Basic Description for PCL Series
Contents
1. pamphlets Basic description of PCL series Pre register preliminary buffer for the next operation 50oo Except PCL5022 5023 6100 6000 The term pre register refers to a register used to prepare for operation Simply put this is just like a waiting room where the data for the next speed pattern is stored As you can see in Table 2 below the pre registers are provided primarily for registers that determine speed patterns Registers that have pre registers Register details Register name PCL3013 5014 PCL6113 6123 6143 PCL6025 6045B Feed amount preset amount or target RO RMV RMV position FL speed R1 RFL RFL FH speed R2 RFH RFH Acceleration rate R3 RUR RUR Deceleration rate R15 RDR RDR Speed multiplication rate R4 RMG RMG Rampdown point R5 RDP RDP Operation mode Operation mode buffer RMD RMD Center position during arc interpolation or main axis feed amount during linear RIP RIP interpolation S curve range during S curve acceleration R16 RUS RUS shared for both S curve range during S curve deceleration acceleration RDS RDS deceleration Start command With preliminary buffer lt Table 2 gt On the models that do not have pre registers PCD series PCL 240 series and PCL5022 5023 if you want to use next different operating pattern after completing one operation first the LSI confirms the end of the previous operation using th2. By overwriting the target position data during operation the target position can be overridden The PCL changes the target position with the start position as the reference point The examples in Figure 8 are as follows When the target position is changed to a point further away than the preset target position during acceleration or constant speed operation the PCL will operate with the current speed pattern and complete the positioning using the new data When target position is changed to a point further away than the preset target position while decelerating the PCL will accelerate again from the current position to the specified operation speed and then complete the positioning using the new data When the motor has already passed the new position or you change the target position so that it is closer than the preset target position while decelerating the motor will decelerate and stop Then it will reverse and complete the positioning using the new data 18 Target position override Figure 8 T Change to far away position Change to far away position Change to already passed position Basic description of PCL series Operation speed override By changing the speed settings during operation you can change the speed and the acceleration rate 1 When the operation speed is changed to a lower speed than the preset while accelerating and if the new speed current speed the motor
3. Major applications Software limit function Positive limit Negative limit Example of the software limit function Can t move in further the negative direction Negative limit position Auto speed change Positive limit position Normal operation range i ps gt Can move in the positive direction Operation after reaching the negative limit position Can t move Can move in the 4 further in the negative direction positive direction Operation after reaching the positive limit position 20 Basic description of PCL series POINT 7 Other useful functions Manual operation input The manual operation input can be used to allow an operator to operate a motor with switches or a manual pulsar instead of through a CPU Using a manual pulsar or switch input each axis can be operated independently First write a start command for manual operation mode with a CPU Then the PCL can output pulses in response to switches or pulsar inputs Synchronous start control A synchronous start can be executed in the following two conditions Start when another axis stops With this function when one axis or multiple axes stop for example when the X and U axes stops or when the X Y and Z axes stop this can be set as the condition for starting another axis Start on an internal synchronous signal There are nine types of timing for the internal synchronous signal comparator
4. The internal action that occurs when a condition is met can be selected from various Figure 14 gt items The PCL3013 5014 and PCL6100 series can store two comparator data However the PLC6100 series have a simplified version of this function This section discusses examples of the comparator function in the PCL3013 5014 We ll refer to comparator 1 data as CMPD1 Comparator 2 data are CMPD2 the countdown counter value is DC and the up down counter value is UDC 1 What kinds of conditions can be specified You decide which conditions will be used for the CMPD1 or CMPD2 and DC or UDC and the signal to be output You can select from 13 types of conditions including those shown below a When UDC is equal to CMPD1 output a signal CMPD1 UDC b When UDC is larger than CMPD1 output a signal CMPD2 UDC c When DC is smaller than CMPD2 output a signal CMPD2 gt DC d When UDC is larger than CMPD1 and is smaller than CMPD2 output a signal CMPD1 UDC CMPD2 2 What does it mean to put out a signal a The CMP terminal goes ON LOW unconditionally when the comparator conditions are met b An INT signal can be output Set bit 12 in R8 Environment register 3 3 What kinds of internal processing will the PCL do when the conditions are met The PCL3013 5014 in addition to turning ON the CMP terminal and outputting an INT signal can do any of the four things below a Do nothing b Immediately stop outputting
5. coordinate position k A oO 0 0 and specify the center and end point coordinates of an arc Then select either a CW or CCW arc interpolation operation Enter the center coordinate and end point coordinates as incremental values from the current position starting point The CW arc interpolation draws an arc from the current coordinates to the end point coordinates 3 in a clockwise direction using the center 2 coordinates as the center of the arc The CCW 1 arc interpolation draws an arc in a Start point 4 Sb 0 0 oO 4 2 3 4 5 6 7 8 9 10 1 12 counterclockwise direction CAEN UNES Figure 2 is an example of drawing an arc with the output 4 X and Y axes in a CW arc interpolation operation pulses Y Y viele Y i es ARRRRRRRRI Mes pulses o N o a 4 X axis X axis CW arc interpolation 90 arc Figure 2 16 Basic description of PCL series What is synthesized constant speed control Figure 3 shows the locus of a two axis interpolation operation Following the basic pulses sent to the main axis pulses are output to each axis In the figure when both the X and Y axis pulses are output they have to feed longer distance x v 2 X compared with single axis feeding rea pulses Therefore with the synthesized constant speed l l control during s
6. drawing a freestyle curve a sequence of short line segments changes in the speed are possible as shown in Figure 3 Figure 3 In order to start the next operation by eliminating the waiting time you have to write the data to each of pre registers for the speed pattern settings as well as the next operation s start command The actual procedure is as follows To operate a motor with the pattern shown in Figure 2 do the following a First write the values for operation 1 in each pre register b Write a start command The moment the start command is written all of the values are copied into the appropriate operation registers and the LSI starts operation C After starting operation the values for operation 2 must be written to the LSI However the pre registers still contain the values that were written in step a above so you only need to overwrite those values that are different from operation 1 However the feed amount preset amount or target position still needs to be written again even if the value is the same as in the previous operation because the counter is reset to zero when the current operation is complete d During the execution of operation 1 write the next operation start command e After operation 2 has started repeats step c and d for subsequent operations 5 Rampdown point auto setting function 240 5000 6100 6000 For positioning operations preset operations with the PCD seri
7. in these series can provide linear interpolation of five or more axes Arc interpolation Arc interpolation between any two axes Between the X and Y axes for the 6025 The interpolation operation can be executed up to the maximum pulse frequency approx 6 5 Mpps with a reference clock of 19 6608 MHz in both linear and arc interpolations What is linear interpolation 2 eeeeeeees Y slave axis End point i coordinates To execute a linear interpolation specify the end 10 4 point coordinates and the desired linear i A el interpolation operation Specify the end point as 3 an incremental number of pulses from the current 2 position on each axis durs The PCL automatically identifies the axis with the coordinate mE larger feed amount as main axis and the other 00 mE EE NC E E EE a g Aa axis is the slave axis The main axis is supplied mur 7 p with pulses and the slave axis is supplied with a pulses v v v Y Y Y reduced number of pulses based on the ve U U interpolation calculations pulses hem Figure 1 shows a two axis linear interpolation with end point coordinates of 10 4 using the X and Y axes 1 Pulse out Two axis linear interpolation Figure 1 kkkkkkkk What is arc interpolation 2 eene Y slave axis To execute an arc interpolation take the current End point position as the starting point
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9. limit 11 Stepper motor out of step detection function 5000 5000 This function detects out of step of stepper lo motors To use this function install an encoder with the same resolution as the stepper motor on the same axis as the stepper motor as shown in Figure 20 The PCL compares the number of pulses output by itself with the pulses returned from the encoder If the difference exceeds a preset value the PCL determines that an out of step condition Encoder 2 pole HB type stepper motor has occurred and its takes a specified action 200 ppr 2 2 phase excitation 200 ppr The action taken when an out of step condition is detected varies with each model Figure 20 1 PCL5000 series This series stops the motor immediately and outputs an INT signal The PCL5000 series has a deflection counter for detecting an out of step motor This counter manages the deflection amount For example if the maximum deflection detection amount is set to 5 when the difference between the number of output pulses and returned pulses is 5 or less the PCL considers that OK If the difference is 6 or more the PCL declares that the motor is out of step and outputs an INT signal 2 PCL6000 series This series detects an out of step condition using Comparator 3 and COUNTERS the deflection counter Therefore the action taken when an out of step is detected can be selected from the actions available when the comparator conditio
10. logic can be selected m Emergency stop signal input When this signal goes ON all the axes stop immediately While this signal is ON no axis can be operated m Interrupt signal output An interrupt signal can be output by 17 types of errors and 19 types of events The error interrupt causes are always unconditionally output However the event causes can be set in the registers 22 Basic description of PCL series POINT 8 A variety of operation modes Roughly speaking the PCL series have 18 operation modes Command continuous Starts by a start command stops by a stop command operation Pulsar continuous After writing a start command synchronizes pulsar input with output operation pulses Switch continuous After writing a start command outputs pulses controlled by a switch operation input Zero return operation Feed to the zero position 13 zero return sequences are available Zero position leave When the zero position sensor is ON it moves the motor to a position operation where the sensor signal goes OFF EIE poswiening Moves to the end limit position or software limit position operation When a motor is on an end limit position or software limit position it kimit leaving egerat on moves it to a position where the limit signal turns OFF Positioning operation Set a target position and start a positioning operation Zero position return Move to a command position or towards a positio
11. pulses C Continue the internal operation but don t output pulses d Change the FH speed or the acceleration deceleration rate to the pre register values gt Select one of the actions the above using bits 20 and 21 in R7 Environment register 2 10 Basic description of PCL series In the PCL6100 series a comparison between inside the range and outside the range as described above in 1 a and d is not possible It must be handled by a CPU Also the PCL6100 series cannot execute internal action 3 c above Therefore when the conditions are met only the CP1 CP2 terminals CMP terminal on the PCL5014 go ON or an INT signal is output In the PCL6000 series in addition to a b and c above they have lots of counters for comparisons and can take various other actions For details see the respective User s manual 4 Example with a PCL3013 5014 8 Using only one comparator 200 000 pulse position when the counter During operation with a preset amount of 50 000 Valde reaches 20 02 Outer Arr INT gnal when the up down counter value exceeds lerate t 7 t MO toward aT OCU pps speeds 20 000 output an INT signal and start an acceleration rate of 500 accelerating he Molor Set as follows RO pre register R1 pre register preset amount 50000 FL speed 1000 R2 pre register FH speed 5000 R3 pre register acceleration rate 1000 R4 pre register multiplication 299 1x R10 comparator 1
12. signal To do this use the following settings R10 comparator 1 data 10 000 R11 comparator 2 data 10 000 10000 0 10000 Set R8 Environment register 3 bit 13 1 output an INT signal when the comparator lt Figure 16 gt conditions are met Set R7 Environment register 2 bits 16 to 19 1000 comparator condition R10 gt counter R11 lt counter Set R7 Environment register 2 bits 20 to 21 01 immediately stop outputting pulses Set R7 Environment register 2 bit 22 0 comparison counter to use Up down counter With these settings if the value of the up down counter becomes smaller than 10 001 or larger than 10 001 the motor will stop immediately and the CMP and INT signals will go LOW ON 5 Software limit 6000 The software limit is different from the hardware end limits such as the EL sensors It is used to set both ends of a range using two comparators Basically the LSI operates with the range of the data from two comparators allowing them to function as software end limits When the comparator conditions are met the machine has moved outside the software limit range the motor stops immediately and cannot rotate any more in the same direction However the motor can be rotated in the opposite direction The software limit function is found in the PCL6025 6045B but not in the PCL5000 or PCL6100 series Example 4 b in Section 9 of Chapter III looks like a software limit function When
13. the comparator conditions are met outside the range the motor stops immediately However the motor cannot be moved any more not even in the opposite direction Therefore in order to make it possible to move the motor with the PCL3013 5014 change bits 20 to 21 selected action when the comparator conditions are met in R7 from 01 to 00 do nothing R7 is Environment register 2 By setting it to do nothing the motor can be rotated in the opposite direction However please note that in this case the motor can also be moved further in the direction it was going when it went past the limit 12 Basic description of PCL series 10 Pulsar input 5000 6100 600 o 1 What is a pulsar Generally pulsars look like the one in Figure 17 The rotating dial is equipped with an encoder and can be turned with the handle on the dial The dial is just like the dial on a safe It clicks as it turns Turn it clockwise to move in the positive direction The pulsar in the photo on the left has two rotary switches The left rotary switch is used to select the axis to move up to six axes can be addressed separately The right rotary switch is used to select the units how many pulses per tick on the dial Basically most pulsars can output A B phase signals When an operator needs to adjust the position of a workpiece on a stage push buttons may be used to adjust it in a positive or negative Figure 17 direct
14. will use S curve deceleration to reach the new speed 2 3 When the operation speed is changed after acceleration is complete the motor will use S curve deceleration to reach the new speed 4 When a higher operation speed is written during acceleration the motor will accelerate to the preset speed without changing the S curve pattern Then it will accelerate again to the new speed 5 When a lower operation speed is written during acceleration and if the new speed speed when the change was written the motor will accelerate to the new speed without changing the S curve characteristics Examples of speed pattern changes by overwriting the speed during S curve acceleration deceleration Time Figure 9 POINT 5 Smooth the speed curve by using the FH correction function What is the FH correction function FH correction function Figure 10 During a positioning operation if the feed amount is very small this function automatically lowers the maximum speed and avoids triangle driving This smoothes the speed curve Automatic correction of the maximum speed for small feed amounts POINT 6 A variety of counters and comparators are built in Beside a dedicated positioning counter the PCL6025 6045B have four counter circuits per axis Counter 1 is exclusively for outputting pulses The input for Counters 2 to 4 can be selected with a CPU All of the counters can latch and reset their counter values from a signal inpu
15. 000 and PCL6100 series Starting on the next page we would like to describe enhanced control functions such as interpolation controls and a target position override function using the PCL6025 6045B for our example the top of the line NPM pulse control models The following descriptions are taken from instruction manual for the PCL6025 6045B The PCL6025 6045B have all the functions that are described in this document However the PCL5022 5023 and PCL6100 series also have some of the functions such as linear interpolation and target position override Please refer to the List of functions 15 Basic description of PCL series Instructions for the PCL6000 series Outline After receiving control commands from a CPU bus interface the PCL6025 6045B controls stepper motors and servomotors that are driven by pulse train inputs One of these LSI chips provides independent control variable continuous operation zero return operation and positioning operation using constant speed linear acceleration deceleration S curve acceleration deceleration of two or 4 axes linear interpolation between two to four axes and arc interpolation between two axes Features POINT 1 Interpolation operation The PCL6025 6045B offers the following interpolation operations Linear interpolation 1 One chip in this series can provide linear interpolation of any two to four axes Two axes only with the 6025 Linear interpolation 2 Multiple chips
16. Instruction documents Pulse Control LSIs Basic Description for PCL Series NPM Nippon Pulse Motor Co Ltd Table of contents l O tin 00032 A NA da iria On Ada a a wee eg 1 PELA AAA AENA 4 2 PCL5000 series 6 cece RR RR IRR 1 3 PCL6100 series 6000 series eee RII nn 1 II Differences between the PCL series and PCD series 2 1 Which should be selected sessiles RII I 2 Comparison of the basic functions in the PCD4500 PCL6100 and PCL6000 series iili 2 2 PCL series features in Table 1 above n RR I I me 2 IIl Major additional facilities and functions of the PCL series 3 1 Encoder input A B phase signal 90 phase difference signal or bi directional pulse signals 3 2 Upldown counter corista ea Xd elt denies hire Fecerat aie RERO LES ia al ada gles 3 3 Servomotor interface Rma 3 4 Pre register preliminary buffer for the next operation ooo nee 4 5 Rampdown point auto setting function ee 5 6 S curve range Setting rexkosesssxenc orelck EA Ae 7 7 Operating speed correction function FH correction function 8 8 Various zero return methods sees ee 8 9 Comparator anar ES LFU Yo RES ae oben 10 OS Pulsar IDDUb ce cer peer deren c1 do ea mp Pb eR a kt SIRO dace P CERA ead 13 11 Stepper motor out of step detection function eee 14 Instructions for the PCL6000 series O
17. N T ZA A AA o de rn 16 Features hihi 16 POINT 1 Interpolation operation lt lt e ene B 16 What is linear interpolation III III 16 What is arc interpolation hh 16 What is synthesized constant speed control 00 cece cere cence nnnes 17 POINT 2 Continuous operation using the pre registers 17 What is a pre register cece cc lh enn ene eens 17 POINT 3 Various acceleration deceleration patterns 18 POINT 4 Target position and speed override during operation 18 Target position override e er rix is ree XE ETE 18 Operation speed override 425 56 tia Rue her AA 19 POINT 5 Smooth the speed curve by using the FH correction function 19 What is the FH correction function I 19 POINT 6 A variety of counters and comparators are built in 19 POINT 7 Other useful functions rrt nn 21 Manual operation input m n nnn nnn 21 Synchronous start control rece dario E FERREA UE aa 21 PUE Ash a reru id a o Pe ea ee 21 Idling pulse outputs en mmn nnne nnn 21 Backlash correction slip correction o sees e eee eee ee ee eens 21 Vibration restriction function 00002 cece eee RH ene eens 21 Simultaneous start simultaneous stop eee eee eee eens 21 Mechanical input Signals gt xe coh dn coud x Eaoe gea ace i Re Connon es 22 Servomotor E 22 Output puls
18. conditions are met start complete acceleration start complete deceleration Select one of these m CPU I F You can select one of the following four types as a CPU hardware interface 1 Fora Z80 CPU 8 bit 2 For a 8086 CPU 16 bit 3 For an H8 CPU 16 bit 4 For a 68000 CPU 16 bit m Idling pulse outputs When starting with acceleration deceleration this function makes it possible to accelerate to the initial speed after a few pulses of operation idling pulses By setting the initial speed higher with acceleration deceleration control a stepper motor can be protected from encountering an out of step condition Backlash correction slip correction The backlash slip correction outputs a number of correction pulses at correction speed just before starting a command operation The backlash correction function is activated each time the feed direction is changed The slip correction function is activated just before a command operation regardless of the operation direction m Vibration restriction function This function adds one pulse of reverse operation and one pulse of forward operation just before completing a command operation so as to limit vibration when stopping The output timing for adding the pulses can be set in the register Simultaneous start simultaneous stop Multiple axes controlled by one IC or multiple axes controlled by multiple ICs can be started simultaneously by commands or external signals Also thi
19. data 20000 Set R8 Environment register 3 bit 13 1 output an INT signal when the comparator conditions are met Set R7 Environment register 2 bits 16 to 19 00100 comparator condition R10 lt counter Set R7 Environment register 2 bits 20 to 21 11 fill R2 and R3 with the pre register values P Preset amount 50 000 lt Figure 15 gt t s Set R7 Environment register 2 bit 22 0 comparison counter to use up down counter Set the up down counter to 0 Control command 61h Set the operation mode buffer control mode buffer and other register values and trigger a start high speed start 13h gt Accelerate from 1 000 pps to 5 000 pps After starting write 7 000 into the R2 pre register and 500 into the R3 pre register Then when the up down counter reaches 20 001 the 20 001 pulse after starting the motor will operate as follows The motor will accelerate from 5 000 pps to 7 000 pps with an acceleration slope of 500 In other words the R2 and R3 pre register values are copied into the registers The CMP signal goes LOW ON The INT signal goes LOW ON 11 Basic description of PCL series b Using two comparators Only possible to Make it possible to operate only within the range Out of range operate in this range Out of range of positions between 10 000 and 10 000 If the machine tries to operate outside this range lt stop immediately and output an INT
20. der input terminal is available except on the PCL 240AK for inputting the Z phase signal that is output once per rotation of the encoder This is usually used together with the ORG signal to perform a precision zero return positioning operation The PCD series only have a down counter However the PCL series have an up down counter as well as a down counter The up down counter counts up while the motor is rotating in a positive direction and it counts down while the motor is rotating in a negative direction This counter is mainly used to count A B phase signals from the encoder Since the counter is counting signals from the encoder you can know the exact current position at the moment you read this counter This counter also can be used in the following way Set it to not count when pulse signals are input such as A B phase signals In addition to A B phase signals bi directional pulse signals which use so called positive and negative direction pulses can also be counted In addition to external signals such as A B phase signals and bi directional pulses the counter can also count pulses output by the PCL itself Servomotor interface 240 5000 8100 5000 These LSIs have INP ERC and ALM terminals for making connections to a servo driver For details about the roles and functions of each signal see the Basics of servo motor control and the Function description list
21. e INT signal or a status register After confirming this you have to write the data for the next operation preset amount FL FH speed acceleration deceleration rate multiplication etc from a CPU If the register value is the same as in the previous operation you only write the preset amount and any other values you want to change The time required to confirm the end of previous operation and write the data for the next operation is only a few us However this interval is simply waiting time before the ultimate operation begins With pre registers you can write the data for the next operation during the current operation so that the next data are available as soon as they can be used Then the LSI can start the next operation immediately without the waiting time described above The operating pattern is a chain of multiple patterns as shown in Figure 2 Without pre registers f During this interval the LSI confirms that operation 1 has stopped and writes the register values and commands for operation 2 Therefore there is a period when everything stops even though it is very short The same is true for the time between operations 2 and 3 etc lt Figure 1 gt 4 Basic description of PCL series With pre registers f Using pre registers the LSI can prepare the data for the next operation during the current operation so that no time is lost between operations Figure 2 In another application
22. e are no functions found in the PCD series which are not found in the PCL series The PCD series have the minimum required functions for controlling stepper motors In addition to these functions the PCL series can handle servomotors and are equipped with the various interfaces encoder inputs and up down counters that are needed to control servomotors The registers related to speed patterns have more bits to handle the high speeds of servomotors Each model also has other functions However to make the selection simple if you want to control a closed loop system using position detection equipment such as encoders you should first consider using the PCL series If you want to control an open loop system using stepper motors you should first consider using the PCD series Table 1 sums up the basic performance offerings of the PCD series PCL6100 series and PCL6000 series Comparison of the basic functions in the PCD4500 PCL6100 and PCL6000 series Model PCD4511 4521 4541 PCL6113 6123 6143 PCL6025 6045B Function Number of axes controlled 1 2 4 1 2 4 2 4 rae le al clock 4 9152 MHz 19 6608 MHz Max 30 MHz 19 6608 MHz Max 20 MHz Maximum pulse output frequency 2 4 Mpps 9 8 Mpps Max 15 MHz 6 5 Mpps Number of registers for specifying d 2 FL FH 2 FL FH 3 FL FH FA for correction Number of speed step settings 8 191 13 bits 16 383 14 bits 65 535 16 bits Speed multiplica
23. e specification e 22 Emergency stop signal inputs esis doi ed ad e oan e o e wero 22 Interrupt signal output Th rer RRR a 22 POINT 8 A variety of operation modes RARERUePTARWe4sSWeLEWad 22 Basic description of PCL series Basic Description for PCL Series This document outlines the major functions of the PCL series pulse control LSIs which are not part of the PCD series Outline The PCD PCL series pulse control LSIs manufactured by NPM now have a varied lineup These products 17 models can be divided into the following three groups according to their command functions and registers PCL 240 family PCD4500 4511 4521 4541 PCL 240AK 240MK 240AS 240MS PCL5000 family PCL5000 series PCL3013 5014 PCL5022 5023 PCL6000 family PCL6100 series 6000 series PCL6113 6123 6143 PCL6025 6045B PCL 240 family In this family each command is allocated a specific bit Basically this is a simple family that has only four modes start mode control mode register select mode and an output mode 8 bits are used for each mode Since the PCL 240 series has a larger number of functions than the PCD series some commands for additional functions are accessed through registers PCL5000 series The PCL5500 series has many more functions than the PCL 240 family with lots of commands and registers The method for writing and reading this series is different from the PCL 240 family The PCL5022 5023 are LSIs for con
24. es we have to set a rampdown point deceleration start point for acceleration deceleration operations in order to tell the LSI the number of residual pulses at which to start deceleration All models in the PCL series have a rampdown point auto setting function Using this function you don t need to write the rampdown point setting register for each operation There are two ways to think about using the PCL series rampdown point auto setting function Basic description of PCL series 1 Count Method PCL 240AK 240MK 3013 5022 6113 6123 6143 This system counts the number of pulses used for acceleration the number of pulses between FL and FH speed When the number of residual pulses is equal to this amount the LSI starts the deceleration Count method f acceleration is equal to the number of residual pulses the LSI starts the deceleration When the number of pulses used for the Counts the number of pulses needed for acceleration Then sets the same number of pulses as the rampdown point Figure 4 gt This method requires the acceleration time deceleration time If you want to change the deceleration time if you want to have an asymmetrical pattern you have to disable the auto setting of the rampdown start point In this case you will have to write a value into the rampdown point setting register just like with the PCD series This is generally referred to manual rampdown point sett
25. however you can select various methods to perform a zero return such as using an encoder Z phase signal and you do not have to use the SD sensor This section discusses typical zero return methods 1 Decelerate on receiving the SD signal and stop on the ORG signal Start deceleration when f SD goes ON FH I Ld Sop when ORG goes ON FL f lt Figure 10 gt 240 5000 6100 6000 This is the normal zero return method the same as the PCD series After starting with an acceleration deceleration pattern when the SD sensor goes ON the motor starts to decelerate When the ORG sensor goes ON the motor stops Basic description of PCL series 2 Turn ON the SD signal and when the ORG signal goes ON the LSI starts counting the EZ pulses When the number of EZ pulses reaches the preset value stop the motor 240 5000 6100 6000 Start deceleration when a SD goes ON The zero return method described in 1 may have a deviation of a few pulses from the actual zero point This is method allows returning to the Aliseda E re eS zero position more accurately using the Z phase and then stop signal from an encoder The number of EZ pulses counted can be set between 1 and 16 FL lt Figure 11 gt 3 When the ORG signal goes ON the motor starts to decelerate and begins counting EZ pulses When the number of EZ pulses counted reaches the preset value the
26. ic description of PCL series 6 Zero position search operation Booo except PCL5022 5023 6000 In this zero search the motor rotates between the EL sensor and EL sensor back and forth and finally finds the zero position from the specified direction Internally this is configured by automatically switching between zero return operations and zero leaving operations 7 Other zero return operations 6000 Other zero return operations are possible with the PCL6025 6045B a return to a memorized ORG signal ON position b the motor decelerates stops and then reverses when the EL signal goes ON When the specified number of EZ pulses is counted the motor stops For the details about methods 5 6 and 7 see the User s Manual for these operation modes 9 Comparator 50oo Except PCL5022 5023 6100 6000 Wh The comparator refers to a comparison circuit en the motor reaches a preset position a signal is output Compare the preset value i e the comparator f data with an internal counter value When the comparison condition is met the LSI will output a signal or the PCL can take further action In simple terms it lets you know when the machine has passed a position with a signal which can be used to have the machine do something else The details of the comparator function vary with each model The PCL6000 series can store five comparator data
27. imultaneous operation of two Ye tput axes the PCL will increase the speed x 1 Y 2 multiplying the pulse output time x y 2 When you want to operate three axes simultaneously An example of two axes interpolation Figure 3 the speed of each axis is multiplied x 1 4 3 POINT 2 Continuous operation using the pre registers xxx What is a pre register kkkkkkkkkkkkkkkkkkkkkkkkkkkkkk The pre registers are registers in which you can write the data feed amount initial speed operation speed acceleration deceleration rate speed multiplication rate rampdown point operation mode arc interpolation center and S curve range during acceleration deceleration needed for the next operation and each subsequent operation The pre registers have the two step design shown in Figure 4 They operate as a FIFO Change 2 1st f i Setting nd l S l Register Operation pre register pre register control circuit Figure 4 Normally operation data is written to the 2nd 7 pre register and when you want to change the o ool current operation such as changing the speed Y axis 2 4 6 Linear interpolation you write new data directly to the registers When the current operation is complete the PCL automatically starts the next operation using the data in the pre register This method of operation eliminates any delay that would interrupt the process and reduces CPU processing time to provide smooth co
28. ing 2 Calculation Method PCL 240AS 240MS 5014 5023 6025 6045B In contrast with the Count Method 1 this method always calculates the number of pulses required to deceleration rate and stop The calculated result is used as the rampdown point The advantage of this method is that the deceleration time can be different from the acceleration time Asymmetrical speed patterns are possible gt This was designed for users who want the deceleration time to be shorter than the acceleration time that would be set using the rampdown point auto setting function Calculation method Calculates the number of pulses needed to reach FL speed from the current FH speed using the current deceleration rate and use this value as the rampdown point Start decelerating using the deceleration rate that is set Elk p I FL Figure 5 t Basic description of PCL series 6 S curve range setting 240 except for the PCL 240AK 240MK 5000 except for the PCL3013 5022 6100 6000 Point A A large rate of acceleration By drawing the tangent you can see how steep the slope is Figure 6 t S curve range By insetting a straight line the acceleration rate will be smaller the slope will be less steep Figure 7 ES With a normal S curve the center point of the S curve point A in Figure 6 has the largest acceleration rate a steep slope This means that the motor must accelerate rapidly at this poin
29. ion However in order to make fine adjustments to the position the pulsar may be more efficient Emergency stop button Multiplier number of pulses per tick on the dial x1 One pulse per tick x10 10 pulses per tick x100 100 pulses per tick Select the axis to control An bare encoder with a marked dial as shown to the left can be purchased and installed on a control panel LE m Figure 19 13 Basic description of PCL series 2 Manual pulsar input on the PCL This is a function used to receive encoder signals from some other encoder than the feedback encoder on the back of the motor Then pulses can be output from the OUT and DIR terminals A manual pulsar is not used to output pulses like a start command However as you turn the dial the motor will rotate and the up down counter can count the amount moved The PCL can read pulsar signals on both the PA and PB terminals The input signal type can be A B phase signals 90 phase difference signals or bi directional pulses positive and negative direction pulses When A B phase signals are selected you can set the multiplier to 1x 2x or 4x The PCL outputs pulses from the OUT and DIR terminals that are synchronized with the speed at which you turn the dial If a stepper motor is used turning too fast may cause it to get out of step Therefore the PCL is set so that it won t output pulses at a high frequency with the FH speed being used as the upper
30. its operation compared with the PCD series 2 Basic description of PCL series IIl Major additional facilities and functions of the PCL series bh Up down counter 240 5000 8100 8000 Though we cannot describe everything in detail here this section will introduce the remarkable functions of the PCL that are not found on the PCD series For an outline of all the functions see the function description list The symbols next to the additional functions or capabilities have the following meaning gt PCL 240 series function except for the PCD series gt PCL5000 series function gt PCL6100 series function gt PCL6000 series function Encoder input A B phase signal 90 phase difference signal or bi directional pulse signals 240 5000 6100 6000 Mainly used to input signals from an encoder mounted on a servomotor In some applications an encoder is mounted on a stepper motor to control the current position Encoder signals are input on the EA EB terminals on the PCL5000 6100 6000 series The input signal type can be either an A B phase signal 90 phase difference signals or a bi directional pulse positive and negative direction pulses If A B phase signals are selected they can be multiplied by 2x or 4x Normally rotation type encoders are mounted at the back of the servomotor Recently however linear type encoders are being installed on linear motion stages that use linear motors An EZ enco
31. motor stops 5000 6100 6000 Start to decelerate when f ORG goes ON This method uses the ORG sensor in place of the SD sensor You can use it if you want to FH Stop after counting avoid using the SD sensor ae the preset number of EZ pulses FL lt Figure 12 gt 4 When the RO pre register set value is reached the motor stops ORG sensor This mode is basically the same as described in 1 to 3 above However the motor will stop when the number of pulses is equal to the RO pre register value and does not require returning to the zero position One example of its use is to zero return the motor using rotation if the ORG sensor is disconnected or broken the ORG signal cannot be input so the motor can never stop Then by setting a rather larger number of pulses in RO the motor can be stopped when it reaches that number of pulses If the motor is stopped in this way arrange to output an error and you will know that there is a problem on or around the Put a large amount in RO as a preset value if the ORG sensor ORG sensor is broken the motor can be stopped when the pulses equal this preset amount Figure 13 5 Moving away from zero position Booo except PCL5022 5023 6000 This method is used to stop the motor after the ORG signal goes ON and then OFF This is used in cases where the first ORG ON does not really occur at the zero position 9 Bas
32. n until the current operation position counter becomes 0 One pulse operation Output just one pulse The IC performs a positioning operation internally However it does not Timer operation output pulses Used as a process timer Pulse synchronized positioning Switch input positioning Output a preset number of pulses each time a switch signal is input Linear interpolation 1 Positioning operation synchronized with the pulsar input Linear interpolation of any two to four axes operation Linear interpolation 2 Linear interpolation of five axes or more using multiple ICs operation Continuous linear Operation using linear interpolation 1 But the operation continues until interpolation operation a stop command is input Continuous linear interpolation 2 operation Arc interpolation operation Operation using linear interpolation 2 But the operation continues until a stop command is input Arc interpolation with any two axes Can draw a perfect right circle In the discussion above we have only been outlining the features and functions of the PCL series For items not described in this document or details of the individual functions see the user s manual for each model We hope this document will be helpful in your selection of a PCL model 23 Basic description of PCL series NPM Nippon Pulse Motor Co Ltd Asia Europe Nippon Pulse Motor Co Ltd 2 16 13 Hongo Bunkyo
33. ns are met Same as in section 9 3 in Chapter III The PCL5000 series has ERA ERB terminals exclusively for connecting an out of step detection encoder With the PCL6000 series the EA EB terminals are shared for use with an out of step detection encoder Just like with a pulsar input you can choose the pulse style A B phase signals 90 phase difference signal or bi directional pulse signals positive and negative direction pulses When A B phase signals are selected you can set the multiplier to 1x 2x or 4x The PCL6100 series does not have an out of step detection function What the PCL6100 series can do is as follows a Count output pulses using COUNTER1 b Count encoder signals EA EB input using COUNTER2 To check during operation c 1 During operation latch COUNTER1 and COUNTERZ2 using the latch command and then check the difference between them using a CPU If you want to perform this check by using an interrupt create a program that will make this comparison at a specified interval using the comparator To check while stopped c 2 Check the COUNTER1 and COUNTER 2 values while stopped to determine if there was an abnormal difference in the counts 14 Basic description of PCL series So the PCL6000 series needs you to write a program to compare the two values and determine if an out of step condition has occurred So far this document has been describing the major functions focused mainly on the PCL5
34. ntinuous operation Although the pre register has of two stages when you are allowed to write to the 2nd pre register by the current operation completing the PCL can output an interrupt signal to a CPU so that the PCL can operate continuously as shown in Figure 5 Continuous interpolation operation of arcs and lines Figure 5 17 POINT 3 Various acceleration deceleration patterns Each speed pattern can specify the following elements independently Initial speed Operation speed Acceleration speed characteristics acceleration rate acceleration S curve range Deceleration characteristics deceleration rate deceleration S curve range Therefore the various acceleration deceleration patterns in Figure 7 can be used The rampdown point can be set automatically as long as the Deceleration time Acceleration time x 2 Operation speed Acceleration S curve range Initial speed Basic description of PCL series Speed pattern Figure 6 Acceleration rate Deceleration rate Deceleration S curve range LA Positioning operation Us feed amount Ramp down point of positioning operation Manual or automatically set Examples of acceleartion deceleration patterns Figure 7 POINT 4 Target position and speed override during operation During operation the target position and speed can be changed freely by overwriting them Target position override
35. s function can stop all the axes at the same time on a command an external signal or by an error stop on any axis 21 Basic description of PCL series Mechanical input signals The following four signals can be input for each axis 1 EL When this signal turns ON while operating in the positive direction the motor stops immediately or decelerates and stops 2 EL When this signal turns ON while operating in the negative direction the motor stops immediately or decelerates and stops 3 SD Used as a deceleration signal or a deceleration stop signal by a software setting 4 ORG Input signal for a zero return operation The input logic for the EL EL signals can be changed with hardware The input logic of the SD ORG signals can be changed with software m Servomotor I F The following interface can be provided for the following three signals on each axis 1 INP Input a positioning complete signal that is output by a servomotor driver 2 ERC Output deflection counter clear signal sent to a servomotor driver 3 ALM Input an alarm signal that is output by a servomotor driver When this input signal goes ON the motor stops immediately or decelerates and stops The input output logic of the INP ERC and ALM signals can be changed with software The ERC signal is a pulse output and the pulse length can be selected Output pulse specification Select either common pulse or two pulse mode The output
36. t So the stepper motor may get out of step PCL series models that have S curve acceleration deceleration can make this intermediate part a straight line except for PCD series and the PCL3013 By providing a straight line here the acceleration rate will be smaller the slope will be less steep and an out of step condition can be prevented By setting the S curve range the length of the straight line can be set freely Basic description of PCL series 7 Operating speed correction function FH correction function 240 except PCL 240AK 240MK 5000 6100 except for the PCL3013 5022 6000 lt Figure 8 gt t lt Figure 9 gt t 8 Various zero return methods In order to eliminate the sharp peak of the triangle shape in Figure 8 in the PCD series you must manually calculate the peak speed FH Then you can set a top speed that is a little smaller than the FH value Models that offer S curve acceleration deceleration except for the PCD series and the PCL3013 have an FH correction function that can automatically set this FH value internally By enabling this function the LSI can create an S curve that uses FH speed as the top speed so that the peak of the shape will be smooth In the PCD series there is no other way to decelerate and perform a zero return than to turn ON the SD sensor to start deceleration and then stop when the ORG sensor turns ON In the PCL series
37. t and respond to operating conditions and commands from a CPU so that you can use them in a variety of applications 19 Counter name Counter1 Command position Basic description of PCL series o Can count Blank Can t count Counter 2 Mechanical position Counter 3 Deflection Counter 4 General purpo se Counter type Up down counter Up down counter Deflection counter Up down counter Bit length 28 28 16 Output pulses o o o Encoder EA EB inputs o o Pulsar PA PB inputs o o Reference clock cycles 2 The PCL6025 6045B have five built in circuits with 28 bit comparators CMP1 to 5 and can select the comparison data shown in the table below In addition there are 9 methods for comparison and four responses to choose from when the conditions are met By using the comparators and counters above you can do the following Interrupt output output comparison results externally use as an internal synchronous start Immediate stop or deceleration stop of the operation Automatic speed change during operation Software limit function Out of step detection for stepper motors Synchronous signal output Comparison data Counter 1 o Can compare Blank Can t compare Counter 2 Counter 3 Counter 4 Positioning counter Current speed Pre register None None
38. tion range 1x to 300x 0 3x to 600x 0 1x to 100x Acceleration rate range 2 to 1 023 10 bits 1 to 16 383 14 bits 1 to 65 535 16 bits Used for both Deceleration rate range acceleration deceleration 1 to 16 383 14 bits 1 to 65 535 16 bits Positioning pulse range 134 217 728 to 134 217 727 134 217 728 to 134 217 727 countdown counter 91918 147215 COP bits 28 bits 28 bits CPU interface 8 bit bus 16 bit bus 16 bit bus Rampdown point range 1 to 65 535 16 bits 1 to 16 777 215 24 bits 1 to 16 777 215 24 bits Table 1 2 PCL series features in Table 1 above 1 The is a large number of speed steps gt Can output high frequency pulses with low speed multiplication gt Finer tuning of the speed setting is possible When the speed setting registers FH or FL speeds are set to the same values as in the PCD the speed multiplication rate can be set between 1 2 to 1 8 2 The acceleration and deceleration rates can be set independently For example a short acceleration with a long deceleration is easily set Except for the PCL3013 3 The setting range of the acceleration deceleration rates and the rampdown point is larger n the PCD series these setting ranges are rather small which places some restrictions on the acceleration speed and the speed setting In the PCL series there is almost no restriction when setting the maximum speed As shown above the PCL series has almost no restriction on
39. trolling two axes The specifications for these LSIs when working on one axis are not as broad as the PCL5014 which can be used for linear interpolation For details about linear interpolation see the user s manual for each model or see page 17 in this document PCL6100 series 6000 series The PCL6000 series has still more functions than the PCL 5000 series such as lots of counters comparators and an arc interpolation function see page 16 The bits for commands registers and status conditions have been named for easy reference This series contains the best models we offer PCL6100 series has fewer functions than the PCL6000 series and they cost much less as well Even though the functions are limited the basic high level functions are still present such as servomotor control and linear interpolation The power supply requirement is just 3 3 V They offer the highest output frequency offered by the NPM pulse control LSIs and they can control high resolution linear motors e When our models are classified by compatibility with software programs there are 6 types as shown below PCD4500 4511 4521 4541 PCL 240AK 240MK 240AS 240MS PCL3013 5014 PCL5022 5023 PCL6113 6123 6143 PCL6025 6045B SS O DBI NS 1 2 3 4 5 6 Basic description of PCL series II Differences between the PCL series and PCD series 1 Which should be selected Except for the excitation sequence output for a 4 pole 2 pole stepper motor ther
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