Home

DMC-41x3 User Manual - Galil Motion Control

1. gt 8 05 1 50 7 55 1 oA H Bi r amp 4 A B Cc D POWER O DMC 41 43 STEPPER SERVO POWER O a o m GALIL MOTION CONTROL MOO Br Aree ag oog O MADE IN USA O O i RESET O fafi o Q O OO A z a o 1 a a a O z g 3 So 5 f gt Se g Ei E pi O tinksact zx 1 O 2 ee O Power O O O O O O alm TR A e 6 75 7 25 OD P P P Boon a ggggg o PERERE o a o CERERE O 123456 123456 123456 123456 0O I O A D D LO a ANALOG ENCODER py I O A D O 1 AGND 18 GND 15 45V 9 AGND 26 MA 8 MA 30 5V Sm Dote opea ono GAREA EME Kue gui mop Pos nom DO 4mA E GpoB lt 5 24V06 MAIA AAI 4AM pag SMe 42004 28D05 12 p03 s ATC sar 23AB qars SLSCOM snoi 27002 11 OPoA HIGH POWER OPTION HP0 Ne SAGNO Ginata ISTP DIR SOND Feta 19 HOMD COO SOURCE DO 8 1 OPA 12 24VDC 15412V 845V a het 41 ENBL 7 Lie 38 FLSC 24RALSC 3 HOME al 500m P98 GND 10 GND S7 FLS ZSRLSB 7 HONA ae risa 22 RLSA 6LSCOM D O i LO 3401g 20ABRT 4 p17 f ssors 18 DI6 DIA O 32pI2 18013 apr 3IGND Z INGOM 4 ERR Gnp O 20 60VDC o W LA a gt GALIL p1 1 Figure 2 3 DMC 41x3 BOX4 Dimensions in inches where x 1 2 3 and 4 axis t Dimensions are subject to change
2. Teaching or Record and Play Back Contour Mode with Teach Record and Play Back CM CD DT RA RD RC Backlash Correction Dual Loop Auxiliary Encoder DV Following a trajectory based on a master Electronic Cam A EM EP ET EB encoder position G EQ Smooth motion while operating in independent Motion Smoothing IT axis positioning Smooth motion while operating in vector or Motion Smoothing IT linear interpolation positioning Smooth motion while operating with stepper Stepper Motion Smoothing KS motors Gantry two axes are coupled by gantry Electronic Gearing Example Gantry Mode GR GM Independent Axis Positioning In this mode motion between the specified axes is independent and each axis follows its own profile The user specifies the desired absolute position PA or relative position PR slew speed SP acceleration ramp AC and deceleration ramp DC for each axis On begin BG the DMC 41x3 profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory The controller determines a new command position along the trajectory every sample period until the specified profile is complete Motion is complete when the last position command is sent by the DMC 41x3 profiler Note The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified The Begin BG command can be issued for
3. Forward Limit Switch When active inhibits motion in forward direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Reverse Limit Switch When active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Home Switch Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Input 1 Input 8 isolated Input 9 Input 16 isolated Uncommitted inputs May be defined by the user to trigger events Inputs are checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W if the high speed position latch function is enabled Latch High speed position latch to capture axis position on occurrence of latch signal AL command arms latch Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W Input 9 is latch E input 10 is latch F input 11 is latch G input 12 is latch H Appendices 192 DMC 41x3 User Manual List of Other Publications Step by Step Design of Motion Control
4. Overview of Galil Amplifiers and Drivers With the DMC 41x3 Galil offers a variety of Servo Amplifiers and Stepper Drivers that are integrated into the same enclosure as the controller Using the Galil Amplifiers and Drivers provides a simple straightforward motion control solution in one box Instead of having to route a 10V motor command signal or STEP DIR to some external box all the wiring is taken care of internally In addition Galil s internal amplifiers reside inside the same box as the controller saving real estate space and the hassle of configuring a separate device A full list of amplifier specifications and details can be found in the Integrated Components starting on pg 196 Chapter 1 Overview 7 DMC 41x3 User Manual DMC 41x3 Functional Elements The DMC 41x3 circuitry can be divided into the following functional groups as shown in Figure 1 4 and discussed below WATCHDOG TIMER ISOLATED LIMITS AND HOME INPUTS RISC BASED HIGH SPEED MAIN ENCODERS MICROCOMPUTER MOTORENCODER AUXILIARY ENCODERS esuEaeere 10 VOLT OUTPUTFOR FOR SERVO MOTORS ABCD PULSE DIRECTION OUTPUT FOR STEP MOTORS i eile tis HIGH SPEED ENCODER 32 g j er VO INTERFACE COMPARE OUTPUT qi 8 PROGRAMMABLE 5 pop EPERE HIGH POWER OPTOISOLATED ns OPTOISOLATED OUTPUTSIGH POWER INPUTS DIGITAL OUTPUTS Galil Amplifiers and Drivers provides a simple straightforward motion control solution HIGH SPEED LATCH FOR EACH AX
5. To insure a position capture within 25 microseconds the input signal must be a transition from high to low Low to high transitions may have greater delay The software commands AL and RL are used to arm the latch and report the latched position respectively The latch must be re armed after each latching event See the Command Reference for more details on these commands Chapter 6 Programming Motion 114 DMC 41x3 User Manual Chapter 7 Application Programming Overview The DMC 41x3 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 41x3 memory freeing the host computer for other tasks However the host computer can send commands to the controller at any time even while a program is being executed Only ASCII commands can be used for application programming In addition to standard motion commands the DMC 41x3 provides commands that allow the DMC 41x3 to make its own decisions These commands include conditional jumps event triggers and subroutines For example the command JP LOOP n lt 10 causes a jump to the label LOOP if the variable n is less than 10 For greater programming flexibility the DMC 41x3 provides user defined variables arrays and arithmetic functions For example with a cut to length operation the length can be specified as a variable in a program which the Operator can change as necessary
6. Isolate Controller Power option and the SR90 SR 49000 Shunt Regulator Option The BOX option is required when the AMP 430x0 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation Figure A1 1 DMC 4143 D3040 BOX4 DMC 4143 with AMP 43040 A1 AMP 430x0 D3040 D3020 198 DMC 41x3 User Manual Electrical Specifications The amplifier is a brush brushless trans conductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage Continuous Current Peak Current Nominal Amplifier Gain Switching Frequency Minimum Load Inductance Brushless Motor Commutation angle 20 80 VDC 7 Amps 10 Amps 0 7 Amps Volt 60 kHz up to 140 kHz available contact Galil Hn ao 4 Ripple Where Vs Supply Voltage lippe 10 of the maximum current at chosen gain setting 120 60 option available The default PWM output operation on the AMP 430x0 D3040 D3020 is Inverter Mode The minimum
7. Results Array elements 0 and 1 will make up the 32 bit floating point value for analog input 3 on the PLC and array elements 2 and 3 will combine for the value of analog input 4 myanalog 0 16412 0x401C myanalog 1 52429 0xCCCD myanalog 2 49347 0xC0C3 myanalog 3 13107 0x3333 Analog input 3 0x401CCCCD 2 45V Analog input 4 0xC0C33333 6 1V Example 3 DMC 4143 connected as a Modbus master to a hydraulic pump The DMC 4143 will set the pump pressure by writing to an analog output on the pump located at Modbus address 30000 and consisting of 2 Modbus registers forming a 32 bit floating point value 1 Begin by opening a connection to the pump which has an IP address of 192 168 1 100 in our example ITHB 192 168 1 100 lt 502 gt 2 2 Dimension and fill an array with values that will be written to the PLC DM pump 2 pump 0 16531 0x4093 pump 1 13107 0x3333 3 Send the appropriate MB command Use function code 16 Start at address 30000 and write to 2 registers using the data in the array pump MBB 16 30000 2 pump Results Analog output will be set to 0x40933333 which is 4 6V Chapter 4 Software Tools and Communication 57 DMC 41x3 User Manual Data Record The DMC 41x3 can provide a binary block of status information with the use of the QR and DR commands These commands along with the QZ command can be very useful for accessing complete controller status The OR command will return 4 bytes of he
8. The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 80 characters x 4000 lines Program Format A DMC 41x3 program consists of DMC instructions combined to solve a machine control application Action instructions such as starting and stopping motion are combined with Program Flow instructions to form the complete program Program Flow instructions evaluate real time conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 41x3 instruction in a program must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 80 characters A carriage return enters the final command on a program line Using Labels in Programs All DMC 41x3 programs must begin with a label and end with an End EN statement Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted in a label The maximum number of labels which may be defined is 510 Valid labels BEGIN SQUARE Chapter 7 Application Programming 115 DMC 41x3 User Manual X1 BEGINI Invalid labels 1Square 123 A Simple Example Program START Beginning of the Program PR 10000 2
9. The short circuit protection will protect against phase to phase shorts a shorted load and a short to ground or chassis The over current shutdown will occur when any one phase exceeds an output greater than 2Amps The over temperature shutdown will occur when the driver temperature exceeds 165 deg C In the event of any of these faults TA 0 will be set and the SDM 44040 will be disabled All 4 axes on the amplifier must be in MO state in order for the error status to be cleared ELO Input If the ELO input on the controller is triggered then the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA 3 will be set and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input A6 SDM 44040 D4040 D4020 228 DMC 41x3 User Manual A7 SDM 44140 D4140 Description The SDM 44140 resides inside the DMC 41x3 enclosure and contains four microstepping drives for operating two phase bipolar stepper motors The drives produce 64 microsteps per full step or 256 steps per full cycle which results in 12 800 steps rev for a standard 200 step
10. Chapter 6 Programming Motion 97 DMC 41x3 User Manual PVB 4500 0 1200 2 point in Figure 6 18 B axis PVA 1000 4000 750 3 point in Figure 6 18 A axis PVB 1000 1000 750 3 point in Figure 6 18 B axis BTAB Begin PVT mode for A and B axes PVA 800 10000 250 4 point in Figure 6 18 A axis PVB 200 1000 250 4 point in Figure 6 18 B axis PVA 4000 0 1000 5 point in Figure 6 18 A axis PVB 900 0 1000 5 point in Figure 6 18 B axis PVA 0 0 0 Termination of PVT buffer for A axis PVB 0 0 0 Termination of PVT buffer for B axis EN NOTE The BT command is issued prior to filling the PVT buffers and additional PV commands are added during motion for demonstration purposes only The BT command could have been issued at the end of all the PVT points in this example The resultant X vs Y position graph is shown in Figure 6 17 with the specified PVT points enlarged X vs Y Commanded Positions 6000 5000 4000 3000 2000 Y Axis Counts 1000 1000 2000 3000 4000 5000 6000 7000 8000 X Axis Counts Figure 6 17 X vs Y Commanded Positions for Multi Axis Coordinated Move Contour Mode The DMC 41x3 also provides a contouring mode This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes This is ideal for following computer generated paths such as parabolic spherical or user defined profiles The path is not limited to straigh
11. EB Contains State of ECAM F ai EC Contains current ECAM index F E EGX Contains ECAM status for each axis F ai EM Contains size of cycle for each axis F Bi EP Contains value of the ECAM table interval y ai E Ox Contains ECAM status for each axis y ai EY Set ECAM cycle count Example Electronic CAM The following example illustrates a cam program with a master axis Z and two slaves X and Y Chapter 6 Programming Motion 93 DMC 41x3 User Manual INSTRUCTION A V1 0 PA 0 0 BGXY AMXY EA Z EM 0 0 4000 EP400 0 ET 0 0 0 ET 1 0 0 ET 2 120 60 ET 3 240 120 ET 4 360 180 ET 5 360 180 ET 6 360 180 ET 7 240 120 ET 8 120 60 ET 9 0 0 ET 10 0 0 EB 1 JGZ 4000 EG 0 0 BGZ LOOP JP LOOP V1 0 EQ2000 2000 MF 2000 ST Z EB 0 EN INTERPRETATION Label Initialize variable Go to position 0 0 on X and Y axes Z axis as the Master for ECAM Change for Z is 4000 zero for X Y ECAM interval is 400 counts with zero start When master is at 0 position 1 point 2 point in the ECAM table 3 point in the ECAM table 4 point in the ECAM table 5 point in the ECAM table 6 point in the ECAM table 7 point in the ECAM table 8 point in the ECAM table 9 point in the ECAM table 10 point in the ECAM table Starting point for next cycle Enable ECAM mode Set Z to jog at 4000 Engage both X and
12. If the condition for the JP command is satisfied the controller branches to the specified label or line number and continues executing commands from this point If the condition is not satisfied the controller continues to execute the next commands in sequence Conditional Meaning JP Loop count lt 10 Jump to Loop if the variable count is less than 10 JS MOVE2 IN 1 1 Jump to subroutine MOVE2 if input 1 is logic level high After the subroutine MOVE2 is executed the program sequencer returns to the main program location where the subroutine was called JP BLUE ABS v2 gt 2 Jump to BLUE if the absolute value of variable v2 is greater than 2 JP C vl v7 lt v8 v2 Jump to C if the value of v1 times v7 is less than or equal to the value of v8 v2 JP A Jump to A Example Using JP command Move the X motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves BEGIN Begin Program count 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec PA 0 Position absolute 0 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec count count 1 Decrement loop counter JP LOOP count gt 0 Test for 10 times thru loop EN End Program Using If Else and Endif Commands The DMC 41x3 provides a structured approach to conditional statements using IF ELSE and ENDIF commands Using the IF and ENDIF Commands
13. Table 2 11 Synopsis of connections required to connect an external amplifier Step A Connect the motor to the amplifier Initially do so with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are Operating properly the motor should stand still even when the amplifiers are powered up A Note Regarding Commutation This section applies to 3 phase external amplifiers only External amplifiers often will perform either trapezoidal or sinusoidal commutation without the need of a controller In this case be sure to use your amplifiers guide to achieve proper commutation Although very rare if an external amplifier requires the controller to perform sinusoidal commutation an additional 10 V motor command line may be required from the DMC In other words two motor axes are needed to commutate a single external sinusoidal amplifier See the BA command for what two motor command lines to use in this case After the two 10 V motor command lines are wired the user can use the sinusoidal commutation methods listed above under Sinusoidal Commutation pg 27 Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller verify that the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolate
14. Y Define table N 1 Repeat the process Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center of the cycle X 1000 and Y 500 This implies that Y must be driven to that point to avoid a jump This is done with the program Chapter 6 Programming Motion 92 DMC 41x3 User Manual INSTRUCTION RUN EBL PA 500 SP 5000 BGY AM AIl EG 1000 AI 1 EQ 1000 EN INTERPRETATION Label Enable cam starting position Y speed Move Y motor After Y moved Wait for start signal Engage slave Wait for stop signal Disengage slave End Command Summary Electronic CAM Command Description EA Pp master Specifies master axes for electronic cam where p X Y Z or W or A B C D E F G H for main encoder as master or M or N a for virtual axis EB n Enables the ECAM EC n ECAM counter sets the index into the ECAM table EG Xr V1 Z W Engages ECAM EM Xr YrZ W Specifies the change in position for each axis of the CAM cycle E P m n Defines CAM table entry size and offset EQ m n Disengages ECAM at specified position ET n Defines the ECAM table entries EW Widen Segment see Application Note 2444 EY Set ECAM cycle count Operand Summary Electronic CAM Command Description eH Ei
15. 4000 count rev encoder SETUP KS16 MT 2 2 2 2 YA64 YB200 YC4000 SHX WT50 Si2 Set the profiler to continue upon error Set step smoothing Motor type set to stepper Step resolution of the microstepping drive Motor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode Chapter 6 Programming Motion 107 DMC 41x3 User Manual MOTION Perform motion SP16384 Set the speed PR10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction MOTION2 SP16384 Set the speed PR 10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction JP MOTION CORRECT Correction code spx _SPX LOOP Save speed value SP2048 Set a new slow correction speed WT100 Stabilize JP END ABS _QSX lt 10 End correction if error is within defined tolerance YRX _QSX Correction move MCX WT100 Stabilize JP LOOP Keep correcting until error is within tolerance END End CORRECT subroutine returning to code SPX spx EN Dual Loop Auxiliary Encoder The DMC 41x3 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation and axis used in circular compare When used the second encoder is typically mounted on the motor or the load but may be mounted in any position The most common use for the second encoder is backlas
16. D3240 207 DMC 41x3 User Manual Electrical Specifications The amplifier is a brush brushless trans conductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage 20 80 VDC Continuous Current 10 Amps Peak Current 20 Amps Nominal Amplifier Gain 1 0 Amps Volt Switching Frequency 24 kHz Minimum Load Inductance L mit Ripple Where Vs Supply Voltage lripple 10 of the maximum current at chosen gain setting Brushless Motor Commutation angle 120 60 option available The default PWM output operation on the AMP 43240 D3240 is Chopper Mode Contact a Galil Applications Engineer to review minimum inductance requirements if a lower inductance motor is required Mating Connectors On Board Connector Terminal Pins 6 pin Molex Mini Fit Jr POWER MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr Power Connectors MOLEX 39 31 0040 MOLENAAR 112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector Phase C N C for Brushed Motors Phase B No Connect Phase A A WIN je A3 AMP 43240 D3240 208 DMC 41x3 User Manual Operation Brushless Motor Setup NOTE If you pur
17. Once activated the input requires the current to go below 0 5mA All Limit Switch and Home inputs use one common voltage LSCOM which can accept up to 24 volts Voltages above 24 volts require an additional resistor 21mA ON lt 0 5 mA OFF 8 1 for 1 4 axes models 16 1 for 5 8 axes models Appendices 177 DMC 41x3 User Manual Analog Inputs Al 8 1 10 volts 12 Bit Analog to Digital converter 16 bit optional Digital Outputs DO 16 1 4mA sinking 25mA sinking sourcing and 500mA sourcing options 8 1 for 1 4 axes models 16 1 for 5 8 axes models Auxiliary Inputs as Uncommitted Inputs The auxiliary pins can be used as uncommitted inputs and are DI 96 81 assigned to the following bits Axis A DI81 DI82 Axis B DI83 DI84 Axis C DI85 DI86 Axis D DI87 DI88 Axis E DI89 DI90 Axis F DI91 DI92 Axis G DI93 DI94 Axis H DI95 DI96 These inputs have the same specifications as listed above for encoder inputs The number of auxiliary inputs is dependent on the number of axes ordered Power Requirements 20 80 Voc 10 W at 25 C 5 12V Power Output Specifications Output Voltage Tolerance Max Current Output 5V 5 1 1A 12V 5 40mA 12V 5 40mA Appendices 178 DMC 41x3 User Manual Performance Specifications Minimum Servo Loop Update Time DMC 4113 DMC 4123 DMC 4133 DMC 4143 DMC 4153 DMC 4163 DM
18. USER MANUAL DMC 41x3 Manual Rev 1 0h Galil Motion Control Inc 270 Technology Way Rocklin California 916 626 0101 support galilmc com galil com 10 2015 Using This Manual This user manual provides information for proper operation of the DMC 41x3 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller It is recommended that the user download the latest version of the Command Reference and User Manual from the Galil Website http www galilmc com support manuals php Your DMC 41x3 motion controller has been designed to work with both servo and stepper type motors Installation and system setup will vary depending upon whether the controller will be used with stepper motors or servo motors To make finding the appropriate instructions faster and easier icons will be next to any information that applies exclusively to one type of system Otherwise assume that the instructions apply to all types of systems The icon legend is shown below E Attention Pertains to servo motor use Attention Pertains to stepper motor use Attention Pertains to controllers with more than 4 axes Please note that many examples are written for the DMC 4143 four axes controller or the DMC 4183 eight axes controller Users of the DMC 4133 3 axis controller DMC 4123 2 axes controller or DMC 4113 1 axis controller should note that the DMC 4133 u
19. 274 The DMC 41x3 can be programmed with the instruction KP 82 4 KD 274 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters Equivalent Filter Form DMC 41x3 Digital D z K z A z Cz z 1 1 B Z B KP KD KI PL K KP KD A KD KP KD C KI B PL Digital D z KP KD 1 274 KI 2 1 z71 1 PL Z PL Continuous G s P Ds I s a s a PID T P KP D T KD 1 KI T a 1 T In 1 PL Chapter 10 Theory of Operation 176 DMC 41x3 User Manual Appendices Electrical Specifications NOTE Electrical specifications are only valid once controller is out of reset Servo Control Motor command line 10 V analog signal Resolution 16 bit DAC or 0 0003 volts 3 mA maximum Output impedance 500 0 Main and auxiliary encoder inputs TTL compatible but can accept up to 12 volts Quadrature phase on CHA CHB Single ended or differential Maximum A B edge rate 15 MHz Minimum IDX pulse width 39 nsec Stepper Control STPn Step TTL 0 5 volts level at 50 duty cycle 3 000 000 pulses sec maximum frequency DIRn Direction TTL 0 5 volts Input Output Opto isolated Inputs DI 16 1 Limit switches home abort reset 2 2 kQ in series with opto isolator Active high or low requires at least 1mA to activate
20. 80000 111999 5117 and reveals the source of the error By ignoring decimals and multiplying by integers first since they carry no error and then adding the decimal back in by dividing by a factor of 10 will allow the user to avoid any errors caused by the limitations of precision of the controller Continuing from the example above var 14 80000 Ignore decimals MG var Print result 1120000 0000 var var 10 Divide by 10 to add in decimal MG var Print correct result 112000 0000 Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The operator is a Logical Or These operators allow for bit wise operations on any valid DMC 41x3 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The ch
21. Axis Position 00029319 Error 00001312 Torque 9 9982 Axis Position 00001612 Error 00000936 Torque 1 7253 Axis Position 00001696 Error 00001076 Torque 1 9834 Axis Position 00002020 Error 00001156 Torque 2 1309 Axis Position 00000700 Error 00001300 Torque 2 3963 Axis Position 00000156 Error 00000792 Torque 1 4599 Axis Position 00002212 Error 00001732 Torque 3 1926 Axis Position 00002665 Error 00001721 Torque 3 1723 Recursed through 8 stacks TAAMAVAW P Chapter 7 Application Programming 132 DMC 41x3 User Manual General Program Flow and Timing information This section will discuss general programming flow and timing information for Galil programming REM vs NO or comments There are 2 ways to add comments to a dmc program REM statements or NO comments The main difference between the 2 is that REM statements are stripped from the program upon download to the controller and NO or comments are left in the program In most instances the reason for using REM statements instead of NO or is to save program memory The other benefit to using REM commands comes when command execution of a loop thread or any section of code is critical Although they do not take much time NO and comments still take time to process So when command execution time is critical REM statements should be used The 2 examples below demonstrate the difference in command execution of a loop containing comments The Galil
22. Conducted at Galil s headquarters in Rocklin CA students will gain detailed understanding about connecting systems elements system tuning and motion programming This is a hands on seminar and students can test their application on actual hardware and review it with Galil specialists Attendees must have a current application and recently purchased a Galil controller to attend this course TIME Two days 8 30 4 30pm http www galilmc com learning training at galil php Appendices 193 DMC 41x3 User Manual Contacting Us Galil Motion Control 270 Technology Way Rocklin CA 95765 Phone 916 626 0101 Fax 916 626 0102 E Mail Address support galilmc com Web 370Hhttp www galilmc com Appendices 194 DMC 41x3 User Manual WARRANTY All controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship for a period of 18 months after shipment Motors and Power supplies are warranted for 1 year Extended warranties are available In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship at our expense only to dest
23. Contact the Galil factory for current dimensions of all products Chapter 2 Getting Started 13 DMC 41x3 User Manual DMC 4183 BOX8 20A09 02 an9 O o9 OO og og Og Og og 8O og Og og OO 0 OOAve 2 VOdO gloa 3980S k NOILdO B3MOd HOIH NOY OOS W130 6 LIVS 6 94 sive DOAve S 8040 Iye ON9 Y0d0 t 8 oa angy ONOV 6 SLNdino H 3 O T a y O T SONY OXO O OWOONT 3SN 148V ONY 073 1SH GNSHO OGAre S W INI GND HO JAAHZ S WODST H3 O T a y O T 0 0 0 g9spect g9Speet g9sgreezt g9srpezs ggrecs 9GSrEect g9SveEect g9spect O O O O 4aM0d youu O ivan O qV183S XNV O 13838 y YSN NI 3AYW iS a JOHLNOD NOILOW TVD O O AH OMIS Y3ddalS esl v Wd H 9 YaMOd O I osi DMC 41x3 User Manual in inches where x 5
24. Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install set up and operate this equipment Never open the controller box when DC power is applied WARNING If the controller was ordered with Galil s internal amplifiers power to the controller and amplifier is typically supplied through the amplifier s power connector If the controller is ordered without internal amplifiers the power will come through a 2 pin connector near the bottom edge of the controller See DMC 41x3 Power Connections pg 15 for the location of the power connections of the DMC 41x3 Different options may effect which connections and what bus voltages are appropriate If using an internal amplifier the ISCNTL Isolate Controller Power pg 181 option will require multiple connections one to power the controller board and another to power the amplifiers If using two banks of amplifiers the ISAMP Isolation of power between each AMP amplifier pg 183 option will require that the amplifiers are powered independently Table 2 1 below shows which power connectors are and required for powering the system based upon the options ordered X designates a required connection these connectors are only populated if required Chapter 2 Getting Started 18 DMC 41x3 User Manual Options Ordered Power Connector Locations ISCNTL AMP SDM AMP SDM ISAMP Controller Pow
25. Saw D Figure 10 1 Elements of Servo Systems The operation of such a system can be divided into three levels the levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming The first level the closing of the loop assures that the motor follows the commanded position This is done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling is the generation of the desired position function This function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the loop forces the motor to follow the commanded position The highest level of control is the motion program This can be stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000 SP 20000 20000 AC 200000 00000 BG X AD 2000 BG Y EN Chapter 10 Theory of Operation 166 DMC 41x3 User Manual This program corresponds to the velocity profi
26. Simply command IP 10 Specify an incremental position movement of 10 on Y axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on Y axis BGY Begin motion on Y axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity correction GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AcC 100000 Specify correction acceleration Dc 100000 Specify correction deceleration BGY Start correction Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 7 axes can be slaved to one master axis The master axis encoder must be input through a main encoder port The electronic cam is a more general type of electronic gearing which allows a table based relationship between the axes It allows synchronizing all the controller axes For example the DMC 4183 controllers may have one master and up to seven slaves To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis Y when the master is X Such a graphic relationship is shown in Figure 6 13 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master axis
27. and multiple configurations LC command set to 0 Full Current Mode causes motor to use 100 of peak current AG while at a resting state profiler is not commanding motion This is the default setting LC command set to 1 Low Current Mode causes motor to use 25 of peak current while at a resting state This is the recommended configuration to minimize heat generation and power consumption LC command set to an integer between 2 and 32767 specifying the number of samples to wait between the end of the move and when the amp enable line toggles Percentage of full AG current used while holding position with LC n n n n n n n n n 0 100 n 1 25 The LC command must be entered after the motor type has been selected for stepper motor operation i e MT 2 2 2 2 LC is axis specific thus LC1 will cause only the X axis to operate in Low Current mode Step Drive Resolution Setting YA command When using the SDM 44040 the step drive resolution can be set with the YA command Step Drive Resolution per Axis YA n n n n n n n n n 1 Fullt n 2 Half n 4 1 4 n 16 1 16 A6 SDM 44040 D4040 D4020 227 DMC 41x3 User Manual 3 When running in full step mode the current to the motor is 70 of maximum All micro step settings are able to deliver full current Protection Circuitry The SDM 44040 has short circuit protection as well as over temperature and under voltage detection
28. o o o o o oooo0oo00000 123456 5V CPU AEN SHn 5V AEN TO DRIVE MOn 0V PIN 2 10K 12V CPU AEN SHn 5V AEN TO DRIVE MOn 0V PIN 2 10K AMP ENABLE POWER PIN 20 CPU AEN SHn 5V AEN TO DRIVE MOn 0V PIN 2 10K AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware 47 DMC 41x3 User Manual 5V LOW AMP ENABLE SINKING 12V LOW AMP ENABLE SINKING ISOLATED SUPPLY LOW AMP ENABLE SINKING AXIS A eo00000000 o o o o o o o o oooo0oo0o0000 AXIS A o0000000 oo00000000 o00000000 AXIS A O0000000 o00000000 CO00000000 5V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 12V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V AMP ENABLE POWER PIN 20 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware 48 DMC 41x3 User Manual 5V LOW AMP ENABLE SOURCING 12V LOW AMP ENABLE SOURCING ISOLATED SUPPLY LOW AMP ENABLE SOURCING AXIS A AXIS A AXIS A o o o o o o o o o o o o o o o o o o o o o o o o oooo0oo00000 o00000000 o00000000 eo00000000 o00000000 O O00000000 5V 5V CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K 5V 12V CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K AMP ENABLE POWER 5V PIN 20 CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K AMP ENABLE RETURN PIN 11 Chap
29. 0 5 0 75 1 0 and 1 4 Amps Phase The step resolution is selectable with options of full half 1 4 and 1 16 A7 SDM 44140 D4140 4 axis Microstep Drives The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution the SDM 44140 drives two The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis Integrated Components 197 DMC 41x3 User Manual A1 AMP 430x0 D3040 D3020 Description The AMP 43040 resides inside the DMC 41x3 enclosure and contains four transconductance PWM amplifiers for driving brushless or brush type servo motors Each amplifier drives motors operating at up to 7 Amps continuous 10 Amps peak 20 80 VDC The gain settings of the amplifier are user programmable at 0 4 Amp Volt 0 7 Amp Volt and 1 Amp Volt The switching frequency is 60 kHz The drive for each axis is software configurable to operate in either a chopper or inverter mode The chopper mode is intended for operating low inductance motors The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43040s are required for 5 thru 8 axis controllers A shunt regulator option is available A two axis version the AMP 43020 is also available If higher voltages are required please contact Galil If the application has a potential for regenerative energy it is recommended to order the controller with the ISCNTL
30. 1 LE n Returns status of Forward Limit switch input of axis n equals O or 1 LRX Returns status of Reverse Limit switch input of axis n equals O or 1 UL Returns the number of available variables TIME Free Running Real Time Clock off by 2 4 Resets with power on Note TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords _LF LR and TIME do not have any associated commands All keywords are listed in the Command Reference Examples of Keywords vi _LFX Assign v1 the logical state of the Forward Limit Switch on the X axis v3 TIME Assign v3 the current value of the time clock v4 _HMW Assign v4 the logical state of the Home input on the W axis Arrays For storing and collecting numerical data the DMC 41x3 provides array space for 24000 elements The arrays are one dimensional and up to 30 different arrays may be defined Each array element has a numeric range of 4 bytes of integer 2 followed by two bytes of fraction 2 147 483 647 9999 Arrays can be used to capture real time data such as position torque and analog input values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Defining Arrays An array is defined with the command DM The user must specify a name and the number of entries to be held in the array An array name can contain up to
31. 10 cycles with an amplitude of 1000 counts and a frequency of 20 Hz Chapter 6 Programming Motion 102 DMC 41x3 User Manual This can be performed by commanding the X and N axes to perform circular motion Note that the value of VS must be VS 2n R F where R is the radius or amplitude and F is the frequency in Hz Set VA and VD to maximum values for the fastest acceleration INSTRUCTION INTERPRETATION VMXN Select Axes VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten Cycles VE BGS Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step output pulses 2 5 specifies a stepper motor with active low step output pulses and reversed direction 2 5 specifies a stepper motor with active high step output pulse and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought of as a simple Resistor Capacitor single pole filter The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pul
32. 6 7 8 13 14 15 16 to act as selective aborts for axes A B C D E F G H respectively ELO Electronic Lock Out Used in conjunction with Galil amplifiers this input allows the user the shutdown the amplifier at a hardware level For more detailed information on how specific Galil amplifiers behave when the ELO is triggered see Integrated in the Appendices If using a 5 8 axis controller with two integrated amplifiers the ELO input on the A D connector should be used If an ELO is sensed both amplifiers will act on it and shut down at a hardware level Forward Limit Switch Low input inhibits motion in forward direction If the motor is moving in the forward direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches The OE command can also be configured so that the axis will be disabled upon the activation of a limit switch Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine
33. A 6000 and B 120 the position and velocity profiles are X 50T 6000 2n sin 2m T 120 Note that the velocity w in count ms is w 50 1 cos 2n T 120 Figure 6 20 Velocity Profile with Sinusoidal Acceleration The DMC 41x3 can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X 50T 955 sin 3T Chapter 6 Programming Motion 100 DMC 41x3 User Manual A complete program to generate the contour movement in this example is given below To generate an array we compute the position value at intervals of 8 ms This is stored at the array POS Then the difference between the positions is computed and is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example INSTRUCTION POINTS DM POS 16 DM DIF 15 c 0 T 0 A V1 50 T V2 3 T V3 955 SIN V2 V1 V4 INT V3 POS C v4 T T 8 C Ct1 JP A C lt 16 B c 0 C D C 1 DIF C POS D POS C Cc C 1 JP C C lt 15 RUN CMX DT3 c 0 E CD DIF C C C 1 JP E C lt 15 CD 0 0 Wait JP Wait CM lt gt 511 EN INTERPRETATION Program defines X points Allocate memory Set initial conditions C is index T is time in ms Argument in degrees Compute position Integer value of V3 Store in array POS Program to find position differences Compute the difference and store Program to run motor Con
34. Amplifier Enable 15 AB B Aux Encoder Input 3 DIR Direction 16 MI l Index Pulse Input 4 HOM Home 17 MB B Main Encoder Input 5 LSCOMn Limit Switch Common 18 GND Digital Ground 6 AA A Aux Encoder Input 19 MCMD Motor Command 7 MI I Index Pulse Input 20 ENBL Amp Enable Power 8 MA A Main Encoder Input 21 HALA Hall A 9 5V 5V 22 RLS Reverse Limit Switch Input 10 GND Digital Ground 23 AB B Aux Encoder Input 11 ENBL Amp Enable Return 24 AA A Aux Encoder Input 12 HALB Hall B 25 MB B Main Encoder Input 13 STP PWM Step 26 MA A Main Encoder Input LSCOMn on JA1 JB1 JC1 and JD1 is common to LSCOMO on J5 LSCOMn on JE1 JF1 JG1 and JH1 is common to LSCOM1 on J8 J4 Analog 15 pin D sub Connector Male Pin Label Description 1 AGND Analog Ground 2 All Analog Input 1 3 Al3 Analog Input 3 4 AIS Analog Input 5 5 Al7 Analog Input 7 6 AGND Analog Ground 7 12V 12V 8 5V 5V 9 AGND Analog Ground 10 Al2 Analog Input 2 11 Al4 Analog Input 4 12 Al6 Analog Input 6 13 Al8 Analog Input 8 14 N C No Connect 15 12V 12V JPn1 Amplifier Enable Jumper Description for DMC 41x3 Jumper Label Function If jumpered Qand P 1 Sink Source Selection 2 Sink Source Selection 3 Sink Source Selection 4 HAEN LAEN Selection 5 5V 12V External Power Selection 6 5V 12V External Power Selection NOTE See Amplifier Enable in Chapter 3 for detailed inf
35. An IF conditional statement is formed by the combination of an IF and ENDIF command The IF command has as it s arguments one or more conditional statements If the conditional statement s evaluates true the command interpreter will continue executing commands which follow the IF command If the conditional statement evaluates false the controller will ignore commands until the associated ENDIF command is executed OR an ELSE command occurs in the program see discussion of ELSE command below NOTE An ENDIF command must always be executed for every IF command that has been executed It is recommended that the user not include jump commands inside IF conditional statements since this causes re direction of command execution In this case the command interpreter may not execute an ENDIF command Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command Chapter 7 Application Programming 124 DMC 41x3 User Manual and has no arguments If the argument of the IF command evaluates false the controller will skip commands until the ELSE command If the argument for the IF command evaluates true the controller will execute the commands between the IF and ELSE command Nesting IF Conditional Statements The DMC 41x3 allows for IF conditional statements to be includ
36. DMC 41x3 allows the user to create up to 510 variables Each variable is defined by a name which can be up to eight characters The name must start with an alphabetic character however numbers are permitted in the rest of the name Spaces are not permitted Variable names should not be the same as DMC 41x3 instructions For example PR is not a good choice for a variable name NOTE It is generally a good idea to use lower case variable names so there is no confusion between Galil commands and variable names Examples of valid and invalid variable names are Valid Variable Names posx posl speedzZ Invalid Variable Names RealLongName Cannot have more than 8 characters 123 Cannot begin variable name with a number speed Z Cannot have spaces in the name Assigning Values to Variables Assigned values can be numbers internal variables and keywords functions controller parameters and strings The range for numeric variable values is 4 bytes of integer 231 followed by two bytes of fraction 2 147 483 647 9999 Numeric values can be assigned to programmable variables using the equal sign Any valid DMC 41x3 function can be used to assign a value to a variable For example vi ABS v2 or v2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters which must be in quotation Examples posxX _TPX Assigns returned va
37. Does not require halls e Quick first time set up e Provides the least amount of movement If no e Not recommended with vertical or hall sensors are available unbalanced loads BX e Does not require halls e Sensitive to noise on feedback lines e Quick first time set up e Requires some movement e may fail at hard stops e No unnecessary movement required e Requires halls BI BC e Best option with a vertical or unbalanced load le Longer first time set up due to additional wiring Table 2 10 Pros and cons of each commutation method lif your motor has halls it is recommended to use the BI BC method Chapter 2 Getting Started 27 DMC 41x3 User Manual The following sections discuss how to wire and configure a motor for sinusoidal commutation using the different commutation methods BZ BX Method WARNING The BZ command must move the motor to find the zero commutation phase This movement is sudden and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The BZ and BX method are wired in the same way Both BZ and BX require encoder feedback to the controller and the motor phases to the drive 1 Check encoder position with the TP command Ensure the motor is in an MO state and move the motor manually in the desired positive direction while monitoring TP If TP reports a smaller or more negative number reverse encoder direction see Step 6 Connecting Encoder Feed
38. Failing to do so can cause harm to the user or to the controller The following instructions are given for Galil products only If wiring an non Galil device follow the NOTE instructions provided with that product Galil shall not be liable or responsible for any incidental or consequential damages that occur to a 3 party device Step 1 Determine Overall System Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 41x3 can control any combination of brushless motors brushed motors and stepper motors Galil has several internal amplifier options that can drive motors directly but can also control external amplifiers using either a 10V motor command line or PWM Step and direction lines There are also several feedback options that the DMC can accept See Part Numbers pg 2 for understanding your complete DMC unit and part number before continuing Step 2 Install Jumpers on the DMC 41x3 The following jumpers are located in a rectangular cut out near the lower left hand corner of the board See Figure 2 3 DMC 41x3 BOX4 Dimensions in inches where x 1 2 3 and 4 axis pg 13 and Figure 2 3 DMC 41x3 BOX4 Dimensions in inches where x 1 2 3 and 4 axis pg 13 for the location of these jumpers Chapter 2 Getting Started 17 DMC 41x3 User Manual Motor Off Jumper It is recommended to use the MO jumper when connecting motors for the first time With
39. For example DP 0 defines the reference position of the X axis to be zero Aeon Ptr Stepper Smoothing Filer Cut Bur Output pe Adds a Delay gt To Stepper Driver Reference Postion RP Step Count Register TD Motion Complete Trippoint When used in stepper mode the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position The MC trippoint Motion Complete is generally more useful than AM trippoint After Motion since the step pulses can be delayed from the commanded position due to stepper motor smoothing Using an Encoder with Stepper Motors An encoder may be used on a stepper motor to check the actual motor position with the commanded position If an encoder is used it must be connected to the main encoder input Note The auxiliary encoder is not available while operating with stepper motors The position of the encoder can be interrogated by using the command TP The position value can be defined by using the command DE Note Closed loop operation with a stepper motor is not possible Command Summary Stepper Motor Operation COMMAND DESCRIPTION DE Define Encoder Position When using an encoder DP Define Reference Position and Step Count Register IT Motion Profile Smoothing Independent Time Consta
40. Light Turns on OE Function Shuts motor off if OE1 or OE3 AEN Output Line Switches to Motor Off state The Jump on Condition statement is useful for branching on a given error within a program The position error of X Y Z and W can be monitored during execution using the TE command Encoder Failure detection The encoder failure detection on the controller operates based upon two factors that are user settable a threshold of motor command output OV a time above that threshold OT in which there is no more than 4 counts of change on the encoder input for that axis The encoder failure detection is activated with the OA command When an encoder failure is detected and OA is set to 1 for that axis the same conditions will occur as a position error Conditions for proper operation of Encoder Failure detection e The axis must have a non zero KI setting order to detect an encoder failure when the axis is not profiling e The IL command must be set to a value greater than the OV setting e The TL command must be set to a value greater than the OV setting Example The A axis is setup with the following settings for encoder failure detection OA 1 OT 500 OV 3 OE 1 ER 1000 The A axis is commanded to move 300 counts but the B channel on the encoder has failed and no longer operates Because the ER setting is greater than the commanded move the error will not be detected by using the OE and ER commands but this condition will be detected as
41. Low Current Mode causes motor to use 25 of peak current while at a resting state This is the recommended configuration to minimize heat generation and power consumption LC command set to an integer between 2 and 32767 specifying the number of samples to wait between the end of the move and when the amp enable line toggles Percentage of full AG current used while holding position with LC n n n n n n n n n 0 100 The LC command must be entered after the motor type has been selected for stepper motor operation i e MT 2 2 2 2 LC is axis specific thus LC1 will cause only the X axis to operate in Low Current mode Over Current Protection The stepper driver also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 10 A the SDM 44140 will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset The amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the AMPERR routine TA 0 will change state reflecting the error NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short from a motor lead to ground A7 SDM 44140 D4140 231 DMC 41x3
42. Microsoft Windows XP SP3 Scope Watch and Viewer support require an Ethernet or PCI connection and controller firmware supporting the DR command No Scope Watch or Viewer support Contact Galil for other OS options The GalilSuitecontains the following tools Tool Description Launcher Launcher Tool with the ability to create custom profiles to manage controller connections Terminal For sending and receiving Galil commands Editor To easily create and work on multiple Galil programs simultaneously Viewer To see a complete status of all controllers on a single screen Scope For viewing and manipulating data for multiple controllers real time Watch For simplified debugging of any controller on the system and a display of I O and motion status Tuner With up to four methods for automatic and manual PID tuning of servo systems Configuration For modifying controller settings backup restore and firmware download The latest version of GalilSuite can be downloaded here http www galilmc com support software downloads php For information on using GalilSuite see the user manual http www galilmc com support manuals php Chapter 4 Software Tools and Communication 62 DMC 41x3 User Manual Creating Custom Software Interfaces Galil provides a programming API so that users can develop their own custom software interfaces to a Galil controller Information on this Galil Communication
43. Output 3 only if Input 1 and Input 2 are high Set Output 4 if element 1 in the array COUNT is non zero The output port can be set by specifying an 16 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 16 bit output port where bit 0 is output 1 bit1 is output2 and so on A 1 designates that the output is on Example Output Port Instruction Interpretation OP6 1 2 Sets outputs 2 and 3 of output port to high All other bits are 0 27 2 6 OPO Clears all bits of output port to zero OP 255 Sets all bits of output port to one 29 22427423 42 6 497 Chapter 7 Application Programming 148 DMC 41x3 User Manual The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move Instruction Interpretation OUTPUT Label PR 2000 Position Command BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec CB1 Clear Output 1 EN End Digital Inputs The general digital inputs for are accessed by using the IN n function or the TI command The IN n function returns the logic level of the specified input n where n is a number 1 through 16 Example Using Inputs to control program flow Instruction Interpretation JP A IN 1 0 Jump to A if input 1 is low JP B IN 2 1 Jump to B if input 2 is high AI 7 Wait until input 7 is high AI 6 Wait until in
44. PVn command The PV command includes the target distance to be moved and target velocity to be obtained over the specified timeframe Positions are entered as relative moves similar to the standard PR command in units of encoder counts and velocity is entered in counts second The controller will interpolate the motion profile between subsequent PV commands using a 3rd order polynomial equation During a PV segment jerk is held constant and accelerations velocities and positions will be calculated every other sample Motion will not begin until a BT command is issued much like the standard BG command This means that the user can fill the PVT buffer for each axis prior to motion beginning The BT command will ensure that all axes begin motion simultaneously It is not required for the t value for each axis to be the same however if they are then the axes will remain coordinated Each axis has a 255 segment buffer This buffer is a FIFO and the available space can be queried with the operand _PVn As the buffer empties the user can add more PVT segments Exiting PVT Mode To exit PVT mode the user must send the segment command PVn 0 0 0 This will exit the mode once the segment is reached in the buffer To avoid an abrupt stop the user should slow the motion to a zero velocity prior to executing this command The controller will instantly command a zero velocity once a PVn 0 0 0 is executed In addition a ST command will also exit PVT mode
45. Q YC Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally YA defines the step drive resolution where YA 1 for full stepping or YA 2 for half stepping The full range of YA is up to YA 9999 for microstepping drives Chapter 6 Programming Motion 105 DMC 41x3 User Manual Error Limit The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor steps Once the value of QS exceeds this limit the controller then performs the following actions 1 The motion is maintained or is stopped depending on the setting of the OE command If OE 0 the axis stays in motion if OE 1 the axis is stopped 2 YS is set to 2 which causes the automatic subroutine labeled POSERR to be executed Correction A correction move can be commanded by assigning the value of QS to the YR correction move command The correction move is issued only after the axis has been stopped After an error correction move has completed and QS is less than three full motor steps the YS error status bit is automatically reset back to 1 indicating a cleared error Example SPM Mode Setup The following code demonstrates what is necessary to set up SPM mode for a full step drive a half step drive and a 1 64th microstepping drive for an axis with a 1 8 step motor and 4000 count rev encoder Note the necessary difference is with the YA command Full
46. Switch Input The forward limit switch FLSx inhibits motion in the forward direction immediately upon activation of the switch The reverse limit switch RLSx inhibits motion in the reverse direction immediately upon activation of the switch If a limit switch is activated during motion the controller will make a decelerated stop using the deceleration rate previously set with the SD command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position The controller can be configured to disable the axis upon the activation of a limit switch see the OE command in the command reference for further detail When a forward or reverse limit switch is activated the current application program that is running in thread zero will be interrupted and the controller will automatically jump to the LIMSWI subroutine if one exists This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch Automatic Subroutines for Monitoring Conditions are discussed in Chapter 7 Application Programming After a limit switch has been activated further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to an inactive state Any attempt at further motion before the logic state has been reset will result in the following error 22 Begin not possible due to li
47. The value of _CS is 0 _VPX and _VPY contain the absolute coordinate of the point A Suppose that the interrogation is repeated at a point halfway between the points C and D The value of _AV is 4000 1500n 2000 10 712 The value of CS is 2 _VPX _VPY contain the coordinates of the point C C 4000 3000 D 03000 R 1500 0000 AD Figure 6 7 The Required Path Vector Mode Mathematical Analysis The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which is also known as the feed rate is the vector sum of the velocities along the X and Y axes Vx and Vy Vs Vx The vector distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point Chapter 6 Programming Motion 84 DMC 41x3 User Manual expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle co
48. all axes either simultaneously or independently XYZ or W axis specifiers are required to select the axes for motion When no axes are specified this causes motion to begin on all axes The speed SP and the acceleration AC can be changed at any time during motion however the deceleration DC and position PR or PA cannot be changed until motion is complete Remember motion is complete when the profiler is finished not when the actual motor is in position The Stop command ST can be issued at any time to decelerate the motor to a stop before it reaches its final position An incremental position movement IP may be specified during motion as long as the additional move is in the same direction Here the user specifies the desired position increment n The new target is equal to the old target plus the increment n Upon receiving the IP command a revised profile will be generated for motion towards the new end position The IP command does not require a begin Note If the motor is not moving the IP command is equivalent to the PR and BG command combination Command Summary Independent Axis COMMAND DESCRIPTION PR X Yy Z W Specifies relative distance PA X Y Z W Specifies absolute position SP X Y Z W Specifies slew speed AC X Y Z W Specifies acceleration rate DC X Y Z W Specifies deceleration rate BG XYZW Starts motion ST XYZW Stops motion before end of move IP X Y Z W
49. amplifier accepts DC supply voltages from 20 80 VDC A2 AMP 43140 D3140 4 axis 20W Linear Servo Drives The AMP 43140 contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 DC Volt input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 kHz A3 AMP 43240 D3240 The AMP 43240 is a multi axis brush brushless amplifiers that is capable of handling 750 watts of continuous power per axis The AMP 43240 Brushless drive module is connected to a DMC The standard amplifier accepts DC supply voltages from 20 80 VDC A4 AMP 435x0 D3540 D3520 The AMP 43540 contains four PWM drives for sinusoidally commutating brushless motors It is capable of up to 8 Amps of continuous current and 15Amps of peak current and requires a single DC supply voltage in the range of 20 80 VDC A5 AMP 43640 D3640 The AMP 43640 contains four linear drives for sinusoidally commutating brushless motors The AMP 43640 requires a single 15 40VDC input Output power delivered is typically 20 W per amplifier or 80 W total Integrated Components 196 DMC 41x3 User Manual A6 SDM 44040 D4040 D4020 4 axis Stepper Drives The SDM 44040 is a stepper driver module capable of driving up to four bipolar two phase stepper motors The current is selectable with options of
50. an additional distance with PR or JG commands or VP or LI coordinated commands Ramped Gearing In some applications especially when the master is traveling at high speeds it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing is engaged For example if the master axis is already traveling at 500 000 counts sec and the slave will be geared at a ratio of 1 1 when the gearing is engaged the slave will instantly develop following error and command maximum current to the motor This can be a large shock to the system For many applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame Galil allows the user to specify an interval of the master axis over which the gearing will be engaged For example the same master X axis in this case travels at 500 000 counts sec and the gear ratio is 1 1 but the gearing is slowly engaged over 30 000 counts of the master axis greatly diminishing the initial shock to the slave axis Figure 6 11 below shows the velocity vs time profile for instantaneous gearing Figure 6 12 shows the velocity vs time profile for the gradual gearing engagement Chapter 6 Programming Motion 87 DMC 41x3 User Manual Scope a x4 A vertical Horizontal t didt Source Scale fdv Offset dv A m RPA Axis A ref 100000 cc 1 oe m RPB Axis B refi 100000 cc S 4 ao m 2 S 1 G A ao x ozelo E
51. as in the following example PATH 2 D CIRCULAR PATH VMXY VECTOR MOTION ON X AND Y vs 10000 VECTOR SPEED IS 10000 VP 4000 0 BOTTOM LINE CR 1500 270 180 HALF CIRCLE MOTION VP 0 3000 TOP LINE CR 1500 90 180 HALF CIRCLE MOTION VE END VECTOR SEQUENCE BGS BEGIN SEQUENCE MOTION EN END OF PROGRAM Chapter 7 Application Programming 116 DMC 41x3 User Manual NOTE The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Difference between NO and using the GalilTools software The GalilTools software will treat an apostrophe commend different from an NO when the compression algorithm is activated upon a program download line gt 80 characters or program memory gt 4000 lines In this case the software will remove all comments as part of the compression and it will download all NO comments to the controller Executing Programs Multitasking The DMC 41x3 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 through 7 where 0 is the main thread Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The main thread differs from the others in the following ways 1 When input interrupts are implemented for limit switches position errors or command errors the subroutines are executed
52. assigned an IP address from the server Setting the board to DHO will prevent the controller from being assigned an IP address from the server The second method to assign an IP address is to use the BOOT P utility via the Ethernet connection The BOOT P functionality is only enabled when DH is set to 0 Either a BOOT P server on the internal network or the Galil software may be used When opening the Galil Software it will respond with a list of all DMC 41x3 s and other controllers on the network that do not currently have IP addresses The user must select the board and the software will assign the specified IP address to it This address will be burned into the controller BN internally to save the IP address to the non volatile memory NOTE if multiple boards are on the network use the serial numbers to differentiate them Chapter 4 Software Tools and Communication 53 DMC 41x3 User Manual Be sure that there is only one BOOT P or DHCP server running If your network has DHCP or BOOT P running it may automatically assign an IP address to the DMC controller upon linking it to the network In order to ensure that the IP address is correct please contact your system administrator before connecting the I O board to the Ethernet network CAUTION The third method for setting an IP address is to send the IA command through the USB port Note The IA command is only valid if DHO is set The IP address may be entered as a 4
53. at 1 800 377 6329 Table 2 2 Configuration commands Part numbers required for a given feedback type 1 All wiring electrical information regarding using analog inputs can be found in the Analog Inputs pg 44 2 Although stepper systems do not require feedback Galil supports a feedback sensor on each stepper axis Servo motors require a position sensor A note about using encoders and steppers When a stepper is used the auxiliary encoder for the corresponding axis is unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input corresponding to that axis The commanded position of the stepper can be interrogated with TD and the encoder position can be interrogated with TP The following steps provide a general guide for connecting encoders to the DMC unit Step A Wire the encoder The pin outs and electrical information for SSI and BiSS options can be found here BISS and SSI BiSS and SSI Absolute Encoder Interface pg 183 The standard encoder options are found here Jn1 Encoder 26 pin HD D Sub Connector Female pg 188 Step B Issue the appropriate configuration commands Find the appropriate configuration commands for your feedback type as shown in Table 2 2 pg 20 Step C Verify proper encoder operation 1 Ensure the motor is off my issuing an MO 2 Check the current position by issuing TP the value reported back is in the units of counts 3
54. axes The movement on each axis will be separated by 20 msec Figure 6 1 shows the velocity profiles for the X Y and Z axis A Begin Program PR 2000 500 100 Specify relative position movement of 2000 500 and 100 counts for X Y and Z axes SP 20000 10000 5000 Specify speed of 20000 10000 and 5000 counts sec AC 500000 500000 500000 Specify acceleration of 500000 counts sec for all axes DC 500000 500000 500000 Specify deceleration of 500000 counts sec for all axes BG X Begin motion on the X axis WT 20 Wait 20 msec BG Y Begin motion on the Y axis WT 20 Wait 20 msec BG Z Begin motion on Z axis EN End Program Chapter 6 Programming Motion 71 DMC 41x3 User Manual VELOCITY COUNTS SEC X axis velocity profile 20000 L NS Y axis velocity profile N F 15000 NL a S 5000 4 P Z axis velocity profile ZA a lt 4 ee N TIME ms Va Va 1 1 0 20 40 60 80 100 10000 Figure 6 1 Velocity Profiles of XYZ Notes on Figure 6 1 The X and Y axis have a trapezoidal velocity profile while the Z axis has a triangular velocity profile The X and Y axes accelerate to the specified speed move at this constant speed and then decelerate such that the final position agrees with the command position PR The Z axis accelerates but before the specified speed is achieved must begin deceleration such that the axis will stop at the commanded position All 3 axes have the same acceleration and deceleration
55. axis model ordered with the BOX8 option BOX8 This option is required if the DMC 41x3 is ordered with internal amplifiers AMP and or SDM This example shows a DMC 41x3 with internal AMPs Table 1 1 Explanation of different form factor options for the DMC 41x3 The full DMC 41x3 part number is a combination of the DMC controller part number DMC 41x3 form factor XXXX Y axis specific options ABCD Y and EFGH Y and optional amplifier types DXXXX Y where Y is customization options for that specific board or set of axis The layout of the full DMC 41x3 part number is shown in Figure 1 3 below Chapter 1 Overview 3 DMC 41x3 User Manual DMC 41X3 XXXX Y ABCD Y EFGH Y aa DXXXX Y Internal Amplifier Axis E H TT Amp if no internal am Internal Amplifier ee Axis A D NoAmp if no internal amp Axis Specific Options Axis Specific Options For axis E H Form Factor eae of Axis 5 6 7 or 8 DMC 41X3 XXXX Y ABCD Y DXXXX Y gt Internal Amplifier Axis A D NoAmp if no internal amp Axis Specific Options Axis A D Form Factor of Axis 1 2 3 or 4 Figure 1 3 Layout of the full DMC 41x3 part number If the part number is not readily available you can determine the information by using the ID command Issuing an ID command when connected to the controller will return your controller s internal hardware configuration The placement of the AMP SDM options is extremely
56. buffer Zero means buffer is full 511 means buffer is empty CAS or CAT Specifies which coordinate system is to be active S or T Operand Summary Coordinated Motion Sequence OPERAND DESCRIPTION The absolute coordinate of the axes at the last intersection along the sequence Distance traveled Number of available spaces for linear and circular segments in DMC 41x3 sequence buffer Zero means buffer is full 511 means buffer is empty Segment counter Number of the segment in the sequence starting at zero Vector length of coordinated move sequence Chapter 6 Programming Motion 83 DMC 41x3 User Manual When AV is used as an operand _AV returns the distance traveled along the sequence The operands VPX and _VPY can be used to return the coordinates of the last point specified along the path Example Traverse the path shown in Figure 6 7 Feed rate is 20000 counts sec Plane of motion is XY VM XY Specify motion plane vs 20000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration VP 4000 0 Segment AB CR 1500 270 180 Segment BC VP 0 3000 Segment CD CR 1500 90 180 Segment DA VE End of sequence BGS Begin Sequence The resulting motion starts at the point A and moves toward points B C D A Suppose that we interrogate the controller when the motion is halfway between the points A and B The value of _AV is 2000
57. byte number delimited by commas industry standard uses periods or a signed 32 bit number e g IA 124 51 29 31 or IA 2083724575 Type in BN to save the IP address to the DMC 41x3 non volatile memory NOTE Galil strongly recommends that the IP address selected is not one that can be accessed across the Gateway The Gateway is an application that controls communication between an internal network and the outside world The third level of Ethernet addressing is the UDP or TCP port number The Galil board does not require a specific port number The port number is established by the client or master each time it connects to the DMC 41x3 board Typical port numbers for applications are Port 23 Telnet Port 502 Modbus Communicating with Multiple Devices The DMC 41x3 is capable of supporting multiple masters and slaves The masters may be multiple PC s that send commands to the controller The slaves are typically peripheral I O devices that receive commands from the controller NOTE The term Master is equivalent to the internet client The term Slave is equivalent to the internet server An Ethernet handle is a communication resource within a device The DMC 41x3 can have a maximum of 8 Ethernet handles open at any time When using TCP IP each master or slave uses an individual Ethernet handle In UDP IP one handle may be used for all the masters but each slave uses one Pings and ARPs do not occupy handles If all 8 handles are
58. changes see section entitled Amplifier Enable in Chapter 3 Error Output The error output is a TTL signal which indicates an error condition in the controller This signal is available on the interconnect module as ERR When the error signal is low this indicates an error condition and the Error Light on the controller will be illuminated For details on the reasons why the error output would be active see Error Light Red LED in Chapter 9 Chapter 8 Hardware amp Software Protection 158 DMC 41x3 User Manual Input Protection Lines General Abort A low input stops commanded motion instantly without a controlled deceleration For any axis in which the Off On Error function is enabled the amplifiers will be disabled This could cause the motor to coast to a stop If the Off On Error function is not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in this chapter The Abort input by default will also halt program execution this can be changed by changing the 5 field of the CN command See the CN command in the command reference for more information Selective Abort The controller can be configured to provide an individual abort for each axis Activation of the selective abort signal will act the same as the Abort Input but only on the specific axis To configure the controller for selective abort issue the command CN 1 This configures the inputs 5
59. circle move Raise Z Chapter 7 Application Programming 153 DMC 41x3 User Manual VP 37600 16000 Return XY to start VE vs 200000 BGS AMS EN le 0 ri 93 X Figure 7 2 Motor Velocity and the Associated Input Output signals Speed Control by Joystick The speed of a motor is controlled by a joystick The joystick produces a signal in the range between 10V and 10V The objective is to drive the motor at a speed proportional to the input voltage Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec The program reads the input voltage periodically and assigns its value to the variable VIN To get a speed of 200 000 ct sec for 10 volts we select the speed as Speed 20000 x VIN The corresponding velocity for the motor is assigned to the VEL variable Instruction A JGO BGX B VIN AN 1 VEL VIN 20000 JG VEL JP B EN Position Control by Joystick This system requires the position of the motor to be proportional to the joystick angle Furthermore the ratio between the two positions must be programmable For example if the control ratio is 5 1 it implies that when the joystick voltage is 5 Volts corresponding to 1028 counts the required motor position must be 5120 counts The variable V3 changes the position ratio Chapter 7 Applicati
60. commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 41x3 command The command reference indicates which commands have an associated operand Status commands such as Tell Position return actual values whereas action commands such as KP or SP return the values in the DMC 41x3 registers The axis designation is required following the command Examples of Internal Variables posx _TPX Assigns value from Tell Position X to the variable posX deriv _KDZ 2 Assigns value from KDZ multiplied by two to variable deriv JP LOOP TEX gt 5 Jump to LOOP if the position error of X is greater than 5 JP ERROR TC 1 Jump to ERROR if the error code equals 1 Operands can be used in an expression and assigned to a programmable variable but they cannot be assigned a value For example KDX 2 is invalid Special Operands Keywords The DMC 41x3 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 41x3 commands Chapter 7 Application Programming 138 DMC 41x3 User Manual Keyword Function BGn Returns a 1 if motion on axis n is complete otherwise returns 0 B Returns serial of the board DA Returns the number of arrays available DL Returns the number of available labels for programming D Returns the available array memory HMn Returns status of Home Switch equals 0 or
61. current resolution for systems with high feedback gain The BOX option is required when the AMP 43640 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation LINK ACT ERROR POWER pois ga ouneuts ae ee wich no URCE 001 1 Stank Figure A5 1 DMC 4143 D3640 BOX4 DMC 4143 with AMP 43640 A5 AMP 43640 D3640 219 DMC 41x3 User Manual Electrical Specifications The amplifier is a brushless type trans conductance linear amplifier for sinusoidal commutation The amplifier outputs a motor current proportional to the command signal input DC Supply Voltage 15 40 VDC In order to run the AMP 43640 in the range of 15 20 VDC the ISCNTL Isolate Controller Power option must be ordered Continuous Current 1 0 Amps Peak Current per axis 2 0 Amps Amplifier gain 0 2 A V Power output per channel 20 W see section below Total max power output 80 W assuming proper thermal mounting and heat dissipation The amplifier has built in thermal protection which will cause
62. eight characters starting with an alphabetic character The number of entries in the defined array is enclosed in Example DM posx 7 Defines an array names posx with seven entries DM speed 100 Defines an array named speed with 100 entries DA posx Frees array space Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the posx array defined with the DM command DM posx 7 would be specified as posx 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Chapter 7 Application Programming 139 DMC 41x3 User Manual Examples DM speed 10 Dimension speed Array speed 0 7650 2 Assigns the first element of the array speed the value 7650 2 speed 0 Returns array element value posx 9 _TPX Assigns the 10 element of the array posx the returned value from the tell position command con 1 COS pos 2 Assigns the second element of the array con the cosine of the variable POS multiplied by 2 timer 0 TIME Assigns the first element of the array timer the returned value of the TIME keyword Using a Variable
63. encoder This method results in a stable system The dual loop method is activated with the instruction DV Dual Velocity where DV 1 1 1 1 activates the dual loop for the four axes and DV 0 0 0 0 disables the dual loop NOTE that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if necessary Sampled Dual Loop Example In this example we consider a linear slide which is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it is best to use a rotary encoder on the motor Connect the rotary encoder to the X axis and connect the linear encoder to the auxiliary encoder of X Assume that the required motion distance is one inch and that this corresponds to 40 000 counts of the rotary encoder and 10 000 counts of the linear encoder Chapter 6 Programming Motion 109 DMC 41x3 User Manual The design approach is to drive the motor a distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program INST
64. error limit ER 1000 a low torque limit TL 3 and set off on Error to 1 for all axes OE 1 The AMP 430x0 requires that the hall commutation for a brushless motor be manually configured Details on how to determine the correct commutation for a brushless motor see Application Note 5489 http www galilmc com support appnotes miscellaneous note5489 pdf Brush Amplifier Operation The AMP 43040 and AMP 43020 also allow for brush operation To configure an axis for brush type operation connect the 2 motor leads to Phase A and Phase B connections for the axis Connect the encoders homes and limits as required Set the controller into brush axis operation by issuing BR n n n n By setting n 1 the controller will operate in brushed mode on that axis For example BR 0 1 0 0 sets the Y axis as brush type all others as brushless If an axis is set to brush type the amplifier has no need for the Hall inputs These inputs can subsequently be used as general use inputs queried with the QH command A1 AMP 430x0 D3040 D3020 200 DMC 41x3 User Manual Setting Amplifier Gain and Current Loop Bandwidth AG command AG setting Gain Value m 0 0 4 A V m 1 0 7 A V m 2 1 0 A V Table A1 1 Amplifier Gain Settings for AMP 430x0 D3040 D3020 The gain is set with the AG command as shown in Table A1 1 for AG n m Select the amplifier gain that is appropriate for the motor The gain settings for the amplifi
65. expects the amplifier to be enabled The DMC 41x3 is designed to be easily interfaced to multiple amplifier manufactures As a result the amplifier enable circuit for each axis is individually configurable through jumper settings The user can choose between High Amp Enable HAEN Low Amp Enable LAEN 5V logic 12V logic external voltage supplies up to 24V sinking or sourcing The different configurations are described below with jumper settings and a basic schematics of the circuit Chapter 3 Connecting Hardware 45 DMC 41x3 User Manual 5V HIGH AMP ENABLE SINKING 12V HIGH AMP ENABLE SINKING ISOLATED SUPPLY HIGH AMP ENABLE SINKING AXIS A AXISA AXIS A o o o o o o o o o o o o o o o o o o o o o o o o oooo0oo0o0000 o00000000 o00000000 eo00000000 o00000000 CO00000000 5V 45V 10K AEN TO DRIVE PIN 2 CPU AEN SHn 5V MOn 0V 12V 5V 10K AEN TO DRIVE PIN 2 CPU AEN SHn 5V MOn 0V AMP ENABLE POWER PIN 20 45V 10K AEN TO DRIVE PIN 2 CPU AEN SHn 5V AMP ENABLE RETURN Mona PIN 11 Chapter 3 Connecting Hardware 46 DMC 41x3 User Manual 5V HIGH AMP ENABLE SOURCING 12V HIGH AMP ENABLE SOURCING ISOLATED SUPPLY HIGH AMP ENABLE SOURCING AXIS A AXISA AXIS A eo00000000 o o o o o o o o o00000000 o o o o o o o o oooo0oo0o0000 oooo0oo00000 O00000000 o o o
66. function L s L s M s Ka Ky Ke H s 3 17 10 s s 2000 Then the open loop transfer function A s is A s L s G s Now determine the magnitude and phase of L s at the frequency w 500 L j500 3 17 10 j500 2 j500 2000 This function has a magnitude of L j500 0 00625 and a phase Arg L j500 180 tan4 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that A j500 1 Arg A j500 135 However since A s L s G s then it follows that G s must have magnitude of G j500 A j500 L j500 160 and a phase arg G j500 arg A j500 arg L j500 135 194 59 In other words we need to select a filter function G s of the form G s P sD so that at the frequency w 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as G j500 P j500D 160 and arg G j500 tan4 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 Therefore D 0 274 and G 82 4 0 274s The function G is equivalent to a digital filter of the form D z KP KD 1 z72 where Chapter 10 Theory of Operation 175 DMC 41x3 User Manual P KP D KD T and KD D T Assuming a sampling period of T 1ms the parameters of the digital filter are KP 82 4 KD
67. general use inputs queried with the QH command Setting Amplifier Gain and Current Loop Bandwidth AG command Select the amplifier gain that is appropriate for the motor The gain settings for the amplifier are identical for the brush and brushless operation The gain is set with the AG command as shown in Table A3 1 for AG n m AG setting Gain Value m 0 0 5 A V m 1 1 0 A V m 2 2 0 A V Table A3 1 Amplifier Gain Settings for AMP 43240 In addition to the gain peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A3 2 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts Note The TL command is limited to 5 with the amplifier gain setting of 2 0A V AU and AW commands With the AMP 43240 the user is also given the ability to choose between normal and high current bandwidth AU In addition the user can calculate what the bandwidth of the current loop is for their specific combination AW A3 AMP 43240 D3240 209 DMC 41x3 User Manual To select normal current loop gain for the X ax
68. host program has gathered on the object that it is tracking The position tracking mode does allow for all of the axes on the controller to be in this mode but for the sake of discussion it is assumed that the robot is tracking only in the X dimension The controller must be placed in the position tracking mode to allow on the fly absolute position changes This is performed with the PT command To place the X axis in this mode the host would issue PT1 to the controller if both X and Y axes were desired the command would be PT 1 1 The next step is to begin issuing PA command to the controller The BG command isn t required in this mode the SP AC and DC commands determine the shape of the trapezoidal velocity profile that the controller will use Example Motion 1 The host program determines that the first target for the controller to move to is located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 counts sec and the velocity is set to 50 000 counts sec The command sequence to perform this is listed below EX1 PT Age Place the X axis in Position tracking mode AC 150000 Set the X axis acceleration to 150000 counts sec2 DC 150000 Set the X axis deceleration to 150000 counts sec2 SP 50000 Set the X axis speed to 50000 counts sec PA 5000 Command the X axis to absolute position 5000 encoder counts EN The output from this code can be seen in Figure 6 2 a screen capture from the GalilTools
69. important for 5 8 axis models Reading the DMC 41x3 part number in Figure 1 3 from left to right the first AMP SDM Axis A D will be placed in the AMP 1 spot as shown in Figure 1 2 and the second AMP SDM Axis E H will be placed in the AMP 2 spot Many Y options can be ordered per board or set of axis if separated by a comma Please use the DMC 41x3 part number generator to check the validity of all part numbers before ordering http www galilmc com products dmc 41x3 part number ph DMC and Form Factor DMC 41X3 XXXX Y Options Option Type Options Brief Description Documentation X 1 2 3 4 5 6 7 and 8 Number of controller axis N A XXXX CARD See Table 1 1 See DMC and Form Factor DMC 41x3 BOX XXXX Y Options starting on pg 180 BOX8 DIN DIN Rail Mount clips BOXn only Y 12 VDC Power Controller with 12 VDC 16 bit 16 bit analog inputs 4 20mA 4 20mA analog inputs TRES Encoder terminating resistors ISCNTL Isolate Controller Power 422 RS 422 on Aux Serial Port ETL ETL Certification MO Motor off jumpers added Table 1 2 Brief list of DMC and Form Factor options Chapter 1 Overview 4 DMC 41x3 User Manual Axis specific options ABCD Y and EFGH Y Option Type Options Brief Description Documentation y SSI SSI feedback BiSS and SSI BiSS and SSI Absolute Encoder Interface starting BISS BISS feedback On pE 83 HSRC 5
70. in use and a 9 master tries to connect it will be sent a reset packet that generates the appropriate error in its windows application NOTE There are a number of ways to reset the controller Hardware reset push reset button or power down controller and software resets through Ethernet or USB by entering RS When the Galil controller acts as the master the IH command is used to assign handles and connect to its slaves The IP address may be entered as a 4 byte number separated with commas industry standard uses periods or as a signed 32 bit number A port number may also be specified but if it is not it will default to 1000 The protocol TCP IP or UDP IP to use must also be designated at this time Otherwise the controller will not connect to the slave Ex IHB 151 25 255 9 lt 179 gt 2 This will open handle 2 and connect to the IP address 151 25 255 9 port 179 using TCP IP Which devices receive what information from the controller depends on a number of things If a device queries the controller it will receive the response unless it explicitly tells the controller to send it to another device If the command that generates a response is part of a downloaded program the response will route to whichever port is specified as the default unless explicitly told to go to another port with the CF command To designate a specific destination for the information add Eh to the end of the command Ex MG EC Hello will send the messag
71. inductance calculations above are based on Inverter mode If you have a motor with lower inductance Chopper mode can be applied for the PWM output Contact a Galil Applications Engineer to review minimum inductance requirements if Chopper mode operation is required A1 AMP 430x0 D3040 D3020 199 DMC 41x3 User Manual Mating Connectors On Board Connector Terminal Pins 6 pin Molex Mini Fit Jr MOLEX 39 31 0060 A B C D 4 pin Motor Power 4 pin Molex Mini Fit Jr Connectors MOLEX 39 31 0040 POWER MOLEX 44476 3112 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector 1 Phase C N C for Brushed Motors Phase B No Connect Phase A Operation Brushless Motor Setup NOTE If you purchased a Galil motor with the amplifier it is ready for use No additional setup is necessary To begin the setup of the brushless motor and amplifier it is first necessary to have communications with the motion controller It is also necessary to have the motor hardware connected and the amplifier powered to begin the setup phase After the encoders and motor leads are connected the controller and amplifier need to be configured correctly in software Take all appropriate safety precautions For example set a small
72. input 1 Wrong encoder connections 2 Encoder is damaged 3 Encoder configuration incorrect Check encoder wiring For single ended encoders CHA and CHB only do not make any connections to the CHA and CHB inputs Replace encoder Check CE command Unable to read main or auxiliary encoder input The encoder works correctly when swapped with another encoder input 1 Wrong encoder connections 2 Encoder configuration incorrect 3 Encoder input or controller is damaged Check encoder wiring For single ended encoders MA and MB only do not make any connections to the MA and MB inputs Check CE command Contact Galil Encoder Position Drifts Swapping cables fixes the problem 1 Poor Connections intermittent cable Review all connections and connector contacts Chapter 9 Troubleshooting 163 DMC 41x3 User Manual Encoder Position Drifts Significant noise can be seen on 1 Noise Shield encoder cables MA and or MB encoder Avoid placing power cables near encoder signals cables Avoid Ground Loops Use differential encoders Use 12V encoders Stability SYMPTOM DIAGNOSIS CAUSE REMEDY Servo motor runs away when Reversed Motor Type corrects Wrong feedback polarity Reverse Motor or Encoder Wiring the loop is closed situation MT 1 remember to set Motor Type back to default value MT 1 Motor oscillates Too hig
73. motion stops at forward limits Off On Error The DMC 41x3 controller has a built in function which can turn off the motors under certain error conditions This function is known as Off On Error To activate the OE function for each axis specify 1 2 or 3 for that axis To disable this function specify O for the axes When this function is enabled the specified motor will be disabled under the following 3 conditions 1 The position error for the specified axis exceeds the limit set with the command ER 2 A hardware limit is reached 3 The abort command is given 4 The abort input is activated with a low signal NOTE If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Examples OE 1 1 1 1 Enable off on error for X Y Z and W OE 0 1 0 1 Enable off on error for Y and W axes and disable off on error for W and Z axes OE 2 3 Enable off on error for limit switch for the X axis and position error or abort input and limit switch for the Y axis Automatic Error Routine The POSERR label causes the statements following to be automatically executed if error on any axis exceeds the error limit specified by ER a encoder failure is detected or the abort input is triggered The error routine must be closed with the RE command The RE command returns from the error subroutine to the main progra
74. not used and should be left open The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM 31 kHz signal is 2 duty cycle for full negative voltage 50 for O Voltage and 99 8 for full positive voltage 31 kHz Switching Frequency In the Sign Magnitude Mode MT1 5 the PWM 62 kHz signal is 0 for O Voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output 62 kHz Switching Frequency PWM Step For stepper motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Sign Direction Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors Error The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER Output 1 Output 8 Output 9 Output 16 DMC 4153 thru 4183 The optically isolated outputs are uncommitted and may be designated by the user to trigger external events The output lines are toggled by Set Bit SB and Clear Bit CB instructions The OP instruction is used to define the state of all the bits of the Output port Encoder MA MB Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximu
75. of the next array element n 0 stops recording Returns a 0 or 1 where O denotes not recording 1 specifies recording in progress IRC Data Types for Recording Data type Description TIME Controller time as reported by the TIME command AFn Analog input n X Y Z W E F G H for AN inputs 1 8 DEX 2 encoder position dual encoder NOX Status bits OP Output RLX Latched position RPX Commanded position SCX Stop code TEX Position error TI Inputs TPX Encoder position TSX Switches only bit 0 4 valid TTX Torque reports digital value 32544 NOTE X may be replaced by Y Z or W for capturing data on other axes Operand Summary Automatic Data Capture RC Returns a 0 or 1 where O denotes not recording 1 specifies recording in progress RD Returns address of next array element Example Recording into An Array During a position move store the X and Y positions and position error every 2 msec RECORD DM XPOS 300 YPOS 300 DM XERR 300 YERR 300 Begin program Define X Y position arrays Define X Y error arrays RA XPOS XERR YPOS YERR RD TPX TEX TPY TEY PR 10000 20000 RC1 BG XY A JP A RC 1 G DONE EN PLAY 0 JP DONE N gt 300 N X POS N Y POS N XERR N YERR N N N 1 DONE EN Select arrays for capture Select data types Specify move distance Start re
76. of the I O A D connector Reset Input Reset Button When the Reset line is triggered the controller will be reset The reset line and reset button will not master reset the controller unless the MRST jumper is installed during a controller reset The RST input uses the INCOM pin of the I O A D connector For 5 8 axis controllers with two integrated amplifiers the RST input for axes E H will also use the INCOM pin of the I O A D connector Uncommitted Digital Inputs The DMC 41x3 has 8 optoisolated inputs These inputs can be read individually using the function IN x where x specifies the input number 1 thru 8 These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller For example the user may wish to have the x axis motor move 1000 counts in the positive direction when the logic state of DI1 goes high The Digital inputs can be used as high speed position latch inputs see High Speed Position Capture The Latch Function for more information This can be accomplished by connecting a voltage in the range of 5V to 28V into INCOMO of the input circuitry from a separate power supply Controllers with more than 4 axes have an additional 8 general optoisolated inputs inputs 9 16 INCOM1 is used for these inputs and is found on the I O E H D Sub connector The grouping is shown in Table 3 1 and Table 3 2 NOTE INCOM1 and LSCOM1 for Inputs 9 16 and Limit and Home Sw
77. of the feedback may cause a servo motor to runaway see Step 7 Setting NOIE Safety Features before Wiring Motors pg 21 regarding Runaway Motors Feedback Type Directions Standard Differential Swap channels A and A Quadrature Single ended Swap channels A and B SSI or BiSS Follow encoder manufacturers instructions Analog feedback Cannot change the direction of feedback without external hardware to invert analog signal Table 2 3 Directions for reversing feedback direction based upon feedback type The polarity of the control loop may still be inverted by either re wiring the motor or using the MT command see Step 7 Setting Safety Features before Wiring Motors pg 21 regarding positive feedback loops Step 7 Setting Safety Features before Wiring Motors This section applies to servo motors only Step A Set Torque Limit TL will limit the output voltage of the 10V motor command line This output voltage is either translated into torque or velocity by the amplifier Galil s internal amplifiers are in torque mode This command should be used to avoid excessive torque or speed when initially setting up a servo system The user is responsible for determining the relationship between the motor command line and the amplifier torque velocity using the documentation of the motor and or amplifier See the TL setting in the Command Reference for more details See the AG command in the command ref
78. operation The amplifier will be shut down regardless of the setting of OE or the presence of the HAMPERR routine NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short from a motor lead to ground Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the AMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle A4 AMP 435x0 D3540 D3520 218 DMC 41x3 User Manual A5 AMP 43640 D3640 Introduction The AMP 43640 contains four linear drives for sinusoidally commutating brushless motors The AMP 43640 requires a single 15 40VDC input Output power delivered is typically 20 W per amplifier or 80 W total The gain of each transconductance linear amplifier is 0 2 A V Typically a 24VDC supply will deliver 1A continuous and 2A peak while a 30VDC will be able to provide 1 0 A continuous and 2 0 A peak The current loop bandwidth is approximately 4 kHz By default the amplifier will use 12 bit DAC s however there is an option for 16 bit DAC s to increase the
79. or BX command Either the BX or BZ command must be executed on every reset or power up of the controller BZ Command A4 AMP 435x0 D3540 D3520 215 DMC 41x3 User Manual Issue the BZ command to lock the motor into a phase Note that this will cause up to a magnetic cycle of motion Be sure to use a high enough value with BZ to ensure the motor is locked into phase properly BX Command Issue the BX command The BX command utilizes a minimal movement algorithm in order to determine the correct commutation of the motor Setting Amplifier Gain and Current Loop Gain The AG command will set the amplifier gain Amps Volt and the AU command will set the current loop gain for the AMP 43540 The current loop gain will need to be set based upon the bus voltage and inductance of the motor and is critical in providing the best possible performance of the system AG command AG setting Gain Value m 0 0 4 A V m 1 0 8 A V m 2 1 6 A V Table A4 1 Amplifier Gain Settings for AMP 43540 The AMP 43540 has 3 amplifier gain settings The gain is set with the AG command as shown in Table A4 1 for AG n m The axis must be in a motor off MO state prior to execution of the AG command With an amplifier gain of 2 1 6A V the maximum motor command output is limited to 5V TL of 5 AU command Proper configuration of the AU command is essential to optimum operation of the AMP 43540 This command sets the
80. potential for regenerative energy it is recommended to order the controller with the ISCNTL Isolate Controller Power option and the SR90 SR 49000 Shunt Regulator Option The BOX option is required when the AMP 43540 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation Figure A4 1 DMC 4143 D3540 BOX4 DMC 4143 with AMP 43540 A4 AMP 435x0 D3540 D3520 213 DMC 41x3 User Manual Electrical Specifications The amplifier is a brush brushless transconductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage Continuous Current Peak Current Nominal Amplifier G ain Switching Frequency Minimum Load Inductance Brushless Motor Commutation angle 20 80 VDC 8 Amps 15 Amps 0 8 Amps Volt 33 kHz Vs V L mH 264 T rinnie A Where Vs Supply Voltage lippe 10 of the maximum current at chosen gain setting 120 The default PWM output operati
81. rate hence the slope of the rising and falling edges of all 3 velocity profiles are the same Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion The user specifies the jog speed JG acceleration AC and the deceleration DC rate for each axis The direction of motion is specified by the sign of the JG parameters When the begin command is given BG the motor accelerates up to speed and continues to jog at that speed until a new speed or stop ST command is issued If the jog speed is changed during motion the controller will make a accelerated or decelerated change to the new speed An instant change to the motor position can be made with the use of the IP command Upon receiving this command the controller commands the motor to a position which is equal to the specified increment plus the current position This command is useful when trying to synchronize the position of two motors while they are moving Note that the controller operates as a closed loop position controller while in the jog mode The DMC 41x3 converts the velocity profile into a position trajectory and a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging COMMAND DESCRIPTION AC X Y Z W Specifies acceleration rate BG XYZW Begins motion
82. retry step 3 6 elf QH m returns 5 Turn off the controller and amplifier and swap motor phases A and B then B and C elf QH mreturns 6 Turn off the controller and amplifier and swap motor phases A and C then B and C 7 The motor should now be wired for sine commutation using the BI BC method Once BI 1 is issued the motor is in a pseudo trapezoidal state you can enable sine commutation by issuing the BC command and commanding a slow jog move Once a hall transition is found the commutation will be in sinusoidal mode Step 9 Connecting External Amplifiers and Motors System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 41x3 There can also be a combination of axes running from Galil integrated amplifiers and drivers and external amplifiers or drivers Table 2 11 below shows a brief synopsis of the connections required the full step by step guide is provided below Chapter 2 Getting Started 29 DMC 41x3 User Manual Motor Type Connection Requirements Servo motors e Power to controller and amplifier Brushed and Brushless e Amplifier enable e Encoder feedback e Motor command line e See amplifier documentation for motor connections Stepper motor e Power to controller and amplifier e Amplifier enable e PWM Step and direction line e Encoder feedback optional e See amplifier documentation for motor connections
83. sinusoidal commutation no Halls required The following sections provide a brief description and guide on how to perform either commutation method including wiring and configuration commands These sections are divided into Trapezoidal and Sinusoidal Trapezoidal Commutation The following amplifiers support trapezoidal commutation A1 AMP 430x0 D3040 D3020 pg 198 A3 AMP 43240 D3240 pg 207 Trapezoidal commutation is a time tested way for determining the motor location within a magnetic cycle However interpretation of hall sensor feedback varies between motor manufactures requiring the user to find the correct wiring combination Before wiring the motor the user should determine which is easier Wiring the hall sensors or wiring the motor phases This method will start with wiring both the halls and motor phases at random then trying each of the 6 wiring combinations of either the halls or the motor phases not both For each combination the user will be asked to check the open loop velocity in both directions Some of the wiring combinations will lead to no motion this is expected The following directions are given using the A axis as an example 1 Wire the 3 motor phase wires and 3 hall sensors randomly Do not connect the motor to any external mechanics or load a free spinning motor is required for testing Take all safety precautions necessary as the motor tests below will result in a runaway condition 2 Se
84. the I O A D D Sub connector labeled as CMP An additional output compare signal is available for 5 8 axes controllers on the I O E H D sub connector Output compare is controlled by the position of any of the main encoder inputs on the controller The output can be programmed to produce either a brief active low pulse 510 nsec based on an incremental encoder value or to activate once one shot when an axis position has been passed When setup for a one shot the output will stay low until the OC command is called again For further information see the command OC in the Command Reference NOTE Output compare is not valid with sampled feedback types such as SSI BiSS and Analog Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA_ Sink Source Error Output The controller provides a TTL signal ERR to indicate a controller error condition When an error condition occurs the ERR signal will go low and the controller LED will go on An error occurs because of one of the following conditions 1 Atleast one axis has a position error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal The ERR signal is found on the I O A D D Sub connector
85. the amplifier and the motor The motor position whether rotary or linear is measured by a sensor The resulting signal called position feedback is returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Figure 10 3 The mathematical model of the various components is given below CONTROLLER dem x w B ne E om ATR j ENCODER Figure 10 3 Functional Elements of a Motion Control System Motor Amplifier The motor amplifier may be configured in three modes Chapter 10 Theory of Operation 168 DMC 41x3 User Manual 1 Voltage Drive 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Drive The amplifier is a voltage source with a gain of K V V The transfer function relating the input voltage V to the motor position P is P V K K S ST 1 ST 1 where T RJ K is and T L R s and the motor parameters and units are K Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to M
86. the operator to enter a jog speed If the operator enters a number out of range greater than 8 million the CMDERR routine will be executed prompting the operator to enter a new number In multitasking applications there is an alternate method for handling command errors from different threads Using the XQ command along with the special operands described below allows the controller to either skip or retry invalid commands OPERAND FUNCTION _EDI Returns the number of the thread that generated an error _ED2 Retry failed command operand contains the location of the failed command _ED3 Skip failed command operand contains the location of the command after the failed command The operands are used with the XQ command in the following format XQ _ED2 or _ED3 ED1 1 Where the 1 at the end of the command line indicates a restart therefore the existing program stack will not be removed when the above format executes The following example shows an error correction routine which uses the operands Chapter 7 Application Programming 128 DMC 41x3 User Manual Example Command Error w Multitasking A JP A EN B N 1 KP N TY EN CMDERR IF _TC 6 N 1 XQ _ED2 ED1 1 ENDIF IF TC 1 XQ _ED3 ED1 1 ENDIF EN Begin thread 0 continuous loop End of thread 0 Begin thread 1 Create new variable Set KP to value of N an invalid value Issue invalid command End of thread 1 Be
87. to Address Array Elements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter Example A Begin Program count 0 DM pos 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec pos count _TPX Record position into array element pos count Report position count count 1 Increment counter JP LOOP count lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named pos The variable count is used to increment the array element counter The above example can also be executed with the automatic data capture feature described below Uploading and Downloading Arrays to On Board Memory The GalilTools software is recommended for downloading and uploading array data from the controller The GalilTools Communication library also provides function calls for downloading and uploading array data from the controller to from a buffer or a file Arrays may also be uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as Al start is the first element of array default 0 end is the last element of array default last element delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 The file is terminated usi
88. to external devices that cannot use DMC code to communicate It is important to note that the Aux port is not an interpreted port and cannot receive DMC Galil commands directly Instead use Cl HCOMINT and the P2 operands to handle received data on this port NOTE If you are connecting the RS 232 auxiliary port to a terminal or any device which is a DATASET it is necessary to use a connector adapter which changes a dataset to a dataterm This cable is also known as a null modem cable CC Command The CC or Configure Communications command configures the auxiliary ports properties including Baud rate handshaking enable disabled port and echo See the CC command in the Command Reference for a full description and command syntax If the CC command is configured for hardware handshaking it is required to use the RTS and CTS lines The RTS line will go high whenever the DMC 41x3 is not ready to receive additional characters The CTS line will inhibit the DMC 41x3 from sending additional characters Note the CTS line goes high for inhibit RS 422 Configuration The DMC 41x3 can be ordered with the auxiliary port configured for RS 422 communication RS 422 communication is a differentially driven serial communication protocol that should be used when long distance serial communication is required in an application For more information see RS 422 Auxiliary Serial Port Serial Communication in the in Appendix Chapter 4 Software To
89. will also turn on at this stage A reset is required to restore the DMC 41x3 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 41x3 is damaged Chapter 1 Overview 10 DMC 41x3 User Manual Chapter 2 Getting Started Dimensions DMC 4143 CARD z 6 85 REF o X m o 4 550 H o to OD_ J o 4 050 2 o Kiba 3 3 614 zeo o Kip3 p o 3 329 fee p lt 0 JTAG w0 02 O 2 849 oo Bios 12 GND 0 alo golog ojo ojo o o R o o ojo alo 1 592 _98 es olo c o o plos ARO Me Colts Be 2o ET i ast olo o 00 0 oF e 218 E GJO00000000 0 000 a 6 BRRiialo 00000000 DMC 4143rev a 5 e J2 0 322 GALIL MOTION CONTROL 9 5 fo oo0000000 o 700 20 60VDC iad oo lt o o 00 o o oo N A O 5 D NO Te 90 lt o oo r mM lt o O Figure 2 1 DMC 41x3 Dimensions in inches where x 1 2 3 and 4 axis Dimensions are subject to change Contact the Galil factory for current dimensions of all products Chapter 2 Getting Started 11 DMC 41x3 User Manual DMC 4183 CARD 10 30 REF _ DMC 41x3 User Manual
90. 0 Speed is 10000 PA 20000 Specify Absolute position BGX Begin motion AD 1000 Wait until 1000 counts SB1 Set output bit 1 EN End program Event Trigger Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR trippoint is used as shown in the next example TRIP Label JG 50000 Specify Jog Speed BGX n 0 Begin Motion REPEAT Repeat Loop AR 10000 Wait 10000 counts TPX Tell Position SB1 Set output 1 WT50 Wait 50 msec CBI Clear output 1 n n 1 Increment counter JP REPEAT n lt 5 Repeat 5 times STX Stop EN End Event Trigger Start Motion on Input This example waits for input 1 to go low and then starts motion Note The Al command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Input Interrupt function II or use a conditional jump on an input such as JP GO IN 1 1 INPUT Program Label AI 1 Wait for input 1 low PR 10000 Position command BGX Begin motion EN End program Event Trigger Set output when At speed ATSPEED Program Label JG 50000 Specify jog speed AC 10000 Acceleration rate BGX Begin motion ASX Wait for at slew speed 50000 SB1 Set output 1 EN End program Event Trigger Change Speed along Vector Path The following program changes the feed rate or vector speed at the specified distance along the vector The
91. 000 10 Compute speed JG VEL Change JG speed JP B Loop Position Tracking The Galil controller may be placed in the position tracking mode to support changing the target of an absolute position move on the fly New targets may be given in the same direction or the opposite direction of the current position target The controller will then calculate a new trajectory based upon the new target and the acceleration deceleration and speed parameters that have been set The motion profile in this mode is trapezoidal There is not a set limit governing the rate at which the end point may be changed however at the standard TM rate the controller updates the position information at the rate of Imsec The controller generates a profiled point every other sample and linearly interpolates one sample between each profiled point Some examples of applications that may use this mode are satellite tracking missile tracking random pattern polishing of mirrors or lenses or any application that requires the ability to change the endpoint without completing the previous move The PA command is typically used to command an axis or multiple axes to a specific absolute position For some applications such as tracking an object the controller must proceed towards a target and have the ability to change the target during the move In a tracking application this could occur at any time during the move or at regularly scheduled intervals For example if a robot was des
92. 0000 Specify relative distances on X and Y axes BG XY Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves X and Y 10000 and 20000 units After the motion is complete the motors rest for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 41x3 have some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines See section on AMPERR Label for Amplifier error routine AUTO Label that will automatically run upon the controller exiting a reset power on AUTOERR Label that will automatically run if there is an EEPROM error out of reset CMDERR Label for incorrect command subroutine COMINT Label for Communications Interrupt see CC Command ININT Label for Input Interrupt subroutine See II Command LIMSWI Label for Limit Switch subroutine MCTIME Label for timeout on Motion Complete trippoint POSERR Label for excess Position Error subroutine TCPERR Label for errors over a TCP connection error code 123 Commenting Programs Using the command NO or Apostrophe The DMC 41x3 provides a command NO for commenting programs or single apostrophe This command allows the user to include up to 78 characters on a single line after the NO command and can be used to include comments from the programmer
93. 00mA Sourcing Outputs 500mA Sourcing Optoisolated Outputs HSRC pg 41 LSNK 25mA Sinking Outputs 25mA Sinking Optoisolated Outputs LSNK pg 39 LSRC 25mA Sourcing Outputs 25mA Sourcing Optoisolated Outputs LSRC pg 40 Table 3 Brief list of axis specific options It is important to note that 1 4 axis models come with a single bank Bank 0 of eight optoisolated specified by ABCD Y 5 8 axis models comes with an additional bank Bank 1 of eight optoisolated outputs specified by EFGH Y See Optoisolated Input Electrical Information pg 35 for further details WARNING If no option is specified the default optoisolated outputs for ABCD and EFGH are 4mA sinking see 4mA Sinking Optoisolated Outputs Default pg 38 for further details AMP SDM DXXXX Y Options Option Type Options Brief Description Documentation XXXX 3020 3040 500 W trapazoidal servo drive A1 AMP 430x0 D3040 D3020 pg 198 2 and 4 axis models 3140 20 W brush type only drive A2 AMP 43140 D3140 pg 204 3240 750 W trapazoidal servo drive A3 AMP 43240 D3240 pg 207 3520 3540 600 W sinusoidal servo drive A4 AMP 435x0 D3540 D3520 pg 213 2 and 4 axis models 3640 20 W sinusoidal servo drive A5 AMP 43640 D3640 pg 219 4040 4020 1 4 A with 1 16 microstepping drive A6 SDM 44040 D4040 D4020 pg 225 4140 3 A with 1 64 microstepping drive A7 SDM 4
94. 040 D4020 Description The SDM 44040 resides inside the DMC 41x3 enclosure and contains four drives for operating two phase bipolar step motors The SDM 44040 requires a single 12 30 VDC input The unit is user configurable for 1 4 A 1 0 A 0 75 A or 0 5 A per phase and for full step half step 1 4 step or 1 16 step A two axis version the SDM 44020 is also available The BOX option is required when the SDM 44040 is order with the DMC 41x3 NOTE Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation A6 SDM 44040 D4040 D4020 225 LINWACT ERROR POWER OUTPUTS E 5 DIR SO nage OLR BRB San See A TION HS HIGH POWER OP Tapa 2EVOS notes Opt SOURCE EON uo BAET Tapie Bore Sow os eon Bow Ttcom AERA aw WRT Hy So Figure A6 1 DMC 4143 D4040 BOX4 DMC 4143 with SDM 44040 DMC 41x3 User Manual Electrical Specifications DC Supply Voltage Max Current per axis 12 30 VDC In order to run the SDM 44040 in the range of 12 20 VDC the ISCNTL Isolate Controller Power option
95. 2 TA2 G A ER TA3 TA3 WT5000 REM the sum of the amperr bits should be 0 with no amplifier error er _TAO mask _TA2 TA3 JP AMPERR er0 REM Notify user amperr has cleared G AMPERR RESOLVED WT3000 RE JS Subroutine Stack Variables a b c d e f g h There are 8 variables that may be passed on the subroutine stack when using the JS command Passing values on the stack is advanced DMC programming and is recommended for experienced DMC programmers familiar with the concept of passing arguments by value and by reference Notes 1 Passing parameters has no type checking so it is important to exercise good programming style when passing parameters See examples below for recommended syntax Do not use spaces in expressions containing Global variables MUST be assigned prior to any use in subroutines where variables are passed by reference Please refer to the JS command in the controller s command reference for further important information Example A Simple Adding Function Add JS SUM 1 2 3 4 5 6 7 8 MG JS EN SUM EN at b ct dt et f g h Executed program from programl dmc 36 0000 Chapter 7 Application Programming 130 DMC 41x3 User Manual Example Variable and an Important Note about Creating Global Variables Var value 5 global 8 JS SUM amp value 1 2 3 4 5 6 7 MG value MG JS EN SUM a b c d e f g h global EN a Executed program from program2
96. 25 32 general output block 4 outputs 33 40 general output block 5 outputs 41 48 general output block 6 outputs 49 56 general output block 7 outputs 57 64 general output block 8 outputs 65 72 general output block 9 outputs 73 80 Reserved Reserved ADDR TYPE 30 31 SW 32 33 SW 34 35 SW 36 37 SW 38 39 SW 40 41 SW 42 UB 43 UB 44 UB 45 UB 46 UB 47 UB 48 UB 49 UB 50 UB 51 UB 52 55 UL 56 59 UL 60 61 UW 62 63 UW 64 65 UW 66 69 SL 70 71 UW 72 73 UW 74 75 UW 76 79 SL 80 81 UW ITEM Reserved Reserved Reserved Reserved Reserved Reserved Ethernet Handle A Status Ethernet Handle B Status Ethernet Handle C Status Ethernet Handle D Status Ethernet Handle E Status Ethernet Handle F Status Ethernet Handle G Status Ethernet Handle H Status error code thread status see bit field map below Amplifier Status Segment Count for Contour Mode Buffer space remaining Contour Mode segment count of coordinated move for S plane coordinated move status for S plane see bit field map distance traveled in coordinated move for S plane Buffer space remaining S Plane segment count of coordinated move for T plane Coordinated move status for T plane see bit field map distance traveled in coordinated move for T plane Buffer space remaining T Plane Chapter 4 Software Tools and Communication 58 DMC 41x3 User Manual ADDR 82 83 84 85 86 89 90 93 94 97 98 101 102 105 106 10
97. 3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input A4 AMP 435x0 D3540 D3520 217 DMC 41x3 User Manual Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 2 or 3 The command will return an eight bit number representing specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label AMPERR in their program to handle amplifier errors As long as a program is executing in thread zero and the AMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA comm
98. 3140 A2 AMP 43140 D3140 204 DMC 41x3 User Manual Electrical Specifications The amplifier is a brush type trans conductance linear amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input DC Supply Voltage 12 30 VDC bipolar In order to run the AMP 43140 in the range of 12 20 VDC the ISCNTL Isolate Controller Power option must be ordered Max Current per axis 1 0 Amps 100mA option Amplifier gain 0 1 A V 10mA V option Power output per channel 20 W Total max power output 60 W Mating Connectors On Board Connector Terminal Pins 4 pin Molex Mini Fit Jr POWER MOLEX 39 01 2045 MOLEX 44476 3112 A B C D 4 pin Motor 2 pin Molex Mini Fit Jr Power Connectors MOLEX 39 01 2025 MOLEX 44A 76 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 Power Supply Ground 3 VS DC Power 4 VS DC Power Motor Connector Motor Lead A 2 Motor Lead A A2 AMP 43140 D3140 205 DMC 41x3 User Manual Operation ELO Input If the ELO input on the controller is triggered then the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To reco
99. 4 550 4 290 oo 4 050 a 3 614 sige 3 329 EB 2 849 oooooobo000 JP5 0 1 592 AR I O 00 300 DMC 4183rve w i bab z GALIL MOTION CONTROL 0 gis Bo RPCIBJOOOO00000 plooo000000 2 5 Bo o 3 i IE g a gt accel ig 5 S O00000000 u25 moo OO 000000 0 000 0 322 5 6 7 and 8 axis Figure 2 2 DMC 41x3 Dimensions in inches where x P o PD aooooooooo ol aooooooooo R RPB4 e fo oO 0 700 oo Oo oO O O O O N xn O co oo Nie fe co oO foe S m oo Dimensions are subject to change Contact the Galil factory for current dimensions of all products 1 Chapter 2 Getting Started 12 DMC 4143 BOX4
100. 4140 D4140 pg 229 ISAMP Isolates power between amplifiers AMP SDM DXXXX Y Internal Amplifier Y Two banks of AMP SDMs required Options starting on pg 183 SR90 SR 49000 Shunt regulator option SSR Solid state relay 100mA 100mA current 1 Not available for all amplifier options see the proper D3140 option only documentation HALLF Filtered hall inputs Table 1 4 Brief list of amplifier options Chapter 1 Overview 5 DMC 41x3 User Manual Overview of Motor Types The DMC 41x3 can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Step motors with step and direction signals 3 Other actuators such as hydraulics and ceramic motors For more information contact Galil The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 41x3 achieves superior precision through use of a 16 Bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feed forward an extra pole filter and integration limits The controller is configured by the factory for standard servo motor operation In this configuration the controller provides an analog signal 10 volts to connect to a servo amplifier This connection is described in Chapter 2 Stepper Motor with Step and Direction Signals The DMC 41x3 can control stepper motors In
101. 500mA sourcing option refereed to as high power sourcing HSRC is capable of sourcing up to 500mA per output and up to 3A per bank The voltage range for the outputs is 12 24 Voc These outputs are capable of driving inductive loads such as solenoids or relays The outputs are configured for hi side sourcing only Electrical Specifications Output PWR Max Voltage 24 Voc Output PWR Min Voltage 12 Voc Max Drive Current per Output 0 5 A not to exceed 3A per Bank Wiring the 500mA Sourcing Optoisolated Outputs With this configuration the output power supply will be connected to Output PWR labeled OPnA and the power supply return will be connected to Output GND labeled OPnB where n denotes 0 or 1 referring to Bank 0 and Bank 1 respectively Note that the load is wired between DO and Output GND The wiring diagram for Bank 0 is shown in Figure 3 12 and Bank 1 in Figure 3 13 Refer to Pin outs in the Appendix for pin out information Output PWR OPOA y 3 3V PN DO 8 1 cpu IRF7342 E3 RSE LOAD g OPOB Output GND Figure 3 12 500mA sourcing wiring diagrams for Bank 0 DO 8 1 Chapter 3 Connecting Hardware 41 DMC 41x3 User Manual Output PWR OP1A 3 3V PR gt AK I DO 16 9 LOAD Output GND X0 tOZLOSNWN OP1B T Figure 3 13 500mA sourcing wiring diagram for Bank 1 DO 16 9 TTL Inputs and Outputs Main Encoder Inputs The main encoder inputs can be conf
102. 5mA sinking wiring diagram for Bank 0 DO 8 1 Chapter 3 Connecting Hardware 39 DMC 41x3 User Manual 4 3 3V Output GND Figure 3 9 25mA sinking wiring diagram for Bank 1 DO 16 9 25mA Sourcing Optoisolated Outputs LSRC Description The 25mA sourcing option refereed to as lower power sourcing LSRC are capable of sourcing up to 25mA per output The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output PWR Max Voltage 24 Voc Output PWR Min Voltage 5 Voc Max Drive Current per Output 25mA Sourcing Wiring the 25mA Sourcing Outputs With this configuration the output power supply will be connected to Output PWR labeled OPnA and the power supply return will be connected to Output GND labeled OPnB where n denotes 0 or 1 referring to Bank 0 and Bank 1 respectively Note that the load is wired between DO and Output GND The wiring diagram for Bank 0 is shown in Figure 3 10 and Bank 1 in Figure 3 11 Refer to Pin outs in the Appendix for pin out information 3 3V Output PWR boren LOAD Output GND Figure 3 10 25mA sourcing wiring diagram for Bank 0 DO 8 1 Chapter 3 Connecting Hardware 40 DMC 41x3 User Manual 3 3V Output PWR LOAD Output GND Figure 3 11 25mA sourcing wiring diagram for Bank 1 DO 16 9 500mA Sourcing Optoisolated Outputs HSRC Description The
103. 6 7 and 8 axis 1 BOX4 Dimensions Figure 2 4 DMC 41x3 Dimensions are subject to change Contact the Galil factory for current dimensions of all products 1 Chapter 2 Getting Started 14 DMC 41x3 Power Connections SDM AMP Power SDM AMP Power Axis A D Axis E H A B C D POWER a E F G H POWER DMC 41 83 1234 56 STEPPER SERVO POWER HAENSNK QQQQ_ 5V QQ A lole atpiolne vs oao LAEN SNK P av 4 GALIL MOTION CONTROL HAENSRO D EPP Isl atoole BlO O c GND OoO MADE IN USA LAENSRC P PPQ TN gt im O O 0O O Law cinkact ERROR Power a AUX SERIAL Oo i ANALOG l me 7 i AXISB i AXISC i AXISD i AXISE i AXISF i AXISG AXISH o EERRRE o CEERRE o CEECEE o CEEE o CERERI o CEEEEE o 123456 123456 123456 123456 123456 123456 123456 123456 I O A D I O E H ANALOG ENCODER Ja I O A D I O E H P T ARXD OuTPUTS gacno JAO 28M ppe SMA agcwp 298v He Gog soup IV 1 O
104. 9 110 111 112 113 114 117 118 119 120 121 122 125 126 129 130 133 134 137 138 141 142 145 146 147 148 149 150 153 154 155 156 157 158 161 162 165 166 169 170 173 174 177 178 181 182 183 184 185 186 189 190 191 192 193 194 197 198 201 202 205 206 209 210 213 214 217 218 219 220 221 222 225 TYPE UW UB UB SL SL SL SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW UB UB SL ITEM A axis status see bit field map below A axis switches see bit field map below A axis stop code A axis reference position A axis motor position A axis position error A axis auxiliary position A axis velocity A axis torque A axis analog input A Hall Input Status Reserved A User defined variable ZA B axis status see bit field map below B axis switches see bit field map below B axis stop code B axis reference position B axis motor position B axis position error B axis auxiliary position B axis velocity B axis torque B axis analog input B Hall Input Status Reserved B User defined variable ZA C axis status see bit field map below C axis switches see bit field map below C axis stop code C axis reference position C axis motor position C axis position error C axis auxiliary position C axis velocity C axis torque C axis analog input C Hall Input
105. A and B axes Label B Report A and B axes positions Wait 1000 milliseconds Jump to B End of program Interrupt subroutine Displays the message Stops motion on A and B axes Loop until Interrupt cleared Specify new speeds Wait 300 milliseconds Begin motion on A and B axes Return from Interrupt subroutine To jump back to the main program using the JP command the RI command must be issued in a subroutine and then the ZS command must be issued prior to the JP command See Application Note 2418 for more information http www galilmc com support a Analog Inputs notes optima note2418 pdf The DMC 41x3 provides eight analog inputs The value of these inputs in volts may be read using the AN n function where n is the analog input 1 through 8 The resolution of the Analog to Digital conversion is 12 bits 16 bit ADC is available as an option Analog inputs are useful for reading special sensors such as temperature tension or pressure The following examples show programs which cause the motor to follow an analog signal The first example is a point to point move The second example shows a continuous move Chapter 7 Application Programming 150 DMC 41x3 User Manual Example Position Follower Point to Point Objective The motor must follow an analog signal When the analog signal varies by 10V motor must move 10000 counts Method Read the anal og input and command A to move to that point Instructio
106. And Bit wise Logical Or On some computers a solid vertical line appears as a broken line Parenthesis SY E oe Q Chapter 7 Application Programming 134 DMC 41x3 User Manual Mathematical operations are executed from left to right Calculations within parentheses have precedence Examples speed 7 5 V1 2 The variable speed is equal to 7 5 multiplied by V1 and divided by 2 count count 2 The variable count is equal to the current value plus 2 result _TPX COS 45 40 Puts the position of X 28 28 in result 40 cosine of 45 is 28 28 temp IN 1 amp IN 2 temp is equal to 1 only if Input 1 and Input 2 are high Mathematical Operation Precision and Range The controller stores non integers in a fixed point representation not floating point Numbers are stored as 4 bytes of integer and 2 bytes of fraction within the range of 2 147 483 647 9999 The smallest number representable and thus the precision is 1 65536 or approximately 0 000015 Example Using basic mathematics it is known that 1 4 80 000 112 000 However using a basic terminal a DMC controller would calculate the following var 1 4 80000 Storing the result of 1 4 80000 in var MG var Prints variable var to screen 111999 5117 The reason for this error relies in the precision of the controller 1 4 must be stored to the nearest multiple of 1 65536 which is 91750 65536 1 3999 Thus 91750 65536
107. B C and D PR 8000 9000 Specify B and D only PR 77 232 Request A B C D values PR Request B value only Explicit Notation The DMC 41x3 provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as A B Cor D An equals sign is used to assign data to that axis For example PRA 1000 Specify a position relative movement for the A axis of 1000 ACB 200000 Specify acceleration for the B axis as 200000 Instead of data some commands request action to occur on an axis or group of axes For example ST AB stops motion on both the A and B axes Commas are not required in this case since the particular axis is specified by the appropriate letter A B Cor D If no parameters follow the instruction action will take place on all axes Here are some examples of syntax for requesting action BG A Begin A only BG B Begin B only BG ABCD Begin all axes BG BD Begin B and D only BG Begin all axes For controllers with 5 or more axes the axes are referred to as A B C D E F G H The specifiers X Y Z W and A B C D may be used interchangeably BG ABCDEFGH Begin all axes BG D Begin D only Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S or T is used to specify the coordinated motion This allows for coordinated motion to be setup for two separate coordinate systems Refer to the CA command in the Command Reference for more information on spe
108. B ao m 4 42765 S E lt ao m 0 442765 2 ao x 022123 3 E ao x 0213 SI 4 100 ms o Trigger Channel lm _RPEa Edge x Level 1000 count S Mode Repeat v READY stop b jdt RPA Gc RPS Figure 6 11 Velocity counts sec vs Time msec Instantaneous Gearing Engagement xil vertical Horizontal didt Source Scale div Offset div A RPA Axis A refl 100000 ce RPB Axis B refi 100000 cc eO al 2 4 o 0 221383 4 42765 COVA PE ao X 0 442765 i E 0 221383 o E RP RP a RP KP N E e e E RP le 100 ms Trigger Channel m _RPEs Edge x Level 1000 count didt RPA didt RPE Figure 6 12 Velocity counts sec vs Time msec Ramped Gearing The slave axis for each figure is shown on the bottom portion of the figure the master axis is shown on the top portion The shock to the slave axis will be significantly less in Figure 6 12 than in Figure 6 11 The ramped gearing does have one consequence There isn t a true synchronization of the two axes until the gearing ramp is complete The slave will lag behind the true ratio during the ramp period If exact position synchronization is required from the point gearing is initiated then the position must be commanded in addition to the gearing The controller keeps track of this position phase lag with the _GP operand The followi
109. C 4173 DMC 4183 Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Number of Variables Array Size Program Size 125 usec 125 usec 250 usec 250 usec 375 usec 375 usec 500 usec 500 usec 1 quadrature count Phase locked better than 0 005 System dependent 2147483647 counts per move Up to 15 000 000 counts sec servo 3 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1x 10 510 24000 elements 30 arrays 4000 lines x 80 characters Appendices 179 DMC 41x3 User Manual Ordering Options Overview The DMC 41x3 can be ordered in many different configurations and with different options This section provides information regarding the different options available on the DMC 41x3 motion controller axis specific options and internal amplifiers For information on pricing and how to order your controller with these options see our DMC 41x3 part number generator on our website http www galilmc com products dmc 41x3 part number php DMC and Form Factor DMC 41x3 XXXX Y Options The following options are the XXXX form factor options that determine how the DMC 41x3 product will be delivered See TABLE for example images CARD This is the default option if none is specified and no internal amplifier is being used If an internal amplifier is be
110. Changes position target IT X Y Z W Time constant for independent motion smoothing AM XYZW Trippoint for profiler complete C XYZW Trippoint for in position Chapter 6 Programming Motion 70 DMC 41x3 User Manual The lower case specifiers x y z w represent position values for each axis The DMC 41x3 also allows use of single axis specifiers such as PRY 2000 Operand Summary Independent Axis IOPERAND DESCRIPTION ACx Return acceleration rate for the axis specified by x DCX Return deceleration rate for the axis specified by x SPX Returns the speed for the axis specified by x PAX Returns current destination if x axis is moving otherwise returns the current commanded position if in a move PRX Returns current incremental distance specified for the x axis Example Absolute Position Movement PA 10000 20000 Specify absolute X Y position AC 1000000 1000000 Acceleration for X Y DC 1000000 1000000 Deceleration for X Y SP 50000 30000 Speeds for X Y BG XY Begin motion Example Multiple Move Sequence Required Motion Profiles X Axis 500 counts Position 20000 count sec Speed 500000 counts sec Acceleration Y Axis 1000 counts Position 10000 count sec Speed 500000 counts sec Acceleration Z Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on X Y and Z
111. Chapter 3 Connecting Hardware 43 DMC 41x3 User Manual For controllers with 5 8 axes the ERR signal is duplicated on the I O E H D Sub connector For additional information see Error Light Red LED in Chapter 9 Troubleshooting Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA_ Sink Source Analog Inputs The DMC 41x3 has eight analog inputs configured for the range between 10V and 10V The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 005V A 16 bit ADC is available as an option Ex DMC 4123 CARD 16bit The analog inputs are specified as AN x where x is a number 1 thru 8 AQ settings The analog inputs can be set to a range of 10V 5V 0 5V or 0 10V this allows for increased resolution when the full 10V is not required The inputs can also be set into a differential mode where analog inputs 2 4 6 and 8 can be set to the negative differential inputs for analog inputs 1 3 5 and 7 respectively See the AQ command in the command reference for more information Electrical Specifications Input Impedance 12 and 16 bit Unipolar 0 5V 0 10V 42kO Bipolar 5V 10V 31kO Chapter 3 Connecting Hardware 44 DMC 41x3 User Manual External Amplifier Interface External Stepper Control The controller provides step and direction STPn DIRn outputs for every axis available on the controller These outputs are typically used for interfacing to external step
112. DC X y Z W Specifies deceleration rate IP X Y Z W Increments position instantly IT X Y Z W Time constant for independent motion smoothing JG x Y Z W Specifies jog speed and direction ST XYZW Stops motion Parameters can be set with individual axes specifiers such as JGY 2000 set jog speed for Y axis to 2000 Chapter 6 Programming Motion 72 DMC 41x3 User Manual Operand Summary Independent Axis IOPERAND DESCRIPTION ACx Return acceleration rate for the axis specified by x DCx Return deceleration rate for the axis specified by x SPx Returns the jog speed for the axis specified by x TVx Returns the actual velocity of the axis specified by x averaged over 0 25 sec Example Jog in X only Jog X motor at 50000 count s After X motor is at its jog speed begin jogging Z in reverse direction at 25000 count s A AC 20000 20000 Specify X Z acceleration of 20000 counts sec DC 20000 20000 Specify X Z deceleration of 20000 counts sec JG 50000 25000 Specify jog speed and direction for X and Z axis BG X Begin X motion AS X Wait until X is at speed BG Z Begin Z motion EN Example Joystick Jogging The jog speed can also be changed using an analog input such as a joystick Assume that for a 10 Volt input the speed must be 50000 counts sec JOY Label JGO Set in Jog Mode BGX Begin motion B Label for loop V1 AN 1 Read analog input VEL V1 50
113. DONE EN C BGS EN Load Program Define Array Initialize Counter Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full wait Begin motion on 500 segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Motion Subroutine Vector Mode Linear and Circular Interpolation Motion The DMC 41x3 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments The Chapter 6 Programming Motion 80 DMC 41x3 User Manual DMC 41x3 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specified for coordinated motion at any given time The command VM m n p where m and n are the coordinated pair and p is the tangent axis Note
114. Description 1 ERR Error Output 16 RST Reset Input 31 GND Digital Ground 2 DIO Digital Input 9 E latch 17 INCOM1 Input Common DI 9 16 32 DI10 Digital Input 10 F latch 3 DI12 Digital Input 12 H latch 18 DI11 Digital Input 11 G latch 33 DI13 Digital Input 13 4 DI15 Digital Input 15 19 DI14 Digital Input 14 34 DI16 Digital Input 16 5 ELO Electronic Lock Out 20 ABRT Abort Input 35 GND Digital Ground 6 LSCOM1 Limit Switch Com E H 21 N C No Connect 36 FLSE Forward Limit Switch E 7 HOME Home Switch E 22 RLSE Reverse Limit Switch E 37 FLSF Forward Limit Switch F 8 HOMF Home Switch F 23 RLSF Reverse Limit Switch F 38 FLSG Forward Limit Switch G 9 HOMG Home Switch G 24 RLSG Reverse Limit Switch G 39 FLSH Forward Limit Switch H 10 HOMH Home Switch H 25 RLSH Reverse Limit Switch H 40 GND Digital Ground 11 OP1A Output GND PWR Bank 1 26 N C No Connect 41 DOS Digital Output 9 12 DO11 Digital Output 11 27 DO10 Digital Output 10 42 DO12 Digital Output 12 13 DO14 Digital Output 14 28 DO13 Digital Output 13 43 D015 Digital Output 15 14 OP1B Output PWR GND Bank 1 29 DO16 Digital Output 16 44 CMP Output Compare E H 15 5V 5V 30 5V 5V ABRT RST and ELO use INCOMO Appendices 187 DMC 41x3 User Manual Jn1 Encoder 26 pin HD D Sub Connector Female Pin Label Description Pin Label Description 1 HALC Hall C 14 FLS Forward Limit Switch Input 2 AEN
115. ERI aia pia 22 A2 AMP 43140 D3140 204 DMC 41x3 User Manual Contents iv DCS CEN ists ss sceaescaes seed a add tesa aL della Sie kad sia 204 Electrical Speck 205 Opere Saa 206 A3 AMP 43240 D3240 207 Description i Electrical Specifications ig MSV SUR O e a E Error Monitoring and Protection ncasa 211 A4 AMP 435x0 D3540 D3520 213 TC SCP URN airone aa e a a te del cocaine 213 Elecirical Opecin atots eee eres POTTS POT SOUT On T TTT 214 OPi eens maa taatee ian aise ieah eer c nausea MeEa tie 215 Error Momiloritig and Protect Oh sccs sists sscecssatsssrntsscecis ariisatiiaiarissaterioneanteecisians 218 A5 AMP 43640 D3640 219 Introduction es Electrical Specifications yai Opari eet a cee th ee ee al aa el A6 SDM 44040 D4040 D4020 225 DCT cca ia hale ees re elas eee steal eesti Electrical Specifications 0 ARON sc stets eaters lcs eter area eae g eters ete asl A7 SDM 44140 D4140 229 MRC ict eects ances ese ee R ee rae scastes 229 Plecrical SP GCHNC APRONS oisinnean aaaeaii anana biain 230 OE RI auod aa setae aaa siesta cd Ra eases 231 DMC 41x3 User Manual Contents v Chapter 1 Overview Introduction The DMC 41x3 Series are Galil s Econo motion controller that is a scaled down version of the DMC 40x0 Acclerra series controller The controller series offers many en
116. EX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor Power Connectors 4 pin MATE N LOK MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector 1 B 2 A 3 B 4 A A7 SDM 44140 D4140 230 DMC 41x3 User Manual Operation The SDM 44140 should be setup for Active High step pulses MT 2 or MT 2 5 The AG command sets the current on each axis and the LC command configures each axis s behavior when holding position These commands are detailed below Current Level Setup AG Command AG configures how much current the SDM 44140 delivers to each motor Four options are available 0 5A 1 0A 2 0A and 3 0Amps NOTE when using the 3 0A setting mounting the unit to a metal or heat dissipating surface is recommended Drive Current Selection per Axis AG n n n n n n n n n 0 n 1 n 2 n 3 0 5A 1 A default 2A 3 0A Low Current Setting LC Command LC configures each motor s behavior when holding position when RP is constant and multiple configurations LC command set to 0 Full Current Mode causes motor to use 100 of peak current AG while at a resting state profiler is not commanding motion This is the default setting LC command set to 1
117. IS in one box Figure 1 4 DMC 41x3 Functional Elements Microcomputer Section The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM The RAM provides memory for variables array elements and application programs The flash EEPROM provides non volatile storage of variables programs and arrays The Flash also contains the firmware of the controller which is field upgradeable Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 15 MHz For standard servo operation the controller generates a 10 volt analog signal 16 Bit DAC For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the DMC 41x3 consists of high speed 100bT Ethernet and a USB programming port General I O The DMC 41x3 provides interface circuitry for 8 bi directional optoisolated inputs 8 optoisolated outputs and 8 analog inputs with 12 Bit ADC 16 Bit optional Unused auxiliary encoder inputs may also be used as additional Chapter 1 Overview 8 DMC 41x3 User Manual inputs 2 inputs each axis The general inputs as well as the index pulse can also be used as high speed latches for each axis A high speed encoder compare output is also provided The DMC 4153 through DMC 4183 controller provides an additional 8 optoisolated inputs and 8 optoisolated outputs System Elem
118. Issue either the BZ or BX command Either the BX or BZ command must be executed on every reset or power up of the controller BZ Command A5 AMP 43640 D3640 222 DMC 41x3 User Manual Issue the BZ command to lock the motor into a phase Note that this will cause up to a magnetic cycle of motion Be sure to use a high enough value with BZ to ensure the motor is locked into phase properly BX Command Issue the BX command The BX command utilizes a minimal movement algorithm in order to determine the correct commutation of the motor Setting Peak and Continuous Current TL and TK The peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A5 1 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts The TL command is limited to 5V for the AMP 43640 This limits to continuous current output of the amplifier to 1A The TK command can be set to 9 998V which provides a peak current output of 2A To set TL and TK for a particular motor find the continuous current and peak current ratings for that motor and divide
119. KS units For example consider a motor with the parameters K 14 16 oz in A 0 1 Nm A R 2Q0 J 0 0283 0z in s 2 104 kg m2 L 0 004H Then the corresponding time constants are Tm 0 04 sec and T 0 002 sec Assuming that the amplifier gain is K 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current which is proportional to the input voltage V with a gain of K The resulting transfer function in this case is P V K K Js where Kt and J are as defined previously For example a current amplifier with K 2 A V with the motor described by the previous example will have the transfer function P V 1000 s2 rad V Chapter 10 Theory of Operation 169 DMC 41x3 User Manual If the motor is a DC brushless motor it is driven by an amplifier that performs the commutation The combined transfer function of motor amplifier combination is the same as that of a similar brush motor as described by the previous equations Velocity Loop The motor driver system may include a velocity loop where the motor velocity is sensed by a tachometer and is fed back to the amplifier Such a system is illustrated in Figure 10 4 Note that the transfer function between the input voltage V and the velocity w is w V K K Js 1 K K K Js 1 K sT 1 where the velocity time constant T equals T4 J K Ky Kg This leads to the transfer function P
120. LI a b c d e f g h lt n VS n Specify vector speed VA n Specify vector acceleration VD n Specify vector deceleration VR n Specify the vector speed ratio BGS Begin Linear Sequence CS Clear sequence LE Linear End Required at end of LI command sequence LE Returns the length of the vector resets after 2147483647 AMS Trippoint for After Sequence complete AV n Trippoint for After Relative Vector distance n IT S curve smoothing constant for vector moves Operand Summary Linear Interpolation IOPERAND DESCRIPTION AV Return distance traveled CS Segment counter returns number of the segment in the sequence starting at zero LE Returns length of vector resets after 2147483647 L Returns number of available spaces for linear segments in DMC 41x3 sequence buffer Zero means buffer full 511 means buffer empty VPm Return the absolute coordinate of the last data point along the trajectory m X Y Z or W or A B C D E F G or H To illustrate the ability to interrogate the motion status consider the first motion segment of our example LMOVE where the X axis moves toward the point X 5000 Suppose that when X 3000 the controller is interrogated using the command MG _AV The returned value will be 3000 The value of _CS _VPX and _VPY will be zero Now suppose that the interrogation is repeated at the second segment when Y 2000 The value of _AV at this point is 7000 CS eq
121. LO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input Using External Amplifiers The BR command must be set to a 1 for any axis where an AMP 43640 is installed but the use of an external axis is required This setting will disable the requirement to have the BA BM and BX or BZ commands executed prior to being able to issue the SH command for that axis BR 1 is required for both external servo and stepper drivers Use the connectors on top of the controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Step 9 Connecting External Amplifiers and Motorsin Chapter 2 Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the HAMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle AS AMP 43640 D3640 224 DMC 41x3 User Manual A6 SDM 44040 D4
122. Leading Zeros LZ command See Chapter 7 Application Programming and the Command Reference Summary of Interrogation Commands RP Report Command Position RL Report Latch RV Firmware Revision Information SC Stop Code TA Tell Amplifier Error TB Tell Status TC Tell Error Code TD Tell Dual Encoder TE Tell Error T Tell Input TR Tell Position TR Trace TS Tell Switches TT Tell Torque TV Tell Velocity For example the following example illustrates how to display the current position of the X axis TP A Tell position A 0 Controllers Response TP AB Tell position A and B 0 0 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PRO Fy fa Request A B C D values PR Request B value only The controller can also be interrogated with operands Chapter 5 Command Basics 67 DMC 41x3 User Manual Operands Most DMC 41x3 commands have corresponding operands that can be used for interrogation Operands must be used inside of valid DMC expressions For example to display the value of an operand the user could use the command MG operand where operand is a valid DMC operand All of the command operands begin with the underscore character _ For example the value of the current position
123. Library can be found here http www galilmc com support manuals galiltools library html HelloGalil Quick Start to PC programming For programmers developing Windows applications that communicate with a Galil controller the HelloGalil library of quick start projects immediately gets you communicating with the controller from the programming language of your choice In the Hello World tradition each project contains the bare minimum code to demonstrate communication to the controller and simply prints the controller s model and serial numbers to the screen Figure 4 1 a Formi Ja GalilClass0 dil 0 5 0 0 Galill dll 1 4 4 10 0 5 143 DMC4183 Rev 1 0 2 IHA IHE MG TIME 1963498 Figure 4 1 Sample program output http www galilmc com support hello_galil html Galil Communication Libraries The Galil Communication Library Galil class provides methods for communication with a Galil motion controller over Ethernet USB RS 232 or PCI buses It consists of a native C Library and a similar COM interface which extends compatibility to Windows programming languages e g VB CH etc A Galil object usually referred to in sample code as g represents a single connection to a Galil controller For Ethernet controllers which support more than one connection multiple objects may be used to communicate with the controller An example of multiple objects is one Galil object containing a TCP handle to a DMC 41
124. Motion will come to a controlled stop using the DC value for deceleration The same controlled stop will occur if a limit switch is activated in the direction of motion As a result the controller will be switched to a jog mode of motion Error Conditions and Stop Codes If the buffer is allowed to empty while in PVT mode then the profiling will be aborted and the motor will come to a controlled stop on that axis with a deceleration specified by the DC command Also PVT mode will be exited and the stop code will be set to 32 During normal operation of PVT mode the stop code will be 30 If PVT mode is exited normally PVn 0 0 0 then the stop code will be set to 31 Additional PVT Information It is the users responsibility to enter PVT data that the system s mechanics and power system can respond to ina reasonable manner Because this mode of motion is not constrained by the AC DC or SP values if a large velocity or position is entered with a short period to achieve it the acceleration can be very high beyond the capabilities of the system resulting in excessive position error The position and velocity at the end of the segment are guaranteed to be accurate but it is important to remember that the required path to obtain the position and velocity in the specified time may be different based on the PVT values Mismatched values for PVT can result in different interpolated profiles than expected but the final velocity and position will be acc
125. Move the motor by hand and re issue TP The returned value should have been incremented or decremented from the first TP If there is no change check the encoder wiring and settings and retest starting at Step 1 Chapter 2 Getting Started 20 DMC 41x3 User Manual 4 Using the encoder specification sheet translate a physical distance of the motor into counts read by the controller For example a 2000 line encoder means that the controller reads 2000 4 8000 counts revolution and a half turn of the motor would be 4000 counts 5 Issue TP to determine the current motor position record this value 6 Move the motor by hand some measured physical distance 7 Query TP again Take the absolute difference from the current TP and the TP recorded from Step 5 8 Determine if the physical distance moved is equal to the expected amount of counts calculated in Step 4 move on to Step 9 Otherwise check the encoder wiring and settings and retest starting at Step 1 9 Perform Step 5 8 again instead moving a physical distance in the opposite direction If the physical distance correctly translates to the expected amount of counts the encoder is wired correctly Step D Reverse encoder direction if necessary Table 2 3 below provides instructions for how to reverse the direction of feedback by rewiring the encoder to the DMC controller The direction of standard quadrature encoders can be be reversed using the CE command Reversing direction
126. ON GA n Specifies master axes for gearing where n X Y Z or W or A B C D E F G H for main encoder as master n CX CY CZ CW or CA CB CC CD CE CF CG CH for commanded position n DX DY DZ or DW or DA DB DC DD DE DF DG DH for auxiliary encoders n Sor T for gearing to coordinated motion GD a b c d e f g h Sets the distance the master will travel for the gearing change to take full effect GPn This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately and the distance traveled since gearing changes take effect over a specified interval GR a b c d e f g h Sets gear ratio for slave axes O disables electronic gearing for specified axis GM a b c d e f g h K 1sets gantry mode 0 disables gantry mode R X Y 2 W Trippoint for reverse motion past specified value Only one field may be used F X Y Z W Trippoint for forward motion past specified value Only one field may be used Example Simple Master Slave Master axis moves 10000 counts at slew speed of 100000 counts sec Y is defined as the master X Z W are geared to master at ratios of 5 5 and 10 respectively GRE Ye 7 Y Specify master axes as Y GR 5 5 10 Set gear ratios PR 10000 Specify Y position SP 100000 Specify Y speed BGY Begin motion Example Electronic Gearing Objective Run two geared motors at speeds of 1 132 and 0 045 times the speed
127. PB ACTS SINK DO 8 1 OPOA GND WAH SAIS DAN BME GAS 43007 38008 13 Dos 430015 28001 13 pow APWR 4mA OP OB 5 24VDC 4 AI5 15 ABs 42 D04 12 D03 42 D012 12 D011 OPT HiH ATG 5 AI7 23AB i4Fig SLSCOM ing 27D02 yop 41D09 270010 11 OPIA SINK DO 16 9 OP1A GND saate ZA 22 ALS Wann 260POA MOD MONY 260P1A icon MO AmA OP1B 5 24VDC wane SAGI 2iHALA 13STP 3 DIR 25RLsD 9 HO BNR 25 RLSH 7 12V 12 HALB 39 FLSD 9HOMC 39FLSH 9 HOMG 19 2 152V BSV 20ENBL 12 HALB 2 AEN Settee 24RLSC snows seriea 24RLSG SUON a UPGD HIGH POWER OPTION HPO HP1 h 1HALC 37Fisg 23888 7HOMA 37FLSF 23RLSF 7 HOME an 22 RLSA 22 RLSE MRST SOURCE DO 8 1 OPOA 12 24VDC 36FLSA 22 FLSA 6lscom seFLse Z2RLSE 6LSCOM 500mA OPOB GND 35GnD AINN 5 ELO 35GND A ELO SOIR OEE Gh aS 3401g 22 ABRT 4017 34116 20 ABRT 4 pris SOURCE DO 16 9 OPIA 12 24VDC sapis J9DI6 3 Dry Sabra 9 0I Dh 500mA OP1B GND 320 18 3 bit 32Dr J8DIN gt 17 INCOM 4 PAR SIGNO 17 INCOM ERR 31GND ig RST 16 RST eno 20 60v0C o O GALIL 2 pin Molex controller power connector Figure 2 5 Power Connector locations for the DMC 41x3 VDC 20 80V DC GROUND Figure 2 6 Power Connector used when controller is ordered without Galil Amplifiers For more information on powering your controller see Step 4 Power the Controller pg 18 For more information regarding connector type and part numbers see Power Connector Part Numbers pg 185 The power spec
128. PF and VF commands are global format commands that affect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m or Sn m following the variable name and the symbol F specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal Instruction Interpretation v1 10 Assign v1 vl Return v1 0000000010 0000 Default Format v1l F4 2 Specify local format 0010 00 New format vl 4 2 Specify hex format 000A 00 Hex value v1 ALPHA Assign string ALPHA to v1 vl S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM Chapter 7 Application Programming 147 DMC 41x3 User Manual The DMC 41x3 position parameters such as PR PA and VP have units of quadrature counts Speed parameters such as SP JG and VS have units of counts sec Acceleration parameters such as AC DC VA and VD have units of counts sec The controller interprets time in milliseconds All input parameters must be converted into these units For example an operator can be prompted to input a number in revolutions A program could be used such that the input number is converted into counts by mul
129. RUCTION DUALOOP CE 0 DEO PR 40000 BGX correct AMX V1 10000 _ DEX V2 _TEX 4 V1 JP END ABS V2 lt 2 INTERPRETATION Label Configure encoder Set initial value Main move Start motion Correction loop Wait for motion completion Find linear encoder error Compensate for motor error Exit if error is small PR V2 4 Correction move BGX Start correction JP correct Repeat END EN Motion Smoothing The DMC 41x3 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value The discontinuous acceleration results in jerk which causes vibration The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration Using the IT Command S When operating with servo motors motion smoothing can be accomplished with the IT command This command filters the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following commands IT X Y Z W Independent time constant The command IT is used for smoothing independent moves of the type JG PR PA and to smooth vector moves of the type VM and LM The smoothing parameters x y z w a
130. Status Reserved C User defined variable ZA D axis status see bit field map below D axis switches see bit field map below D axis stop code D axis reference position D axis motor position D axis position error D axis auxiliary position D axis velocity D axis torque D axis analog input D Hall Input Status Reserved D User defined variable ZA Axis Information ADDR 226 227 228 229 230 233 234 237 238 241 242 245 246 249 250 253 254 255 256 257 258 261 262 263 264 265 266 269 270 273 274 277 278 281 282 285 286 289 290 291 292 293 294 297 298 299 300 301 302 305 306 309 310 313 314 317 318 321 322 325 326 327 328 329 330 333 334 335 336 337 338 341 342 345 346 349 350 353 354 357 358 361 362 363 364 365 366 369 TYPE UW UB UB SL SL SL SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW UB UB SL ITEM E axis status see bit field map below E axis switches see bit field map below E axis stop code E axis reference position E axis motor position E axis position error E axis auxiliary position E axis velocity E axis torque E axis analog input E Hall Input Status Reserved E User defined variable ZA F axis status see bit field map below F axis switches see bit field map below F axis stop code F axis
131. Stepping Drive X axis SETUP OE1 KS16 MT 2 YA1 YB200 YC4000 SHX WT50 Si Set the profiler to stop axis upon error Set step smoothing Motor type set to stepper Step resolution of the full step drive Motor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode Half Stepping Drive X axis SETUP OE1 KS16 MT 2 YA2 YB200 YC4000 SHX WT50 Y S1 Set the profiler to stop axis upon error Set step smoothing Motor type set to stepper Step resolution of the half step drive Motor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode 1 64 Step Microstepping Drive X axis SETUP OE1 KS16 MT 2 YA64 YB200 YC4000 SHX WT50 Ysl y Set the profiler to stop axis upon error Set step smoothing Motor type set to stepper Step resolution of the microstepping drive Motor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode Chapter 6 Programming Motion 106 DMC 41x3 User Manual Example Error Correction The following code demonstrates what is necessary to set up SPM mode for the X axis detect error stop the motor correct the error and return to the main code The drive is a full step drive with a 1 8 step motor and 4000 c
132. Systems by Dr Jacob Tal Motion Control Applications by Dr Jacob Tal Motion Control by Microprocessors by Dr Jacob Tal Training Seminars Galil a leader in motion control with over 500 000 controllers working worldwide has a proud reputation for anticipating and setting the trends in motion control Galil understands your need to keep abreast with these trends in order to remain resourceful and competitive Through a series of seminars and workshops held over the past 20 years Galil has actively shared their market insights in a no nonsense way for a world of engineers on the move In fact over 10 000 engineers have attended Galil seminars The tradition continues with three different seminars each designed for your particular skill set from beginner to the most advanced MOTION CONTROL MADE EASY WHO SHOULD ATTEND Those who need a basic introduction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30 pm ADVANCED MOTION CONTROL WHO SHOULD ATTEND Those who consider themselves a servo specialist and require an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of Motion Control Made Easy or equivalent is required Analysis and design tools as well as several design examples will be provided TIME 8 hours 8 00 am 5 00 pm PRODUCT WORKSHOP WHO SHOULD ATTEND Current users of Galil motion controllers
133. TE An application program must be running for CMDERR to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the LIMSWI routine to function the DMC 41x3 must be executing an applications program from memory This can be a very simple program that does nothing but loop on a statement such as H LOOP JP HLOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed LOOP JP LOOP EN LIMSWI MG LIMIT OCCURRED R XQ LOOP JG 5000 BGX Dummy Program Jump to Loop Limit Switch Label Print Message Return to main program Download Program Execute Dummy Program Jog Begin Motion Now when a forward limit switch occurs on the X axis the LIMSWI subroutine will be executed Notes regarding the LIMSWI Routine 1 The RE command is used to return from the LIMSWI subroutine 2 The LIMSWI subroutine will be re executed if the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error LOOP JP LOOP EN POSERR V1 _TEX MG EXCESS POSITION ERROR MG ERROR V1 RE XQ LOOP JG 100000 BGX Example Input Interrupt A TT JG 30000 60000 BGXW LOOP JP LOOP EN ININT STXW AM TEST JP TEST JG 30000 6000 BGXW RIO IN 1 0 Dummy Program Loop Position Er
134. This is done with the instruction EAp where p X Y Z W E F G H p is the selected master axis For the given example since the master is x we specify EAX Step 2 Specify the master cycle and the change in the slave axis or axes In the electronic cam mode the position of the master is always expressed modulo one cycle In this example the position of x is always expressed in the range between 0 and 6000 Similarly the slave position is also redefined such that it starts at zero and ends at 1500 At the end of a cycle when the master is 6000 and the slave is 1500 the positions of both x and y are redefined as zero To specify the master cycle and the slave cycle change we use the instruction EM EM x y z w Chapter 6 Programming Motion 90 DMC 41x3 User Manual where x y z w specify the cycle of the master and the total change of the slaves over one cycle The cycle of the master is limited to 8 388 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 Step 3 Specify the master interval and starting point Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are
135. Tools software will treat an apostrophe comment different from an NO when the compression algorithm is activated upon a program download line gt 80 characters or program memory gt 4000 lines In this case the software will remove all comments as part of the compression and it will download all NO comments to the controller Note Actual processing time will vary depending upon number of axes communication activity number of threads currently executing etc a i 0 initialize a counter t TIME set an initial time reference loop NO this comment takes time to process this comment takes time to process i it l this comment takes time to process JP loop i lt 1000 MG TIME t display number of samples from initial time reference EN When executed on a DMC 4123 the output from the above program returned a 116 which indicates that it took 116 samples TM 1000 to process the commands from t TIME to MG TIME t This is about 114ms 2ms Now when the comments inside of the loop routine are changed into REM statements a REM statement must always start on a new line the processing is greatly reduced When executed on the same DMC 4123 the output from the program shown below returned a 62 which indicates that it took 62 samples to process the commands from t TIME to MG TIME t This is about 60ms 2ms and about 50 faster than when the comments where downloaded to the controller a i 0 initialize a counter t TIME
136. User Manual Under Voltage Protection If the supply to the amplifier drops below 12 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 12V threshold TA 0 will tell the user whether the supply is in the acceptable range Note If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered ELO Input If the ELO input on the controller is triggered then the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA 3 will change state and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input A7 SDM 44140 D4140 232 DMC 41x3 User Manual
137. V 1 K s sT 1 K Figure 10 4 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Figure 10 5 VOLTAGE SOURCE y i K 1 ow ast 3 CURRENT SOURCE V W P VELOCITY LOOP V W j P Cea g Figure 10 5 Mathematical model of the motor and amplifier in three operational modes Encoder The encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the position resolution is increased to 4N quadrature counts rev Chapter 10 Theory of Operation 170 DMC 41x3 User Manual The model of the encoder can be represented by a gain of Kp 4N 2n count rad For example a 1000 lines rev encoder is modeled as K 638 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65536 and the output voltage range is 10V or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count Digital Filter The digital filter has three element in series PID low pass and a notch filter The transfer function of the filter The transfer function of the filter elements are PID D 2 X 2 4 CZ Z Z 1 es 1B OW pass 2 S j Z B Z z Z z Notch Wig
138. WI NI e Part number ordering example DMC 4113 CARD P2422 ETL ETL Certified DMC 41x3 The DMC 41x3 can be ordered in a configuration that is ETL listed ETL Mark is shown in Figure A 2 on ETL LISTED Il CONFORMS TO CRs UL STD 61010 1 3137106 CERTIFIED TO CAN CSA STD 22 2 NO 61010 1 Figure A 2 ETL Mark with ETL Option Part number ordering example DMC 4143 BOX4 ETL MO Motor Off Jumpers Installed When a jumper is installed on the MO pins the controller will be powered up in the motor off state This option will cause jumper to be installed at the factory Part number ordering example DMC 4123 BOX4 MO D3520 Axis specific ABDC Y EFGH Y Options The following options are the Y configuration options that can be added to the axis specific part numbers Often multiple Y options can be ordered per bank of 4 axis as long as they re separated by a comma Appendices 182 DMC 41x3 User Manual BiSS and SSI BiSS and SSI Absolute Encoder Interface The DMC 41x3 controller can be configured to support BiSS and SSI encoders See the SS and SI commands in the DMC 41x3 Command Reference www galilmc com support manuals com41x3 index html Pin out information is shown below Jn1 Encoder 26 pin HD D Sub Connector SSI or BiSS option Pin Label Description Pin Label Description 1 HALC Hall C 14 FLS Forward Limit Switch Inpu
139. X Using Communication Interrupt The DMC 41x3 provides a special interrupt for communication allowing the application program to be interrupted by input from the user The interrupt is enabled using the Cl command The syntax for the command is Cl n n 0 Don t interrupt Port 2 m Interrupt on lt enter gt Port 2 E2 Interrupt on any character Port 2 nes Clear any characters in buffer The COMINT label is used for the communication interrupt For example the DMC 41x3 can be configured to interrupt on any character received on Port 2 The HCOMINT subroutine is entered when a character is received and the subroutine can decode the characters At the end of the routine the EN command is used EN 1 will re enable the interrupt and return to the line of the program where the interrupt was called EN will just return to the line of the program where it was called without re enabling the interrupt As with any automatic subroutine a program must be running in thread 0 at all times for it to be enabled Example A DMC 41x3 is used to jog the A and B axis This program automatically begins upon power up and allows the user to input values from the main serial port terminal The speed of either axis may be changed during motion by specifying the axis letter followed by the new speed value An S stops motion on both axes Instruction Interpretation AUTO Label for Auto Execute speedA 10000 Initial A speed speedB 10000 Initi
140. X axis in Position tracking mode AC 150000 Set the X axis acceleration to 150000 counts sec2 DC 150000 Set the X axis deceleration to 150000 counts sec2 SP PA WT PA WT PA EN 50000 Set the X axis speed to 50000 counts sec 5000 Command the X axis to abs position 5000 encoder counts 300 2000 Change end point position to 2000 200 8000 Change end point position to 8000 Figure 6 5 demonstrates the use of motion smoothing IT on the velocity profile in this mode The jerk in the system is also affected by the values set for AC and DC Chapter 6 Programming Motion 75 DMC 41x3 User Manual g 3 R g Vertical _ Horizontal ee didt Source Scale div Offset div a m RPA Axis A refi 2000 couri 0 RPA Axis A ref 10000 cous 2 Fae ao xj 2 NS y ao 0 221383 i j el ao A a0 oy N ZN E se f J 0O Be ao 7 Y 4 t 150 ms 1 o 4 42765 COV NSHY ai 0 442765 0 221383 z R R E E 0 221383 ar ar er er er e an an er GE E RE B e K 1 2 3 4 4 Trigger j _ __ a Channel W _RP y Edge x Level 0 counts Kon Mode Repeat v READY RPA djdt_ RPA Figure 6 4 Position and Velocity vs Time msec for Motion 3 Scope Lx A Vertical Horizontal H a didt Source Scale fdv Offset div i Pd MO _RPAAxis Aref 2000 couri 0 Fd fe mM RPA Axis Arefim 10000 co 2 P te e
141. Y when Master 0 Begin jog on Z axis Loop until the variable is set Disengage X and Y when Master 2000 Wait until the Master goes to 2000 Stop the Z axis motion Exit the ECAM mode End of the program The above example shows how the ECAM program is structured and how the commands can be given to the controller Figure 6 14 shows the GalilTools scope capture of the ECAM profile This shows how the motion will be seen during the ECAM cycles The first trace is for the A axis the second trace shows the cycle on the B axis and the third trace shows the cycle of the C axis oe ao NEN p eo ad Pix ifn Ae ERE Figure 6 14 ECAM cycle with Z axis as master Chapter 6 Programming Motion 94 DMC 41x3 User Manual PVT Mode The DMC 41x3 controllers now supports a mode of motion referred to as PVT This mode allows arbitrary motion profiles to be defined by position velocity and time individually on all 8 axes This motion is designed for systems where the load must traverse a series of coordinates with no discontinuities in velocity By specifying the target position velocity and time to achieve those parameters the user has control over the velocity profile Taking advantage of the built in buffering the user can create virtually any profile including those with infinite path lengths Specifying PVT Segments PVT segments must be entered one axis at a time using the
142. a is given by VS _ 100000 _ 06 T 0357 ly 0407 5 Figure A 9 Vector Velocity Profile a 05s VA 2000000 The slew time Ts is given by T D T 2N 0 05 0 307s VS 100000 The total motion time Tt is given by T 2 Ta 0 4075 VS The velocities along the X and Y axes are such that the direction of motion follows the specified path yet the vector velocity fits the vector speed and acceleration requirements For example the velocities along the X and Y axes for the path shown in Figure A 8 are given in Figure A 10 Figure A 10 shows the vector velocity It also indicates the position point along the path starting at A and ending at D Between the points A and B the motion is along the Y axis Therefore Vy Vs and Vx 0 Between the points B and C the velocities vary gradually and finally between the points C and D the motion is in the X direction Figure A 10 Vector and Axes Velocities Chapter 6 Programming Motion 86 DMC 41x3 User Manual Electronic Gearing This mode allows up to 8 axes to be electronically geared to some master axes The masters may rotate in both directions and the geared axes will follow at the specified gear ratio The gear ratio may be different for each axis and changed during motion The command GA XYZW or GA ABCDEFGH specifies the master axes GR x y z w specifies the gear ratios for the slaves where the ratio may be a numbe
143. a encoder failure When the axis is commanded to move a 300 counts the position error will cause the motor command voltage to be increased to a value that will be greater than the OV value 3 volts in this case Once the motor command output is greater than the OV threshold for more than than the 500ms defined by the OT command AND there has been less than 4 counts of change on the encoder then the controller will turn off that axis due to an encoder failure The motor will have moved some distance during this operation but it will be shut down before a full runaway condition occurs Using Encoder Failure to detect a hard stop or stalled motor The encoder failure detection can also be used to detect when an axis is up against a hard stop In this scenario the motor command will be commanded above the OV threshold but because the motor is not moving the controller will detect this scenario as an encoder failure Programmable Position Limits The DMC 41x3 provides programmable forward and reverse position limits These are set by the BL and FL software commands Once a position limit is specified the DMC 41x3 will not accept position commands beyond the limit Motion beyond the limit is also prevented Chapter 8 Hardware amp Software Protection 160 DMC 41x3 User Manual Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog BG XYZ Begin
144. a jumper installed at the MO location the controller will boot up in the motor off state where the amplifier enable signals are toggled to inhibit disable USB Port Baud Rate Jumpers If using the USB port for communication the baud rate is set via jumpers To set the baud rate use the jumper settings as found in Baud Rate Selection pg 52 Master Reset and Upgrade Jumpers Jumpers labeled MRST and UPGD are the Master Reset and Upgrade jumpers respectively When the MRST pins are jumpered the controller will perform a master reset upon a power cycle the reset input pulled down or a push button reset Whenever the controller has a master reset all programs arrays variables and motion control parameters stored in EEPROM will be erased and restored back to factory default settings The UPGD jumper enables the user to unconditionally update the controller s firmware This jumper should not be used without first consulting Galil Step 3 Install the Communications Software After applying power to the controller a PC is used for programming Galil s development software enables communication between the controller and the host device The most recent copy of Galil s development software can be found here http www galilmc com support software downloads ph Step 4 Power the Controller Dangerous voltages current temperatures and energy levels exist in this product and the associated amplifiers and servo motor s
145. a series of lines Note changes on a program line will not be saved unless a lt return gt is given lt cntrl gt P Chapter 7 Application Programming 156 DMC 41x3 User Manual The lt cntrl gt P command moves the editor to the previous line lt cntrl gt l The lt cntrl gt l command inserts a line above the current line For example if the editor is at line number 2 and lt cntrl gt l is applied a new line will be inserted between lines 1 and 2 This new line will be labeled line 2 The old line number 2 is renumbered as line 3 lt cntrl gt D The lt cntrl gt D command deletes the line currently being edited For example if the editor is at line number 2 and lt cntrl gt D is applied line 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q The lt cntrl gt Q quits the editor mode In response the DMC 41x3 will return a colon After the Edit session is over the user may list the entered program using the LS command If no operand follows the LS command the entire program will be listed The user can start listing at a specific line or label using the operand n A command and new line number or label following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation LS List entire program LS 5 Begin listing at line 5 2LS 15 9 List lines 5 thru 9 LS A 9 List line label A thru line 9 LS A A 5 List line label A an
146. ader information and specific blocks of information as specified by the command arguments QR ABCD EFGHST Each argument corresponds to a block of information according to the Data Record Map below If no argument is given the entire data record map will be returned Note that the data record size will depend on the number of axes The following is the byte map for the binary data ADDR 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 TYPE UB UB UB UB UW UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB SW SW Data Record Map Key Acronym Meaning UB Unsigned byte UW Unsigned word SW Signed word SL Single long record UL Unsigned long General Controller Information and Status ITEM 1 Byte of Header 2 Byte of Header 3 Byte of Header 4 Byte of Header sample number general input block 0 inputs 1 8 general input block 1 inputs 9 16 general input block 2 inputs 17 24 general input block 3 inputs 25 32 general input block 4 inputs 33 40 general input block 5 inputs 41 48 general input block 6 inputs 49 56 general input block 7 inputs 57 64 general input block 8 inputs 65 72 general input block 9 inputs 73 80 general output block 0 outputs 1 8 general output block 1 outputs 9 16 general output block 2 outputs 17 24 general output block 3 outputs
147. ains the number of available arrays _DM contains the number of available array elements _AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to specify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation Download Code A Program Label PR1000 Position Relative 1000 BGX Begin PR5000 Position Relative 5000 EN End From Terminal XQ A Execute A 2003 PR5000 Error on Line 3 STOT Tell Error Code 7 Command not valid while running Command not valid while running Change the BGX line to BGX AMX and re download the program XQ A Execute A Program Flow Commands The DMC 41x3 provides instructions to control program flow The controller program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements Event Triggers amp Trippoints To function independently from the host computer the DMC 41x3 can be programmed to make decisions based on the occurrence of an event Such events include waiting for motion to be complete waiti
148. al B speed CI 2 Set Port 2 for Character Interrupt JG speedA speedB Specify jog mode speed for A and B axis BGXY Begin motion PRINT Routine to print message to terminal MG P2 TO CHANGE SPEEDS Print message MG P2 TYPE A OR B MG P2 TYPE S TO STOP JOGLOOP Loop to change Jog speeds JG speedA speedB Set new jog speed JP JOGLOOP EN End of main program COMINT Interrupt routine JP A P2CH A Check for A JP B P2CH B Check for B JP C P2CH S Check for S ZS1 C1I2 JP JOGLOOP Jump if not X Y S A JS NUM speedX val New X speed ZS1 C1I2 JIP PRINT Jump to Print B JS NUM speedY val New Y speed ZS1 C1I2 JP PRINT Jump to Print C ST AMX CI 1 Stop motion on S MG 8 THE END ZS EN 1 End Re enable interrupt NUM Routine for entering new jog speed MG ENTER P2CH S AXIS Prompt for value SPEED N NUMLOOP CI 1 Check for enter Chapter 7 Application Programming 143 DMC 41x3 User Manual NMLP Routine to check input from terminal JP NMLP P2CD lt 2 Jump to error if string JP ERROR P2CD 2 Read value val P2NM EN End subroutine ERROR CI 1 Error Routine MG INVALID TRY AGAIN Error message JP NMLP EN End Output of Data Numeric and String Numerical and string data can be output from the controller using several methods The message command MG can output string and numerical data Also the controller can be commanded to return the values of variables and arrays as well as other information usin
149. an Z p Z p The filter parameters K A C and B are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are K KP KD A KD KP KD C Kl B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD I s a s a where P KP D T KD l KI T 1 1 a In T B where T is the sampling period and B is the pole setting For example if the filter parameters of the DMC 41x3 are KP 16 KD 144 Kl 2 PL 0 75 T 0 001 s the digital filter coefficients are Chapter 10 Theory of Operation 171 DMC 41x3 User Manual K 160 A 0 9 C 2 a 250 rad s and the equivalent continuous filter G s is G s 16 0 144s 2000 s 250 s 250 The notch filter has two complex zeros zand 7 and two complex poles pand The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of the resonance poles The notch poles P and p are programmable and are selected to have sufficient damping It is best to select the notch parameters by the frequency terms The poles and zeros have a frequency in Hz selected by the command NF The real part of the poles is set by NB and the real part of the zeros is set by NZ The most simple procedure for setting the notch filter identify the resonance frequency and set NF to the same value Set NB
150. and in the command reference for details There is no limit on encoder line density however the input frequency to the controller must not exceed 3 750 000 full encoder cycles second 15 000 000 quadrature counts sec For example if the encoder line density is 10 000 cycles per inch the maximum speed is 200 inches second If higher encoder frequency is required please consult the factory The standard encoder voltage level is TTL 0 5v however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 41x3 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 41x3 can accept analog feedback 10v instead of an encoder for any axis For more information see the command AF in the command reference To interface with other types of position sensors such as absolute encoders Galil can customize the controller and command set Please contact Galil to talk to one of our applications engineers about your particular system requirements Watch Dog Timer The DMC 41x3 provides an internal watch dog timer which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AMPEN which can be used to switch the amplifiers off in the event of a serious DMC 41x3 failure The AMPEN output is normally high During power up and if the microprocessor ceases to function properly the AMPEN output will go low The error light
151. and is a monitoring function only and does not generate an error condition See the TA command for detailed information on bit status during error conditions Under Voltage Protection If the supply to the amplifier drops below 18 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 18V threshold NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 20 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the AMP 43540 is a trans conductance amplifier the amplifier will never go into this mode during normal
152. and needs to be reconfigured The motor is running away because the controller is registering the axis is in an inactive and is not attempting to control it s movement See Step 9 Connecting External Amplifiers and Motors pg 29 for configuring the amplifier enable signal 2 The motor and encoder are in opposite polarity causing a positive feedback loop Reversed polarity is when a positive voltage on the motor command line results in negative movement of the motor This will result in a positive feedback loop and a runaway motor The following steps can be taken to detect reverse polarity the A axis is used as an example 1 After connecting your servo motor using either Step 8 Wiring Motors to Galil s Internal Amps pg 23 or Step 9 Connecting External Amplifiers and Motors pg 29 issue the following commands MO A KIA 0 KPA 0 KDA 0 SHA 2 Check your current position by issuing TP A 3 Seta small positive voltage on your motor command line using the OF command use a high enough voltage to get the motor to move This will cause a runaway like condition so have an appropriate OE set see Step B Example OFA 0 5 4 Ifthe motor has not been disabled by O GI disable it by issuing MO A 5 Check the position again by using TP A 6 If TP has increased than the motor command line and encoder are in correct polarity If TP has decreased than the motor command line is in opposite polarity with the encoder I
153. antly different from the response of an activated limit switch When the abort input is activated the controller stops generating motion commands immediately whereas the limit switch response causes the controller to make a decelerated stop NOTE The effect of an Abort input is dependent on the state of the off on error function OE Command for each axis If the Off On Error function is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no longer under servo control If Chapter 3 Connecting Hardware 33 DMC 41x3 User Manual the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running are terminated when a transition in the Abort input is detected This can be configured with the CN command For information see the Command Reference OE and CN ELO Electronic Lock Out Input Used in conjunction with Galil amplifiers this input allows the user the shutdown the amplifier at a hardware level For more detailed information on how specific Galil amplifiers behave when the ELO is triggered see Integrated in the Appendices The ELO input uses the INCOM pin of the I O A D connector For 5 8 axis controllers with two integrated amplifiers the ELO input for axes E H will also use the INCOM pin
154. aracters can be individually separated by using bit wise operations as illustrated in the following example Chapter 7 Application Programming 135 DMC 41x3 User Manual TEST len 123456 Flen FRAC len Flen 10000 Flen len1 Flen amp 00FF len2 Flen amp FF00 100 len3 len amp 000000FF len4 len amp 0000FF00 100 len5 len amp 00FF0000 10000 len6 len amp FF000000 1000000 MG len6 S4 MG len5 S4 MG len4 5S4 MG len3 5S4 MG len2 5S4 MG len1 5S4 EN Begin main program Set len to a string value Define variable Flen as fractional part of variable len Shift Flen by 32 bits IE convert fraction Flen to integer Mask top byte of Flen and set this value to variable len1 Let variable len top byte of Flen Let variable len3 bottom byte of len Let variable len4 second byte of len Let variable lenS third byte of len Let variable len6 fourth byte of len Display len6 as string message of up to 4 chars Display len5 as string message of up to 4 chars Display len4 as string message of up to 4 chars Display len3 as string message of up to 4 chars Display len as string message of up to 4 chars Display len1 as string message of up to 4 chars This program will accept a string input of up to 6 characters parse each character and then display each character Notice also that the values used for maskin
155. as thread 0 To begin execution of the various programs use the following instruction XQ A n Where n indicates the thread number To halt the execution of any thread use the instruction HX n where n is the thread number Note that both the XQ and HX commands can be performed by an executing program The example below produces a waveform on Output 1 independent of a move TASK1 Task1 label ATO Initialize reference time CB1 Clear Output 1 LOOP1 Loop1 label AT 10 Wait 10 msec from reference time SB1 Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference CB1 Clear Output 1 JP LOOP1 Repeat Loop1 TASK2 Task2 label XQ TASK1 1 Execute Task1 LOOP2 Loop2 label PR 1000 Define relative distance BGX Begin motion AMX After motion done WT 10 Wait 10 msec JP LOOP2 IN 2 1 Repeat motion unless Input 2 is low HX Halt all tasks The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 TASK1 is executed within TASK2 Chapter 7 Application Programming 117 DMC 41x3 User Manual Debugging Programs The DMC 41x3 provides commands and operands which are useful in debugging application programs These commands include interrogation commands to monitor program execution determine the state of the controller and the contents of the controllers program array and variable space Operands also contain important status information wh
156. ay counter B Loop counter CD DX I I I 1 Specify contour data I I 1 Increment array counter JP B 1I lt 500 Loop until done CD 0 0 End countour buffer Wait IP Wait CM lt gt 511 Wait until path is done EN End program For additional information about automatic array capture see Chapter 7 Arrays Virtual Axis The DMC 41x3 controller has two additional virtual axes designated as the M and N axes These axes have no encoder and no DAC However they can be commanded by the commands AC DC JG SP PR PA BG IT GA VM VP CR ST DP RP The main use of the virtual axes is to serve as a virtual master in ECAM modes and to perform an unnecessary part of a vector mode These applications are illustrated by the following examples ECAM Master Example Suppose that the motion of the XY axes is constrained along a path that can be described by an electronic cam table Further assume that the ecam master is not an external encoder but has to be a controlled variable This can be achieved by defining the N axis as the master with the command EAN and setting the modulo of the master with a command such as EMN 4000 Next the table is constructed To move the constrained axes simply command the N axis in the jog mode or with the PR and PA commands For example PAN 2000 BGN will cause the XY axes to move to the corresponding points on the motion cycle Sinusoidal Motion Example The x axis must perform a sinusoidal motion of
157. ay memory or variable memory the DMC 41x3 has several useful commands The command DM will return the number of array elements currently available The command DA will return the number of arrays which can be currently defined For example a standard DMC 14113 will have a maximum of 24000 array elements in up to 30 arrays If an array of 100 elements is defined the command DM will return the value 15900 and the command DA will return 29 To list the contents of the variable space use the interrogation command LV List Variables To list the contents of array space use the interrogation command LA List Arrays To list the contents of the Program space use the interrogation command LS List To list the application program labels only use the interrogation command LL List Labels Operands In general all operands provide information which may be useful in debugging an application program Below is a list of operands which are particularly valuable for program debugging To display the value of an operand the message command may be used For example since the operand ED contains the last line of program execution the command MG _ED will display this line number Chapter 7 Application Programming 118 DMC 41x3 User Manual _ED contains the last line of program execution Useful to determine where program stopped _DL contains the number of available labels _UL contains the number of available variables _DA cont
158. back pg 20 2 Select which axis will be using sinusoidal commutation by issuing the BA command 3 Set brushless modulus using the BM configuration command BM is the distance in counts of a single magnetic cycle of the motor This can be calculated by dividing counts revolution of the encoder by the number of pole pairs of the motor For a linear motor the number of encoder counts per magnetic phase may need to be calculated from motor and encoder manufacturers information 4 Try commutating the motor using either BZ or BX command Note that the BZ and BX commands require a single argument which is the user allotted maximum voltage to be applied on the motor command line during the commutation routine Ensure that the command voltage for BZ or BX is sufficient to move the motor a If the commutation fails and TC 1 returns error codes 114 BZ command runawayor 160 BX failure turn off the controller and amplifier and swap motor leads A and B and re perform steps 1 4 b If the commutation fails and TC 1 returns error code 112 BZ timeout try increasing the timeout time with the BZ lt t command t defaults to 1000 msec 5 Once commutation succeeds servo the motor SH and test commutation by jogging the motor slowly JG 1000 BG A a If the motor stalls cogs or runs away turn off the controller and amplifier and swap motor leads A and B and re perform steps 1 4 b If the motor rotates smoothly 360 deg in both directi
159. both AT and WT can be used to have the program execution be held up for n number of samples rather than milliseconds For example WT 400 or WT 400 0 will hold up program execution for 400 msec regardless of what is set for TM By contrast WT 400 1 will hold up program execution for 400 samples For the default TM of 1000 the servo update rate is 976us per sample so the difference between WT n 0 and WT n 1 is minimal The difference comes when the servo update rate is changed With a low servo update rate it is often useful to be able to time loops based upon samples rather than msec and this is where the unscaled WT and AT are useful For example MAIN Label T 250 250us update rate MOVE Label PRX 1000 Position Relative Move BGX Begin Motion MCX Wait for motion to complete WE 2ps Wait 2 samples 500us SB1 Set bit 1 EN End Program In the above example without using an unscaled WT the output would either need to be set directly after the motion was complete or 2 ms after the motion was complete By using WT n 1 and a lower TM greater delay resolution was achieved Chapter 7 Application Programming 122 DMC 41x3 User Manual Conditional Jumps The DMC 41x3 provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition The conditional jump determines if a condition is satisfied and then branches to a ne
160. by two ASCII upper case characters followed by applicable arguments A space may be inserted between the instruction and arguments A semicolon or lt return gt is used to terminate the instruction for processing by the DMC 41x3 command interpreter NOTE If you are using a Galil terminal program commands will not be processed until an lt return gt command is given This allows the user to separate many commands on a single line and not begin execution until the user gives the lt return gt command NOTE All DMC commands are two letters sent in upper case For example the command PR 4000 lt return gt Position relative Chapter 5 Command Basics 65 DMC 41x3 User Manual Implicit Notation PR is the two character instruction for position relative 4000 is the argument which represents the required position value in counts The lt return gt terminates the instruction The space between PR and 4000 is optional For specifying data for the A B C and D axes commas are used to separate the axes If no data is specified for an axis a comma is still needed as shown in the examples below If no data is specified for an axis the previous value is maintained To view the current values for each command type the command followed by a for each axis requested PR 1000 Specify A only as 1000 PR 2000 Specify B only as 2000 PR 3000 Specify C only as 3000 PR 4000 Specify D only as 4000 PR 2000 4000 6000 8000 Specify A
161. cessary signals to run external amplifiers In order to use the full torque limit make sure the AG setting for the axes using external amplifiers are set to 0 or 1 Set the BR command to 1 for any axis that will be setup to run external amplifiers this will disable the hall error protection For more information on connecting external amplifiers see Step 9 Connecting External Amplifiers and Motors in Chapter 2 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will also monitor for illegal Hall states 000 or 111 with 120 phasing The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 1 2 or 3 Th
162. chased a Galil motor with the amplifier it is ready for use No additional setup is necessary To begin the setup of the brushless motor and amplifier it is first necessary to have communications with the motion controller It is also necessary to have the motor hardware connected and the amplifier powered to begin the setup phase After the encoders and motor leads are connected the controller and amplifier need to be configured correctly in software Take all appropriate safety precautions For example set a small error limit ER 1000 a low torque limit TL 3 and set off on Error to 1 for all axes OE 1 The AMP 43240 requires that the hall commutation for a brushless motor be manually configured Details on how to determine the correct commutation for a brushless motor see Application Note 5489 http www galilmc com support appnotes miscellaneous note5489 pdf Brushed Motor Operation The AMP 43240 allows for brush operation To configure an axis for brush type operation connect the 2 motor leads to Phase A and Phase B connections for the axis Connect the encoders homes and limits as required Set the controller into brush axis operation by issuing BR n n n n By setting n 1 the controller will operate in brushed mode on that axis For example BR 0 1 0 0 sets the Y axis as brush type all others as brushless If an axis is set to brush type the amplifier has no need for the Hall inputs These inputs can subsequently be used as
163. cifying a coordinate system For example BG S Begin coordinated sequence S BG TD Begin coordinated sequence T and D axis Controller Response to DATA The DMC 41x3 returns a for valid commands and a for invalid commands For example if the command BG is sent in lower case the DMC 41x3 will return a bg invalid command lower case Chapter 5 Command Basics 66 DMC 41x3 User Manual DMC 41x3 returns a When the controller receives an invalid command the user can request the error code The error code will specify the reason for the invalid command response To request the error code type the command TC1 For example TC1 Tell Code command 1 Unrecognized command Returned response There are many reasons for receiving an invalid command response The most common reasons are unrecognized command such as typographical entry or lower case command given at improper time such as during motion or a command out of range such as exceeding maximum speed A complete listing of all codes is listed in the TC command in the Command Reference section Interrogating the Controller Interrogation Commands The DMC 41x3 has a set of commands that directly interrogate the controller When the command is entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and
164. conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 1 2 or 3 The command will return an eight bit number representing specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA1 will return hall errors on the appropriate axes TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label HAMPERR in their program to amplifier errors As long as a program is executing in thread zero and the AMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition See the TA command for detailed information on bit status during error conditions Hall Error Protection During normal operation the controller should not have any Hall errors Hall errors can be caused by a faulty Hall effect sensor or a noisy environment The state of the Hall inputs can also be monitored through the QH command Hall errors will cause the amplifier to be disabled if OE 1 is set and will cause the controller to enter the AMPERR subroutine if it is included in a running program Under Voltage Protection If the supply to the amp
165. conds of power up it is normal for the red LED to turn on while it is performing a self test If the self test detects a problem such as corrupted memory or damaged hardware the error light will stay on to signal a problem with the board To fix this problem a Master Reset may be required The Master Reset will set Chapter 9 Troubleshooting 164 DMC 41x3 User Manual the controller back to factory default conditions so it is recommended that all motor and O cables be removed for safety while performing the Master Reset Cables can be plugged back in after the correct settings have been loaded back to the controller when necessary To perform a Master Reset find the jumper location labeled MR or MRST on the controller and put a jumper across the two pins Power up with the jumper installed The Self Test will take slightly longer up to Sseconds After the error light shuts off it is safe to power down and remove the Master Reset jumper If performing a Master Reset does not get rid of the error light the controller may need to be sent back to the factory to be repaired Contact Galil for more information Chapter 9 Troubleshooting 165 DMC 41x3 User Manual Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Figure 10 1 COMPUTER CONTROLLER DRIVER ee
166. connect to a DMC controller see this two minute video http www galilmc com learning two minute display php gt video connecting to ethernet controller For connecting using serial see USB Port pg 52 for proper configuration of the Main DMC 41x3 serial port See the GalilSuite manual for using the software to communicate http www galilmc com support manuals galilsuite index html Chapter 2 Getting Started 19 DMC 41x3 User Manual Step 6 Connecting Encoder Feedback The type of feedback the unit is capable of depends on the options ordered Table 2 2 shows the different Encoder feedback types available for Standard DMC 41x3 models and additional feedback types available as options Note that each feedback type has a different configuration command See the Command Reference for full details on how to properly configure each axis Different feedback types can be used on the same controller For instance one axis could be using Standard quadrature and the next could be using SSI on the same DMC unit By default all axis are configured for Standard quadrature Feedback Type Configuration Command Part Number Required Connection Location Standard quadrature CE Standard on all units Encoder Step Dir CE Standard on all units Encoder Standard on all units 1 AF Analog 12 bit Standard 16 bit optional Analog SSI SI SSI option Encoder BISS SS BiSS option Encoder None F Other Contact Galil
167. cording now at rate of 2 msec Begin motion Loop until done Print message End program Play back Initial Counter Exit if done Print Counter Print X position Print Y position Print X error Print Y error Increment Counter Done End Program Chapter 7 Application Programming 141 DMC 41x3 User Manual De allocating Array Space Array space may be de allocated using the DA command followed by the array name DA 0 deallocates all the arrays Input of Data Numeric and String NOTE The IN command has been removed from the DMC 41x3 firmware Variables should be entered by sending data directly from the host application Sending Data from a Host The DMC 41x3 can accept ASCII strings from a host This is the most common way to send data to the controller such as setting variables to numbers or strings Any variable can be stored in a string format up to 6 characters by simply specifying defining that variable to the string value with quotes for example varS STRING Will assign the variable varS to a string value of STRING To assign a variable a numerical value the direct number is used for example varN 123456 Will assign the variable varN to a number of 123 456 All variables on the DMC 41x3 controller are stored with 4 bytes of integer and 2 bytes of fractional data Operator Data Entry Mode The Operator Data Entry Mode provides for un buffered data entry through the aux
168. d additional 5 lines Chapter 7 Application Programming 157 DMC 41x3 User Manual Chapter 8 Hardware amp Software Protection Introduction The DMC 41x3 provides several hardware and software features to check for error conditions and to inhibit the motor on error These features help protect the various system components from damage WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machine Since the DMC 41x3 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 41x3 Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 41x3 includes hardware input and output protection lines for various error and mechanical limit conditions These include Output Protection Lines Amp Enable This signal goes low when the motor off command is given when the position error exceeds the value specified by the Error Limit ER command or when off on error condition is enabled OE1 and the abort command is given Each axis amplifier has separate amplifier enable lines This signal also goes low when the watch dog timer is activated or upon reset NOTE The standard configuration of the AEN signal is high amp enable HAEN Both the polarity and the amplitude can be changed To make these
169. d by sending the command EO 1 to the controller Unsolicited Messages Generated by Controller When the controller is executing a program it may generate responses which will be sent via the USB port or Ethernet handles This response could be generated as a result of messages using the MG command OR as a result of acommand error These responses are known as unsolicited messages since they are not generated as the direct response to a command Messages can be directed to a specific port using the specific Port arguments see the MG and CF commands in the Command Reference If the port is not explicitly given or the default is not changed with the CF command unsolicited messages will be sent to the default port The default port is the main serial port When communicating via an Ethernet connection the unsolicited messages must be sent through a handle that is not the main communication handle from the host The GalilTools software automatically establishes this second communication handle The controller has a special command CW which can affect the format of unsolicited messages This command is used by Galil Software to differentiate response from the command line and unsolicited messages The command CW1 causes the controller to set the high bit of ASCII characters to 1 of all unsolicited characters This may cause characters to appear garbled to some terminals This function can be disabled by issuing the command CW2 For more informa
170. d from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 kOfresistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal is defaulted to 5V high amp enable the amplifier enable signal will be high when the controller expects the amplifier to be enabled If the amplifier requires a different configuration it is recommended it is ordered with the desired configuration see ordering options here Pin outs for the amplifier enable signal is found on the 26 pin D sub connector Jn1 Encoder 26 pin HD D Sub Connector Female pg 188 For re configuring the DMC 41x3 for a different amplifier enable option see Amplifier Enable pg 45 Once the amplifier enable signal is correctly wired issuing a MO will disable the amplifier and an SH will enable it Step C Connect the Encoders optional for stepper systems See Step 6 Connecting Encoder Feedback pg 20 Step D Connect the Command Signals Chapter 2 Getting Started 30 DMC 41x3 User Manual The DMC has two ways of controlling amplifiers 1 Using a motor command line 10V analog output The motor and the amplifier may be configured in torque or v
171. d with the default TM of 1000 Velocity counts second Position counts v t 1000 1 1000 p t 1000 1 1000 a v 25 pone p 0 to 25 57 v 5 _ p 25 to 5 151 V 75 9375 p 5 to 75 214 v 1 dont p 75 to 1 245 v 1 25 337E p 1 to 1 25 245 v 1 5 JEO p 1 25 to 1 5 214 v 1 75 jE p 1 5 to 1 75 151 V2 p 1 75 to 2 57 The DMC program is shown below and the results can be seen in Figure 6 16 Chapter 6 Programming Motion 96 DMC 41x3 User Manual INSTRUCTION INTERPRETATION PVT Label PVX 57 437 256 Incremental move of 57 counts in 256 samples with a final velocity of 437 counts sec PVX 151 750 256 Incremental move of 151 counts in 256 samples with a final velocity of 750 counts sec PVX 214 937 256 Incremental move of 214 counts in 256 samples with a final velocity of 937 counts sec PVX 245 1000 256 Incremental move of 245 counts in 256 samples with a final velocity of 1000 counts sec PVX 245 937 256 Incremental move of 245 counts in 256 samples with a final velocity of 937 counts sec PVX 214 750 256 Incremental move of 214 counts in 256 samples with a final velocity of 750 counts sec PVX 151 437 256 Incremental move of 151 counts in 256 samples with a final velocity of 437 counts sec PVX 57 0 256 Incremental move of 57 counts in 256 samples with a final velocity of O counts sec PVX 0 0 0 Termination of PVT bu
172. de vl v1 JS L Switch direction EN End subroutine L PR vl v1 BGX Define X Y Begin X AMX BGY AMY After motion on X Begin Y EN End subroutine Stack Manipulation It is possible to manipulate the subroutine stack by using the ZS command Every time a JS instruction interrupt or automatic routine such as POSERR or LIMSWI1 is executed the subroutine stack is incremented by 1 Normally the stack is restored with an EN instruction Occasionally it is desirable not to return back to the program line where the subroutine or interrupt was called The ZS1 command clears 1 level of the stack This allows the program sequencer to continue to the next line The ZSO command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is often desirable to restart the program sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of the LIMSWI routine Auto Start Routine The DMC 41x3 has a special label for automatic program execution A program which has been saved into the controller s non volatile memory can be automatically executed upon power up or reset by beginning the program with the label HAUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 41x3 program s
173. design of control systems System Design and Compensation The closed loop control system can be stabilized by a digital filter which is preprogrammed in the DMC 41x3 controller The filter parameters can be selected by the user for the best compensation The following discussion presents an analytical design method The Analytical Method The analytical design method is aimed at closing the loop at a crossover frequency Wc with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Consider a system with the following parameters K 0 2 Nm A Torque constant J 2 107 kg m System moment of inertia R 2 Q Motor resistance K 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of theDMC 41x3 outputs 10V for a 16 bit command of 32768 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of we 500 rad s and a phase margin of 45 degrees The first step is to develop a mathematical model of the system as discussed in the previous system Motor M s P I Kt Js2 1000 s2 Amp K 2 Amp V DAC Ky 10 32768 0003 Encoder K 4N 2n 636 ZOH H s 2000 s 2000 Compensation Filter G s P sD Chapter 10 Theory of Operation 174 DMC 41x3 User Manual The next step is to combine all the system elements with the exception of G s into one
174. detected and sets the encoder reading at this point to zero The 4 different motion possibilities for the home sequence are shown in the following table Direction of Motion Switch Type CN Setting Initial _HMX state Stage 1 Stage 2 Stage 3 Normally Open CN 1 1 Reverse Forward Forward Normally Open CN 1 0 Forward Reverse Forward Normally Closed CN 1 0 Forward Reverse Forward Normally Closed CN 1 1 Reverse Forward Forward Example Homing Instruction Interpretation HOME Label CN 1 Configure the polarity of the home input AC 1000000 Acceleration Rate DC 1000000 Deceleration Rate SP 5000 Speed for Home Search HM Home BG Begin Motion AM After Complete MG AT HOME Send Message EN End Figure 6 22 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 Chapter 6 Programming Motion 112 DMC 41x3 User Manual HOME SWITCH _HMX 0 _HMX 1 POSITION VELOCITY MOTION BEGINS IN H FORWARD i DIRECTION i POSITION VELOCITY MOTION CHANGES DIRECTION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD INDEX i POSITION i INDEX PULSES i i POSITION Figure 6 22 Homing Sequence for Normally Closed Switch and CN 1 Example Find Edge EDGE Label AC 2000000 Acceleration rate DC 2000000 Deceleration rate SP 8000 Speed FE Find edge command BG Begi
175. dmc 36 0000 36 0000 Example Working with Arrays Array DM speeds 8 DM other 256 JS zeroAry speeds 0 JS zeroAry other 0 EN zeroAry a b 0 b b 1 JP zeroAry b lt a 1 EN Example Abstracting Axes Axes JS runMove 0 10000 1000 100000 100000 MG Position JS EN runMove aasta PR a SPva C AC a d DCea 6 BG a MC a EN TP a Chapter 7 Application Programming 131 DMC 41x3 User Manual Example Local Scope Local JS POWER 2 2 MG JS JS POWER 2 16 MG JS JS POWER 2 8 MG JS POWER NO base a exp c 1 unpassed v IF b 0 special EN 1 ENDIF IF b lt 0 specie case exponent 0 invert result d 1 b G ABS b ELSE d 0 ENDIF PWRHLPR c c a b b 1 JP PWRHLPR b gt 0 IF d 1 if inversion required c 1 c ENDIF EN c Executed program from programl dmc 4 0000 65536 0000 0 0039 Example Recursion although the stack depth is only 16 Galil DMC code does support recursion JS AxsInfo 0 MG Z22 0 Recursed through JS stacks EN AxsInfo NO axis 1 List info for h a b a 41 1000000 convert to Galil String MG b S1 Axis N MG F8 0 Position TP h Errori TE h Torgues _ TT h F1 4 IF a 7 recursion exit condition EN 1 ENDIF JS AxsInfo a 1 stack uf 1 EN JS 1 as recursion closes add up stack depths Executed program from programl dmc
176. e Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which is designed to help the stability and accuracy Typically such a filter produces in addition to the proportional gain damping and integrator The combination of the three functions is referred to as a PID filter The filter parameters are represented by the three constants KP KI and KD which correspond to the proportional integral and derivative term respectively The damping element of the filter acts as a predictor thereby reducing the delay associated with the motor response The integrator function represented by the parameter KI improves the system accuracy With the KI parameter the motor does not stop until it reaches the desired position exactly regardless of the level of friction or opposing torque The integrator also reduces the system stability Therefore it can be used only when the loop is stable and has a high gain The output of the filter is applied to a digital to analog converter DAC The resulting output signal in the range between 10 and 10 Volts is then applied to
177. e Hello to handle 3 TP EF will send the z axis position to handle 6 Chapter 4 Software Tools and Communication 54 DMC 41x3 User Manual Multicasting A multicast may only be used in UDP IP and is similar to a broadcast where everyone on the network gets the information but specific to a group In other words all devices within a specified group will receive the information that is sent in a multicast There can be many multicast groups on a network and are differentiated by their multicast IP address To communicate with all the devices in a specific multicast group the information can be sent to the multicast IP address rather than to each individual device IP address All Galil controllers belong to a default multicast address of 239 255 19 56 The controller s multicast IP address can be changed by using the IA gt u command Using Third Party Software Galil supports DHCP ARP BOOT P and Ping which are utilities for establishing Ethernet connections DHCP is a protocol used by networked devices clients to obtain the parameters necessary for operation in an Internet Protocol network ARP is an application that determines the Ethernet hardware address of a device at a specific IP address BOOT P is an application that determines which devices on the network do not have an IP address and assigns the IP address you have chosen to it Ping is used to check the communication between the device at a specific IP address and the h
178. e ao je el amp x A F gmi m 0 221383 0 D Fi ao w 4 42765 Sil E J m 0 442765 2 iF YP ao b salen Sa EN PER im y 0 221383 3 A j a FA 4 J ao m 0 221383 S 4 f 150m a e i d X Pj s3 Ld Trigger if Channel Ml RPA Edge Level Ocounts a Mode Repeat m READY FPA JS RFA Figure 6 5 Position and Velocity vs Time msec for Motion 3 with IT 0 1 Note the controller treats the point where the velocity passes through zero as the end of one move and the beginning of another move IT is allowed however it will introduce some time delay Trippoints Most trippoints are valid for use while in the position tracking mode There are a few exceptions to this the AM and MC commands may not be used while in this mode It is recommended that AR MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position Command Summary Position Tracking Mode COMMAND DESCRIPTION AC n n n n n n n n Acceleration settings for the specified axes AP n n n n n n n n trippoint that holds up program execution until an absolute position has been reached DC n n n n n n n n Deceleration settings for the specified axes Fon n n n n n n n trippoint to hold up program execution until n number of counts have passed in the forward direction Only one axis at a time may be specified Ron n n n n n n n trippoint to hold up program execution unt
179. e command will return an eight bit number representing specific conditions TA 0 will return errors with regard to under voltage over voltage over current and over temperature TA 1 will return hall errors on the appropriate axes TA 2 will monitor if the amplifier current exceeds the continuous setting and TA 3 will return if the ELO input has been triggered The user also has the option to include the special label HAMPERR in their program to handle soft or hard errors As long as a program is executing in thread zero and the AMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Hall Error Protection During normal operation the controller should not have any Hall errors Hall errors can be caused by a faulty Hall effect sensor or a noisy environment The state of the Hall inputs can also be monitored through the QH command Hall errors will cause the amplifier to be disabled if OE 1 is set and will cause the controller to enter the AMPERR subroutine if it is included in a running progra
180. e least filtering resulting in trapezoidal velocity profiles Larger values of the smoothing parameters imply heavier filtering and smoother moves Note that KS is valid only for step motors Homing The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference This reference is connected to the Home input line The HM command initializes the motor to the encoder index pulse in addition to the Home input The configure command CN is used to define the polarity of the home input The Find Edge FE instruction is useful for initializing the motor to a home switch The home switch is connected to the Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew speed and slew until a transition is detected on the Homing line The motor will then decelerate to a stop A high deceleration value must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch The Home HM command can be used to position the motor on the index pulse after the home switch is detected This allows for finer positioning on initialization The HM command and BG command causes the following sequence of events to occur Stage 1 Upon begin the motor accelerates to the slew speed specified by the JG or SP commands The direction of its motion is determined by the state of the homing input If _HMX reads 1 initially the motor will go in t
181. e m m a a 4g I DDt PA DDD Dw an JP ilt anl filtered output Use this instead of AN 1 1 AN 1 set initial value k1 k2 1 this condition must be met use division of m 2 n for elimination of round off increase kl less filtering increase k2 more filtering 32 64 k2 32 64 O set initial time reference oop calculate filtered output and then way 2 samples from last time reference last AT 2 1 or ATO 1 k1 AN 1 k2 an1 AT 2 1 loop Chapter 7 Application Programming 151 DMC 41x3 User Manual Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal which activates the cutter Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 2m inches and it corresponds to 4000 quadrature one inch of travel equals 4000 2n 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to 11 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Figure 7 1 The prog
182. e protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the AMPERR routine if included in the program on the controller A1 AMP 430x0 D3040 D3020 203 DMC 41x3 User Manual A2 AMP 43140 D3140 Description The AMP 43140 resides inside the DMC 41x3 enclosure and contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 VDC input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 kHz The AMP 43140 can be ordered to have a 100mA maximum current output where the gain of the amplifier is 10mA V Order as D3140 100mA The BOX option is required when the AMP 43140 is ordered with the DMC 41x3 NOTE Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation DMC 4143 GALL MOTION CONTROL Figure A2 1 DMC 4143 D3140 BOX4 DMC 4143 with AMP 4
183. e the motor see Chapter 5 Command Basics and Chapter 6 Programming Motion pg 69 for details Step 10 Tune the Servo System Adjusting the tuning parameters is required when using servo motors A given set of default PID s is provided but are not optimized and should not be used in practice For the theory of operation and a full explanation of all the PID and other filter parameters see Chapter 10 Theory of Operation pg 166 For additional tuning resources and step by step tuning guides see the following Application Notes Manual Tuning Methods http www galilmc com support appnotes optima note3413 pdf Manual Tuning using the Velocity Zone method http www galilmc com support appnotes miscellaneous note5491 pdf Autotuning Tools GalilSuite http www galilmc com support manuals galilsuite tuner html Chapter 2 Getting Started 31 DMC 41x3 User Manual Chapter 3 Connecting Hardware Overview The DMC 41x3 provides optoisolated digital inputs for forward limit reverse limit home and abort signals The controller also has 8 optoisolated uncommitted inputs for general use as well as 8 optoisolated outputs and 8 analog inputs configured for voltages between 10 volts 4183 Controllers with 5 or more axes have an additional 8 optoisolated inputs and an additional 8 optoisolated outputs This chapter describes the inputs and outputs and their proper connection Overview of Optoisolated Inputs Limit
184. ected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detecting the transition in the logic state on the Home Input the motor will decelerate to a stop at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of HV counts sec When the logic state changes again the motor moves forward in the direction of increasing encoder count at the same speed until the controller senses the index pulse After detection it decelerates to a stop moves back to the index and defines this position as 0 The logic state of the Home input can be interrogated with the command MG_HMxX This command returns a 0 or 1 if the logic state is low or high respectively The state of the Home input can also be interrogated indirectly with the TS command For examples and further information about Homing see command HM FI FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state The ABRT input uses the INCOM pin of the O A D connector For 5 8 axis controllers with two integrated amplifiers the ABRT input for axes E H will also use the INCOM pin of the I O A D connector NOTE The response of the abort input is signific
185. ed within other IF conditional statements This technique is known as nesting and the DMC 41x3 allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to specify a variety of different cases for branching Command Format IF ELSE and ENDIF Format Description IF conditional statement s Execute commands proceeding IF command up to ELSE commana if conditional statement s is true otherwise continue executing at ENDIF command or optional ELSE command ELSE Optional command Allows for commands to be executed when argument of IF command evaluates not true Can only be used with IF command ENDIF Command to end IF conditional statement Program must have an ENDIF command for every IF command Example using IF ELSE and ENDIF TEST BT 473 MG WAITING FOR INPUT 1 LOOP JP LOOP EN ININT IF IN 1 0 IF IN 2 0 MG INPUT 1 AND INPUT 2 ARE ACTIVE ELSE MG ONLY INPUT 1 IS ACTIVE ENDIF ELSE MG ONLY INPUT 2 IS ACTIVE ENDIF WAIT JP WAIT IN 1 0 RIO INPUT 2 IN 2 0 Subroutines Begin Main Program TEST Enable input interrupts on input 1 and input 2 Output message Label to be used for endless loop Endless loop End of main program Input Interrupt Subroutine IF conditional statement based on input 1 2 IF conditional statement executed if 1 IF conditional true Message to be
186. elocity mode In the torque mode the amplifier gain should be such that a 10V signal generates the maximum required current In the velocity mode a command signal of 10V should run the motor at the maximum required speed 2 Using step 0 5V PWM and direction 0 5V toggling line this is referred to as step dir for short Pin outs for the command signals are found under the 26 pin D sub connector Jn1 Encoder 26 pin HD D Sub Connector Female 188 For full electrical specifications refer to External Amplifier Interface pg 45 To configure the command signal type and other configuration commands see Table 2 12 below for a brief synopsis For a full list of configuration commands see the Command Reference Step E Issue the appropriate configuration Commands Command Description The motor type command configures what type of control method to use MT switches axis between motor command or step dir options TL Servo only Limits the motor command line s continuous output in Volts TK Servo only Limits the motor command line s peak output in Volts Table 2 12 Brief listing of most commonly used configuration commands for the motor command and step dir lines Step F If using a servo motor continue to Step 10 Tune the Servo System pg 31 If using a stepper motor skip to Step G Step G Enable and use your motor A SH will enable the external amplifier once enabled you can send DMC motion commands to mov
187. ents As shown in Figure 1 5 the DMC 41x3 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Power Supply Amplifier Driver Computer DMC 41x3 Controller Figure 1 5 Elements of Servo Systems Motor A motor converts current into torque which produces motion Each axis of motion requires a motor sized properly to move the load at the required speed and acceleration Galil s MotorSizer Web tool can help you with motor sizing www galilmc com support motorsizer The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step motors the controller can be configured to control full step half step or microstep drives An encoder is not required when step motors are used Other motors and devices such as Ultrasonic Ceramic motors and voice coils can be controlled with the DMC 41x3 Amplifier Driver For each axis the power amplifier converts a 10 volt signal from the controller into current to drive the motor For stepper motors the amplifier converts step and direction signals into current The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation is required or the controller must be configured to provide sinusoidal commutation The amplifiers may be either pulse w
188. equences The controller can monitor several important conditions in the background These conditions include checking for the occurrence of a limit switch a defined input position error or a command error Automatic monitoring is enabled by inserting a special predefined label in the applications program The pre defined labels are SUBROUTINE DESCRIPTION LIMSWI Limit switch on any axis goes low ININT Input specified by Il goes low POSERR Position error exceeds limit specified by ER MCTIME Motion Complete timeout occurred Timeout period set by TW command CMDERR Bad command given AUTO Automatically executes on power up AUTOERR Automatically executes when a checksum is encountered during AUTO start up Check error condition with _RS bit O for variable checksum error bit 1 for parameter checksum error bit 2 for program checksum error bit 3 for master reset error there should be no program AMPERR Error from internal Galil amplifier Chapter 7 Application Programming 126 DMC 41x3 User Manual For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the POSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt subroutine When the specified input occurs the program will be executed automatically NO
189. er AMP SDM Power Axis A D AMP SDM Power Axis E H Axis A D Axis E H 2 pin Molex near bottom 6 or 4 pin Molex 6 or 4 pin Molex X X X X X X X X x X X X X X x X X X X X X Table 2 1 Available power connectors based upon option ordered In this configuration the amplifiers are sharing power Their bus voltages and grounds must be from the same source to prevent damage to the controller and amplifiers NOTE If the 12V option is ordered the DMC should be upgraded to ISCNTL and powered accordingly The DMC 41x3 power should never be plugged in HOT Always power down the power supply before installing or removing the power connector to the controller NOTE Any E Stop or Disconnect switches should be installed on the AC input to the DC power supply Relays and or other switches should not be installed on the DC line between the Galil and the Power supply This is shown in Figure 2 7 with a DMC 4183 and 2 AMP 43040 s BREAKER OR RELAY L L V N N V d POWER SUPPLY SERVO DMC 41X3 Figure 2 7 Wiring for DMC 4183 with Amplifiers The green power light indicator should go on when power is applied Step 5 Establish Communications with Galil Software See Ethernet Configuration pg 53 for details on using Ethernet with the DMC 41x3 To configure your NIC card using Windows to
190. er are identical for the brush and brushless operation The amplifier gain command AG can be set to 0 1 or 2 corresponding to 0 4 0 7 and 1 0 A V In addition to the gain peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A1 2 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts AU and AW commands With the AMP 43040 and 43020 the user is also given the ability to choose between normal and high current bandwidth AU In addition the user can calculate what the bandwidth of the current loop is for their specific combination AW To select normal current loop gain for the X axis and high current loop gain for the Y axis issue AU 0 1 The command AW is used to calculate the bandwidth of the amplifier using the basic amplifier parameters To calculate the bandwidth for the X axis issue AWX v n where v represents the DC voltage input to the card represents the inductance of the motor in millihenries and n represents O or 1 for the AU setting NOTE For most applications unless the motor has more than 5 mH of inductance wit
191. erence for current gains of Galil s internal amplifiers The amplifier gain can also be used to change the ratio of outputting amps of the amplifier per commanded volts of the controller This is another way to limit the amount of current but can also maintain the resolution of the 10V motor command line Step B Set the Error Limit Chapter 2 Getting Started 21 DMC 41x3 User Manual When ER error limit and OE off on error is set the controller will automatically shut down the motors when excess error TE gt ER has occurred This is an important safety feature during set up as wrong polarity can cause the motor to run away see Step C below for more information regarding runaway motors NOTE Off on error OE requires the amplifier enable signal to be connected from the controller to the amplifier This is automatic when using Galil s internal amplifiers see Step 9 Connecting External Amplifiers and Motors pg 29 for external amplifiers Step C Understanding and Correcting for Runaway Motors A runaway motor is a condition for which the motor is rotating uncontrollably near it s maximum speed in a single direction This is often caused by one of two conditions 1 The amplifier enable signal is the incorrect logic required by the amplifier This is only applicable to external amplifiers only If the motor is in a MO state when the motor runs away the MO command is toggling your amplifier on enabled
192. es toggling LIMSWI command errors POSERR and amplifier errors TA AMPERR and more For a full list of features and how to program each see Chapter 8 Hardware amp Software Protection pg 158 Step 8 Wiring Motors to Galil s Internal Amps Table 2 4 below provides a general overview of the connections required for most systems connecting to a DMC internal amplifier and controller system Following the table is a step by step guide on how to do so Motor Type Required Connections Brushless servo motor e Power to controller and internal amplifier e Motor power leads to internal amplifiers e Encoder feedback e Hall sensors Not required for sinusoidal amplifiers Brushed servo motor e Power to controller and internal amplifier e Motor power leads to internal amplifiers e Encoder feedback Stepper motor e Power to controller and internal amplifier e Motor power leads to internal amplifier e Encoder feedback optional Table 2 4 Synopsis of connections required to connect a motor to Galil s internal amplifiers Step A Connect the encoder feedback optional for steppers See Step 6 Connecting Encoder Feedback pg 20 Step B Connect the motor power leads and halls if required to the internal amplifiers Table 2 5 lists each of Galil s internal amplifiers and where to find documentation for pin outs of the amplifier connections and electrical specifications In addition it describes the commutati
193. eter specifications for describing the coordinated axes and the tangent axis VM m n p m n specifies coordinated axes p specifies tangent axis such as X Y Z W p N turns off tangent axis Before the tangent mode can operate it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m n command m defines the scale factor in counts degree and n defines the tangent position that equals zero degrees in the coordinated motion plane The operand _TN can be used to return the initial position of the tangent axis Chapter 6 Programming Motion 82 DMC 41x3 User Manual Example Assume an XY table with the Z axis controlling a knife The Z axis has a 2000 quad counts rev encoder and has been initialized after power up to point the knife in the Y direction A 180 circular cut is desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion is CCW ending at 3000 0 Note that the 0 position in the XY plane is in the X direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First X Y and Z are driven to the starting point and later the cut is performed Assume that the knife is engaged with output bit 0 EXAMPLE XYZ 2000 360 500 R 3000 0 180 BO A 3000 0 TN G p Ua p vaosQqHs x K N G ALL DONE Gl Example program XY coordinate with Z as tangent 2000 360 counts degree pos
194. executed if 2 IF conditional is true ELSE command for 2 IF conditional statement Message to be executed if 2 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 1 IF conditional statement is false End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 2 are not active End Input Interrupt Routine without restoring trippoints A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program location where the subroutine was called unless the subroutine stack is manipulated as described in the following section Example An example of a subroutine to draw a square 500 counts per side is given below The square is drawn at vector position 1000 1000 Chapter 7 Application Programming 125 DMC 41x3 User Manual M Begin Main Program CB1 Clear Output Bit 1 pick up pen VP 1000 1000 LE BGS Define vector position move pen AMS Wait for after motion trippoint SB1 Set Output Bit 1 put down pen JS Square CB1 Jump to square subroutine EN End Main Program Square Square subroutine v1 500 JS L Define length of si
195. f q and a traversed angle d The notation for q is that zero corresponds to the positive horizontal direction and for both q and d the counter clockwise CCW rotation is positive Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE The motion can be initiated with a Begin Sequence BGS command Once motion starts additional segments may be added The Clear Sequence CS command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or AB1 ST stops motion at the specified deceleration AB1 aborts the motion instantaneously The Vector End VE command must be used to specify the end of the coordinated motion This command requires the controller to decelerate to a stop following the last motion requirement If a VE command is not given an Abort AB1 must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 41x3 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or _LM returns the available spaces for motion segments that can be sent to the buffer 511 returned means the buffer is empty and 511 segments can be sent A zero means the buffe
196. f the system has reverse polarity take the following steps to correct for it Brushed Motor Choose one of the following 1 Reverse the direction of the motor leads by swapping phase A and phase B 2 Reverse the direction of the encoder see Step 6 Connecting Encoder Feedback pg 20 Brushless Motor Choose one of the following Chapter 2 Getting Started 22 DMC 41x3 User Manual 1 Reverse direction of the encoder see Step 6 Connecting Encoder Feedback pg 20 2 Reverse direction of the motor by swapping any two motor phases or two hall sensors if using a trapezoidal amplifier The motor will now have to be re commutated by using either the Trapezoidal or Sinusoidal method see Step 8a Commutation of 3 phased Brushless Motors pg 24 Non wiring Options You can reverse the direction of the motor command line by using the MT command or reverse direction of the feedback by using the CE command standard quadrature and step direction feedback only It is not recommended to correct for polarity using configuration commands as an unexpected condition may arise where these settings are accidentally over ridden causing a runaway See the Command Reference for more details Step D Other Safety Features This section only provides a brief list of safety features that the DMC can provide Other features include Encoder Failure Detection OA OT OV Automatic Subroutines to create an automated response to events such as limit switch
197. ffer BTX Begin PVT EN Actual Velocity and Position vs Time 1200 5 1400 1200 z 1000 8 1000 F g 800 2 E aou 8 Velocit S 600 een 8 600 Position 2 400 8 8 400 amp gt 204 200 0 0 oe 8 8S 8S amp o S FEES SIE SESS Time Samples Figure 6 16 Actual Velocity and Position vs Time of Parabolic Velocity Profile Multi Axis Coordinated Move Many applications require moving two or more axes in a coordinated move yet still require smooth motion at the same time These applications are ideal candidates for PVT mode In this example we will have a 2 dimensional stage that needs to follow a specific profile The application requires that the certain points be met however the path between points is not important Snooth motion between points is critical X axis Y axis 500 500 1500 5000 2500 4000 3300 4200 7300 3300 The resultant DMC program is shown below The position points are dictated by the application requirements and the velocities and times were chosen to create smooth yet quick motion For example in the second segment the B axis is slowed to 0 at the end of the move in anticipation of reversing direction during the next segment INSTRUCTION INTERPRETATION PVT Label PVA 500 2000 500 1 point in Figure 6 18 A axis PVB 500 5000 500 1 point in Figure 6 18 B axis PVA 1000 4000 1200 2 point in Figure 6 18 A axis
198. for more information This option is only valid with the AMP 43140 Part number ordering example DMC 4143 BOX4 D3140 SSR 100mA 100mA Maximum Current output for AMP 43140 The 100mA option configures the AMP 43140 D3140 for 10mA V gain with a maximum current output of 100mA This option is only valid with the AMP 43140 Part number ordering example DMC 4143 BOX4 ISCNTL D3140 100mA HALLF Filtered Hall Sensor Inputs The HALLF option will place a capacitor between the hall input and digital GND to filter unwanted noise This results in cleaner more reliable hall sensor reads The HALLF option is only available for Galil s internal PWM amplifiers Part number ordering example DMC 4143 BOX4 D3040 HALLF Appendices 184 DMC 41x3 User Manual Power Connector Part Numbers Overview The DMC 41x3 uses Molex Mini Fit Jr Receptacle Housing connectors for connecting DC Power to the Amplifiers Controller and Motors This section gives the specifications of these connectors For information specific to your Galil amplifier or driver refer to the specific amplifier driver in the Integrated Components section Molex Part Numbers There are 3 different Molex connectors used with the DMC 41x3 The type of connectors on any given controller will be determined be the Amplifiers Drivers that were ordered Below are tables indicating the type of Molex Connectors used and the specific part numbers used on each Amplifier or D
199. g are represented in hexadecimal as denoted by the preceding S For more information see section Sending Messages To illustrate further if the user types in the string TESTME at the input prompt the controller will respond with the following T Response from command MG len6 S4 E Response from command MG len5 S4 S Response from command MG len4 S4 T Response from command MG len3 S4 M Response from command MG len2 S4 E Response from command MG len1 S4 Functions FUNCTION DESCRIPTION SIN n Sine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution COS n Cosine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution TAN n Tangent of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution ASIN n Arc Sine of n between 90 and 90 Angle resolution in 1 64000 degrees ACOS n Arc Cosine of n between 0 and 180 Angle resolution in 1 64000 degrees ATAN n Arc Tangent of n between 90 and 90 Angle resolution in 1 64000 degrees COM n 1 s Complement of n ABS n Absolute value of n FRAC n Fraction portion of n INT n Integer portion of n RND n Round of n Rounds up if the fractional part of n is 5 or greater SQR n Square root of n Accuracy is 004 IN n Return digital input at general input n where n starts at 1 OUT n Return digital output at genera
200. g program ALT Label for alternative program DP 0 0 Define Position of X and Y axis to be 0 LMXY Define linear mode between X and Y axes LI 4000 0 lt 4000 gt 1000 Specify first linear segment with a vector speed of 4000 and end speed 1000 LI 1000 1000 lt 4000 gt 1000 Specify second linear segment with a vector speed of 4000 and end speed 1000 LI 0 5000 lt 4000 gt 1000 Specify third linear segment with a vector speed of 4000 and end speed 1000 LE End linear segments BGS Begin motion sequence EN Program end Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS to be scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided in half Chapter 6 Programming Motion 78 DMC 41x3 User Manual Command Summary Linear Interpolation COMMAND DESCRIPTION LM XYZW Specify axes for linear interpolation LM ABCDEFGH same controllers with 5 or more axes LM Returns number of available spaces for linear segments in DMC 41x3 sequence buffer Zero means buffer full 511 means buffer empty LI x y Z w lt n Specify incremental distances relative to current position and assign vector speed n
201. g the interrogation commands the interrogation commands are described in chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is result In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Position of A is TPA Specifying the Port for Messages The port can be specified with the specifier P1 for the main USB P2 for auxiliary serial port or En for the Ethernet port MG P2 Hello World Sends message to Auxiliary Port Formatting Messages String variables can be formatted using the specifier Sn where n is the number of characters 1 thru 6 For example MG STR S3 This statement returns 3 characters of the string variable named STR Numeric data may be formatted using the Fn m expression following the completed MG statement Sn m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is result F5 2 If the value of the
202. gain for the current loop on the amplifier The goal is to set the gain as high as possible without causing the current loop to go unstable In most cases AU 0 should not be used Table A4 2 indicates the recommended AUn m settings for 24 and 48 VDC power supplies To set the AU command put the axis in a motor off MO state set the preferred AG setting and then set the AU setting To verify that the current loop is stable set the PID s to O KP KD and KI and then enable the axis SH An unstable current loop will result in oscillations of the motor or a high frequency buzz from the motor Vsupply VDC Inductance L mH m 24 0 24 L lt 1 1 24 1 lt L lt 2 3 2 24 2 3 lt L lt 4 2 3 24 4 2 lt L 4 48 0 48 L lt 2 4 1 48 2 4 lt L lt 4 2 2 48 4 2 lt L lt 7 3 48 7 lt L 4 Table A4 2 Amplifier Current Loop Gain Settings A4 AMP 435x0 D3540 D3520 216 DMC 41x3 User Manual Setting Peak and Continuous Current TL and TK To set TL and TK for a particular motor find the continuous current and peak current ratings for that motor and divide that number by the amplifier gain For example a particular motor has a continuous current rating of 2 0A and peak current rating of 5 0 A With an AG setting of 1 the amplifier gain of the AMP 43540 is 0 8A V TL setting 2 0A 0 8A V 2 5V TL n 2 5 TK setting 5 0A 0 8A V 7 5V TK n 6 25 Scope o vertical H
203. ger n N Suppresses carriage return line feed Sn Sends the first n characters of a string variable where n is 1 thru 6 Displaying Variables and Arrays Variables and arrays may be sent to the screen using the format variable or array x For example v1 returns the value of v1 Example Printing a Variable and an Array element Instruction DISPLAY DM posA 7 PR 1000 BGX AMX vl _TPA posA 1 _TPA vl Interpretation Label Define Array posA with 7 entries Position Command Begin After Motion Assign Variable v1 Assign the first entry Print v1 Interrogation Commands The DMC 41x3 has a set of commands that directly interrogate the controller When these command are entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The Chapter 7 Application Programming 145 DMC 41x3 User Manual format of the returned data can be changed using the Position Format PF and Leading Zeros LZ command For a complete description of interrogation commands see Chapter 5 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by theses interrogation commands BL LE DE PA DP 2 PR 2 EM TN FEE VE LP TE TP The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the deci
204. gin command error subroutine If error is out of range KP 1 Set N to a valid number Retry KP N command If error is invalid command TY Skip invalid command End of command error routine Example Communication Interrupt A DMC 4113 is used to move the A axis back and forth from 0 to 10000 This motion can be paused resumed and stopped via input from an auxiliary port terminal BEGIN cc 9600 0 1 0 CI 2 MG P2 Type 0 to stop motion MG P2 Type 1 to pause motion MG P2 Type 2 to resume motion rate 2000 SPA rate LOOP PAA 10000 BGA AMA PAA 0 BGA AMA JP LOOP EN COMINT JP STOP P2CH 0 JP PAUSE P2CH 1 JP RESUME P2CH 2 EN1 1 STOP STA ZS EN PAUSE rate _SPA SPA 0 EN1 1 RESUME SPA rate EN1 1 Label for beginning of program Setup communication configuration for auxiliary serial port Setup communication interrupt for auxiliary serial port Message out of auxiliary port Message out of auxiliary port Message out of auxiliary port Variable to remember speed Set speed of A axis motion Label for Loop Move to absolute position 10000 Begin Motion on A axis Wait for motion to be complete Move to absolute position 0 Begin Motion on A axis Wait for motion to be complete Continually loop to make back and forth motion End main program Interrupt Routine Check for S stop motion Check for P pause motion Check for R resume motion Do nothing Routine for stopping motion Stop motion on A axis Zero p
205. h compensation described below The second encoder may be a standard quadrature type or it may provide pulse and direction The controller also offers the provision for inverting the direction of the encoder rotation The main and the auxiliary encoders are configured with the CE command The command form is CE x y z w or a b c d e f g h for controllers with more than 4 axes where the parameters x y z w each equal the sum of two integers m and n m configures the main encoder and n configures the auxiliary encoder Using the CE Command m Main Encoder n Second Encoder 0 Normal quadrature 0 Normal quadrature 1 Pulse amp direction 4 Pulse amp direction 2 Reverse quadrature 8 Reversed quadrature 3 Reverse pulse amp direction 12 Reversed pulse amp direction For example to configure the main encoder for reversed quadrature m 2 and a second encoder of pulse and direction n 4 the total is 6 and the command for the X axis is CE 6 Additional Commands for the Auxiliary Encoder The command DE x y z w can be used to define the position of the auxiliary encoders For example DE 0 500 30 300 sets their initial values The positions of the auxiliary encoders may be interrogated with the command DE For example Chapter 6 Programming Motion 108 DMC 41x3 User Manual DE returns the value of the X and Z auxiliary encoders The auxiliary encoder position may be assigned to variables w
206. h a 24V supply or 10 mH of inductance with a 48 volts supply the normal current loop bandwidth option should be chosen AW will return the current loop bandwidth in Hertz Scope ix A Vertical Horizontal didt Source Scale Jdiv Offset div a BO TA AxisAtordm 2v ais amp sO vit ae amp sO x i al e A ao yt al e BS ao x i a e so xi ae e so ai Als e ao xj 1 Sa e sm e e Trigger Channel m _TAv Edge x Level 0 1 v Mode Repeat v READY 4 GTA 9 080 TAi Figure A1 2 Peak Current Operation Chopper Mode The AMP 430x0 can be put into what is called a Chopper mode The chopper mode is in contrast to the normal inverter mode in which the amplifier sends PWM power to the motor of VS In chopper mode the amplifier sends a 0 to VS PWM to the motor when moving in the forward direction and a 0 to VS PWM to the motor when moving in the negative direction This mode is set with the AU command A setting of 0 5 is Chopper mode with normal current bandwidth A setting of 1 5 is Chopper mode with high current bandwidth A1 AMP 430x0 D3040 D3020 201 DMC 41x3 User Manual This mode is useful when using low inductance motors because it reduces the losses due to switching voltages across the motor windings It is recommended to use chopper mode when using motors with 200 500uH inductance Using External Amplifiers Use connectors on top of controller to access ne
207. h gain or too little Decrease KI and KP Increase KD damping Operation SYMPTOM DIAGNOSIS CAUSE REMEDY Controller rejects Response of controller from Anything Correct problem reported by TC1 commands TC1 diagnoses error Motor Doesn t Move Response of controller from Anything Correct problem reported by SC TC1 diagnoses error Error Light Red LED The red error LED has multiple meanings for Galil controllers Here is a list of reasons the error light will come on and possible solutions Under Voltage If the controller is not receiving enough voltage to power up Under Current If the power supply does not have enough current the red LED will cycle on and off along with the green power LED Position Error If any axis that is set up as a servo MT command has a position error value TE that exceeds the error limit ER the error light will come on to signify there is an axis that has exceeded the position error limit Use a DP 0 to set all encoder positions to zero or a SH Servo Here command to eliminate position error Invalid Firmware If the controller is interrupted during a firmware update or an incorrect version of firmware is installed the error an light will come on The prompt will show up as a greater than sign gt instead of the standard colon prompt Use GalilTools software to install the correct version of firmware to fix this problem Self Test During the first few se
208. hanced features compared to prior generation Econo series controllers including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 41x3 provides two communication channels a high speed 100BaseT Ethernet connection and a USB programming port There is an auxiliary RS 232 port that can be used to communicate to external devices such as HMI s The controllers allow for high speed servo control up to 15 million encoder counts sec and step motor control up to 3 million steps per second Sample rates as low as 62 usec per axis are available A Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field The DMC 41x3 is available with up to eight axes in a single stand alone unit The DMC 4113 4123 4133 4143 are one thru four axes controllers and the DMC 4153 4163 4173 4183 are five thru eight axes controllers All eight axes have the ability to use Galil s integrated amplifiers or drivers and connections for integrating external devices Designed to solve complex motion problems the DMC 41x3 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences contouring and a PVT Mode The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth fol
209. has been written by the user The CN command can be used to change the polarity of the limit switches The OE command can also be configured so that the axis will be disabled upon the activation of a limit switch Software Protection The DMC 41x3 provides a programmable error limit as well as encoder failure detection It is recommended that both the position error and encoder failure detection be used when running servo motors with the DMC 41x3 Along with position error and encoder failure detection then DMC 41x3 has the ability to have programmable software limit Position Error The error limit can be set for any number between 0 and 2147483647 using the ER n command The default value for ER is 16384 Example ER 200 300 400 500 Set X axis error limit for 200 Y axis error limit to 300 Z axis error limit to 400 counts W axis error limit to 500 counts Chapter 8 Hardware amp Software Protection 159 DMC 41x3 User Manual ER 1 10 Set Y axis error limit to 1 count set W axis error limit to 10 counts The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position If the absolute value of the error exceeds the value specified by ER the controller will generate several signals to warn the host system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error
210. he HSRC option modifies the digital outputs on the DMC 41x3 to be capable of sourcing up to 500mA per output For detailed information see the 500mA Sourcing Optoisolated Outputs HSRC section in Chapter 3 Connecting Hardware Part number ordering example DMC 4113 CARD ABCD HSRC AMP SDM DXXXX Y Internal Amplifier Options The following options are the Y configuration options that can be added to the DXXXX Y amplifier part number Often multiple Y options can be ordered per board as long as they re separated by a comma ISAMP Isolation of power between each AMP amplifier The ISAMP option separates the power pass through between the Axes 1 4 amplifier and the Axes 5 8 amplifier This allows the 2 internal amplifiers to be powered at separate voltages Appendices 183 DMC 41x3 User Manual If the ISCNTL option is NOT ordered on the DMC 41x3 the amplifier with the higher bus voltage will automatically power the controller The amplifier with the higher voltage and the voltage level does not have to be specified during time of purchase as long as the voltage falls within the range of 20 80VDC This option is only valid on the 5 8 Axes amplifier board Part number ordering example DMC 4183 BOX8 D3040 D3040 ISAMP SR90 SR 49000 Shunt Regulator Option The SR 49000 is a shunt regulator for the DMC 41x3 controller and internal amplifiers This option is highly recommended for any application where there is a large
211. he positive direction QH should return the sequence 132645 a If the order is reversed swap Hall A and Hall C b If all 6 states are not seen one of the hall inputs is miswired or not connected 3 Select which axis will be using sinusoidal commutation by issuing the BA command 4 Set brushless modulus using the BM configuration command BM is the distance in counts of a single magnetic cycle of the motor This can be calculated by dividing counts revolution of the encoder by the number of pole pairs of the motor For a linear motor the number of encoder counts per magnetic phase may need to be calculated from motor and encoder manufacturers information 5 Initialize the motor for hall commutation BI 1 6 Test the motor for proper commutation by enabling the motor SH and jogging the motor slowly JG 1000 BG A If the motor rotates 360 degrees without cogging running away or stalling skip to step 7 a If the motor stalls cogs or runs away issue an MO and try initialization using BZ If the motor stalls cogs or runs away after BZ turn off the controller and amplifier and swap motor phases A and B and retry steps 3 6 b If commutation is still not successful after 6 a issue the appropriate BA BM and BZ commands but do not servo Check the hall state with QH If QH shows either of the two values shown below then turn off the controller and amplifier and rewire the motor based on the following and then
212. he reverse direction first direction of decreasing encoder counts If _HMX reads 0 initially the motor will go in the forward direction first CN is the command used to define the polarity of the home input With CN 1 the default value a normally open switch will make _HMX read 1 initially and a normally closed switch will make _HMX read zero Chapter 6 Programming Motion 111 DMC 41x3 User Manual Furthermore with CN 1 a normally open switch will make _HMX read 0 initially and a normally closed switch will make _HMX read 1 Therefore the CN command will need to be configured properly to ensure the correct direction of motion in the home sequence Upon detecting the home switch changing state the motor begins decelerating to a stop NOTE The direction of motion for the FE command also follows these rules for the state of the home input Stage 2 The motor then traverses at HV counts sec in the opposite direction of Stage 1 until the home switch toggles again If Stage 3 is in the opposite direction of Stage 2 the motor will stop immediately at this point and change direction If Stage 2 is in the same direction as Stage 3 the motor will never stop but will smoothly continue into Stage 3 Stage 3 The motor traverses forward at HV counts sec until the encoder index pulse is detected The motor then decelerates to a stop and goes back to the index The DMC 41x3 defines the home position as the position at which the index was
213. he termination resistors installed If a combination of differential encoder inputs with termination resistors and single ended encoders is required on the same controller contact Galil directly Part number ordering example DMC 4113 CARD TRES ISCNTL Isolate Controller Power The ISCNTL option isolates the power input for the controller from the power input of the amplifiers With this option the power is brought in through the 2 pin Molex connector on the side of the controller as shown in the DMC 41x3 Power Connections section in Chapter 2 This option is not valid when Galil amplifies are not ordered with the DMC 41x3 Part number ordering example DMC 4113 BOX4 ISCNTL D3020 Appendices 181 DMC 41x3 User Manual RS 422 Auxiliary Serial Port Serial Communication The default serial configuration for the DMC 41x3 is to have RS 232 communication on the Aux P2 serial port The controller can be ordered to have RS 422 for this port RS 422 communication is a differentially driven serial communication protocol that should be used when long distance serial communication is required in an application See the JP1 Jumper Description for DMC 41x3 section for termination resistor options for CTS and RXD signals RS 422 Auxiliary Port Standard connector and cable when DMC 41x3 is ordered with RS 422 Option Pin Signal CTS RXD TXD RTS GND CTS RXD TXD RTS WO COOINID WM B
214. hich option you have The amount of uncommitted optoisolated outputs the DMC 41x3 has depends on the number of axis For instance 1 4 axis models come with a single bank of 8 outputs Bank 0 DO 8 1 5 8 axis models come with an additional bank of 8 outputs Bank 1 DO 16 9 for a total of 16 outputs The wiring pins for Bank 0 are located on J5 I O A D 44 pin HD D Sub Connector Female and the pins for wiring Bank 1 are located on J8 I O E H 44 pin HD D Sub Connector Female See the Pin outs in the Appendix for more details Wiring diagrams electrical specifications and details for each bank and output type are provided below 4mA Sinking Optoisolated Outputs Default Description The default outputs of the DMC 41x3 are capable of 4mA and are configured as sinking outputs The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output PWR Max Voltage 24 Voc Output PWR Min Voltage 5 Voc ON Voltage No Load Output PWR 5V 5c 0 1 Voc Max Drive Current per Output 4mA Sinking Wiring the 4mA Sinking outputs With this configuration the output power supply will be connected to Output PWR labeled OPnB and the power supply return will be connected to Output GND labeled OPnA where n denotes 0 or 1 referring to Bank 0 and Bank 1 respectively Note that the load is wired between Output PWR and DO The wiring diagram for Bank 0 is show
215. hieve higher speeds Below is the equation that can be used to calculate the desired maximum commutation speed in counts per second cts s mx 10 Speed ctsis TM Xn Where m is the number of counts per magnetic cycle cts magnetic cycle n is the desired number of TM samples per magnetic cycle 8 or more recommended samples magnetic cycle Example Assume that an encoder provides 4000 cts rev and that a motor has 2 pole pairs Each pole pair represents a single magnetic cycle m can be calculated as follows 4000 16 rev m cts rev 2000 cts magnetic cycle magnetic cycles If TM 250 is set and 8 servo samples per magnetic cycle is desired the maximum speed in counts per second would be 6 2000 cts magnetic cycle x1 OF us s Speed 25 Ois sample x 8 1 000 000 cts s samples magnetic ccycle Finding Proper Commutation The 6 commands used for set up are the BA BM BX BZ BC and BI commands Please see the command reference for details For detailed information on setting up commutation on the AMP 43640 can be found here 1 Issue the BA command to specify which axis you want to use the sinusoidal amplifier on 2 Calculate the number of encoder counts per magnetic cycle For example in a rotary motor that has 2 pole pairs and 10 000 counts per revolution the number of encoder counts per magnetic cycle would be 10 000 2 5000 Assign this value to BM 3
216. ich can help to debug a program Trace Commands The trace command causes the controller to send each line in a program to the host computer immediately prior to execution Tracing is enabled with the command TR1 TRO turns the trace function off Note When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed NOTE When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed Error Code Command When there is a program error the DMC 41x3 halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG _ED The user can obtain information about the type of error condition that occurred by using the command TC1 This command reports back a number and a text message which describes the error condition The command TCO or TC will return the error code without the text message For more information about the command TC see the Command Reference Stop Code Command The status of motion for each axis can be determined by using the stop code command SC This can be useful when motion on an axis has stopped unexpectedly The command SC will return a number representing the motion status See the command reference for further information RAM Memory Interrogation Commands For debugging the status of the program memory arr
217. idth modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 volts should run the motor at the maximum speed Galil offers amplifiers that are integrated into the same enclosure as the DMC 41x3 See the Integrated section in the Appendices or http galilmc com products accelera dmc41x3 html for more information Chapter 1 Overview 9 DMC 41x3 User Manual Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 41x3 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as MA and MB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended MA and MB or differential MA MA and MB MB The DMC 41x3 decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization The DMC 41x3 can be ordered with 120 Q termination resistors installed on the encoder inputs See the Ordering Options in the Appendix for more information The DMC 41x3 can also interface to encoders with pulse and direction signals Refer to the CE comm
218. ier when powered regardless of load The minimum power that the amplifier will consume is roughly P A min drop across Op amp power stages drop across sense resistor op amp supply Pa min 4 iti 5 N Where N 1 5W for 24V and N 3W for 48V For example assume a 24VDC supply and a motor with R 4Q and K 5V RPM and desired output currents of 1 and 5 amps First calculate the minimum power used in the amplifier P nin lamp 4 i i 5 1 5 6W P min Samp 4 5 5 5 4 3 5 125W The power used by the motor will vary by its velocity even though the power lost in the motor is a constant for each value of current The more power sent to the motor the less power will be dissipated by the amplifier as heat Power Dissipated by the Amplifier for a Given Velocity and Current 25 20 a 1 Amp e 5 Amp Power Watts Velocity kRPM Figure A5 2 Power Dissipation for Velocity and Current AS AMP 43640 D3640 221 DMC 41x3 User Manual Operation Commutation Related Velocity When using sinusoidal commutation and higher speed applications it is a good idea to calculate the speed at which commutation can start to affect performance of the motor In general it is recommended that there be at least 8 servo samples for each magnetic cycle The time for each sample is defined by TM TM 1000 is default and is in units of us per sample or us sample TM can be lowered to ac
219. ifications for the controller are provided in Power Requirements pg 178 and the power specifications for each amplifier are found under their specific section in the appendix see Integrated Components pg 196 Chapter 2 Getting Started 15 DMC 41x3 User Manual CARD All standoff locations must be used when mounting the CARD version of the DMC 41x3 controllers There are 6 standoff locations for the DMC 4143 controller and 8 standoff locations for the DMC 4183 controller See Figure 2 1 and Figure 2 2 for mounting hole sizing and locations The minimum standoff height that should be used for the DMC 41x3 CARD controllers is 0 656 BOX4 and BOX8 All 4 mounting holes should be used to mount the controller to a secure base See Figure 2 3 and Figure 2 4 for mounting hole locations and sizes If the controller is shipped with internal amplifiers the base of the DMC 41x3 is used as the heat sync for those amplifiers Elements You Need For a complete system Galil recommends the following elements DMC 41x3 motion controller where x designates the number of axis 1 8 Motor Amplifiers Integrated when using Galil amplifiers and drivers Power Supply for Amplifiers and controller Brush or Brushless Servo motors with Optical Encoders or stepper motors a Cables for connecting to the DMC 41x3 PC Personal Computer USB or Ethernet for DMC 41x3 6 GalilSuite or GalilSuite Lite Free software package Pee on GalilSu
220. igned to follow a moving object at a specified distance and the path of the object wasn t known the robot would be required to constantly monitor the motion of the object that it was following To remain within a specified distance it would also need to constantly update the position target it is moving towards Galil motion controllers support this type of motion with the position tracking mode This mode will allow scheduled or random updates to the current position target on the fly Based on the new target the controller will either continue in the direction it is heading change the direction it is moving or decelerate to a stop Chapter 6 Programming Motion 73 DMC 41x3 User Manual The position tracking mode shouldn t be confused with the contour mode The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate In this mode the position can be updated randomly or at a fixed time rate but the velocity profile will always be trapezoidal with the parameters specified by AC DC and SP Updating the position target at a specific rate will not allow the user to create a custom profile The following example will demonstrate the possible different motions that may be commanded by the controller in the position tracking mode In this example there is a host program that will generate the absolute position targets The absolute target is determined based on the current information the
221. igured for quadrature default or pulse and direction inputs This configuration is set through the CE command The encoder connections are found on the HD D sub Encoder connectors and are labeled MA MA MB MB The negative inputs are the differential inputs to the encoder inputs if the encoder is a single ended 5V encoder then the negative input should be left floating If the encoder is a single ended and outputs a 0 12V signal then the negative input should be tied to the 5V line on the DMC 41x3 When the encoders are setup as step and direction inputs the MA channel will be the step or pulse input and the MB channel will be the direction input The encoder inputs can be ordered with 120 Q termination resistors installed See TRES Encoder Termination Resistors pg 181 in the Appendix for more information Electrical Specifications Maximum Voltage 12 Voc Minimum Voltage 12 Voc Maximum Frequency Quadrature 15 MHz inputs are internally pulled up to 5V through a 4 7 kQ resistor inputs are internally biased to 1 3V pulled up to 5V through a 7 1 kQ resistor pulled down to GND through a 2 5 KQ resistor The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 The Aux encoder inputs are not avai
222. il n number of counts have passed in the reverse direction Only one axis at a time may be specified PT n n n n n n n n Command used to enter and exit the Trajectory Modification Mode PA n n n n n n n n Command Used to specify the absolute position target SP n n n n n n n n Speed settings for the specified axes Chapter 6 Programming Motion 76 DMC 41x3 User Manual Linear Interpolation Mode The DMC 41x3 provides a linear interpolation mode for 2 or more axes In linear interpolation mode motion between the axes is coordinated to maintain the prescribed vector speed acceleration and deceleration along the specified path The motion path is described in terms of incremental distances for each axis An unlimited number of incremental segments may be given in a continuous move sequence making the linear interpolation mode ideal for following a piece wise linear path There is no limit to the total move length The LM command selects the Linear Interpolation mode and axes for interpolation For example LM YZ selects only the Y and Z axes for linear interpolation When using the linear interpolation mode the LM command only needs to be specified once unless the axes for linear interpolation change Specifying Linear Segments The command LI x y z w or LI a b c d e f g h specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis posit
223. ile is triangular because the controller doesn t have sufficient time to reach the set speed of 50000 counts sec before it is commanded to change direction The below code is used to simulate this scenario EX2 PT 1 Place the X axis in Position tracking mode Ac 150000 Set the X axis acceleration to 150000 counts sec2 DC LS00007 Set the X axis deceleration to 150000 counts sec2 SP 50000 Set the X axis speed to 50000 counts sec PA 5000 Command the X axis to abs position 5000 encoder counts MF 4200 PA 2000 Change end point position to position 2000 EN ee Ny Vertical Horizontal fo N didt Source Scale fdv Offset div et WO RPA Axis Aref 1000 cour S 0 __RPA Axis A ref 10000 coui gmi m 2 ag f jmi Pe ao eee 4 o j 7 Aa 2 1 0 221383 0 4 42765 0 442765 COVASHPE 0 221383 z E E EJ E 0 221383 F EP e ee B ee E fe am en en ee we ew 101 562 ni 3 92 ey Trig Channel Ml RPE Edge Level 0 counts Mode Repeat v READY FERJE Figure 6 3 Position and Velocity vs Time msec for Motion 2 Example Motion 3 In this motion the host program commands the controller to begin motion towards position 5000 changes the target to 2000 and then changes it again to 8000 Figure 6 4 shows the plot of position vs time and velocity vs time Below is the code that is used to simulate this scenario EX3 PT 1 Place the
224. iliary RS 232 port In this mode the DMC 41x3 provides a buffer for receiving characters This mode may only be used when executing an applications program The Operator Data Entry Mode may be specified for Port 2 only This mode may be exited with the or lt escape gt key NOTE Operator Data Entry Mode cannot be used for high rate data transfer Set the third field of the CC command to one to set the Operator Data Entry Mode To capture and decode characters in the Operator Data Mode the DMC 41x3 provides special the following keywords Keyword Function P2CH Contains the last character received P2ST Contains the received string P2NM Contains the received number P2CD Contains the status code 1 mode disabled 0 nothing received 1 received character but not lt enter gt 2 received string not a number 3 received number NOTE The value of P2CD returns to zero after the corresponding string or number is read These keywords may be used in an applications program to decode data and they may also be used in conditional statements with logical operators Chapter 7 Application Programming 142 DMC 41x3 User Manual Example Instruction Interpretation JP LOOP P2CD lt gt 3 Checks to see if status code is 3 number received JP P P2CH V Checks if last character received was a V PR P2NM Assigns received number to position JS XAXIS P2ST X Checks to see if received string is
225. inary myarray 1 85 which is 01010101in binary 3 a Send the appropriate MB command Use function code 15 Start at output 0 and set clear all 16 outputs based on the data in myarray MBB 15 0 16 myarray 3 b Set the outputs using the SB command B2001 SB2003 SB2005 SB2007 SB2008 SB2010 SB2012 SB2014 Results Both steps 3a and 3b will result in outputs being activated as below The only difference being that step 3a will set and clear all 16 bits where as step 3b will only set the specified bits and will have no affect on the others Bit Number Status Bit Number Status 0 0 8 1 1 1 9 0 2 0 10 1 3 1 11 0 4 0 12 1 5 1 13 0 6 0 14 1 7 1 15 0 Chapter 4 Software Tools and Communication 56 DMC 41x3 User Manual Example 2 DMC 4143 connected as a Modbus master to a 3rd party PLC The DMC 4143 will read the value of analog inputs 3 and 4 on the PLC located at addresses 40006 and 40008 respectively The PLC stores values as 32 bit floating point numbers which is common 1 Begin by opening a connection to the PLC which has an IP address of 192 168 1 10 in our example ITHB 192 168 1 10 lt 502 gt 2 2 Dimension an array to store the results DM myanalog 4 3 Send the appropriate MB command Use function code 4 as specified per the PLC Start at address 40006 Retrieve 4 modbus registers 2 modbus registers per 1 analog input as specified by the PLC MBB 4 40006 4 myanalog
226. inations in the United States and for products within warranty Call Galil to receive a Return Materials Authorization RMA number prior to returning product to Galil Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer alteration modification negligence or misuse is not covered by this warranty EXCEPT AS SET FORTH ABOVE GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES COPYRIGHT 3 97 The software code contained in this Galil product is protected by copyright and must not be reproduced or disassembled in any form without prior written consent of Galil Motion Control Inc Appendices 195 DMC 41x3 User Manual Integrated Components Overview When ordered the following components will reside inside the box of the DMC 41x3 motion controller The amplifiers and stepper drivers provide power to the motors in the system and the interconnect modules and communication boards provide the connections for the signals and communications A1 AMP 430x0 D3040 D3020 2 and 4 axis 500W Servo Drives The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless amplifiers that are capable of handling 500 watts of continuous power per axis The AMP 43040 43020 Brushless drive modules are connected to a DMC 41x3 The standard
227. inertial load or a gravitational load To calculate if your system requires a Shut Regulator see Application Note 5448 Shunt Regulator Operation linked below http www galilmc com support appnotes miscellaneous note5448 pdf The SR 49000 is installed inside the box of the DMC 41x3 controller so it does not effect the form of the unit The SR 49000 can be ordered to activate at different voltage levels 33V 66V and 90V These would be ordered as SR33 SR66 and SR90 respectively SR90 is typically ordered because Galil s internal amplifiers can generally be powered up to 80VDC As a functional example SR90 shunt regulator activates when the voltage supplied to the amplifier rises above 90V When activated the power from the power supply is dissipated through a5 Q 20W power resistor When used a 5 8 axis controller with two internal amplifiers the SRn where n is 33 66 or 90 option can protect both internal amplifiers However with an ISAMP ISAMP Isolation of power between each AMP amplifier option the SRn option will only protect the first four axis with internal amplifiers Part number ordering example DMC 4143 BOX4 D3040 SR90 SSR Solid State Relay Option for AMP 43140 The SSR option configures the AMP 43140 D3140 with Solid State Relays on the motor power leads that are engaged and disengaged when the amplifier is enabled and disabled See the SSR Option in the AMP 43140 section of the Appendix
228. ing used the BOXn where n stands for 4 or 8 option is required Part number ordering example DMC 4153 CARD BOX4 BOX8 The BOX4 or BOX8 option on the DMC 41x3 provides a metal enclosure for the controller BOX4 is the box for the 1 4 axis controllers the BOX8 is for 5 8 axis controllers The BOXn option is required when using Galil internal amplifiers and is recommended for any application that requires CE certification Part number ordering example DMC 4113 BOX4 The following options are the Y configuration options that can be added to the DMC part number Often multiple Y options can be ordered per board as long as they re separated by a comma DIN DIN Rail Mounting The DIN option on the DMC 41x3 motion controller provides DIN rail mounts on the base of the controller This will allow the controller to be mounted to any standard DIN rail Requires BOX4 or BOX8 option Part number ordering example DMC 4113 BOX4 DIN 12V Power Controller with 12VDC The 12V option allows the controller to be powered with a regulated 12V supply The tolerance of the 12V input must be within 5 If ordered with an internal amplifier the 12V will automatically be upgraded to the ISCNTL option see ISCNTL Isolate Controller Power pg 181 In either case the DMC controller board will be powered through the 2 pin Molex connector near the bottom of the controller as shown in the DMC 41x3 Power Connections pg 15 Molex connector part n
229. internal servo amplifier for brushed mode BR Also used to ignore halls when the use of external amplifiers is required in lieu of an internal Configures the current loop update rate G Can also be used to switch capable amplifiers between chopper and inverter mode TL TK Limits motor command line output in Volts thus limiting the current in the amplifier YA Stepper drive resolution microstepping configuration LC Configures stepper motor current at holding or rest positions Table 2 6 Sample of motor and amplifier configuration commands Step D If using a servo motor continue to Step 10 Tune the Servo System pg 31 If using a stepper continue on to Step E Step E Enable and use your motor A SH will enable the internal amplifier and a MO will disable the internal amplifier Once enabled you can send DMC motion commands to move the motor see Chapter 5 Command Basics and Chapter 6 Programming Motion pg 69 for details Step 8a Commutation of 3 phased Brushless Motors If a motor is not correctly commutated it will not function as expected Commutation is the act of properly getting each of the 3 internal phases of a servo motor to switch at the correct time to allow smooth 360 degree rotation in Chapter 2 Getting Started 24 DMC 41x3 User Manual both directions The two most common methods for doing so are trapezoidal commutation use of Hall sensors and through position sensor algorithms
230. ion Up to 511 incremental move segments may be given prior to the Begin Sequence BGS command Once motion has begun additional LI segments may be sent to the controller The clear sequence CS command can be used to remove LI segments stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or AB The command ST causes a decelerated stop The command AB causes an instantaneous stop and aborts the program and the command AB1 aborts the motion only The Linear End LE command must be used to specify the end of a linear move sequence This command tells the controller to decelerate to a stop following the last LI command If an LE command is not given an Abort AB1 must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 41x3 sequence buffer to ensure continuous motion If the controller receives no additional LI segments and no LE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or _LM returns the available spaces for LI segments that can be sent to the buffer 511 returned means the buffer is empty and 511 LI segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent at PC bus speeds The instruction _CS returns the segment counter As the segments are processed _CS inc
231. ion loop is closed before the backlash whereas the linear sensor provides accurate load position information The operation principle is to drive the motor to a given rotary position near the final point Once there the load position is read to find the position error and the controller commands the motor to move to a new rotary position which eliminates the position error Since the required accuracy is 0 5 micron the resolution of the linear sensor should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000 count per revolution results in a rotary resolution of 0 25 micron This results in equal resolution on both linear and rotary sensors To illustrate the control method assume that the rotary encoder is used as a feedback for the X axis and that the linear sensor is read and stored in the variable LINPOS Further assume that at the start both the position of X and the value of LINPOS are equal to zero Now assume that the objective is to move the linear load to the position of 1000 The first step is to command the X motor to move to the rotary position of 1000 Once it arrives we check the position of the load If for example
232. ions for each method follow on pg 27 BZ Method The BZ method forces the motor into a zero degree magnetic phase by exciting only two of the three phases The location on the motor within it s magnetic phases is known and sinusoidal commutation is initialized Commands required BA BM BZ BX Method The BX method uses a limited motion algorithm to determine the proper location of the motor within the magnetic cycle It is expected to move no greater than 10 degrees of the magnetic cycle The last stage of the BX command will lock the motor into the nearest 15 degree increment Commands required BA BM BX BI BC Method The motor initially boots up in a pseudo trapezoidal mode The BC function monitors the status of the hall sensors and replaces the estimated commutation phase value with a more precise value upon the first hall transition The motor is then running in a sinusoidally commutated mode and the use of the halls are no longer required Commands required BA BM BI BC BZ and QH are used to aid in the wiring process and initial set up for this method Note These list the minimum required commands to provide commutation There are many more commutation configuration commands available not discussed here See the Command Reference for details Method PRO CON e Can be used with vertical or unbalanced loads le Can cause significant motor movement BZ e Less sensitive to noise than BX e May fail at hard stops e
233. is and high current loop gain for the Y axis issue AU 0 1 The command AW is used to calculate the bandwidth of the amplifier using the basic amplifier parameters To calculate the bandwidth for the X axis issue AWX yv n where v represents the DC voltage input to the card represents the inductance of the motor in millihenries and n represents O or 1 for the AU setting NOTE For most applications unless the motor has more than 5 mH of inductance with a 24V supply or 10 mH of inductance with a 48 volts supply the normal current loop bandwidth option should be chosen AW will return the current loop bandwidth in Hertz Scope im gt bd A Yertical Horizontal didt Source Scale fdv Offset dv _TTA Axis A torom 2V j 3 Pa a xj j 2 3 G x 1 al E A a mj 0 D m x i an G E a x 1 S2 amp a xj 1 Sj 3 n yi an amp Sm Trigger Channel W _TTAv Edge x Level 0 1v Mode Repeat v READY 4 m 5G TA t 19 ms 1 dt 74 6H Figure A3 2 Peak Current Operation Chopper Mode The AMP 43240 runs in what is called a Chopper mode The chopper mode is in contrast to the normal inverter mode AMP 43040 in which the amplifier sends PWM power to the motor of VS In chopper mode the amplifier sends a 0 to VS PWM to the motor when moving in the forward direction and a 0 to VS PWM to the motor when mo
234. istance from the A or B or C or D or E or F or G or H ast AR or AD command has elapsed Only one axis may be specified at a time AP X or Y or Z or W Halts program execution until after absolute position occurs A or Bor Cor D or E or For Gor H Only one axis may be specified at a time MF X or Y or Zor W Halt program execution until after forward motion reached A or Bor Cor D or E or For Gor H absolute position Only one axis may be specified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs MR X or Y or Zor W Halt program execution until after reverse motion reached A or Bor Cor D or E or F or Gor H absolute position Only one axis may be specified If position is already past the point then MR will trip immediately Will function on geared axis or aux inputs MC X or Y or Zor W Halt program execution until after the motion profile has been A or BorCorDorEorForGorh completed and the encoder has entered or passed the specified position TW x y z w sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stop code will be set to 99 An application program will jump to abel MCTIME Al n Halts program execution until after specified input is at specified logic level n specifies input line Positive is high logic evel negative is low level n 1 through 8 for DMC 4113 4123 4133 4143 n 1 through 16 fo
235. itches for axes 5 8 are found on the connectors for the E H axes These are NOT the same INCOMO and LSCOM0 for axes 1 4 Chapter 3 Connecting Hardware 34 DMC 41x3 User Manual Optoisolated Input Electrical Information Electrical Specifications INCOM LSCOM Max Voltage 24 Voc INCOM LSCOM Min Voltage 0 Voc Minimum current to turn on Inputs 1 2 mA Minimum current to turn off Inputs once activated hysteresis 0 5 mA Maximum current per input 11 mA Internal resistance of inputs 2 2 kQ 1 See the Input Current Limitations section on pg 186 for more details The DMC 41x3 s optoisolated inputs are rated to operate with a supply voltage of 5 24 VDC The optoisolated inputs are powered in banks For example INCOM Bank 0 located on the 44 pin I O A D D sub connector provides power to DI 8 1 digital inputs the abort input ABRT reset RST and electric lock out ELO Table 3 1 shows all the input banks power commons and their corresponding inputs for 1 4 axis controllers and Table 3 2 shows the input banks for 5 8 axis controllers Common Signal Common Signal Location Powers Inputs Labeled INCOM Bank 0 1 0 A D D Sub Connector DI 8 1 ABRT RST ELO LSCOM Bank 0 1 0 A D D Sub Connector FLSA RLSA HOMA FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD Table 3 1 1 4 axis controller INCOM and LSCOM banks and corresponding inputs powered Common Signal Com
236. ite is highly recommended for first time users of the DMC 41x3 It provides step by step instructions for system connection tuning and analysis Chapter 2 Getting Started gt 16 DMC 41x3 User Manual Installing the DMC Amplifiers and Motors Installation of a complete operational motion control system consists of the following steps Step 1 Step 2 Step 3 Step 4 Step 5 Determine Overall System Configuration pg 17 Install Jumpers on the DMC 41x3 pg 17 Install the Communications Software pg 18 Power the Controller pg 18 Establish Communications with Galil Software pg 19 Step 6 Connecting Encoder Feedback pg 20 Optional for steppers Step 7 Setting Safety Features before Wiring Motors pg 21 Servo motors only Step 8 Wiring Motors to Galil s Internal Amps pg 23 Internal amplifiers only Step 8a Commutation of 3 phased Brushless Motors pg 24 Brushless motors only Step 9 Connecting External Amplifiers and Motors pg 29 External amplifiers only Step 10 Tune the Servo System pg 31 Servo motors only Electronics are dangerous Only a certified electrical technician electrical engineer or electrical professional should wire the DMC product and related components Galil shall not be liable or responsible for any incidental or WARNING consequential damages All wiring procedures and suggestions mentioned in the following sections should be done with the controller in a powered off state
237. ith the instructions V1 _DEX The command TD XYZW returns the current position of the auxiliary encoder The command DV 1 1 1 1 configures the auxiliary encoder to be used for backlash compensation Backlash Compensation There are two methods for backlash compensation using the auxiliary encoders 1 Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies the KP proportional and KI integral terms to the position error based on the load encoder and applies the KD derivative term to the motor
238. ition 500 is 0 degrees in XY plane 3000 count radius start at 0 and go to 180 CCW End vector Disengage knife Move X and Y to starting position move Z to initial tangent position Start the move to get into position When the move is complete Engage knife Wait 50 msec for the knife to engage Do the circular cut After the coordinated move is complete Disengage knife End program Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION VM m n Specifies the axes for the planar motion where m and n represent the planar axes and p is the tangent axis VP m n Return coordinate of last point where m X Y Z or W CR r e d lt n gt m amp amp Specifies arc segment where r is the radius is the starting angle and is the travel langle Positive direction is CCW VS s t Specify vector speed or feed rate of sequence VA s t Specify vector acceleration along the sequence VD s t Specify vector deceleration along the sequence VR s t Specify vector speed ratio BGST Begin motion sequence S or T CSST Clear sequence S or T AV s t Trippoint for After Relative Vector distance AMST Holds execution of next command until Motion Sequence is complete TN m n Tangent scale and offset ES m n Ellipse scale factor IT S S curve smoothing constant for coordinated moves LM Return number of available spaces for linear and circular segments in DMC 41x3 sequence
239. l output n where n starts at 1 AN n Return analog input at general analog in n where n starts at 1 Note that these functions are multi valued An application program may be used to find the correct band Functions may be combined with mathematical expressions The order of execution of mathematical expressions is from left to right and can be over ridden by using parentheses Examples v1 ABS V7 The variable v1 is equal to the absolute value of variable v7 v2 5 SIN pos The variable v2 is equal to five times the sine of the variable pos v3 IN 1 The variable v3 is equal to the digital value of input 1 v4 2 5 AN 5 The variable v4 is equal to the value of analog input 5 plus 5 then multiplied by 2 Chapter 7 Application Programming 136 DMC 41x3 User Manual Variables For applications that require a parameter that is variable the DMC 41x3 provides 510 variables These variables can be numbers or strings A program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by program calculations For example a cut to length application may require that a cut length be variable Example posx 5000 Assigns the value of 5000 to the variable posx PR posx Assigns variable posx to PR command JG rpmy 70 Assigns variable rpmY multiplied by 70 to JG command Programmable Variables The
240. lable for any axis that is configured for step and direction outputs stepper Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 V The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a Chapter 3 Connecting Hardware 42 DMC 41x3 User Manual voltage that is of the full voltage range for example connect the input to the 5 volts on the Galil if the signal is 0 12V logic Example A DMC 4113 has one auxiliary encoder This encoder has two inputs channel A and channel B Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal will be connected to AA and the second to AB AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Electrical Specifications Maximum Voltage 12 Voc Minimum Voltage 12 Voc inputs are internally pulled up to 5V through a 4 7kQ resistor inputs are internally biased to 1 3V pulled up to 5V through a 7 1kQ resistor pulled down to GND through a 2 5kO resistor Output Compare The output compare signal is a TTL output signal and is available on
241. lable for users who wish to develop their own custom application programs to communicate to the controller Custom application programs can utilize API function calls directly to our DLLs At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers Controller Response to Commands Most DMC 41x3 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return Multiple commands may be concatenated by inserting a semicolon between each command After the instruction is decoded the DMC 41x3 returns a response to the port from which the command was generated If the instruction was valid the controller returns a colon or the controller will respond with a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the USB port back through the USB port and to commands which are sent via the Ethernet port back through the Ethernet port Chapter 4 Software Tools and Communication 50 DMC 41x3 User Manual For instructions that return data such as Tell Position TP the DMC 41x3 will return the data followed by a carriage return line feed and It is good practice to check for after each command is sent to prevent errors An echo function is provided to enable associating the DMC 41x3 response with the data sent The echo is enable
242. ler will attempt to lower the speed to 5000 but will reach that at a different point Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 0 5 results in the specification VS 2000 to be divided by two Compensating for Differences in Encoder Resolution By default the DMC 41x3 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in the Command Reference Trippoints The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Tangent Motion Several applications such as cutting require a third axis i e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 41x3 allows one axis to be specified as the tangent axis The VM command provides param
243. les shown in Figure 10 2 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The following section explains the operation of the servo system First it is explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined X VELOCITY Y VELOCITY X POSITION Y POSITION TIME Figure 10 2 Velocity and Position Profiles Operation of Closed Loop Systems To understand the operation of a servo system we may compare it to a familiar closed loop operation adjusting the water temperature in the shower One control objective is to keep the temperature at a comfortable level say 90 degrees F To achieve that our skin serves as a temperature sensor and reports to the brain controller The brain compares the actual temperature which is called the feedback signal with the desired level of 90 degrees F The difference between the two levels is called the error signal If the feedback temperature is too low the error is positive and it triggers an action which raises the water temperature until the temperature error is reduced sufficiently The closing of the servo loop is very similar Suppose that we want the motor position to be at 90 degrees The motor position is measured by a position sensor
244. lifier drops below 18 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 18V threshold NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 40 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the AMP 43240 is a transconductance amplifier the amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the AMPERR routine NOTE If this fault occurs it is indicative of a problem at the system level An over current faul
245. lil if a permanent swap is required Several options are available Chapter 4 Software Tools and Communication 51 DMC 41x3 User Manual USB Port The USB port on the DMC 41x3 is a USB to serial converter It should be setup for 115 2kB 8 Data bits No Parity 1 Stop Bit and Flow Control set for Hardware The baud rate can be changed to 19200 baud by installing the 19 2 jumper on JP1 but this configuration is only recommended if a slower baud rate is required from the host communication The USB port on the DMC 41x3 is a Female Type B USB port The standard cable when communicating to a PC will be a Male Type A Male Type B USB cable When connected to a PC the USB connection will be available as a new serial port connection ex with GalilTools COM3 115200 The USB port is not recommended when using the GalilTools Scope In this case the Ethernet connection is advised for higher performance Baud Rate Selection JP1 JUMPER SETTINGS 19 2 BAUD RATE ON 19200 OFF recommended 115200 USB Driver The USB port on the DMC 41x3 utilizes a USB to serial converter The driver for this device is expected to be loaded automatically upon connection of the controller in most OS s If the driver does not load or is not installed automatically it can be downloaded from the mfg website here http www ftdichip com Drivers VCP htm RS 232 Port The main purpose of the auxiliary RS232 port is to connect
246. lowing of complex contours the DMC 41x3 provides continuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with multiple master axes as well as gantry mode operation For synchronization with outside events the DMC 41x3 provides uncommitted 1 0 including 8 optoisolated digital inputs 16 inputs for DMC 4153 thru DMC 4183 8 optically isolated outputs 16 outputs for DMC 4153 thru DMC 4183 and 8 analog inputs for interface to joysticks sensors and pressure transducers Further I O is available if the auxiliary encoders are not being used 2 inputs each axis Dedicated optoisolated inputs are provided for forward and reverse limits abort home and definable input interrupts Commands are sent in ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen and program development using many environments such as Visual Basic C C etc Drivers for Windows XP Vista and 7 32 amp 64 bit as well as Linux are available Chapter 1 Overview 1 DMC 41x3 User Manual Part Numbers The DMC controller board comes in two sizes 1 4 axis models labeled A D and 5 8 axis models labeled E H The number of axis is designated by x in the part number DMC 41x3 In addition Axis A D and Axis E H have their own set of axis specific options that can be ordered For example Axis A D can have a different set of feedback options as Axis E H even though
247. lue from TPX command to variable posx speed 5 75 Assigns value 5 75 to variable speed input IN 2 Assigns logical value of input 2 to variable input v2 vlitv3 v4 Assigns the value of v1 plus v3 times v4 to the variable v2 var CAT Assign the string CAT to var MG var S3 Displays the variable var CAT Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as SP or PR PR v1 Assign vl to PR command Chapter 7 Application Programming 137 DMC 41x3 User Manual SP vS 2000 Assign vS 2000 to SP command Displaying the value of variables at the terminal Variables may be sent to the screen using the format variable For example v1 returns the value of the variable v1 Example Using Variables for Joystick The example below reads the voltage of an X Y joystick and assigns it to variables vX and vY to drive the motors at proportional velocities where 10 Volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 JOYSTIK Label JG 0 0 Set in Jog mode BGXY Begin Motion ATO Set AT time reference LOOP Loop vX AN 1 20000 vY AN 2 20000 Read joystick X Read joystick Y JG vX vY Jog at variable vX vY AT 4 Wait 4ms from last time reference creates a deterministic loop time JP LOOP Repeat EN End Operands Operands allow motion or status parameters of the DMC 41x3 to be incorporated into programmable variables and expressions Most DMC
248. m A1 AMP 430x0 D3040 D3020 202 DMC 41x3 User Manual Under Voltage Protection If the supply to the amplifier drops below 18 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 18V threshold NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 20 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the AMP 43040 is a trans conductance amplifier the amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the AMPERR routine NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short from a motor lead to ground Over Temperature Protection The amplifier is also equipped with over temperatur
249. m NOTE The Error Subroutine will be entered again unless the error condition is cleared Example A JP A EN Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor AMX After motor stops SHX Servo motor here to clear error RE Return to main program Limit Switch Routine The DMC 41x3 provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automatic execution of a limit switch subroutine The LIMSWI label specifies the start of the limit switch subroutine This label causes the statements following to be automatically executed if any limit switch is activated and that axis motor is moving in that direction The RE command ends the subroutine The state of the forward and reverse limit switches may also be tested during the jump on condition statement The _LR condition specifies the reverse limit and _LF specifies the forward limit X Y Z or W following LR or LF specifies the axis The CN command can be used to configure the polarity of the limit switches Chapter 8 Hardware amp Software Protection 161 DMC 41x3 User Manual Limit Switch Example A JP A EN LIMSWI V1 _LFX V2 _LRX JP LF V1 0 JP LR V2 0 JP END LF G FORWARD LIMIT STX AMX PR 1000 BGX AMX P END LR G REVERSE LIMIT STX AMX R1000 BGX AMX END q se 4k tg vs Dummy Progra
250. m Limit Switch Utility Check if forward limit Check if reverse limit Jump to LF if forward Jump to LR if reverse Jump to end LF Send message Stop motion Move in reverse End LR Send message Stop motion Move forward End Return to main program Chapter 8 Hardware amp Software Protection 162 DMC 41x3 User Manual Chapter 9 Troubleshooting Overview The following discussion may help you get your system to work Potential problems have been divided into groups as follows 1 Installation 2 Stability and Compensation 3 Operation 4 Error Light Red LED The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM DIAGNOSIS CAUSE REMEDY Motor runs away with no connections from controller to amplifier input Adjusting offset causes the motor to change speed 1 Amplifier has an internal offset 2 Damaged amplifier Adjust amplifier offset Amplifier offset may also be compensated by use of the offset configuration on the controller see the OF command Replace amplifier Motor is enabled even when MO command is given The SH command disables the motor 1 The amplifier requires the a different Amplifier Enable setting on the Interconnect Module Refer to Chapter 3 or contact Galil Unable to read main or auxiliary encoder input The encoder does not work when swapped with another encoder
251. m frequency does not exceed 15 000 000 quadrature states sec The controller performs quadrature decoding of the encoder signals resulting in a resolution of quadrature counts 4 x encoder cycles Note Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses into CHA and direction into Channel B and using the CE command to configure this mode Encoder Index MI Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Encoder MA MB MI Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Auxiliary Encoder AA AB Aux A Aux B Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for step motors Abort A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program Reset A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored Electronic Lock Out Input that when triggered will shut down the amplifiers at a hardware level Useful for safety applications where amplifiers must be shut down at a hardware level Appendices 191 DMC 41x3 User Manual
252. mal point using the PF command Position Format is specified by PF m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format Hex values are returned preceded by a and in 2 s complement Hex values should be input as signed 2 s complement where negative numbers have a negative sign The default format is PF 10 0 If the number of decimal places specified by PF is less than the actual value a nine appears in all the decimal places Example Instruction Interpretation DP21 Define position TPA Tell position 0000000021 Default format PF4 Change format to 4 places TPA Tell position 0021 New format sPE 4 Change to hexadecimal format TPA Tell Position 0015 Hexadecimal value PF2 Format 2 places TPA Tell Position 99 Returns 99 if position greater than 99 Adding Leading Zeros from Response to Interrogation Commands The leading zeros on data returned as a response to interrogation commands can be added by the use of the command LZ The LZ command is set to a default of 1 LZO Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 Response With Leading Zeros LZ1 Enables the LZ function TP Tell Position Interrogation Command 9 5 Response Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of inte
253. male Pin Label Description Pin Label Description Pin Label Description 1 ERR Error Output 16 RST Reset Input 31 GND Digital Ground 2 DI1 Digital Input 1 A latch 17 INCOMO Input Common DI 1 8 32 DI2 Digital Input 2 B latch 3 DI4 Digital Input 4 D latch 18 DI3 Digital Input 3 C latch 33 DI5 Digital Input 5 4 DI7 Digital Input 7 19 DI6 Digital Input 6 34 DI8 Digital Input 8 5 ELO Electronic Lock Out 20 ABRT Abort Input 35 GND Digital Ground 6 LSCOMO Limit Switch Com A D 21 N C No Connect 36 FLSA Forward Limit Switch A 7 HOMA Home Switch A 22 RLSA Reverse Limit Switch A 37 FLSB Forward Limit Switch B 8 HOMB Home Switch B 23 RLSB Reverse Limit Switch B 38 FLSC Forward Limit Switch C 9 HOMC Home Switch C 24 RLSC Reverse Limit Switch C 39 FLSD Forward Limit Switch D 10 HOMD Home Switch D 25 RLSD Reverse Limit Switch D 40 GND Digital Ground 11 OPOA Output GND PWR Bank 0 26 OPOA Output GND PWR Bank 0 41 DO1 Digital Output 1 12 DO3 Digital Output 3 27 DO2 Digital Output 2 42 DO4 Digital Output 4 13 DO6 Digital Output 6 28 DOS Digital Output 5 43 DO7 Digital Output 7 14 OPOB Output PWR GND Bank 0 29 DO8 Digital Output 8 44 CMP Output Compare A D 15 5V 5V 30 5V 5V J8 I O E H 44 pin HD D Sub Connector Female For DMC 4153 thru DMC 4183 controllers only Pin Label Description Pin Label Description Pin Label
254. ministic loop time is to have a trippoint that will wait a specified time independent of the time it took to execute the loop code In this definition the AT command is a perfect fit The below code is an example of a PLC type scan thread that runs at a 500ms loop rate A typical implementation would be to run this code in a separate thread ex XQ plcscan 2 this code will set output 3 high if inputs 1 and 2 are high and input 3 is low else output 3 will be low if input 4 is low output 1 will be high and ouput 3 will be low regardless of the states of inputs 1 2 or 3 Ana DUD HPA HAA A A R R R R R R plcscan ATO set initial time reference scan REM mask inputs 1 4 ti _TIO amp F REM variables for bit 1 and bit 3 b1 0 b3 0 REM if input 4 is high set bit 1 and clear bit 3 REM ti amp 8 gets 4th bit if 4th bit is high result 8 IF ti amp 8 8 b1 1 ELSE REM ti amp 7 get lower 3 bits if 011 then result 3 IF ti amp 7 3 b3 1 ENDIF ENDIF REM set output bits 1 and 3 accordingly REM set outputs at the end for a PLC scan OB1 b1 0B3 b3 REM wait 500ms for 500 samples use AT 500 1 REM the will reset the time reference AT 500 JP scan Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 41x3 provides the use of the following mathematical operators Operator Function Addition iE Subtraction Multiplication Division Modulus Logical
255. mit switch error The operands _LFx and _LRx contain the state of the forward and reverse limit switches respectively x represents the axis X Y Z W etc The value of the operand is either a 0 or 1 corresponding to the logic state of the limit switch Using a terminal program the state of a limit switch can be printed to the screen with the command MG_LFx or MG_LRx This prints the value of the limit switch operands for the x axis The logic state of the limit switches can also be interrogated with the TS command For more details on TS see the Command Reference Chapter 3 Connecting Hardware 32 DMC 41x3 User Manual Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user There are three homing routines supported by the DMC 41x3 Find Edge FE Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX BGX The Find Edge routi
256. mmand reference for more information about TV The Torque information is represented as a number in the range of 32767 Maximum negative torque is 32767 Maximum positive torque is 32767 Zero torque is 0 QZ Command The QZ command can be very useful when using the QR command since it provides information about the controller and the data record The QZ command returns the following 4 bytes of information BYTE INFORMATION 0 Number of axes present 1 number of bytes in general block of data record 2 number of bytes in coordinate plane block of data record 3 Number of Bytes in each axis block of data record Chapter 4 Software Tools and Communication 61 DMC 41x3 User Manual GalilSuite Windows and Linux GalilSuite is Galil s latest set of development tools for the latest generation of Galil controllers It is highly recommended for all first time purchases of Galil controllers as it provides easy set up tuning and analysis GalilSuite replaces GalilTools with an improved user interface real time scopes advanced tuning methods and communications utilities Supported Controllers DMC40x0 DMC41x3 DMC30010 DMC21x3 2 RIO47xxx DMC18x6 PCI Driver required separate installer DMC18x0 PCI Driver required separate installer DMC18x2 PCI Driver required separate installer Contact Galil for other hardware products Supported Operating Systems Microsoft Windows 8 Microsoft Windows 7
257. mon Signal Location Powers Inputs INCOM Bank 0 1 0 A D D Sub Connector DI 8 1 ABRT RST ELO LSCOM Bank 0 1 0 A D D Sub Connector FLSA RLSA HOMA FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD INCOM Bank 1 1 O E H D Sub Connector DI 16 9 LSCOM Bank 1 1 O E H D Sub Connector FLSE RLSE HOME FLSF RLSF HOMF FLSG RLSG HOMG FLSH RLSH HOMH Table 3 2 5 8 axis controller INCOM and LSCOM banks and corresponding inputs powered The full pin outs for each bank can be found in the Pin outs pg 187 Chapter 3 Connecting Hardware 35 DMC 41x3 User Manual Wiring the Optoisolated Digital Inputs To take full advantage of optoisolation an isolated power supply should be used to provide the voltage at the input common connection Connecting the ground of the isolated power to the ground of the controller will bypass optoisolation and is not recommended if true optoisolation is desired If there is not an isolated supply available the 5 Voc 12 Voc and GND controller references may be used to power INCOM LSCOM The current supplied by the controller references are limited see 5 12V Power Output Specifications pg 178 in the Appendices for electrical specifications Using the controller reference power completely bypasses optoisolation and is not recommended for most applications Banks of inputs can be used as either active high or low Connecting V to INCOM LSCOM will configure the inputs f
258. motor The maximum step rate generated by the controller is 6 000 000 microsteps second The SDM 44140 drives motors operating at up to 3 Amps at 20 to 60 VDC available voltage at motor is 10 less There are four software selectable current settings 0 5 A 1 A 2 A and 3 A Plus a selectable lowcurrent mode reduces the current by 75 when the motor is not in motion No external heat sink is required The BOX option is required when the SDM 44140 is order with the DMC 41x3 NOTE Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation pMc 4143 MOTION GAUL ADE IN USA OUP Figure A7 1 DMC 4143 D4140 DMC 4143 with SDM 44140 A7 SDM 44140 D4140 229 DMC 41x3 User Manual Electrical Specifications DC Supply Voltage Max Current per axis Max Step Frequency 20 60 VDC 3 0 Amps Selectable with AG command 6 MHz Motor Type Bipolar 2 Phase Switching Frequency 60 kHz Minimum Load Inductance 0 5 mH Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr MOL
259. must be ordered Maximum Step Frequency 6 MHz Motor Type Mating Connectors Bipolar 2 Phase On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor Power Connectors 4 pin Molex Mini Fit Jr MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector 1 B 2 A 3 B 4 At 1 4 Amps Phase Amps Selectable with AG commana A6 SDM 44040 D4040 D4020 226 DMC 41x3 User Manual Operation The SDM 44040 should be setup for Active High step pulses MT 2 or MT 2 5 The AG command sets the current on each axis the LC command configures each axis s behavior when holding position and the YA command sets the step driver resolution These commands are detailed below see also the command reference for more information Current Level Setup AG Command AG configures how much current the SDM 44040 delivers to each motor Four options are available 0 5A 0 75A 1 0A and 1 4 Amps Drive Current Selection per Axis AG n n n n n n n n n 0 0 5 A n 1 0 75 A default n 2 10A n 3 1 4 A Low Current Setting LC Command LC configures each motor s behavior when holding position when RP is constant
260. n Interpretation POINTS Label SP 7000 Speed AC 80000 DC 80000 Acceleration LOOP VP AN 1 1000 Read and analog input compute position PA VP Command position BGA Start motion AMA After completion JP LOOP Repeat EN End Example Position Follower Continuous Move Method Read the anal og input compute the commanded position and the position error Command the motor to run at a speed in proportions to the position error Instruction Interpretation CONT Label AC 80000 DC 80000 Acceleration rate JG 0 Start job mode BGX Start motion LOOP vp AN 1 1000 Compute desired position ve vp _TPA Find position error vel ve 20 Compute velocity JG vel Change velocity JP LOOP Change velocity EN End Example Low Pass Digital Filter for the Analog inputs Because the analog inputs on the Galil controller can be used to close a position loop they have a very high bandwidth and will therefor read noise that comes in on the analog input Often when an analog input is used in a motion control system digital filter may be app but not for closed loop control the higher bandwidth is not required In this case a simple lied to the analog input and the output of the filter can be used for in the motion control application This example shows how to apply a simple single pole low pass digital filter to an analog input This code is commonly run in a separate thread XQ filt 1 example of executing in thread 1 f RE
261. n Present in Present in Presentin Present in Data Data Record Data Record Data Record Data Record Data Record Data Record Data Record Record Bytes 2 3 of Header Bytes 2 and 3 make a word which represents the Number of bytes in the data record including the header Byte 2 is the low byte and byte 3 is the high byte NOTE The header information of the data records is formatted in little endian reversed network byte order Thread Status 1 Byte BIT 7 BIT6 BITS BIT4 BIT3 BIT2 BIT1 BITO Thread 7 Thread 6 Thread 5 Thread 4 Thread 3 Thread 2 Thread 1 Thread 0 Running Running Running Running Running Running Running Running Coordinated Motion Status for S or T Plane 2 Byte BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in N A N A N A N A N A N A N A Progress BIT 7 BIT 6 BIT5 BIT 4 BIT 3 BIT 2 BIT1 BITO Motion is Topan Motion is stopping due Mouonis N A N A __ making final N A N A N A slewing to ST or Limit decel Switch Axis Status 1 Word BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in Mode of Mode of FE Find Edge Home HM in 1 Phase of HM 2 Phase of HM Mode of Motion Progress Motion PA or Motion PA only in Progress Progress complete complete or Fl Coord Motion PR command issued BIT7 BIT 6 BIT5 BIT 4 BIT 3 BIT 2 BIT1 BITO Negative Mode of Motion is Motion is Motionis Latch i
262. n addition the SPM mode can be used as a method to correct for friction at the end of a microstepping move This capability provides closed loop control at the application program level SPM mode can be used with Galil and non Galil step drives SPM mode is configured executed and managed with seven commands This mode also utilizes the POSERR automatic subroutine allowing for automatic user defined handling of an error event Internal Controller Commands user can query Qs Error Magnitude pulses User Configurable Commands user can query amp change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status A pulse is defined by the resolution of the step drive being used Therefore one pulse could be a full step a half step or a microstep When a Galil controller is configured for step motor operation the step pulse output by the controller is internally fed back to the auxiliary encoder register For SPM the feedback encoder on the stepper will connect to the main encoder port Enabling the SPM mode on a controller with YS 1 executes an internal monitoring of the auxiliary and main encoder registers for that axis or axes Position error is then tracked in step pulses between these two registers QS command TP x YA x YB S TD
263. n in Figure 3 6 and Bank 1 in Figure 3 7 Refer to Pin outs in the Appendix for pin out information ty Output PWR coal bopa OPOA Output GND Figure 3 6 4mA sinking wiring diagram for Bank 0 DO 8 1 Chapter 3 Connecting Hardware 38 DMC 41x3 User Manual 4 3 3V Output GND Figure 3 7 4mA sinking wiring diagram for Bank 1 DO 16 9 25mA Sinking Optoisolated Outputs LSNK Description The 25mA sinking option refereed to as lower power sinking LSNK are capable of sinking up to 25mA per output The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output PWR Max Voltage 24 Voc Output PWR Min Voltage 5 Voc ON Voltage No Load Output PWR 5V 5c 1 2 Voc Max Drive Current per Output 25mA Sinking Wiring the 25mA Sinking Outputs When wiring the 25mA sinking outputs the load is wired in the same fashion as the 4mA sinking outputs The output power supply will be connected to Output PWR labeled OPnB and the power supply return will be connected to Output GND labeled OPnA where n denotes 0 or 1 referring to Bank 0 and Bank 1 respectively Note that the load is wired between Output PWR and DO The wiring diagram for Bank 0 is shown in Figure 3 8 and Bank 1 in Figure 3 9 Refer to Pin outs in the Appendix for pin out information 3 3V Output PWR Spiel LOAD Output GND DOJ 8 1 Figure 3 8 2
264. n mark responses to commands sent to the controller the TCP handshaking is not required Packets must be limited to 512 data bytes including UDP TCP IP Header or less Larger packets could cause the controller to lose communication NOTE In order not to lose information in transit the user must wait for the controller s response before sending the next packet Addressing There are three levels of addresses that define Ethernet devices The first is the MAC or hardware address This is a unique and permanent 6 byte number No other device will have the same MAC address The DMC 41x3 MAC address is set by the factory and the last two bytes of the address are the serial number of the board To find the Ethernet MAC address for a DMC 41x3 unit use the TH command A sample is shown here with a unit that has a serial number of 3 Sample MAC Ethernet Address 00 50 4C 38 00 03 The second level of addressing is the IP address This is a 32 bit or 4 byte number that usually looks like this 192 168 15 1 The IP address is constrained by each local network and must be assigned locally Assigning an IP address to the DMC 41x3 controller can be done in a number of ways The first method for setting the IP address is using a DHCP server The DH command controls whether the DMC 41x3 controller will get an IP address from the DHCP server If the unit is set to DH1 default and there is a DHCP server on the network the controller will be dynamically
265. n motion AM After complete MG FOUND HOME Send message DP 0 Define position as 0 EN End Command Summary Homing Operation COMMAND DESCRIPTION FE XYZW Find Edge Routine This routine monitors the Home Input FI XYZW Find Index Routine This routine monitors the Index Input HM XYZW Home Routine This routine combines FE and FI as Described Above SC XYZW Stop Code TS XYZW Tell Status of Switches and Inputs Operand Summary Homing Operation Operand Description HMx Contains the value of the state of the Home Input SCX Contains stop code TSX Contains status of switches and inputs Chapter 6 Programming Motion 113 DMC 41x3 User Manual High Speed Position Capture The Latch Function Often it is desirable to capture the position precisely for registration applications Position capture can be programmed to latch on either a corresponding input see Table 6 1 or on the index pulse for that axis The position can be captured for either the main or auxiliary encoder within 25 microseconds of an high to low transition Input 1 A axis latch Input 9 E axis latch Input 2 B axis latch Input 10 F axis latch Input 3 C axis latch Input 11 G axis latch Input 4 D axis latch Input 12 H axis latch Table 6 1 Inputs and corresponding axis latch NOTE Latching is not valid with sampled feedback types such as SSI BiSS and Analog
266. nd n are numbers between 0 and 1 and determine the degree of filtering The maximum value of 1 implies no filtering resulting in trapezoidal velocity profiles Smaller values of the smoothing parameters imply heavier filtering and smoother moves The following example illustrates the effect of smoothing Figure 6 21 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing PR 20000 Position AC 100000 Acceleration Dc 100000 Deceleration SP 5000 Speed Ee 5 Filter for smoothing BG X Begin Chapter 6 Programming Motion 110 DMC 41x3 User Manual ACCELERATION VELOCITY No smoothing ACCELERATION VELOCITY Ss y smoothing a O Q ran 2 g lt Figure 6 21 Trapezoidal velocity and smooth velocity profiles Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command smoothes the frequency of step motor pulses Similar to the command IT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS X Y Z W where x y z w is an integer from 0 5 to 128 and represents the amount of smoothing The smoothing parameters x y z w and n are numbers between 0 5and 128 and determine the degree of filtering The minimum value of 0 5 implies th
267. ndent and follows prescribed velocity profile Velocity control where no final endpoint is Independent Jogging JG AC DC ST prescribed Motion stops on Stop command Absolute positioning mode where absolute Position Tracking PA AC DC SP PT position targets may be sent to the controller while the axis is in motion Motion Path described as incremental position Contour Mode CM CD DT points versus time Motion Path described as incremental position PVT Mode PV BT velocity and delta time 2 to 8 axis coordinated motion where path is Linear Interpolation Mode LM LI LE VS VR VA described by linear segments VD 2 D motion path consisting of arc segments and Vector Mode Linear and Circular Interpolation VM VP CR VS VR VA linear segments such as engraving or quilting Motion VD VE Third axis must remain tangent to 2 D motion Wector Mode Linear and Circular Interpolation VM VP CR VS VA VD path such as knife cutting Motion with Tangent Motion TN VE Electronic gearing where slave axes are scaled to Electronic Gearing GA GD _GP GR GM master axis which can move in both directions if gantry Master slave where slave axes must follow a Electronic Gearing and Ramped Gearing GA GD _GP GR Chapter 6 Programming Motion 69 DMC 41x3 User Manual Moving along arbitrary profiles or Contour Mode mathematically prescribed profiles such as sine lor cosine trajectories CM CD
268. ne will cause the motor to accelerate and then slew at constant speed until a transition is detected in the logic state of the Home input The direction of the FE motion is dependent on the state of the home switch High level causes forward motion The motor will then decelerate to a stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP When using the FE command it is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine is initiated by the command sequence FIX BGX Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command and then moves back to the index pulse and speed HV Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HMX BGX Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is det
269. nerate a trajectory along these points it interpolates linearly between the points The resulting interpolated points include the position 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are A CMX Specifies X axis for contour mode CD 48 2 Specifies first position increment and time interval 2 ms CD 240 3 Specifies second position increment and time interval 2 ms CD 48 4 Specifies the third position increment and time interval 2 ms CD 0 0 End Contour buffer Wait JIP Wait CM lt gt 511 Wait until path is done EN POSTION COUNTS 336 288 w 192 4 ve TNE ns 1 4 8 12 16 n 4 8 Z SEATI SEQUENT SEGMENTS Figure 6 19 The Required Trajectory Additional Commands _CM gives the amount of space available in the contour buffer 511 maximum Zero parameters for DT followed by zero parameters for CD will exit the contour mode If no new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a Specifying a 1 for the DT or as the time interval in the CD command will pause the contour buffer Issuing the CM command will clear the contour buffer Chapter 6 Programming Motion 99 DMC 41x3 User Manual Command Summary Contour Mode COMMAND DESCRIPTION CM XYZW Specifies which axes for cont
270. ng lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 41x3 provides a special feature for automatic capture of data such as position position error inputs or torque This is useful for teaching motion trajectories or observing system performance Up to eight types of data can be captured and stored in eight arrays The capture rate or time interval may be specified Recording can done as a one time event or as a circular continuous recording Chapter 7 Application Programming 140 DMC 41x3 User Manual Command Summary Automatic Data Capture Command Description IRA Selects up to eight arrays for data capture The arrays must be defined with the DM nf m o p command RD Selects the type of data to be recorded where type1 type2 type3 and type 4 represent the typel type2 type3 ty various types of data see table below The order of data type is important and corresponds pe4 with the order of n m o p arrays in the RA command RC n m The RC command begins data collection Sets data capture time interval where n is an integer between 1 and 8 and designates 2 msec between data m is optional and specifies the number of elements to be captured If m is not defined the number of elements defaults to the smallest array defined by DM When m is a negative number the recording is done continuously in a circular manner _RD is the recording pointer and indicates the address
271. ng example will demonstrate how the command is used Example Electronic Gearing Over a Specified Interval Objective Run two geared motors at speeds of 1 132 and 045 times the speed of an external master Because the master is traveling at high speeds it is desirable for the speeds to change slowly Solution Use a DMC 4133 controller where the Z axis is the master and X and Y are the geared axes We will implement the gearing change over 6000 counts 3 revolutions of the master axis MO Z Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GD 6000 6000 Specify ramped gearing over 6000 counts of the master axis GR 1 132 045 Specify gear ratios Question What is the effect of the ramped gearing Answer Below in the example titled Electronic Gearing gearing would take effect immediately From the start of gearing if the master traveled 6000 counts the slaves would travel 6792 counts and 270 counts Chapter 6 Programming Motion 88 DMC 41x3 User Manual Using the ramped gearing the slave will engage gearing gradually Since the gearing is engaged over the interval of 6000 counts of the master the slave will only travel 3396 counts and 135 counts respectively The difference between these two values is stored in the _GPn operand If exact position synchronization is required the IP command is used to adjust for the difference Command Summary Electronic Gearing COMMAND DESCRIPTI
272. ng for a specified amount of time to elapse or waiting for an input to change logic levels The DMC 41x3 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the controller can make decisions based on its own status or external events without intervention from a host computer Chapter 7 Application Programming 119 DMC 41x3 User Manual DMC 41x3 Event Triggers Command Function AM XYZWorS Halts program execution until motion is complete on the ABCDEFGH specified axes or motion sequence s AM with no parameter tests for motion complete on all axes This command is useful for separating motion sequences in a program AD X or Y or Z or W Halts program execution until position command has reached A or Bor Cor D or E or F or G or H the specified relative distance from the start of the move Only one axis may be specified at a time ARXorYorZorW Halts program execution until after specified d
273. nt KS Stepper Motor Smoothing T Motor Type 2 2 2 5 or 2 5 for stepper motors RP Report Commanded Position TD Report number of step pulses generated by controller TP Tell Position of Encoder Chapter 6 Programming Motion 104 DMC 41x3 User Manual Operand Summary Stepper Motor Operation IOPERAND DESCRIPTION DEX Contains the value of the step count register for the x axis DPx Contains the value of the main encoder for the x axis ITx Contains the value of the Independent Time constant for the x axis KSX Contains the value of the Stepper Motor Smoothing Constant for the x axis MTx Contains the motor type value for the x axis RPX Contains the commanded position generated by the profiler for the x axis TDx Contains the value of the step count register for the x axis TPx Contains the value of the main encoder for the x axis Stepper Position Maintenance Mode SPM The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle the event of stepper motor position error The mode looks at position feedback from the main encoder and compares it to the commanded step pulses The position information is used to determine if there is any significant difference between the commanded and the actual motor positions If such error is detected it is updated into a command value for operator use I
274. ntains four transconductance PWM amplifiers for driving brushless or brush type servo motors Each amplifier drives motors operating at up to 10 Amps continuous 20 Amps peak 20 80 VDC The gain settings of the amplifier are user programmable at 0 5 Amp Volt 1 0 Amp Volt and 2 0 Amp Volt The switching frequency is 24 kHz The drive operates in a Chopper Mode The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43240s can be used in 5 thru 8 axis controllers A shunt regulator option is available If higher voltages are required please contact Galil If the application has a potential for regenerative energy it is recommended to order the controller with the ISCNTL Isolate Controller Power option and the SR90 SR 49000 Shunt Regulator Option The BOX option is required when the AMP 43240 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation Figure A3 1 DMC 4143 D3240 BOX4 DMC 4143 with AMP 43240 A3 AMP 43240
275. nts of the continuous filter are P 50 D 0 98 The filter equation may be written in the continuous equivalent form G s 50 0 98s 098 s 51 The system elements are shown in Figure 10 6 FITER Z0 DAC 5 MOTOR y L S 2000 500 gt ae 50 0 980s sam 10008 4 7 Ere ENCODER 318 Figure 10 6 Mathematical model of the control system The open loop transfer function A s is the product of all the elements in the loop A s 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency w at which A j w equals one This can be done by the Bode plot of A j w as shown in Figure 10 7 Magnitude 3 W 200 W eds Figure 10 7 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s Chapter 10 Theory of Operation 173 DMC 41x3 User Manual Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 j200 j200 2000 a Arg A j200 tan71 200 51 180 tan 4 200 2000 a 76 180 6 110 Finally the phase margin PM equals PM 180 a 70 As long as PM is positive the system is stable However for a well damped system PM should be between 30 and 45 The phase margin of 70 given above indicated over damped response Next we discuss the
276. o so by watching the different hall transitions by using the QH command and rotating the motor by hand in an MO state If the motor and encoder polarity are correct than TP A should report a smaller number when QH A reports 1 than when QH A reports 3 If TP A is larger when QH A reports 1 than 3 then the motor is ina positive feedback state and will runaway when sent movement commands Reverse the encoder feedback as described in Step 6 Connecting Encoder Feedback pg 20 10 Issue MO Aand set OFA 0 Set small and appropriate values of KP Aand KD A and verify the motor holds position once a SH Ais issued The motor is now under closed loop control Chapter 2 Getting Started 26 DMC 41x3 User Manual 11 Double check commutation by issuing a small jog command JGA 1000 BGA and verify the motor spins smoothly for more than 360 degrees If the user monitors QH during the jog movement it should report a number 1 6 transitioning through the following sequence 1 3 2 6 4 5 and repeating 12 If no runaway occurs the motor is ready to be tuned Skip to Step 10 Tune the Servo System pg 31 Sinusoidal Commutation The following amplifiers support sinusoidal commutation A4 AMP 435x0 D3540 D3520 pg 213 A5 AMP 43640 D3640 pg 219 Galil provides several sinusoidal commutation methods The following list provides a brief description of how each method works and Table 2 10 discusses the pros and cons of each Detailed instruct
277. odbus structure This is necessary for sending configuration and special commands to an I O device The formats vary depending on the function code that is called For more information refer to the Command Reference Chapter 4 Software Tools and Communication 55 DMC 41x3 User Manual The third level of Modbus communication uses standard Galil commands Once the slave has been configured the commands that may be used are IN AN SB CB OB and AO For example AO 2020 8 2 would tell I O number 2020 to output 8 2 volts If a specific slave address is not necessary the I O number to be used can be calculated with the following 1 O Number HandleNum 1000 Module 1 4 BitNum 1 Where HandleNum is the handle number from 1 A to 8 8 Module is the position of the module in the rack from 1 to 16 BitNum is the I O point in the module from 1 to 4 Modbus Examples Example 1 DMC 4143 connected as a Modbus master to a RIO 47120 via Modbus The DMC 4143 will set or clear all 16 of the RIO s digital outputs 1 Begin by opening a connection to the RIO which in our example has IP address 192 168 1 120 IHB 192 168 1 120 lt 502 gt 2 Issued to DMC 4143 2 Dimension an array to store the commanded values Set array element 0 equal to 170 and array element 1 equal to 85 array element 1 configures digital outputs 15 8 and array element 0 configures digital outputs 7 0 DM myarray 2 myarray 0 170 which is 10101010 in b
278. of an external master The master is driven at speeds between 0 and 1800 RPM 2000 counts rev encoder Solution Use a DMC 4133 controller where the Z axis is the master and X and Y are the geared axes MO Z Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GR 1 132 045 Specify gear ratios Now suppose the gear ratio of the X axis is to change on the fly to 2 This can be achieved by commanding GR 2 Specify gear ratio for X axis to be 2 Example Gantry Mode In applications where both the master and the follower are controlled by the DMC 41x3 controller it may be desired to synchronize the follower with the commanded position of the master rather than the actual position This eliminates the coupling between the axes which may lead to oscillations For example assume that a gantry is driven by two axes X Y on both sides This requires the gantry mode for strong coupling between the motors The X axis is the master and the Y axis is the follower To synchronize Y with the commanded position of X use the instructions Chapter 6 Programming Motion 89 DMC 41x3 User Manual GA CX Specify the commanded position of X as master for Y GR 1 Set gear ratio for Y as 1 1 GM 1 Set gantry mode PR 3000 Command X motion BG X Start motion on X axis You may also perform profiled position corrections in the electronic gearing mode Suppose for example that you need to advance the slave 10 counts
279. often an encoder and the position feedback is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called over damped response Chapter 10 Theory of Operation 167 DMC 41x3 User Manual The results may be worse if we turn the faucet too fast The overreaction results in temperature oscillations When the response of the system oscillates we say that the system is unstable Clearly unstable responses are bad when we want a constant level What causes the oscillations The basic cause for the instability is a combination of delayed reaction and high gain In the case of the temperature control the delay is due to the water flowing in the pipes When the human reaction is too strong the response becomes unstabl
280. ograms for the DMC 41x3 may also be created and edited locally using the DMC 41x3 when using a program such as hyper terminal or telnet The DMC 41x3 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number or label by specifying a line number or label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN Line numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 80 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below Edit Mode Commands lt RETURN gt Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of lt RETURN gt will cause the editor to advance
281. ols and Communication 52 DMC 41x3 User Manual Ethernet Configuration Communication Protocols The Ethernet is a local area network through which information is transferred in units known as packets Communication protocols are necessary to dictate how these packets are sent and received The DMC 41x3 supports two industry standard protocols TCP IP and UDP IP The controller will automatically respond in the format in which it is contacted TCP IP is a connection protocol The master or client connects to the slave or server through a series of packet handshakes in order to begin communicating Each packet sent is acknowledged when received If no acknowledgment is received the information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connection If information is lost the controller does not return a colon or question mark Because UDP does not provide for lost information the sender must re send the packet It is recommended that the motion control network containing the controller and any other related devices be placed on a closed network If this recommendation is followed UDP IP communication to the controller may be utilized instead of a TCP connection With UDP there is less overhead resulting in higher throughput Also there is no need to reconnect to the controller with a UDP connection Because handshaking is built into the Galil communication protocol through the use of colon or questio
282. on Programming 154 DMC 41x3 User Manual INSTRUCTION FUNCTION A Label V3 5 Initial position ratio DPO Define the starting position JGO Set motor in jog mode as zero BGX Start B VIN AN 1 Read analog input V2 V1 V3 Compute the desired position V4 V2 _TPX _TEX Find the following error V5 V4 20 Compute a proportional speed JG V5 Change the speed JP B Repeat the process EN End Backlash Compensation by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective way to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method described below This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The slide is to be controlled by a rotary motor which is coupled to the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy is for 0 5 micron The basic dilemma is where to mount the sensor If you use a rotary sensor you get a 4 micron backlash error On the other hand if you use a linear encoder the backlash in the feedback loop will cause oscillations due to instability An alternative approach is the dual loop where we use two sensors rotary and linear The rotary sensor assures stability because the posit
283. on method and whether halls are required Chapter 2 Getting Started 23 DMC 41x3 User Manual Amplifier Commutation Halls Required A1 AMP 430x0 D3040 D3020 pg 198 Trapezoidal Halls required for brushless motors A2 AMP 43140 D3140 pg 204 Brushed No A3 AMP 43240 D3240 pg 207 Trapezoidal Halls required for brushless motors A4 AMP 435x0 D3540 D3520 pg 213 Sinusoidal Halls optional for brushless motors A5 AMP 43640 D3640 pg 219 Sinusoidal Halls optional for brushless motors A6 SDM 44040 D4040 D4020 pg 225 N A stepper No A7 SDM 44140 D4140 pg 229 N A stepper No Table 2 5 Amplifier documentation location commutation and hall requirements for each internal amplifier Pin outs for the hall signals is found on the 26 pin D sub connector Jn1 Encoder 26 pin HD D Sub Connector Female pg 188 If wiring 3 phased brushless motors NOTE Skip to the additional instructions provided in Step 8a Commutation of 3 phased Brushless Motors pg 24 to find proper commutation Step C Issue the appropriate configuration commands Table 2 6 provides a brief list of configuration commands that may need to be set depending on your motor type and motor specifications Command Description MT Configures an axis for use with either a stepper or servo motor AG Amplifier gain A V for servos or A Phase for steppers Will configure an
284. on on the AMP 435x0 D3540 D3520 is Inverter Mode The minimum inductance calculations above are based on Inverter mode If you have a motor with lower inductance Chopper mode can be applied for the PWM output Contact a Galil Applications Engineer to review minimum inductance requirements if Chopper mode operation is required Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor Power Connectors 4 pin Molex Mini Fit Jr MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector 1 Phase C 2 Phase B N C for Brushed Motors 3 No Connect 4 Phase A A4 AMP 435x0 D3540 D3520 214 DMC 41x3 User Manual Operation Commutation Related Velocity When using sinusoidal commutation and higher speed applications it is a good idea to calculate the speed at which commutation can start to affect performance of the motor In general it is recommended that there be at least 8 servo samples for each magnetic cycle The time for each sample is defined by TM TM 1000 is default and is in units of us per sample or us sample TM can be lowered to achieve higher speeds Below is the equa
285. on the A axis can be assigned to the variable V with the command V _TPA The Command Reference denotes all commands which have an equivalent operand as Operand Usage Also see description of operands in Chapter 7 Application Programming Command Summary For a complete command summary see Command Reference manual http www galilme com support manuals php Chapter 5 Command Basics 68 DMC 41x3 User Manual Chapter 6 Programming Motion Overview The DMC 41x3 provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 4113 are single axis controllers and use X axis motion only Likewise the DMC 4123 use X and Y the DMC 4133 use X Y and Z and the DMC 4143 use X Y Z and W The DMC 4153 use A B C D and E The DMC 4163 use A B C D E and F The DMC 4173 use A B C D E F and G The DMC 4183 use the axes A B C D E F G and H The example applications described below will help guide you to the appropriate mode of motion interchanged with ABCD For controllers with 5 or more axes the specifiers ABCDEFGH are used XYZ and W may be master such as conveyer speed EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each axis Independent Axis Positioning PA PR SP AC DC is indepe
286. ons the motor is properly wired and commutated Note Commutation initialization is required each time the controller is booted up BI BC Method NOTE The motor must have hall sensors to work with BI BC In addition the AMP 43640 is a special case that supports hall initialization through it s general inputs rather than standard hall pins To query hall state in this case use _BCx rather than QH See the BI command for more information BI BC method uses the motors hall sensors to initialize the brushless degrees of the motor The halls motor phases and encoder feedback must all be wired to the DMC The hall inputs must be aligned so that hall A aligns with the excitement of motor phase A and B hall B aligns with the excitement of motor phases B and C and hall C aligns with the excitement of motor phases C and A Setting up the motor for BI BC initialization Chapter 2 Getting Started 28 DMC 41x3 User Manual may require wiring changes to both the motor leads and the hall inputs The following steps will ensure that the correct configuration is reached 1 Put the motor in an MO state Move the motor shaft manually in the direction desired for positive movement a If TP is decreasing reverse encoder direction See Step 6 Connecting Encoder Feedback pg 20 2 Continue to move the motor in the positive direction by hand but now monitor the state of QH QH should change as the motor continues to rotate in t
287. or active low as current will flow through the diode when the inputs are pulled to the isolated ground Connecting the isolated ground to INCOM LSCOM will configure the inputs for active high as current will flow through the diode when the inputs are pulled up to V Figure 3 1 Figure 3 5 are the optoisolated wiring diagrams for powering INCOM LSCOM Bank 0 and INCOM LSCOM Bank 1 and their corresponding inputs 5V INCOM 2 2K CPU DI 8 1 PS2805 Figure 3 1 Digital Inputs 1 8 DI 8 1 5V INCOM1 2 2K CPU DI 16 9 PS2805 Figure 3 2 Digital Inputs 9 16 DI 16 9 Chapter 3 Connecting Hardware 36 DMC 41x3 User Manual 5V LSCOM 2 2K CPU FLS_ A B C D RLS_ A B C D HOME_ A B C D PS2805 Figure 3 3 Limit Switch Inputs for Axes A D 5V LSCOM1 2 2K CPU FLS_ E F G H RLS_ E F G H HOME_ E F G H PS2805 Figure 3 4 Limit Switch Inputs for Axes E H 5V INCOM 2 2K CPU ELO ABRT RST PS2805 Figure 3 5 ELO Abort and Reset Inputs Chapter 3 Connecting Hardware 37 DMC 41x3 User Manual Optoisolated Outputs The DMC 41x3 has several different options for the uncommitted digital outputs labeled as DO The default outputs are 4mA sinking which are ideal for interfacing to TTL level devices Additional options include 25mA sinking lower power sinking LSNK 25mA sourcing low power sourcing LSRC and 500mA sourcing outputs high power sourcing HSRC Please refer to your part number to determine w
288. orizontal didt Source Scale div Offset div m TTA Axis A tore ao jmi ao jmi a0 2O jml 2v S 3 1 Co NH gt z E E EJ EJ EJ EJ E a gt EP E e RE ee 1 1 1 1 1 1 RF e Ie AHEHE Sms Trigger Channel W _TTAv Edge v Level 0 1 v Mode Repeat v READY Stop dT1A 9 03 V_TTA Z Figure A4 2 Peak Current Operation Brushed Motor Operation The AMP 43540 can be setup to run brushed motors by setting the BR command to 1 for a particular axis Wire the motor power leads to phases A and C on the motor power connector Do not set BA BM or use the BX command for any axis that is driving a brushed motor Using External Amplifiers The BR command must be set to a 1 for any axis where an AMP 43540 is installed but the use of an external axis is required This setting will disable the requirement to have the BA BM and BX or BZ commands executed prior to being able to issue the SH command for that axis BR 1 is required for both external servo and stepper drivers Use the connectors on top of the controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Step 9 Connecting External Amplifiers and Motors in Chapter 2 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA
289. ormation Appendices 188 DMC 41x3 User Manual J1 Ethernet RJ45 Pin Signal TXP TXN RXP NC NC RXN NID OBR W NM NC NC The Ethernet connection is Auto MDIX 100bT 10bT J2 USB The USB port on the DMC 41x3 is a Female Type B USB port The standard cable when communicating to a PC will be a Male Type A Male Type B USB cable J3 RS 232 Auxiliary Port Female Standard connector and cable 9Pin Pin Signal 1 NC RXD TXD NC GND NC RTS CTS WOlOIN D W B W NM NC 5V with APWR Jumper J3 RS 422 Auxiliary Port Non Standard Option Standard connector and cable when DMC 41x3 is ordered with RS 422 Option For detailed information on the RS 422 option see RS 422 Auxiliary Serial Port Serial Communication in the Appendices Pin Signal 1 CTS RXD TXD RTS GND CTS RXD TXD WOlOIN D W BRl W N RTS JP1 Jumper Description for DMC 41x3 Appendices 189 DMC 41x3 User Manual Label Function If jumpered ARXD RS 422 Option Only Connects a 120 Q Termination resistor between the differential Receive inputs on the Aux Serial port Pins 2 and 7 on RS 422 Auxiliary Port ACTS RS 422 Option Only Connects a 120 Q Termination resistor between the differential Clea
290. ost computer The DMC 41x3 can communicate with a host computer through any application that can send TCP IP or UDP IP packets A good example of this is Telnet a utility that comes with most Windows systems Modbus An additional protocol layer is available for speaking to I O devices Modbus is an RS 485 protocol that packages information in binary packets that are sent as part of a TCP IP packet In this protocol each slave has a 1 byte slave address The DMC 41x3 can use a specific slave address or default to the handle number The port number for Modbus is 502 The Modbus protocol has a set of commands called function codes The DMC 41x3 supports the 10 major function codes Function Code Definition 01 Read Coil Status Read Bits 02 Read Input Status Read Bits 03 Read Holding Registers Read Words 04 Read Input Registers Read Words 05 Force Single Coil Write One Bit 06 Preset Single Register Write One Word 07 Read Exception Status Read Error Code 15 Force Multiple Coils Write Multiple Bits 16 Preset Multiple Registers Write Words 17 Report Slave ID The DMC 41x3 provides three levels of Modbus communication The first level allows the user to create a raw packet and receive raw data It uses the MBh command with a function code of 1 The format of the command is MBh 1 len array where lenis the number of bytes array is the array with the data The second level incorporates the M
291. ount rev encoder setup OE 1 KS 16 MT 2 2 2 2 YA 2 YB 2007 YC 4000 SH A Wr 100 motion SP 5P2 PR 1000 BG A EN Set the profiler to stop axis upon error Set step smoothing Motor type set to stepper Step resolution of the drive Motor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Perform motion Set the speed Prepare mode of motion Begin motion End of program subroutine REM When error occurs the axis will stop due to OE1 In REM POSERR query the status YS and the error QS correct REM and return to the main code POSERR Wr 100 spsave _SPA JP return YSA lt gt 2 SP64 MG ERROR QSA YRA _QSA MC A Automatic subroutine is called when _YS 2 Wait helps user see the correction Save current speed setting Return to thread zero if invalid error Set slow speed setting for correction Else error is valid use QS for correction Wait for motion to complete MG CORRECTED ERROR NOW QSX WT 100 return SPA spsave RE 0 Wait helps user see the correction Return the speed to previous setting Return from POSERR Example Friction Correction The following example illustrates how the SPM mode can be useful in correcting for X axis friction after each move when conducting a reciprocating motion The drive is a 1 64th microstepping drive with a 1 8 step motor and
292. ouring mode Any non contouring axes may be operated in other modes CM ABCDEFGH Contour axes for DMC 4183 CD x y Z W Specifies position increment over time interval Range is 32 000 CD 0 0 0 0 ends the contour buffer This is much like the LE or VE commands CD a b c d e f g h Position increment data for DMC 4183 DT n Specifies time interval 2 sample periods 1 ms for TM1000 for position increment where n is an integer between 1 and 8 Zero ends contour mode If n does not change it does not need to be specified with each CD CM Amount of space left in contour buffer 511 maximum General Velocity Profiles The Contour Mode is ideal for generating any arbitrary velocity profiles The velocity profile can be specified as a mathematical function or as a collection of points The design includes two parts Generating an array with data points and running the program Generating an Array An Example Consider the velocity and position profiles shown in Figure 6 20 The objective is to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe the position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner 1 cos 27 B X 4 Asin 27 B Note w is the angular velocity X is the position and T is the variable time in milliseconds In the given example
293. per drivers but they can be configured for a PWM output See the MT command for more details PWM Step and Sign Direction Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA_ Sink Source External Servo Control The DMC 40x0 command voltage ranges between 10V and is output on the motor command line MCMn where nis A H This signal along with GND provides the input to the motor amplifiers The amplifiers must be sized to drive the motors and load For best performance the amplifiers should be configured for a torque current mode of operation with no additional compensation The gain should be set such that a 10 volt input results in the maximum required current Motor Command Line Electrical Specifications Output Voltage 10 VDC Motor Command Output Impedance 500 Q The standard configuration of the amplifier enable signal is 5V active high amp enable HAEN sinking In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed by configuring the Amplifier Enable Circuit on the DMC 41x3 NOTE Many amplifiers designate the enable input as inhibit Amplifier Enable This section describes how to configure the DMC 41x3 for different Amplifier Enable configurations The default configuration of the amplifier enable signal is 5V active high amp enable HAEN sinking In other words the AEN signal will be high when the controller
294. profiler is complete This is Chapter 6 Programming Motion 103 DMC 41x3 User Manual caused by the stepper motor smoothing filter KS To understand this consider the steps the controller executes to generate step pulses First the controller generates a motion profile in accordance with the motion commands Second the profiler generates pulses as prescribed by the motion profile The pulses that are generated by the motion profiler can be monitored by the command RP Reference Position RP gives the absolute value of the position as determined by the motion profiler The command DP can be used to set the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Third the output of the motion profiler is filtered by the stepper smoothing filter This filter adds a delay in the output of the stepper motor pulses The amount of delay depends on the parameter which is specified by the command KS As mentioned earlier there will always be some amount of stepper motor smoothing Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver The pulses which are generated by the smoothing filter can be monitored by the command TD Tell Dual TD gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position
295. pter 7 Application Programming 115 OND E aaa j Program Format Executing Programs Multitas Debugging Programs Program Flow Commands Mathematical and Functiona Var iables um Input of Data Numeric ad Sirie Output of Data Numeric and D Hardware FO ccs aaa eee acta i caste EE Example Applicatio Using the DMC Editor to Enter Programs fAdvanwed Chapter 8 Hardware amp Software Protection 158 Introduction Hardware Protection Software Protection ee apter 9 Troubleshootin Overview Chapter 10 Theory of Operation 163 166 Overview Operation of Closed Loop Systems System Modeling io cscsssdeascasansvesars System Analysis System Design and Compensation Appendices 177 Electrical Specifications Performance Specifications 7 Ordering Options sssri 180 Power Connector Part Numbers Input Current Limitations Pa OG asne Signal Deverindons List of Other Publications 193 Training Seminars a193 Contacting Us 194 I a ai Sand apn ca E Sane ae ip re 195 Integrated Components 196 CDE gat ee ee eee ene ee eee een ee ee 196 A1 AMP 430x0 D3040 D3020 198 Description Electrical Speci cations Operatio i Error Monitoring and Protection eee ee RE EA
296. put 6 is low Example Start Motion on Switch Motor A must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor A must stop turning Solution Connect panel switch to input 1 of DMC 41x3 High on input 1 means switch is in on position Instruction Interpretation S JG 4000 Set speed AI 1 BGA Begin after input 1 goes high AI 1 STA Stop after input 1 goes low AMA JP S After motion repeat EN The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is of the full voltage range for example connect the input to 5 volts if the signal is a O 12 volt logic Example A DMC 4113 has one auxiliary encoder This encoder has two inputs channel A and channel B Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal Chapte
297. r 7 Application Programming 149 DMC 41x3 User Manual will be connected to AA and the second to AB AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Input Interrupt Function The DMC 41x3 provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the Il m n o command The m specifies the beginning input and n specifies the final input in the range The parameter o is an interrupt mask If m and n are unused o contains a number with the mask For example II 5 enables inputs 1 and 3 A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RI command is used to return from this subroutine to the place in the program where the interrupt had occurred Important Use the RI command not EN to return from the ININT subroutine Example Input Interrupt Instruction A EEL JG 30000 20000 BG AB B TP AB WT 1000 JP B EN ININT MG Interrupt has occurred ST AB LOOP JP LOOP IN 1 0 JG 15000 10000 WT 300 BG AB RI Jumping back to main program with ININT Interpretation Label A Enable input 1 for interrupt function Set speeds on A and B axes Begin motion on
298. r DMC 4153 4163 4173 4183 Also n 17 48 ASXYZWS Halts program execution until specified axis has reached its slew ABCDEFGH speed AT n m For m omitted or 0 halts program execution until n msec from reference time AT O sets reference AT n waits n msec from reference AT n waits n msec from reference and sets new reference after elapsed time For m 1 Same functionality except that n is number of samples rather than msec AV n Halts program execution until specified distance along a coordinated path has occurred WT n m For m omitted or 0 halts program execution until specified time lin msec has elapsed For m 1 Same functionality except that n is number of samples rather than msec Event Trigger Examples Event Trigger Multiple Move Sequence The AM trippoint is used to separate the two PR moves If AM is not used the controller returns a for the second PR command because a new PR cannot be given until motion is complete TWOMOVE Label PR 2000 Position Command BGX Begin Motion AMX Wait for Motion Complete PR 4000 Next Position Move BGX Begin 2 move EN End program Chapter 7 Application Programming 120 DMC 41x3 User Manual Event Trigger Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period SETBIT Label SP 1000
299. r To Send inputs on the Aux Serial port Pins 1 and 6 on RS 422 Auxiliary Port APWR Connects 5V to pin 9 on the Aux serial port connector J3 OPT Reserved MO When controller is powered on or reset Amplifier Enable lines will be in a Motor Off state A SH will be required to re enable the motors 19 2K Baud Rate setting see table below UPGD Applied for recovery from a failed firmware upgrade MRST Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated Note The ARXD and ACTS jumpers should be installed for single drop RS 422 For multi drop the jumpers should be installed on the last device Baud Rate Jumper Settings 19 2 BAUD RATE ON 19200 OFF 115200 Recommended Appendices 190 DMC 41x3 User Manual Signal Descriptions Outputs Inputs Motor Command 10 Volt range signal for driving amplifier In servo mode motor command output is updated at the controller sample rate In the motor off mode this output is held at the OF command level Amplifier Enable Signal to disable and enable an amplifier Amp Enable goes low on Abort and OE1 PWM Step PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a conventional amplifier that accepts a 10 Volt analog signal this pin is
300. r between 127 9999 with a fractional resolution of 0001 There are two modes standard gearing and gantry mode The gantry mode enabled with the command GM allows the gearing to stay enabled even if a limit is hit or an ST command is issued GR 0 0 0 0 turns off gearing in both modes The command GM x y z w select the axes to be controlled under the gantry mode The parameter 1 enables gantry mode and 0 disables it GR causes the specified axes to be geared to the actual position of the master The master axis is commanded with motion commands such as PR PA or JG When the master axis is driven by the controller in the jog mode or an independent motion mode it is possible to define the master as the command position of that axis rather than the actual position The designation of the commanded position master is by the letter C For example GACX indicates that the gearing is the commanded position of X An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the X and Y motor form a circular motion the Z axis may move in proportion to the vector move Similarly if X Y and Z perform a linear interpolation move W can be geared to the vector move Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced
301. r is full and no additional segments can be sent As long as the buffer is not full additional segments can be sent at PC bus speeds The operand _CS can be used to determine the value of the segment counter Chapter 6 Programming Motion 81 DMC 41x3 User Manual Additional commands The commands VS n VA n and VD n are used for specifying the vector speed acceleration and deceleration IT is the s curve smoothing constant used with coordinated motion Specifying Vector Speed for Each Segment The vector speed may be specified by the immediate command VS It can also be attached to a motion segment with the instructions VP x y lt n gt m CR r e 6 lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condition will not be met The control
302. ram starts at a state that we define as A Here the controller waits for the input pulse on 11 As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle INSTRUCTION FUNCTION A Label AIl Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AMX After motion is complete SB1 Set output bit 1 WT 20 Wait 20 ms CB1 Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process STARTPULSE It MOTOR VELOCITY OUTPUTPULSE TNE INTERVALS moe wa realy move Figure 7 1 Motor Velocity and the Associated Input Output signals X Y Table Controller An X Y Z system must cut the pattern shown in Figure 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool Chapter 7 Application Programming 152 DMC 41x3 User Manual The solid curves in Figure 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate is 0 1 g The motion starts at point A with the Z axis raised An X Y motion to point B is followed by lowering the Z axis and performing a cut along the circle Once the circular motion is completed the Z axis is raised and
303. reases starting at zero This function allows the host computer to determine which segment is being processed Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 41x3 computes the vector speed based on the axes specified in the LM mode For example LM XYZ designates linear interpolation for the X Y and Z axes The vector speed for this example would be computed using the equation VS2 XS2 YS2 ZS2 where XS YS and ZS are the speed of the X Y and Z axes The controller always uses the axis specifications from LM not LI to compute the speed IT is used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trippoint which halts program execution until the vector distance of n has been reached Chapter 6 Programming Motion 77 DMC 41x3 User Manual An Example of Linear Interpolation Motion LMOVE label DP 0 0 Define position of X and Y axes to be 0 LMXY Define linear mode between X and Y axes LI 5000 0 Specify first linear segment LI 0 5000 Specify second linear segment LE End linear segments vs 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector distance of 4000 is reached vs 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached vs 4000 Change vector speed EN Program end In this example the XY system is
304. reference position F axis motor position F axis position error F axis auxiliary position F axis velocity F axis torque F axis analog input F Hall Input Status Reserved F User defined variable ZA G axis status see bit field map below G axis switches see bit field map below G axis stop code G axis reference position G axis motor position G axis position error G axis auxiliary position G axis velocity G axis torque G axis analog input G Hall Input Status Reserved G User defined variable ZA H axis status see bit field map below H axis switches see bit field map below H axis stop code H axis reference position H axis motor position H axis position error H axis auxiliary position H axis velocity H axis torque H axis analog input H Hall Input Status Reserved H User defined variable ZA Will be either a Signed Word or Unsigned Word depending upon AQ setting See AQ in the Command Reference for more information Chapter 4 Software Tools and Communication 59 DMC 41x3 User Manual Data Record Bit Field Maps Header Information Byte 0 1 of Header BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT9 Block Present T Block 1 N A N A N A N A A Present in in Data Record Data Record BIT 8 Block Present in Data Record BIT 7 BIT 6 BITS BIT 4 BIT 3 BIT 2 BIT 1 BITO H Block G Block F Block E Block D Block C Block B Block A Block Present in Present in Present in Present i
305. required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trippoint which slows the speed to 1000 count s Once the motors reach the corner the speed is increased back to 4000 counts s Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications such as CNC it is necessary to attach various speeds to different motion segments This can be done by two functions lt n and gt m For example LI x y z w lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point As an example consider the followin
306. river For more information on the connectors go to _http www molex com On Board Connector Common Mating Connectors Crimp Part Number Type MOLEX 39 31 0060 MOLEX 39 01 2065 MOLEX 44476 3112 6 Position MOLEX 39 31 0040 MOLEX 39 01 2045 MOLEX 44476 3112 4 Position MOLEX 39 31 0020 MOLEX 39 01 2025 MOLEX 44476 3112 2 Position The mating connectors listed are not the only mating connectors available from Molex See 366Hhttp www molex com for the full list of available mating connectors Galil Amplifier Driver On Board Connector Type None MOLEX 39 31 0020 2 Position AMP43040 Motor MOLEKH 38 31 0060 4 Position AMP 43140 Morar MOLEXH 38 31 0020 2 Position SDM 44040 Motor MOLEX 38 31 0000 4 Position me ee e Appendices 185 DMC 41x3 User Manual Input Current Limitations The current for an optoisolated input shall not exceed 11mA Some applications may require the use of an external resistor R to limit the amount of current for an input These external resistors can be placed in series between the inputs and their power supply Vs To determine if an additional resistor R is required follow Equation A1 below for guidance imde er ey R 22002 Equation A1 Current limitation requirements for each input Appendices 186 DMC 41x3 User Manual Pin outs J5 1 O A D 44 pin HD D Sub Connector Fe
307. rogram stack End Program Routine for pausing motion Save current speed setting of A axis motion Set speed of A axis to zero allows for pause Re enable trippoint and communication interrupt Routine for resuming motion Set speed on A axis to original speed Re enable trippoint and communication interrupt For additional information see section on Using Communication Interrupt Example Ethernet Communication Error This simple program executes in the DMC 41x3 and indicates via the serial port when a communication handle fails By monitoring the serial port the user can re establish communication if needed Chapter 7 Application Programming 129 DMC 41x3 User Manual LOOP Simple program loop JP LOOP EN TCPERR Ethernet communication error auto routine MG P1 _IA4 Send message to serial port indicating which handle did not receive proper acknowledgment RE Example Amplifier Error The program below will execute upon the detection of an error from an internal Galil Amplifier The bits in TA1 will be set for all axes that have an invalid hall state even if BR1 is set for those axes this is handled with the mask variable shown in the code below AMPERR REM mask out axes that are in brushed mode for TA1 mask _BRH 128 _BRG 64 _BRF 32 _BRE 16 _BRD 8 _BRC 4 _ BRB 2 BRA mask COM mask mask _TAl amp mask amp SO000FFFF REM amplifier error status MG A ER TAO TAO G A ER TA1 mask G A ER TA
308. ror Routine Read Position Error Print Message Print Error Return from Error Download program Execute Dummy Program Jog at High Speed Begin Motion Label Input Interrupt on 1 Jog Begin Motion Loop Input Interrupt Stop Motion Test for Input 1 still low Restore Velocities Begin motion Return from interrupt routine to Main Program and do not re enable trippoints Chapter 7 Application Programming 127 DMC 41x3 User Manual Example Motion Complete Timeout BEGIN Begin main program TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command BGX Begin motion MCX Motion Complete trippoint EN End main program MCTIME Motion Complete Subroutine MG X fell short Send out a message EN End subroutine This simple program will issue the message X fell short if the X axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error BEGIN Begin main program speed 2000 Set variable for speed JG speed BGX Begin motion LOOP JG speed WT100 Update Jog speed based upon speed variable JP LOOP EN End main program CMDERR Command error utility JP DONE ED lt gt 2 Check if error on line 2 JP DONE TC lt gt 6 Check if out of range G SPEED TOO HIGH Send message G TRY AGAIN Send message ZS1 Adjust stack JP BEGIN Return to main program DONE End program if other error ZSO0 Zero stack EN End program The above program prompts
309. rresponds to the positive direction of the X axis and the CCW direction of rotation is positive Angles are expressed in degrees and the resolution is 1 256th of a degree For example the path shown in Figure A 8 is specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 00 000 m mi Figure A 8 X Y Motion Path The first line describes the straight line vector segment between points A and B The next segment is a circular arc which starts at an angle of 180 and traverses 90 Finally the third line describes the linear segment between points C and D Note that the total length of the motion consists of the segments A B Linear 10000 units RAQ2Qn B C Circular 15708 360 C D Linear 10000 Total 35708 counts In general the length of each linear segment is Lee Yk Where Xk and Yk are the changes in X and Y positions along the linear segment The length of the circular arc is L R AO 27 360 The total travel distance is given by D YL k l The velocity profile may be specified independently in terms of the vector velocity and acceleration For example the velocity profile corresponding to the path of Figure A 8 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Figure A 9 Chapter 6 Programming Motion 85 DMC 41x3 User Manual Velocity 100 The acceleration time T
310. rrogation commands may be formatted locally To format locally use the command Fn m or Sn m on the same line as the interrogation command The symbol F specifies that the response should be Chapter 7 Application Programming 146 DMC 41x3 User Manual returned in decimal format and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal TP F2 2 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 00 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by VF m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format The default format for VF is VF 10 4 Hex values are returned preceded by a and in 2 s complement Instruction Interpretation v1 10 Assign v1 vl Return v1 gt 0000000010 0000 Response Default format VEF2 2 Change format vl Return v1 710 00 Response New format VE 2 2 Specify hex format vl Return v1 0A 00 Response Hex value VF1 Change format vl Return v1 29 Response Overflow Local Formatting of Variables
311. s armed 3rd Phase of HM Motor Off Direction Move Motion slewing stopping due making final in Progress to ST of Limit decel Contour Switch Axis Switches 1 Byte BIT 7 BIT 6 BIT5 BIT 4 BIT 3 BIT 2 BIT1 BITO Latch Occurred State of N A N A State of State of State of Home Stepper Mode Latch Input Forward Limit Reverse Limit Input Chapter 4 Software Tools and Communication 60 DMC 41x3 User Manual Amplifier Status 4 Bytes BIT 25 BIT 24 ELO Active ELO Active Axis E H Axis A D BIT 23 BIT 22 BIT 21 BIT 20 BIT 19 BIT 18 BIT 17 BIT 16 Peak Current Peak Current Peak Current Peak Current Peak Current Peak Current Peak Current Peak current H axis G axis F axis E axis D axis C axis B axis A axis BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Hall Error Hall Error Hall Error Hall Error Hall Error Hall Error Hall Error Hall Error H axis G axis F axis E axis D axis C axis B axis A axis BIT 7 BIT 6 BIT5 BIT 4 BIT 3 BIT 2 BIT 1 BITO Under Voltage Over Temp Over Voltage Over Current Under Voltage Over Temp Over Voltage Over Current Axis E H Axis E H Axis E H Axis E H Axis A D Axis A D Axis A D Axis A D Notes Regarding Velocity and Torque Information The velocity information that is returned in the data record is 64 times larger than the value returned when using the command TV Tell Velocity See co
312. scope Scope IE eae y i D o A T Vertical Horizontal dit Source Scale jav Offset dv mO RPA Axis Aref y soo counts 5S oe eo x s0000 E 2 so x 2 canes A F so x 0 221383 8 0 B so x 4 42765 BN ao x 0 442765 a 2 Fd Jao m 0 221333 3 E eO m 0 221383 4 o Soms Trigger Channel W _RP y Edge x Level 2500 count gt Mode Repeat v READY Stop FPA Figure 6 2 Position vs Time msec Motion 1 Example Motion 2 The previous step showed the plot if the motion continued all the way to 5000 however partway through the motion the object that was being tracked changed direction so the host program determined that the actual target position should be 2000 counts at that time Figure 6 2 shows what the position profile would look like if the move was allowed to complete to 5000 counts The position was modified when the robot was at a position of 4200 counts Figure 6 3 Note that the robot actually travels to a distance of almost 5000 counts before it turns around This is a function of the deceleration rate set by the DC command When a direction change is Chapter 6 Programming Motion 74 DMC 41x3 User Manual commanded the controller decelerates at the rate specified by the DC command The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position In Figure 6 3 the velocity prof
313. ses for a more smooth operation of the stepper motor Use of KS is most applicable when operating in full step or half step operation KS will cause the step pulses to be delayed in accordance with the time constant specified When operating with stepper motors you will always have some amount of stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving back and forth For example when operating with servo motors the trippoint AM After Motion is used to determine when the motion profiler is complete and is prepared to execute a new motion command However when operating in stepper mode the controller may still be generating step pulses when the motion
314. ses the axes denoted as ABC the DMC 4123 uses the axes denoted as AB and the DMC 4113 uses the A axis only Examples for the DMC 4183 denote the axes as A B C D E F G H Users of the DMC 4153 5 axes controller DMC 4163 6 axes controller or DMC 4173 7 axes controller should note that the DMC 4153 denotes the axes as A B C D E the DMC 4163 denotes the axes as A B C D E F and the DMC 4173 denotes the axes as A B C D E F G The axes A B C D may be used interchangeably with X Y Z W Machinery in motion can be dangerous WARNING It is the responsibility of the user to design effective error handling and safety protection as part of the machinery Galil shall not be liable or responsible for any incidental or consequential damages DMC 41x3 User Manual Contents ii Contents Contents iii Chapter 1 Overview Introduction Part NUMDGTS soca scarce Overview of Motor Typed sii ccct tes oases acer A Overview of Extemeal Aimplitiot ocna aA Overview of Galil Amplifiers and Drivers DMC 41x3 Functional Elements Chapter 2 Getting Started 11 TEGO i ea eh la shy caches ate aioe ace dun bio id dae ll DMC 41x3 Power Connections Elements You Need s Installing the DMC Amplifiers atid Motors ascris 17 Chapter 3 Connecting Hardware 32 Rs ati a encoe uae a a Overview of Optoiso lated Timote oicc Optoisolated Input Electrical Information Optoisolated G
315. set an initial time reference loop REM this comment is removed upon download and takes no time to process REM this comment is removed upon download and takes no time to process i itl REM this comment is removed upon download and takes no time to process JP loop i lt 1000 MG TIME t display number of samples from initial time reference EN WT vs AT and coding deterministic loops The main difference between WT and AT is that WT will hold up execution of the next command for the specified time from the execution of the WT command AT will hold up execution of the next command for the specified time from the last time reference set with the AT command Chapter 7 Application Programming 133 DMC 41x3 User Manual A ATO set initial AT time reference WT 1000 1 wait 1000 samples t1l TIME AT 4000 1 wait 4000 samples from last time reference t2 TIME t1l REM in the above scenario t2 will be 3000 because AT 4000 1 will have REM paused program execution from the time reference of ATO REM since the WT 1000 1 took 1000 samples there was only 3000 samples left REM of the 4000 samples for AT 4000 1 MG t t2 this should output 1000 3000 EN End program Where the functionality of the operation of the AT command is very useful is when it is required to have a deterministic loop operating on the controller These instances range from writing PLC type scan threads to writing custom control algorithms The key to having a deter
316. specified by the instruction EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0 Step 4 Specify the slave positions Next we specify the slave positions with the instruction ET n x y z w where n indicates the order of the point The value n starts at zero and may go up to 256 The parameters x y z w indicate the corresponding slave position For this example the table may be specified by ET 0 0 ET 1 3000 ET 2 2250 ET 3 1500 This specifies the ECAM table Step 5 Enable the ECAM To enable the ECAM mode use the command EBn where n 1 enables ECAM mode and n 0 disables ECAM mode Step 6 Engage the slave motion To engage the slave motion use the instruction EG x y z w where x y z w are the master positions at which the corresponding slaves must be engaged If the value of any parameter is outside the range of one cycle the cam engages immediately When the cam is engaged the slave position is redefined modulo one cycle Step 7 Disengage the slave motion To disengage the cam use the command EQ x y z w Chapter 6 Programming Motion 91 DMC 41x3 User Manual where x y z w are the master positions at which the corresponding slave axes are disengaged 3000 250 Ai araa A SE re Poa hehe SS 0 2000 4000 o Ma
317. ster X Figure 6 13 Electronic Cam Example This disengages the slave axis at a specified master position If the parameter is outside the master cycle the stopping is instantaneous To illustrate the complete process consider the cam relationship described by the equation Y 0 5 xX 100 sin 0 18 X where X is the master with a cycle of 2000 counts The cam table can be constructed manually point by point or automatically by a program The following program includes the set up The instruction EAX defines X as the master axis The cycle of the master is 2000 Over that cycle Y varies by 1000 This leads to the instruction EM 2000 1000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18X and X varies in increments of 20 the phase varies by increments of 3 6 The program then computes the values of Y according to the equation and assigns the values to the table with the instruction ET N Y EN JP LOOP N lt 100 INSTRUCTION INTERPRETATION SETUP Label EAX Select X as master EM 2000 1000 Cam cycles EP 20 0 Master position increments 0 Index LOOP Loop to construct table from equation P N 3 6 Note 3 6 0 18 20 S SIN P 100 Define sine position Y N 10 S Define slave position ET N
318. t 2 AEN Amplifier Enable 15 AB Data Dn or SLO 3 DIR Direction 16 MI l Index Pulse Input 4 HOM Home 17 MB B Main Encoder Input 5 LSCOMn Limit Switch Common 18 GND Digital Ground 6 AA Clock Cn or MA 19 MCMD Motor Command 7 MI I Index Pulse Input 20 ENBL Amp Enable Power 8 MA A Main Encoder Input 21 HALA Hall A 9 5V 5V 22 RLS Reverse Limit Switch Input 10 GND Digital Ground 23 AB Data Dn or SLO 11 ENBL Amp Enable Return 24 AA Clock Cn or MA 12 HALB Hall B 25 MB B Main Encoder Input 13 STP PWM Step 26 MA A Main Encoder Input a Only one ground pin must be connected to the encoders digital ground signal LSCOMn on JA1 JB1 JC1 and JD1 is common to LSCOMO on J5 LSCOMn on JE1 JF1 JG1 and JH1 is common to LSCOM1 on J8 LSNK 25mA Sinking Outputs The LSNK option modifies the digital outputs on the DMC 41x3 to be capable of sinking up to 25mA per output For detailed information see the 25mA Sinking Optoisolated Outputs LSNK section in Chapter 3 Connecting Hardware Part number ordering example DMC 4113 CARD ABCD LSNK LSRC 25mA Sourcing Outputs The LSRC option modifies the digital outputs on the DMC 41x3 to be capable of sourcing up to 25mA per output For detailed information see the 25mA Sourcing Optoisolated Outputs LSRC section in Chapter 3 Connecting Hardware Part number ordering example DMC 4113 CARD ABCD LSRC HSRC 500mA Sourcing Outputs T
319. t is usually due to a short across the motor leads or a short from a motor lead to ground A3 AMP 43240 D3240 211 DMC 41x3 User Manual Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the AMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle A3 AMP 43240 D3240 212 DMC 41x3 User Manual A4 AMP 435x0 D3540 D3520 Description The AMP 43540 resides inside the DMC 41x3 enclosure and contains four sinusoidally commutated PWM amplifiers for driving brushless servo motors Each amplifier drives motors operating at up to 8 Amps continuous 15 Amps peak 20 80 VDC The gain settings of the amplifier are user programmable at 0 4 Amp Volt 0 8 Amp Volt and 1 6 Amp Volt The switching frequency is 33 kHz The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43540s can be used for 5 thru 8 axis controllers A shunt regulator option is available A two axis version the AMP 43520 is also available If higher voltages are required please contact Galil If the application has a
320. t line and arc segments and the path length may be infinite Required XY Points 6000 5000 4000 3000 Y Axis Counts 2000 1000 0 1000 2000 3000 4000 5000 6000 7000 8000 X Axis Counts Figure 6 18 Required XY Points Chapter 6 Programming Motion 98 DMC 41x3 User Manual Specifying Contour Segments The Contour Mode is specified with the command CM For example CMXZ specifies contouring on the X and Z axes Any axes that are not being used in the contouring mode may be operated in other modes A contour is described by position increments which are described with the command CD x y z w over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2 sample period 1 ms for TM1000 where n is a number between 1 and 8 The controller performs linear interpolation between the specified increments where one point is generated for each sample If the time interval changes for each segment use CD x y z w n where n is the new DT value Consider for example the trajectory shown in Figure 6 19 The position X may be described by the points Point 1 X 0 at T Oms Point 2 X 48 at T 4ms Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 DX 48 Time 4 DT 2 Increment 2 DX 240 Time 8 DT 3 Increment 3 DX 48 Time 16 DT 4 When the controller receives the command to ge
321. t the PID s and BR to zero and disable off on error OE to allow for full rotation of the motor in open loop Issue the following commands from a Galil terminal program KPA 0 KDA 0 KIA 0 BRA 0 OE 0 SHA 3 Place a small offset voltage on the motor command line using the OF command ex OFA 0 5 The smallest OF possible to see motion is recommended If no motion presents itself increase in small increments until you see motion If your OF is beyond what is expected to see motion record no motion using one of the tables below Table 2 8 for swapping motor phases or Table 2 9 for swapping halls and try the next wiring combination Note To stop the motor from spinning use either the MO A command or issue OFA 0 4 Once spinning check the velocity of the motor with the TV A command Record this value under Velocity in either Table 2 8 or Table 2 9 5 Issue an equal but opposite OF For example if you previously issued OFA 0 5 now issue OFA 0 5 Record this velocity under Velocity 6 Issue OFA 0 or MO A to stop the motors Power down the controller and amplifiers system and swap 2 wires of the hall sensors or motor power leads whichever method is being used Remember chose one or the other not both Keep track of what cable combinations have been tested labeling the phases maybe useful in the example table in Table 2 7 motor phases were recorded based upon their insulation color 7 Repeat s
322. teps 2 6 for every possible wiring combination there will be six and Table 2 8 or Table 2 9 below should be completely filled out Chapter 2 Getting Started 25 DMC 41x3 User Manual 8 The correct wiring combination will be the one with the least difference in magnitude between the velocities in the positive and negative direction In the case where there are two combinations that meet this criteria choose the combination that has the higher velocities In the example table shown in Table 2 7 Trial 1 would be the correct choice Trial Phase A Phase B Phase C Velocity Velocity 1 Red White Black 153700 160000 2 Red Blach White Ua motion Uo motion 3 White Black Red Ua motion Uo motion 4 White Red Black 141000 189000 5 Black Red White To motion Uo motion 6 Black White Red 70000 92000 Table 2 7 Example table showing realistic test results using this commutation method Trial Phase A Phase B Phase C Velocity Velocity 1 2 Table 2 8 Table provided for use with swapping motor phases to achieve trapezoidal communication Trial Hall A Hall B Hall C Velocity Velocity Table 2 9 Table provided for use with swapping hall leads to achieve trapezoidal communication 9 Check that the motor phases and encoder feedback are in proper polarity to avoid a runaway condition D
323. ter 3 Connecting Hardware 49 DMC 41x3 User Manual Chapter 4 Software Tools and Communication Introduction The default configuration DMC 41x3 has one USB port one RS 232 port and one Ethernet port The auxiliary RS 232 port is the data term and can be configured with the software command CC This configuration can be saved using the Burn BN instruction The Ethernet port is a 10 100BASE T connection that auto negotiates the speed and half or full duplex The GalilTools software package is available for PC computers running Microsoft Windows or Linux to communicate with the DMC 41x3 controller This software package has been developed to operate under Windows and Linux and include all the necessary drivers to communicate to the controller In addition GalilTools includes a software development communication library which allows users to create their own application interfaces using programming environments such as C C Visual Basic and LabVIEW The following sections in this chapter are a description of the communications protocol and a brief introduction to the software tools and communication techniques used by Galil At the application level GalilSuite is the basic development software that the majority of users will need to communicate with the controller to perform basic setup and to develop application code dmc programs that is downloaded to the controller At the Galil API level the Galil Communication Library is avai
324. that number by the amplifier gain For example a particular motor has a continuous current rating of 0 5A and peak current rating of 1 5A The gain of the AMP 43640 is 0 2A V TL setting 0 5A 0 2A V 2 5V TL n 2 5 TK setting 1 5A 0 2A V 7 5V TK n 7 5 Scope x vertical Horizontal A dfdt Source Scale div Offset div Ye _TTA Axis A torda 2V 3 D 2 1 0 COV 4 iK S iK ER EJ E E RR ER RA RA E Ie RP RR RR RA RA RA 1 2 3 4 3 Trigger Channel Mi TTA Edge v Level O 1 Mode Repeat v READY dT 9 030 TA dt 13 ms 1 dt 74 6H Figure A5 3 Peak Current Operation Brushed Motor Operation The AMP 43640 must be configured for brushed motor operation at the factory Contact Galil prior to placing the order Once the amplifier is configured for a brushed motor the controller needs to be set for brushed mode by setting the BR command to a value of 1 The A and C motor phases are used for connecting to the brushed motor B phase is a no connect AS AMP 43640 D3640 223 DMC 41x3 User Manual ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will change state and the HAMPERR routine will run when the ELO input is triggered To recover from an E
325. the amplifier to be disabled until the temperature of the transistors falls below the threshold Mating Connectors On Board Connector Terminal Pins 6 pin Molex Mini Fit Jr POWER MOLEX 44476 3112 MOLEX 39 31 0060 AA a aE M A B C D 4 pin Motor 4 pin Molex Mini Fit Jr MOLEX 44476 3112 Power Connectors MOLEX 39 31 0040 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector 1 Phase C 2 Phase B 3 No Connect 4 Phase A A5 AMP 43640 D3640 220 DMC 41x3 User Manual Power Unlike a switching amplifier a linear amplifier does not have a straightforward relationship between the power delivered to the motor and the power lost in the amplifier Therefore determining the available power to the motor is dependent on the supply voltage the characteristics of the load motor and the required velocity and current All of the power delivered by the power supply is either used in the motor or lost in the amplifier Power of Power Supply P P Pa The power to the motor is both the power used to provide motion and the power lost to heat Power of the motor P Work Power Lost in Motor P K Velocity iti Rn Power of amplifier P V ix R K Velocity xi In addition there is a minimum power dissipated by the amplif
326. the commas which separate m n and p are not necessary For example VM XWZ selects the XW axes for coordinated motion and the Z axis as the tangent Specifying the Coordinate Plane The DMC 41x3 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T To specify vector commands the coordinate plane must first be identified This is done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applied to the active coordinate system until changed with the CA command Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence Note This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y specifies the coordinates of the end points of the vector movement with respect to the starting point Non sequential axis do not require comma delimitation The command CR r q d define a circular arc with a radius r starting angle o
327. the load position is 980 counts it implies that a correction of 20 counts must be made However when the X axis is commanded to be at the position of 1000 suppose that the actual position is only 995 implying that X has a position error of 5 counts which will be eliminated once the motor settles This implies that the correction needs to be only 15 counts since 5 counts out of the 20 would be corrected by the X axis Accordingly the motion correction should be Correction Load Position Error Rotary Position Error Chapter 7 Application Programming 155 DMC 41x3 User Manual The correction can be performed a few times until the error drops below 2 counts Often this is performed in one correction cycle Example INSTRUCTION FUNCTION A Label DPO Define starting positions as zero LINPOS 0 PR 1000 Required distance BGX Start motion B AMX Wait for completion WT 50 Wait 50 msec LINPOS _DEX Read linear position ERR 1000 LINPOS _TEX Find the correction JP C ABS ERR lt 2 Exit if error is small PR ERR Command correction BGX JP B Repeat the process C Using the DMC Editor to Enter Programs Advanced The GalilTools software package provides an editor and utilities that allow the upload and download of DMC programs to the motion controller In most instances the user will use Galil software or a host application to download programs to the Galil controller rather than using the ED command Application pr
328. the motion continues to point C etc Assume that all of the 3 axes are driven by lead screws with 10 turns per inch pitch Also assume encoder resolution of 1000 lines per revolution This results in the relationship 1 inch 40 000 counts and the speeds of 1 in sec 40 000 count sec 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 0 1g 38 6 in s2 1 544 000 count s Note that the circular path has a radius of 2 or 80000 counts and the motion starts at the angle of 270 and traverses 360 in the CW negative direction Such a path is specified with the instruction CR 80000 270 360 Further assume that the Z must move 2 at a linear speed of 2 per second The required motion is performed by the following instructions INSTRUCTION FUNCTION A Label XY Circular interpolation for XY P 160000 160000 Positions E End Vector Motion S 200000 Vector Speed A 1544000 Vector Acceleration GS Start Motion Z R 80000 270 360 Z R 80000 270 360 n 40000 Q n S R 80000 Eo ee ee ee ee ee ee pe eR a es os ph aces N Z S When motion is complete R 80000 Move Z down P 80000 Z speed GZ Start Z motion Wait for completion of Z motion Circle S 40000 Feed rate GS Start circular move S Wait for completion R 80000 Move Z up GZ Start Z move Z Wait for Z completion R 21600 Move X P 20000 Speed X GX Start X X Wait for X completion R 80000 Lower Z GZ Z second
329. they reside on the same DMC 41x3 board The DMC 41x3 can also be ordered with optional internal amplifiers labeled as AMP or SDM These amplifiers are sandwiched to the back of the DMC 41x3 board The abstract internal layout of a DMC 41x3 with optional AMP SDM is shown for 1 4 axis in Figure 1 1 Figure 1 1 Abstract layout of a 1 4 axis DMC 41x3 and optional internal amp The 5 8 axis models have room for an additional bank of internal amplifiers as shown in Figure 1 2 Figure 1 2 Abstract layout of a 5 8 axis DMC 41x3 and optional internal amps It is important to note that if the DMC 41x3 is ordered without optional AMP SDM options that it can come in either a card or box form factor ordered as CARD or BOXn respectively where n denotes 4 for 1 4 axis models or 8 for 5 8 axis models If the DMC 41x3 is ordered with an optional AMP SDM then it must be ordered with a BOXn Table 1 1 below shows the different form factors and the appropriate part numbers to order them Chapter 1 Overview 2 DMC 41x3 User Manual Form Factor example Part Number Description CARD DMC 41x3 1 4 axis model ordered with the CARD option CARD DMC 41x3 5 8 axis model ordered with the CARD option DMC 41x3 1 4 axis model ordered with the BOX4 option BOX4 This option is required if the DMC 41x3 is ordered with internal amplifiers AMP or SDM This example shows a DMC 41x3 with an internal AMP DMC 41x3 1 4
330. this mode the controller provides two signals to connect to the stepper motor Step and Direction For stepper motor operation the controller does not require an encoder and operates the stepper motor in an open loop fashion Chapter 2 describes the proper connection and procedure for using stepper motors If encoders are available on the stepper motor Galil s Stepper Position Maintenance Mode may be used for automatic monitoring and correction of the stepper position See Stepper Position Maintenance Mode SPM in Chapter 6 for more information Overview of External Amplifiers The amplifiers should be suitable for the motor and may be linear or pulse width modulated An amplifier may have current feedback voltage feedback or velocity feedback Amplifiers in Current Mode Amplifiers in current mode should accept an analog command signal in the 10 volt range The amplifier gain should be set such that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V Amplifiers in Velocity Mode For velocity mode amplifiers a command signal of 10 volts should run the motor at the maximum required speed The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed Stepper Motor Amplifiers For step motors the amplifiers should accept step and direction signals Chapter 1 Overview 6 DMC 41x3 User Manual
331. tion see the CW command in the Command Reference USB and RS 232 Ports The USB port by default is an interpreted serial communication port for the DMC 41x3 and will receive and respond to DMC commands The RS232 DB9 port is the auxiliary port by default and is used to connect to external devices that do not use DMC code such as bar code readers or other RS232 sensors and displays The controller can read and write generic data but the user must write their own communication routines A full description of the USB and RS232 default configuration settings can be found in the following sections The US command Rev D firmware or greater can reverse the main and auxiliary port such that the RS232 port would interpret DMC commands and the USB port would be available for generic data The following are several points to consider when switching the USB and RS232 ports with US e Anull modem cable is required for interfacing to the RS232 port Baud rates are set via the controller s jumpers Firmware cannot be loaded from the RS232 port The user must switch back to USB mode to load firmware via serial Ethernet firmware updates are supported in both modes e When using the USB port in swapped mode the remote device must interface to the USB to serial converter on the controller On a PC this is done with a device driver The USB to serial UART is an FT232 from FTDI See the US command in the command reference for further detail Contact Ga
332. tion that can be used to calculate the desired maximum commutation speed in counts per second cts s mx 10 Speed crsis TM Xn Where m is the number of counts per magnetic cycle cts magnetic cycle n is the desired number of TM samples per magnetic cycle 8 or more recommended samples magnetic cycle Example Assume that an encoder provides 4000 cts rev and that a motor has 2 pole pairs Each pole pair represents a single magnetic cycle m can be calculated as follows 4000 16 rev m cts rev 2000 cts Imagnetic cycle magnetic cycles If TM 250 is set and 8 servo samples per magnetic cycle is desired the maximum speed in counts per second would be 2000 6 wil magnetiecyele 7 10h sis 1 000 000 Speed PE F530 5 5 X81 cts s us s samples Imagnetic cycle Setting up the Brushless Mode and finding proper commutation The 6 commands used for set up are the BA BM BX BZ BC and BI commands Please see the command reference for details Further information on setting up commutation on the AMP 43540 can also be found here 1 Issue the BA command to specify which axis you want to use the sinusoidal amplifier on 2 Calculate the number of encoder counts per magnetic cycle For example in a rotary motor that has 2 pole pairs and 10 000 counts per revolution the number of encoder counts per magnetic cycle would be 10 000 2 5000 Assign this value to BM 3 Issue either the BZ
333. tiplying it by the number of counts revolution Instruction RUN G ENTER OF REVOLUTIONS n1 1 rev JP rev nl 1 PR n1 2000 G ENTER SPEED IN RPM sl1 1 spd JP spd sl 1 SP s1 2000 60 G ENTER ACCEL IN RAD SEC2 al 1 acc JP acc al 1 AC al 2000 2 3 14 BG EN Hardware I O Digital Outputs Interpretation Label Prompt for revs Wait until user enters new value for n1 Convert to counts Prompt for RPMs Wait for user to enter new value for s1 Convert to counts sec Prompt for ACCEL Wait for user to enter new value for a1 Convert to counts sec Begin motion End program The DMC 41x3 has an 8 bit uncommitted output port the DMC 4153 through DMC 4183 has an additional 8 outputs Each bit on the output port may be set and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit Example Set Bit and Clear Bit Instruction Interpretation SB6 Sets bit 6 of output port CB4 Clears bit 4 of output port Example Output Bit The Output Bit OB instruction is useful for setting or clearing outputs depending on the value of a variable array input or expression Any non zero value results in a set bit Instruction OB1 POS OB 2 IN 1 OB 3 QIN 1 amp IN 2 OB 4 COUNT 1 Interpretation Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 Set
334. to about one half of NF and set NZ to a low value between zero and 5 ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 sT 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 41x3 controller and the following parameters K 0 1 Nm A Torque constant J 2 104 kg m System moment of inertia R 2 Q Motor resistance K 4 Amp Volt Current amplifier gain KP 12 5 Digital filter gain KD 245 Digital filter zero KI 0 No integrator N 500 Counts rev Encoder line density T 1 ms Sample period The transfer function of the system elements are Motor M s P I K Js 500 s rad A Amp K 4 Amp V Chapter 10 Theory of Operation 172 DMC 41x3 User Manual DAC Ky 0 0003 V count Encoder K 4N 2n 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 T 0 001 Therefore D z 1030 z 0 95 Z Accordingly the coefficie
335. tour Mode 8 millisecond intervals Contour Distance is in DIF End contour buffer Wait until path is done End the program Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 41x3 automatic array capture feature to capture position data The captured data may then be played back in the contour mode The following array commands are used DM C n RA C RD _TPX RC n m RC or _RC Dimension array Specify array for automatic record up to 4 for DMC 4143 Specify data for capturing such as _TPX or _TPZ Specify capture time interval where n is 2 sample periods 1 ms for TM1000 m is number of records to be captured Returns a 1 if recording Chapter 6 Programming Motion 101 DMC 41x3 User Manual Record and Playback Example RECORD Begin Program DM XPOS 501 Dimension array with 501 elements RA XPOS Specify automatic record RD _TPX Specify X position to be captured MOX Turn X motor off RC2 Begin recording 4 msec interval at TM1000 A JP A RC 1 Continue until done recording COMPUTE Compute DX DM DX 500 Dimension Array for DX c 0 Initialize counter L Label D C 1 DELTA XPOS D XPOS C DX C DELTA Compute the difference Store difference in array C C 1 Increment index JP L C lt 500 Repeat until done PLAYBCK Begin Playback CMX Specify contour mode DT2 Specify time increment I 0 Initialize arr
336. ty of the base C class See the getting started guide and the hello examples in lib for more info For more information on the Galil Communications Library see the online user manual http www galilmc com support manuals galiltools library html Chapter 4 Software Tools and Communication 64 DMC 41x3 User Manual Chapter 5 Command Basics Introduction The DMC 41x3 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands are sent in ASCII The DMC 41x3 instruction set is BASIC like and easy to use Instructions consist of two uppercase letters that correspond phonetically with the appropriate function For example the instruction BG begins motion and ST stops the motion Commands can be sent live over the communications port for immediate execution by the DMC 41x3 or an entire group of commands can be downloaded into the DMC 41x3 memory for execution at a later time Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter This section describes the DMC 41x3 instruction set and syntax A summary of commands as well as a complete listing of all DMC 41x3 instructions is included in the Command Reference http www galilmc com support manuals php Command Syntax ASCII DMC 41x3 instructions are represented
337. uals 1 VPX 5000 and _VPY 0 Example Linear Move Make a coordinated linear move in the ZW plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 counts sec LM ZW LI 40000 30000 LE vs 100000 VA 1000000 VD 1000000 BGS Specify axes for linear interpolation Specify ZW distances Specify end move Specify vector speed Specify vector acceleration Specify vector deceleration Begin sequence Note that the above program specifies the vector speed VS and not the actual axis speeds VZ and VW The axis speeds are determined by the controller from VS VVZ VW Chapter 6 Programming Motion 79 DMC 41x3 User Manual The result is shown in Figure 6 6 30000 27000 POSITION W 3000 FEEDRATE VELOCITY Z AXIS VELOCITY W AXIS Example Multiple Moves 36000 40000 POSITION Z 05 06 TIME sec TIME sec TIME sec Figure 6 6 Linear Interpolation This example makes a coordinated linear move in the XY plane The Arrays VX and VY are used to store 750 incremental distances which are filled by the program LOAD LOAD DM VX 750 VY 750 COUNT 0 N 0 LOOP VX COUNT N VY COUNT N N N 10 COUNT COUNT 1 JP LOOP COUNT lt 750 A LM XY COUNT 0 LOOP2 JP LOOP2 LM 0 JS C COUNT 500 LI VX COUNT VY COUNT COUNT COUNT 1 JP LOOP2 COUNT lt 750 LE AMS MG
338. umbers and power connector pin outs can be found here Power Connector Part Numbers pg 185 Part number ordering example DMC 4113 CARD 12V Appendices 180 DMC 41x3 User Manual 16 bit 16 bit Analog Inputs The 16 bit option provides 16 bit analog inputs on the DMC 41x3 motion controller The standard resolution of the analog inputs is 12 bits Part number ordering example DMC 4113 CARD 16bit 4 20mA 4 20mA analog inputs The 4 20mA option converts all 8 analog inputs into 4 20mA analog inputs This is accomplished by installing 4750 precision resistors between the analog inputs and ground When using this option the analog inputs should be configured for 0 10V analog inputs using the AQ command AQ n 4 The equation for calculating the current is Ima 2 105 V Where Ima current in mA V Voltage reading from DMC 41x3 Part number ordering example DMC 4113 CARD 4 20mA TRES Encoder Termination Resistors The TRES option provides termination resistors on all of the main and auxiliary encoder inputs on the DMC 41x3 motion controller The termination resistors are 120 Q and are placed between the positive and negative differential inputs on the Main A B Index channels as well as the Auxiliary A and B channels as in Figure A 1 MAMB MAAABE MAMB MAA ABE CPU Installed whenTRES option is ordered Figure A 1 Encoder Inputs with TRES option NOTE Single ended encoders will not operate correctly with t
339. urate Chapter 6 Programming Motion 95 DMC 41x3 User Manual The t value is entered in samples which will depend on the TM setting With the default TM of 1000 one sample is 976us This means that a t value of 1024 will yield one second of motion The velocity value v will always be in units of counts per second regardless of the TM setting Command Summary PVT COMMAND DESCRIPTION PVa p v t Specifies the segment of axis a for a incremental PVT segment of p counts an end speed of v counts sec in a total time of t samples PVa Contains the number of PV segments available in the PV buffer for a specified axes BT Begin PVT mode BTa Contains the number PV segments that have executed PVT Examples Parabolic Velocity Profile In this example we will assume that the user wants to start from zero velocity accelerate to a maximum velocity of 1000 counts second in 1 second and then back down to 0 counts second within an additional second The velocity profile would be described by the following equation and shown in Figure 6 15 v t 1000 1 1000 Desired Velocity Profile Figure 6 15 Parabolic Velocity Profile To accomplish this we need to calculate the desired velocities and change in positions In this example we will assume a delta time of of a second which is 256 samples 1024 samples 1 secon
340. utul anann TEL ipe and a ee eal kee a es Analog Inputs External Amplifier Interface Chapter 4 Software Tools and Communication 50 Mi Rg a ak aa att case Sete 50 Controller Response t Commands cesses core leases Latta esau da anal 50 Unsolicited Messages Generated by Comtrollet 5c cccssosssssscttsranissscicssoasassscatsonssinsicitinss Pil USB and RS 232 Ports Data RECORD acanna wae GalilSuite Windows and Linux coli Creatine Custom Sofware Waters ce oosina 63 Chapter 5 Command Basics 65 MUA ha ic a aa aac Command git eA CIN siaina Controller Response to DATA Interrogating the Controller Chapter 6 Programming Motion 69 MSN os is ies ee as eae seete tare ota ee eit recat gadis 69 Independent Axis POSIONING esos cescursera aceite spas caer A 70 Pdependent NOP osna 2 Position Tracking S Lingat Interpol atin Modo caca A Vector Mode Linear and Circular Interpolation Motion eee 80 Electronic Gearing Electronic Cam PV TMOJE EEES Contour Mode DMC 41x3 User Manual Contents iii Vial ANE ge ree em REET PPE Tee INDE PONS VI PEDROS TTT PPE TIO ESI Tor rem Ene ET OTTER Terre ye TTT 102 Stepper Motor Oper m i Stepper Position Maintenance Mode SPM Dual ne Anali Encoder asisas High Speed Position Capture The Latch Function eisni ET m Cha
341. variable result is equal to 4 1 this statement returns the following The Final Value is 00004 10 If the value of the variable result is equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 Chapter 7 Application Programming 144 DMC 41x3 User Manual The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppressed by sending N at the end of the statement This is useful when a text string needs to surround a numeric value Example A JG 50000 BGA ASA MG The Speed is TVA F5 0 N MG counts sec EN When HA is executed the above example will appear on the screen as The Speed is 50000 counts sec Using the MG Command to Configure Terminals The MG command can be used to configure a terminal Any ASCII character can be sent by using the format n where n is any integer between 1 and 255 Example MG 07 255 sends the ASCII characters represented by 7 and 255 to the bus Summary of Message Functions function description ER Surrounds text string Fn m Formats numeric values in decimal n digits to the left of the decimal point and m digits to the right Pl P2 or E Send message to Main Serial Port Auxiliary Serial Port or Ethernet Port n m Formats numeric values in hexadecimal n Sends ASCII character specified by inte
342. vector distance is measured from the start of the move or from the last AV command VECTOR Label VMXY VS 5000 Coordinated path VP 10000 20000 Vector position VP 20000 30000 Vector position VE End vector BGS Begin sequence AV 5000 After vector distance vs 1000 Reduce speed EN End Chapter 7 Application Programming 121 DMC 41x3 User Manual Event Trigger Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves MOVES Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration BGX Start Motion AD 10000 Wait a distance of 10 000 counts SP 5000 New Speed AMX Wait until motion is completed WT 200 Wait 200 ms PR 10000 New Position SP 30000 New Speed AC 150000 New Acceleration BGX Start Motion EN End Define Output Waveform Using AT The following program causes Output 1 to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec OUTPUT Program label ATO Initialize time reference SB1 Set Output 1 LOOP Loop AT 10 After 10 msec from reference CB1 Clear Output 1 AT 40 Wait 40 msec from reference and reset reference SB1 Set Output 1 JP LOOP Loop EN End Program Using AT WT with non default TM rates By default both WT and AT are defined to hold up program execution for n number of milliseconds WT n or AT n The second field of
343. ver from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input SSR Option The AMP 43140 linear amplifier require a bipolar power supply It is possible that the plus and minus V and V rise to nominal voltage at different rates during power up and any difference between voltage levels will be seen as an offset in the amplifier This offset may cause a slight jump during power up prior to the controller establishing closed loop control When ordered with the SSR option a solid state relay is added to the amplifier This relay disconnects the amplifier power from the motor power leads when the controller is placed in the motor off state If the MO jumper is installed or the MO command is burned into memory the addition of the SSR option will eliminate any jump due to the power supply Using External Amplifiers Use connectors on top of controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Step 9 Connecting External Amplifiers and Motors in Chapter 2 A2 AMP 43140 D3140 206 DMC 41x3 User Manual A3 AMP 43240 D3240 Description The AMP 43240 resides inside the DMC 41x3 enclosure and co
344. ving in the negative direction Using External Amplifiers Use connectors on top of controller to access necessary signals to run external amplifiers In order to use the full torque limit make sure the AG setting for the axes using external amplifiers are set to O or 1 Set the BR command to 1 for any axis that will be setup to run external amplifiers this will disable the hall error protection For more information on connecting external amplifiers see Step 9 Connecting External Amplifiers and Motors in Chapter 2 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the Optoisolated Input Electrical Informationsection in Chapter 3 Connecting Hardware for information on connecting the ELO input A3 AMP 43240 D3240 210 DMC 41x3 User Manual Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will also monitor for illegal Hall states 000 or 111 with 120 phasing The controller will monitor the error
345. w location or subroutine Unlike event triggers the conditional jump instruction does not halt the program sequence Conditional jumps are useful for testing events in real time They allow the controller to make decisions without a host computer For example the DMC 41x3 can decide between two motion profiles based on the state of an input line Command Format JP and JS FORMAT DESCRIPTION JS destination logical condition Jump to subroutine if logical condition is satisfied JP destination logical condition Jump to location if logical condition is satisfied The destination is a program line number or label where the program sequencer will jump if the specified condition is satisfied Note that the line number of the first line of program memory is 0 The comma designates IF The logical condition tests two operands with logical operators Logical operators OPERATOR DESCRIPTION lt less than gt greater than lequal to lt less than or equal to gt greater than or equal to lt gt not equal Conditional Statements The conditional statement is satisfied if it evaluates to any value other than zero The conditional statement can be any valid DMC 41x3 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions If no conditional statement is given the jump will always occur Examples Number v1 6 Numeric E
346. x3 for commands and responses and one Galil object containing a UDP handle for unsolicited messages from the controller If recordsStart is used to begin the automatic data record function the library will open an additional UDP handle to the controller transparent to the user The library is conceptually divided into six categories 1 Connecting and Disconnecting functions to establish and discontinue communication with a controller 2 Basic Communication The most heavily used functions for command and response and unsolicited messages Programs Downloading and uploading embedded programs Arrays Downloading and uploading array data Advanced Lesser used calls Or U D Data Record Access to the data record in both synchronous and asynchronous modes Chapter 4 Software Tools and Communication 63 DMC 41x3 User Manual C Library Windows and Linux The Linux version libGalil so is compatible with g and the Windows version Galil1 dll with Visual C 2008 Contact Galil if another version of the C library is required See the getting started guide and the hello cpp example in lib COM Windows To further extend the language compatibility on Windows a COM Component Object Model class built on top of the C library is also provided with Windows releases This COM wrapper can be used in any language and IDE supporting COM Visual Studio 2005 2008 etc The COM wrapper includes all of the functionali
347. xpression vl v7 6 ABS v1 gt 10 Array Element vi lt count 2 Variable vi lt v2 Internal Variable _TPX 0 _TVX gt 500 I O v1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 41x3 will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The operand between any two conditions requires that only one statement be true for the combined statement to be true NOTE Each condition must be placed in parentheses for proper evaluation by the controller In addition the DMC 41x3 executes operations from left to right See Mathematical and Functional Expressions for more information For example using variables named v1 v2 v3 and v4 JP TEST vl lt v2 amp v3 lt v4 Chapter 7 Application Programming 123 DMC 41x3 User Manual In this example this statement will cause the program to jump to the label TEST if v1 is less than v2 and v3 is less than v4 To illustrate this further consider this same example with an additional condition JP TEST vl lt v2 amp v3 lt v4 w5 lt v6 This statement will cause the program to jump to the label TEST under two conditions 1 If v1 is less than v2 and v3 is less than v4 OR 2 If v5 is less than v6 Using the JP Command

DMC-41x3 User Manual - Galil Motion Control

Contents

Download Pdf Manuals

Related Search

Related Contents