64SPU-1 Data Sheet
Contents
1. D actuator position feedback for the system To select potentiometer feedback jumper JMP 1 should be OPEN For MA3 encoder feedback jumper JMP 1 should be closed With JMP 1 open Feedback potentiometer wipers Use good quality 10K linear pots The ve direction of the pots should match the ve direction of rotation of the drive motors otherwise the motor drive will be unstable OR With JMP 1 closedFeedback signals from US Digital MA3 absolute position encoders Only the 12bit PWM MA3 encoder types are supported 10bit PWM and analogue types are NOT supported S 964SPU 1 BFF Design Ltd H 2 amp m 8H 2 let JMP 2 Normal ops M am A pins 2 amp 3 connected J 1 a ee 1 amp 2 connected and amp 5 comected 1 i i i i i i th 2 3 DOF x Moation amp Force Controller 64SPU 1 R2 L nes 2010 BFF Designite a L oH ste F gt as U8232R J J gt OV amp 5V supply for the feedback pots or encoders conveniently located beside the feedback signal connections DO NOT drive other electrical equipment from the 5V connection on the 64SPU 1 board CN4 3 Auxilliary Outputs Aux Out 1 is pre programmed as indicated below Aux Out 2 to 4 are available for future upgrades and may be re programmed by advanced users to provide alternative motor controller drive outputs Customers can contact me for examples of 20X2 chip flash programming Au2. Test With a flight sim active start the motion driver with your working bff configuration file Start the PID Servo Controller software from the motion driver window If the 64SPU 1 card is powered up and operational and the serial comms are running properly you should see the card go through its initialisation LED sequence data sheet section 4 ending with the green LED flickering very quickly at the servo loop refresh frequency Is it doing this Is the PID servo controller refresh speed reported by the software good and steady Allow the comms to run for a while and monitor the card for yellow or red LED activity If the PID Servo Controller runs but the card does not respond with its active channel LED sequence and green LED flickering then the software should report a comms time out There is a problem with the serial comms check the COM port number in the bff config file the baud setting in the PID26 cfg file and your cable connections Try an alternative port or try it on an alternative PC to try and narrow down the problem If the servo loop is active then manually move one of the feedback device positions and check that the position feedback is being reported in the PID Servo Controller window smoothly and continuously Check each active feedback channel If there is no movement reported then check the feedback device connections and the devices themselves Open the Actuator Details window on the PID Servo Controller fo
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4. STOP SWITCHES IN OBVIOUS AND ACCESSIBLE POSITIONS WHICH ALSO CUT ELECTRICAL POWER TO THE MOTOR CONTROLLERS NEVER MAKE ANY WIRING OR CONNECTION ADJUSTMENTS WHEN THE SERVO DRIVE IS ACTIVE AND THE 64SPU 1 IS OPERATING ALWAYS POWER DOWN THE SYSTEM BEFORE MAKING ANY ADJUSTMENTS 1 64SPU 1 Features 2C data output for use with Devantech MD03 motor speed controllers 12C 400KHz Baud 2 or 3 channel output for 2 or 3 DOF motion systems Selectable Potentiometer 10 bit or MA3 Digital Encoder 12 bit position feedback Built in fast smoothing on the potentiometer feedback to reduce signal noise For best potentiometer feedback performance use the 12ADC 1 12bit converter card with the 64SPU 1 Firmware B requires PID Servo Controller V2 6beta963 Built in Pause Output trip loop e 64MHz chip speed giving up to 50Hz control loop refresh speeds PC and connection dependent Up to 70Hz when used with the 12ADC 1 12bit converter card Direct connection to PC USB or Serial port physical serial port or USB virtual Com port with Latency Timing set to 1ms recommended for fastest speeds 115200 baud serial comms LED status and error indicators On board 20X2 micro controller re programmable in situ to allow firmware upgrades or customised programming 2 Connections and Settings Refer to photo A CN3 1 Position Feedback inputs Signal connections from either potentiometer or MA3 encoders that provide B C
5. USB cable NOTE these fittings are NOT included in the standard 64SPU 1 card 3 IMPORTANT BFF PID Servo Controller Software Settings Individual drive channels can enabled or disabled and reads and writes to the I2C bus can be completely disabled through the settings in the PID Servo Controller s PID26 cfg configuration file Line 29 of the PID26 cfg file contains an 8bit binary entry and the enable disable settings are made by altering the individual bits of the binary number EG Line 29 will look something like 00111111 where bit7 is the leftmost or MSB and bit0 is the rightmost or LSB The bit designations are Bit7 MSB 12C Write Disable 0 enable 1 disable Bit6 2C Read Disable 0 enable 1 disable Bit5 Channel 1 enable 1 enable 0 disable Bit4 Channel 2 enable 1 enable 0 disable Bit3 Channel 3 enable 1 enable 0 disable Bit2 MA3 Encoder 1 Direction Reverse 1 normal 0 reverse Bit1 MA3 Encoder 2 Direction Reverse 1 normal 0 reverse Bit0 LSB MA3 Encoder 3 Direction Reverse 1 normal 0 reverse If you are using MD03 current and temperature monitoring and or MA3 Encoder position feedback it is necessary to disable any channels that are not in use in your system EG if you have a 2 DOF platform drive in which channel 1 is not used then set bit5 0 etc Otherwise the encoder pulse in measurement made by the board s IC on the channel 1 feedback will timeout and the control loop refresh speed wil
6. prevent injury or damage to personnel or equipment Re connect the 24V power supply to the MDO3 s Test This check is to confirm the unloaded operation of the closed loop servo drive Power up the 64SPU 1 and start the motion driver and PID Servo Controller as before When the 64SPU 1 starts the servo loop it will generate a demanded motor speed in the direction required to close any existing position error If the pots have the correct electrical sense then the motor direction of rotation should reduce the position error and the motors will drive to and stop at the demanded position If the pot sense is wrong then the motor will drive at speed to the end stops in this case reverse the pot ve direction of rotation or reverse the motor ve direction of rotation or in the case of MA3 encoders reverse the encoder ve direction of rotation by adjusting bits 0 to 2 in the PID26 cfg binary entry Confirm that the servo loop is operating normally and steadily If operation is correct then the motor position will follow adjustments made to the position demand output of the motion driver either using the Manual Adjustment button features by making a flight sim active or by using the Joystick Input mode requires motion driver v2 6 or later If the servo loop is stable you can experiment with the PID servo loop settings for the actuators see 16 section 5 3 of the motion driver user manual Once this check has been complet
7. to 115200 for the 64SPU 1 to operate with its default programming For other BFF Servo Controller set up information eg PID settings and system tuning see the BFF Motion Driver User Manual 4 Operation and LED Sequences Make any settings required to the PID26 cfg config file see section above Set the correct COM port number in the motion driver bff configuration file you are using parameter Port COM Ensure all connections are made and secure on the 64SPU 1 and the jumper setting is as required Power up the 64SPU 1 before starting the BFF PID Servo Controller software When the 64SPU 1 powers up the Amber LED will come on followed by 2 or 3 flashes of the Green LED 2 Green flashes indicate potentiometer feedback is selected 3 flashes indicate MA3 encoder feedback is enabled If the 12ADC 1 12bit pot feedback converter card is connected the Green LED will flash 4 times Firmware B programming The Amber LED will then light and the 64SPU 1 will command zero speed from the MDO3 s and wait for data from the PC With the BFF Motion Driver v2 6 or later running on your PC start the PID Servo Controller software If the comms are operational and the 64SPU 1 is receiving data it will flash the Amber LED once and then make three flashes to indicate the status of each channel red for disabled green for enabled So for example Amber then Green Green Red indicates channels 1 and 2 are enabled and channel 3 is disabled If all channe
8. BFF Design Ltd 64MHz Signal Processor Unit 64SPU 1 Firmware B 2 r ren JMP 2 Normali ops gt pins 2 amp 3 connected 36 For mode 2 ops q 1 amp 2 connected and amp 5 connected 2 3 DDF Motion amp Faxed Controller Z 64SPU 1 R2 S EE gt F x Rod D t E D y U8232R Optional gt The 64SPU 1 Signal Processor Unit is designed for use with the BFF PID Servo Controller software as part of a DIY motion platform closed loop position feedback PID servo control system V2 6beta96 or later of the PID Servo Controller V2 6beta963 for Firmware B support and v2 6 or later of the BFF Motion Driver software are required For details of a typical overall system arrangement see the illustrative System Wiring Diagram at the end of this document IMPORTANT THE 64SPU 1 IS INTENDED FOR USE AS PART OF A PROPERLY PROTECTED CLOSED LOOP SERVO DRIVE IF YOU USE THE 64SPU 1 YOU MUST ENSURE YOUR DRIVE IS FULLY PROTECTED AGAINST UNCONTROLLED MOTOR DRIVE IN THE EVENT OF WIRING COMPONENT OR OTHER FAULTS OCCURRING IN YOUR SYSTEM THIS IS ESPECIALLY IMPORTANT IN HOME BUILT SYSTEMS THE 64SPU 1 HAS A NUMBER OF BUILT IN SAFETY CUTOFF FEATURES HOWEVER IT CAN NOT DETECT ALL FAULT EVENTS THAT MIGHT OCCUR INA SYSTEM YOU MUST FIT OVER TRAVEL CUT OFF SWITCHES TO CUT ELECTRICAL POWER TO THE MOTOR CONTROLLERS IN THE EVENT OF ACTUATOR OVER TRAVEL YOU MUST ALSO FIT ONE OR MORE EMERGENCY
9. U 1 Servo system set up checks with MD03 s This appendix outlines a series of checks to confirm the proper set up and operation of the 64SPU 1 card and servo system A motion platform closed loop servo drive is a relatively complicated system and it is strongly recommend that a step by step process is taken to setting up and commissioning the card and system In this way proper operation can be confirmed at each stage prior to final loaded operation of the system and any set up issues more easily identified and addressed along the way 1 64SPU 1 Check 1 PC Card Serial Comms Configuration Connect at least one feedback pot or encoder to the 64SPU 1 card CN3 1 and set jumper JMP 1 to suit the feedback device type pot or MA3 encoder DO NOT mechanically connect the feedback device to the actuator or platform Move the pots encoder shafts to a roughly mid position Bypass the trip loop on CN4 1 Connect the card to the PC with suitable download cable DO NOT connect anything to the I2C connector CN4 2 on the card no SDA SCL 0 or 5V Disable any unused feedback channels using the binary settings in the PID26 cfg file see section 3 of the 64SPU 1 data sheet Disable both I2C Read and Write using the binary settings in the PID26 cfg file in the binary number entry set bits 6 amp 7 1 Connect 5V and ground logic supply to the card and check the power up LED sequence is correct see section 4 of the data sheet
10. a registers in the 64SPU 1 chip at the time of the error If you need help understanding an error the hardware is reporting then email me the PID err log and PID_SC log files and can have a look at the data NOTE the card will perform a check on the MD03 motor controllers at startup ie after it has received its start signal from the PID Servo Controller software If a controller specified as active is not responding on the I2C bus then an Error 5 will be reported and the 64SPU 1 card will flash all three LED s together If you wish to run test the 64SPU 1 card and comms without active MD03 s present then DISABLE the read and write bits in the binary entry line in the PID26 cfg file see section 3 above 5 Important Notes Please read all of this data sheet thoroughly before using the 64SPU 1 1 Note that v2 6 or later of the BFF Motion Driver software and v2 6beta96 or later of the BFF PID Servo Controller Software are required for the 64SPU 1 to operate v2 6beta963 or later of the PID Servo Controller is required for full Firmware B features to be operational 2 The safety of your motion platform drive system should be foremost in your mind as you build and operate your platform Carefully consider the limit switch requirements discussed in section 2 D above Carefully consider the provision of prominent and accessible Emergency Stop buttons switches 3 Never make any wiring or connection adjustments when the servo drive is active an
11. d the 64SPU 1 is operating Always power down the system before making any adjustments If you are also using the BFF I2C Isolator card make sure that also is powered down before attempting any hardware adjustments 4 Carefully consider the 5V power supply requirements described in section 2 F above An inadequate or unregulated 5V power supply will cause problems with the 64SPU 1 function 5 Do not power other electrical equipment from the 64SPU 1 power connections Also use a dedicated battery supply for the MD03 motor speed controllers driven by the 64SPU 1 card If other equipment is also supplied by the battery supply and that equipment is connected to the same PC by its own USB or serial connection then a ground loop can be formed This can induce large currents to flow through the 40SPU serial USB cable which will disrupt the communications and potentially damage the card 6 Ensure all connections to the feedback potentiometers or encoders are absolutely secure Erratic feedback signals can be caused by intermittent connections on any of the feedback device power or signal lines and erratic feedback positions will cause the servo drive to react erratically Loss of position feedback when the drive is in operation may result in fast drive to the actuator end stops The 64SPU 1 includes some feedback signal loss detection on MA3 encoder input and due to loss of OV or 5V connections to the potentiometers However this will not protect from erra
12. der types are supported and that they have a single turn 360 degree electrical travel not the multi turn capability of some potentiometers This may affect the physical location of their fitment on the platform However MA3 levels of feedback performance can now be obtained from potentiometers using the newly available 12ADC 1 12bit potentiometer feedback converter card This requires Firmware B programming of the 64SPU 1 Also the speed of USB Serial cable comms can be raised by adjusting the Latency Timing setting of the virtual COM port to 1ms This can be done in the COM port s advanced settings accessible through the windows Device Manager 6 Revision History Firmware A June 2010 first release Firmware B August 2010 added support for the 12ADC 1 12bit potentiometer feedback converter card Requires PID Servo Controller v2 6beta963 or later Feb 2011 Updated data sheet to 1 2 for Rev 2 cards with UB232R USB module provision To upgrade the firmware on your 64SPU 1 card please email me at lan pbuiltforfun co uk for the latest firmware program and instructions Typical Overall System Wiring aunt Olde FNI an B493q9q AIS T 24 01 f 3924Ip T NdS 9 VO AO 492uv09 4ov od SSSOAW J0 pua puana y m wea AVMY T ndSt9 daar Guam any 2160 ay ul sdoo piony wwoo SiCOdW puv T NdSb waamzaq y3zbua 241 4 XOW woz4ng dois fiovabsawg jonuew v sv pappo 2q PINOYS YOUMS JN vuollippo uy
13. ecent v2 versions For the 64SPU 1 card to operate fully V2 6beta96 of the PID Servo Controller must be used Red and Amber LEDs Flashing an active feedback channel has gone to its high or low limit eg for wiring disconnect Drive will be cut and remain cut Check the feedback device wiring and connections and trace the fault before reseting the 64SPU 1 NOTE the 64SPU 1 is not able to detect a disconnect in the potentiometer wiper lines but can detect loss of 0 or 5V supply to the pots and loss of signal pulse from MA3 encoders Error Reports to PID Servo Controller software Cards running with PID Servo Controller v2 6beta96 or later will report hardware errors to the PID Servo Controller which will be displayed on screen as a user error message The 64SPU 1 Firmware A error numbers are 1 Data from PC appears to be corrupted 2 No active channels defined all the output channels may have been disabled in the PID26 cfg file needs one at least Wrong version of PID Servo Controller try the most recent version available on the web site 4 Feedback has gone out of range One of the feedback signals has gone out of range Check the feedback devices and connections 5 No response from at least one MD03 motor controller specified as active in the PID26 cfg file If a hardware error is reported a data dump is made to files PID err log and PID_SC log the motion driver working directory These contain the values of all the dat
14. ed the basic unloaded operation of the servo drive will have been confirmed and subsequent stages of assembly and commissioning of your motion platform can be tackled 17
15. ersonnel or equipment Re connect the 24V power supply to the MDO3 s Test This stage 3 check is to confirm the unloaded operation of the drive motors Power up the 64SPU 1 and start the motion driver and PID Servo Controller as before Confirm that the servo loop is operating normally and steadily Confirm that the motor output shaft speed varies in magnitude and reverses direction as the feedback pots are manually adjusted to vary the error between the feedback position and the demanded position ie as the speed demand output of the PID Servo Controller varies with the position error changes Switching the PID Servo Controller to Drive mode with the Motion Driver still on Hold mode will allow the position error to be adjusted to generate the maximum speed demand output ie maximum motor drive speed Monitor the servo system for signs of interruptions as the motors are running check for amber or red LED flashes or erratic servo loop refresh times or time out messages on the PID Servo Controller If these are present while the motors are running then the system may be affected by electrical noise from the motors or fluctuations in the logic supply to the 64SPU 1 card and MD0O3 s Make sure noise reduction capacitors are fitted to the motors as described in the MD03 documentation Make sure your 5V logic supply is regulated and of adequate current capacity 14 In preparation for further testing adjust the feedback pot po
16. itch then you must wire a short loop between the connectors to disable the trip detection CN4 1 Lower connection pair provides alternative OV and 5V power in connections for the board see F below for important comments on the logic voltage power supply F DC 1 Power in connector to suit 2 1mm power plugs tip ve The board supply must be a REGULATED 5V DC supply of at least 500mA capacity An unregulated voltage or inadequate current capacity may result in voltage dips which can cause the board s IC to drop out or the MDO3 s to mis function The board circuit includes capacitors to stabilise the 5V lines however there is a limit to the level of protection this can give in the face of an irregular logic supply voltage NOTE the board is not fitted with inverted polarity protection not not reverse the polarity of the supply It is recommended that the logic supply is separate from the main motor power supply Do not connect other electrical equipment to the 5V connections on the board as this might introduce disruptive voltage spikes or dips which can affect the 64SPU 1 function G G Stereo jack socket for PC connection You MUST use either a PICAXE AXE027 USB download cable or a AXE026 Serial download cable In my testing the AXE026 Serial cable results in noticeably faster refresh speeds than the default USB cable connection however it requires a physical COM port installed on your PC Serial PCI cards are not expensive The s
17. l slow to a crawl This setting will also disable any read attempts to a MDO3 controller not present in the system which could also disrupt the 64SPU 1 operation Bit6 If you are testing your comms with no MDO3 controllers connected to the 64SPU 1 the I2C reads to those controllers should be disabled Also a small speed performance gain may be obtained in full operation if the I2C reads are disabled completely To do this set bit6 1 If you do this the MDO3 controller current and temperature monitoring on the PID Servo software will be disabled Bit7 MSB If required the I2C writes to the MD03 speed controllers can be completely disabled This is particularly useful for testing purposes as it allows the full two way comms between the 64SPU 1 and the PC to the checked without risk of activating the physical drives To disable the 12C writes set bit7 1 If 12C writes are enabled the 64SPU 1 card will check for active MD03 controllers on the 12C bus and report an error 5 green amber amp red LEDS flash together if any active controllers are not responding BitsO 2 The direction of ve feedback from MA3 encoders can be reversed by altering these bits set 0 to reverse the MA3 s default ve direction NOTE the ve direction of MA3 output can not be altered by reversing the 0 and 5V supply as with a potentiometer BAUD Setting Line 28 of the PID26 cfg file contains the baud rate setting for the serial comms to the 64SPU 1 This must be set
18. ls are disabled the Red and Green LED s will flash together to indicate an error Full comms between the PID Servo Controller and the 64SPU 1 should then commence and the Green LED should be seen flickering at the servo loop refresh speed at the higher refresh speeds the flickering may be difficult to discern Subsequent Error Codes are Red Green and Amber LED s flashing together at PID Servo Controller startup This indicates one of the active MD03 s is not responding on the I2C bus check the wiring and 5V logic supply and the dip switch settings on the MDO3 s If you are using the I2C Isolator Card then check that this has power The MDO3 causing the fault can be identified by checking bytes 31 ch 1 32 ch 2 and 33 ch 3 in the PlD err log file for a 255 entry The MDO3 test consists of requesting the current firmware version from the MDO3 s at the time of writing this is 13 however a null response returns a 255 value for the revision Red and Green LEDs flashing after the initialization sequences Trip loop has been opened Normally due to a Pause Output switch being tripped opened If you are not using this trip loop then you may have forgotten to wire a short loop between the two trip connectors on CN4 1 Close the loop to return to normal operation Occasional Amber blinks these indicate solitary serial in timeouts detected by the 64SPU 1 The 64SPU 1 will react to sustained timeouts by closing the drive to the
19. motors see next item However it is programmed to ignore single short timeouts and try again immediately to receive data from the PC You may notice these solitary timeout events are more common when using the USB download cable on my systems they are very rare when using a physical serial port connection Comms timeouts of duration longer than 80 ms will cause the motor drive to be cut Red LED flashing with intervening green amp amber flickers Sustained time out gt 80 ms on serial in the comms between the PC and 64SPU 1 have been interrupted This is usually because the PID Servo Software has been closed or has stopped sending data The green amp amber flickers show the 64SPU 1 s further attempts to receive data the unit will try to re establish comms and will pick up normal operation when the PID Servo Controller software re starts The unit is programmed to be sensitive to loss of comms between it and the PC this is to ensure as far as is possible that the drive to the motors is cut if communications with the controlling PC software is interrupted or lost The unit may have to be powered down amp back up and the PID servo Controller software restarted if repeated successive comms interrupts occur Amber LED flashing received serial data appears to be corrupted Red LED flashing wrong version of PID Servo Controller software This is to check for very old versions of the software but will not differentiate between r
20. peed of the USB Serial cable comms can be improved by changing the Latency Timing of the virtual COM port to 1ms in the port s advanced settings The USB download cable connects to a USB port to communicate through a virtual serial port installed by the cable drivers these drivers should be provided with your AXE027 cable or downloaded from the PICAXE web site NOTE neither cable is included with the 64SPU 1 purchase you must supply your own H 5 Pin Jumper JMP 2 Used to set the operating OR programming mode of the 64SPU 1 card For normal operation pins 2 and 3 of JMP 2 must be connected To re program the on board 20X2 microcontroller pins 1 and 2 should be connected and pins 4 and 5 connected To re flash the chip you will need the Programming Editor software available free from the PICAXE web site and a BAS program for the chip THIS IS FOR ADVANCED USERS ONLY BEFORE any attempt is made to re flash the microcontroller the 64SPU 1 card MUST be powered down and all connections to the motor speed controllers disconnected l Blank J JMP 1 Input select jumper OPEN for potentiometer feedback input to CN3 2 or CLOSED for MA3 encoder feedback to CN3 1 SUPPLIED CLOSED SO REMOVE THE JUMPER LINK TO USE POTENTIOMETER FEEDBACK K Shown in the diagram are the optional socket and data LED for a UB232R mini USB module If fitted this module can provide a direct USB connection to the card via a standard mini B
21. r an active channel so that you can see both the demanded and actual actuator position bars Move the feedback position pot encoder manually to bring the position feedback towards the position demand As the actual position approaches the demanded position you should see the speed demand output reduce to zero as the position error reduces to zero Whether or not the speed demand stays at zero depends on your PID settings and in particular the setting see section 5 3 of the Motion Drive user manual If this all works satisfactorily then you can go on to check the trip loop function by momentarily breaking the trip loop connections you should see red and green LED s flashing together If you are using feedback potentiometers then check the out of range trip by moving one potentiometer to the end of its electrical travel red and amber LED s should flash together If you are using MS3 position encoders then check the loss of pulse trip by momentarily disconnecting one of the MA3 encoders from connector CN3 1 If all this works properly then go on to the next test 10 2 Check 2 MD03 motor controller 12C READ comms checks Configuration As for Check 1 above with feedback devices connected and trip loop by passed and additionally Power down the 64SPU 1 Connect the MDO3 motor controllers for the active channels to CN4 2 on the card Make sure the connected MDO3 s have the correct dip switch settings for their actuator numbe
22. rs DO NOT make ANY connections to the high current motor 24V supply end of the MDO3 s Inthe PID26 cfg file enable I2C Read only bit 6 0 DO NOT enable I2C write at this stage Test Power up the 64SPU 1 and start the motion driver and PID Servo Controller as before Confirm that the operation of the servo loop as reported by the software and the 64SPU 1 LED s is normal and steady You should be able to see some minimal activity in the Current and Temperature read back bars in the PID Servo Controller window If so this indicates that the 64SPU 1 has found the MDO3 s and is successfully reading their 12C data registers You will expect to see a very slight increase in the servo loop refresh time reported by the software Check the security of the 12C wiring between the MDO3 s and the card make sure moving the wires slightly does not interrupt the servo loop operation If the servo loop is very much slower and or erratic than there may be a problem with the I2C comms check the MD03 connections to the card check that 5V is getting to the MDO3 logic voltage input Check that the dip switch settings match the active output channel settings of the system ie that the card is not trying to read data from a non existing I2C address Make sure that your I2C lines are short no longer than say 200mm If all is well go on to Check 3 to start to check the I2C write comms 3 Check 3 MD03 motor controller 12C WRITE comms checks
23. sitions to set the feedback positions equal to the demanded positions with the PID Servo Controller in Hold mode to minimise the speed demand output from the PID software 15 6 Check 4 Closed Servo Loop Test Configuration As for Check 3 3 above with feedback devices connected and trip loop by passed and additionally Power down the 64SPU 1 and MDO3 s e Mechanically fit the feedback pots encoders to the motors so that they correctly report the physical rotation of the drive This may need mechanical elements of the actuator drives to be assembled so that the pots can be mounted properly It is best if this test is carried out with the actuators unloaded ie not driving the weight of the motion platform This will reduce the potential for equipment damage should the servo loop become unstable The pots should be fitted so that they operate comfortably within their electrical travel range when the actuator strokes over its full mechanical travel They should also be fitted so that their ve electrical rotation matches the ve direction of drive of the actuator motors If this is not the case then the servo loop will drive the motors in the opposite direction to that required to close the position error and the system will drive hard against its end stops If necessary fit over stoke cut off switches to the actuators to protect against uncontrolled drive of the motors e ENSURE all equipment is properly secured and guarded to
24. stage 1 Configuration As for Check 2 above with feedback devices connected and trip loop by passed and additionally Power down the 64SPU 1 DO NOT make ANY connections to the high current motor 24V supply end of the MDO3 s Inthe PID26 cfg file enable I2C Write bit 7 0 Test Power up the 64SPU 1 and start the motion driver and PID Servo Controller as before Confirm that the servo loop is operating normally and steadily This stage 1 check is to confirm that I2C writes to the MDO3 s does not disrupt the servo loop operation If this is so move on to Check 3 stage 2 12 4 Check 3 MD03 motor controller 12C WRITE comms checks stage 2 Configuration As for Check 3 1 above with feedback devices connected and trip loop by passed and additionally Power down the 64SPU 1 Connect your 24V power supply to the high current V and GND connectors at the motor 24V supply end of the MD03 s DO NOT connect your motors to the MDO3 s at this stage DO NOT connect any other equipment to the 24V power supply especially equipment that is connected by its own USB or Serial connections to the PC Test Power up the 64SPU 1 and start the motion driver and PID Servo Controller as before Confirm that the servo loop is operating normally and steadily This stage 2 check is to confirm that the main power connections to the MDO3 s do not disrupt the servo loop operation The voltage across the MD03 motor connec
25. tic feedback due to loose connections in the potentiometer wiper lines or from some types of intermittent wiring faults Make sure all connections and wiring are secure 7 During your initial system set up and testing set the 12C Write Disable bit bit7 in the PID26 cfg to 1 to disable all writes to the MD03 speed controllers as described in section 3 above This will allow you to check your system wiring position feedback function comms etc without activation of the drive motors Alternatively remove the main power fuses to ensure no power is available for the motors 8 It is recommended that initial set up and testing of the servo drive hardware and system be undertaken with the drive actuators mechanically disconnected from the motion platform This will allow the stability of the electric motor motion output to be assessed without risk of damage to the platform 9 On testing originally found that the best servo drive performance was obtained using US Digital MA3 absolute position encoder input for position feedback and connection to a physical Serial COM port on the PC The MA3 encoders exhibit lower noise levels than potentiometers and allow sharper gains to be used in the PID Servo Controller settings The Physical COM port connection appears to allow faster servo loop refresh speeds than comms through the USB virtual COM port and these higher loop speeds also improve the motion quality Note that only the 12bit PWM MA3 enco
26. tors can also be checked at this stage confirm the motor connector voltage varies in magnitude and reverses polarity as the feedback pots are manually adjusted to bring the feedback position close to the demanded position and the speed demand output of the PID Servo Controller varies If this is so move on to Check 3 stage 3 First adjust the feedback pot positions to set the feedback positions equal to the demanded positions with the PID Servo Controller in Hold mode This is to ensure in the next test there is minimal speed demand when the software and servo loop is powered up 13 5 Check 3 MD03 motor controller 12C WRITE comms checks stage 3 motor run test Warning From this stage on the system checks involve applying voltage to the drive motors This will result in drive output from the motor shafts ENSURE THAT ALL PRECAUTIONS ARE TAKEN TO PROPERLY SECURE THE MOTORS AND PROTECT PERSONNEL AND EQUIPMENT FROM INJURY OR DAMAGE Configuration As for Check 3 2 above with feedback devices connected and trip loop by passed and additionally Power down the 64SPU 1 and MDO3 s Connect your drive motors to the MOT connectors at the motor 24V supply end of the MDO3 s DO NOT mechanically connect the motors to the platform their output shafts must be free to rotate unloaded ENSURE the motors are securely held down on a work bench or similar ENSURE their output shafts are guarded to prevent accidental contact with p
27. x Out 1 is SyRen controller high low enable High for drive low for stop drive CN4 2 I2C outputs to the Devantech MD03 motor speed controllers The OV and 5V connections can be used for the logic supply to the MD03 s Note the I2C bus wire lengths must be kept to less than approximately 300mm The MDO3 controllers must be set to the correct I2C addresses Actuator 1 0xB0 Actuator 2 0xB2 Actuator 3 0xB4 see your MD03 documentation for the correct dip switch settings for this Your normally closed actuator end of travel limit switches and an Emergency Stop switch MUST be wired in series in the 5V line to the MD03 s to power down the controllers if the actuators over stroke or an emergency stop is required To make your motion platform drive failsafe it is essential that the logic supply voltage to the motor controllers is cut when over travel conditions occur Alternative emergency cut of arrangements can be considered however it is essential that if loss of motion control is suffered for whatever reason then the drive to the motors is cut This is best achieved by limit switches that are physically triggered by the over travel E CN4 1 Upper connection pair is a normally closed pause switch loop If this loop goes open the drive to the motors is cut by the 64SPU 1 and the red and green LEDS flash together A Pause Output or Drive Enable switch can be wired in this loop If you don t use a Pause Enable sw
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