave uses one Pings and ARPs do not occupy handles If all 6 handles are in use and a 7 master tries to connect it will be sent a reset packet that generates the appropriate error in its windows application NOTE There are a number of ways to reset the controller Hardware reset push reset button or power down controller and software resets through Ethernet or RS232 by entering RS The only reset that will not cause the controller to disconnect is a software reset via the Ethernet When the Galil controller acts as the master the IH command is used to assign handles and connect to its slaves The IP address may be entered as a 4 byte number separated with commas industry standard uses periods or as a signed 32 bit number A port number may also be specified but if it is not it will default to 1000 The protocol TCP IP or UDP IP to use must also be designated at this time Otherwise the controller will not connect t
62. 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 Therefore 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 Appendices 169 Output Command Result CB Vout 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 To DMC 14XX 5V 1 4 NEC2505 1 8 RPx2 77 DMC 14XX I O OUTC Figure A 11 IOM 1964 Digital Output Configured as Open Collector 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 Digi
63. the drivers should accept an analog signal in the 10 Volt range as a command The amplifier gain should be set so that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers a command signal of 10 Volts should run the motor at the maximum required speed For step motors the driver should accept step and direction signals For start up of a step motor system refer to Step 8c Connecting Step Motors 8 Chapter 2 Getting Started DMC 14x5 6 For the DMC 1416 the internal amplifier is a 20V to 60V PWM amplifier in either a brush or brushless configuration so only a brush or brushless DC servo motor may be used The WSDK software is highly recommended for first time users of the DMC 14XX It provides step by step instructions for system connection tuning and analysis Installing the DMC 14XX Controller Installation of a complete operational DMC 14XX system consists of 9 steps Step 1 Determine overall motor configuration Step 2 Configuring jumpers on the DMC 14XX Step 3 Connect the DC power supply and serial cable to the DMC 14XX Step 4 Install the communications software Step 5 Establish communications between the DMC 14XX and the host PC Step 6 Set up axis for sinusoidal commutation DMC 1415 only Step 7 Make connections to amplifier and encoder Step 8a Connect standard servo motor Step 8b Connect b
64. the format byte and the axes byte For example the command PR 1000 500 would be A7 02 00 03 03 E8 FE 0C where A7 is the command number for PR 02 specifies 2 bytes for each data field 00 S is not active for PR 03 specifies bit 0 is active for A axis and bit 1 is active for B axis 2 2 3 03 E8 represents 1000 FE OC represents 500 Example The command ST S would be A1 0001 where is the command number for ST 00 specifies 0 data fields 01 specifies stop the coordinated axes S DMC 14x5 6 TTChapter 5 Command Basics 51 Binary Command Table reserved 80 reserved reserved 1 6 KI 82 RP D8 KD 83 TP D 84 __ AF TE DA 85 D 866 reserved 87 88 lt mz oo A n vp BH DD OR A3 T JDE NN B re S T DR s LEVE E REM VA 21 uU NC 00 4 B6 _ 5 E i Q reserved reserved ive Ge TM B9 reserved 2 90 reserved reserved Q n N gt L 5 5 2 B B I Q 1 reserved AL OOo zm L L C T L C C E E E E E E E reserved reserved reserved reserved reserved A4 AS DO reserved A6 HAT EAT 1 FD reserved
65. to SP command DMC 14x5 6 Chapter 7 Application Programming 113 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 14XX to be incorporated into programmable variables and expressions Most DMC 14XX commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 14XX 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 14XX registers The axis designation is required following the command Examples of Internal Variables POSX _TPX Assigns value from Tell 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 _KPX 2 is invalid Special Operands Keywords The DMC 14XX provides a few additional operands which give access to internal variables that are not accessible by standard DMC 14XX commands Operand Function Free Running Real Ti
66. to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are operating properly the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller you need to verify that the ground level of the amplifier 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 resistor and measure the voltage across 18 Chapter 2 Getting Started DMC 14x5 6 DMC 14x5 6 Step C Step D the resistor Only if the voltage is zero proceed to connect the two ground signals directly The amplifier enable signal is used by the controller to disable the motor This signal is labeled AMPEN on the ICM 1460 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
67. to the ground GND of the interconnect and connect the GND of the interconnect to the GND of the amplifier DMC 14x5 6 Chapter 3 Connecting Hardware 35 DMC 14XX ICM 1460 Connection to 5V or 12V made through jumper at JP4 Removing the jumper allows the user to connect a load e g optoisolator or relay between AMPEN and their own supply at the desired voltage level up to 24V SERVO MOTOR AMPLIFIER 7407 Open Collector Buffer The Enable signal can be inverted by using a 7406 Analog Switch Figure 3 1 Connecting AEN to the motor amplifier TTL Inputs As previously mentioned the DMC 14XX has 7 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 14XX without resetting the PC Analog Inputs The DMC 14XX has 2 analog inputs configured for the range between 10 and 10V The inputs are decoded by a 12 bit ADC giving a voltage resolution of approximately 005V The impedance of these inputs is 10Kohms The analog inputs are specified as 9 AN n where n is the number 1 or 2 TTL Outputs The DMC 14XX provides three general use outputs an output compare and 4 status outputs The general use outputs are TTL and are accessible through the ICM 1460 as OUTI thru OUT3 These
68. using the DMC 1416 with the brush amplifier connect the motor leads to the corresponding screw terminals on the 5 pin power connector labeled M and M If using the DMC 1416 with the brushless amplifier connect the three phases to the respective screw terminals on the 5 pin power connector labeled A B and C In addition the Hall effect sensors must be connected to the controller for proper phase initialization These are connected to the corresponding pins on the 15 Pin D connecter J5 labeled Hall 1 Hall 2 and Hall 3 It is assumed that the encoder is already connected to the ICM 1460 or the 15 Pin D connector and verified operational Step C Reconnect power to controller Reconnect the 5 pin power connector to the DMC 1416 20 60VDC This will power the motor and allow communication with the controller Test the communication by sending the TP command and receiving a valid response Step D Test polarity of the feedback loop With the hardware connections complete the next step is to test the polarity of the feedback loop to limit a runaway situation For this procedure please refer to Step 8a Connect Standard Servo Motor for the section Check the Polarity of the Feedback Loop Note Before the PR moves are issued in the tests but after the error limits have been set the SH command needs to be sent to turn on the servo motor Step 9 Tune the Servo System DMC 14x5 6 The system compensation provides fast and accurate resp
69. 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 Controller 5bV 6 1 4 NEC2505 1 8 RPx2 e IR6210 E VCC 11 IN OUT PWROUT e Controller GND 1 8 RPx3 e 1 0 e OUTC Figure A 8 IOM 1964 High Power Digital Output 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 14XX controller DB 14064 daughter board from the output circuit VOC e V ISO PWROUT 1 External 5 _ Isolated 6 Power Supply GND gg OUTC Figure 4 9 IOM 1964 High Power Output Load and Power Supply Connections 168 Appendices DMC 14x5 6 DMC 14x5 6 The power outputs must be connected in a driving configuration as shown on the previous page Here are the voltage outputs to expect after the Clear Bit and Set Bit commands are given Output Command Result CB Vows Viso SB Vowr GNDigo Standard Digital Outputs The I O banks 2 7 can be configured as optically isolated digital outputs however these banks do not have the high power capacity as in banks 0 1 In order to configure a bank as outputs the optical isolator chips Ux1 and Ux2 are inserted and
70. with that definition The DMC 14XX accepts single ended or differential encoder feedback with or without an index pulse If you are not using the AMP 1460 or the ICM 1460 you will need to consult the appendix for the encoder pin outs for connection to the motion controller The AMP 1460 and the ICM 1460 can accept encoder feedback from a 10 pin ribbon cable or individual signal leads For a 10 pin ribbon cable encoder connect the cable to the protected header connector labeled JP2 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 CHB and INDEX These labels represent channel A channel B and the INDEX pulse respectively 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 Verify proper encoder operation Once the encoder is connected as described above turn the motor shaft and interrogate the position with the instruction TP return The controller response will vary as the motor is turned At this point if TP does not vary with encoder rotation there are three possibilities 1 The encoder connections are incorre
71. 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 Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state NOTE The response of the abort input 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 NOTE The effect of an Abort input is dependent on the state of the off on error function for each axis If the Off On Error function is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no 34 Chapter 3 Connecting Hardware DMC 14x5 6 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 inform
72. 0 pin Connector Pin out Pin Signal Block Bit IN n OUT n Bit No 1 8 72 7 2 9 73 0 3 IO 8 71 6 1 4 9 4 5 IO 8 70 5 6 IO 9 75 2 7 IO 8 69 4 8 IO 9 76 3 9 IO 8 68 3 10 IO 9 TI 4 11 8 67 2 12 9 78 5 13 IO 8 66 1 6 79 9 14 15 IO 8 65 0 16 IO 9 80 7 17 7 64 7 18 GND GND 19 IO 7 63 6 20 GND GND 21 7 02 5 22 GND GND 23 IO 7 61 4 DMC 14x5 6 Appendices 171 GND 60 GND 59 GND 58 GND GND I O 24 25 GND I O 26 27 28 GND 29 30 31 GND VO VO IO IO 5V VO IO VO IO IO Io IO IO IO o0w t TN N 57 56 55 54 53 52 51 50 49 ND ND ND ND ND OD NO 32 33 34 35 36 37 38 39 40 41 5V D w CI sb c ve TAN NH c OO c t 40 41 39 42 38 43 37 44 36 45 35 46 34 47 33 48 32 sb ow cb ow TN cb ow TN FTN TN 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 GND 31 GND 30 GND 29 GND 28 GND 27 GND GND I O 58 59 60 61 GND I O GND 62 63 GND 64 65 GND 66 67 GND 68 DMC 14x5 6 172 Appendices 69 70 71 72 73 74 75 76 TI 78 79 80 GND IO Io IO VO VO 5
73. 000 Loop PA BG AM WT 500 TP 30 Chapter 2 Getting Started Interpretation Label Define current position as zero Set initial value of V1 Label for loop Move motor V1 counts Start motion After motion is complete Wait 500 ms Tell position DMC 14x5 6 V1 V1 1000 JP Loop 1 EN Increase the value of V1 Repeat if V1 10001 End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ Execute Program A Example 11 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction 30000 SP 5000 4000 Interpretation Label Define initial position Set target Set speed Start motion Wait until X moved 4000 Tell position End program To start the program command XQ 4B Execute Program B Example 12 Control Variables Objective To show how control variables may be utilized Instruction A DPO PR 4000 SP 2000 BG AM WT 500 B V1l _TP 2 BG AM WT 500 Vil JP 4C V1 0 JP 4B Interpretation Label Define current position as zero Initial position Set speed Move Wait until move is complete Wait 500 ms Determine distance to zero Command move 1 2 the distance Start motion After motion Wait 500 ms Report the value of V1 Exit if position 0 Repeat otherwise End To start the program comman
74. 0msec for tool to be in cutting position Second circle move Clear output bit to raise cutting tool Wait 1000msec for tool to raise Return XY to start DMC 14x5 6 0 4 9 3 X Figure 7 2 Motor Velocity and the Associated Input Output signals DMC 14x5 6 Chapter 7 Application Programming 129 THIS PAGE LEFT BLANK INTENTIONALLY 130 Chapter 7 Application Programming DMC 14x5 6 Chapter 8 Hardware amp Software Protection Introduction The DMC 14XX 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 14XX is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 14XX Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 14XX includes hardware input and output protection lines for error and mechanical limit conditions These include Output Protection Lines DMC 14x5 6 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 condition is enabled
75. 15 1416 1425 series controller with the DB 14064 daughter board module 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 160 Appendices DMC 14x5 6 DMC 14x5 6 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 n 2 n 4 n 4 8 ns5 16 ng 32 n 64 ng 128 where n represents the block If the n value is a one then the block of 8 I O points is to be configured as an output If the n value is a zero then the block of 8 I O points will be configured as an input For example if block 4 and 5 is to be configured as an output CO 12 is issued BEEN MN NE 49 4 1 CN 72 4 o9 73 7 12 LI LS The simplest method for determining n Step 1 Determine which 8 bit I O blocks to be configured as outputs Step 2 From the table determine the decimal value for each I O block to be set as an output Step 3 Add up all of the values determined in step 2 This is the value to be used for n For example if blocks 2 and 3 are to be outputs then n is 3
76. 2 63 67 190 Index Vector Mode Circle 127 28 Circular Interpolation 65 67 116 127 Clear Sequence 60 62 66 67 Ellipse Scale 67 Feedrate 62 66 67 101 127 28 Tangent 56 Vector Speed 60 66 67 101 128 Wire Cutter 126 WSDK 152 Z Zero Stack 109 125 DMC 14x5 6
77. 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 sec 2 BG Begin motion EN End program Programmable Hardware I O Digital Outputs The DMC 14XX has an 3 bit uncommitted output port for controlling external events For example Instruction Interpretation SB3 Sets bit 3 of output port Clears bit 1 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 Interpretation OB1 POS Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 OB 2 IN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 DMC 14x5 6 Chapter 7 Application Programming 123 OB 3 GIN 1 amp IN 2 Set Output 3 only if Input 1 and Input 2 are high OB 2 COUNT 1 Set Output 2 if element 1 in the array COUNT is non zero The output port can be set by specifying an 3 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 3 bit output port where 20is output 1 2lis output 2 and so on A 1 designates that the output is on For example Instruction Interpretation OP6 Sets outputs 2 and 3 of output port to high other bits are 0 21 22 6 Clears all bits of output port to zero OP 7 Sets all bits of output port to
78. 3 4 34 1 15 4 33 0 17 3 32 7 19 3 31 6 21 3 30 5 23 3 29 4 25 3 28 3 27 3 27 2 29 3 26 1 31 3 25 0 33 2 24 7 35 2 23 6 37 2 22 5 39 2 21 4 41 2 20 3 162 Appendices DMC 14x5 6 DMC 14x5 6 18 50 PIN IDC Pin O O O 5V O O O O O O O O GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND Signal 1 0 VO VO 1 0 1 0 y o 1 0 1 0 1 0 1 0 y o VO y o y o 1 0 1 0 y o 1 0 VO 5 1 0 1 0 O1O1 071 O1 O1 O1 C101 NNN Block ODD O Bit IN n OUT n 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 80 79 78 2 5 4 Bit No AON Appendices 3 IOM 1964 Opto Isolation Module for Extended I O Controllers Description 164 Appendices 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 4 9 3 9 2 75 9 1 9 0 9 GND GND GND GND E GND 2 GND GND GND GND GND GND GND GND GND z GND GND
79. 4 Index 156 Quadrature 156 Error Handling 93 Error Code 107 114 117 19 126 27 Error Handling 33 106 7 132 34 Error Limit 19 20 35 107 131 33 DMC 14x5 6 Off On Error 19 34 35 131 133 Example Wire Cutter 126 Execute Program 31 F Feedrate 62 66 67 101 127 28 FIFO 48 Filter Parameter Damping 27 136 140 Gain 119 Integrator 27 140 144 45 PID 22 140 144 149 Proportional Gain 27 140 Stability 135 36 140 146 Find Edge 34 46 Formatting 119 12022 Variable 32 Frequency 5 86 146 48 Function 34 49 60 77 78 91 95 99 101 103 107 110 15 119 20 Functions Arithmetic 91 103 111 113 123 G Gain 8 119 Proportional 27 140 Gear Ratio 69 Gearing 55 56 68 70 152 H Halt 61 95 99 124 Abort 33 34 60 66 131 133 151 Off On Error 19 34 35 131 133 Stop Motion 60 66 108 134 Hardware 33 123 131 Address 115 17 184 Amplifier Enable 35 131 Offset Adjustment 135 Output of Data 119 TTL 5 33 35 131 Home Input 34 114 Home Inputs 87 Homing 34 Find Edge 34 I O Amplifier Enable 35 131 Digital Input 33 35 112 124 Digital Output 112 123 Home Input 34 114 Index 187 Output of Data 119 TTLS 33 35 131 ICB 1460 8 ICM 1100 18 19 35 Independent Motion Jog 59 69 75 100 101 133 Index 156 Index Pulse 19 34 ININT 107 8 Input Interrupt 101 107 8 125 ININT 107 8 Input of Data 118 Inputs Analog 115 Index 156 Interconnect Module 157
80. 4 at 2 msec etc DMC 14x5 6 Chapter 6 Programming Motion 75 The programmed commands to specify the above example are Instruction Description A Label 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 DT4 Specifies the third time interval 2 ms CD 48 WC Specifies the third position increment Exits contour mode EN POSITION COUNTS 336 Seu NEU ene 288 ee 240 12 96 dax TIME ms 1 1 1 0 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 i SEGMENT 3 Figure 6 5 The Required Trajectory Additional Commands The command WC is used as a trippoint When Complete or Wait for Contour Data This allows the DMC 14XX 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 76 Chapter 6 Programming Motion DMC 14x5 6 CM XY Specifies which axes for contouring mode Any non contouring axes may be operated in other modes Specifies position increme
81. 49 WSDK 152 Special Label 93 133 Specification 60 62 67 Stability 83 135 36 140 146 Stack 106 109 125 Zero Stack 109 125 Status 49 53 62 96 98 117 Interrogation 27 53 54 62 68 119 120 Stop Code 53 117 136 Tell Code 53 Step Motor 86 KS Smoothing 56 61 62 66 67 85 86 Step Motors 8 11 156 PWM 155 56 155 56 155 56 155 56 Stop Abort 33 34 60 66 131 133 151 Stop Code 53 107 114 117 19 117 126 27 136 Stop Motion 60 66 108 134 Stop Motion or Program 157 Subroutine 33 65 93 102 8 125 132 33 157 Automatic Subroutine 106 107 Synchronization 5 70 Syntax 49 50 T Tangent 56 Teach 80 Data Capture 116 17 Latch 53 Play Back 56 117 Record 56 76 80 115 117 Tell Code 53 Tell Error 53 Position Error 107 8 114 116 17 Tell Position 47 53 Tell Torque 53 Terminal 33 49 114 Theory 28 137 Damping 27 136 140 Digital Filter 49 144 45 147 49 Modelling 137 140 41 144 PID 22 140 144 149 Stability 135 36 140 146 Time Clock 114 TIME 114 15 Time Interval 75 76 80 116 Timeout 13 99 107 108 MCTIME 99 107 108 Torque Limit 21 Trigger 91 98 100 102 9 Trippoint 57 61 62 67 76 100 105 106 153 Trippoints 31 Index 189 Troubleshooting 135 TTL 5 33 35 131 Tuning SDK 27 Stability 135 36 140 146 WSDK 152 U Upload 152 User Unit 123 V Variable 32 Internal 103 113 114 Vector Acceleration 62 63 67 128 Vector Deceleration 6
82. 5 Pin MOLEX Brushless Config Standard Servo 1 MOTOR A Motor 2 MOTOR B Motor 3 MOTOR C Ground 4 GROUND 5 V INPUT 11 RS232 Main port DB 9 Pin Male 1 RTS 6 RTS 2 Transmit data output 7 CTS 3 Receive Data input 8 RTS 4 CTS 9 No connect 5 Ground DMC 14x5 6 Appendices 155 Pin Out Description OUTPUTS Analog Motor Command Amp Enable PWM STEP OUT PWM STEP OUT Sign Direction Error Output 1 Output 3 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 Signal to disable and enable an amplifier Amp Enable goes low on Abort and OE1 PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a conventional amplifier that accepts a 10 Volt analog signal this pin is not used and should be left open The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM signal is 2 duty cycle for full negative voltage 50 for 0 Voltage and 99 8 for full positive voltage 24kHz switching frequency In the Sign Magnitude Mode Jumper SM the PWM signal is 0 for 0 Voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output 50kHz switching fre
83. 6 is a single axis Ethernet controller integrated with an internal brush or brushless power amplifier Performance capability of these controllers includes 12 MHz encoder input frequency 16 bit motor command output DAC 2 billion counts total travel per move 250 usec minimum sample rate and non volatile memory for program and parameter storage Designed for maximum flexibility the DMC 14XX can be interfaced to a variety of motors and drives including step motors brush and brushless servo motors and hydraulics The DMC 1415 can also be configured to provide sinusoidal commutation for brushless motors The controller accepts feedback from a quadrature linear or rotary encoder with input frequencies up to 12 million quadrature counts per second An additional encoder input is available on the DMC 1415 and DMC 1416 for gearing or cam applications hand wheel inputs or dual loop operation Modes of motion include jogging point to point positioning electronic cam electronic gearing and contouring Several motion parameters can be specified including acceleration and deceleration rates and slew speed The DMC 14XX also provides motion smoothing to eliminate jerk For synchronization with outside events the DMC 14XX provides uncommitted I O The DMC 1415 and DMC 1416 provide 7 digital inputs 3 digital outputs and 2 analog inputs The DMC 1425 provides up to 3 digital inputs 3 digital outputs and 2 analog inputs Committed digital inputs are provid
84. 61 95 99 101 2 124 Off On Error 131 133 Off On Error 19 34 35 46 131 133 Offset Adjustment 135 Operand Internal Variable 103 113 114 Operators Bit Wise 103 111 Optoisolation Home Input 34 114 Output Amplifier Enable 35 131 ICM 1100 19 35 Motor Command 21 22 144 Output of Data 119 Outputs Interconnect Module 157 P PID 22 140 144 149 DMC 14x5 6 Play Back 56 117 POSERR 106 8 132 33 Position Error 107 8 114 116 17 Position Capture 90 Latch 53 Teach 80 Position Error 19 35 107 8 114 116 17 131 33 136 139 POSERR 106 8 Position Latch 90 157 Position Limit 132 Program Flow 92 98 Interrupt 101 106 8 125 Stack 106 109 125 Programmable 113 14 123 132 EEPROM 3 Programming Halt 61 95 99 101 2 124 Proportional Gain 27 140 Protection Error Limit 19 20 35 107 131 33 Torque Limit 21 PWM 4 155 56 155 56 155 56 155 56 Q Quadrature 5 123 126 132 143 156 Quit Abort 33 34 60 66 131 133 151 Stop Motion 60 66 108 134 R Record 56 76 80 115 117 Latch 53 Teach 80 Register 114 Reset 33 36 47 102 131 133 153 154 155 S Scaling Ellipse Scale 67 S Curve 85 Motion Smoothing 56 85 86 SDK 27 Selecting Address 115 17 184 Serial Port 12 Servo Design Kit 8 SDK 27 Sine 56 74 112 Single Ended 5 19 21 Slew 56 99 101 126 Slew Speed 157 Smoothing 56 61 62 66 67 85 86 Software DMC 14x5 6 SDK 27 Terminal
85. 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 both directions Note When using Galil Windows software the timeout must be set to a minimum of 10 seconds time out 10000 when executing the BS command This allows the software to retrieve all 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 occurs 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 It is very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configur
86. 9 ACMD Phase B also Sign when JP3 1 Reset 20 Error 2 Amp Enable 21 ACMD also PWM when JP3 jumpered 3 Output 3 22 Output 2 4 Output 1 23 Circular Compare 5 Analog 1 24 Analog 2 6 Input 7 25 Input 6 7 Input 5 26 Input 4 8 Input 3 27 Input 2 28 Forward Limit 10 5V 29 Reverse Limit 11 Ground 30 Home 12 12V 31 12V 13 Ground 32 Main A 14 Main A 33 Main B 15 Main B 34 Main Index 16 Main Index 35 Auxiliary A 36 Auxiliary B 37 Abort These inputs are TTL active low and will be activated when set to OV J3 DMC 1425 General I O 37 PIN D type Female 1 Reset 2 Amp Enable sign Y 20 Error Y step 21 ACMDX X step 3 Output 3 22 Output 2 4 Output 1 23 Circular Compare 5 Analog 1 24 Analog 2 DMC 14x5 6 Appendices 153 6 Y Encoder Index Input 7 id 7 Reverse Limit Y Input 5 12 8 Input 3 Y Encoder Index 9 Input 1 and X latch 104 5V 11 Ground 12 12V 13 Ground 14 X Encoder A 15 X Encoder B 16 X Encoder Index 17 Y Encoder A 18 Y Encoder B 19 ACMDY sign X 25 Home Y Input 6 26 Forward Limit Y Input 4 27 Input 2 and Y latch 28 Forward Limit X 29 Reverse Limit X 30 Home X 31 12v 32 X Encoder A 33 X Encoder B 34 X Encoder Index 35 Y Encoder A 36 Y Encoder B 37 Abort These inputs are TTL active low and will be activated when set to O
87. DMC 14x5 6 Motion Smoothing The DMC 14XX 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 Using the IT and VT Commands S 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 has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following commands IT x y Independent time constant VTn Vector time constant The command IT is used for smoothing independent moves of the type JG PR PA and the command VT is used to smooth vector moves of the type VM and LM The smoothing parameters x y 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 th
88. IP or UDP IP packets A good example of this is Telnet a utility that comes with most Windows systems Chapter 4 Communication 43 Data Record The DMC 14x5 provide a block of status information with the use of a single command QR This command along with the QZ command can be very useful for accessing complete controller status The QR command will return 4 bytes of header information and specific blocks of information as specified by the command arguments QR ABCDEFGHST Each argument corresponds to a block of information according to the Data Record Map below If no argument is given the entire data record map will be returned Note that the data record size will depend on the number of axes Data Record Map DATA TYPE ae cC mom e oum rcc ere ee 2 44 Chapter 4 Communication ITEM 1 byte of header 2 byte of header 3 byte of header 4 byte of header sample number general input 0 general input 1 general input 2 general input 3 general input 4 general input 5 general input 6 general input 7 general input 8 general input 9 general output 0 general output 1 general output 2 general output 3 general output 4 general output 5 general output 6 general output 7 general output 8 general output 9 error code general status segment count of coordinated move for S plane coordinated move
89. JS instruction interrupt or automatic routine such 85 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 command at the end of the LIMSWI routine Auto Start Routine The DMC 14XX has two special labels 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 On power up if there is a checksum error then AUTO does not execute but AUTOERR executes instead The program must be saved into non volatile memory using the command BP 106 Chapter 7 Application Programming DMC 14x5 6 Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 14XX program sequences The DMC 14XX can monitor several important conditions in the background These conditions include c
90. M Memory Interrogation Commands For debugging the status of the program memory array memory or variable memory the DMC 14XX 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 1415 will have a maximum of 2000 array elements in up to 14 arrays If an array of 100 elements is defined the command DM will return the value 1900 and the command DA will return 13 96 Chapter 7 Application Programming DMC 14x5 6 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 la
91. Motion 77 ACCELERATION VELOCITY POSITION Figure 6 6 Velocity Profile with Sinusoidal Acceleration The DMC 14XX can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X 501 955 sin 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 78 Chapter 6 Programming Motion DMC 14x5 6 Contour Mode Example Instruction POINTS DM POS 16 DM DIF 15 C 0 T 0 A V1 50 T V2 3 T V3 955 SIN V2 V1 V4 INT V3 POS C V4 T T 8 1 lt 16 0 1 DIF C POS D POS C 1 JP lt 15 EN RUN CMX DT3 C 0 E CD DIF C WC 1 JP lt 15 EN Interpretation Program defines X points Allocate memory Set initial conditions C is index T is time in ms Argument in degrees Compute position Integer value of V3 Store in array POS Program to find position differences Compute the difference and store End first program Program to run motor Contour Mode 4 millisecond intervals Contour Distance is in DIF Wait for completion Stop Contour End the
92. NET utility in the Registry Select Find Ethernet Controller under Non PnP Tools and the DMCNET window will appear and search for all controllers on the network Once DMCNET is finished searching the user can highlight one of the listed controllers and give it an IP address by selecting the Assign button From there the user can add the controller to the Galil registry by selecting the Register button The Connects button in DMCNET will provide a list of communication handles the controller maintains Furthermore the Free Handles button frees all handles Show Galil Ethernet Controller Network File Serial Number IP Address Available Sessions DMC2280 Rev hbeta 10 0 41 43 Galil DMC 2120 2 axis controller revision hbeta 10 0 41 50 Assign Connections Free Handles Register Refresh Close Ready DMCNET Utility If the two methods above are unsuccessful in assigning an IP address to a controller the third option is connecting to the controller serially and using the A command to assign the IP address See the controller command reference for information on the command Although the IP address can be assigned serially the user must still register the controller as an Ethernet controller in order to communicate it over Ethernet Follow the steps above for registering an Ethernet controller but don t click the Assign IP Address button Just click F
93. NSIBLE 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 Appendices 185 Index A Abort 33 34 60 66 131 133 151 Off On Error 19 34 35 131 133 Stop Motion 60 66 108 134 Absolute Position 56 57 100 104 Absolute Value 71 104 112 132 Acceleration 101 2 118 123 181 Address 115 17 184 Jumpers 39 Ampflier Gain 4 Amplifier AMP 1460 8 Amplifier Enable 35 131 Amplifier Gain 141 145 147 Amplifiers 8 156 Connections 157 Analog Input 115 Analysis SDK 27 WSDK 152 Arithmetic Functions 91 103 111 113 123 Array 3 56 65 77 80 91 96 103 111 114 22 123 152 Automatic Subroutine 106 107 CMDERR 107 109 LIMSWI 33 106 7 132 34 MCTIME 99 107 108 POSERR 106 8 132 33 Auxiliary Encoder 80 85 Dual Encoder 53 117 B Backlash 56 Backlash Compensation 83 Dual Loop 56 80 85 Baud Rate 15 39 Begin Motion 93 96 100 101 107 8 117 19 123 125 Binary 49 52 186 Index Bit Wise 103 111 Burn EEPROM 3 6 Capture Data Record 56 76 80 115 117 Circle 127 28 Circular Interpolation 65 67 127 Clear Sequence 60 62 66 67 Clock 114 CMDERR 107 109 Code 107 114 117 19 126 27 Command Syntax 49 50 Command Summary 54 57 59 62 67 114 116 Commanded Po
94. Note On the ICM 1460 the PULSE signal is output to pin 4 ACMD and the direction signal is output to pin 38 ACMD2 Stepper Motor Jumper Selection Rev E or newer The newest version of the DMC 1425 the controller is configurable for stepper or servo through jumpers instead of needing rework done by the factory The configuration is as follows JP2 JP2 JP1 JP3 JP3 SMX SMY Y Step SD MC X Servo Y Servo Both X Servo Y Stepper X X Top Row Bottom Row X Stepper Y Stepper X X X Both Note1 When the Y axis is set for stepper mode the pulse output for the Y axis is on the same pin as the error output meaning that the red LED will be on To permanently disable the red LED contact Galil Note2 When the controller is configured for X servo and Y stepper the amp enable signal for the X axis is no longer available as it is used for Y sign 10 Chapter 2 Getting Started DMC 14x5 6 O JP3 JP3 O O SD MC SD MC Setting for analog motor command Setting for step direction output Figure 2 3 Jumper settings for motor command output Setting the Baud Rate on the DMC 14XX The jumpers labeled 96 and 12 at JP1 allows the user to select the serial communication baud rate The baud rate can be set using the following table SWITCH SETTINGS BAUD RATE 2 4 OFF OFF 19200 The default ba
95. 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 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 7OGRCM32 HL OPTO 22 G4PB24 Note for interfacing to OPTO 22 G4PB24 When using the OPTO 22 G4PB24 I O mounting rack the user will only have access to 48 of the 64 I O points available on the controller Block 5 and Block 9 must be configured as inputs and will be grounded by the I O rack J 50 PIN IDC Pin Signal Block Bit IN n Bit No OUT n 1 4 40 7 3 4 39 6 5 4 38 5 7 4 37 4 9 4 36 3 11 4 35 2 1
96. O27 1 026 1 025 OUTC25 32 I OC25 32 OUTC25 32 I OC25 32 PWROUT32 PWROUT31 PWROUT30 PWROUT29 PWROUT28 PWROUT27 PWROUT26 PWROUT25 I O24 I O23 1 022 1 021 1 020 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 Silkscreen on Rev A board is incorrect for these terminals O O O Gc Qum Appendices 175 CB 50 80 Adapter Board The CB 50 80 adapter board can be used to convert the 2 50 Pin Ribbon Cables from a DB 14064 to a CABLE 80 The CABLE 80 is used to connect to the IOM 1964 Connectors JC8 and JC6 50 Pin Male IDC J9 80 Pin High Density Connector AMP PART 3 178238 0
97. P 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Similar to the gearing mode the DMC 1425 uses only X and Y main axes as the master or slave while the DMC 1415 and DMC 1416 use the auxiliary encoder as the 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 shown in Figure 6 4 Step 1 Selecting the master axis DMC 1425 only 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 p is the selected master axis 70 Chapter 6 Programming Motion DMC 14x5 6 In this example x axis will be the master Thus we specify EAX Step 2 Specify the master cycle and the change in the slave axes In the electronic cam mode the position of the master is always expressed 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 bot
98. SRI a E 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 Variables For applications that require a parameter that is variable the DMC 14XX provides 126 variables These variables can be numbers or strings A program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by program calculations For example a cut to length application may require that a cut length be variable 112 Chapter 7 Application Programming DMC 14x5 6 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 14XX allows the user to create up to 126 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
99. Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Size Variable Range Variable Resolution Array Size Program Size Fast Update Rate Mode Normal Firmware Fast Firmware 250 usec 125 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 126 user variables 2 billion 1 104 2000 elements 14 arrays 500 lines x 80 characters The DMC 14x5 6 can operate with much faster servo update rates This mode is known as fast mode and allows the controller to operate with the following update rates 1 2 axis 125 usec In order to run the motion controller in fast mode the fast firmware must be uploaded This can be done through the Galil terminal software such as Galil SmartTerminal and WSDK The fast firmware can be downloaded from the Galil website To set the update rate use command TM When the controller is operating with the fast firmware the following functions are disabled Gearing mode Ecam mode 152 Appendices DMC 14x5 6 Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in thread 2 8 Tell Velocity Interrogation Command TV Connectors for DMC 14XX J3 DMC 1415 General I O 37 PIN D type Female 9 Input 1 and latch 17 Auxiliary A 18 Auxiliary B jumpered 1
100. The Windows Servo Design Kit WSDK32 which is useful for tuning servos and viewing useful controller information can be downloaded off the CD as well However WSDK32 is a purchase only software package and is password protected on the CD Contact Galil for purchase information Using Windows 98 Second Edition SE NT 4 ME 2000 or XP The Galil Software CD ROM will open an HTML page automatically as soon a Instead Explore the CD and go to the July2000 CD folder To install the basic communications software click on DMCTERM and then run the application DMCTERM The other basic terminal software is called DMCWIN32 and is located under July2000 CD DMCWIN The Windows Servo Design Kit WSDK32 which is useful for tuning servos and viewing useful controller information can be downloaded off the CD as well However WSDK32 is a purchase only software package and is password protected on the CD Contact Galil for purchase information Step 5 Establishing Communication between the DMC 14XX and the host PC Communicating through the RS 232 Serial Communications Port Connect the DMC 14XX serial port to your computer via the Galil CABLE 9PIN D RS 232 Cable Using Galil Software for DOS To communicate with the DMC 14XX type TALK2DMC at the prompt Register the controller as a DMC 1412 and assign the proper baud rate and comm port Once you have established communication the terminal display should show a colon If you do not receive a colon
101. The conditional statements are combined in pairs using the operands amp and The amp operand between 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 14XX executes operations from left to right For further information on Mathematical Expressions and the bit wise operators amp and see pg 110 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 Chapter 7 Application Programming 103 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 i
102. V Pins 6 7 25 and 26 represent Index Y Home Y Reverse Limit Y and Forward Limit Y The states of these inputs are mapped to inputs 7 6 5 and 4 respectively Standard input interrogation commands can be used to read these inputs MG IN n as well as the TS and MG_LFY or MG LRY switch commands Pin 8 has the option to be used as Y Encoder instead of Input 3 When configured for stepper mode J3 DMC 1416 General I O 37 PIN D type Female 1 Reset Amp Enable Output 3 Output 1 2 3 4 5 Analog 1 6 Input 7 7 Input 5 8 Input 3 2 9 Input 1 and latch 2 10 5V 11 Ground 12 12V 13 Ground 14 20 Error 21 NC 22 Output 2 23 Circular Compare 24 Analog 2 25 Input 6 26 Input 4 27 Input 2 28 Forward Limit 29 Reverse Limit 30 Home 31 12v 32 33 154 DMC 14x5 6 15 MB 34 IDX 16 IDX 35 Auxiliary A 17 Auxiliary A 36 Auxiliary B 18 Auxiliary B 37 Abort 19 NC If the controller is older than Rev C These pins will have no connection To add encoder signals in this case contact Galil These inputs are active low and will be activated when set to OV 14 DMC 1416 Encoders 15 Pin D type 1 A 9 VCC 2 GROUND 10 NC 3 A 11 A 4 B 12 B 5 1 13 1 6 HALL 1 14 HALL 2 7 HALL 3 15 GROUND 8 NC 15 DMC 1416 Power
103. V Screw Terminal Listing DMC 14x5 6 REV A B TERMINAL tn FWY N N N N NYRR Re RP e 4 Ln A LU Ne DN amp WN KF Rev A B boards orange and Rev C boards black have the pinouts listed below REV C TERMINAL wo A N 12 11 14 13 16 15 18 17 20 19 22 21 24 NN NY NY 0 LABEL GND 5V GND 5V 1 080 1 079 1 078 I O77 I O76 I O75 I O74 I O73 OUTC73 80 I OC73 80 I O72 I O71 I O70 I O69 I O68 I O67 I O66 I O65 OUTC65 72 I OC65 72 26 25 24 23 22 21 20 19 18 17 DESCRIPTION Ground 5V DC out Ground 5V DC out I O bit 80 I O bit 79 I O bit 78 I O bit 77 I O bit 76 I O bit 75 I O bit 74 I O bit 73 Out common for I O 73 80 I O common for I O 73 80 I O bit 72 I O bit 71 I O bit 70 I O bit 69 I O bit 68 I O bit 67 I O bit 66 I O bit 65 Out common for I O 65 72 I O common for I O 65 72 GND N UU BR 5V BANK N A N A N A N A OO OO gt a OC OC OC OC O A NNN Appendices 173 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 69 174 Appendices 23 26 25 28 27 30 29 32 31 34 33 36 35 38 37 40 39 42 41 44 43 46 45 48 47 50 49 52 51 54 53 56 55 58 57 60
104. above Programming error Avoid resetting position error at end of move with SH command 136 Chapter 9 Troubleshooting DMC 14x5 6 Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Fig 10 1 COMPUTER DMC 14x5 6 CONTROLLER DRIVER ENCODER im 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 Chapter 10 Theory of Operation 137 The highest level of control is the motion program This can b
105. ake HMX read 1 initially and a normally closed switch will make _HMX read zero Furthermore with CN 1 a normally open switch will make HMX read 0 initially and a normally closed switch will make HMX read 1 Therefore the CN command will need to be configured properly to ensure the correct direction of motion in the home sequence Upon detecting the home switch changing state the motor begins decelerating to a stop Note The direction of motion for the FE command also follows these rules for the state of the home input Stage 2 The motor then traverses at 256 counts sec in the opposite direction of Stage 1 until the home switch toggles again If Stage 3 is in the opposite direction of Stage 2 the motor will stop immediately at this point and change direction If Stage 2 is in the same direction as Stage 3 the motor will never stop but will smoothly continue into Stage 3 Stage 3 The motor traverses forward at 256 counts sec until the encoder index pulse is detected The motor then stops immediately The DMC 141X defines the home position as the position at which the index was detected and sets the encoder reading at this point to zero DMC 14x5 6 Chapter 6 Programming Motion 87 88 Chapter 6 Programming Motion The 4 different motion possibilities for the home sequence are shown in the following table Direction of Motion Switch Type CN Setting Initial HMX state Stage 3 Normally Open Reverse Forward Forwa
106. al statement Label to be used for a loop Chapter 7 Application Programming 105 JP WAIT IN 1 0 IN 2 0 Loop until both input 1 and input 2 are not active RIO End Input Interrupt Routine without restoring trippoints Subroutines A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program location where the subroutine was called unless the subroutine stack is manipulated as described in the following section Example An example of a subroutine which draws a square 500 counts per side is given below The square is drawn at vector position 1000 1000 Instruction Interpretation M Begin Main Program 1 Clear Output Bit 1 pick up pen VP 1000 1000 LE 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 1 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
107. 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 14XX Find Edge FE Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX return BGX return where X could be any axis on the controller X or Y 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 or Y Find Index will cause the motor to accelerate to the user defined slew speed
108. aracters 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 statement This is useful when a text string needs to surround a numeric value Chapter 7 Application Programming 119 Example A JG 50000 BGX ASX MG The Speed is TVX F5 1 N EA MG counts sec EA EN When A is executed the above example will appear on the screen on handle A as The speed is 50000 counts sec Summary of Message Functions 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 Displaying Variables and Arrays Variables and a
109. atements 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 94 Chapter 7 Application Programming DMC 14x5 6 REM HALF CIRCLE MOTION VP 0 3000 REM TOP LINE 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 DMC 14x5 6 The DMC 14XX can run up to two independent programs simultaneously These programs are called threads and are numbered 0 and 1 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 A n Where n indicates the thread number To halt the executi
110. ation 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 1460 or AMP 1460 as INI IN7 The inputs can be accessed directly from the 37 Pin D cable or connector on the controller also Fora description of the pin outs consult the appendix 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 Functions and Expressions NOTE For systems using the ICM 1460 or AMP 1460 interconnect module there is an option to provide opto isolation on the inputs In this case the user provides an isolated power supply 45V to 24V and ground For more information consult Galil Amplifier Interface The DMC 14XX 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 14XX also provides an amplifier enable signal AEN This signal is activated under the following conditions the watchdog time
111. bels 126 max _UL contains the number of available variables 126 max _DA contains the number of available arrays 14 max _DM contains the number of available array elements 2000 max _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 specify 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 Instruction Interpretation 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 1 Tell Error Code 7 Command not valid while Command not valid while running 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 14x5 6 Chapter 7 Application Programming 97 Program Flow Commands The DMC 14XX provides instructions to control program flow The DMC 14XX program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements
112. c 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 or Y 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 low CN 1 no connection or a 5V input will be read as a 1 while grounding the switch will return a 0 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 0 while grounding the switch will return a 1 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 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 DMC 14x5 6 Chapter 3 Connecting Hardware 33 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
113. cam PA 500 Y starting position SP 5000 Y speed BGY Move Y motor AM After Y moved All Wait for start signal EG 1000 Engage slave AI 1 Wait for stop signal EQ 1000 Disengage slave EN End The following example illustrates a cam program with a master axis X and a single slave Y Instruction Interpretation A V1 0 Label Initialize variable 0 0 BGXY AMXY Go to position 0 0 on X and Y axes EA X Z axis as the Master for ECAM EM 4000 0 Change for X is 4000 zero for Y EP400 0 ECAM interval is 400 counts with zero start ET 0 0 When master is at 0 position 1st point ET 1 20 2nd point in the ECAM table ET 2 60 3rd point in the ECAM table ET 3 120 4th point in the ECAM table ET 4 140 5th point in the ECAM table ET 5 140 6th point in the ECAM table ET 6 140 7th point in the ECAM table 74 Chapter 6 Programming Motion DMC 14x5 6 ET 7 120 ET 8 60 ET 9 20 ET 10 0 EB 1 JGX 4000 EG 0 BGX LOOP JP LOOP 10 EQ 2000 MF2000 STX EB 0 EN Contour Mode 8th point in the ECAM table 9th point in the ECAM table 10th point in the ECAM table Starting point for next cycle Enable ECAM mode Set Z to jog at 4000 Engage both X and Y when Master 0 Begin jog on Z axis Loop until the variable is set Disengage Y when Master 2000 Wait until the Master goes to 2000 Stop the Z axis motion Exit the ECAM mode End of the program The DMC 14XX also provides a contouring mode This mode allows any arbitrary posi
114. 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 Note that only one pair of axes can be specified for coordinated motion at any given time Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is 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 DMC 14x5 6 Chapter 6 Programming Motion 65 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 The command CR 1 0 6 define a circular arc with a radius starting angle of and a traversed angle The notation for is that zero corresponds to the positive horizontal direction and for both 0 and 6 the counter clockwise CCW rotation is positive Up to 255 segments of CR or VP may be specified in a single sequence and must be ended wit
115. command After the instruction is decoded the DMC 14x5 returns a response to the port from which the command was generated If the instruction was valid the controller returns a colon or a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the main RS 232 port back through the RS 232 port and to commands which are sent via the Ethernet port back through the Ethernet port For instructions that return data such as Tell Position TP the DMC 14x5 will return the data followed by a carriage return line feed and It is good practice to check for after each command is sent to prevent errors An echo function is provided to enable associating the DMC 2x00 response with the data sent The echo is enabled by sending the command EO 1 to the controller Unsolicited Messages Generated by Controller DMC 14x5 6 When the controller is executing a program it may generate responses which will be sent via the main RS 232 port or Ethernet port This response could be generated as a result of messages using the MG or IN command OR as a result of a command error These responses are known as unsolicited messages since they are not generated as the direct response to a command Messages can be directed to a specific port using the specific Port arguments see MG and IN commands described in the Command Reference If the port is not explicitly given unsolicited messages will b
116. controller also has 3 uncommitted TTL inputs 3 TTL outputs and 2 analog inputs 12 bit 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 switch 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 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 logi
117. ct 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 Chapter 2 Getting Started 19 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 sinusoidal commutation only Please consult factory before operating with sinusoidal commutation Hall sensors are only used with sinusoidal commutation on the DMC 1415 and are not necessary for proper operation The use of hall sensors allows the controller to automatically estimate the commutation phase upon reset and also provides the controller the ability to set a more precise commutation phase Without hall sensors the commutation phase must be determined manually The hall effect sensors are connected to the digital inputs of the controller These inputs can be used with the general purpose inputs bits 7 Each set of inputs must use inputs that are in consecutive order The input lines are specified with the command BI For example if the Hall sensors are connected to i
118. ction H s 1 1 sT 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 144 Chapter 10 Theory of Operation DMC 14x5 6 System Analysis DMC 14x5 6 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 14XX controller and the following parameters K 0 1 Nm A Torque constant J22404 kg m System moment of inertia Rz2 Q Motor resistance K 4 Amp Volt Current amplifier gain KP 12 5 Digital filter gain KD 245 Digital filter zero 0 No integrator N 500 Counts rev Encoder line density T 1 ms Sample period The transfer function of the system elements are Motor M s P I Kt Js2 500 82 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 5 245 0 001 Therefore D z 1030 z 0 95 Z Accordingly the coefficients of the continuous filter are P 50 D 0 98 The filter equation may be written in the continuous equivalent form G s 50 0 985 098 5 51 The system elements are shown in Fig 10 7 Chapter 10 Theory of Operation 145 FILTER ZOH DAC AMP MOTOR
119. ction 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 and Y 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 Enable off on error for X and Y OE 0 1 Enable off on error for Y axis and disable off on error for X axis Automatic Error Routine The POSERR label causes the statements following to be automatically 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 Instruction Interpretation A JP Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor
120. d DMC 14x5 6 Execute Program A Chapter 2 Getting Started 31 This program moves the motor to an initial position of 1000 and returns it to zero on increments of half the distance Note TP is an internal variable which returns the value of the position Internal variables may be created by preceding a DMC 141X instruction with an underscore Example 13 Control Variables and Offset Objective Illustrate the use of variables in iterative loops and use of multiple instructions on one line Instruction A KIO DPO V1 8 V2 0 B OF V1 WT 200 V2 _TP JP C ABS V2 lt 2 MG V2 1 1 1 JP 4B Interpretation Set initial values Initializing variables to be used by program Program label B Set offset value Wait 200 msec Set variable V2 to the current position Exit if error small Report value of V2 Decrease Offset Return to top of program End This program starts with a large offset and gradually decreases its value resulting in decreasing error 32 Chapter 2 Getting Started DMC 14x5 6 Chapter 3 Connecting Hardware Overview The DMC 1415 and DMC 1416 provide digital inputs for forward limit reverse limit home and abort signals The controller also has 7 uncommitted TTL inputs for general use 3 TTL outputs and 2 analog inputs 12 bit The DMC 1425 provides digital inputs for X and Y forward limit X and Y reverse limit X and Y home input and abort input The
121. d 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 134 Chapter 8 Hardware amp Software Protection DMC 14x5 6 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 e Installation Motor runs away when connected to amplifier with Amplifier offset too Adjust amplifier offset no additional inputs large Same as above but offset adjustment does not stop Damaged amplifier Replace amplifier the motor Controller does not read changes in encoder position Wrong encoder Check encoder wiring connections Same as above Bad encoder Check the encoder signals Replace encoder if necessary Same as above Bad controller Connect the encoder to different axis input If it works controller failure Repair or replace DMC 14x5 6 Chapter 9 Troubleshooting 135 Communication Stability Symptom Using DMCWIN DMCDOS DMCTERM or WSDK cannot communicate with the controller over RS 232 Using DMCWIN DMCTERM or WSDK cannot communicate with the controller over Ethe
122. d 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 Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on DMC 1425 A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program 156 Appendices DMC 14x5 6 Reset input A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored Forward Limit Switch When active inhibits motion in forward direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Reverse Limit Switch When active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Home Switch Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Input 1 In
123. des an internal PWM amplifier for connection directly to a brush or brushless motor Either the brush or brushless amplifier must be specified at the time of purchase Sinusoidal Commutation Please consult the factory before operating with sinusoidal commutation Sinusoidal commutation is configured through a single software command BA This setting causes the controller to reconfigure the control axis to output two commutated phases The DMC 1415 requires two DAC outputs for a single axis of commutation Therefore sinusoidal commutation is not Chapter 2 Getting Started 9 available on the DMC 1425 In standard servo operation the DMC 1415 has one DAC for the single axis Issuing the BA command will enable the second DAC for commutation Further instruction for sinusoidal commutation connections are discussed in Step 6 Stepper Motor Operation To configure the DMC 141X for stepper motor operation the controller requires that the command MT be given and jumpers placed to designate stepper motor The installation of the stepper motor jumper is discussed in the following section entitled Configuring Jumpers on the DMC 14XX Further instructions for stepper motor connections are discussed in Step 8c Step 2 Configuring Jumpers on the DMC 14XX Master Reset and Upgrade Jumper JP1 contains two jumpers MR and UP The MR jumper is the Master Reset jumper When MR is connected the controller will perform a master reset upon PC power u
124. dinated motion S refers to the coordinate system that can be used on the card For example BGS Begin coordinated sequence on S coordinate system 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 an application program 50 TTChapter 5 Command Basics DMC 14x5 6 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 1 B axis or 2 data field Bit 0 A axis or 1 data field Datafields Format Datafields must be consistent with
125. distance from the start of the move Only one axis may be specified at a time AR X or Y 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 Halts program execution until after absolute position occurs Only one axis may be specified at a time MF X or Y Halt program execution until after forward motion reached absolute position Only one axis may be specified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs MR X or Y 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 MCXor Y Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW x y sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stop code will be set to 99 An application program will jump to label MCTIME Al n 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 7 for DMC 14XX AS YorS Halts program execution until specified axis has reached its slew speed AT Halts program ex
126. e GA CX indicates that the gearing is the commanded position of X 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 DMC 14x5 6 Command Description GAn Specifies master axes for gearing where X Y or A B for main encoder as master CX CY or CA CB for commanded position Example Electronic Gearing DMC 1415 or DMC 1416 Objective Run a geared motor at a speed of 1 132 times the speed of an external master The master is driven at speeds between 0 and 1800 RPM 2000 counts rev encoder and is connected through the auxiliary encoder inputs Solution Use a DMC 1415 controller where the X axis auxiliary is the master and X axis main is the geared axis GR 1 132 Specify gear ratio 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 Electronic Gearing DMC 1425 Objective Gear an X axis slave motor at a speed of 2 5 times the speed of the Y axis master GAY Specify Y axis as the master for X GR2 5 Specify gear ratio for X to be 2 5 times the Y axis master Chapter 6 Programming Motion 69 Example Gantry Mode In applications where both the mast
127. e They allow the DMC 14XX to make decisions without a host computer For example the DMC 14XX 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 102 Chapter 7 Application Programming DMC 14x5 6 DMC 14x5 6 JP destination logical condition Jump to location if logical condition is satisfied The destination is a program line number or label where the program sequencer will jump if the specified condition is satisfied Note that the line number of the first line of program memory is 0 The comma designates IF The logical condition tests two operands with logical operators Logical operators e gt o y y eea Conditional Statements The conditional statement is satisfied if it evaluates to any value other than zero The conditional statement can be any valid DMC 14XX numeric operand including variables array elements numeric 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 14XX will accept multiple conditions in a single jump statement
128. e 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 14 is specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 20000 10000 10000 20000 Figure A 14 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 RJA 82 15708 360 C D Linear 10000 Total 35708 counts In general the length of each linear segment is Le Xk Yk 180 Appendices DMC 14x5 6 DMC 14x5 6 Where Xk and Yk are the changes in X and Y positions along the linear segment The length of the circular arc is Lk 6 2000 The total travel distance is given by D 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 14 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity
129. e 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 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 14XX 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 Parameters can be set with individual axis specifiers such as JGY 2000 set jog speed for Y axis to 2000 or ACX Y 400000 set acceleration for X and Y axes to 400000 Operand Summary Independent Axis DMC 14x5 6 _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the
130. e modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing Instruction Interpretation PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT 5 Filter value BG X Begin DMC 14x5 6 Chapter 6 Programming Motion 85 ACCELERATION VELOCITY ACCELERATION VELOCITY Figure 6 7 Trapezoidal velocity and smooth velocity profiles Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command smoothes the frequency of step motor pulses Similar to the commands IT and VT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS xy where x y is an integer from 0 5 to 8 and represents the amount of smoothing The command IT is used for smoothing independent moves of the type JG PR PA and the command VT is used to smooth vector moves of the type VM and LM The smoothing parameters x y and n are numbers between 0 5 and 8 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 86 Chapter 6 Programming Motion DMC 14x5 6 Homing The Find Edge FE and Home HM instructions may be used to h
131. e sent to the default port The default port is determined by the state of the USB Ethernet dip switch when the system is reset The controller has a special command CW which can affect the format of unsolicited messages This command is used by Galil Software to differentiate response from the command line and unsolicited messages The command CW1 causes the controller to set the high bit of ASCII characters to 1 of all unsolicited characters This may cause characters to appear garbled to some terminals This function can be disabled by issuing the command CW2 For more information see the CW command in the Command Reference Chapter 4 Communication 47 When hardware handshaking is used characters which are generated by the controller are placed in a single character buffer before they are sent out of the controller When this buffer becomes full the controller must either stop executing commands or ignore additional characters generated for output The command CW 1 causes the controller to ignore all output from the controller while the FIFO is full The command CW 0 causes the controller to stop executing new commands until more room is made available in the FIFO This command can be very useful when hardware handshaking is being used and the communication line between controller and terminal will be disconnected In this case characters will continue to build up in the controller until the FIFO is full For more information see the CW
132. e sequence starting at zero Vector length of coordinated move sequence buffer Zero means buffer is full 255 means buffer is empty When AV is used as an operand _AV returns the distance traveled along the sequence The operands _VPX and _VPY can be used to return the coordinates of the last point specified along the path Chapter 6 Programming Motion 67 Example Traverse the path shown in Fig 6 3 Feedrate is 20000 counts sec Plane of motion is XY Instruction Interpretation 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 the 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 R 1500 B 4000 0 A 0 0 Figure 6 3 The Required Path Electronic Gearing This mode allows multiple axes to be electronically geared to some mast
133. e stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000 SP 20000 20000 AC 200000 00000 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 138 Chapter 10 Theory of Operation DMC 14x5 6 X VELOCITY Y VELOCITY X POSITION Y POSITION rd TIME Figure 10 3 Velocity and Position Profiles Operation of Closed Loop Systems DMC 14x5 6 To understand the operation of a servo system we may compare it to a familiar closed loop operation adjusting the water temperature in the shower One control objective is to ke
134. e ue cete dur ebbe 126 Wire Cutter ire DUI eo pete tee LO e epp re toU 126 X Y Table Controller rettet e e rer ee gt ese 127 Chapter 8 Hardware amp Software Protection 131 Introd CtlOD p paiement er epe ip eot ate ae 131 Hardware Protection x seemed te aeg d 131 Output Protection Lares better beer Hp EAE 131 Input Protection Lines iuam ert re terree ag e ehe 132 Software ProtectOn ob aede ate detecto a trate me trud ia 2 132 Programmable Position Limits 132 Otft On BIHOF Ace ete o ed 133 Automatic Error Routine 133 Limit Switch Routine on acere de Ret at RE kids 133 Chapter 9 Troubleshooting 135 euh iS 135 InstallatlOn oot Ra tete o ER RISE eiua 135 rom 136 Stability so Si Oma ND me REP Sup dh ius 136 eet TP Om ete ut prr ne ub enis 136 Chapter 10 Theory of Operation 137 OVervIeW re eludere One ad bete aam 137 Operation of Closed Loop Systems essent nennen nennen nne 139 System e nei edes e epi 140 Motor Amplifiet 5 5 ocn 2 0 ac o E bith avian nana 141 iv Contents DMC 14x5 6 DAC oen penam teo M a Bask an eU onan Seius 144 Digital Filter o eret te a e a La aere ed pese ds 144 144 System Analys18 3 5 eoe eem exe 145 0 147 The Analytical 110100065 147 Appendices 151 Electrical Specificat
135. ector distance VS 1000 Reduce speed EN End DMC 14x5 6 Chapter 7 Application Programming 101 Event Trigger Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves Instruction Interpretation MOVES Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration 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 BGX Start Motion 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 50 msec Instruction Interpretation OUTPUT Program label ATO Initialize time reference SB1 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 14XX 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 tim
136. ecution 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 AVn Halts program execution until specified distance along a coordinated path has occurred WT Halts program execution until specified time in msec has elapsed Chapter 7 Application Programming 99 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 Instruction TWOMOVE PR 2000 BGX AMX PR 4000 BGX EN Interpretation Label Position Command Begin Motion Wait for Motion Complete Next Position Move Begin 2nd move 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 Instruction SETBIT SP 10000 PA 20000 BGX AD 1000 SBI EN Interpretation Label Speed is 10000 Specify Absolute position Begin motion Wait until 1000 counts Set output bit 1 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 Instruction TRIP JG 50000 BGX n 0 REPEAT AR 10000 TPX SBI
137. ed 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 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 24 Chapter 2 Getting Started DMC 14x5 6 DMC 14x5 6 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 argument is a real number which represents the voltage to be applied to the amplifier during the initialization When the voltage is specified by a positive number the initialization process will end up in the motor off
138. ed for forward and reverse limits abort home and definable input interrupts Event triggers can automatically check for elapsed time distance and motion complete The DMC 14XX is easy to program Instructions are represented by two letter commands such as BG for Begin and SP for Speed Conditional instructions Jump statements and arithmetic functions are included for writing self contained applications programs An internal editor allows programs to be quickly entered and edited and support software such as the WSDK allows quick system set up and tuning Commands may also be sent in Binary to decrease processing time To prevent system damage during machine operation the DMC 14XX provides many error handling features These include software and hardware limits automatic shut off on excessive error abort input and user definable error and limit routines The DMC 1415 and DMC 1425 are designed for stand alone applications and provide non volatile storage for programs variables and array elements The DMC 1416 provides an internal brush or brushless power amplifier for a standard DC servo motor Chapter 1 Overview 1 Overview of Motor Types The DMC 14XX can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Brushless servo motors with sinusoidal commutation 3 Step motors with step and direction signals 4 Other actuators such as hydraulics For more information contact Galil
139. elow allows the controller to either skip or retry invalid commands Function EDI Returns the number of the thread that generated an error ED2 Retry failed command operand contains the location of the failed command _ED3 Skip failed command operand contains the location of the command after the failed command The operands are used with the XQ command in the following format XQ _ED2 or ED3 ED1 1 Where the 1 at the end of the command line indicates a restart therefore the existing program stack will not be removed when the above format executes The following example shows an error correction routine which uses the operands Example Command Error w Multitasking Instruction Interpretation HA Begin thread 0 continuous loop End of thread 0 Chapter 7 Application Programming 109 B N 1 KPN TY EN CMDERR IF TC 6 N 1 XQ ED2 ED1 1 ENDIF IF TC21 XQ ED3 ENDIF EN Begin thread 1 Create new variable Set KP to value of N an invalid value Issue invalid command End of thread 1 Begin command error subroutine If error is out of range KP 1 Set N to a valid number Retry KP N command If error is invalid command TY Skip invalid command End of command error routine Example Ethernet Communication Error This simple program executes in the IOC 7007 and indicates via the serial port when a communication handle fails By monitoring the
140. ep and direction signals from the controller to respective signals on your step motor amplifier The step and direction signals are labeled ACMD pwm and ACMD2 sign respectively on the ICM 1460 Consult the documentation for your step motor amplifier Step C Configure DMC 141X for motor type using MT command You can configure the DMC 141X 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 8d Connect brush or brushless servo motor to DMC 1416 The DMC 1416 provides an integrated brush or brushless amplifier and DC to DC converter to be used with DC brush or brushless motors Warning The DMC 1416 is powered up in the motor on SH condition unless the MO jumper is selected It is recommended that this jumper be installed see Step 2 Configuring Jumpers on the DMC 14XX for the initial power up of the system This will prevent runaway of the system due to positive feedback This jumper can then be removed once polarity has been configured properly To connect the DC brush or brushless motor follow this procedure 26 Chapter 2 Getting Started DMC 14x5 6 Step A Disconnect controller power Unplug the 5 pin power connector J5 from the front of the DMC 1416 This will power down the controller so that the motor may be connected Step B Connect DC brush or brushless motor If
141. ep 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 at the right rate If you turn it too slowly the temperature response will be s
142. er Warning Damage to the DMC 1416 will occur if a supply larger than 60V is connected to the controller Chapter 2 Getting Started 11 4 Applying power will turn on the green LED power indicator Step 4 Installing the Communications Software After applying power to the computer you should install the Galil software that enables communication between the controller and PC The CD ROM used for the following installations is Version 11 01 Using DOS Using the Galil Software CD ROM go to the directory July2000 CD DMCDOS DISK1 Type INSTALL at the DOS prompt and follow the directions Using Windows 3 x 16 bit versions Explore the Galil Software CD ROM and go to the directory July2000 CD DMCWIN Run DMCWINI6 and follow the directions The Windows Servo Design Kit WSDK16 which is useful for tuning servos and viewing useful controller information can be downloaded off the CD as well However WSDK16 is a purchase only software package and is password protected on the CD Contact Galil for purchase information Using Windows 95 or 98 First Edition The HTML page that opens automatically from the CD ROM does not contain the necessary software for Windows 95 or Windows 98 First Edition Instead Explore the CD and go to the July2000 CD folder To install the basic communications software click on DMCTERM and then run the application DMCTERM Another terminal software is called DMCWIN32 and is located under July2000 CD DMCWIN
143. er and the follower are controlled by the DMC 1425 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 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 IP 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 Instruction Interpretation GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance S
144. er axes With the DMC 1415 or DMC 1416 the master is always the auxiliary encoder With the DMC 1425 the master will be the 68 Chapter 6 Programming Motion DMC 14x5 6 X or Y axis 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 for the DMC 1425 The GA command is unnecessary for the DMC 1415 or DMC 1416 as the auxiliary encoder is automatically used GR x y 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 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 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 position of that axis rather than the actual position The designation of the commanded position master is by the letter C For exampl
145. escribed 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 Chapter 6 Programming Motion 81 Output Buffer Output To Stepper Driver Stepper Smoothing Filter Motion Profiler Adds a Delay
146. et 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 For example the following example illustrates how to display the current position of the X axis TP X lt enter gt Tell position X DMC 14x5 6 TTChapter 5 Command Basics 53 0000000000 Controllers Response TP XY lt enter gt Tell position X and Y 0000000000 0000000000 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PR Request X Y values PR Request Y value only The controller can also be interrogated with operands Operands Most DMC 14XX 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
147. f the external low or high input signal The DMC 141X 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 command to arm the latch 2 Test to see if the latch has occurred Input 1 goes low by using the AL command Example V1 _AL returns the state of the latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the report latch RL command RL Note The latch must be re armed after each latching event Example High Speed Latch Instruction Interpretation Latch Latch program JG 5000 Jog BG Begin AL Arm Latch Wait Loop for Latch 1 JP Wait _AL 1 Wait for latch Result _RL Report position Result Print result EN End 90 Chapter 6 Programming Motion DMC 14x5 6 Chapter 7 Application Programming Overview The DMC 14XX provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 14XX 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 14XX provides commands that allow the DMC 14XX to make its own decisions These commands include conditional jumps
148. f cutter JP CUT Repeat process EN End program 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 DMC 14x5 6 Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is RESULT In addition to variables functions and commands responses can be used in the message command For example MG The input is IN 1 MG The proportional Gain of X is KPX 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 ch
149. ffected 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 Green Link LED The second green LED is lit when there is an Ethernet connection to the controller This LED tests only for the physical connection not for an active or enabled link Yellow Activity LED The yellow LED indicates traffic across the Ethernet connection This LED will show both transmit and receive activity across the connection If there is no Ethernet connection or IP address assigned the LED will flash at regular intervals to show that the BOOTP packets are being broadcast Chapter 3 Connecting Hardware 37 THIS PAGE LEFT BLANK INTENTIONALLY 38 Chapter 3 Connecting Hardware DMC 14x5 6 Chapter 4 Communication Introduction The DMC 14XX has one RS232 port and one Ethernet port The RS 232 port is the data set The Ethernet port is a 10 link The RS 232 is a standard serial link with communication baud rates up to 19 2kbaud RS232 Port The DMC 14XX has a single RS232 connection for sending and receiving commands from a PC or other terminal The pin outs for the RS232 connection are as follows RS232 Port1 DATATERM 1 CTS output 6 CTS output 2 Transmit Data output 7 RTS input 3 Receive Data input 8 CTS output 4 RTS input 9 No connect Can connect to 5V or sample clock 5 Ground RS 232 Configuration DMC 14
150. ges Back Cancel In the Ethernet Parameters window there are additional options under the Unsolicited Messages section to Use current CF Setting Receive Through Second Handle and Receive Through Same Handle The default selection is Use current CF setting which means that messages will be sent through the handle that s currently configured on the controller i e no changes are made If Receive Through Second Handle is selected the controller will open a second TCP UDP handle between the controller and computer over which unsolicited message are sent A second thread listens for messages which provides a faster response when compared to receiving messages through the same handle If Receive Through Same Handle is selected unsolicited message are sent back through the same handle that the terminal is using Now the Galil software must poll to get these messages which 16 Chapter 2 Getting Started DMC 14x5 6 DMC 14x5 6 slows the response time For more information contact Galil Once all the Ethernet parameters are entered select Assign IP Address The software will search for controllers that do not have IP addresses Once the controller has been found and the IP address is assigned select Finish and the controller will be entered in the Galil Registry Connect to the controller through the Terminal Another method of connecting to an Ethernet Controller is using the DMC
151. h 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 deceleration 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 ABI must be used to abort the coordinated motion sequence The user must keep enough motion segments in the DMC 14XX 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 255 returned means the buffer is empty and 255 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 spec
152. h 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 where x y specify the cycle of the master and the total change of the slaves over one cycle On the DMC 1415 and DMC 1416 x will always be the slave cycle and y will be the master 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 DMC 1425 EM 1500 6000 DMC 1415 1416 Step 3 Specify the master interval and starting point Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are specified by the instruction EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0 Step 4 Specify the slave positions Next we specify the slave positions with the instruction ET n x y DMC 1425 ET n x DMC 1415 1416 DMC 14x5 6 Chapter 6 Programming Motion 71 where n indicates the order of the point The value n start
153. hapter 3 Connecting Hardware 33 ecd te meae dde ti etu ede eie ec efe ete 33 Using eit nih 5 Pe eee eto 33 Limit S witch Input dede e oie dome Pec toe 33 Home Switch Pere d rete eaten oh 34 Abort Input erret ee eti eee me eet dide e edi 34 Uncommitted Digital Inputs eese ener enne 35 Amiplifier Interface mee ee ee RED SEET E SR bie aN 35 TTL Inputs tene tete RO T re RE rrr ROO re GE 36 Analog Inputs 36 TTL Outputs 36 Chapter 4 Communication 39 Introduction c3 ape ata at ER OU Alen alee a PR ER eerta 39 ENPAVAYO E EE 39 RS232 Poitl 39 RS 232 Confisuration 12 ma ot e e eed bcati 39 Ethemet Configurati n 05 a ri Dr 40 Communication Protocols 5 2 neo pE RA pei bcati at 40 AdtessIng 5 coi ean pom br aide npe eat 40 Communicating with Multiple Devices eee eene 42 M ltic sting iino oer aep abate nme at 43 Using Third Party Software aii Rr b pe pbi ett 43 Data Record sesto ione npe aprecio m ODE d 44 D ta R cord DR ORO ante S A 44 Explanation of Status Information and Axis Switch Information 45 Notes Regarding Velocity and Torque Information eee 46 QZ Command 47 Controller Response to Commands 0 0 eee cee essent nennen eene enne 47 Unso
154. hase B These inputs should be connected to the two sinusoidal signals generated by the controller The first signal is the main controller motor output ACMD The second signal utilizes the second DAC on the controller and is brought out on the ICM 1460 at pin 38 ACMD2 Chapter 2 Getting Started 23 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 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 you are using 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 lt CR gt On the other hand if you are using a rotary motor with 4000 counts per revolution and 3 magnetic cycles per revolution three pole pairs the command is BM 1333 333 lt CR gt 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 BS 2 700 lt CR gt will test the brushless axis with a voltage of 2 volts applying it for
155. he load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Chapter 6 Programming Motion 83 Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies the KP proportional and KI integral terms to the position error based on the load encoder and applies the KD derivative term to the motor encoder This method results in a stable system Note It is recommended that the resolution of the rotary encoder be greater than the effective resolution of the load encoder for stability The dual loop method is activated with the instruction DV Dual Velocity where DV 1 activates the dual loop for the four axes and DV 0 disables the dual loop Note that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure
156. he motor amplifier will be disabled Note This function requires the AEN signal to be connected from the controller to the amplifier Step B Setting Torque Limit as a Safety Precaution 20 Chapter 2 Getting Started DMC 14x5 6 To limit the maximum voltage signal to your amplifier the DMC 141X controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque 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 TL 1 lt CR gt Sets torque limit to 1 Volt 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 wil
157. he pull down menu Make sure to select Serial as the Connection Type The next step is to select the Comm Port being used on the PC and the Comm Speed for data transfer Hardware handshaking will be selected by default Select Next and the controller will be entered into the registry Connect to the controller by selecting the Terminal utility and choosing the controller from the registry list Serial Parameters Comm Port Comm Speed 19200 Handshake Options Hardware RTS CTS Recommended Requires all 9 pins to be connected Software 401777010 lt Back Cancel Note Be sure to configure the Comm Speed jumpers for the same Comm Speed in the Galil Registry No jumpers on the DMC 14XX indicates a Comm Speed of 19200 bits per second 14 Chapter 2 Getting Started DMC 14x5 6 DMC 14x5 6 Using Non Galil Communication Software The DMC 14XX serial port is configured as DATASET Your computer or terminal must be configured as a DATATERM for full duplex no parity 8 data bits one start bit and one stop bit Check to insure that the baud rate switches have been set to the desired baud rate as described above Your computer needs to be configured as a dumb terminal which sends ASCII characters as they are they are typed to the DMC 14XX An example of a dumb terminal would by HyperTerminal that is available under the Start menu Programs Accessories Communications in the Wi
158. hecking 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 _ O LIMSWI Limit switch on any axis goes low ININT Input specified by II goes low FCMDERR For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the POSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt subroutine When the specified input occurs the program will be executed automatically NOTE An application program must be running for automatic monitoring to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the LIMSWI routine to function the DMC 14XX must be executing an applications program from memory This can be a very simple program that does nothing but loop on a statement such as LOOP JP LOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed Instruction Interpretation ED Edit Mode 000 LOOP Dummy Program 001 JP LOOP EN Jump to Loop 002 LIMSWI Limit Switch Label 003 MG LIMIT OCCURRED Print Message 004 RE Return to ma
159. his command will not work through the Ethernet 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 uses the variable LEN to length The IN command is used to prompt the operator to enter the length and the entered value is assigned to the variable LEN Instruction BEGIN AC 800000 DC 800000 SP 5000 LEN 3 4 CUT All IN enter Length IN LEN PR LEN 4000 BGX AMX SBI Interpretation LABEL Acceleration Deceleration Speed Initial length in inches Cut routine Wait for start signal Prompt operator for length in inches Specify position in counts Begin motion to move material Wait for motion done Set output to cut 118 Chapter 7 Application Programming DMC 14x5 6 WT100 CB1 Wait 100 msec then turn of
160. his function has a magnitude of 10500 0 00625 and a phase Arg L j500 180 tan 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 2 L s G s then it follows that G s must have magnitude of 201500 1A j500 L j500 I 160 and a phase arg G j500 arg A j500 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 o 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as 16 j500 I IP 05000 160 and arg G j500 tan 1 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 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 4 148 Chapter 10 Theory of Operation DMC 14x5 6 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 14XX can be programmed with the instruction KP 20 6 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters Equivalent Fi
161. if you are changing an existing controller this field will already have an entry Pressing the down arrow to the right of this field will reveal a menu of valid controller types Note If you are communicating to the DMC 14XX controller via the RS232 connection the controller must be registered as a DMC 1412 The registry information will show a default Comm Port of 2 and a default Comm Speed of 9600 appears This information should be changed as necessary to reflect the computers Comm Port and the baud rate set by the controller s baud rate jumpers The registry entry also displays timeout and delay information These are advanced parameters that should only be modified by advanced users see software documentation for more information Once you have set the appropriate Registry information for your controller Select OK and close the registry window You will now be able to communicate with the DMC 14XX Once the entry has been selected click on the OK button If the software has successfully established communications with the controller the registry entry will be displayed at the top of the screen 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 re
162. ified Recording can be done as a one time event or as a circular continuous recording Command Summary Automatic Data Capture RA n m o pl Selects up to four arrays for data capture The arrays must be defined with the DM command RD typel type2 type3 type4 Selects the type of data to be recorded where typel type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command The RC command begins data collection Sets data capture time interval where 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 116 Chapter 7 Application Programming DMC 14x5 6 DMC 14x5 6 Data Types for Recording 00000 Note X may be replaced by Y for capturing data on the other axis Operand Summary Automatic Data Capture Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress RD Returns address of next array element Example Recording into An A
163. ify a variety of different cases for branching Command Format IF ELSE and ENDIF Function Condition IF conditional statement s 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 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 Instruction TEST 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 Interpretation 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 TF 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 condition
164. ifying Linear Segments The command LI x y specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis position Up to 255 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 the controller 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 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 ABI must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 14XX sequence buffer to ensure continuous motion If the controller receives no additional LI segments and no LE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM LM returns the available spaces for LI segments that can be sent to the buffer 255 returned means the buffer is empty and 255 LI segments can be sent A zero means the buffer is full and no additional segments can
165. ifying 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 commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second 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 Changing Feedrate The command VR n allows the feedrate VS to be scaled from and 10 times with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the 66 Chapter 6 Programming Motion DMC 14x5 6
166. imeout Instruction BEGIN TW 1000 PA 10000 BGX MCX EN MCTIME MG X fell short EN 108 Chapter 7 Application Programming Interpretation 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 DMC 14x5 6 DMC 14x5 6 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 Instruction BEGIN IN ENTER SPEED SPEED JG SPEED BGX JP 4BEGIN EN CMDERR JP DONE _ED lt gt 2 JP DONE _TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN 751 JP BEGIN DONE ZSO EN Interpretation 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 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 b
167. in Win 95 98 Ethernet Parameters IP Address 24 51 29 31 Assign IP Address Do Not Open Multi cast Handle Ethernet Protocol Unsolicited Messages TCP Use current CF Setting c In C Receive Through Second Handle CF is sent to redirect messages Receive Through Same Handle is sent to redirect messages lt Back Cancel Ethernet Parameters Window Win 98SE 2000 ME NT 4 XP The second method for setting an IP address is to send the command through the DMC 14XX main RS 232 port The IP address you want to assign may be entered as a 4 byte number delimited by commas industry standard uses periods or a signed 32 bit number Ex IA 124 51 29 31 or IA 2083724575 Type in BN to save the IP address to the controller s non volatile memory DMC 14x5 6 Chapter 4 Communication 41 NOTE Galil strongly recommends that the IP address selected is not one that can be accessed across the Gateway The Gateway is an application that controls communication between an internal network and the outside world The third level of Ethernet addressing is the UDP or TCP port number The Galil controller does not require a specific port number The port number is established by the client or master each time it connects to the controller Communicating with Multiple Devices The DMC 14XX is capable of supporting multiple masters and slaves The masters may be multiple PC s
168. in program control Q Quit Edit Mode XQ LOOP Execute Dummy Program JG 5000 Jog BGX Begin Motion Now when a forward limit switch occurs on the X axis the LIMSWI subroutine will be executed Notes regarding the LIMSWI 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 commanded to move DMC 14x5 6 Chapter 7 Application Programming 107 Example Position Error Instruction Interpretation ED Edit Mode 000 LOOP Dummy Program 001 JP LOOP EN Loop 002 POSERR Position Error Routine 003 1 TEX Read Position Error 004 MG EXCESS POSITION ERROR Print Message 005 MG ERROR V1 Print Error 006 RE Return from Error control Q Quit Edit Mode XQ LOOP Execute Dummy Program 100000 Jog at High Speed BGX Begin Motion Now when excess position error occurs on the X axis the POSERR subroutine will be executed Example Input Interrupt Instruction HA 30000 60000 BGXY LOOP JP LOOP EN ININT STXY AM TEST JP TEST IN 1 0 JG 30000 6000 BGXY RIO Interpretation Label Input Interrupt on 1 Jog Begin Motion Loop Input Interrupt Stop Motion Test for Input 1 still low Restore Velocities Begin motion Return from interrupt routine to Main Program and do not re enable trippoints Example Motion Complete T
169. inish once the IP address has been entered in the text box and the controller will be entered into the Galil registry Connect to the controller through the Terminal When connecting to a controller via Ethernet the user must be aware of the type of Ethernet cable being used and the method of communication To connect the controller directly to the PC use a crossover or null modem Ethernet cable This type of cable allows for the crossing of signals between the PC and the controller If instead the connection to the controller is through a network hub a Chapter 2 Getting Started 17 straight through cable must be used Hubs perform the signal crossing function of a null modem cable If the wrong cable is used communication with the controller will not be possible Note If an Ethernet controller is connected in a LAN make sure the assigned IP address is allowed Also Galil strongly recommends the IP address selected cannot be accessed across the Gateway The Gateway is an application that controls communication between an internal network and the outside world Ask your network administrator for acceptable IP addresses Sending Test Commands to the Terminal After you connect your terminal press lt return gt or the lt enter gt key on your keyboard In response to carriage return lt return gt the controller responds with a colon Now type TPX lt return gt This command directs the controller to return the current positi
170. ion for ICM 1460 rev F and above The ICM 1460 module from Galil has an option for opto isolated inputs and outputs Any of the following pins can be chosen to be the input output common pin labeled as 12V pin 2 labeled as 12V and pin 13 labeled as CMP ICOM When pin 1 is used as input output common the 12V output be comes inaccessible when pin 2 is used the 12V becomes inaccessible and when pin13 is used the output compare function is not available The common point need to be specified at the time of ordering The ICM 1460 can also be configured so that the opto common is jumped with Vcc 5V in this case no screw connections is needed and the internal 5V will be used for powering the input output Option for separate input output commons is also available this will require the use of both pin 1 and pin 2 on the screw connection When selecting this option both 12V and 12 becomes inaccessible ICM 1460 TO CONTROLLER CONNECTIONS OPTO COMMON vcc RP2 RP4 2 2K RP3 RP1 4 7K OHMS IN x To controller IN x Figure 1 Opto isolated Inputs The signal IN x is one of the isolated digital outputs where x stands for the digital input terminals The OPTO COMMON point should be connected to an isolated power supply in order to obtain isolation from the controller By connecting the OPTO COMMON to the side of the power supply the inputs will be activated by sinking current By connecting the
171. ion is referred to as Applications Programming and is discussed in the following chapter Binary commands cannot be used in Applications programming This section describes the DMC 14XX instruction set and syntax A summary of commands as well as a complete listing of all DMC 14XX instructions is included in the Command Reference Command Syntax ASCII DMC 14XX 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 enter is used to terminate the instruction for processing by the DMC 14XX command interpreter Note If you are using a Galil terminal program commands will not be processed until an enter command is given This allows the user to separate many commands on a single line and not begin execution until the user gives the enter command IMPORTANT All DMC 14XX commands are sent in upper case For example the command PR 4000 enter 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 enter terminates the instruction The space between PR and 4000 is optional When specifying data for the X and Y axes on the DMC 1425 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
172. ional 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 80 Chapter 6 Programming Motion DMC 14x5 6 Specifying Stepper Motor Operation DMC 14x5 6 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
173. ions iode ree ede def e copes petes 151 SerVo Cotrol m eie ec deine piede tust 151 Stepper Control ee ein ten det Hte ede 151 Input Output SS 2 151 Power Requirements iicet ponere Ep eR ERR ee e pena 151 Performance Specifications e ere GO D RED tpe pie ERREUR 152 Fast Update Rate Mode ttd teer aera PG ite beer ens 152 Connectors for DMC IAXX Pete ERE REED RD gt 153 13 DMC 1415 General I O 37 PIN D type eene 153 13 DMC 1425 General I O 37 PIN D type eese nennen 153 J3 DMC 1416 General I O 37 PIN D type eese 154 14 DMC 1416 Encoders 15 Pin D type cece sess 155 15 DMC 1416 Power 5 Pin MOLEX Brushless Config Standard Servo 155 J1 RS232 Main port DB 9 Pin Male esee nennen 155 Pin Out Descriptions ierat empor Ro e nbn e RD Her o Rats 156 ICM 1460 Interconnect Module sees ennt entrent 157 Opto Isolation Option for ICM 1460 rev and above seen 159 64 Extended I O of the DMC 1415 1416 1425 Controller eene 160 Configuring the I O of the DMC 1415 1416 1425 with DB 14064 160 Connector Description ep pe eerte tot apetece a e e 162 IOM 1964 Opto Isolation Module for Extended I O Controllers sees 164 Descriptions chi nce eR e bei edd 164 OVEIVIEW A E 165 Configuring Ha
174. is shown in Fig A 15 Velocity 10000 time s Ta 0 05 T 0 357 Ti 0 407 Figure A 15 Vector Velocity Profile The acceleration time T is given by VS 100000 _ a 0 055 VA 2000000 The slew time Ts is given by D _ 35708 Ts Ta VS 100000 The total motion time Tt is given by 0 05 0 3075 EH 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 14 are given in Fig A 16 Appendices 181 Fig A 16 a 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 Vs 0 Between the points the velocities vary gradually and finally between points and D the motion is in the X direction B C Vector Velocity X Velocity b Y Velocity time Figure A 16 Vector and Axes Velocities 182 Appendices DMC 14x5 6 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 DMC 14x5 6 Galil a leader in motion co
175. is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if necessary Sampled Dual Loop Example In this example we consider a linear slide that is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it is best to use a rotary encoder on the motor Connect the rotary encoder to the main encoders input and connect the linear encoder to the auxiliary encoder input Let the required motion distance be one inch and assume that this corresponds to 40 000 counts of the rotary encoder and 10 000 counts of the linear encoder The design approach is to drive the motor a distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program Instruction Interpretation DUALOOP Label CE0 Configure encoder DEO Set initial value PR 40000 Main move BG Start motion Correct Correction loop AM Wait for motion completion V1 10000 _DE Find linear encoder error V2 _TE 4 V1 Compensate for motor error JP END ABS V2 lt 2 V2 4 Exit if error is small Correction move BG Start correction JP Correct Repeat END EN 84 Chapter 6 Programming Motion
176. ith 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 DMC 14x5 6 Chapter 7 Application Programming 127 Instruction A OPO VM XY VP 160000 0 VE VS 200000 VA 1544000 BGS AMS SB1 WT1000 CR 80000 270 360 VE VS 40000 BGS AMS WT1000 PR 21600 SP 20000 BGX AMX SB1 WT1000 CR 80000 270 360 VE VS 40000 BGS AMS WT1000 VP 37600 16000 VE VS 200000 BGS AMS EN 128 Chapter 7 Application Programming Interpretation Label Set all output bits low Circular interpolation for XY Positions End Vector Motion Vector Speed Vector Acceleration Start Motion When motion is complete Set output bit to lower cutting tool Wait 1000msec for tool to be in cutting position Circle Feedrate Start circular move Wait for completion Clear output bit to raise cutting tool Wait 1000msec for tool to raise Move X Speed X Start X Wait for X completion Set output bit to lower cutting tool Wait 100
177. ively 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 AMP MOTOR ENCODER Figure 10 4 Functional Elements of a Motion Control System 140 Chapter 10 Theory of Operation DMC 14x5
178. iven 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 Interpretation A Label All Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AMX After motion is complete SB1 Set output bit 1 WT 20 Wait 20 ms Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process 126 Chapter 7 Application Programming DMC 14x5 6 START PULSE 11 BMC _ MOTOR VELOCITY OUTPUT PULSE 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 system must cut the pattern shown in Fig 7 2 The X Y table moves the plate while digital output raises and lowers the cutting tool The solid curves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feedrate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate is 0 1 g The motion starts at point A with the output bit off An X Y motion to point B is followed by setting an output bit to engage the cutting tool along the circle Once the circular motion is completed the output bit is cleared which raises the tool and the motion continues to point C etc Assume that both of the axes are driven by lead screws w
179. k 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 14XX 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 14XX 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 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 14XX Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 14XX can accept analog feedback instead of an encoder for any axis For more information see 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 customi
180. l not operate properly if the torque limit is below the normal operating range See description of TL in the command reference Step C Disable motor Issue the motor off command to disable the motor MO lt CR gt Turns motor off Step D Connecting the Motor Once the parameters have been set connect the analog motor command signal ACMD to the amplifier input Issue the servo here command to turn the motors on To test the polarity of the feedback command a move with the instruction SH lt CR gt Servo Here to turn motors on PR 1000 lt CR gt Position relative 1000 counts BG lt CR gt Begin motion 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 In this case 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 lo
181. leration 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 Instruction Interpretation 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 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 Chapter 6 Programming Motion 61 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 a Zero means buffer full 255 means buffer empty AMS AMT v Operand Summary Linear Interpolation _AV Return distance traveled Segment counter returns number of the segment in the sequence being processed starting at zero Zer
182. licited Messages Generated by Controller esee 47 Galil Software Tools Libraries eese enne ener ener enne 48 Chapter 5 Command Basics 49 Introduction ehe tbt Ee HR ee e E OQ Eee RC ERE OE Perte 49 Command Syntax ASCIL oce epe eee e e Dr ee e e iere edes 49 Coordinated Motion with more than 1 axis 50 Command Syntax Binary oeir i a EE E aA E E EE E E en 50 Binary Command Format essere nennen rennen 51 Binary Command 52 Controller Response to DATA nennen eene nenne ener 53 Interrogating the essent nennen ener enne nennen nre 53 Interrogation 53 Summary of Interrogation Commands eese eene 53 Interrogating Current Commanded Values eene 54 Operands cs i una ete d e de eee RR e i AR pete des 54 Command Summary ione dee oie b eiie eee eec 54 Chapter 6 Programming Motion 55 ii Contents DMC 14x5 6 DMC 14x5 6 VV SEVIS REM HC MP oF eee RI 55 Independent Axis Positioning 324 205 2 en e t 56 Command Summary Independent Axis eene 57 Independent JOggme equ es cetetale eee ide bees 59 Command Summary Jogging eese eene eene nennen 59 59 Linear Interpolation Mode 25 sss esgic a ae ES DO Hepat rd 60 Specifying
183. ll position which returns the position of the main encoder The position error which is the difference between the commanded position and the actual position can be interrogated by the instructions TE Tell error Example 4 Absolute Position Objective Command motion by specifying the absolute position Instruction Interpretation Define the current position as 0 PA 7000 Sets the desired absolute position BG Start motion Example 5 Velocity Control Jogging Objective Drive the motor at specified speeds Instruction Interpretation JG 10000 Set Jog Speed AC 100000 Set acceleration DC 50000 Set deceleration BG Start motion after a few seconds command JG 40000 New speed and Direction TV Returns speed This causes velocity changes including direction reversal The motion can be stopped with the instruction ST Stop Example 6 Operation Under Torque Limit DMC 14x5 6 The magnitude of the motor command may be limited independently by the instruction TL The following program illustrates that effect Instruction Interpretation TL 0 2 Set output limit to 0 2 volts JG 10000 Set speed BG Start motion The motor will probably not move as the output signal is not sufficient to overcome the friction If the motion starts it can be stopped easily by a touch of a finger Increase the torque level gradually by instructions such as TL 1 0 Increase torque limit to 1 volt TL 9 98 Increase torque limit to maxim
184. low causing discomfort Such a slow reaction is called an overdamped response Chapter 10 Theory of Operation 139 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 constants KP KI and KD which correspond to the proportional integral and derivative term respect
185. lter Form DMC 14XX Digital D z K z A Z Cz z 1 Digital D z 4 KP 4 KD 1 z7 KI2 1 z KD KI K KP KD 4 KD KP KD C KI2 Continuous G s P Ds I s PID T P 4KP D 4T KD I KI2T DMC 14x5 6 Chapter 10 Theory of Operation 149 THIS PAGE LEFT BLANK INTENTIONALLY 150 Chapter 10 Theory of Operation DMC 14x5 6 Appendices Electrical Specifications Servo Control ACMD Amplifier Command A A B B IDX IDX Encoder and Auxiliary Stepper Control Pulse Direction Input Output Uncommitted Inputs Limits Home Abort Inputs OUTT 1 thru OUT 3 Outputs Power Requirements 5V 400 mA 12V 40 mA 12V 40mA DMC 14x5 6 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 12MHz 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 Can accept up to 12V signal TTL Appendices 151 The 12V DC to DC converter on the DMC 1416 is maxed out at 40mA Do not attempt to draw any more current out of the 12V pins 5V 5A available 12v 100mA available Performance Specifications Minimum Servo Loop Update Time DMC 1415 1425 1416 Position Accuracy Velocity Accuracy Long Term Short
186. me Clock off by 2 4 Resets with power on Note TIME does not use an underscore character _ as other keywords e These keywords have corresponding commands while the keywords _LF _LR and TIME do not have any associated commands All keywords are listed in the Command Reference manual 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 V4 HMW Assign V4 the logical state of the Home input on the W axis 114 Chapter 7 Application Programming DMC 14x5 6 Arrays For storing and collecting numerical data the DMC 14XX provides array space for 2000 elements The arrays are one dimensional and up to 14 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
187. n for the information add Eh to the end of the command Ex MG EC Hello will send the message Hello to handle 3 TP EF will send the z axis position to handle 6 Multicasting A multicast may only be used in UDP IP and is similar to a broadcast where everyone on the network gets the information but specific to a group In other words all devices within a specified group will receive the information that is sent in a multicast There can be many multicast groups on a network and are differentiated by their multicast IP address To communicate with all the devices in a specific multicast group the information can be sent to the multicast IP address rather than to each individual device IP address AII Galil controllers belong to a default multicast address of 239 255 19 56 The controller s multicast IP address can be changed by using the IA u command Using Third Party Software DMC 14x5 6 Galil supports ARP BOOT P and Ping which are utilities for establishing Ethernet connections ARP is an application that determines the Ethernet hardware address of a device at a specific IP address BOOT P is an application that determines which devices on the network do not have an IP address and assigns the IP address you have chosen to it Ping is used to check the communication between the device at a specific IP address and the host computer The DMC 14XX can communicate with a host computer through any application that can send TCP
188. n sequence Instruction Interpretation 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 Example Using JP command Move the X motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves Instruction Interpretation BEGIN Begin Program COUNT 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 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 14XX 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
189. n 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 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 00 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by 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 Vl 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 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 f
190. nce 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 the motors reach the corner the speed is increased back to 4000 cts s 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 For example LI x y 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 dece
191. nd 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 DMC 14x5 6 The lower case specifiers x y represent position values for each axis The DMC 14XX also allows use of single axis specifiers such as PRY 2000 Operand Summary Independent Axis Operand Description _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the speed for the axis specified by x PAx Returns the last command position at which motion stopped _PRx Returns current incremental distance specified for the x axis 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 Chapter 6 Programming Motion 57 Example Multiple Move Sequence Required Motion Profiles X Axis 2000 counts Position 15000 count sec Speed 500000 counts sec Acceleration Y Axis 100 counts Position 5000 count sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on X and Y axes The movement on each axis will be separated by 40 msec Fig 6 1 shows the velocity profiles for the X and
192. ndows operating systems Sending Test Commands to the Terminal After you connect your terminal press carriage return or the enter key on your keyboard In response to carriage return CR the controller responds with a colon Now type TPX CR This command directs the controller to return the current position of the X axis The controller should respond with a number such as 0000000 Communicating through the Ethernet Using DOS The Galil software in DOS does not support communication over Ethernet Using Galil Software for Windows 3 x 95 and 98 SE The controller must be registered in the Windows registry for the host computer to communicate with it The registry may be accessed via Galil software such as WSDK or DTERM From WSDK the registry is accessed under the FILE menu From DTERM it is accessed under the REGISTRY menu Use the Add button to add a new entry in the registry Choose DMC 1415 as the controller type Enter the IP address obtained from your system administrator Select the button corresponding to the UDP or TCP protocol in which you wish to communicate with the controller If the IP address has not been already assigned to the controller click on ASSIGN IP ADDRESS Note When communicating via the Ethernet both the DMC 1425 and DMC 1416 will be registered as DMC 1415 controllers ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do not have an IP address
193. nputs 5 6 and 7 use the instruction BI5 CR Step 8a Connect Standard Servo Motor The following discussion applies to connecting the DMC 14XX 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 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 D Before connecting the motor amplifiers to the controller read the following discussion on setting Error Limits and Torque Limits Step A Set the Error Limit as a Safety Precaution Usually there is uncertainty about the correct polarity of the feedback The wrong polarity causes the motor to run away from the starting position Using a terminal program such as DMCTERM the following parameters can be given to avoid system damage Input the commands ER 2000 CR Sets error limit to be 2000 counts OE 1 CR Disables amplifier when excess error exists If the motor runs away and creates a position error of 2000 counts t
194. nt over time interval Range is 32 000 Zero ends contour mode 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 Waits for previous time interval to be complete before next data record is processed Operand Summary Contour Mode DMC 14x5 6 lcs Return segment number 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 2x T B X AT B A 21 sin 2nT 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 50T 6000 27 sin 2x T 120 Note that the velocity in count ms is 50 1 cos 2x 1 120 Chapter 6 Programming
195. nto the following functional groups as shown in Figure 1 1 and discussed below WATCHDOG TIMER ISOLATED LIMITS AND gt HOME INPUTS ETHERNET 68331 HIGH SPEED I MAIN ENCODERS MICROCOMPUTER MOTOR ENCODER AUXILIARY ENCODERS WITH INTERFACE 10 VOLT OUTPUT FOR RS 232 1 Meg RAM FOR SERVO MOTORS 2 Meg FLASH EEPROM XY Z W PULSE DIRECTION OUTPUT FOR STEP MOTORS y HIGH SPEED ENCODER INTERFACE COMPARE OUTPUT 2 UNCOMMITTED 7 PROGRAMMABLE 3 PROGRAMMABLE ANALOG INPUTS INPUTS OUTPUTS HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 14XX Functional Elements Microcomputer Section The main processing unit of the DMC 14XX is a specialized 32 bit Motorola 68331 Series Microcomputer with 1 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 14XX firmware Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 12 MHz For standard servo operation the controller generates a 10 Volt analog signal 16 Bit DAC For sinusoidal commutation operation the controller uses two DACs to generate two 10Volt analog signals For stepper motor operation the controller generates a step and direction signal Communication
196. ntrol with over 250 000 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 15 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 seminar 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 30 pm ADVANCED MOTION CONTROL WHO SHOULD ATTEND Those who consider themselves a servo specialist and require an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of 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 00 am 5 00 pm 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
197. o means buffer full 255 means buffer empty 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 VPX 5000 and __VPY 0 62 Chapter 6 Programming Motion DMC 14x5 6 Example Linear Move Make a coordinated linear move in the XY plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 counts sec Instruction Interpretation LM XY Specify axes for linear interpolation LI40000 30000 Specify XY 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 VX and VY the axis speeds are determined by the DMC 14XX from VS The resulting profile is shown in Figure 6 2 DMC 14x5 6 Chapter 6 Programming Motion 63 30000 27000 POSITION Y 3000 0 4000 36000 40000 POSITION X FEEDRATE 0 0 1 0 5 0 6 TIME sec VELOCITY X
198. o the slave Ex IHB 151 25 255 9 lt 179 gt 2 This will open handle 2 and connect to the IP address 151 25 255 9 port 179 using TCP IP An additional protocol layer is available for speaking to I O devices Modbus is an RS 485 protocol that packages information in binary packets that are sent as part of a TCP IP packet In this protocol each slave has a 1 byte slave address The DMC 14XX can use a specific slave address or default to the handle number The Modbus protocol has a set of commands called function codes The DMC 14XX supports the 10 major function codes Function Code Definition 01 Read Coil Status Read Bits 02 Read Input Status Read Bits 03 Read Holding Registers Read Words 04 Read Input Registers Read Words 05 Force Single Coil Write One Bit 06 Preset Single Register Write One Word 07 Read Exception Status Read Error Code 15 Force Multiple Coils Write Multiple Bits 16 Preset Multiple Registers Write Words 17 Report Slave ID 42 Chapter 4 Communication DMC 14x5 6 The DMC 14XX provides three levels of Modbus communication The first level allows the user to create a raw packet and receive raw data It uses the MBh command with a function code of 1 The format of the command is MBh 1 len array where lenis the number of bytes array is the array with the data The second level incorporates the
199. ollowing 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 122 Chapter 7 Application Programming DMC 14x5 6 0010 00 New format 1 1 4 2 Specify hex format 000A 00 Hex value VIZ ALPHA Assign string ALPHA to VI V1 S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 14XX 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 number 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 Instruction Interpretation RUN Label IN ENTER OF REVOLUTIONS N1 Prompt for revs PR N1 2000 Convert to counts IN ENTER SPEED IN RPM S1 Prompt for RPMs SP S1
200. ome 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 Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew speed and slew until a transition 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 Home HM command can be used to position the motor on the index pulse after the home switch is detected This allows for finer positioning on initialization The HM command and BG command causes the following sequence of events to occur Stage 1 Upon begin the motor accelerates to the slew speed specified by the JG or SP commands The direction of its motion is determined by the state of the homing input If HMX reads initially the motor will go in the reverse direction first direction of decreasing encoder counts If HMX reads 0 initially the motor will go in the forward direction first CN is the command used to define the polarity of the home input With CN 1 the default value a normally open switch will m
201. on This protocol is similar to communicating via RS232 If information is lost the controller does not return a colon or question mark Because the protocol does not provide for lost information the sender must re send the packet Although UDP IP is more efficient and simple Galil recommends using the TCP IP protocol TCP IP insures that if a packet is lost or destroyed while in transit it will be resent Ethernet communication transfers information in packets The packets must be limited to 470 data bytes orless Larger packets could cause the controller to lose communication NOTE In order not to lose information in transit Galil recommends that the user wait for an acknowledgement of receipt of a packet before sending the next packet Addressing There are three levels of addresses that define Ethernet devices The first is the Ethernet or hardware address This is a unique and permanent 6 byte number No other device will have the same Ethernet address The DMC 14XX Ethernet address is set by the factory and the last two bytes of the address are the serial number of the controller The second level of addressing is the IP address This is a 32 bit or 4 byte number The IP address is constrained by each local network and must be assigned locally Assigning an IP address to the controller can be done in a number of ways The first method is to use the BOOT P utility via the Ethernet connection the DMC 14XX must be connected to
202. on of any thread use the instruction HX 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 Instruction Interpretation Task1 label ATO Initialize reference time Clear Output 1 LOOPI Loop label AT 10 Wait 10 msec from reference time SB1 Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference Clear Output 1 JP LOOP1 Repeat Loop1 TASK2 Task2 label XQ 1 Execute Task1 LOOP2 Loop2 label PR 1000 Define relative distance Chapter 7 Application Programming 95 BGX Begin motion AMX After motion done WT 10 Wait 10 msec 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 the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 14XX provides commands and operands which are useful in debugging application programs These commands include interrogation commands to monitor program execution determine the state of the controller and the contents of the controllers program array and variable space Operands also contain important status information which can help to debug a program Trace Commands The trace command causes the controller to send each line in a program to the host com
203. on of the X axis The controller should respond with a number such as 0000000 Step 6 Set up axis for sinusoidal commutation DMC 1415 only This step is only required when the controller will be used to control a brushless motor with sinusoidal commutation Please consult the factory before operating with sinusoidal commutation The command BA is used to specify sinusoidal commutation mode for the DMC 1415 In this mode the controller will output two sinusoidal phases for the DACs Once specified follow the procedure outlined in Step 8b Step 7 Make connections to amplifier and encoder Once you have established communications between the software and the DMC 14XX you are ready to connect the rest of the motion control system The motion control system generally consists of an ICM 1460 Interface Module a servo amplifier and a motor to transform the current from the servo amplifier into torque for motion Galil also offers the AMP 1460 Interface Module which is an ICM 1460 equipped with a servo amplifier for a DC motor A signal breakout board of some type is strongly recommended If you are using a breakout board from a third party consult the documentation for that board to insure proper system connection If you are using the ICM 1460 or AMP 1460 with the DMC 14XX connect the 37 pin cable between the controller and interconnect module Here are the first steps for connecting a motion control system Step A Connect the motor
204. one 29421422 The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move Instruction Interpretation OUTPUT Label PR 2000 Position Command BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec CB1 Clear Output 1 EN End Digital Inputs The DMC 1415 and DMC 1416 has seven digital inputs for controlling motion by local switches while the DMC 1425 has 3 digital inputs The IN n function returns the logic level of the specified input 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 14XX High on input 1 means switch is in on position Instruction Interpretation S JG 4000 Set speed 124 Chapter 7 Application Programming DMC 14x5 6 AI 1 BGX Begin after input 1 goes high AI LSTX Stop after input 1 goes low AMX JP 5 After motion repeat EN
205. onse by adjusting the filter parameters 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 Windows Servo Design Kit WSDK software If the torque limit was set as a safety precaution in the previous step you may want to increase this value See Step B of the above section Setting Torque Limit as a Safety Precaution 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 CR Tell error a few times and get varying responses especially with reversing polarity it indicates system vibration When this happens simply reduce KD Chapter 2 Getting Started 27 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 lt CR gt Proportion gain TE lt CR gt Tell error As the proportional gain is increased the error dec
206. op polarity and encoder polarity can also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section Sometimes the feedback polarity is correct the motor does not attempt to run away but the direction of motion is reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals DMC 14x5 6 Chapter 2 Getting Started 21 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 TT lt CR gt Tell torque 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 AMP 1460 Description Connection Channel A MA Channel B MB Channel A
207. outputs can be turned On and Off with the commands SB Set Bit CB Clear Bit OB Output Bit and OP Output Port For more information about these commands see the Command 36 Chapter 3 Connecting Hardware DMC 14x5 6 DMC 14x5 6 Reference The value of the outputs can be checked with the operand _OP and the function OUT see Chapter 7 Mathematical Functions and Expressions The output compare signal is TTL and is available on the ICM 1460 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 There are four status LEDs on the controller which indicate operating and error conditions on the controller Below is a list of those LEDs and their functions Green Power LED The green status LED indicates that the 5V power has been applied properly to the controller Red Status Error LED The red error LED will flash on initially at power up and stay lit for approximately 1 8 seconds After this initial power up condition the LED will illuminate for the following reasons 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 a
208. p axis for sinusoidal commutation DMC 1415 only 18 Step 7 Make connections to amplifier and encoder sees 18 Step 8a Connect Standard Servo Motor sse 20 Step 8b Connect brushless motor for sinusoidal commutation DMC 1415 only 23 Step 8c Connect 1 nennen nennen rennes 26 Step 8d Connect brush or brushless servo motor to 1416 26 Step 9 Tune the Servo System sse eene nennen 27 Design Examples iacebat d Ce ete tr p P Ceo crede 28 28 Example 2 Profiled 8 28 Example 4 Absolute Position esee eene ener nennen enne enne 29 Example 5 Velocity Control Jogging eene 29 Example 6 Operation Under Torque Limit eere 29 Example 7 Interrogation ente Cut hated d 30 Example 8 Operation in the Buffer Mode seen 30 Example 9 Motion Programs eesesseeeeeeeeeeeeerenen rennen ennemi eene 30 DMC 14x5 6 Contents e i Example 10 Motion Programs with Loops eene eene 30 Example 11 Motion Programs with Trippoint esee 31 Example 12 Control 31 Example 13 Control Variables and Offset essere 32 C
209. p 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 UP 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 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 UP Jumper and use the update firmware function on the Galil Terminal to re load the system firmware Stepper Motor Jumpers Hardware Rev A D If the DMC 14XX will be driving a stepper motor special stepper mode jumpers must be connected Location JP2 on the DMC 14XX contains the jumper SMX If stepper motors are being used this jumper must be installed In addition to the SMX jumper the controller output must be configured for stepper output by the placement of jumpers at location JP3 This jumper location controls whether the controller will output the analog motor command signal MC or the step and direction signals SD Figure 2 3 shows how these jumpers should be configured for stepper mode Please note the standard DMC 1425 only provides access to one axis when in stepper mode For both axes as steppers order as DMC 1425 STEPPER
210. put 7 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 used for the high speed latch Only 3 inputs for the DMC 1425 Latch input High speed position latch to capture axis position in less than 1 usec on occurrence of latch signal AL command arms latch Input 1 is latch for X axis Input 2 is latch for Y axis if using DMC 1425 Analog input 12 bit resolution ICM 1460 Interconnect Module The ICM 1460 Rev C Interconnect Module provides easy connections between the DMC 14XX series controllers and other system elements such as amplifiers encoders and external switches The ICM 1460 accepts the 37 pin cable from the DMC 1415 DMC 1425 or DMC 1416 and breaks the pins out to screw type terminals Each screw terminal is labeled for quick connection of system elements The ICM 1460 is packaged as a circuit board mounted to a metal enclosure A version of the ICM 1460 is also available with a servo amplifier see AMP 1460 Features e Breaks out 37 pin ribbon cable into individual screw type terminals e Clearly identifies all terminals e Available with on board servo drive see AMP 1460 e 10 pin IDC connectors for main encoder Specifications Rev A F RevG Label Description Terminal Terminal AMPEN SIGN Y Amplifier enable X axis or Y Axis Sign Output for Stepper X Axis Motor
211. puter immediately prior to execution Tracing is enabled with the command 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 To route the trace to the controller s serial port use CFS To route the trace to the Ethernet use CFA TH shows which Ethernet handles are in use CW1 or CW2 may need to be issued of no output is seen Error Code Command When there is a program error the DMC 14XX 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 Breakpoint Command The BK command is used to set breakpoint in application programs and the SL command is used to single step from the breakpoint RA
212. quency For step motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Upon Reset the output will be low if the SM jumper is on If the SM jumper is not on the output will be tristate 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 3 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 INPUTS Main Encoder A B Main Encoder Index I Main Encoder A B I Aux Encoder A B A Abort input Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximum frequency does not exceed 12 000 000 quadrature states sec The controller performs quadrature decoding of the encoder 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 an
213. r 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 1460 interface board To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AEN signal note the state of the jumper on the ICM AMP 1460 When JP4 has a jumper from AEN to SV default setting the output voltage is 0 5V To change to 12 volts pull the jumper out and rotate it so that it connects the pins marked AEN and 12V If the jumper is removed entirely the output 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 jumper JP4 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
214. 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 o is o V Ka Ky Js 1 Kg Ky Ko Js U Ko ST 1 where the velocity time constant T1 equals TI Kc Kg This leads to the transfer function P V MIK s sT1 1 K 0 Figure 10 5 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Fig 10 6 142 Chapter 10 Theory of Operation DMC 14x5 6 VOLTAGE SOURCE V E W P E etos ST_ 1 ST 1 S CURRENT SOURCE V W VELOCITY LOOP V W P K ST 1 S Figure 10 6 Mathematical model of the motor and amplifier in three operational modes Encoder The encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the
215. rators The operator amp is a Logical And The operator is a Logical Or These operators allow for bit wise operations on any valid DMC 14XX numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The characters can be individually separated by using bit wise operations as illustrated in the following example Instruction Interpretation TEST Begin main program IN ENTER LEN S6 Input character string of up to 6 characters into variable LEN FLEN FRAC LEN Define variable FLEN as fractional part of variable LEN FLEN 10000 FLEN Shift FLEN by 32 bits IE convert fraction FLEN to integer LEN1 FLEN amp 00FF Mask top byte of FLEN and set this value to variable LEN2 FLEN amp FF00 100 Let variable LEN2 top byte of FLEN
216. rd FORCES MM NE Normally Closed o ema Jem Forward Normally Closed CN 1 Reverse Forward Forward Example Homing Instruction Interpretation HOME Label CN 1 Configure the polarity of the home input AC 1000000 Acceleration Rate DC 1000000 Deceleration Rate SP 5000 Speed for Home Search HM Home BG Begin Motion AM After Complete MG AT HOME Send Message EN End Figure 6 8 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 DMC 14x5 6 HOME _HMX 0 _HMX 1 MOTION BEGINS IN FORWARD DIRECTION MOTION CHANGES DIRECTION E MOTION IN FORWARD DIRECTION TOWARD INDEX INDEX PULSES VELOCITY e POSITION VELOCITY POSITION VELOCITY POSITION POSITION DMC 14x5 6 Figure 6 8 Homing Sequence for Normally Closed Switch and CN 1 Example Find Edge EDGE Label AC 2000000 Acceleration rate DC 2000000 Deceleration rate SP 8000 Speed Chapter 6 Programming Motion 89 FE Find edge command BG Begin motion AM After complete MG FOUND HOME Send message Define position as 0 EN End High Speed Position Capture Often it is desirable to capture the position precisely for registration applications The DMC 141X provides a position latch feature This feature allows the position to be captured in less than psec o
217. rd Record BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 N A N A N A N A N A N A BBlock A Block Present Present in Data in Data Record Record Bytes 2 3 of Header Bytes 2 and 3 make a word which represents the Number of bytes in the data record including the header Byte 2 is the low byte and byte 3 is the high byte NOTE The header information of the data records is formatted in little endian DMC 14x5 6 Chapter 4 Communication 45 General Status Information 1 Byte BIT 7 BIT BIT BIT BIT BIT 2 BIT 1 BIT 0 6 5 3 Program N A N A N A N A Waiting for Trace On Echo On Running input from IN command Axis Switch Information 1 Byte BIT 7 BIT 6 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Latch State of N A N A State of State of State of SM Occurred Latch Forward Reverse Home Jumper Input Limit Limit Input Installed Axis Status Information 2 Byte BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Movein Modeof Modeof FE Home Ist Phase 2 Phase Mode of Progress Motion Motion Find HM in of HM of uer Motion complete PA or PA only cred or FI Coord PR 5 command Motion issued BIT 7 BIT 6 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Negative Modeof Motion Motionis 8 Off On Motor Direction Motion is stopping making armed Error Off Move slewing dueto ST final armed Contour or Limit decel Switch Coordinated Motion Status Information for S or T plane 2 Byte BIT 15 BIT BIT 13 BIT 12 BIT
218. rdware Banks eese ener ener 166 Digital Inputs jen eiae db npe eee cedere pepe bend 166 High Power Digital essere eene nre enne 168 169 Electrical Specifications nae e baie bia lane oda e edt 170 Relevant DMC Commands essere 0 7 171 JS 80 pin Connector Pin 000 0000 171 Screw Terminal Listing bU a tereti aita 173 CB 50 80 Adapter Boards aisi nho tae eite e t ite tert 176 evident 176 CB 50 80 erecta o erit tia ee ord 178 Coordinated Motion Mathematical Analysis eese nnne 179 Iast ot Other Publications nate Grp rete epe atia ets 183 Traming Seminars 4 45 eoe eio eo nte dee eatin dee rt n ert etta 183 Gontactng US tono LE AT eL reif Ec 184 WARRANTY irent d eb geste 185 Index 186 DMC 14x5 6 Contents v THIS PAGE LEFT BLANK INTENTIONALLY vi Contents DMC 14x5 6 Chapter 1 Overview Introduction DMC 14x5 6 The DMC 1400 series of motion controllers were developed specifically for one or two axis applications allowing it to be smaller in size 1 2 size card and lower in cost than the Optima series multi axis controllers This manual covers three Ethernet based stand alone controllers in the DMC 1400 Econo series The DMC 1415 is a state of the art single axis motion controller that communicates via the Ethernet The DMC 1425 is the identical controller configured for basic two axis applications The DMC 141
219. reases Again the system may vibrate if the gain is too high In this case reduce KP Typically KP should not be greater than KD 4 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 lt CR gt becomes zero As KI is increased its effect is amplified and it may lead to vibrations If this occurs simply reduce KI 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 Example 1 System Set up This example assigns the system filter parameters error limits and enables the automatic error shut off Instruction Interpretation KP 10 Set proportional gain KD 100 Set damping KI 1 Set integral 1 Set error off ER 1000 Set error limit Example 2 Profiled Move Objective Rotate a distance of 10 000 counts at a slew speed of 20 000 counts sec and an acceleration and deceleration rates of 100 000 counts s Instruction Interpretation PR 10000 Distance SP 20000 Speed DC 100000 Deceleration AC 100000 Acceleration BG Start Motion In response the motor turns and stops Example 3 Position Interrogation The position of the axis may be interrogated with the instruction 28 Chapter 2 Getting Started DMC 14x5 6 TP Te
220. ring Conditions eene 107 Mathematical and Functional Expressions eene enne 110 Mathematical Operators de p tette oett deepest e Reges 110 Bit Wase Operators opt rente i ee p it ent e e pP ex pde 111 Igino re 112 A E E a Ea 112 8010 Programmiable ei atem ori E Hp eic RR Rd 113 etae e e e mr OPERE RO A 114 Special Operands Keywords 7 114 hun omm 115 Definng Arrays 115 Assignment of Array Entries cmo ne cmn cR One ties 115 Automatic Data Capture into Arrays 116 Deallocating Array Space iis ee atem OBERE yao RARE 118 Input of eren nennen enne 118 Input of 12810 118 119 Sending Messages addere dare trea e tte cients plies bee doe c uada 119 Displaying Variables and Arrays eese nee 120 Interrogation Commands 120 Formatting Variables and Array Elements essere 122 Converting to User Units redet niece iere irt dee He 123 Programmable Hardware 1 123 Digital Outputs 3 5 rt tei ceo AR O E 123 Digital Inputs odere create tte eere Ee ERES ERR eee eee e 124 Input Interrupt Funct ON rete 125 Example 2 2 riot eere rete eet ta eere Deo dapes ea
221. rives An encoder is not required when step motors are used Amplifier Driver 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 10 Volts should run the motor at the maximum speed For step motors the amplifiers should accept step and direction signals 4 Chapter 1 Overview DMC 14x5 6 Encoder For the DMC 1416 the power amplifier is internal to the unit The controller may be purchased with either a brush or brushless PWM amplifier The amplifier requires a single external DC power supply from 20 to 60 Volts The amplifier provides 6 amps continuous at 12 amps peak An encoder translates motion into electrical pulses which are fed back into the controller The DMC 14XX accepts feedbac
222. rnet Symptom Motor runs away when the loop is closed Motor oscillates e Operation Controller rejects command Anything Interrogate the cause with TC or Responded with a TCI Motor does not start or complete a move During a periodic operation motor drifts slowly Improper settings jumper configurations and or cable type IP address not assigned to controller IP address not allowed in the internal LAN and or improper Ethernet cable used Wrong feedback polarity Positive Feedback Make sure that the baud rate set in the software corresponds to the baud rate set by the jumpers on the controller Make sure a straight through RS 232 cable is used Follow the steps in Chapter for establishing an Ethernet connection Invert the polarity of the loop by inverting the motor leads brush type or the encoder channel B if single ended channel A A and B B if differential Too high gain or too little Decrease KI and KP Increase KD damping Noise on limit switches stops the motor Noise on the abort line aborts the motion Encoder noise To check the cause interrogate the stop code SC If caused by limit switch or abort line noise reduce noise Interrogate the position periodically If controller states that the position is the same at different locations it implies encoder noise Also use a scope to see the noise Reduce noise Use differential encoder inputs Same as
223. rray During a position move store the X and Y positions and position error every 2 msec Instruction Interpretation RECORD Begin program DM XPOS 300 YPOS 300 DM XERR 300 YERR 300 RA XPOS XERR YPOS YERR RD TPX TEX TPY TEY Define X Y position arrays Define X Y error arrays Select arrays for capture Select data types PR 10000 20000 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 DONE Done N Print Counter X POS N Print X position Y POS N Print Y position XERR N Print X error YERR N Print Y error N N 1 Increment Counter JP DONE N lt 300 Jump to DONE as long as there are positions left EN End Program Chapter 7 Application Programming 117 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 Note The IN command is only valid when communicating through RS232 T
224. rrays 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 Instruction Interpretation DISPLAY Label DM 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 14XX has a set of commands that directly interrogate the controller When these command 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 5 120 Chapter 7 Application Programming DMC 14x5 6 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 negati
225. rushless motor for sinusoidal commutation DMC 1415 only Step 8c Connect step motor Step 8d Connect brush or brushless servo motor to DMC 1416 Step 9 Tune servo system Step 1 Determine Overall Motor Configuration DMC 14x5 6 Before setting up the motion control system the user must determine the desired motor configuration The DMC 141X can control standard brush or brushless servo motors sinusoidally commutated brushless motors or stepper motors For control of other types of actuators such as hydraulics please contact Galil The following configuration information is necessary to determine the proper motor configuration Standard Servo Motor Operation The DMC 141X has been setup by the factory for standard servo motor operation providing an analog command signal of 10 volt The position of the jumpers at JP3 determines the type of output the controllers will provide analog motor command or PWM output The installation of these jumpers is discussed in the section Configuring Jumpers on the DMC 14XX Figure 2 3 shows how the jumpers are configured for the standard output mode The DMC 14XX controller will output the analog command signal to either brush or brushless servo amplifiers Please note that if the brushless amplifier provides the sinusoidal commutation the standard servo motor operation from the controller will be used If the commutation is to be performed by the controller please see below The DMC 1416 provi
226. s 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 1415 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 estimate 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 14XX 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 NOTE Hardware revisions A D need factory reconfiguration in order to control steppers Hardware revisions E or newer have jumpers for stepper configuration 2 Chapter 1 Overview DMC 14x5 6 DMC 14XX Functional Elements The DMC 14XX circuitry can be divided i
227. s at zero and may go up to 256 The parameters x y indicate the corresponding slave position For this example the table may be specified by ET 0 0 ET 0 0 ET 1 3000 DMC 1425 ET 1 3000 DMC 1415 1416 ET 2 2250 ET 2 2250 ET 3 1500 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 where x y are the master positions at which the corresponding slaves must be engaged If the value of any parameter is outside the range of one cycle the cam engages immediately When the cam is engaged the slave position is redefined modulo one cycle Step 7 Disengage the slave motion To disengage the cam use the command EQxy where x y are the master positions at which the corresponding slave axes are disengaged 72 Chapter 6 Programming Motion DMC 14x5 6 3000 2250 1500 0 2000 4000 6000 Master X 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 gt X 100 sin 0 18 X where X is the master with a cycle of 2000 counts The cam table can be constructed manually
228. s 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 All DMC 1415 1416 1425 controllers have general purpose I O connections On the DMC 1415 and DMC 1416 there are 7 TTL inputs and 3 TTL outputs On the DMC 1425 there are 3 TTL inputs and 3 TTL outputs The DMC 1415 1416 1425 and DB 14064 however has an additional 64 digital input output points The 64 I O points on the DB 14064 are attached via two 50 pin ribbon cable header connectors A CB 50 80 adapter card is used to connect the two 50 pin ribbon cables to a 80 pin high density 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 Appendices 165 Configuring Hardware Banks The extended I O on the DMC 1415 1416 1425 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 Resistor Pack for outputs Na OUT Resistor Pack for inputs U03 U04 Input Buffer IC s NI 0 Resistor Pack for outputs 1 02 Output Buffer IC s
229. s 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 14XX 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 and Y can be monitored during execution using the TE command Programmable Position Limits The DMC 14XX 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 14XX will not accept position commands beyond the limit Motion beyond the limit is also prevented Example DPO 0 Define Position BL 2000 4000 Set Reverse position limit FL 2000 4000 Set Forward position limit 132 Chapter 8 Hardware amp Software Protection DMC 14x5 6 JG 2000 2000 Jog BG XY 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 14XX controller has a built in fun
230. sition 69 70 109 117 137 39 Communication 3 8 Baud Rate 15 39 Handshake 39 Serial Ports 12 Compensation Backlash 56 Conditional jump 91 98 101 4 125 Configuring Encoders 84 Contour Mode 55 56 75 80 Control Filter Damping 27 136 140 Gain 119 Integrator 27 140 144 45 Proportional Gain 27 140 Coordinated Motion 50 55 65 67 Circular 65 67 116 127 Contour Mode 55 56 75 80 Ecam 71 72 74 Electronic Cam 55 56 70 73 Electronic Gearing 55 56 68 70 Gearing 55 56 68 70 Linear Interpolation 55 60 62 64 75 DMC 14x5 6 Cosine 56 111 12 115 Cycle Time Clock 114 D DAC 140 14445 147 Damping 27 136 140 Data Capture 116 17 Data Record 44 45 46 47 Debugging 96 Deceleration 118 Differential Encoder 19 21 136 Digital Filter 49 144 45 147 49 Gain 8 Stability 83 Digital Input 33 35 112 124 Digital Output 112 123 Dip Switch Address 115 17 184 Download 49 91 116 Dual Encoder 53 83 84 117 Backlash 56 Dual Loop 56 80 85 Dual Loop 56 80 85 84 Backlash 56 E Ecam 71 72 74 Electronic Cam 55 56 70 73 Echo 46 47 Edit Mode 97 107 Editor 30 91 92 EEPROM 3 Electronic Cam 55 56 70 73 Electronic Gearing 55 56 68 70 Ellipse Scale 67 Enable Amplifer Enable 35 131 Encoder Auxiliary Encoder 80 85 Differential 19 21 136 Dual Encoder 53 117 Index Pulse 19 34 Quadrature 5 123 126 132 143 Encoders 84 Auxiliary Encoders 156 Dual Loop 8
231. sponse from the Galil controller If this message appears you must click OK In this case there is most likely an incorrect setting of the serial communications port The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software The user must also insure that the proper serial cable is being used see appendix for pin out of serial cable Once you establish communications click on the menu for terminal and you will receive a colon prompt Communicating with the controller is described in later sections Using Galil Software for Windows 98 SE NT 4 2000 ME and XP The registration process for the DMC 1415 1416 1425 controllers in these operating systems is very similar to the Windows 3 x 95 98 FE procedure In DMC Terminal or WSDK the Galil registry is accessed in the File menu by selecting Register Controller In DMCWIN just click on the Registry menu button The Galil Registry Dialog is shown below DMC 14x5 6 Chapter 2 Getting Started 13 Edit Registry x Properties Non PnP Tools New Controller Find Ethernet Controller Plug and Play Device Bl Nor Plug and Play Device Close Select the button that says New Controller under the Non PnP Tools and then select DMC 1415 DMC 1416 or DMC 1425 from t
232. st compensation The following discussion presents an analytical design method The Analytical Method DMC 14x5 6 The analytical design method is aimed at closing the loop at a crossover frequency oc 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 kgm System moment of inertia R 2 Q Motor resistance K 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of the DMC 14XX 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 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 52 Amp K 2 Amp V DAC Kg 10 32768 0003 Encoder Kf 4 2 6 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 H s 3 17 106 s2 s 2000 Chapter 10 Theory of Operation 147 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 17106 1 500 2 j500 2000 T
233. tal 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 170 Appendices DMC 14x5 6 e Maximum sink current 2mA Relevant DMC Commands COn Configures the 64 bits of extended I O in 8 banks of 8 bits each n nj 2 n 4 n4 8 ns 16 ng 32 n 64 128 no where n is a 1 or 0 1 for outputs and 0 for inputs The x is the bank number OP m n o p q m 8 standard digital outputs n extended I O banks 0 amp 1 outputs 17 32 o extended I O banks 2 amp 3 outputs 33 48 p extended I O banks 4 amp 5 outputs 49 64 q extended I O banks 6 amp 7 outputs 65 80 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 O or 1 also able to use logical conditions TI n Returns the state of 8 digital inputs as binary 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 J5 8
234. tation phase is re set 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 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 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 8 where 8 implies the largest amount of smoothing See Command Reference regarding KS The DMC 14XX profiler commands the step motor amplifier All DMC 141X 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 14XX6 you must follow this procedure Step A Install SMX and SD jumpers In order for the DMC 141X to operate in stepper mode the corresponding stepper motor jumper installed For a discussion of SM jumpers see section Step 2 Install jumpers on the DMC 141X Step B Connect step and direction signals from controller to motor amplifier Connect the st
235. ters the final command on a program line Using Labels in Programs All DMC 14XX 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 92 Chapter 7 Application Programming DMC 14x5 6 The maximum number of labels which may be defined is 126 Valid labels BEGIN SQUARE begin1 Invalid labels 1 Square 123 A Simple Example Program Instruction START PR 10000 20000 BG XY AM WT 2000 JP START EN Interpretation Beginning of the Program Specify relative distances on X and Y axes Begin Motion Wait for motion complete Wait 2 sec Jump to label START 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 ST or HX command is issued Special Labels The DMC 141X also has some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines The following table lists the automatic subroutines supported by the controller Sample programs for these subroutines can be found in the section Automatic Subroutines for Monitoring Conditions AUTO AUTOERR ININT LIMSWI POSERR MCTIME
236. 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 VOC To Controller 5 e 4 1 8 RPx3 1 4 NEC2505 1 8 RPx2 gt 7 9 e 1 0 Sf v fe Controller O OUTC Figure A 10 IOM 1964 Digital Output with Internal Pullup Resistor The resistor pack RPx3 limits the amount of current available to source as well as affecting the low level voltage at the I O output The maximum sink current is 2mA regardless of RPx3 or I OC voltage determined by the NEC2505 optical isolator IC The maximum source current is determined by dividing the external power supply voltage by the resistor value of RPx3 The high level voltage at the I O output is equal to the external supply voltage at 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
237. tion curve to be prescribed for any motion 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 CMXY specifies contouring on the X and Y 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 over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2 ms where n is a number between 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 Point 1 Point 2 Point 3 Point 4 X 0 at T Oms X 48 at T 4ms X 288 at T 12ms X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 Increment 2 Increment 3 DX 240 DX 48 Time Increment 4 DT 2 Time Increment 8 DT 3 DX 48 Time Increment 16 DT 4 When the controller receives the command to generate a trajectory along these points it interpolates linearly between the points The resulting interpolated points include the position 12 at 1 msec position 2
238. tion ramp DC for each axis On begin BG the DMC 14XX 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 14XX profiler Note The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified 56 Chapter 6 Programming Motion DMC 14x5 6 The Begin BG command can be issued for all axes either simultaneously or independently X or Y 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 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 comma
239. tions WT 1000 Wait 1000 milliseconds JP B Jump to B EN End of program ININT Interrupt subroutine MG Interrupt has occurred Displays the message ST XY Stops motion on X and Y axes LOOP JP Loop until Interrupt cleared LOOP IN 1 0 JG 15000 10000 Specify new speeds WT 300 Wait 300 milliseconds BG XY Begin motion on X and Y axes RI Return from Interrupt subroutine DMC 14x5 6 Chapter 7 Application Programming 125 Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal which activates the cutter Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 27 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Fig 7 1 The program starts at a state that we define as A Here the controller waits for the input pulse on As soon as the pulse is g
240. 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 DMC 1400 Series Command Reference 54 TTChapter 5 Command Basics DMC 14x5 6 Chapter 6 Programming Motion Overview The DMC 14XX provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 1415 and DMC 1416 are single axis controllers and use X axis motion only The DMC 1425 is a two axis controller and uses both X and Y The example applications described below will help guide you to the appropriate mode of motion In these examples the DMC 1415 and DMC 1416 may perform single moves only while the DMC 1425 is capable of performing multiple axis moves Example Application Mode of Motion Absolute or relative positioning where each axisis 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 axis coordinated motion where path is described Linear Interpolation by linear segments 2 D
241. type or it may be of the pulse and direction type The controller also offers the provision for inverting the direction of the encoder rotation The main and auxiliary encoders are configured with the CE command The command form is CE x where x equals the sum of n and m below Normal quadrature Normal quadrature Pulse amp direction Pulse amp direction Reverse pulse amp direction Reversed pulse amp direction For example to configure the main encoder for reversed quadrature m 2 and a second encoder of pulse and direction n 4 the total is 6 and the command is CE6 Additional Commands for the Auxiliary Encoder The DE command can be used to define the position of the auxiliary encoders For example DEO sets the initial value The positions of the auxiliary encoders may be interrogated with DE For example DE returns the value of the auxiliary encoder The auxiliary encoder position may be assigned to variables with the instructions DE The current position of the auxiliary encoder may also be interrogated with the TD command Backlash Compensation DMC 14x5 6 The dual loop methods can be used for backlash compensation This can be done by two approaches 1 Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and t
242. ud rate for the controller is 19 2K Selecting MO as default on the DMC 14XX The default condition for the motor on the DMC 14XX is in the servo on SH state This will enable the amplifiers upon power up of the controller This state can be changed to the motor off MO default by placing a jumper at JP2 across the MO terminals This will power up the controller with the amplifiers disabled and the motor command off The SH command must then actively be given in order for the servos or steppers to operate Step 3 Connecting DC power and the Serial Cable to the DMC 14XX DMC 14x5 6 1 2 Insert 37 pin cable to J3 If using serial communications use the 9 pin RS232 ribbon cable to connect the SERIAL port of the DMC 14XX to your computer or terminal communications port The DMC 14XX serial port is configured as DATASET Your computer or terminal must be configured as a DATATERM for full duplex no parity 8 bits data one start bit and one stop bit Your computer needs to be configured as a dumb terminal which sends ASCII characters as they are typed to the DMC 14XX Connections to the controller for Ethernet communication are covered in Step 5 For the DMC 1415 and DMC 1425 apply 12 5V power to the J5 connector For the DMC 1416 apply a single external DC supply from 20 to 60 volts to the 5 pin box connector at the locations V PWR and GND This supply provides power for both the motion controller and the internal PWM amplifi
243. um 9 98 Volts The maximum level of 10 volts provides the full output torque Chapter 2 Getting Started 29 Example 7 Interrogation The values of the parameters may be interrogated using a For example the instruction KP Return gain The same procedure applies to other parameters such as KI KD FA etc Example 8 Operation in the Buffer Mode The instructions may be buffered before execution as shown below Instruction PR 600000 SP 10000 WT 10000 BG Interpretation Distance Speed Wait 10000 milliseconds before reading the next instruction Start the motion Example 9 Motion Programs Motion programs may be edited and stored in the memory They may be executed at a later time The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited For example in response to the first ED command the Galil Windows software will open a simple editor window From this window the user can type in the following program A PR 700 SP 2000 BG EN Define label Distance Speed Start motion End program This program can be downloaded to the controller by selecting the File menu option download Once this is done close the editor Now the program may be executed with the command XQ A Start the program running Example 10 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction A DPO V1 1
244. umber 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 SH lt CR gt Enable X axis motor PRX 1 BZX CR Move X motor close to zero commutation phase BG CR Begin motion on X axis AM CR Wait for motion to complete on X axis BZX 1 CR 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 Chapter 2 Getting Started 25 that occurs the controller computes the commutation phase and sets it For example to initialize the motor upon power or reset the following commands may be given SH lt CR gt Enable motor BC lt CR gt Enable the brushless calibration command PR 50000 lt CR gt Command a relative position movement BG lt CR gt Begin motion When the hall sensors detect a phase transition the commu
245. uts 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 Appendices 167 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 that 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 High Power Digital Outputs The first two banks on the IOM 1964 banks 0 and 1 have high current output drive capability The IOM 1964 is shipped with banks 0 and 1 configured as outputs Each output can drive up to 500mA of continuous current Configuring a bank of I O as outputs is done by inserting the optical isolator NEC2505 IC s into the Ux1 and Ux2 sockets The digital input IC s Ux3 and Ux4 are removed The resistor packs RPx2 and RPx3 are inserted and the input resistor pack RPx4 is removed Each bank of eight outputs shares one I OC connection
246. ve 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 Instruction Interpretation DP21 Define position TPX Tell position 0000000021 Default format PF4 Change format to 4 places TPX Tell position 0021 New format 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 Example Using the LZ command LZO Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 0000000000 0000000007 Response from Interrogation Command With Leading Zeros 121 Enables the LZ function TP Tell Position Interrogation Command DMC 14x5 6 Chapter 7 Application Programming 121 9 5 0 7 Response from Interrogation Command Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrogation commands may be formatted locally To format locally use the command Fn m or n m o
247. with seven entries DM SPEED 100 Defines an array named speed with 100 entries DM 0 Frees array space Assignment of Array Entries DMC 14x5 6 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 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 first 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 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 For example Instruction Interpretation A Begin Program COUNT 0 DM POS 10
248. x5 6 Configure your PC for 8 bit data one start bit one stop bit full duplex and no parity The baud rate for the RS232 communication can be selected by selecting the proper jumper configuration on the DMC 14XX according to the table below Baud Rate Selection JUMPER SETTINGS BAUD RATE Lom xe T OFF 19200 Handshaking Modes The RS232 port is configured for hardware handshaking In this mode the RTS and CTS lines are used The CTS line will go high whenever the DMC 14XX is not ready to receive additional characters The RTS line will inhibit the DMC 14XX from sending additional characters Note The Chapter 4 Communication 39 RTS line goes high for inhibit This handshake procedure ensures proper communication especially at higher baud rates Ethernet Configuration Communication Protocols The Ethernet is a local area network through which information is transferred in units known as packets Communication protocols are necessary to dictate how these packets are sent and received The DMC 14XX supports two industry standard protocols TCP IP and UDP IP The controller will automatically respond in the format in which it is contacted TCP IP is a connection protocol The master must be connected to the slave in order to begin communicating Each packet sent is acknowledged when received If no acknowledgement is received the information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connecti
249. ze the controller and command set Please contact Galil to talk to one of our applications engineers about your particular system requirements Watch Dog Timer DMC 14x5 6 The DMC 14XX 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 14XX 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 for each axis will also turn on at this stage A reset is required to restore the DMC 14XX to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 14XX is damaged Chapter 1 Overview 5 THIS PAGE LEFT BLANK INTENTIONALLY 6 Chapter 1 Overview DMC 14x5 6 Chapter 2 Getting Started The DMC 141X Motion Controller Figure 2 1 Outline of the DMC 1415 DMC 1425 JP4 J2 JP2 3 2 J1 J4 J3 4 J5 Figure 2 2 Outline of the DMC 1416 DMC 14x5 6 Chapter 2 Getting Started 7 DMC 141X Flash EEPROM Motorola 68331 microprocessor GL 1800 custom gate array J Lr 10Base T Ethernet connection 37 Pin D connection for controller signal break out 15 Pin D connection for controller main encoder breakout DMC 1416 6 Pin power connector for 5V 12V and 12V input DMC 1415 DMC 1425 N 9 J3 4 5 Pin

DMC-1415/1416/1425 USER MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents