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FlexMotion-6C Hardware User Manual

1. 2 1 Controller Configuration 2 1 PC FlexMotion 6C Controllers 2 2 PCI FlexMotion 6C Controllers 2 2 Hardware Installation 2 2 Chapter 3 Hardware Overview User Connectors 3 2 Test Connectors 3 3 ISA Bus Address Table PC FlexMotion 6C Only 3 3 Motion I O Configuration 3 7 Selecting an Isolated External Internal Voltage Supply Configuration 3 8 Locating the Isolated Supply Jumper Block JP2 3 8 How to Set the Isolated Supply Jumpers JP2 for Internal 5 V Supply 3 8 How to Set the Isolated Supply Jumpers JP2 for External Isolated Supply ISO
2. 4 6 Axes 4 6 Motion Resources 4 7 Vector Spaces 4 8 Onboard Programs 4 9 Find Home and Find Index 4 10 Find Home 4 10 Find Index 4 10 Host Communications 4 11 Packets Handshaking and FIFO Buffers 4 11 Return Data Buffer 4 12 Error Stack 4 13 Chapter 5 Signal Connections Motion I O Connector 5 1 Motion Axis Sign
3. 5 14 PWM Features 5 17 Appendix A Specifications Appendix B Cable Connector Descriptions Appendix C Technical Support Resources Glossary Index Figures Figure 3 1 PC FlexMotion 6C Parts Locator Diagram 3 1 Figure 3 2 PCI FlexMotion 6C Parts Locator Diagram 3 2 Figure 3 3 Factory Default DIP Switch Setting 3 4 Figure 3 4 Internal 5 V Supply Configuration Limit Switch Connection Example 3 9 Figure 3 5 External Voltage Supply Configuration Limit Switch Connection Example 3 10 Figure 3 6 Optocoupled Motion I O DIP Resistor Networks 3 11 Figure 3 7 Encoder Input Termination SIP Resistor Networks 3 12 Figure 4 1 Servo Axis Resources 4 6 Figure 4 2 Stepper Axis Resources 4 6 Figure 4 3 3D Vector Space 4 8 Fi
4. 10 V 32 768 to 32 767 Stepper Performance Trajectory update rate range 125 to 500 s sample Max update rate 125 s axis Multi axis synchronization lt 1 update sample Position accuracy Open loop stepper 1 full half or microstep Encoder feedback 1 quadrature count Analog feedback 1 LSB Long term velocity accuracy Oscillator based 100 ppm Double buffered trajectory parameters Position range 231 steps Max relative move size 231 steps Velocity range 1 to 1 500 000 steps s RPM range 10 5 to 106 revolutions minute Acceleration deceleration 4 000 to 128 000 000 steps s2 RPS s range 10 1 to 108 revolutions s2 S curve time range 1 to 32 767 samples Following error range 0 to 32 767 counts Gear ratio 32 767 1 to 1 32 767 Appendix A Specifications National Instruments Corporation A 3 FlexMotion 6C Hardware User Manual Stepper outputs Max pulse rate 1 5 MHz full half and microstep Min pulse width
5. 3 9 RP3 and RP10 DIP Resistor Networks 3 10 Selecting Encoder Termination Networks 3 11 Contents FlexMotion 6C Hardware User Manual vi www natinst com Chapter 4 Functional Overview Dual Processor Architecture 4 1 Embedded Real Time Operating System RTOS 4 1 Enhanced PID Functions 4 2 Trajectory Generators 4 2 Trapezoidal Point to Point Position Control 4 3 Velocity Control 4 3 Move Blending 4 3 Electronic Gearing 4 4 Linear and Circular Interpolation 4 4 Analog Feedback 4 5 Flash Memory 4 5 Axes Motion Resources and Vector Spaces
6. Host 5 V This is the host computer s internal 5 V supply It is used to detect when the host computer is powered and as an interlock to shut down external motion system components when the host computer is turned off Caution The host 5 V signal is limited to lt 100 mA and should not be used to power any external devices except those intended in the host bus monitor circuits on the UMI and drive units E Stop The optoisolated Emergency Stop input signal when enabled in software can be used to kill all motion by zeroing the analog outputs and freezing the stepper pulse and or direction outputs Auxiliary 24 Bit Digital I O Connector All of FlexMotion 6C s general purpose digital I O lines are available on a separate 50 pin box header connector The pinout of the connector and electrical characteristics of the I O signals follow the OPTO 22 type standard Each output circuit can sink 24 mA and source 3 mA Through a standard 50 pin ribbon cable the 24 bits of digital I O can be directly interfaced to industry standard signal conditioning racks with relays optoisolated I O or special function modules including the National Instruments 6B Series signal conditioning devices Chapter 5 Signal Connections National Instruments Corporation 5 15 FlexMotion 6C Hardware User Manual Figure 5 7 gives the pinout of the auxiliary 24 bit digital I O connector Figure 5 7 50 Pin Digital I O Connector Pin Assignments
7. 4 Encoders 1 through 4 Voltage range 0 to 24 V Output low voltage lt 1 2 V at 50 mA sink Output high voltage open collector with built in pull up to ISO See Table 3 2 Optocoupler TLP627 or equivalent Polarity Programmable active high or active low Appendix A Specifications National Instruments Corporation A 5 FlexMotion 6C Hardware User Manual Inhibit enable output Open collector Number of outputs 6 1 per axis Voltage range 0 to 12 V Output low voltage lt 1 1 V at 100 mA sink Buffer MC1413 or equivalent Polarity Programmable active high or active low Control MustOn mustOff or automatic when axis off Analog inputs Number of inputs 8 multiplexed Voltage range 10 V Input resistance 20 k min Resolution 12 bit 0 0049 V LSB Analog reference output 7 5 V nominal Reference drift 25 ppm C type Error Pos
8. it is necessary to supply an external isolated voltage source ISO on the 100 pin connector to power these isolated I O circuits Alternatively you can forgo the optoisolation and set onboard jumpers to use the computer s internal 5 V supply to power the motion I O circuits In this case the motion I O signals will be non isolated Locating the Isolated Supply Jumper Block JP2 Refer to Figures 3 1 and 3 2 for the location of the isolated supply jumper block JP2 You use this 6 pin jumper block to select between the computer s internal 5 V supply or an external isolated ISO power source for the FlexMotion 6C optocoupled circuitry Note The FlexMotion 6C isolated supply jumpers are factory configured for external isolated voltage source and motion I O will not function properly until a ISO voltage is supplied or the jumpers are reconfigured to use the internal 5 V supply How to Set the Isolated Supply Jumpers JP2 for Internal 5 V Supply To use the internal 5 V supply for isolated ISO and isolated return ISORTN place the jumpers on jumper block JP2 as shown in Figure 3 4 You must also change DIP resistor networks RP3 and RP10 from 2 2 k to 470 The appropriate DIP resistor networks are included in the FlexMotion 6C accessory pack that ships with the controller When changing networks be careful to install the resistor network with the correct pin 1 orientation You can then connect your limit and home
9. 3 11 FlexMotion 6C Hardware User Manual Figure 3 6 Optocoupled Motion I O DIP Resistor Networks Table 3 2 shows the correct DIP resistor values for each range of external and internal isolated supply voltage Note The resistor networks used for RP3 and RP10 are 16 pin DIP packages with 15 resistor bused pull up networks Bourns part number 4116R 002 RRR or equivalent RRR resistor value Selecting Encoder Termination Networks FlexMotion 6C offers high speed differential or single ended encoder inputs with user configurable termination for optimum encoder signal performance The termination is provided by SIP resistor networks RP6 RP8 RP11 RP13 and RP15 These networks are dual termination networks The terminated Table 3 2 Motion I O Resistor Values Isolated Supply Voltage DIP Resistor Network 5 V internal 470 5 to 12 V external 470 10 to 18 V external 1 k 18 to 24 V external 2 2 k factory default RP3 RP10 5 V ISO ISORTN OptoCoupled Output ie Breakpoint etc Connected to internal FlexMotion circuits RP3 RP10 GND ISO OptoCoupled Input ie Limits Home etc Connected to internal FlexMotion circuits 16 ISO 9 1 8 Chapter 3 Hardware Overview FlexMotion 6C Hardware User Manual 3 12 www natinst com encoder signals are pulled up to 5 V and pulled down to GND through appropriate resistance values as shown in Figure 3 7 Th
10. 300 ns at 1 5 MHz Step output mode Step and direction or CW CCW Stepper outputs Open collector TTL Voltage range 0 to 5 V Output low voltage lt 0 6 V at 64 mA sink Polarity Programmable active high or active low System Safety Watchdog timer function Resets controller to startup state Watchdog timeout 63 ms E Stop input Optocoupled Voltage range 0 to 24 V Optocoupler TLP626 or equivalent Max input current 10 mA built in current limiting resistor Control Disable all axes and command outputs Motion I O Encoder inputs Quadrature incremental Max count rate Encoders 1 and 2 16 MHz Encoders 3 and 4 1 MHz Encoders 5 and 6 2 MHz Encoder signal options Differential or single ended A A B B Index Index per axis Differential input threshold 0 3 V typical Differential line receiver MC3486 or equivalent Voltage range 0 to 5 V Min inde
11. architecture that can be tailored to any motion application requirement An encoder input channel converts quadrature signals on Phase A and Phase B into 32 bit up down counter values Quadrature signals are generated by optical magnetic laser or electronic devices that provide two signals Phase A and Phase B that are 90 out of phase The leading phase A or B determines the direction of motion The four transition states of the relative signal phases provide distinct pulse edges that cause count up or count down pulses in the direction determined by the leading phase A typical encoder with a specification of N N number lines per unit of measure revolutions or linear distance will produce 4 N quadrature counts per unit of measure The count is the basic increment of position in FlexMotion systems Note Determine quadrature counts by multiplying the encoder resolution in encoder lines by 4 The encoder resolution is the number of encoder lines between consecutive encoder indexes marker or Z bit If the encoder does not have an index output the resolution would be referred to as lines per revolution or lines per unit of measure inch centimeter millimeter and so on Encoder lt 1 6 gt Index Encoder lt 1 6 gt Index Chapter 5 Signal Connections National Instruments Corporation 5 9 FlexMotion 6C Hardware User Manual The Index input is primarily used with the Find Index function This function u
12. 5 V supply 3 8 to 3 9 PC FlexMotion 6C controllers 2 2 PCI FlexMotion 6C controllers 2 2 connectors See also motion I O connector auxiliary 24 bit digital I O connector 5 14 to 5 18 50 pin connector pin assignments figure 5 15 digital I O port configuration figure 5 16 cable connectors B 1 to B 3 first 50 pin motion I O pin assignments B 2 second 50 pin motion I O pin assignments B 3 physical specifications A 7 reserved connectors note 3 3 user connectors 3 2 D DAC resources 4 7 diagnostic resources online C 1 Digital Ground signal table 5 3 digital I O connector See auxiliary 24 bit digital I O connector DIP resistor networks RP3 and RP10 3 10 to 3 11 motion I O DIP resistor values table 3 11 optocoupled motion I O DIP resistor networks figure 3 11 DIP switch settings See ISA bus address table documentation about the manual ix conventions used in manual ix related documentation x dual processor architecture 4 1 to 4 5 E electronic gearing 4 4 embedded real time operating system RTOS 4 1 to 4 2 Encoder lt 1 6 gt Index signal reference direction and description table 5 3 using with Find Index function 5 8 to 5 9 Encoder lt 1 6 gt Index signal reference direction and description table 5 3 using with Find Index function 5 8 to 5 9 Encoder lt 1 6 gt Phase A signal quadrature encoder input 5 7 to 5 8 reference direction and description table 5 3
13. 6C Hardware User Manual 3 Hardware Overview This chapter presents an overview of the hardware functionality on the FlexMotion 6C controller The FlexMotion 6C controller comes in two versions PC FlexMotion 6C for ISA bus computers PCI FlexMotion 6C for PCI bus computers Figures 3 1 and 3 2 show the PC FlexMotion 6C and PCI FlexMotion 6C parts locator diagrams Figure 3 1 PC FlexMotion 6C Parts Locator Diagram 1 Assembly Number Label 2 Serial Number Label 3 100 Pin Motion I O Connector 4 Encoder Termination SIP Resistor Networks 5 ISA bus Address DIP Switch 6 MC68331 CPU 7 50 Pin Auxiliary 24 Bit Digital I O Connector 8 4 Pin Auxiliary Power Connector 9 10 Pin Test Connector 10 ADSP 2111 DSP 11 10 Pin Serial Port Connector 12 Isolated Supply Jumpers JP2 13 Motion I O DIP Resistor Networks 8 9 11 12 13 1 2 4 3 5 7 6 10 Chapter 3 Hardware Overview FlexMotion 6C Hardware User Manual 3 2 www natinst com Figure 3 2 PCI FlexMotion 6C Parts Locator Diagram User Connectors The 100 pin motion I O connector provides all of the signals for the six axes of closed loop motion control including encoder feedback limit and home inputs breakpoint outputs trigger inputs and A D converter signals Refer to Chapter 5 Signal Connections for the complete details of the signals in the motion I O connector The 50 pin auxiliary 24 bit digital I O connector provides an
14. ISA and PCI bus computers These controllers provide fully programmable motion control for up to six independent or coordinated axes of motion with dedicated motion I O for limit and home switches and additional I O for general purpose functions You can configure up to two of the axes for stepper motor control You can use these controllers for all position and velocity control applications including the following Point to point positioning Velocity profiling 3 D Linear interpolation Electronic gearing Circular helical and spherical interpolation Time based motion integration Vector space motion Servo axes can control servo motors servo hydraulics servo valves and other servo devices Servo axes always operate in closed loop mode These axes use quadrature encoders or analog inputs for position and velocity feedback and provide analog command outputs with an industry standard range of 10 V FlexMotion 6C can also be configured for up to two stepper axes to control stepper motors These axes can operate in open or closed loop mode They use quadrature encoders for position and velocity feedback closed loop only and provide step direction or clockwise CW counter clockwise CCW digital command outputs All stepper axes support full half and microstepping applications Chapter 1 Introduction FlexMotion 6C Hardware User Manual 1 2 www natinst com FlexMotion 6C s high performa
15. PWM features 5 17 to 5 18 specifications A 6 axes functional overview 4 6 to 4 7 servo axis resources figure 4 6 stepper axis resources figure 4 6 Axis lt 1 6 gt Forward Limit Input signal limit and home input control 5 5 to 5 6 reference direction and description table 5 3 Axis lt 1 6 gt Home Input signal limit and home input control 5 5 to 5 6 reference direction and description table 5 3 Axis lt 1 6 gt Inhibit signal description 5 5 reference direction and description table 5 3 Axis lt 1 6 gt Reverse Limit Input signal limit and home input control 5 5 to 5 6 reference direction and description table 5 3 B blending moves 4 3 to 4 4 Breakpoint Output lt 1 4 gt signal purpose and use 5 11 reference direction and description table 5 3 breakpoint outputs See trigger inputs and breakpoint outputs BridgeVIEW software 1 3 Index FlexMotion 6C Hardware User Manual I 2 www natinst com C cable connector pin assignments B 1 to B 3 circular interpolation 4 4 to 4 5 communications See host communications configuration bus related configuration 2 1 motion I O configuration 3 7 to 3 12 encoder termination network selection 3 11 to 3 12 isolated external internal voltage supply configuration 3 8 to 3 11 locating isolated supply jumper block JP2 3 8 overview 2 1 RP3 and RP10 DIP resistor networks 3 10 to 3 11 setting isolated supply jumper block for internal
16. The 24 bit digital I O port is configured in hardware as three 8 bit digital I O ports as shown in Figure 5 8 The bits in a port are typically controlled and read with byte wide bitmapped commands Port 1 bit 0 Port 1 bit 2 Port 1 bit 3 Port 1 bit 4 Port 1 bit 5 Port 1 bit 6 Port 1 bit 7 Port 2 bit 0 Port 2 bit 1 Port 2 bit 2 Port 2 bit 3 Port 2 bit 4 Port 2 bit 5 Port 2 bit 6 Port 2 bit 7 Port 3 bit 0 Port 3 bit 1 Port 3 bit 2 Port 3 bit 3 Port 3 bit 4 Port 3 bit 5 Port 3 bit 6 Port 3 bit 7 5 V Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground Digital Ground 49 50 47 48 45 46 43 44 41 42 39 40 37 38 35 36 33 34 31 32 29 30 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 Port 1 bit 1 Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 16 www natinst com Figure 5 8 Auxiliary 24 Bit Digital I O Port Configuration Each port has different characteristics and features that you can configure and access through software Port 1 is bidirectional and can be configure
17. User Manual Error Stack To handle run time or modal errors FlexMotion 6C maintains an error stack If an error is detected during command execution the Command ID Resource ID and Error Code are placed on a last in first out LIFO stack and the error message bit in the CSR is set Since commands can be buffered in the command FIFO errors detected at command execution time are delayed and are not reported as packet errors They are pushed on the error stack to be read back by the host at a later time This error handling structure also correctly detects errors generated by incorrectly sequenced programs and other modal errors The error stack is organized as a LIFO buffer so that old errors can be ignored and the most recent error is readily available to be read with the Read Error Message function just like any other status or data value Older errors can then be read back in the inverse order to which they were generated and reviewed for their relevance The error stack can hold up to 30 errors If the error stack fills up before any error message is read back an unlikely event additional error messages are thrown away Note Refer to the Error Codes section of your FlexMotion software reference for additional information on types of errors and possible reasons for their occurrence If the host or onboard program is correctly written you should not see any packet or modal errors These error handling structures are used mostly d
18. axis Relative to Captured Position The polarity of the high speed input is programmable in software as active low inverting or active high non inverting You can also use a trigger input as a latching general purpose digital input by simply ignoring the captured position The trigger functions as a one shot and must be enabled appropriately Breakpoint Output lt 1 4 gt A breakpoint output can be programmed to transition when the associated encoder value equals the breakpoint position You can use a breakpoint output to directly control actuators or as a trigger to synchronize data acquisition or other functions in the motion control system You can program breakpoints as either Absolute Modulo or Relative position Breakpoints are one shot and must be enabled and re enabled each time they occur to function properly The Enable Breakpoint function also allows you to preset the breakpoint output to a known state so that the transition when the breakpoint occurs can be low to high high to low or toggle You can read the status of the breakpoint function at any time When a breakpoint is enabled its corresponding status bit is reset to FALSE and its status goes TRUE when the breakpoint occurs Note The Read Breakpoint Status function does not return the digital I O value of the breakpoint outputs it returns the enabled occurred status instead You can directly set and reset breakpoint outputs so you can use them as general
19. each ADC input channel the analog signal to be measured should be connected to the channel input and its ground reference connected to the Analog Input Ground connection Note If an external reference voltage is used it must not be connected to the analog reference output since this is an output signal only You should however connect the external reference s digital ground to the Analog Input Ground pin for proper A D reference and improved voltage measurement Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 14 www natinst com Other Motion I O Connections FlexMotion 6C provides other motion I O connections as follows ISO This is the external isolated voltage supply input used to power all of the optoisolated I O circuitry when an external isolated voltage supply is selected When the internal 5 V supply is selected this signal is connected to the host computer s 5 V supply through a thermally resetable fuse In this configuration the I O circuits are non isolated and up to 0 5 A is available at this connection to power external sensors and devices ISORTN This is the current return connection for the external isolated voltage supply All optoisolated circuitry is referenced to this signal connection Note See Selecting an Isolated External Internal Voltage Supply Configuration in Chapter 3 Hardware Overview for further information on how to use the ISO and ISORTN connections
20. online problem solving and diagnostic resources C 1 software related resources C 2 Worldwide technical support C 2
21. purpose digital outputs Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 12 www natinst com Wiring Concerns Caution Keep trigger input and breakpoint output signals and their ground connections wired separately from the motor driver amplifier signal and encoder signal connections Wiring these signals near each other can cause faulty operation Excessive input voltages can cause erroneous operation and or component failure Trigger Input and Breakpoint Output Circuits Figures 5 5 and 5 6 show a simplified schematic diagram of the circuits used by the trigger inputs and breakpoint outputs for signal isolation The trigger inputs use optocouplers rated in excess of 10 MHz to provide minimum latency on these signals Figure 5 5 Trigger Input Circuit Figure 5 6 Breakpoint Output Circuit Note See Selecting an Isolated External Internal Voltage Supply Configuration in Chapter 3 Hardware Overview for information on selecting the appropriate DIP resistor value RP3 RP10 ISO OptoCoupled Trigger Input Connected to internal FlexMotion circuits GND TLP2631 5 V RP3 RP10 5 V ISO ISORTN TLP627 OptoCoupled Breakpoint Output Connected to internal FlexMotion circuits Chapter 5 Signal Connections National Instruments Corporation 5 13 FlexMotion 6C Hardware User Manual Analog Inputs FlexMotion 6C has the following ADC input signals Analog Input lt 1 8
22. two built in programs to aid in initializing your system and establishing a repeatable zero position reference for system wide operation and control Find Home You use the Find Home function to search for a home switch stop on a specific edge of the switch or optionally go past and approach the home switch edge from a programmed direction You can specify the initial search direction and are guaranteed to find the home switch if one exists because end of travel limit conditions are handled by reversing the home search direction Note Refer to the Find Home and Index Functions section of the FlexMotion Software Reference for more information on the Find Home function Find Index You can use the Find Index function to search one revolution for the Index mark of the feedback encoder The program records the index position and returns the axis to the captured position plus or minus an optional programmable offset The encoder index mark is accurate to one quadrature count and provides a much more repeatable reference than a typical home switch Note The Find Index function is only available on closed loop axes with quadrature encoder feedback The encoder must provide a valid properly phased index signal See Figure 5 3 Quadrature Encoder Phasing Diagram for more information Refer to the Find Home amp Index Functions section of the FlexMotion Software Reference for more information on the Find Index function Chapter 4 Func
23. 100 101100111 101100111 PID Servo Loop 16 Bit D A Converter 32 Bit Encoder Interface 10 V A B Index Axis Resource Z X Y X Y Z 3D Vector Space Axis X Axis Y Axis Z Chapter 4 Functional Overview National Instruments Corporation 4 9 FlexMotion 6C Hardware User Manual Vector spaces are configured by mapping axes to the vector space Vector spaces are logical not physical and do not require motion resources other than those used by the axes themselves Note Refer to the Axis and Resource Configuration section of the FlexMotion Software Reference for more information on configuring vector spaces Onboard Programs FlexMotion 6C has full onboard programmability with the capability of executing up to 10 simultaneous motion programs in a real time preemptive multitasking environment This extremely powerful feature is designed for real time applications that need tight synchronization and or minimum latency from a motion or other I O event and fast command execution You can execute the entire FlexMotion function set from onboard programs In addition the onboard programs support basic math and data operation functions on up to 120 general purpose variables Onboard programs also offer high level event based functions such as Jump to Label on Condition and Wait on Condition which allow you to sequence and make decisions in your programs Onboard programs can even start
24. 3 398 3F0 Diskette Controller 3A0 Bisynchronous 1 3F8 Serial Port 1 3A8 Bisynchronous 1 1 Blank table cells indicate this base address is typically available for plug in controllers 3B0 Monochrome Printer Table 3 1 ISA Bus Address Map Continued Base Address DIP Switch Address Typical Use1 Base Address DIP Switch Address Typical Use1 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 Chapter 3 Hardware Overview FlexMotion 6C Hardware User Manual 3 8 www natinst com Selecting an Isolated External Internal Voltage Supply Configuration The FlexMotion 6C controller provides optoisolation on the motion I O signals Isolated I O reduces noise sensitivity by breaking ground loops and isolating the FlexMotion 6C and host PC s ground from field sensors and external device ground wiring These optocoupled signals include forward reverse and home limit inputs trigger inputs breakpoint outputs and E Stop input Optocoupled signals require a power supply to power the isolation circuits If your motion system uses optoisolation for limits and or other motion I O
25. 64 13 63 12 62 11 61 10 60 9 59 8 58 7 57 6 56 5 55 4 54 3 53 2 52 1 51 ISO Axis 3 Forward Limit Input Axis 3 Home Input Axis 3 Reverse Limit Input Trigger Input 3 Breakpoint Output 3 Axis 4 Home Input Axis 4 Forward Limit Input Trigger Input 4 Axis 4 Reverse Limit Input ISORTN Breakpoint Output 4 Analog Reference Output Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 Analog Input 5 Analog Input 6 Analog Input 7 Analog Input 8 Analog Input Ground Analog Output 3 Analog Output Ground Analog Output 4 Encoder 3 Phase A Encoder 3 Phase A Encoder 3 Phase B Encoder 3 Phase B Encoder 3 Index Encoder 3 Index Encoder 4 Phase A Encoder 4 Phase A Encoder 4 Phase B Encoder 4 Phase B Encoder 4 Index Encoder 4 Index Digital Ground Stepper 5 Step CW Stepper 5 Dir CCW Axis 3 Inhibit Host 5 V Stepper 6 Step CW Stepper 6 Dir CCW Axis 4 Inhibit Digital Ground Axis 1 Inhibit Axis 5 Inhibit Axis 6 Inhibit Axis 2 Inhibit Chapter 5 Signal Connections National Instruments Corporation 5 3 FlexMotion 6C Hardware User Manual Table 5 1 describes the signals on the motion I O connector Table 5 1 Motion I O Signal Connections Signal Name Reference Direction Description Analog Output lt 1 6 gt Analog Output Ground Output Analog motor command Analog Output Ground Reference for Vout Stepper lt 5 6 gt Step CW Digital Ground Output Stepper only mo
26. Encoder lt 1 6 gt Phase A signal quadrature encoder input 5 7 to 5 8 reference direction and description table 5 3 Encoder lt 1 6 gt Phase B signal quadrature encoder input 5 7 to 5 8 reference direction and description table 5 3 Index National Instruments Corporation I 3 FlexMotion 6C Hardware User Manual Encoder lt 1 6 gt Phase B signal quadrature encoder input 5 7 to 5 8 reference direction and description table 5 3 encoder resources 4 7 encoder signals 5 7 to 5 11 encoder input circuit 5 10 to 5 11 quadrature encoder phasing diagram 5 9 signal descriptions 5 7 to 5 9 wiring concerns 5 9 encoder termination networks selecting 3 11 to 3 12 resistor values table 3 12 SIP resistor networks figure 3 12 enhanced PID functions 4 2 environment specifications A 7 equipment optional 1 4 error stack 4 13 E Stop signal description 5 14 reference direction and description table 5 3 F FIFO buffers 4 11 to 4 12 Find Home function 4 10 5 6 Find Index function 4 10 5 9 flash memory 4 5 FlexMotion 6C controllers See also PC FlexMotion 6C controller PCI FlexMotion 6C controller functional overview See functional overview installation 2 2 to 2 3 National Instruments application software 1 3 optional equipment 1 4 overview and features 1 1 to 1 2 See also hardware overview requirements for getting started 1 2 software programming choices 1 3 functional over
27. Motion Control FlexMotion 6C Hardware User Manual FlexMotion 6C Hardware User Manual July 1999 Edition Part Number 321944B 01 Worldwide Technical Support and Product Information www natinst com National Instruments Corporate Headquarters 11500 North Mopac Expressway Austin Texas 78759 3504 USA Tel 512 794 0100 Worldwide Offices Australia 03 9879 5166 Austria 0662 45 79 90 0 Belgium 02 757 00 20 Brazil 011 284 5011 Canada Ontario 905 785 0085 Canada Qu bec 514 694 8521 China 0755 3904939 Denmark 45 76 26 00 Finland 09 725 725 11 France 01 48 14 24 24 Germany 089 741 31 30 Hong Kong 2645 3186 India 91805275406 Israel 03 6120092 Italy 02 413091 Japan 03 5472 2970 Korea 02 596 7456 Mexico D F 5 280 7625 Mexico Monterrey 8 357 7695 Netherlands 0348 433466 Norway 32 27 73 00 Singapore 2265886 Spain Madrid 91 640 0085 Spain Barcelona 93 582 0251 Sweden 08 587 895 00 Switzerland 056 200 51 51 Taiwan 02 2377 1200 United Kingdom 01635 523545 For further support information see the Technical Support Resources appendix To comment on the documentation send e mail to techpubs natinst com Copyright 1998 1999 National Instruments Corporation All rights reserved Important Information Warranty The FlexMotion 6C controllers are warranted against defects in materials and workmanship for a period of one year from the date of shipment as evidenced by receipts or other documentation Na
28. N Encoder 4 Trigger Input Axis 4 Home Input Encoder 3 Trigger Input Axis 3 Home Input ISO Axis 6 Inhibit Axis 2 Inhibit Digital Ground Stepper 6 Dir CCW Host 5 V Stepper 5 Dir CCW Digital Ground Encoder 4 Index Encoder 4 Phase B Encoder 4 Phase A Encoder 3 Index Encoder 3 Phase B Encoder 3 Phase A Analog Output Ground Analog Input Ground Analog Input 7 Analog Input 5 Analog Input 3 Analog Input 1 Encoder 4 Breakpoint Output Axis 4 Reverse Limit Input Axis 4 Forward Limit Input Encoder 3 Breakpoint Output Axis 3 Reverse Limit Input Axis 3 Forward Limit Input 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 National Instruments Corporation C 1 FlexMotion 6C Hardware User Manual C Technical Support Resources This appendix describes the comprehensive resources available to you in the Technical Support section of the National Instruments Web site and provides technical support telephone numbers for you to use if you have trouble connecting to our Web site or if you do not have internet access NI Web Support To provide you with immediate answers and solutions 24 hours a day 365 days a year National Instruments maintains extensive online technical support resources They are available to you at no cost are updated daily and can be found i
29. ORTN Axis 6 Home Input Axis 6 Forward Limit Input Axis 5 Home Input Axis 5 Forward Limit Input Encoder 2 Trigger Input Axis 2 Home Input Encoder 1 Trigger Input Axis 1 Home Input ISO Analog Output 6 Analog Output Ground Encoder 6 Index Encoder 6 Phase A Encoder 5 Index Encoder 5 Phase B Encoder 5 Phase A Analog Output 2 Encoder 6 Phase B Digital Ground Encoder 2 Index Encoder 2 Phase B Encoder 2 Phase A Encoder 1 Index Encoder 1 Phase B Encoder 1 Phase A E Stop Axis 6 Reverse Limit Input Axis 5 Reverse Limit Input Encoder 2 Breakpoint Output Axis 2 Reverse Limit Input Axis 2 Forward Limit Input Encoder 1 Breakpoint Output Axis 1 Reverse Limit Input Axis 1 Forward Limit Input 49 50 47 48 45 46 43 44 41 42 39 40 37 38 35 36 33 34 31 32 29 30 27 28 25 26 23 24 21 22 19 20 17 18 15 16 13 14 11 12 9 10 7 8 5 6 3 4 1 2 Appendix B Cable Connector Descriptions National Instruments Corporation B 3 FlexMotion 6C Hardware User Manual Figure B 2 Second 50 Pin Motion I O Connector Pin Assignment Axis 5 Inhibit Axis 1 Inhibit Axis 4 Inhibit Stepper 6 Step CW Axis 3 Inhibit Stepper 5 Step CW Encoder 4 Index Encoder 4 Phase B Encoder 4 Phase A Encoder 3 Index Encoder 3 Phase B Encoder 3 Phase A Analog Output 4 Analog Output 3 Analog Input 8 Analog Input 6 Analog Input 4 Analog Input 2 Analog Reference Output ISORT
30. Opto 22 compatible interface to 24 bits of user configured digital I O Refer to Chapter 5 Signal Connections for the complete details of the signals in the auxiliary 24 bit digital I O connector 1 4 Pin Auxiliary Power Connector 2 10 Pin Test Connector 3 50 Pin Auxiliary 24 Bit Digital I O Connector 4 ADSP 2111 DSP 5 Assembly Number Label 6 100 Pin Motion I O Connector 7 Isolated Supply Jumpers JP2 8 Encoder Termination SIP Resistor Networks 9 Motion I O DIP Resistor Networks 10 Serial Number Label 11 10 Pin Serial Port Connector 12 MC68331 CPU 7 8 11 10 9 1 4 3 5 6 12 2 Chapter 3 Hardware Overview National Instruments Corporation 3 3 FlexMotion 6C Hardware User Manual Test Connectors The 10 pin test connector is a proprietary interface for production testing and troubleshooting Do not plug anything into this connector Note Misuse of the reserved connectors may seriously damage the FlexMotion 6C controller Unauthorized use of the reserved connectors will void any warranty coverage for the product With the FlexMotion 6C controller properly installed only two connectors are typically used the 100 pin motion I O connector and the 50 pin auxiliary 24 bit digital I O connector You use cables and accessories to connect to your motion system Interface accessories for the FlexMotion 6C family vary from the enhanced Universal Motion Interface UMI units with signal conditioning a
31. al Instruments be liable for any damages arising out of or related to this document or the information contained in it EXCEPT AS SPECIFIED HEREIN NATIONAL INSTRUMENTS MAKES NO WARRANTIES EXPRESS OR IMPLIED AND SPECIFICALLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE CUSTOMER S RIGHT TO RECOVER DAMAGES CAUSED BY FAULT OR NEGLIGENCE ON THE PART OF NATIONAL INSTRUMENTS SHALL BE LIMITED TO THE AMOUNT THERETOFORE PAID BY THE CUSTOMER NATIONAL INSTRUMENTS WILL NOT BE LIABLE FOR DAMAGES RESULTING FROM LOSS OF DATA PROFITS USE OF PRODUCTS OR INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF ADVISED OF THE POSSIBILITY THEREOF This limitation of the liability of National Instruments will apply regardless of the form of action whether in contract or tort including negligence Any action against National Instruments must be brought within one year after the cause of action accrues National Instruments shall not be liable for any delay in performance due to causes beyond its reasonable control The warranty provided herein does not cover damages defects malfunctions or service failures caused by owner s failure to follow the National Instruments installation operation or maintenance instructions owner s modification of the product owner s abuse misuse or negligent acts and power failure or surges fire flood accident actions of third parties or other events outside reasonable control Copyright Under the co
32. als 5 4 Limit and Home Inputs 5 5 Wiring Concerns 5 7 Limit and Home Input Circuit 5 7 Encoder Signals 5 7 Wiring Concerns 5 9 Encoder Input Circuit 5 10 Trigger Inputs and Breakpoint Outputs 5 11 Wiring Concerns 5 12 Trigger Input and Breakpoint Output Circuits 5 12 Contents National Instruments Corporation vii FlexMotion 6C Hardware User Manual Analog Inputs 5 13 Wiring Concerns 5 13 Other Motion I O Connections 5 14 Auxiliary 24 Bit Digital I O Connector
33. an unshielded cable can permit noise to corrupt the encoder signals resulting in lost counts and reduced motion system accuracy Phase A Phase B Index Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 10 www natinst com Encoder Input Circuit Figure 5 4 shows a simplified schematic diagram of the circuit used for the Phase A Phase B and Index encoder inputs FlexMotion 6C supports both single ended A B Index and differential A A B B Index Index encoder input configurations Both phases A and B are required for proper encoder counter operation and the signals must support the 90 phase difference within system tolerance The Index signal is optional but highly recommended and required for initialization functionality with the Find Index function Figure 5 4 Encoder Input Circuit Note See Selecting Encoder Termination Networks section in Chapter 3 Hardware Overview for information on selecting the appropriate SIP resistor values When connecting to single ended encoder inputs the unused differential input must be left unconnected Connecting unused inputs to 5 V or Digital Ground will not damage the encoder input circuit but will cause faulty operation of the encoder channel Single ended encoders must have TTL compatible output drivers Encoders with open collector outputs can be interfaced but require you to add external 2 2 k pull up resistors to 5 V from the encoder Phase A B and Ind
34. and stop other onboard programs Implementing part or all of your motion application as an onboard program or programs offloads the host PC from handling these real time tasks and events This leaves the host PC more available for the other integrated tasks such as data acquisition image processing user interface data analysis and or overall measurement and automation system control Onboard programs can also isolate your application from the host PC s non real time operating system Only the bus power is required to correctly execute an onboard FlexMotion program once it is started and this program continues to run even if the host PC hangs assuming the host power supply remains You can run onboard programs from RAM or optionally save them to flash ROM FlexMotion 6C has 32 KB of each type of memory for program object storage With an average command size of 10 bytes a single program which can be entirely stored in either RAM or ROM but not split between both can be as large as 3 200 commands Conversely the FlexMotion 6C Chapter 4 Functional Overview FlexMotion 6C Hardware User Manual 4 10 www natinst com can simultaneously execute 10 programs five from RAM and five from ROM each up to 640 commands long Note Refer to the Onboard Programming Functions section of the FlexMotion Software Reference for detailed information on all of these onboard programming features Find Home and Find Index FlexMotion 6C features
35. ating three revolutions for every two revolutions of the master Each slave axis can have its own gear ratio independent and relative to the master axis You can also superimpose any move type on top of the geared slave because its trajectory generators are not used for gearing Again the target position command values are combined digitally using superposition This very powerful feature allows registration moves in an electronically geared master slave system Note Refer to the FlexMotion Software Reference for more information on electronic master slave gearing Linear and Circular Interpolation You can synchronize and control multiple axes to perform 2D and 3D linear interpolation 2D circular interpolation and 3D helical and spherical interpolation FlexMotion 6C generates linear interpolated moves by scaling the velocity acceleration deceleration and S curve values appropriately so that the axes assigned to the 2D 3D move will travel in a straight line in 2D or 3D space and arrive at their target positions simultaneously Chapter 4 Functional Overview National Instruments Corporation 4 5 FlexMotion 6C Hardware User Manual For circular helical and spherical arcs the FlexMotion 6C embedded CPU calculates points along the arc segment and the DSP performs a cubic spline algorithm that interpolates between these points The resulting arc is extremely smooth and accurate with none of the chordal error associated with bl
36. ation about these products Motion Signal and Motion I O Connections The external motion I O connector on the FlexMotion 6C controllers is a 100 pin female right angle metal shell type connector The auxiliary 24 bit digital I O connector is a 50 pin male box header connector You can use any compatible mating connector Mating connector types include insulation displacement ribbon cable connectors and discrete wire mating connectors National Instruments Corporation 2 1 FlexMotion 6C Hardware User Manual 2 Configuration and Installation This chapter describes how to configure and install your FlexMotion 6C controller Software Installation Install your FlexMotion software along with your Motion VI libraries if appropriate before you install the FlexMotion 6C controller Refer to the release notes included with your FlexMotion 6C controller for specific instructions on the software installation sequence for your host PC Controller Configuration There are two types of required configuration to be performed on the FlexMotion 6C controllers before they are installed in the host computer bus related configuration and motion I O related configuration The motion I O related configuration consists of setting the isolated voltage supply jumpers to configure the optoisolated I O for internal non isolated 5 V or external isolated ISO supply Your FlexMotion 6C has full optoisolation on the motion I O signals b
37. cket identifier word command and data content and a packet terminator word This approach to communications enhances the accuracy of data communications speeds the processing of the transferred command and data and organizes operation into powerful high level motion functions Each word in a packet is sent over the host PC bus after checking the Ready to Receive RTR handshaking bit in the CSR Refer to the Read Communication Status read_csr function in the FlexMotion Software Reference for the Status bitmap and more information on the status reported in the CSR Command and data packets are checked for packet format errors as the packets are received by the controller If a packet error is detected it is immediately reported by setting an error bit in the CSR Once the packet is received without error the command and data is stored in a FIFO buffer Chapter 4 Functional Overview FlexMotion 6C Hardware User Manual 4 12 www natinst com This FIFO can hold up to 16 commands The FlexMotion 6C RTOS will process commands whenever it is not busy with higher priority tasks In the unlikely occurrence that the FIFO fills up before any commands can be processed the host detects a Not Ready to Receive condition and waits for available room in the FIFO before sending additional packets Each command is processed and a determination is made whether to execute the command immediately or store it away in an onboard program to be executed la
38. code that identifies a specific location or series of locations in memory or on a host PC bus system amplifier the drive that delivers power to operate the motor in response to low level control signals In general the amplifier is designed to operate with a particular motor type you cannot use a stepper drive to operate a DC brush motor for instance Analog Input lt 1 8 gt 12 bit analog ADC input Analog Output lt 1 6 gt DAC voltage output API application programming interface axis unit that controls a motor or any similar motion or control device Axis lt 1 6 gt Inhibit axis 1 through 6 inhibit output Axis lt 1 6 gt Forward Limit Input axis 1 through 6 forward clockwise limit switch Axis lt 1 6 gt Home Input axis 1 through 6 home input Axis lt 1 6 gt Reverse Limit Input axis 1 through 6 reverse counter clockwise limit input B b bit one binary digit either 0 or 1 base address memory address that serves as the starting address for programmable or I O bus registers All other addresses are located by adding to the base address Glossary National Instruments Corporation G 3 FlexMotion 6C Hardware User Manual binary a number system with a base of 2 buffer temporary storage for acquired or generated data software bus the group of conductors that interconnect individual circuitry in a computer Typically a bus is the expansion vehicle to which I O or other devices are connecte
39. d byte eight related bits of data an eight bit binary number Also used to denote the amount of memory required to store one byte of data C CCW counter clockwise implies direction of rotation of the motor closed loop a motion system that uses a feedback device to provide position and velocity data for status reporting and accurately controlling position and velocity CPU central processing unit crosstalk an unwanted signal on one channel due to an input on a different channel CW clockwise implies direction of motor rotation D DC direct current dedicated assigned to a particular function DGND digital ground signal digital ground reference signal for digital I O digital I O port a group of digital input output signals DIP dual inline package DLL dynamic link library provides the API for the motion control controllers drivers software that communicates commands to control a specific motion control controller Glossary FlexMotion 6C Hardware User Manual G 4 www natinst com E encoder device that translates mechanical motion into electrical signals used for monitoring position or velocity in a closed loop system encoder resolution the number of encoder lines between consecutive encoder indexes marker or Z bit If the encoder does not have an index output the encoder resolution can be referred to as lines per revolution F f farad filtering a type of signal conditioning that
40. d as a byte wide 8 bit input or output port All bits in the port follow this directional configuration Port 2 is also bidirectional but I O bits 3 and 4 are input only If port 2 is configured as outputs you cannot use bits 3 and 4 Port 3 is a dedicated output port and the bits in it cannot be used as inputs Port 1 Port 2 Port 3 bit 0 bit 1 bit 2 bit 3 bit 4 bit 5 bit 6 bit 7 Input or Output to or from FlexMotion controller Output from FlexMotion controller Input or Output to or from FlexMotion controller Indicates input only bit 0 bit 1 bit 2 bit 3 bit 4 bit 5 bit 6 bit 7 bit 0 bit 1 bit 2 bit 3 bit 4 bit 5 bit 6 bit 7 Chapter 5 Signal Connections National Instruments Corporation 5 17 FlexMotion 6C Hardware User Manual With all three ports configured as outputs you have 22 output bits I O bits 3 and 4 in port 2 are input only and are not usable Conversely it is possible to configure the ports for a maximum of 16 inputs and eight outputs All ports have bitwise programmable polarity and you can configure each bit as active low inverting or active high non inverting Software commands that read and write the port use logical values TRUE FALSE for each bit Depending upon the programmed polarity for a bit a TRUE value may correspond to a high voltage active high or low voltage active low on the physical pin Reads from input pins always return the logic
41. d direction Note After a Find Home sequence is complete the home input should be disabled since it is no longer required assuming you do not want to stop on it the next time the system moves past it Chapter 5 Signal Connections National Instruments Corporation 5 7 FlexMotion 6C Hardware User Manual Wiring Concerns Caution For the end of travel limits to function correctly the forward limit must be located at the forward or positive end of travel and the reverse limit at the negative end of travel Failure to do so may result in motion that stops at but then travels through a limit potentially damaging the motion system Miswired limits may prevent motion from occurring at all Keep limit and home switch signals and their ground connections wired separately from the motor driver amplifier signal and encoder signal connections Wiring these signals near each other can cause faulty motion system operation Limit and Home Input Circuit Figure 5 2 shows a simplified schematic diagram of the circuit used by the limit and home switch inputs for input signal isolation Figure 5 2 Limit and Home Input Circuit Note See Selecting an Isolated External Internal Voltage Supply Configuration in Chapter 3 Hardware Overview for information on selecting appropriate DIP resistor values Caution Excessive input voltages can cause erroneous operation and or component failure Verify that your input voltage is within the specificati
42. d description table 5 3 host communications 4 11 to 4 13 error stack 4 13 packets handshaking and FIFO buffers 4 11 to 4 12 return data buffer 4 12 I installation of hardware 2 2 to 2 3 I O connectors See connectors motion I O connector ISA bus address table 3 3 to 3 7 address map table 3 4 to 3 7 DIP switch settings 3 3 to 3 4 factory default DIP switch setting figure 3 4 ISO signal description 5 14 reference direction and description table 5 3 setting isolated supply jumpers external isolated supply 3 9 to 3 10 internal 5 V supply 3 8 to 3 9 isolated external internal voltage supply configuration 3 8 to 3 11 locating isolated supply jumper block JP2 3 8 RP3 and RP10 DIP resistor networks 3 10 to 3 11 setting isolated supply jumper block for internal 5 V supply 3 8 to 3 9 ISORTN signal description 5 14 reference direction and description table 5 3 setting isolated supply jumpers external isolated supply 3 9 to 3 10 internal 5 V supply 3 8 to 3 9 J jumper block JP2 See isolated external internal voltage supply configuration L LabVIEW software 1 3 LabWindows CVI software 1 3 limit and home inputs 5 5 to 5 7 circuit figure 5 7 signal descriptions 5 5 to 5 6 wiring concerns 5 7 linear and circular interpolation 4 4 to 4 5 M manual See documentation MOMO MustOn MustOff protocol 5 17 motion axis signals Analog Output Ground 5 4 to 5 5 Analog Outp
43. e User Manual 218 270 220 278 Parallel Port 2 228 280 230 288 238 290 240 298 248 2A0 250 2A8 2B0 308 Prototype Card 2B8 310 Prototype Card 2C0 318 Prototype Card Table 3 1 ISA Bus Address Map Continued Base Address DIP Switch Address Typical Use1 Base Address DIP Switch Address Typical Use1 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 Chapter 3 Hardware Overview FlexMotion 6C Hardware User Manual 3 6 www natinst com 2C8 320 2D0 328 2D8 330 2E0 338 2E8 Serial Port 4 340 2F0 348 2F8 Serial Port 2 350 300 Prototype Card 358 360 PC Network 3B8 Monochrome Printer 368 PC Network 3C0 EGA VGA Adapter 370 3C8 EGA VGA Adapter Table 3 1 ISA Bus Address Map Continued Base Address DIP Switch Address Typical Use1 Base Address DIP Switch Address Typical Us
44. e low Outputs Voltage range 0 to 5 V Output low voltage lt 0 5 V at 24 mA sink Output high voltage gt 2 4 V at 3 mA source Polarity Programmable active high or active low PWM outputs Number of PWM outputs 2 Max PWM frequency 32 kHz Resolution 8 bit Duty cycle range 0 to 255 256 Clock sources Internal or external counter input Power Requirements Max 5 V 3 2 0 A 12 V 3 150 mA 12 V 3 200 mA Power consumption 14 2 W Appendix A Specifications National Instruments Corporation A 7 FlexMotion 6C Hardware User Manual Physical Dimensions Not Including Connectors PC FlexMotion 6C 33 8 by 9 9 cm 13 3 by 3 9 in PCI FlexMotion 6C 31 2 by 9 9 cm 12 3 by 3 9 in Connectors Motion I O connector 100 pin female high density metal shell D type Auxiliary 24 bit digital I O connector 50 pin male box header Serial port connector 10 pin male box header Environment Operating te
45. e recommended values for these terminator resistor SIP networks is dependent upon two primary factors the maximum frequency of the encoder input signals and the presence or lack of a differential line driver at the encoder source end The FlexMotion 6C accessory pack shipped with the controller includes appropriate SIP resistor networks Note When changing networks be careful to install the correct resistor network with the correct pin 1 orientation in the socket Figure 3 7 Encoder Input Termination SIP Resistor Networks Table 3 3 lists the recommended termination networks for various encoder types Note The resistor networks used for RP6 RP8 RP11 RP13 and RP15 are 10 pin SIP packages with eight channel dual termination resistor networks Bourns part number 4610X 104 RRR RRR or equivalent R1 R2 resistor values Table 3 3 Encoder Termination Resistor Values Encoder Type SIP Termination Resistor Network R1 R2 Differential 1 MHz 180 390 factory default Differential lt 1 MHz 1 5 3 3 k Single ended 1 5 3 3 k Connected to internal FlexMotion circuits 9 R2 R1 10 1 2 5 V 5 V 100 RP6 8 11 13 and 15 100 A B Index A B Index Gnd National Instruments Corporation 4 1 FlexMotion 6C Hardware User Manual 4 Functional Overview This chapter presents an overview of the motion control algorithms and embedded firmware functional
46. e1 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 Chapter 3 Hardware Overview National Instruments Corporation 3 7 FlexMotion 6C Hardware User Manual Motion I O Configuration The FlexMotion 6C controller has a number of user configurable components shown previously in Figures 3 1 and 3 2 You can use these components to tailor and optimize the motion I O circuits to satisfy specific application requirements All of these user configurable components are mounted in sockets for easy replacement in the field The FlexMotion 6C controller ships with an accessory pack that includes an appropriate assortment of single inline package SIP and dual inline package DIP resistor networks and jumpers 378 Parallel Port 1 3D0 CGA MCGA Adapter 380 SDLC Bisynchronous 3D8 CGA MCGA Adapter 388 SDLC Bisynchronous 3E0 Factory Default 390 3E8 Serial Port
47. ections FlexMotion 6C Hardware User Manual 5 4 www natinst com Motion Axis Signals The following signals control the servo amplifier or stepper driver Analog Output lt 1 6 gt These 16 bit analog outputs are typically the servo command outputs for each axis They can drive the industry standard 10 V output and can be software limited to any positive or negative voltage range desired They also feature a software programmable voltage offset Although typically used as the command output of an axis control loop unused analog outputs can also function as independent analog outputs for general purpose control Analog Output Ground To help keep digital noise separate from the analog outputs there is a separate return connection You should use this analog output ground connection and not Digital Ground digital I O reference as the reference for the analog outputs when connecting to servo amplifiers Stepper lt 5 6 gt Step CW and Dir CCW These open collector signals are the stepper command outputs for each axis The FlexMotion 6C supports both major industry standards for stepper command signals step and direction or independent CW and CCW pulse outputs The output configuration and signal polarity is software programmable for compatibility with various third party drives When step and direction mode is configured each commanded step or microstep produces a pulse on the step output The direct
48. ended straight line segment approaches You can use FlexMotion 6C s infinite trajectory control processing to blend any arc move into another 2D or 3D arc or 2D or 3D vector straight line segment without stopping the axes involved Note Refer to the FlexMotion Software Reference for more information on circular helical and spherical arcs Analog Feedback The FlexMotion 6C controller has an 8 channel multiplexed 12 bit ADC The converted analog values are broadcast to both the DSP and CPU via a dedicated internal high speed serial bus The multiplexer scan rates is approximately 50 s per enabled ADC channel This produces the high sampling rates required for PID feedback loop closure joystick inputs or monitoring analog sensors Flash Memory Nonvolatile memory on the FlexMotion 6C controller is implemented with flash ROM This means that the FlexMotion 6C controller can electrically erase and reprogram its own ROM Since all of the FlexMotion 6C controller s embedded firmware including the RTOS and DSP code is stored in flash memory you can upgrade the onboard firmware contents in the field for support and new feature enhancement Flash memory also allows objects such as programs and data arrays to be stored in nonvolatile memory It is possible to save the entire parameter state of the controller with the Save Default Parameters function On the next power cycle the FlexMotion 6C controller will automatically load and retu
49. event that causes or starts some form of data capture TTL transistor transistor logic V V volts VCC positive voltage supply velocity mode move the axis continuously at the specified velocity W watchdog a timer task that shuts down resets the motion controller if any serious error occurs word the standard number of bits that a processor or memory manipulates at one time typically 8 16 or 32 bit National Instruments Corporation I 1 FlexMotion 6C Hardware User Manual Index Numbers 5 V signal See Host 5 V signal 5 V supply setting isolated supply jumpers for 3 8 to 3 9 24 bit digital I O connector See auxiliary 24 bit digital I O connector A ADC resources 4 7 analog feedback 4 5 Analog Input Ground signal purpose and use 5 13 reference direction and description table 5 4 Analog Input lt 1 8 gt signal purpose and use 5 13 reference direction and description table 5 4 analog inputs signal descriptions 5 13 wiring concerns 5 13 Analog Output Ground signal description 5 4 reference direction and description table 5 3 Analog Output lt 1 6 gt signal description 5 4 reference direction and description table 5 3 Analog Reference signal purpose and use 5 13 reference direction and description table 5 4 auxiliary 24 bit digital I O connector 5 14 to 5 18 50 pin connector pin assignments figure 5 15 digital I O port configuration figure 5 16
50. ex signals The differential nature of the encoder inputs also allows any encoder to satisfy the phasing requirements shown in Figure 5 4 Phases A and B can be swapped and or the polarity of an individual phase can be inverted by To Encoder Circuits 5 V 100 100 A B Index A B Index Gnd 100 pF 100 pF Chapter 5 Signal Connections National Instruments Corporation 5 11 FlexMotion 6C Hardware User Manual swapping connectors from the non inverting A or B to the inverting A or B signals or vice versa Similarly single ended signals can be inverted by simply connecting them to the inverting A or B input Trigger Inputs and Breakpoint Outputs FlexMotion 6C offers additional high performance features in the encoder FPGA The first four encoder channels have high speed position capture trigger inputs and breakpoint outputs These optoisolated signals are useful for high speed synchronization of motion with actuators sensors and other parts of the complete motion system Trigger Input lt 1 4 gt When enabled an active transition on a trigger input causes instantaneous position capture lt 100 ns latency of the corresponding encoder count value You can use this trigger functionality for applications ranging from simple position tagging of sensor data to complex camming systems with advance retard positioning and registration An available FlexMotion 6C position mode is move an
51. filters unwanted signals from the signal being measured filter parameters indicates the control loop parameter gains PID gains for a given axis following error trip point the difference between the instantaneous commanded trajectory position and the feedback position freewheel the condition of a motor when power is de energized and the motor shaft is free to turn with only frictional forces to impede it full step full step mode of a stepper motor for a two phase motor this is done by energizing both windings or phases simultaneously G Gnd ground GND ground H half step mode of a stepper motor for a two phase motor this is done by alternately energizing two windings and then only one In half step mode alternate steps are strong and weak but there is significant improvement in low speed smoothness over the full step mode hex hexadecimal Glossary National Instruments Corporation G 5 FlexMotion 6C Hardware User Manual home switch input a physical position determined by the mechanical system or designer as the reference location for system initialization Frequently the home position is also regarded as the zero position in an absolute position frame of reference host computer computer into which the motion controller is plugged I ID identification in inches index marker between consecutive encoder revolutions I O input output the transfer of data to and from a computer system invo
52. gt FlexMotion 6C includes an eight channel multiplexed 12 bit ADC capable of measuring 10 V inputs You can configure each ADC channel for motion feedback simple A D conversion or both You can read back the digital value of analog voltage on any of the controller s eight ADC channels by using the Read ADC function The values read back will be in the range of 2048 to 2047 11 bits with a voltage resolution of 0 0049 V per LSB least significant bit When configured as analog feedback an analog sensor acts like a limited range absolute position device with a full scale position range of 2048 counts You can map any ADC channel as feedback to any axis You can enable and disable individual ADC channels in software You should disable unused ADC channels for the highest multiplexer scan rate performance Properly enabled the scan rate is high enough to support analog feedback at the highest PID sample rate Analog Reference For convenience 7 5 V nominal analog reference voltage is made available You can use this output as a low current supply to sensors that require a stable reference Analog Input Ground To help keep digital noise out of the analog input there is a separate return connection is provided You should use this analog input ground connection and not Digital Ground digital I O reference or Analog Output Ground as the reference for the analog inputs Wiring Concerns For proper use of
53. guration controller board ID verification and for future reference of this address from software Caution DIP switch positions 7 and 8 must be off for the PC FlexMotion 6C to function properly The factory default base address for your controller is 0x3E0 as shown in Figure 3 3 Figure 3 3 Factory Default DIP Switch Setting Note For Windows 3 1 and DOS Users Certain addresses that are typically used for host computer functions such as serial and parallel I O ports and display adapters are indicated in the following list However since not all manufacturers use these standards please verify that an address is truly available and not used before setting the PC FlexMotion 6C DIP switch to that address For Windows 2000 NT 98 95 Users Controller address selection is determined by registry control within the operating system Refer to the release notes included with your FlexMotion 6C controller for step by step instructions for installing under these operating systems Table 3 1 ISA Bus Address Map Base Address DIP Switch Address Typical Use1 Base Address DIP Switch Address Typical Use1 200 Game I O 258 208 260 210 268 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 1 O N 2 3 4 5 6 7 8 Chapter 3 Hardware Overview National Instruments Corporation 3 5 FlexMotion 6C Hardwar
54. gure 5 1 100 Pin Motion I O Connector Pin Assignment 5 2 Figure 5 2 Limit and Home Input Circuit 5 7 Figure 5 3 Quadrature Encoder Phasing Diagram 5 9 Figure 5 4 Encoder Input Circuit 5 10 Figure 5 5 Trigger Input Circuit 5 12 Figure 5 6 Breakpoint Output Circuit 5 12 Contents FlexMotion 6C Hardware User Manual viii www natinst com Figure 5 7 50 Pin Digital I O Connector Pin Assignments 5 15 Figure 5 8 Auxiliary 24 Bit Digital I O Port Configuration 5 16 Figure B 1 First 50 Pin Motion I O Connector Pin Assignment B 2 Figure B 2 Second 50 Pin Motion I O Connector Pin Assignment B 3 Tables Table 3 1 ISA Bus Address Map 3 4 Table 3 2 Motion I O Resistor Values 3 11 Table 3 3 Encoder Termination Resistor Values 3 12 Table 5 1 Motion I O Signal Connecti
55. inout In this chapter lines above signal names indicate that signal is active low Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 2 www natinst com Figure 5 1 100 Pin Motion I O Connector Pin Assignment ISO Axis 1 Forward Limit Input Axis 1 Home Input Axis 1 Reverse Limit Input Trigger Input 1 Trigger Input 1 Breakpoint Output 1 Axis 2 Home Input Axis 2 Forward Limit Input Axis 2 Reverse Limit Input Axis 5 Forward Limit Input Breakpoint Output 2 Axis 5 Home Input Axis 5 Reverse Limit Input Axis 6 Forward Limit Input Axis 6 Reverse Limit Input Axis 6 Home Input E Stop ISORTN Encoder 1 Phase A Encoder 1 Phase A Encoder 1 Phase B Encoder 1 Phase B Encoder 1 Index Encoder 1 Index Encoder 2 Phase A Encoder 2 Phase A Encoder 2 Phase B Encoder 2 Phase B Encoder 2 Index Encoder 2 Index Digital Ground Encoder 5 Phase A Encoder 5 Phase A Encoder 5 Phase B Encoder 5 Phase B Encoder 5 Index Encoder 5 Index Encoder 6 Phase A Encoder 6 Phase A Encoder 6 Phase B Encoder 6 Phase B Encoder 6 Index Encoder 6 Index Digital Ground Analog Output Ground Analog Output 1 Analog Output 2 Analog Output 5 Analog Output 6 50 100 49 99 48 98 47 97 46 96 45 95 44 94 43 93 42 92 41 91 40 90 39 89 38 88 37 87 36 86 35 85 34 84 33 83 32 82 31 81 30 80 29 79 28 78 27 77 26 76 25 75 24 74 23 73 22 72 21 71 20 70 19 69 18 68 17 67 16 66 15 65 14
56. ion applications Move Blending You can use the FlexMotion 6C controller to blend moves together with a programmable blend factor Using the user defined blend factor the FlexMotion 6C DSP chip starts a second trajectory generator with the second move on an axis while the first trajectory generator is still Chapter 4 Functional Overview FlexMotion 6C Hardware User Manual 4 4 www natinst com decelerating from the previous trajectory move The two position command outputs are combined digitally by superposition You can use FlexMotion 6C s infinite trajectory control processing to automatically and smoothly blend any move type into any other move without stopping the axis or axes involved Note Refer to the FlexMotion Function Reference for more information on blending and blend factors Electronic Gearing With electronic gearing you can slave both position and velocity on one or more axes to a master position velocity source for synchronous ratio based motion The master can be the feedback of an axis an independent encoder input or ADC channel or even the trajectory generator output of another axis A slave axis operates in a special mode that calculates an instantaneous position command value that is a ratio of the master position Since this calculation is completed every PID update the axis accurately tracks the ratio of the master position velocity For example setting a gear ratio of 3 2 results in the slave axis rot
57. ion output signal level indicates the command direction of motion either forward or reverse CW and CCW mode produces pulses steps on the CW output for forward commanded motion and pulses on the CCW output for reverse commanded motion Analog Input lt 1 8 gt Analog Input Ground Input 12 bit analog ADC input Analog Input Ground Reference for analog inputs Overline indicates that the signal is active low Table 5 1 Motion I O Signal Connections Continued Signal Name Reference Direction Description Chapter 5 Signal Connections National Instruments Corporation 5 5 FlexMotion 6C Hardware User Manual In either case you can set the active polarity of both outputs to active low inverting or active high non inverting For example with step and direction you can make a logic high correspond to either forward or reverse direction The Step CW and Dir CCW outputs are driven by high speed open collector TTL buffers that feature high sink current capability Caution Do not connect these outputs to anything other than a 5 V circuit The output buffers will fail if subjected to voltages in excess of 5 5 V Axis lt 1 6 gt Inhibit Use the inhibit output signals to control the enable inhibit function of a servo amplifier or stepper driver When properly connected and configured the inhibit function causes the connected motor to be de energized and its shaft turns freely These open collect
58. itive full scale error 2 5 LSB max Bipolar zero error 4 LSB max Negative full scale error 2 LSB max Relative accuracy 1 LSB Conversion time 10 s Multiplexor scan rate 50 s enabled channel Converter AD7890 10 or equivalent Analog outputs Number of outputs 6 Voltage range 10 V Output current 10 mA Resolution 16 bits 0 000305 V LSB Settling time 1 s 1 LSB step Gain accuracy 2 Drift 25 ppm C type Appendix A Specifications FlexMotion 6C Hardware User Manual A 6 www natinst com 24 Bit Digital I O Ports 3 8 bit ports Line direction individual bit programmable Max number of input ports 2 Max number of output ports 3 Inputs Voltage range 0 to 5 V Input low voltage 0 8 V Input high voltage 2 0 V Polarity Programmable active high or activ
59. ity on the FlexMotion 6C controller Dual Processor Architecture The FlexMotion 6C controller allows you to perform up to six axes of simultaneous coordinated motion control in a preemptive multitasking real time environment FlexMotion 6C s high performance capabilities result from an advanced dual processor architecture using a Motorola MC68331 real time 32 bit CPU combined with an Analog Devices ADSP 2111 DSP and custom FPGAs Its FIFO bus interface and powerful function set provide high speed communications while off loading complex motion functions from the host PC for optimized system performance FlexMotion 6C uses the digital signal processor for all closed loop control including position tracking PID control closed loop computation and motion trajectory generation The DSP chip is supported by custom FPGAs and I O processors that perform the high speed encoder interfacing position capture and breakpoint functions motion I O processing and stepper pulse generation for hard real time functionality The embedded multitasking real time CPU handles host communications command processing multi axis interpolation onboard program execution error handling general purpose digital I O and overall motion system integration functions Embedded Real Time Operating System RTOS The embedded firmware is based upon the RTXC embedded RTOS kernel for optimum system performance in varying motion applications Motion tasks are priori
60. lving communications channels operator interface devices and or motion control interfaces interlock 5 V bus interlock voltage inverting the polarity of a switch limit switch home switch etc in active state If these switches are active low they are said to have inverting polarity IRQ interrupt request ISA industry standard architecture 16 bit AT bus interface standard K k kilo the standard metric prefix for 1 000 or 103 used with units of measure such as volts hertz and meters K kilo the prefix for 1 024 or 210 used with B in quantifying data or computer memory L limit switch end of travel position input sensors that alert the control electronics that physical end of travel is being approached and that the motion should stop Glossary FlexMotion 6C Hardware User Manual G 6 www natinst com M m meters microstep The proportional control of energy in the coils of a Stepper Motor that allows the motor to move to or stop at locations other than the fixed magnetic mechanical pole positions determined by the motor specifications This capability facilitates the subdivision of full mechanical steps on a stepper motor into finer microstep locations that greatly smooth motor running operation and increase the resolution or number of discrete positions that a stepper motor can attain in each revolution modulo position treat the target position as within the range of total quadrature counts pe
61. ming choices 1 3 software related resources C 2 specifications A 1 to A 7 24 bit digital I O A 6 environment A 7 motion I O A 3 to A 5 physical A 7 power requirements max A 6 servo performance A 1 to A 2 stepper performance A 2 to A 3 system safety A 3 Stepper lt 5 6 gt Dir CCW signal description 5 4 to 5 5 reference direction and description table 5 3 Stepper lt 5 6 gt Step CW signal description 5 4 to 5 5 reference direction and description table 5 3 stepper performance specifications A 2 to A 3 system safety specifications A 3 T technical support resources C 1 to C 2 termination networks See encoder termination networks selecting trajectory generators 4 2 to 4 5 electronic gearing 4 4 linear and circular interpolation 4 4 to 4 5 move blending 4 3 to 4 4 trapezoidal point to point position control 4 3 velocity control 4 3 trapezoidal point to point position control 4 3 Trigger Input lt 1 4 gt signal purpose and use 5 11 reference direction and description table 5 3 trigger inputs and breakpoint outputs 5 11 to 5 12 breakpoint output circuit figure 5 12 signal descriptions 5 11 trigger input circuit figure 5 12 wiring concerns 5 12 U user connectors 3 2 V vector spaces 4 8 to 4 9 velocity control 4 3 Index National Instruments Corporation I 7 FlexMotion 6C Hardware User Manual W Web support from National Instruments C 1 to C 2
62. mperature 0 to 55 C Storage temperature 20 to 70 C Relative humidity range 10 to 90 noncondensing National Instruments Corporation B 1 FlexMotion 6C Hardware User Manual B Cable Connector Descriptions This appendix describes the connector pinout for the cables that connect to your FlexMotion controllers Figures B 1 and B 2 show the pin assignment for the two 50 pin connectors on the R1005050 cables This cable splits the 100 pin motion I O signals into two 50 pin groups for easy interfacing to industry standard 50 pin terminal blocks Notice that the first 50 pin group is a complete 4 axis subsystem with all of the required inputs and outputs for motion control In many applications you do not need any of the signals in the second 50 pin group and only one 50 pin screw terminal block is required For more information on signal features and capabilities please refer to Chapter 5 Signal Connections Appendix B Cable Connector Descriptions FlexMotion 6C Hardware User Manual B 2 www natinst com Figure B 1 First 50 Pin Motion I O Connector Pin Assignment Analog Output 5 Analog Output 1 Digital Ground Encoder 6 Index Encoder 6 Phase B Encoder 6 Phase A Encoder 5 Index Encoder 5 Phase B Encoder 5 Phase A Encoder 2 Index Encoder 2 Phase B Encoder 2 Phase A Encoder 1 Index Encoder 1 Phase B Encoder 1 Phase A IS
63. mproved low speed smoothness FlexMotion 6C also supports dual loop feedback configurations where the primary sensor is used for position feedback and the secondary feedback is used for velocity estimation and feedback damping Note Refer to the Axis and Resource Configuration section of the FlexMotion software reference for more information on enhanced PID and dual loop feedback functions Trajectory Generators FlexMotion 6C trajectory generators are responsible for calculating the instantaneous position command that controls acceleration and velocity while it moves the axis to its target position This command is then sent to the PID servo loop or stepper pulse generator depending on axis configuration To implement infinite trajectory control FlexMotion 6C has 12 trajectory generators implemented in the DSP chip two per axis Each generator Chapter 4 Functional Overview National Instruments Corporation 4 3 FlexMotion 6C Hardware User Manual calculates an instantaneous position each PID update period While simple point to point moves require only one trajectory generator two simultaneous generators are required for unsurpassed blended move and infinite trajectory control processing The following sections describe the five primary trajectory types supported by the FlexMotion 6C controller Trapezoidal Point to Point Position Control Like virtually all motion controllers FlexMotion 6C implements trapezoidal profile c
64. n the Technical Support section of our Web site at www natinst com support Online Problem Solving and Diagnostic Resources KnowledgeBase A searchable database containing thousands of frequently asked questions FAQs and their corresponding answers or solutions including special sections devoted to our newest products The database is updated daily in response to new customer experiences and feedback Troubleshooting Wizards Step by step guides lead you through common problems and answer questions about our entire product line Wizards include screen shots that illustrate the steps being described and provide detailed information ranging from simple getting started instructions to advanced topics Product Manuals A comprehensive searchable library of the latest editions of National Instruments hardware and software product manuals Hardware Reference Database A searchable database containing brief hardware descriptions mechanical drawings and helpful images of jumper settings and connector pinouts Application Notes A library with more than 100 short papers addressing specific topics such as creating and calling DLLs developing your own instrument driver software and porting applications between platforms and operating systems Appendix C Technical Support Resources FlexMotion 6C Hardware User Manual C 2 www natinst com Software Related Resources Instrument Driver Network A libra
65. nce capabilities are the result of an advanced dual processor architecture using a Motorola MC68331 real time 32 bit CPU combined with an Analog Devices ADSP 2111 digital signal processor DSP and custom field programmable gate arrays FPGA Its first in first out FIFO bus interface and powerful function set provide high speed communications while offloading complex motion functions from the host PC for optimum command throughput and system performance You can use FlexMotion 6C s full onboard programming to execute up to 10 simultaneous motion programs in a preemptive real time multitasking operating system environment Motion profiles are controlled with enhanced PID PIVff servo updates at 62 s per axis and encoder feedback rates up to 16 MHz Each axis has optoisolated motion I O for end of travel limit and home switch inputs breakpoint output and trigger input FlexMotion 6C controllers also have non dedicated user I O including 24 bits of digital I O and eight analog inputs for 10 V signals providing motion PID feedback for loop closure joystick inputs or coarse monitoring of analog sensors What You Need to Get Started To set up and use your FlexMotion 6C controller you will need the following K One of the FlexMotion 6C controllers PC FlexMotion 6C PCI FlexMotion 6C K FlexMotion 6C Hardware User Manual K FlexMotion Software Reference Manual K One of the following software packages and documen
66. nd pluggable screw terminal connectors to simple screw terminal blocks Drive units are available to supply pluggable connectors power supplies amplifier drivers and direct motion system interfacing capabilities ISA Bus Address Table PC FlexMotion 6C Only For backward compatibility with non Plug and Play computers the PC FlexMotion 6C controller has an onboard DIP switch selectable address setting You must set the desired address for all communications with the FlexMotion 6C controller prior to inserting the controller into the computer The ISA bus is designed to support many peripheral device controllers as long as all of the controllers have different distinct ISA bus addresses You must use an address that is not currently used by another controller to avoid conflict during host communications and the potential for faulty operation Set the controller address using the DIP switch as shown in Figure 3 1 Table 3 1 lists the possible base addresses for the PC FlexMotion 6C along with the corresponding settings for the address selector DIP switch All addresses in this table are hexadecimal Positions 1 through 6 are used for setting the base address Positions 7 and 8 are used for internal test and must be left off Chapter 3 Hardware Overview FlexMotion 6C Hardware User Manual 3 4 www natinst com Write down the base I O address that you select and the DIP switch configuration This information will be used for further confi
67. not required If the motion I O is not needed by the axis you can reuse the signals as general purpose I O by disabling their indicated function FlexMotion 6C supports axes with optional secondary feedback resources encoders or ADCs and or secondary output resources DACs or stepper outputs Two feedback resources are used when implementing dual loop control Defining two output resources is useful when controlling axes with multiple motors such as gantry systems where two DAC outputs can be configured with different torque limits and or offsets Note Refer to the Axis and Resource Configuration section of the FlexMotion Software Reference for more information on configuring axes Motion Resources Encoder DAC and ADC resources that are not used by an axis are available for nonaxis or nonmotion specific applications You can directly control an unmapped DAC as a general purpose analog output 10 V Similarly you can use any ADC channel to measure potentiometers or other analog sensors If an encoder resource is not needed for axis control you can use it for any number of other functions including position or velocity monitoring as a digital potentiometer encoder input or as a master encoder input for master slave and electronic gearing applications Chapter 4 Functional Overview FlexMotion 6C Hardware User Manual 4 8 www natinst com Four of the six encoders feature high speed capture trigger inputs and breakpoint ou
68. oller 3 2 PC FlexMotion 6C controller See also FlexMotion 6C controllers configuration 2 2 ISA bus address table 3 3 to 3 7 address map table 3 4 to 3 7 DIP switch settings 3 3 to 3 4 factory default DIP switch setting figure 3 4 parts locator diagrams 3 1 PCI Local Bus Specification 2 2 PCI FlexMotion 6C controller See also FlexMotion 6C controllers configuration 2 2 parts locator diagrams 3 2 physical specifications connectors A 7 dimensions A 7 PID functions enhanced 4 2 power requirement specifications A 6 problem solving and diagnostic resources online C 1 programs onboard 4 9 to 4 10 Find Home function 4 10 5 6 Find Index function 4 10 5 9 PWM pulse width modulation and counter features 5 17 to 5 18 Index FlexMotion 6C Hardware User Manual I 6 www natinst com R real time operating system RTOS embedded 4 1 to 4 2 requirements for getting started 1 2 reserved connectors note 3 3 return data buffer 4 12 RP3 and RP10 DIP resistor networks 3 10 to 3 11 motion I O DIP resistor values table 3 11 optocoupled motion I O DIP resistor networks figure 3 11 RTOS embedded real time operating system 4 1 to 4 2 S safety specifications A 3 servo performance specifications A 1 to A 2 signal connections See auxiliary 24 bit digital I O connector motion I O connector software National Instruments application software 1 3 onboard programs 4 9 to 4 10 software program
69. on range Encoder Signals FlexMotion 6C offers six channels of differential or single ended quadrature encoder inputs Encoder lt 1 6 gt Phase A Encoder lt 1 6 gt Phase A Encoder lt 1 6 gt Phase B Encoder lt 1 6 gt Phase B RP3 RP10 ISO OptoCoupled Limit Home Input Connected to internal FlexMotion Limit Home circuits GND TLP626 Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 8 www natinst com The encoder inputs provide position and velocity feedback for absolute and relative positioning of axes in any motion system configuration If an encoder resource is not needed for axis control it is available for other functions including position or velocity monitoring digital potentiometer encoder inputs or as a master encoder input for master slave or electronic gearing applications The first four encoder channels Encoder lt 1 4 gt are implemented in a FPGA and are high performance with extended input frequency response and advanced features such as trigger inputs and breakpoint outputs Encoders 1 and 2 have a maximum count frequency of 16 MHz while Encoders 3 and 4 are limited to 1 MHz Encoders 5 and 6 have a maximum count frequency of 2 MHz but do not offer the trigger or breakpoint functionality Since you can map any encoder to any axis this variation of performance and features across the six encoder channels results in a extremely flexible
70. ons 5 3 Table 5 2 Enhanced I O Features 5 17 National Instruments Corporation ix FlexMotion 6C Hardware User Manual About This Manual This manual describes the electrical and mechanical aspects of each controller in the FlexMotion 6C family of motion controllers and contains information concerning their operation and programming Unless otherwise noted text applies to all controllers in the FlexMotion 6C family The FlexMotion 6C family of motion controllers includes the following controllers PC FlexMotion 6C PCI FlexMotion 6C The FlexMotion 6C controllers are high performance motion controllers for ISA and PCI bus computers Conventions The following conventions appear in this manual lt gt Angle brackets that contain numbers separated by an ellipsis represent a range of values associated with a bit or signal name for example DBIO lt 3 0 gt This icon denotes a note which alerts you to important information This icon denotes a caution which advises you of precautions to take to avoid injury data loss or a system crash This icon denotes a warning which advises you of precautions to take to avoid being electrically shocked italic Italic text denotes variables emphasis a cross reference or an introduction to a key concept This font also denotes text tha
71. ontrol for point to point moves FlexMotion 6C has enhanced the trapezoidal profile to offer independent acceleration and deceleration value programming and S curve smoothing jerk control of the acceleration deceleration inflection points Motion occurs first with a programmable acceleration smoothed by the S curve value then for a period at a constant velocity if required and then with a programmed deceleration stopping at the desired target position You can interrupt motion by executing a stop or kill motion function Motion is automatically halt stopped if an enabled limit or home input signal becomes active during the move Note Refer to the FlexMotion Software Reference for more information on the programming of trapezoidal trajectory control parameters Velocity Control Velocity control is a simple variation of trapezoidal position control The same trajectory generator implements a continuous velocity control mode If you select this mode the target position is effectively set to infinity and the axis moves at the programmed constant velocity You can change velocity on the fly and all existing acceleration deceleration and S curve limits are in effect during the velocity transition You can interrupt motion by executing a stop or kill function Motion is automatically halt stopped if an enabled limit or home input signal becomes active This mode is useful for jogging moves simple speed control and continuous contouring mot
72. or inhibit signals feature high current sink capability and can directly drive most driver amplifier inhibit input circuits They are protected from excessive pull up voltage with a diode clamp to internal 12 V While the industry standard for inhibits is active low inverting these outputs have programmable polarity and can be set to active high non inverting for increased flexibility and unique drive compatibility Inhibit output signals are activated automatically upon a Kill Motion command or any motion error that causes a kill motion condition for example following error trip You can also directly control the inhibit output signals to enable or disable a driver or amplifier Limit and Home Inputs The following signals control limit and home inputs Axis lt 1 6 gt Forward Limit Input Axis lt 1 6 gt Home Input Axis lt 1 6 gt Reverse Limit Input These optoisolated inputs are typically connected to limit switches located at physical ends of travel and or at a specific home position Limit and home inputs may be software enabled and disabled at any time When enabled an active transition on a limit or home input causes a full torque halt stop of the associated motor axis In addition an active forward or Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 6 www natinst com reverse limit input will impede future commanded motion in that direction for as long as the signal is acti
73. period and duty cycles may be independently controlled through software commands You can think of PWM as a digital representation of an analog value because the duty cycle is directly proportional to the desired output value PWM outputs are typically used for transmitting an analog value through a optocoupler A simple lowpass filter will turn a PWM signal back into its corresponding analog value You can use the PCLK input instead of the internal source as the clock for the PWM generators The programmable polarity of these bits is in effect whether or not you are using them for their alternative features or as general purpose digital I O National Instruments Corporation A 1 FlexMotion 6C Hardware User Manual A Specifications This appendix lists the hardware and software performance specifications for the FlexMotion 6C controller Servo Performance PID update rate range 62 5 to 500 s sample Max PID update rate 62 5 s axis 6 axis PID update rate 375 s total Trajectory update rate Same as PID update rate Multi axis synchronization lt 1 update sample Position accuracy Encoder feedback 1 quadrature count Analog feedback 1 LSB Long term velocity accuracy Oscillator based 100 ppm Double buffered trajecto
74. pplication designer is ultimately responsible for verifying and validating the suitability of National Instruments products whenever National Instruments products are incorporated in a system or application including without limitation the appropriate design process and safety level of such system or application National Instruments Corporation v FlexMotion 6C Hardware User Manual Contents About This Manual Conventions ix Related Documentation x Chapter 1 Introduction About the FlexMotion 6C Controllers 1 1 What You Need to Get Started 1 2 Software Programming Choices 1 3 National Instruments Application Software 1 3 Optional Equipment 1 4 Motion Signal and Motion I O Connections 1 4 Chapter 2 Configuration and Installation Software Installation
75. pyright laws this publication may not be reproduced or transmitted in any form electronic or mechanical including photocopying recording storing in an information retrieval system or translating in whole or in part without the prior written consent of National Instruments Corporation Trademarks BridgeVIEW CVI FlexCommander FlexMotion LabVIEW natinst com and National Instruments are trademarks of National Instruments Corporation Product and company names mentioned herein are trademarks or trade names of their respective companies WARNING REGARDING MEDICAL AND CLINICAL USE OF NATIONAL INSTRUMENTS PRODUCTS National Instruments products are not designed with components and testing for a level of reliability suitable for use in or in connection with surgical implants or as critical components in any life support systems whose failure to perform can reasonably be expected to cause significant injury to a human Applications of National Instruments products involving medical or clinical treatment can create a potential for death or bodily injury caused by product failure or by errors on the part of the user or application designer Because each end user system is customized and differs from National Instruments testing platforms and because a user or application designer may use National Instruments products in combination with other products in a manner not evaluated or contemplated by National Instruments the user or a
76. r revolution for an axis N noise an undesirable electrical signal noise comes from external sources such as the AC power line motors generators transformers fluorescent lights soldering irons CRT displays computers electrical storms welders radio transmitters and internal sources such as semiconductors resistors and capacitors Noise corrupts signals you are trying to send or receive noninverting the polarity of a switch limit switch home switch etc in active state If these switches are active high they are said to have non inverting polarity O open loop refers to a motion control system where no external sensors feedback devices are used to provide position or velocity correction signals P PID proportional integral derivative control loop PIVff proportional integral velocity feed forward port 1 a communications connection on a computer or a remote controller 2 a digital port consisting eight lines of digital input and or output Glossary National Instruments Corporation G 7 FlexMotion 6C Hardware User Manual position breakpoint position breakpoint for an encoder can be set in absolute or relative quadrature counts When the encoder reaches a position breakpoint the associated breakpoint output immediately transitions power cycling turning the host computer off and then back on which causes a reset of a the motion controller PWM Pulse Width Modulation a method of controlling
77. r in any open compatible ISA or PCI expansion slot in your computer The typical power required for each FlexMotion 6C controller is given in Appendix A Specifications The following are general installation instructions but consult your computer user manual or technical reference manual for specific instructions and warnings Caution flexmotion 6c controllers are sensitive electronic devices shipped in an antistatic bag open only at an approved workstation and observe precautions for handling electrostatic sensitive devices 1 Turn off and unplug your computer 2 Remove the top cover or access port to the ISA or PCI expansion slots in your computer 3 Remove the expansion slot connector port cover on the back panel of the computer if installed 4 Insert the FlexMotion 6C controller into a 5 V ISA or PCI slot as appropriate Gently rock the controller to ease it into place It may be a tight fit but do not force the controller into place Chapter 2 Configuration and Installation National Instruments Corporation 2 3 FlexMotion 6C Hardware User Manual 5 If available screw the mounting bracket of the FlexMotion 6C controller to the back panel rail of the computer 6 Replace the cover 7 Plug in the 100 pin cable for motion I O to the FlexMotion 6C controller 8 Plug in and turn on your computer Your PC PCI FlexMotion 6C controller is installed National Instruments Corporation 3 1 FlexMotion
78. rance 01 48 14 24 24 Germany 089 741 31 30 Hong Kong 2645 3186 India 91805275406 Israel 03 6120092 Italy 02 413091 Japan 03 5472 2970 Korea 02 596 7456 Mexico D F 5 280 7625 Mexico Monterrey 8 357 7695 Netherlands 0348 433466 Norway 32 27 73 00 Singapore 2265886 Spain Madrid 91 640 0085 Spain Barcelona 93 582 0251 Sweden 08 587 895 00 Switzerland 056 200 51 51 Taiwan 02 2377 1200 United Kingdom 01635 523545 National Instruments Corporation G 1 FlexMotion 6C Hardware User Manual Glossary Prefix Meaning Value p pico 10 12 n nano 10 9 micro 10 6 m milli 10 3 k kilo 103 M mega 106 Numbers Symbols degrees percent plus or minus positive of or plus negative of or minus per ohm percent 5 V 5 VDC source signal A A amperes absolute mode treat the target position loaded as position relative to zero 0 while making a move Glossary FlexMotion 6C Hardware User Manual G 2 www natinst com absolute position position relative to zero acceleration deceleration a measurement of the change in velocity as a function of time Acceleration and deceleration describes the period when velocity is changing from one value to another active high a signal is active when its value goes high 1 active low a signal is active when its value goes low 0 A D analog to digital address character
79. rimary output resource a DAC is by definition a servo axis Figure 4 1 Servo Axis Resources Figure 4 2 Stepper Axis Resources 0101011101101 11101101100 101100111 101100111 PID Servo Loop 16 Bit D A Converter 32 Bit Encoder Interface 10 V A B Index 01011010 010010110 Stepper Control Loop Stepper Pulse Generator 32 Bit Encoder Interface A B Index 101100111 101100111 Chapter 4 Functional Overview National Instruments Corporation 4 7 FlexMotion 6C Hardware User Manual In its default configuration FlexMotion 6C comes preconfigured as six servo axes with Encoder 1 and DAC 1 mapped to Axis 1 Encoder 2 and DAC 2 mapped to Axis 2 and so on through Axis 6 However it is simple for advanced users to map any feedback and output resource to any axis This flexibility allows you to tailor each axis to accommodate your specific motion system requirements Note For many servo applications the factory default mapping of encoders and DACs to axes will meet your typical system requirement Available feedback resources are Encoder lt 1 6 gt and ADC lt 1 8 gt Available output resources are DAC lt 1 6 gt and Stepper lt 5 6 gt Axes use the dedicated motion I O signal lines assigned to them A forward and reverse limit input a home input and an inhibit output are dedicated to each axis Since there are six identical sets of these motion I O signals mapping is
80. rn the configuration to these new saved default values The FPGA configuration program is also stored in the flash ROM Upon power up the encoder FPGA is booted with this program This means that updates to the FPGA program can be performed in the field A flash memory download utility is included with the FlexMotion software which ships with the controller Chapter 4 Functional Overview FlexMotion 6C Hardware User Manual 4 6 www natinst com Axes Motion Resources and Vector Spaces FlexMotion 6C can control up to six axes of motion The axes can be completely independent simultaneously coordinated or mapped in multidimensional groups called vector spaces You can also synchronize vector spaces for multi vector space coordinated motion control Axes At a minimum an axis consists of a trajectory generator a PID or stepper control block and at least one output resource either a DAC output or a stepper pulse generator output Servo axes must have either an encoder or ADC channel feedback resource Closed loop stepper axes also require a feedback resource open loop stepper axes do not These axis configurations are shown in Figures 4 1 and 4 2 With FlexMotion 6C you configure an axis with the Configure Axis Resources function This action maps one or two feedback resources and one or two output resources to the axis An axis with its primary output resource a stepper output is by definition a stepper axis An axis with its p
81. ry parameters Absolute position range 231 counts Max relative move size 231 counts Velocity range 1 to 16 000 000 counts s RPM range 10 5 to 106 revolutions minute Acceleration deceleration 4 000 to 128 000 000 counts s2 RPS s range 10 1 to 108 revolutions s2 S Curve time range 1 to 32 767 samples Following error range 0 to 32 767 counts Gear ratio 32 767 1 to 1 32 767 Servo control loop modes PID PIVff S Curve Dual Loop PID Kp Ki and Kd gains 0 to 32 767 Integration limit Ilim 0 to 32 767 Derivative sample period Td 1 to 63 samples Appendix A Specifications FlexMotion 6C Hardware User Manual A 2 www natinst com Feedforward Aff Vff gains 0 to 32 767 Velocity feedback Kv gain 0 to 32 767 Servo command analog outputs Voltage range 10 V Resolution 16 bits 0 000305 V LSB Programmable torque velocity limits Positive limit 10 V 32 768 to 32 767 Negative limit 10 V 32 768 to 32 767 Programmable offset
82. ry with hundreds of instrument drivers for control of standalone instruments via GPIB VXI or serial interfaces You also can submit a request for a particular instrument driver if it does not already appear in the library Example Programs Database A database with numerous non shipping example programs for National Instruments programming environments You can use them to complement the example programs that are already included with National Instruments products Software Library A library with updates and patches to application software links to the latest versions of driver software for National Instruments hardware products and utility routines Worldwide Support National Instruments has offices located around the globe Many branch offices maintain a Web site to provide information on local services You can access these Web sites from www natinst com worldwide If you have trouble connecting to our Web site please contact your local National Instruments office or the source from which you purchased your National Instruments product s to obtain support For telephone support in the United States dial 512 795 8248 For telephone support outside the United States contact your local branch office Australia 03 9879 5166 Austria 0662 45 79 90 0 Belgium 02 757 00 20 Brazil 011 284 5011 Canada Ontario 905 785 0085 Canada Qu bec 514 694 8521 China 0755 3904939 Denmark 45 76 26 00 Finland 09 725 725 11 F
83. ses the number of counts per revolution or linear distance to initiate a search move that locates the index position When a valid index signal transition occurs during a Find Index sequence the position of the index signal is captured very accurately You then use this captured position to establish a reference zero position for absolute position control or any other motion system position reference required Figure 5 3 shows the quadrature encoder phasing diagram Figure 5 3 Quadrature Encoder Phasing Diagram Wiring Concerns The encoder inputs are connected to quadrature decoder counter circuits It is very important to minimize noise at this interface Excessive noise may overwhelm the digital filters on these encoder input signals resulting in loss of counts or extra counts and erroneous closed loop motion operation Verify the encoder connections before powering up the system Caution Wire encoder signals and their ground connections separately from all other connections Wiring these signals near the motor drive amplifier or other signals can cause positioning errors and faulty operation Encoders with differential line driver outputs are strongly recommended for all applications and must be used if the encoder cable length is longer than 10 feet Shielded 24 AWG wire is the minimum recommended size for the encoder cable Cables with twisted pairs and an overall shield are recommended for optimized noise immunity Caution Use of
84. switches between the limit or home input and the ISORTN ground referenced signals on the 100 pin motion I O connector Chapter 3 Hardware Overview National Instruments Corporation 3 9 FlexMotion 6C Hardware User Manual Figure 3 4 Internal 5 V Supply Configuration Limit Switch Connection Example Caution Do not connect an external voltage source to the ISO or ISORTN signals on the 100 pin motion I O connector if you have the jumpers set for internal 5 V supply When the jumpers are set for internal 5 V the I O circuitry uses voltages already present on the FlexMotion 6C controller Improper signal connections can damage the FlexMotion 6C controller and void the warranty How to Set the Isolated Supply Jumpers JP2 for External Isolated Supply ISO To configure the motion I O circuits to use an external voltage source for ISO and ISORTN place the jumpers on jumper block JP2 as shown in Figure 3 5 The FlexMotion 6C controller comes factory configured for 18 to 24 V external isolated supply with DIP resistor networks RP3 and RP10 set at 2 2 k refer to the following section RP3 and RP10 DIP Resistor Networks for more information on DIP resistor value and ISO voltage range selection Apply a positive voltage 24 V maximum from an external supply to the ISO input connect the ISORTN to the external isolated supply return ground and connect the limit or home switch between the limit or home input and the ISORTN gro
85. t is a placeholder for a word or value that you must supply bold Bold text denotes items that you must select or click on in the software such as menu items and dialog box options Bold text also denotes parameter names FlexMotion 6C Refers to the PC FlexMotion 6C and the PCI FlexMotion 6C motion controllers FlexMotion Refers to both the FlexMotion Software Reference Manual and the software reference FlexMotion Software Reference Online Help About This Manual FlexMotion 6C Hardware User Manual x www natinst com Related Documentation The following documents contain information you may find helpful as you read this manual FlexMotion Software Reference Manual FlexMotion Software Reference Online Help FlexMotion VI Online Help PCI Local Bus Specification Revision 2 1 Your computer s technical reference manual National Instruments Corporation 1 1 FlexMotion 6C Hardware User Manual 1 Introduction This chapter describes the FlexMotion 6C controllers and their operation About the FlexMotion 6C Controllers Thank you for purchasing a FlexMotion 6C motion controller FlexMotion 6C controllers have advanced motion control performance along with easy to use software tools and add on motion VI libraries for use with LabVIEW and BridgeVIEW LabVIEW for Industrial Automation The FlexMotion 6C line of motion controllers are a combination of servo and stepper motor controllers for
86. tation LabVIEW LabWindows CVI BridgeVIEW FlexMotion software includes FlexCommander K Your computer with an available ISA or PCI slot as appropriate Chapter 1 Introduction National Instruments Corporation 1 3 FlexMotion 6C Hardware User Manual Software Programming Choices You have several options to choose from when programming your National Instruments FlexMotion 6C controller You can use National Instruments application software FlexMotion VIs for LabVIEW and BridgeVIEW or the FlexMotion software Programming the FlexMotion 6C controller is straightforward using a simple but powerful high level function set application programming interface API All setup and motion control functions are easily executed by calling into either a static or dynamically linked library DLL These libraries are callable from C Visual Basic and other high level languages Full function set implementations are available for LabVIEW LabWindows CVI BridgeVIEW and other industry standard software programs National Instruments Application Software LabVIEW and BridgeVIEW based on the graphical programming language G feature interactive graphics and a state of the art user interface In LabVIEW and BridgeVIEW you can create 32 bit compiled programs and stand alone executables for custom automation data acquisition test measurement and control solutions National Instruments offers the FlexMotion VI Librar
87. ter Commands are also checked for data and modal sequence errors at this time A modal error is flagged by setting the error message bit in the CSR A modal error is functionally different from the packet communication error described above See Error Stack of this chapter for additional information on modal errors Return Data Buffer Data or status requested by the host with a command is buffered in the return data FIFO buffer RDB The RDB is 26 words deep and is large enough to hold the biggest return data packet or many smaller return data packets When data exists in the RDB the Ready to Send bit in the CSR is set The host can then perform a bus read to get the return data from the controller You can use the RDB in two ways as a temporary buffer holding a single data return packet or as a small FIFO buffer Typically once the requested data is available in the RDB it is read back by the host It is possible however to request a number of pieces of data and leave them in the buffer RDB for retrieval at a later time The FlexMotion software supports both ways of using the RDB If the RDB fills up and there is no place to put requested return data FlexMotion 6C will generate an error and set the error message bit in the CSR Note Refer to the FlexMotion Software Reference for more information on RDB buffering and readback Chapter 4 Functional Overview National Instruments Corporation 4 13 FlexMotion 6C Hardware
88. the average current in a motors phase windings by varying the on time duty cycle of transistor switches Q quadrature counts the encoder line resolution times four R RAM random access memory relative breakpoint sets the position breakpoint for an encoder in relative quadrature counts relative position The destination or target position for motion specified with respect to the current location regardless of its value relative position mode position relative to current position ribbon cable a flat cable in which the conductors are side by side RPM revolutions per minute units for velocity RPSPS or RPS S revolutions per second squared units for acceleration and deceleration S s seconds servo specifies an axis that controls a servo motor stepper specifies an axis that controls a stepper motor stepper lt 5 6 gt Dir CCW direction output or counter clockwise direction control stepper lt 5 6 gt Step CW stepper pulse output or clockwise direction control Glossary FlexMotion 6C Hardware User Manual G 8 www natinst com T toggle changing state from high to low back to high and so on torque force tending to produce rotation trapezoidal profile a typical motion trajectory where a motor accelerates up to the programmed velocity using the programmed acceleration traverses at the programmed velocity then decelerates at the programmed acceleration to the target position trigger any
89. tional Instruments will at its option repair or replace equipment that proves to be defective during the warranty period This warranty includes parts and labor The media on which you receive National Instruments software are warranted not to fail to execute programming instructions due to defects in materials and workmanship for a period of 90 days from date of shipment as evidenced by receipts or other documentation National Instruments will at its option repair or replace software media that do not execute programming instructions if National Instruments receives notice of such defects during the warranty period National Instruments does not warrant that the operation of the software shall be uninterrupted or error free A Return Material Authorization RMA number must be obtained from the factory and clearly marked on the outside of the package before any equipment will be accepted for warranty work National Instruments will pay the shipping costs of returning to the owner parts which are covered by warranty National Instruments believes that the information in this document is accurate The document has been carefully reviewed for technical accuracy In the event that technical or typographical errors exist National Instruments reserves the right to make changes to subsequent editions of this document without prior notice to holders of this edition The reader should consult National Instruments if errors are suspected In no event shall Nation
90. tional Overview National Instruments Corporation 4 11 FlexMotion 6C Hardware User Manual Host Communications The host computer communicates with a FlexMotion 6C controller through a number of I O port addresses on the host bus The host bus can be any of the supported bus standards ISA or PCI The primary bidirectional data transfer port is at the controller s base address This port supports FIFO data passing in both send and readback directions The FlexMotion 6C controller has both a command buffer for incoming commands and a return data buffer RDB for readback data At address offsets from the controller s base address are two read only status registers The communications status register CSR provides bits for communications handshaking as well as real time error reporting and general status feedback to the host PC The move complete status MCS register provides instantaneous motion status of all axes Packets Handshaking and FIFO Buffers This section briefly describes how commands and data are passed between the host computer and the FlexMotion 6C controller This information is provided for reference purposes The FlexMotion software that ships with the controller includes drivers DLLs and C function libraries that handle the host to controller communications automatically with built in error reporting Data passed to or from the FlexMotion 6C controller is handled in a packet format A packet consists of a pa
91. tized Task execution order depends upon its priority the state of the entire motion system I O or other system events and the real time clock Chapter 4 Functional Overview FlexMotion 6C Hardware User Manual 4 2 www natinst com The DSP chip being a separate processor operates independently from the CPU but is closely synchronized by an internal packet based command data and messaging event structure FlexMotion 6C is truly a multiprocessing as well as a multitasking embedded controller Enhanced PID Functions The DSP chip implements an enhanced PID PIVff closed loop servo control algorithm PID update rates are user programmable and can be as fast as 62 s per axis The trajectory generators calculate the instantanous desired position in each PID update period for unsurpassed trajectory control and smoothness On stepper axes the DSP chip services the stepper pulse generators each update period resulting in accurate step pulse frequency outputs In addition to the standard PID loop control terms FlexMotion 6C adds the following features An integration limit value to minimize the effects of integrator windup by limiting the contribution on the integral sum A derivative sample time multiplier to minimize quantization induced torque noise and control the effect of the derivative gain Velocity and acceleration feedforward for following error minimization A velocity estimator and feedback gain for i
92. tor step or clockwise control Stepper lt 5 6 gt Dir CCW Digital Ground Output Stepper only motor direction or counter clockwise control Axis lt 1 6 gt Inhibit Digital Ground Output Amplifier drive inhibit Encoder lt 1 6 gt Phase A Digital Ground Input Phase A encoder input Encoder lt 1 6 gt Phase A Digital Ground Input Phase A differential encoder input Encoder lt 1 6 gt Phase B Digital Ground Input Phase B encoder input Encoder lt 1 6 gt Phase B Digital Ground Input Phase B differential encoder input Encoder lt 1 6 gt Index Digital Ground Input Index or marker input Encoder lt 1 6 gt Index Digital Ground Input Index or marker differential input Digital Ground Reference for digital I O Host 5 V Digital Ground Output 5 V host bus interlock ISO ISORTN Input Isolated voltage supply Trigger Input lt 1 4 gt ISORTN Input Trigger input for high speed capture Breakpoint Output lt 1 4 gt ISORTN Output Breakpoint output Axis lt 1 6 gt Forward Limit Input ISORTN Input Forward clockwise limit input Axis lt 1 6 gt Home Input ISORTN Input Home input Axis lt 1 6 gt Reverse Limit Input ISORTN Input Reverse counter clockwise limit input E Stop ISORTN Input Emergency Stop input ISORTN Reference for isolated signals Analog Reference Analog Input Ground Output 7 5 V nom output Chapter 5 Signal Conn
93. tputs These features are implemented in the encoder processor FPGA and are fully functional when an encoder is used as feedback to an axis or as an independent input resource Note Once mapped to an axis all features and functions of a resource are available as part of the axis It is not necessary to remember or use the resource number directly when accessing these features Resources are referenced by axis number once assigned to that axis Vector Spaces Vector spaces are logical multidimensional groups of axes They can be either single dimensional two dimensional with x and y axes or three dimensional with x y and z axes FlexMotion 6C supports up to three separate one or two axis vector spaces or two three axis vector spaces defined at the same time Figure 4 3 shows a single three axis vector space Figure 4 3 3D Vector Space Vector spaces facilitate 2D and 3D interpolation linear circular helical and spherical You can send many FlexMotion 6C commands to a vector space to define vector position vector velocity vector acceleration and so on 0101011101101 11101101100 101100111 101100111 PID Servo Loop 16 Bit D A Converter 32 Bit Encoder Interface 10 V A B Index Axis Resource 0101011101101 11101101100 101100111 101100111 PID Servo Loop 16 Bit D A Converter 32 Bit Encoder Interface 10 V A B Index Axis Resource 0101011101101 11101101
94. und on the 100 pin motion I O connector 470 RP3 and RP10 I O Pin ISORTN JP2 5 V Optocoupler on the FlexMotion Board F2 Limit Switch Chapter 3 Hardware Overview FlexMotion 6C Hardware User Manual 3 10 www natinst com Figure 3 5 External Voltage Supply Configuration Limit Switch Connection Example RP3 and RP10 DIP Resistor Networks The DIP resistor networks RP3 and RP10 provide the current source for the optocoupled inputs and the pull ups for the optocoupled outputs as shown in Figure 3 6 One end of these resistors is connected to the ISO voltage source and the other end is connected to the individual input or output signal via the optocoupler component The correct operating value of these resistor networks depends upon the external isolated supply voltage used The FlexMotion 6C controller ships with 2 2 k networks installed in RP3 and RP10 for use with 24 V external isolated supplies If a different value is needed you can change these networks by removing them from their sockets and replacing them with the appropriate value network Note When changing networks be careful to install the correct resistor network value for the ISO voltage supplied with the correct pin 1 orientation in the socket 2 2 k RP3 and RP10 ISO ISORTN JP2 5 V Optocoupler on the FlexMotion Board F2 Limit Switch 24 V Chapter 3 Hardware Overview National Instruments Corporation
95. uring application development and debugging National Instruments Corporation 5 1 FlexMotion 6C Hardware User Manual 5 Signal Connections This chapter describes how to make input and output signal connections directly to the FlexMotion 6C controller and briefly describes the associated FlexMotion 6C I O circuitry The FlexMotion 6C has two connectors that handle all signals to and from the external motion system 100 pin motion I O connector 50 pin auxiliary 24 bit digital I O connector You can connect to your motion system with cables and accessories varying from simple screw terminal blocks to enhanced UMI units and drive units Caution Turn off power to all devices when connecting or disconnecting FlexMotion 6C motion I O and auxiliary digital I O cables Failure to do so may damage the FlexMotion 6C controller Motion I O Connector The motion I O connector contains all of the signals required to control up to six axes of servo and stepper motion including motor command analog and stepper outputs encoder feedback inputs forward home and reverse limit inputs breakpoint outputs trigger inputs and inhibit outputs This connector also contains eight channels of 12 bit A D inputs for analog feedback or general purpose analog input Figure 5 1 shows the pin assignments for the 100 pin motion I O connector on the PC FlexMotion 6C and PCI FlexMotion 6C controllers A signal description follows the connector p
96. ut you can forgo the isolation and the need for an external supply by using the computer s internal 5 V supply to power the I O circuits Refer to Chapter 3 Hardware Overview for information on setting the isolated voltage supply jumpers The bus related configuration is different for each bus type ISA or PCI of FlexMotion 6C controller Chapter 2 Configuration and Installation FlexMotion 6C Hardware User Manual 2 2 www natinst com PC FlexMotion 6C Controllers The PC FlexMotion 6C controllers may occupy any available 16 bit ISA slot in the host computer The bus communication address of the FlexMotion 6C controller is set with a DIP switch located on the controller See Chapter 3 Hardware Overview for more information on setting the address DIP switch You can install multiple PC FlexMotion 6C controllers with different address selections for each in the host computer PCI FlexMotion 6C Controllers The PCI FlexMotion 6C controller is fully compatible with the PCI Local Bus Specification Revision 2 1 This compatibility allows the computer to automatically perform all bus related configuration and requires no user interaction There are no jumpers to configure for bus related configuration Note Refer to the release notes included with your software for information on assigning a controller s board ID and verifying the bus address of your controller Hardware Installation You can install the FlexMotion 6C controlle
97. ut lt 1 6 gt 5 3 5 4 Axis lt 1 6 gt Inhibit signal 5 3 5 5 Stepper lt 5 6 gt Dir CCW signal 5 3 5 4 to 5 5 Index National Instruments Corporation I 5 FlexMotion 6C Hardware User Manual Stepper lt 5 6 gt Step CW signal 5 3 5 4 to 5 5 motion I O configuration 3 7 to 3 12 encoder termination network selection 3 11 to 3 12 isolated external internal voltage supply 3 8 to 3 11 locating isolated supply jumper block JP2 3 8 RP3 and RP10 DIP resistor networks 3 10 to 3 11 setting isolated supply jumper block for internal 5 V supply 3 8 to 3 9 motion I O connector 5 1 to 5 14 analog inputs 5 13 encoder signals 5 7 to 5 11 limit and home inputs 5 5 to 5 7 motion axis signals 5 4 to 5 5 other motion I O connections 5 14 overview 1 4 5 1 pin assignments figure 5 2 signal connections table 5 3 to 5 4 specifications A 3 to A 5 trigger inputs and breakpoint outputs 5 11 to 5 12 motion resources 4 7 to 4 8 move blending 4 3 to 4 4 MustOn MustOff MOMO protocol 5 17 N National Instruments Web support C 1 to C 2 O onboard programs 4 9 to 4 10 Find Home function 4 10 5 6 Find Index function 4 10 5 9 online problem solving and diagnostic resources C 1 optional equipment 1 4 optoisolation power supply See isolated external internal voltage supply configuration P packets 4 11 to 4 12 parts locator diagrams PC FlexMotion 6C controller 3 1 PCI FlexMotion 6C contr
98. value of the input bits Writes to input pins do nothing Writes to output pins set reset the logic levels of the output bits Reads from output pins return the logic levels last written to the port FlexMotion software supports the MustOn MustOff MOMO protocol for setting and resetting the output bits in a port The MOMO approach allows you to define which bits must be On active which bits must be Off non active and which bits you want to stay in the same state In this way an individual bit or bits can be set or reset without worrying about the values of the other bits in the port Of course the entire port can also be set or reset at any time PWM Features FlexMotion 6C offers a couple of special features on the 24 bit digital I O connector You can configure the input only I O bit 3 of port 2 as a PCLK input and the output only I O bits 0 and 1 of port 3 as PWM outputs When configured for their alternate functions you cannot use these bits general purpose digital I O Table 5 2 lists these alternative functions Table 5 2 Enhanced I O Features I O Bit Port Direction Feature I O Bit 3 2 Input only General Purpose input or PCLK input I O Bit 0 3 Output only General purpose output or PWM1 Output I O Bit 1 3 Output only General purpose output or PWM2 Output Chapter 5 Signal Connections FlexMotion 6C Hardware User Manual 5 18 www natinst com The two PWM outputs generate periodic waveforms whose
99. ve Note While limit and home transitions are edge detected and always stop motion active signals should remain active to prevent motion from proceeding further into the limit Pulsed limit signals will stop motion but they do not prevent further motion in that direction The input polarity of these signals is software programmable for active low inverting or active high non inverting You can use software disabled limit and home inputs as general purpose inputs You can read the status of these inputs at any time and set and change their polarity as required Limit and home inputs are a per axis enhancement on the FlexMotion 6C controllers and are not required for basic motion control These inputs are part of a system solution for complete motion control All motion control functions may be operated without limit switches except the Find Home function which requires enabled limit and home inputs for operations Note Both limits and home inputs must be enabled to use the Find Home function During Find Home function execution the first active limit signal in the search direction will not simply stop the motor but will cause motion to turn around and travel in the opposite direction and continue to search for the home switch Similarly during Find Home you can use a home switch to either stop motion or to begin a predetermined sequence of homing moves to find the correct edge of the home switch and to approach it from the desire
100. view 4 1 to 4 13 See also hardware overview analog feedback 4 5 axes 4 6 to 4 7 dual processor architecture 4 1 to 4 5 embedded real time operating system RTOS 4 1 to 4 2 enhanced PID functions 4 2 flash memory 4 5 host communications 4 11 to 4 13 error stack 4 13 packets handshaking and FIFO buffers 4 11 to 4 12 return data buffer 4 12 motion resources 4 7 to 4 8 onboard programs 4 9 to 4 10 Find Home function 4 10 5 6 Find Index function 4 10 5 9 trajectory generators 4 2 to 4 5 electronic gearing 4 4 linear and circular interpolation 4 4 to 4 5 move blending 4 3 to 4 4 trapezoidal point to point position control 4 3 velocity control 4 3 vector spaces 4 8 to 4 9 H handshaking 4 11 to 4 12 hardware installation 2 2 to 2 3 hardware overview 3 1 to 3 12 See also functional overview ISA bus address table 3 3 to 3 7 address map table 3 4 to 3 7 DIP switch settings 3 3 to 3 4 factory default DIP switch setting figure 3 4 Index FlexMotion 6C Hardware User Manual I 4 www natinst com motion I O configuration 3 7 to 3 12 encoder termination network selection 3 11 to 3 12 isolated external internal voltage supply configuration 3 8 to 3 11 parts locator diagrams PC FlexMotion 6C controller 3 1 PCI FlexMotion 6C controller 3 2 reserved connectors note 3 3 user connectors 3 2 home inputs See limit and home inputs Host 5 V signal description 5 14 reference direction an
101. x pulse width 83 ns Appendix A Specifications FlexMotion 6C Hardware User Manual A 4 www natinst com Forward reverse and home inputs Optocoupled Number of inputs 18 3 per axis Voltage range 0 to 24 V Optocoupler TLP626 or equivalent Max input current 10 mA built in current limiting resistor Polarity Programmable active high or active low Control Individual enable disable stop on input prevent motion Find Home Trigger inputs Optocoupled Number of inputs 4 Encoders 1 through 4 Voltage range 0 to 24 V Optocoupler TLP2631 or equivalent Max input current 10 mA built in current limiting resistor Polarity Programmable active high or active low Min pulse width 83 ns Capture latency lt 100 ns Capture accuracy 1 count Max repetitive capture rate 1 kHz Breakpoint outputs Optocoupled Number of outputs
102. y a series of virtual instruments VIs for using LabVIEW and BridgeVIEW with National Instruments motion control hardware The Motion VI library implements the full function set API and a powerful set of demo functions example programs and fully operational high level application routines ANSI C based LabWindows CVI also features interactive graphics and a state of the art user interface Using LabWindows CVI you can generate C code for custom data acquisition test and all measurement and automation solutions The FlexMotion software includes a series of sample programs for using LabWindows CVI with National Instruments motion control hardware Chapter 1 Introduction FlexMotion 6C Hardware User Manual 1 4 www natinst com Optional Equipment National Instruments offers a variety of products to use with FlexMotion 6C controllers including cables Universal Motion Interfaces UMIs drive units and other accessories as follows Cables and cable assemblies UMI wiring connectivity blocks with integrated motion signal conditioning and motion inhibit functionality Servo motor compatible driver amplifier units with integrated power supply and wiring connectivity Connector blocks shielded and unshielded 50 pin screw terminal wiring aids Refer to Appendix C Technical Support Resources or visit our online catalog at www natinst com for information on how to contact National Instruments for specific inform

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