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Getting Started - QuickSilver Controls, Inc.

1. Memory Address of words Stored Elements 2500 1 5 length lower byte 78 checksum upper byte 2501 1 0 2502 2 833 time data stored in native units 2504 2 110 2506 1 13 length lower byte 199 checksum upper byte 2507 1 0 2508 2 250 time data stored in native units 2510 2 31 2512 2 32 2514 2 33 2516 2 273804 velocity data stored in native units 2518 2 35 SilverMax User Manual 4 01 92 Register File Details Alternative An alternative to the format detailed above for importing Register File Details requires putting all of the information for the Register File on the same line as the Register File Import Directive The Register File Import Directive NVRegFile may be followed with the optional directives for starting address startAdr xxxx and data format colXFmt format as described above In addition the Register File Details may be supplied on the same line using the following directives separated by commas Register File Name Directive name Specifies the name of the Register File Example namezreg file 1 Number of registers Directive numRegs Specifies the number of registers in this Register File and must be a number between 1 and 10 Example numRegs 4 Data Directive data This is an optional parameter if followed by data and must be the last directive It specifies the 32 bit data to be stored to non volatile memory The data is to be enclosed in pa
2. Power Supplies SilverMax operates from a supply voltage of 12 VDC to 48 VDC and has to be initialized for the specific operating voltage 10 output tolerance The power supply can be a switching or linear type but should be chosen so that the power output meets or exceeds the power requirement of the SilverMax Check the product datasheets for maximum current specifications on the QCI web site http www SilverMax us MINIMUM POWER SUPPLY SPECIFICATIONS REGULATED SUPPLY OVER CURRENT FOLD BACK PROTECTION 10 OUTPUT TOLERANCE SHORT CIRCUIT PROTECTION 2 0 LOAD REGULATION OVER VOLTAGE PROTECTION QCI strongly recommends voltage clamping protection on all DC power supplies Voltage clamping controls the back EMF generated by electric motors during the deceleration of large inertial loads External power supply clamp modules are available from all authorized QCI Distributors For more information on the QCI voltage clamp modules see Technical Documents QCI TDOO6 Cabling QCI offers cabling for use with SilverMax and accessory products for general applications These cables have documentation describing physical dimensions and pin outs Custom User Manufactured Cabling If an application requires custom cabling the correct pinout must be used to develop the correct wiring harness SilverMax 17 23 and 34 frame sizes have different cabling specifications that must be followed The following are some design requirements that are i
3. Put the calculator into hex input mode by clicking the Hex button Be sure the Qword button is selected to ensure no rounding occurs Now enter the hexadecimal number into the calculator A to F is used in Hex mode Hexadecimal Word 0x9COA Edit View Help d 39 946 The hexadecimal number can now be converted to a r rr SE e Hex Ze Dec C Oct C Bin E Degrees Radians Wa Decimal Number 39946 Seige ES zl ee fs se ape e ee a This number can now be used in an ASCII string ave m ep xl wl 4 os ce o x SA eee PE T Ea aa decimal by simply clicking the Dec button Note Binary hex and decimal values may be entered directly into the Windows Calculator providing a simple conversion process SilverMax User Manual 4 0 184 Appendix E SilverMax Mechanical Dimensions SilverMax 17 Frame Mechanical Data All measurements listed are in inches CAD files are available from the QCI website www quicksilvercontrols com Male 15 Pin HD Connector _ 1 220 Ge Nk 2 000 0 866 SCH Pe 0 240 0 790 FLAT ZEN a Bi 0 177 E 1 785 l Gr 1 220 N Geer 0 198 Fa 0 590 4x 4 40 1 789 0 17 Deep See Table Model Type Length w o shaft in 17 1 2 74 17H 1 2 7
4. eeeeeeeeeeeeeeeeen 45 lee 46 Drogdr mming 5 6 14 31 85 DFANCHING niesen a a 20 43 109 conditional program How 43 44 proportional gain bp 160 174 protocol Nee 9 15 24 27 62 76 77 141 143 146 154 183 9 bit binary eeh 1 141 146 175 183 checksum 41 49 87 92 93 96 135 137 141 146 150 QuickControl tools 5 6 30 45 71 register UE 18 41 88 100 lte UE 88 100 response packets 142 148 152 returned data response 149 scaling 17 18 19 32 33 41 69 78 80 88 91 95 116 118 123 180 scaling parameters seseseoeeeeeeeeaeen 18 19 41 80 S CUIVE facht 160 serial communications 5 24 31 34 39 61 62 68 77 81 122 141 143 148 150 176 189 190 191 serial interface 8 17 24 27 36 39 43 100 103 141 150 SOMO sic SE dons see 5 7 9 11 13 15 22 25 27 31 32 34 40 43 47 53 58 61 62 71 75 79 91 95 97 100 102 105 107 109 111 113 119 121 123 127 129 131 135 139 140 142 143 145 148 150 151 153 SilverMax User Manual 4 0 154 157 160 162 164 166 168 169 170 173 175 177 180 190 191 COMMUTATION cecece ee eeeeeeeee eens 116 117 161 control loop 25 31 157 164 166 169 servo sample rate cceeeseeeeeeeeeeeeeeeeeeeeeeeeees 176 shutdown 41 56 106 127 131 133 139 140 controlled re 128 1
5. Polling Routine repeated loop This can be done at any baud rate supported by the serial interface Send Poll Command Receive Response Check for Command Completion Send Clear Poll Command Exit Polling Routine 35 This basic polling routine could be extended to monitor the other status words the Internal Status Word and UO Status Word This would increase the details available to and improve the capabilities of the host control program The Internal Status Word available via the Read Internal Status RIS command provides information about the current operation of SilverMax Status items such as whether the voltage is too high or low and current error conditions are available in this word The I O Status Word provides the state of all seven of the digital I O lines the internal and external index and the over temperature detection circuit Detailed information on the status words is available in Chapter 3 Standalone Configuration A common mode of SilverMax operation is to download programs into the SilverMax and allow it to run completely independent of any other controller This is referred to as a standalone configuration because the SilverMax can actually operate in a system with only a power supply connection This enables SilverMax to take on PLC like qualities and operate a small system Often in this configuration the digital I O is used to initiate the required operations by programming the
6. Initialization utility within 3 1 for initialization sequence files Motion Tuning Tuning utility within 3 1 Unknown SilverMax Wizard Establishes communication with Legacy SilverMax SilverMax Firmware Download Wizard Downloads firmware to SilverMax Setup Menu Comm Port Selects Baud Rate COM port and Protocol for QuickControl Simulator Allows user to setup computer as a SilverMax simulator with ID and com Register Devices Allows user to manually registers devices into QuickControl Options Allows user to edit other setup specifications Polling When checked starts QuickControl polling the network for any connected SilverMax and then displays the state of the device in the Device Status window Verbose When checked enables extra error messages and warnings Window Menu New Window Creates a new program window Cascade Cascades current program windows Tile Displays current program windows in a tile arrangement Arrange Icons Arranges and aligns minimized program icons Current Program List A list of programs currently open in QuickControl Help Menu Help Topics Opens help menu for tutorials and information on QuickControl About QuickControl Displays date and version of QuickControl and product support information SilverMax User Manual 4 01 18 2 Icon Bar The QuickControl Icon Bar provides shortcuts to certain functions that may be used repetitively while using the QuickControl soft
7. Make sure the move is within the torque limits of SilverMax One of biggest problems with tuning a high inertial mismatch system is insufficient torque While SilverMax is trying to move a very large load 100 times the rotor inertia monitor the torque with the strip chart to make sure it does not max out 2 Disable Anti Hunt and Drag Mode Turn off Anti Hunt Mode feature and Drag mode Anti Hunt and Drag Mode can distort the true output of the SilverMax 3 Start with the Factory Defaults SilverMax Initialization Wizard x Press Download to initialize SilverMax or change the Exit factory default parameters using the Initialize Parameter Edit ERL Error Limits E Browser or Interview z T Options Cancel Download File Moving Error Limit To SilverMax Interview f Description o counts _ Description Holding Error Limit T Drag Mode Initialize Parameter Browser File F Communications 200 counts ARSE Mot Units iis Factory Default Initialization gop S ww Ce E Servo Tuning Delay to Holding oma E Motion FS C Native f i 5 Save imil Rema CH E H ae Save ave As E Error Limits E Misc Do not change the default tuning parameters 4 Set Ki to zero Once a stable system has been established the integrator value can be turned up Test the move Note any changes in the SilverMax operation or sound 5 Increase Kv2 and Kvff Increase both velocity terms to
8. Position ER AF ele Kaff XT arget Acceleration Lony _upper_word _used Enz D arget_ Position Position x Position Where Al 32768 o M 32768 _ Zo 32768 T _the_sample _ period 120 e seconds SilverMax User Manual 4 01 158 Acceleration Feedback Low Pass Filter AF Fa 215 za hizk Acceleration 47 LL Feedback L Gain BN N Acceleration fitereo 1 AF H ES Ka gt BE Ge A fo As Acceleration Ae gt Ki Ke a First Velocity Feedback Low Pass Filter 7 le T 1 KF Fv1 2M5 ox Re Velocity 1 Se N Bi Feedback ob KER AN Nw f ain Position e val y a 1028 gt DK H ES Velocity Once KS from motor d J Ke iere ced shaft 4000 rev pa Li Ge SS Sa ee Velocity 2 l Feedback Gain VF Fv2 25 Kv2 gt amp 4 iak lt E j Acceleration N ck Feedforward S Velocity Twice e Gain Gr Filtered ka gt Li SCH alt Second Velocity Feedback Low Pass Filter Velocity Target Acceleration Feedforward Gain N d Target Velocit Trajectory g y eg Generator Target Position E Position Error Limiter 16 bits Target Acceleration and Target Velocity are scaled such that the maximum values of each are represented by 2 15 1 2415 lt X lt 2415 1 Limiter 16 bits 2415 lt X lt 2 15 1 Limiter 16 bits D Tmax lt X lt Tmax Sum of Non Integral Terms Pos
9. The data format for each column can be different Putting the appropriate number in place of the X in the Data Format Directive specifies the data format of a specific column Note the column numbers are zero based i e 0 1 2 so that the first column s column number would be 0 Example coloFmt time the first column s data format is time This data format directive will cause the first column of each Register File Array entry that follows to be imported in time format QuickControl will convert the time data to Native SilverMax Units The data will be stored to memory in Native SilverMax Units If the data format for a column is not specified with a directive it will be set to the default long format Example NVRegArray name reg file array 1 col 4 row 6 startAdr 2500 coloFmt time The Register File Array data that follows this directive will be stored to non volatile memory location 2500 and the column will be in time format There will be 6 entries in this array and each entry has 4 columns Register File Array Details The lines in the imported text file following the Register File Array Import Directive should include the 32 bit data for the Register File Array defined by the directive The data of each Register File Array row must be contained on one line of the text file The data must be separated by commas and listed in the following format lt row 1 1st reg data gt lt row 1 2nd reg data lt row 1 last re
10. When the Check Holding Currents box is selected as shown in the QuickControl screenshot SilverMax checks another condition besides position error before entering Anti Hunt SilverMax compares the actual torque required by closed loop control as indicated by the current flow through the motor windings to the open loop torque limit If the closed loop torque required exceeds the open loop torque limit SilverMax will not enter Anti Hunt SilverMax does not compare the closed loop torque used to the open loop torque limit if the Check Holding Currents condition is disabled Anti Hunt Delay AHD Command The AHD command sets the time delay SilverMax uses before entering Anti Hunt This delay is useful for allowing a system to settle before switching to open loop control since position error and torque must remain within the limits set with the AHC command for the duration of the delay Anti Hunt Mode AHM Command The AHM command controls the operation of Anti Hunt Anti Hunt operates in one of two states shown in the QuickControl screenshot In its default state SilverMax will only enter Anti Hunt when SilverMax is holding a position meaning that the e ee ge aaa Trajectory Generator is inactive If this default setting is Anti Hunt Mode enabled ma changed SilverMax can enter Anti Hunt when moving or when e only when stopped Description holding position This means that SilverMax can switch to open eier when moving or
11. e Digital Inputs All seven of the I O lines can be used as digital inputs allowing SilverMax to react to on off inputs like a PLC e Digital Outputs All seven of the I O lines can also be configured for use as digital outputs allowing SilverMax to send on off signals and control simple systems e Analog Inputs I O lines 4 5 6 and 7 can be configured as 0 to 5 V analog inputs allowing SilverMax to use analog signals for direct motion control or as analog sensor inputs e High Speed I O Functions SilverMax can use its I O lines for two special high speed I O functions scalable internal encoder output and scalable step and direction input These I O functions are used in several SilverMax applications including electronic gearing and camming operations For normal uses the fastest sampling rate for a SilverMax I O line is once every servo cycle every 120 usec For high speed functions however the maximum sampling rate is about 1 MHz or once every 1 usec These functions can be used in many different types of applications This chapter covers each I O function s operation the commands used with each function and the different uses for each function in a SilverMax application Input and Output Operation SilverMax has seven fully programmable I O lines Each line can be used as a digital output or a digital input while some of the lines can be used as analog inputs or configured for special uses Each UO line can be configu
12. loop control whenever the position error is low enough so an doot entire move could be executed using open loop control It is d rarely needed but useful for some applications SilverMax User Manual 4 01 60 Error Limits ERL and Torque Limits TQL Commands These commands are covered in their own sections but are important for Anti Hunt When SilverMax enters Anti Hunt the ERL delay timer starts Until the timer expires SilverMax applies torque equal to the open loop moving torque limit as set by the TQL command After the timer expires SilverMax uses torque equal to the open loop holding torque limit This is true even if the AHM command is set to allow Anti Hunt operation while moving or stopped In this case once the ERL timer expires SilverMax will use the open loop holding torque limit torque during the move If the optional closed loop torque condition has been enabled with the AHC command the Check Holding Currents box in QuickControl SilverMax will compare the closed loop torque being used to the open loop moving torque limit before the ERL timer expires After the ERL timer expires SilverMax compares closed loop torque to the open loop holding torque limit Multi Tasking Multi tasking is a very important feature of SilverMax SilverMax can execute programs with multi tasking either enabled or disabled With multi tasking disabled a program executes one command ata time Ifa command starts a move that takes twenty
13. Register Store Non Volatile Store Actual Position 1 Get the current direction flag from Data Register 31 and Store it a NY Memory address 1004 NY memory address 1004 was selected becasue it is the first address availabe after saving the position data to N Y memory address 1000 This is due to each saved data register needing 4 words total Register Store Non Volatile Store User 31 Power Low Recovery Program Save Position amp Direction to NV Memory SilverMax User Manual 4 01 136 Time Needed For Saving to NV Memory Total time to save a data register in the buffer to the NV memory ranges from 7 2 msec to 14 4 msec The average time is 7 2 msec However if the memory address to which the data is saved lies across a memory boundary addresses divisible by 32 double the average save time is needed Therefore when using the Register Store Non Volatile RSN the maximum time needed to save 5 data registers is 5 data registers x 7 2 msec 36 msec Add another 7 2 msec to account for the possible crossing of a memory boundary Total NV save time 36 msec 7 2 msec 43 2 msec The reason for this time is that the NV memory of SilverMax needs to be charged before each save cycle This process allows a greater assurance of the integrity of the stored data In order to minimize save time the Register Store Multiple RSM command stores multiple registers up to ten sequential registers using the
14. Simple Kill Motor Shutdown from Moving Error 140 Chapter 9 Serial Communication and Networking ccccccesseseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 141 Selecting a Protocol and Interface ccccscccceeccssssseseeeeeeeeeeeeeeeceeaeeeeeeeeesesseeqaeeeseeeesecseeeneseeeeeeeeeessenaaas 141 SilvetMax elen Uer te E 142 Communication Port Settings E 142 SilverMax Packets EE 142 SilveiMax deele 143 Geleet Te e 143 9 Bit Binary Communications ebe Ee ee eg 146 Serial IMS ACS gheet eege to det eats eect iat teeteeda tated Snaeetets 150 Comparing RS 485 and RS 282 aive ane ianen terete id EA R daa a 150 Choosing RS 252 Or EE 152 Implementing a SilverMax Communications Network cccccceeteeeeeeeenneeeeeeecaeeeeeeeeeeeeeeeneeeeeeeenaeeeeees 152 General requirements EE 152 Example Wiring Diagram S eres ee Eege Eed Eeer 153 Additional information and Troubleshooting WEE 156 Chapter 10 Tuning SilverMax ServOMOtoSS sssssssessesssssseseessesesseseseeseeseeseesaeseeseesaeses 157 Control System OVEN E 157 SilverMax PVIA Servo Ee dn Lu EE 157 SilverMax 8 le e te Keen Ee 160 Primary Command Sisin E E E A A E E E 160 Associated COMMAS eeh 160 Overview of the Control System Parameterg AAA 161 Silv rMax Control Panel seitdita eean eae a e ie se geed ebe Beie aM EBEN EES 170 SilverMax User Manual 4 0 vii Example 10 1 Tuning a 100 1 Inertial Mismatch c ccc eeeeeeeeeeeceee tree ee eeeeeeeeeeeeeee
15. Simple Kill Motor Shutdown from Moving Error This exercise shows that moving error can be used to shutdown the SilverMax drive It provides an opportunity to investigate the association between Kill Motor Conditions and Error Limits 1 Turn OFF the polling from QuickControl to SilverMax 2 Open the File QCIl Examples Motor Shutdown Kill Motor Recovery Simple Shutdown qcp 3 Edit the torque parameters of Line 3 TQL Command so that all parameters equal 35 4 Run the program IMPORTANT In this exercise you MUST hold the SilverMax firmly with one hand and restrict the shaft with the other If the motor is NOT held the motor and cable may spin out of control 5 While the motor is moving back amp forth hold the motor with one hand and restrict the SilverMax shaft motion with the other hand NOTE The driver should disable kill quickly as the Moving Error easily achieves the 200 counts set by the Error Limits ERL command on Line 5 of the program 6 Edit the Error Limits command and set the Moving Error to 2000 counts Click OK and Run the program again 7 While the motor is moving back amp forth hold the motor Firmly with one hand restrict the SilverMax shaft motion a small amount with the other hand and let go quickly The motor should servo back the small amount of restricted motion Repeat a few times 8 Repeat Step 7 again This time restrict the motion until the 2000 count 1 2 revolution Error Li
16. Anti Hunt is mainly used in two situations 1 Holding position firm and steady without servo dithering 2 A particular operation requires using open loop control for part of a move or hold SilverMax User Manual 4 01 58 If the accuracy of final position in an application requires strict compliance Anti Hunt may need to be turned off because it creates a feedback deadband around the final position When the shaft is anywhere inside this deadband SilverMax ignores position feedback and it will not correct the final position error Likewise when Anti Hunt is used during a move SilverMax ignores position feedback as well as velocity and acceleration feedback and blindly commutates the motor based only on the target position In general open loop control should not be used during motion unless there is a specific design reason e g it eliminates dither in slow high inertia moves Anti Hunt Operation Anti Hunt essentially sets up a deadband around the target position Inside this deadband SilverMax uses open loop control and therefore ignores error feedback The width of the deadband is defined by the Anti Hunt Constants AHC command When the position error the difference between actual position and target position becomes low enough to enter the deadband SilverMax performs some other checks explained below and then enters Anti Hunt by switching to open loop control When the position error becomes too large SilverMax immediately s
17. R Command Buffer Size HW lt i gt Start of Command Buffer LW 211 R W Kill Motor Conditions HW lt gt Kill Motor States LW 212 R Analog Input 1 Data HW lt gt Analog Input 2 Data LW 213 R Analog Input 3 Data HW lt gt Analog Input 4 Data LW 214 R V Driver Voltage HW lt gt Temperature of controller proc raw data LW 215 R HC Processor Voltage HW lt gt Driver Temperature LW 216 R Max Drive Voltage ADC count HW lt gt Drive V Calibrate counts volt LW 217 R W Max Driver Temperature HC series counts HW lt gt HC Processor Calibrate data counts volt LW 218 R W Non Volatile Memory Load Address last attempted HW lt gt l MSTATE of command that executed loading LW useful for debugging 219 R Module ID int com addresses HW hi byte group id low byte unit id lt gt SEQ_PNT int RAM pointer for program download LW QuickControl use UO Filter Data for all seven UO lines 220 UO Line Filter Count 0 no filter HW lt gt I O Line Present Count LW thru R W Note If data is positive I O line is considered high if negative low Counter will count 226 t up with high levels and down with low levels jumping to filter count when it crosses zero count value hysteresis 297 R W Factory Reserved Alignment Data Modifications may affect servo operation Set by the Factory Block 228 t R W Error Location block buffer location r
18. Registers 17 18 and 19 are the operational registers The upper word of Register 17 indicates whether the data in the user registers has been used when the IMS operation copies data from the user defined registers to the Profile Move registers it writes a 1 here indicating the velocity segment parameters are now stale The lower word of Register 17 contains the register reference number of the first of four user registers if using the register based queue or a O if using the Interpolated Move Queue see IMQ Command via a host through the serial interface This value will have to be written to Register 17 with a Write Register command in a loop after the IMS operation transfers the data and writes a 1 to the upper word Register 18 is where the segment time the first data parameter is copied just before execution of that segment Register 18 is decremented every servo cycle 120 usec until it reaches O If there is a still a 1 in the upper word of register 17 at this point fresh data has not been loaded the IMS operation uses the value in Register 19 as a default deceleration value to stop current motion and exit IMS The four user defined registers can be any four sequential user registers these four registers make up the register based queue They must be loaded with Time Position Acceleration and Velocity data in that order of the next velocity segment to execute There are two options to successfully strea
19. around For a general move use the present position plus or minus 1 073 741 824 This value is large enough to project moves properly while remaining small enough to never wrap around the register range and project movement in the opposite direction If the segment comes to a halt decelerates to zero velocity give the desired ending position of the move In this case the position parameter is used to direct the motion profile to a specific location Acceleration 1 to 2 147 483 647 Scaled from a 0 2000RPM 120usec value Acceleration or deceleration used in reaching the ending velocity of the segment Since the acceleration corresponding to the full scale value is physically impossible to achieve limit acceleration values to approximately 1 2 of this scale 1073741823 A 0 indicates a constant velocity segment Velocity 0 to 2 147 483 647 Scaled from a 0 4000RPM value Unless the segment is the last segment of the profile this should be the desired ending velocity of the segment When specifying the last segment of a profile set velocity to the starting velocity of the segment Do not set as the ending velocity of the segment to zero this will cause the IMS to undershoot the desired ending position Velocity Profile Segment 3 ramp down with 0 05 deceleration Segment 2 ramp to 2000 rpm with 0 05 acceleration o gt o 2 ER gt Segment 1 Segment 4 ramp to 1000 rpm Change deceleration wi
20. Kill Molor Recovery Load and Run Program Fault Recovery A simple move back and forth loop The Silve Max will continue its mation until the lt ill Motor Conditions are met Move revs ramp tine 500 04 mSec total time 2000 04 mSec Move 2 revs ramp time 500 04 mSec total time 2000 04 mSec Jump to FOREVER fault has occurred By default SilverMax disables the Motor Driver So now the motor must be returned to operating status Give the motor a little time to stop This can be increased if needed Delay for 500 mSec Now that the motor is stopped set the T arget Position to the Actual Position This effectively zeroes the Position error Target to Position Re set the Kill Motor Conditions This is required before motion is resumed again Kill Motor Conditions If 1 0 3 is LOW Now re enable the motor driver Form here on the motor will have power to the rotor Enable Motor Driver Just a wait before calling the next program Delay for 500 mSec Run a system recovery program from here This following program could be a Homing routine that would recover from the error Load and Run Program Home the SilverMax 132 Kill Motor Recovery from Controlled Shutdown Initializing SilverMax for Controlled Shutdown Controlled shutdown requires adding a few extra elements to the SilverMax startup The most important is to add the EMT
21. LIMITS Low Voltage Trip Read the factory set ADC calibration data from NY Low Voltage Trip 10 volts memory Athe analog inputs are factory calibrated LIMITS Over Voltage Trip This command reads the calibration data from NV memory and calibrates the ADC Over Voltage Trip 52 volts d Calibrate Analog Input from Non Volatile LIMITS Error Limits Phase Align torque limits Be HE oving Limit 500 counts Ges Es olding 0 Holding Limit 200 counts Closed Loop Moving 0 Delay to Holding 125 mSec Open Loop Holding 0 Kill Disable Drivers Open Loop Moving 0 Setup Final Kill Motor Conditions Go Open Loop Kill Motor Recovery and Power Low Recovery Single Loop Control Kill Motor Recovery _ Program Kill Motor Recovery LIMITS Kill Motor Conditions Kill Motor Conditions lf Over Temperature Motor Constants MCT Power Low Recovery Phase Advance PAC Program Power Low Recovery The commands are set dependent on input voltage by a factory derived formula These commands should only be eded by tne Street ee MSC Set Digital Input Filters M Motor And Phase Advance Constants Digital Input Filter Molor Constants SE A0 Lines 10 mSec ase Advance Constants This command is edited the same time MCT is edited Disable Done Bit The edit dialog box does both at the same time Modulo Clear Phase Advance Constants
22. Mode commands such as Velocity Mode VMP and Scaled Step amp Direction SSD completely suspend program execution until a command with override capability is sent from a host controller When using this type of command the intention would be to put SilverMax into the desired mode for continued use Mode commands like motion commands can use stop conditions to stop motion and end execution Data Register Commands Data register commands that write data to non volatile memory will suspend program execution during the storing process The non volatile memory takes a certain amount of time to complete a write cycle due to the physical characteristics of the non volatile memory storage cells Miscellaneous and Initialization commands All other commands execute within a single servo cycle and therefore do not effectively block program execution Commands such as Torque Limits TQL Zero Target and Position ZTP and communication commands fall into this category SilverMax User Manual 4 01 43 Program Flow Control Programs do not just sequence from one line to the next Branching both conditional and non conditional can be performed at any time Using the Jump JMP Program Call PCL Program Return PRT and Load and Run Program LRP commands very complex program flow control can be accomplished Common conditional program flow techniques IF statements FOR loops etc can be created using the program flow commands Conditional Progra
23. To save any changes made to the initialization file click the Save button To save the changes to another initialization file with a new filename select the Save As button and then enter the desired filename SilverMax Factory Default Initialization File The Initialization program file contains the following programs MAIN INIT The Main Initialization program contains all of the initialization commands for SilverMax This program is shown in the next section and is described in detail STARTUP RECOVERY The Startup Recovery is used if a Kill Motor Condition is tripped during execution of the factory default initialization The Startup Recovery program will cause the Status LED to flash KILL MOTOR RECOVERY This program is called whenever a condition set in the Kill Motor Conditions KMC command is tripped This may be modified if special processing is required For example if SilverMax is required to set an error output anytime it detected a jam Moving Error needs to be set in the KMC command because a mechanical jam will induce moving error Then add a Set Output Bit SOB command to the Kill Motor Recovery program POWER LOW RECOVERY This program is called whenever voltage drops below the specified threshold in the Low Voltage Trip LVT command and may be modified if special processing is required on a Power Low condition For example if SilverMax is required to save the current position at the time of a power loss so it can cont
24. allowing other devices to transmit on the line All SilverMax Tx lines are tied together as are all Rx lines The collected lines are connected to the host using the same null modem configuration as in a single servo system RS 232 Communications Connect up to 4 more SilverMax Tx Rx GND Power Supply S 12 to 48 Volts SilverMax VC RS 485 Network RS 485 is a more robust communication protocol designed specifically to work with multiple nodes The three wire system has three signals A B and logic ground All A lines are tied together as are all B lines Logic ground lines should be tied together to improve noise reduction Standard RS 485 supports 32 nodes SilverMax uses special half power RS 485 chips that allow up to 64 nodes per network QCI RS485 RS 485 Communications RS 232 RS 232 Connect up to Host PC To 63 more or RS 485 SilverMax PLC Converter Units Power Supply 12 to 48 Volts SilverMax SilverMax User Manual 4 01 154 Connection Topology RS 485 networks require termination The recommended wiring method is a daisy chain style connection which usually requires the simplest termination This type of network uses termination at the host node and the last node furthest from host Backbone stub type connections can usually use the same simple termination More complex wiring methods require more complicated termination unique to each system The backbone system can use the simple
25. command configures SilverMax for external encoder usage See Chapter 6 for details on using external encoders The Control Constants typically need to be configured differently for dual loop operation The default control constants are optimized for single loop operation Motion parameters become related to external encoder counts rather than internal encoder counts The feedforward acceleration and velocity terms are relative to full speed in internal not according to the SCR encoder counts while the feedback terms are relative to the external not according to the SCR encoder counts Thus the feedback terms may need to be different from the feedforward terms for example If the external encoder had three times the resolution of the internal encoder the feedback terms would need to be three times as large as the feedforward terms to balance their gains Overview of the Control System Parameters A good understanding of the SilverMax control parameters and settings is useful when figuring what changes should be made to optimize the operation of SilverMax QCI recommends that all users are educated on the parameter descriptions and their functions in the control system before tuning the SilverMax The typical parameter ranges listed in the table below represents values that have been implemented in working applications and are to be utilized as a guide for user applications Some applications may need values outside the typical range listed in the ta
26. leie EE 24 141 Start character ce ceccceseceeeeeeeeeeeeeaees 143 145 COMMUNICATIONS ccceeeeceeceeeseeeeeesseeeeteneeeeenes 8 control constants 53 117 121 161 162 Control svsiem 53 157 161 data registers 18 30 39 41 47 65 71 87 88 97 100 112 119 121 137 177 179 register watch tool s es 79 ole 26 71 105 110 152 digital outputs 0 0 1 3 11 13 65 105 111 COW MIO AGING EE 44 drive enable accer 50 52 98 190 191 error liMits oee 25 56 57 130 180 factory defaults EE 8 host 1 6 16 17 27 30 34 36 40 43 47 51 53 54 56 62 63 65 68 71 72 78 81 87 100 103 105 109 113 119 122 124 128 130 131 141 142 148 151 155 177 configuration EEN 2 hybrid confguraton 3 4 5 47 initialization 2 5 8 15 18 21 22 24 26 28 29 127 129 134 170 ml E 22 SilverMax User Manual 4 0 INTEIVIGW eege Ed tannic 24 29 parameters irpan aa e at 24 29 input mode 63 71 80 111 112 123 184 lgl nie EE 63 HEES ees 38 71 76 77 80 82 105 111 115 128 175 integrator gain RI 168 169 interpolated MOTION eeeeeeeeeeeeeeeeeeeeeeee 103 jump commands 43 44 49 50 81 83 180 math operations EE 67 MEMOTY ANEN 5 15 17 19 22 26 31 39 43 45 49 68 87 88 91 96 112 129 131 134 135 137 176 180 communications buffer a 39 143 EE EE 42 pro
27. scales value and imports with position units set in QuickControl Scaling acc scales value and imports with acceleration units set in QuickControl Scaling vel scales value and imports with velocity units set in QuickControl Scaling time number of servo ticks 120 usec 1 tick The data format for each data entry column can be different Putting the appropriate number in place of the X in the Data Format Directive specifies the data format of a specific data entry column Note the column numbers are zero based i e 0 1 2 so that the first column s column number would be 0 SilverMax User Manual 4 01 91 Example col0Fmt time the format for the first column of data is time This data format directive will cause the first data entry of each Register File that follows to be imported in time format QuickControl will convert the time data to Native SilverMax Units The data will be stored to memory in Native SilverMax Units Note If the data format for an entry column is not specified with a directive it defaults to long format Example NVReoFile startAdr 2500 coloFmt time Using Register File Import Directive and both optional directives The Register File data that follows this directive will be stored to non volatile memory location 2500 and the first data entry column will be in time format Register File Details The lines in the import text file following the Register File Directive should include details na
28. unacceptable and in severe cases can cause large oscillations in the whole system SilverMax has a unique operation called Anti Hunt that is designed to eliminate dither by switching from closed loop control to open loop control see previous section on torque limits When using open loop control SilverMax ignores any error feedback so small errors in position do not result in constant corrections These constant small corrections are what cause servo dither In addition to eliminating dither SilverMax can use Anti Hunt to help smooth out some kinds of motion profiles by using open loop control during some parts of the move This section explains the operation of Anti Hunt describes how to use it and covers the commands used to set it up Using Anti Hunt Anti Hunt is used to automatically switch between closed loop and open loop control based on position error and torque level SilverMax can be set to enter Anti Hunt only when holding a position or it can be set to enter Anti Hunt any time position error is low enough When using open loop control to hold position SilverMax ignores small position errors and lets the shaft sit at the position it held when it stopped When using open loop control during a move SilverMax ignores small errors and commutates the motor based only on the motion profile from the Trajectory Generator Both settings for Anti Hunt can make SilverMax operate more smoothly but they also limit the final position accuracy
29. when loading the Register File to know the correct number of words to load and to verify the accuracy of the data The second word of the Register File is a 0 or Null and is added by SilverMax The Null word is a safety feature to prevent SilverMax from trying to execute the data as a program The data from the selected data registers is stored sequentially into the third and subsequent words of the Register File Register File Memory Usage Example starting at address 2500 Memory Address of words Stored Elements 2500 1 Length lower byte Checksum upper byte 2501 1 Null Word 0 2503 2 Data from 1 Register 2505 2 Data from 2 Register 2507 2 Data from 3 Register 2509 2 Data from 4 Register 2511 2 Data from 5 Register 2513 2 Data from 6 Register 2515 2 Data from 7 Register SilverMax User Manual 4 01 87 From the example the total memory usage is 16 words to describe data in 7 registers A stored Register File may be loaded from non volatile memory into selected data registers The number of data registers loaded from the Register File must be equal to the number of registers stored Registers Files may be loaded using the following commands RLN Register Load Non Volatile single register load RLM Register Load Multiple multiple register load Register Files Names in QuickControl QuickControl simplifies Register File usage by allowing custom naming of
30. 006 N m 0 73757 8 8509 141 61 1 0 10197 10 197 1 0197 10 kgf m 7 2331 86 798 1388 8 9 8067 1 100 1 105 kgf cm 7 2331 10 0 86798 13 888 9 8067 10 1 10 1 1000 gf cm 7 2331 10 8 6798 10 1 3888 10 9 8067 10 1 10 110 1 Additional Conversion Data Length 1 inch 0 0254 meters Temperature F T 9 5 32 Mass 1 ounce 0 02835 kilograms Velocity 1 revolution second rps 60 revolutions minute rpm SilverMax User Manual 4 0 181 SilverMax User Manual 4 0 182 Appendix D Binary Hexadecimal and Decimal Conversions There are three standard numerical bases used when working with SilverMax Because many of the status words and parameters are defined in a bitwise fashion the most direct representation is a binary number SilverMax also uses parameters in either decimal format or hexadecimal format This appendix explains how to convert between these values For this example a generic 16 bit binary word has been selected 16 Bit Binary Word 1001110000001010 Begin by copying the binary word into the second row of the table The next step is to convert the binary number into a hexadecimal number This is done by first grouping the binary values into sets of 4 called nibbles In hexadecimal a nibble represents a value of 0 to 15 The letters A B C D E F are used in place of 10 11 12 13 14 15 respectively This gives a numbering system as shown in the following set 0 1 2 3 4 5 6 7 8 9 A B C D E
31. 10 500 501 502 503 504 505 506 507 508 509 nvRegFile startadr 0x3FF reg file 6 1 600 Include Reg File Adv Example Include 2 txt G nvRegarray name profile6 1000 G nNvRegarray name profile7 row 2 col 2 1000 122 1000 122 Number of Rows and Cols automatically calculated NvRegarray name profiles 11 12 13 14 21 22 23 24 31 32 33 34 41 42 43 44 The following will import a non volatile register file named reg file df The data for each column Cregister will be in a different data format The data format is not specified for the 7th column it will be set to the default dong note the column register numbers are zero based Ci e 0 1 2 note when using the Data Format Directive CcolxFmt with units scaled by Quickcontrol Ce o pos vel acc the QCP file must have the scaling set BEFORE importing the register file Reg File Adv Example qcp has scaling set to 4000counts lrev therefore values associated with scaled units are as Follows pos in revs S vel in rps S acc in rps s l NvRegFile col0Fmt hex collFmt uLong col2Fmt pos c0l3F mt acc col4Fmt vel col5Fmt time reg file df 7 100 101 60000 20000 100000 105 106 Reserve memory for an array ending at 3000 but do note initialize it nvRegarray name profile9 row 3 col 2 endAdr 3000 Reserve memory for an array starting at 2900 but do not initailizae it G nNvRegarray name profilelo row 3 col 2
32. 10 times the default values Test the move Note any changes in operation or sound If a high frequency screeching occurs in a low inertia system lower the Kv2 and Kvff until the sounds subside If excessive overshoot occurs increase Kv2 and Kvff Typical adjustments are by a factor of 2 i e either divide by 2 or multiply by 2 Typically Kv2 and Kvff are adjusted until there is some noise during the move but not at rest SilverMax User Manual 4 01 171 6 Reduce Fv1 and Fv2 Reduce Fv1 by 3 times the default setting and set Fv2 to three times Fv1 Example Default Fv1 209Hz Fv2 209Hz Change to Fv1 70Hz Fv2 210Hz This helps reduce the high frequency noise in the system Test the move Most noise should have quieted and the overshoot minimized Keep decreasing the velocity filters until almost all the noise goes away Remember to keep Fv2 three times greater than Fv1 Typically Fv2 should be well above the total time of the system s shortest move For example if a 100ms move is as fast as SilverMax will go 100ms 10Hz then Fv2 should be set to about 100HZz 7 Iterate Kv2 and Kvff Fv1 Fv2 With noise gone or greatly reduce increase Kv1 and Kvff to decrease the overshoot When noise and overshoot have been minimized go to the next step 8 Reduce Kv2 and Kvff by 10 Loosen up the system by decreasing both velocity terms by 10 Test the move Bring up the Strip Chart and observe the position error incurr
33. 100 COMM Petocd Si Increment 25 Move 20 counts erial Interface ramp time 30 mSec ela AL ae total time 100 mSec_ E Auto ee j Move 40 counts ramp time 30 mSec total time 100 mSec COMM ACK Delay Move 20 counts Bl ACK Delay Auto NN ramp time 30 mSec Startup Error Conditions total time 100 mSec A special Startup Kill Motor Recover program is Delay for 200 mSec used for only a short time during initialization It allows Go Closed Loop the motor to come up to a point where it can MOTION Torque Limits communicate with a host before it gets shut down by Torque Limits an existing error condition Closed Loop Holding 75 The following commands setup a minimum set of error Closed Loop Moving 100 conditions and configure the Startup Kill Motor E ae SE z A L Recovery to be run in the event of an existing error pen Loop omg Swe Kill Motor Recovery MOTION Anti Hunt Constants Program Startup Recovery Anti Hunt Constants Kill Motor Conditions Out of Anti Hunt Error 10 counts If Over Temperature Into Anti Hunt Error 4 counts Error Limts MOTION Anti Hunt Delay Moving Limit 0 counts Anti Hunt Delay 150 mSec Holding Limit 0 counts MOTION Set S Curve Factor Delay to Holding 0 mSec Startup Power Low Recovery Sue Factor 0 This is simular to the above explained Startup Kill Motor Recovery Power Low Recovery Program Startup Recovery
34. 100 Hz then the delay should be at least 10 or 20 milliseconds This keeps SilverMax from transitioning between the moving and holding states while still moving The velocity feedforward term must equal the sum of the two velocity feedback terms Making it anything else will create a velocity dependent following error if the feedforward is less or leading error if the feedforward is greater than the sum of the other two Belt Driven Positioning Tables Direct Drive The high torque of SilverMax coupled with its PVIA servo technology is ideal for direct drive belt applications Direct drive belt applications have two challenges high inertial mismatch and vibrations from flexure of the belt QCI recommends tuning the high inertial mismatch first After the high inertial mismatch is tuned the vibration caused by belt resonance can be tuned out of the system This is accomplished by SilverMax User Manual 4 01 173 increasing the Ka gain value to 5 or 10 times the default value and increasing the Fa filter to a frequency above the belt resonance typically 1500 to 2000HZ Operation from an External Encoder Tuning a SilverMax that is operating from external encoder requires adjustments to the proportional gain Kp It must be properly adjusted in relation to the resolution of the external encoder If the external encoder resolution is double 2X the resolution of the SilverMax internal encoder then the default Kp value should be decreased by
35. D KOK DEn D i E SE SE SE Sc Sr Se E 3 SS S E SS SS S SE SE E S SE i S SC SS SE SE SE GE SE S as Poe GE Bas Geena see E E S E SE SE SE SE E SC OES SE SE Zi EE Se SE SES E D GE r S S Se Ee o o o e enoo Ee O E SE E SE Es e GE RA Ke e o SS e SS SE SC S SC EE SE E GE EE SS S SE SS E ee SS BES SS E S E Se S SS SS E E E SE SS SS DEE z SS S E E S a sie E SC SE SS Se SE SH SE es S SE S e BRRR Ee SE SS S Se S SE e SS E Sr E E e D E e SS S Se S Ss s E E SS SS S E SS SS E Se E SS i BA G GE P S ss oS ZS E SS 8 E E E SE E SH SE S S E SE SE ies E SE E es ZE SS 338 fe 38 S S Se SE S ee Se Ge SE 35 ie Ges S Si S ae Fe Si SE Ss gt SS Se SE Ses SE Bisa iar eta SE Se SE EE EE SE SE em SS E E S E SE SS SE EE E SE SE E EE EE SE E Kp 10 Kv2 3 Although the system has more damping it is unable to match the velocity of the calculated trajectory Velocity feedback subtracts some component of the velocity Kv2 x velocity from the calculated torque As Kv2 increases the velocity feedback will cause a greater velocity error in the system To compensate for this a Velocity Feedforward Kvff term is added to the syste
36. Defined by LVT command 13 Yes Over Voltage Over voltage error has occurred Defined by OVT command 12 Yes Wait Delay Exhausted The wait delay timer has expired Input Found On Last An input used as a stop condition was found during the last ues Move move Latched but automatically cleared on next move 10 Yes Halt Command Sent The halt command HLT was received by SilverMax 9 Yes Il Error Holding error limit set with the Error Limits ERL command g has been exceeded with SilverMax in a holding control state 8 Yes Moving Error Moving error limit set with the ERL command has been exceeded with SilverMax in a moving control state Internal sensor determines over temperature condition and 7 No Over Temperature clears this bit when true Bit is shared by drive enable lines on 34 frame servos disable high enable low 6 No UO 3 Status of I O line 3 normally high low when triggered 5 No I O 2 Status of I O line 2 normally high low when triggered 4 No UO 1 Status of I O line 1 normally high low when triggered 3 No ee Result of the last calculation was negative CLC command 2 No eee Result of the last calculation was positive CLC command 1 No SEN Ge Result of the last calculation was zero CLC command 0 Yes Index Sensor Found An index sensor has been detected Torque Limits The software based integrated design of SilverMax allows it to dynamic
37. Downloads all programs in the active file to SilverMax Run Downloads and Runs all programs in the active file Scaling Allows user to adjust program scaling parameters and other program related settings including upload password Test Line Tests the specific highlighted line of program Trace Traces a program through all lines Single Step Runs a program line by line via user prompting Program List The list of selectable programs currently open in the active QuickControl file QCP No of words used window Shows how many words are being used in the currently displayed program DEVICE TO PROGRAM Reboot Reboots the currently selected SilverMax Desc Allows user to select the SilverMax being programmed and displays the registered label and ID number Type Displays type of SilverMax currently being programmed It is important to note that while the Save icon does save to the hard drive of the PC it does not save to SilverMax non volatile memory and while the Download and Run buttons do save to SilverMax non volatile memory they do not save to the hard drive of the PC SilverMax User Manual 4 01 19 4 Program Window This area of the QuickControl Screen displays the active program opened It is where all program lines are created viewed and edited The interface allows the user to single click on the line to highlight that particular line or double click on the line to edit the contents parameters of
38. F Binary nibbles are converted to a number by adding up the value of each binary digit The table below shows the value of each bit in a nibble If a bit is set to 1 its associated value is added into the nibble Remember to convert the numbers 10 15 to A F for Hexadecimal notation The example binary word grouped in nibbles 1001 1100 0000 1010 pivaves 4 2 itte 4 2 ilie 4 2 delt saywa t 0 0 4 RES ESA ESEAESER Eo The nibbles are now joined together to form the Hexadecimal word Hexadecimal Word 9COA When working in hexadecimal programmers use a Ox notation at the beginning of the number to identify it as a hexadecimal value This avoids any confusion as to the base system of the number Hexadecimal Word 0x9COA Hexadecimal is useful for programmers who are writing software in Basic Visual Basic C C or working with the SilverMax 9 bit binary protocol SilverMax User Manual 4 0 183 For those who are trying to put together ASCII strings on a PLC or other simple controller the number needs to be converted to decimal The easiest way to do this is to use the Scientific Calculator application available in Microsoft Windows however many other calculator applications exist that can supply this functionality The MS Calculator is found in Start gt Programs gt Accessories 7 Calculator If the calculator does not appear like the image to the Edt view Help right select View gt Scientific
39. I O and power lines of the servomotor A PC running QuickControl is used to program and setup the SilverMax for standalone operation After the SilverMax standalone configuration is completed and operating correctly the PC can be disconnected Recommend Parts List SilverMax servomotor OCT Breakout module 12 to 48 VDC power supply System inputs and or outputs not required PC running QuickControl SilverMax cable Power supply wires I O wires not required DB9 serial cable arwWN gt OND Generic Standalone Setup SilverMax can be configured for standalone operation without a breakout module and without using OC cables QCI recommends using QCI cables and a breakout module because of better reliability and ease of installation Likewise using the QuickControl software is not a requirement since the servomotor will respond to 8 bit ASCII strings or to 9 bit binary commands sent from any device capable of issuing them SilverMax User Manual 4 01 1 over an RS 232 or RS 485 serial connection However QuickControl will usually allow faster prototyping and is required to change the factory default initialization settings Host Configuration Host configuration involves a SilverMax that is entirely controlled by a host PC Programmable Logic Controller PLC Human Machine Interface HMI or other such device The host is connected to the SilverMax through an RS 232 or RS 485 serial communication link The host can issue a wide r
40. Move Commands Profile Move PMV Profile Move Continuous PMC Profile Move Override PMO and Profile Move Exit PME SilverMax User Manual 4 0 177 Dedicated Data Registers This type of data register is dedicated to a specific SilverMax function SilverMax uses this data extensively for many internal operations Some data registers contain factory specific data that directly affects the servomotor operation Modifications to this type of data may cause the servo to operate unexpectedly The table below provides information on dedicated data registers 0 through 10 These specific registers are used frequently when programming and operating SilverMax Data Type Dedicated Data Register Description Register High word HW lt i gt Low word LW 0 R W Target Position calculated position data from trajectory generator 1 R W Actual Position current internal encoder position count 2 R W Last Index encoder position count of the last internal index trigger 3t R Internal Status Word current kill state HW lt gt Current Process State LW 4 R W Last Trigger Position encoder position count when last stop condition was satisfied 5 R W Delay Counter clock ticks for the internal delay DLY counter 1 tick 120 usec zb R Max Position Error HW lt i gt Current Position Error LW SE R Velocity 1 current vel 1 filter HW lt gt Velocity 2 current vel 279 filter LW
41. New Program enter a name and select OK The screen will display a new blank program This new program resides in the same QCP file as the first program To view all programs present in the current QCP file expand the Program List drop down box located in the middle of the Program Info Toolbar The first program listed is Program Name 0 The 0 on the end of the name designates that it is the first program created in this QCP file Additional programs created in this file will be listed in the order they were created with an increasing number 1 2 3 etc appended to the name Managing NV Memory Program Storage By default QuickControl organizes the NV memory locations of all programs downloaded to SilverMax including the Initialization program Initialization programs are always stored at NV memory address 0 The first program listed in a QCP file program 0 is stored to NV memory address 512 by default The last command in the default Initialization program is an LRP at 512 By default on power up or reboot SilverMax executes the Initialization program stored at NV 0 and then executes any program stored at NV 512 This is can be changed by modifying the LRP in the Initialization program or the NV memory location where the program is stored in SilverMax To manually control the NV memory storage address of a program select a program for display in QuickControl select Programs from the main menu and Program Details from the pull
42. Reference QCI SKO Start Up Kit SilverMax personal computer and power supply not included provide a means for testing and evaluating a SilverMax servomotor through an Optical I O board With a standard PC serial COM port and a power supply any SilverMax can be fully programmed and operated through an Optical I O board with the RS 232 communication protocol The SilverMax Interface cable is included in each kit to connect a SilverMax to the Optical I O board An additional cable is provided for the connection of the I O board and a personal computer Also included are the QuickControl Software the SilverMax User Manual and the SilverMax Command Reference NOTE 34 frame Start Up Kits include a Line Power cable not shown which is required in 34 frame SilverMax applications to power the servomotor This cable DOES NOT need to be purchased separately from the Start Up Kit SilverMax User Manual 4 01 9 Setup QCI SK fs Start up Kit The Training Breakout Module QCI BO T is the focus of this start up kit for prototyping and evaluating 17 and 23 frame SilverMax servos Technical document QCI TD016 contains details on its operation and specifications Below is a picture of the Training Breakout Module with important areas numbered and labeled 2 Power Switch 4 9 Pin Female Receptacle 5 9 Pin Male Receptacle tox F Afs Terminal labeled Vx 3 15 Pin Female Receptacle 1 Main Te
43. Register Files This allows a Register File to be referred to by name rather than by memory location Any program in the QCP where the Register File name was defined may use the Register File name Register File names may be assigned from the Edit Register File dialog which is accessible from the Programs menu or from any Register File Command RSN RSM RLN and RLM dialog box Register File Array A Register File Array is simply a collection of Register Files Each entry row into the array can be treated as a Register File The number of registers columns for each row of the array must be the same A Register File Array is created within a text file and then linked to a QCP using Register File Import This QuickControl feature is designed to ease the loading of data files that can be thousands of bytes in length Linking Text Files QuickControl Programs Upon completion of text file containing a register file or register file array it must be linked to a QuickControl program The text file must be saved in the same directory that the QCP file will be saved in If the text file will import any data associated with units see Data Format Directive the QCP must have the appropriate scaling set and saved BEFORE the text file is linked The following procedure describes the linking of a text file to a QCP From the Programs menu click on Register Files and then the Add Register File button Or from one of the Register File Command dialog boxes
44. SS SES SS SE Sample ms 200 Cor Select Channels Cancel 4 mm Si fal uu El d g H here the shaft actually at ER Y Magb200 Glen S a SCH SC SE SE Ss SE Gs SS e SE E GE Si S SS Se E n SS E SE SE EE S SE E SS S EE E GE SE E 2805 SE E S E SE SE SC SE SS SS ie SS SS SE SE ES SS es ES SE E SC Ss E E SE ss Se SE E GE SE Se SE na E SE SCH g e SE SC i S S EE SE E ES Se GE E a SS SS GE ZE SE F SE Es Se E ae Ge SS S SS e ee es Lee ee SE E SE oe eee eee f SE ee SS E S Se SE SE SE Se SN a E SE E E EE E SS E SE Se E SE SE E S S SE EE E SE E EE f z j ee GE E SE 2 ee E d to make the motor move is require A large amount of error Setting Kp 2 doubles the torque and produces the following profile GK Select Channels Cancel p es ajelen BUE adeirlal EI Position E SEET SE SC EE S S SE SE ee SE Y Mad Sample ms 200 Glen S Y Minj SE E s SE SE SS cs Sees Ss SE SE SE a E EE SE SS ae SE SE E E SE E SE sete a
45. X Internal Encoder Output A B Index Modulo Output x Index alt i Index SE Step alt Direction alt Index These lines can be used for A amp B quadrature step up step down or step and direction signals Using Digital Inputs Digital inputs and digital outputs are the most basic uses for the SilverMax I O A digital input could be a switch that closes and opens sending a signal to SilverMax while a digital output might be a solid state relay or a light connected to a SilverMax I O line Digital inputs and outputs are used by SilverMax for several purposes Digital inputs may be used for program flow purposes for motion control stop on input purposes or for Kill Motor triggers Digital outputs may be used in user programs for signaling external devices like PLCs or controlling external devices like relays This section covers the uses of digital inputs and outputs and the commands used with them General Digital Inputs The four uses of SilverMax digital inputs are general digital inputs motion control inputs modulo trigger input and Kill Motor inputs By using an I O line as a digital input a SilverMax program can react to an on off signal from an external source by using a command that controls program flow based on I O status There are several commands a SilverMax program can use to do this The wait on bit commands WBS and WBE can stop program execution until a digital input signal changes while jump co
46. a byte at a time upper byte first The final byte is the checksum Example Send a Read Register RRG command and receive the following response packet Command RRG Command Number 12 Address 16 Data Register 1 Response Packet with field data shown in Hex Address Length Command Value of Register 1 Checksum 0x10 0x05 0x0C 0x00000FA0 0x30 Byte stream with data shown in Hex 10 05 0C 00 00 OF AO 30 NAK RESPONSE The NAK response packet is sent when the command issued is not a valid command This occurs if the command packet is improperly formatted when the parameters are invalid or when a command is sent at an invalid time such as requesting a motion when SilverMax is already busy Note the new NAK Indicator byte included in the packet 9 Bit Binary NAK Response Packet Data Transmission Order P NAK Response Command Address Length NAK Indicator Code Number Checksum l 1 Byte 255 1 Byte 9th bit set 1 Byte OxFF 2 Bytes 1 Byte 1 Byte The first byte is the address of the responding SilverMax with the 9th bit set The second byte is the length This is defined as the number of bytes starting with the NAK indicator through the command number The third byte is the NAK Indicator The fixed value of 255 OxFF indicates this is a NAK response packet This byte is always included to indicate a NAK SilverMax User Manual 4 01 149 e The four
47. address SilverMax User Manual 4 01 134 Other Related Commands Disable Motor Driver DMD Disables the motor driver and shorts the windings together The SilverMax will be unable to move when attempting any motion command This is a software disable that can be overcome by the EMD command Register Store Non Volatile RSN Stores data from a Data Register to the selected non volatile memory address See the SilverMax Command Reference for details on this command Register Store Multiple RSM Stores data from an array of Data Registers to the selected non volatile memory address A checksum value is calculated from the array and stored with the array Data from the selected Data Registers is stored sequentially to non volatile memory Data is also copied from the Data Registers sequentially Recovering and Processing Saved Information e Position e Direction e Last Point in Program In many applications the SilverMax must retain its absolute position Once the LVT limit is reached the Power Low Recovery program is called which can use the Register Store Non Volatile RSN command to write the current position and other data to the non volatile memory Power Low Recovery and Restoration of Direction and Position The following QuickControl program is an example of the process and commands needed to recover the last known position and direction of the servo when the supply power was shut off Line Oper Label Comma
48. allows the TTL signal from SilverMax to be interfaced to other types of circuits and used to trigger higher power outputs A full description of the OC optical isolation module can be found on the QCI website SilverMax User Manual 4 0 106 Analog Inputs I O lines 4 5 6 and 7 can be used as analog inputs These lines have an effective internal impedance of approximately 200 kO connected to the internal 5 VDC power supply giving a slight bias on input This resistance should be considered in circuit designs that are passive or that have high impedance UO lines used as analog inputs must be driven from a low impedance source 10 or less or with capacitance across the input A minimum 0 01 uF capacitor can be used at the input to provide the low impedance source The internal analog to digital converter ADC provides 10 bit resolution of the 0 to 5 V input signal The ADC is referenced to the internal 5 V power supply This power supply can provide up to 100 mA to input devices Using this power supply minimizes the effects from power supply variation since this causes the input and the ADC to be referenced to the same supply SilverMax implements a 5 msec filter on all analog channels to reduce the effects of noise amp transients This means that analog signals are averaged over 5 msec before being used The filtered signal is updated every servo cycle 120 usec High Speed UO Functions Special I O circuitry in SilverMax allows the I O
49. and 20 000 Converting to hexadecimal this gives to 16 bit values OxOFAO and 0x4E20 Concatenating them yields the single 32 bit value OXOFA04E20 Converting this to decimal gives the final value to be transmitted 262 164 000 See Appendix X for information on converting hexadecimal and decimal numbers The response to the RRG command is in hexadecimal For more information on serial communications see Chapter 9 SilverMax User Manual 4 01 122 Data Monitor eae ie ls ks Display Format Close ESE EEN Log To File DMLog bt ScnrepcProtocal a Receive Transmk Ax Tx Data Siert I Dats Ony 16 12 2074 t0 000C 1770 2710 16 11 207 2621640001 Custroen Transit Enter data in same forma as selected in I Transmit at next receive Display Format ot copy a previous transmission by Double Clicking on Uansmission eer 2071 Using the Data Monitor Tool to Update Torque Limits Input Mode Torque Input Mode TIM configures the SilverMax for direct torque control based on the value contained in register 12 The value in register 12 is limited and scaled based on other register values For more detailed information on the general operation of input modes please see Chapter 6 In this section only the specific details pertaining to Torque Input Mode are discussed In order to properly use TIM several things should be taken into consideration First TIM is limited by the closed loop running torque limit The
50. at the same time They usually have a separate wire or wires for each signal In a SilverMax network this means that a transmission from a host and a response from a servo will not interfere with each other Half duplex systems use the same line s to transmit and receive In these systems only one node can be transmitting at any time Half duplex systems require the addition of a delay before transmitting a response This delay gives the communication circuitry time to switch modes ACK Delay This is a setting within SilverMax that causes a time delay between the receipt of a command packet and the transmission of a response packet This delay is required in half duplex systems to give devices time to switch from transmit to receive and vice versa Termination Differential communication systems usually require biasing resistors The collection of resistors is referred to as termination The networking section of this document covers termination in detail This table lists the industry standard specifications for RS 232 and RS 485 Cabling Single ended Balanced differential 1 transmit 64 transmitters 1 2 load Rx Number of Devices 1 receive 64 receivers Communication Mode Full duplex Half duplex Maximum Line Distance 50 feet at 19 2 kbps 4000 feet at 100 kbps 19 2 kbps for 50 feet Maximum Data Rate 115kps for 6 feet 10 MB s for 50 feet 5 VDC min 1 5 VDC min B gt A 15 VDC max 5 VDC max
51. basic programs allow the servomotor to execute complex motion profiles while monitoring and controlling I O lines and serial communications A complete understanding of the internal memory organization leads to a powerful control of programs and data In QuickControl this organization is controlled automatically although the settings have override capacity SilverMax Operation The motion of SilverMax follows a trajectory that is calculated by the Trajectory Generator a specialized processor that translates the supplied motion guidelines into a complete trajectory A trajectory is made up of a series of data points to be used each servo cycle These data points consist of a target position velocity and acceleration used throughout the servo cycle The DSP chip running the patented SilverMax PVIA servo loop uses the differences supplied by the feedback system between the target and actual parameters to generate the SilverMax torque The Trajectory Generator can receive motion parameters from one of two sources The first of these is the integrated controller within SilverMax The controller is used anytime a SilverMax is executing an internal program or a command received from a host When configured to follow an external encoder the incoming encoder signals are processed by the Trajectory Generator to create the matching motion The Direction DIR command can be used to switch the positive sense of the servomotor causing trajectories to run i
52. click on the Edit Register File button Memory Mode Auto memory mode further simplifies Register File usage When Auto memory mode is selected for a particular Register File QuickControl will assign the memory location of that Register File during program download Auto memory mode is the most efficient use of memory and reduces the chances of memory conflicts A Register File may be set to Auto memory mode in the Edit Register File dialog SilverMax User Manual 4 01 88 Register File Options in QuickControl Non volatile Register File System xj OK Cancel Properties Delete File r Display Register Files Import Register File Arrays og Fis C Register File Array Rows From Text File Import Register File Data from File Cancel MONE TIME IMPORT One Time Import will import the Register Files and or Register File Arrays from the selected file once The Register Files and or Register File Arrays will be become part of the active qep SilverMax Factory Default Initialization qcp Select File to Import LINK If Link is checked the Register Files and or Register File Arrays will be imported from the selected file on every download of SilverMax Factory Default Initialization qcp T Link file to program at download Select File to Link Note The Selected File needs to be in the same Directory as kuer au Factory Default Initialization qcp I Delete
53. command to the startup program Multi Tasking will allow SilverMax to continue a program operation while processing the shutdown condition Also at startup issue the KED command This command over rides the default setting that disables the motor drivers on shutdown allowing SilverMax to complete any programmed motion while processing the shutdown condition Handling the Shutdown In the controlled shutdown scenario the SilverMax does not stop the motion in process Instead the Recovery Program is called allowing SilverMax to stop the motion or not in a controlled manner In the example shown Fault Recovery Program a Velocity Mode command is issued with a velocity of zero This will bring SilverMax to a controlled stop Processing the Error Condition Depending on the shutdown condition enabled there may be a number of different things that must be done to clear the error and continue operation or simply alert the system or operator of an error Alerting the system or operator may involve toggling a Digital Output Line In this example nothing was required other then re issuing the KMC command Continuing Operation Continuing is less complicated because SilverMax does not have to be re initialized This may be as simple as doing a Load and Run Program of the corrective action program Line Oper Label Command This program performs three tasks It will move back and forth until 1 0 3 goes low and runs Kill Motor Recovery 1
54. consists of issuing the POL command receiving the Polling Status Word checking the word for the desired condition and repeating until the condition is met Once the condition is met the Polling Status Word is cleared using the Clear Poll CPL command The delay between repetitions can vary depending on the desired polling rate and the communications baud rates An example of a polling routine is shown on the next page that can be used to retrieve the polling status word after command execution This would be used for waiting until a motion completes before sending the next command The actual ASCII strings making up the commands are included for reference See Chapter 9 for more information on serial communications and the SilverMax Command Reference for details on this command SilverMax User Manual 4 01 34 Polling Routine Example Example 8 Bit ASCII Code Send an initial Poll command 16 0 CR Poll Clear Entire Status Word 16 1 65535 CR Clear Poll Actual Poll command 16 0 CR Poll SilverMax Response 10 0000 2000 CR Command Complete OR 10 CR No bits set Command Not Complete Clear Only Bit 13 16 1 8192 CR Clear Poll NOTE 8192 in decimal equals 2000 in hexadecimal SilverMax User Manual 4 01 Begin Polling Routine Send Poll Command Polling must be initialized by first sending a Poll then Send Clear Poll Command a Clear Poll Send Motion Command
55. create CTL files Event lists CTL files are command lists that are sent by a host to SilverMax via the serial interface They are not downloaded to SilverMax and executed from the command buffer like a program QCP file Create Event Creates a new event Edit Event Edits an existing event Lite Edit Event Temporary modification of an event for execution Copy Event Copies a selected event Delete Event Deletes a selected event Execute Event Executes a selected event Define Event Template Creates and defines a new event template Edit Event Template Edits a selected event template Copy Event Template Copies a selected event template Delete Event Template Deletes a selected event template Edit Data Template Edits a selected data template Define Data Template Creates and defines a new data template Copy Data Template Copies a selected data template Delete Data Template Deletes a selected data template Save Events Database Saves the selected event template View Menu Toolbar When checked Toolbar will be displayed Status Bar When checked Status Bar will be displayed Device Status When checked Device Status will be displayed SilverMax User Manual 4 01 17 Program Menu Add Line Adds a new line to a program Insert Line Inserts a line above the selected line in a program Edit Line Edits the selected line in a program Delete Line Deletes the selected line in a progr
56. either 8 Bit ASCII or 9 Bit Binary communication protocol See Chapter 9 for a complete discussion on differences between communication protocols SIF Serial Interface Line 8 Choose either RS 232 or RS 485 serial communications hardware interface See Chapter 9 for a complete discussion on differences between serial interfaces The Auto check box within this command automatically configures the serial interface to match the interface currently setup in SilverMax If changing the interface type uncheck the box or no change will occur BRT Baud Rate Line 10 Change the BAUD rate of the SilverMax This does NOT change the PC s baud rate Select Normal mode to choose from a list of baud rates ADL ACK Delay Line 12 This command sets the time delay SilverMax waits before sending an Acknowledgement ACK Negative Acknowledgement NAK or data to the Host PC after SilverMax receives a command MCT Motor Constants Line 28 This command initializes the driver stage to produce appropriate drive signals to the SilverMax It is dependant on both the SilverMax type and the supply voltage These parameters must be downloaded from the DeviceDB txt file into the MCT command the Initialization Wizard does this automatically Auto is the default setting and recommended by OC Press Manual to select a voltage and press Advanced to change the K factor This is for advanced users with very specific application settings Contact OC Produ
57. factor e g for an A amp B quadrature output with a scaling parameter of 4 4000 counts from the internal encoder would be scaled to 250 pulses which decodes to 1000 counts Three commands are used with the modulo internal encoder output function The Modulo Set MDS command enables the modulo output function and starts the signal from I O lines 6 and 7 the lines that the modulo output function uses The MDS command sets the modulo divisor 1 to 256 the signal type step and direction step up step down or A and B quadrature and the encoder source internal or external The Modulo Trigger MDT command enables a special modulo function that uses the state of I O 1 as a trigger to start and stop the modulo internal encoder output signal on I O lines 6 and 7 The Modulo Clear MDC command disables the modulo output function and frees the I O lines used by the modulo output function More information on these commands is available in the SilverMax Command Reference SilverMax User Manual 4 0 118 Chapter 7 Torque Control SilverMax Torque Overview SilverMax generates torque based on current position error inputs from the trajectory generator and values set by the Control Constants CTC and Filter Constants FLC commands This process is what defines SilverMax or any other system as a servomotor The entire torque equation is listed in Chapter 10 as well as a flow chart of the entire PVIA servo loop The torque value gene
58. hunt constants set the thresholds used to determine if the current position is sufficiently close to the target to allow the motor to enter into and remain in Anti Hunt The first parameter is the maximum error allowed in the Anti Hunt before the unit will revert to normal closed loop operation The second parameter is the maximum error allowed at the end of motion before going into Anti Hunt These two parameters should be set to zero before tuning the SilverMax This allows the true settling response of the SilverMax to be monitored Once the tuning of the SilverMax is complete the two parameters should be set back to there original values S Curve Factor SCF With the SCF command the shape of the motion profile acceleration can be varied from a linear profile to a full S curve profile All basic motion commands incorporate the s curve factor This command can be set at any time except during a motion allowing each motion profile to be tailored for the best shape Torque Limits TQL This command specifies the torque limits for the different operating states of SilverMax The two SilverMax operating modes are Open Loop and Closed Loop with each mode having both a Moving or Holding condition state The four parameters for the SilverMax torque limits are Closed Loop Holding Closed Loop Moving Open Loop Holding and Open Loop Moving For most applications the Closed Loop Moving torque limit is set to 100 and the Open Loop Holding torque limit
59. in the accumulator by the value in the selected register and stores the result in the accumulator The numbers are considered signed binary numbers Mult Unsigned 32 32 bit i e Acc Acc Reg This command multiplies the value in the accumulator by the value in the selected register and stores the result in the accumulator The numbers are considered unsigned binary numbers Save i e Reg Acc This command stores the value in the accumulator in the selected register Save L Word to H Word i e Reg H Word Acc L Word This command stores the lower word bits 0 15 of the value held in the accumulator in the upper word of the selected register Save L Word to L Word i e Reg L Word Acc L Word This command stores the lower word of the value held in accumulator in the lower word of the selected register Save to Reg Ref i e Reg Acc Reg Value of Reg This command reads the value of the selected register and then stores the value held in the accumulator in the register number that matches the value of the selected register Shift Reg Left This command performs a binary bit shift left operation on the selected register The lowest bit is always set to zero after the operation Shift Reg Right w Sign Extend This command performs a binary bit shift right operation on the selected register The highest bit is not changed in order to preserve the original sign although a one in bit 31 is shifted to bit 30 The lowest bit is disc
60. is 12 OxOC in Hexadecimal 0A 000C 0005 06A3 lt CR gt The current contents of this register are Ox506A3 or 329379 in decimal NAK PACKET The NAK response uses as the start character It is followed by the ID command number NAK code and a lt CR gt SilverMax User Manual 4 01 145 8 Bit ASCII NAK Response Packet data transmission order Command Start Character ID Number NAK Code Ending Character 1 Byte 2 Bytes 4 Bytes 4 Bytes 1 Byte lt CR gt Example NAK response for a Read Register RRG Command Number 0x0C from SilverMax 10 Ox0A with an invalid Data Register parameter 0A 000C 0007 lt CR gt Example NAK response for a Move Relative Time Based MRT Command Number 0xB1 if SilverMax 16 0x10 is already in motion The SilverMax will NAK back Device Busy as follows 10 00B1 0002 lt CR gt 9 Bit Binary Communications The more advanced 9 bit binary protocol uses hex values rather than ASCII characters and error checking to provide greater speed and reliability than the 8 bit ASCII protocol Each command and response packet includes length and checksum data SilverMax will reject any packet in which the error checking data does not match The ninth bit used in this protocol is the parity bit available as part of standard serial communication drivers In this protocol however the bit is not implemented to create even or odd parity but rather to serve as a flag indicating t
61. it were part of this file Example Include Position Data File Register File Import Directives Formatting The following formats are used to specify the Register File Import Directives Register File Import Directive NVRegFile This directive informs QuickControl that a Register File is to be imported Example NVReoFile startAdr 2500 col0Fmt time There are two optional directives that may appear with the Register File Import directive Starting Address and Data Format If these directives are used they need to be on the same line as the Register File Import Directive and must be separated by commas Starting Address Directive startAdr This directive specifies the non volatile memory address of the Register File The starting address may be in decimal or hexadecimal form Example startAdr 2500 If the starting address is not specified with this directive the Register File starting address will be set to the default Auto memory mode In Auto memory mode QuickControl assigns the Register File starting address when the QCP is downloaded Data Format Directive colXFmt This directive specifies the format of imported data When using this directive ensure that proper scaling is defined in the QCP file and saved BEFORE linking the text file to the QCP The following data formats are accepted long imports data as a 32 bit signed value hex imports data as a hexadecimal value uLong imports data as a 32 bit unsigned value pos
62. last move was in positive direction Or the calculation will be negative if last move was in the negative direction Accumulator 10 Accumulator 10 User 31 Skip Jump over the CDA move if the last calculation determined that the last motion was positive Jump to CW MOVE If Last Calc was Positive Move back and forth Cycle the power during this motion to test the Power Low Recovery for your system CEW Write 1 to Register 31 as a flag that the SilverMax MOVE began 4 negative direction motion Write 1 to User 31 Register Move to absolute position zero Move to 0 revs ramp time 39 96 mSec total time 2000 04 mSec Write 1 to Register 31 as a flag that the SilverMax began a positive direction mation Write 1 to User 31 Register Move to absolute position 1 revolution Move to 1 revs ramp time 39 96 mSec total time 2000 04 mSec Jump to CCW MOVE Cw MOVE Prower Low Recovery Here we will save the motor Position and Direction while the power is falling It is important that this be done in a timely manner so that it is done before all power is lost Note If driving a large inertial load a time delay or Hard Stop Move may need to be added in order to ensure no movement takes place when storing the position register Disable Motor Driver Get the current position from Data Register 1 and Store it a NY Memory address 1000
63. limits at any time by inserting a TQL command anywhere in an application program However the TQL command is a class D command See SilverMax Command Reference for command classifications This means the TQL command can only be executed from within a program or sent from a host while SilverMax is idle For direct access to the torque limits even during program execution specific data registers are available for modification Refer to the Register Control section of this chapter for more information Edit TQL Torque Limits Bae f x Cancel Maemm __ Caneel _ Closed LoopHeldng 75 Description Defaut Closed Loop hoving 1100 j ZB Open Loop Holding 30 S D fArtiHunt Torque JF ue 5 e GG Mona Open Loop Moving 30 ee C Naive Torque Limits TQL Command in QuickControl SilverMax User Manual 4 01 119 SilverMax Units of Torque The Normal units selection displays the Torque Limits TQL command as percent values When working in the software QuickControl automatically converts a torque percentage into the actual number that SilverMax understands However when working with an independent host values must be sent in Native SilverMax torque units The following table shows the corresponding percent and native values for the various SilverMax models For example to configure a 34N 1 with a 30 torque limit multiply the 100 value 20000 by 0 3 30 100 giving a result of 6000 SilverMax Model 100 To
64. low Once an input is low a move is executed If I O 1 is low the LED output 2 will flash during the motion If I O 5 is set low the second RRV move will run and the LED will be off Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers 1 Power up the SilverMax and start QuickControl Start polling the motor and verify that the system is operating properly Ensure that the I O 1 switch is toggled up so that I O 1 is high 2 Select File Open Navigate to QCI Examples Multi Tasking and select the file Using Multi Tasking for Advanced IO Conirol qcp 3 Click the Run button to download and run the program 4 SilverMax will run the program and wait in the Forever loop for an input The I O 1 switch or the push button UCD switch will select the Move1 or Move2 routines If I O 1 is selected switch it back to the up position immediately The push button momentary switch will automatically return to its start position If 1 is chosen the LED will flash three times at the beginning of the move The LED is connected to I O 2 and is configured as an active low output When SilverMax issues a Clear Output Bit COB command the LED turns on CLC WCL and WCW Commands There are three commands that have not yet been covered in this chapter that can be very im
65. match SilverMax baud rate is adjustable internally by the Baud Rate BRT command the default is 57600 baud SilverMax has an additional parameter the Acknowledgement Delay ADL adjusted by the command of the same name This parameter is a specified time delay between receipt of a command and the transmission of a response from SilverMax This delay is used primarily in networks and is discussed in the networking section of this chapter SilverMax Packets All SilverMax serial communications are accomplished using packets A packet is a collection of bytes of information with a particular format There are two kinds of packets command and response Command Packet Command packets are sent from a host to one or more SilverMax ALL SILVERMAX COMMUNICATION BEGINS WITH A COMMAND PACKET SENT FROM A HOST SilverMax is a slave device and does not initiate communication Regardless of the protocol chosen the basic structure of a command packet is the same Each command packet includes an ID a command number and parameters ID SilverMax Address The ID is sent as a value in the range of 1 to 255 The ID is the first piece of information in a command packet Every SilverMax that receives the packet checks if the ID in the packet corresponds to its Unit Group or Global ID Packets not containing one of these IDs are ignored Packets sent to the Unit ID will be aced upon and a response packet sent Packets addressed to a Group or the Global ID will b
66. met Normally the motor driver is disabled when a KMC setting is met The KED command is used to leave the driver enabled if continuing operation is required In order for this command to function SilverMax must be set up for Multi Tasking operation See Enable Multi Tasking EMT Without Multi Tasking the driver will be disabled when a KMC setting is tripped whether or not this command has been issued This command is very useful when a controlled shutdown of SilverMax is needed For example if there is a need to slowly ramp down the speed of SilverMax a Velocity Mode Program Type VMP command can be used in the recovery program to decelerate to zero velocity with a given deceleration Kill Disable Driver KDD Configures SilverMax to disable the motor driver and shorts the windings together when a KMC setting is met If the SilverMax is moving it will stop immediately in an uncontrolled manner SilverMax will be unable to move until re enabled using the Enable Motor Driver EMD command This is the default setting for the SilverMax This is the default state of the servo SilverMax User Manual 4 01 129 Other Relevant Commands Error Limits ERL Error Limits set the Moving Error limits and Holding Error limits used by the KMC command Kill conditions triggered by error limits set bits contained in both the Internal Status Word and in the Polling Status Word The Polling Status Word bits can alert a host controller to the condition if S
67. method these inputs can be used to redirect program operation Over Temperature Always Used Over Temperature must always be enabled so that the SilverMax can halt operation if it gets too hot The over temperature is actually a combination of the servo driver thermal sensor not settable and the internal electronics temperature sensor Settable using the Maximum Temperature Trip MTT command Either of the two can cause this condition In addition the 34 frame driver enable line triggers the same OverTemp flag when voltage drops below roughly 10VDC on the enable line Note that on the 34 frame servos the OverTemp error signifies two different faults Motion and Holding Errors Most Commonly used Condition In any servo system the most common need for servo shutdown is when moving or holding position error exceeds a set limit Using the Error Limits ERL command the amount of acceptable error can be set for both the Moving Error and the Holding Error When the error exceeds the limit these flags will be triggered Typically the Moving Error is set to a larger value because of the dynamic conditions encountered during a move One or both of these conditions can be used for shutdown it varies depending on the needs of the system Halt Command was sent Used to re initialize SilverMax after a Halt The Halt HLT command when sent from a host system will cause the SilverMax to shutdown This leaves the SilverMax in a disabled
68. oe ee ee ee This example ages the CLC command to upc ale the closed loop rain hong Wile 15000 te Accumulator OT Recker Low Wod Closed Loon Torque HotdAm 206 Low woud Secumulabo 0y Using CLC Command to Update Closed Loop Moving Torque Limit Updating the torque limits externally requires some type of host In the following example QuickControl s Data Monitor tool used to impersonate an external host updates register 207 A single command is all that is needed to change torque limit parameters The Write Register Immediate WRI command allows a host to change the value in a SilverMax register The Read Register RRG command retrieves the current contents of a register for the host In the example shown here the Data Monitor first reads register 207 Then the WRI command writes new torque limits to register 207 The RRG command is issued again to confirm that the adjusted torque limit has been stored The parameter transmitted in the WRI command is a decimal value The high word open loop holding limit and low word open loop moving limit both 16 bit values must be put together concatenated as a 32 bit decimal number Converting the numbers to hexadecimal concatenating them and then converting back to decimal is the easiest way to accomplish this In this example the open loop holding limit will be set to 20 and the open loop moving limit to 100 Converting to native torque units this yields values of 4 000
69. on a signal from an external source like a PLC This is one way to allow an external host device to control motion All SilverMax motion commands have stop conditions that can be tied to the state of an I O line The I O line used must be configured as an input and must not be in use as an output an analog input or as a high speed input Stop conditions are explained in detail in Chapter 4 Kill Motor on Input Digital inputs using I O lines 1 2 or 3 can be used as Kill Motor Conditions to immediately stop the motor and end any move Kill Motor Conditions are covered in detail in Chapter 8 As with other digital inputs the Kill Motor routine can be set up to trigger based on a high or a low state of an I O line If an I O line is to be used as a Kill Motor input extreme care must be taken to ensure that the I O line is not used for another function If an I O conflict occurred on that line the Kill Motor routine might not start when it was intended to Modulo Trigger Input I O 1 can be used as a special digital input to trigger the scaled internal encoder output function The input is configured with the Modulo Trigger MDT command and functions just like any of the other digital input functions More information on this command is available in the SilverMax Command Reference Configure I O CIO Command The ClO command configures one I O line at a time At power up all SilverMax I O lines are configured as inputs The ClO command is need
70. one half 0 5X If the external encoder is one third 0 33X the resolution of the internal encoder then the default Kp value should be increased by a factor of three 3X SilverMax User Manual 4 01 174 Appendix A F Appendix A SilverMax E Series Specifications Electrical Specifications Supply Power Input Voltage 12 VDC to 48 VDC regulated See QCI technical document TD002 for supply details Each servomotor must be initialized for the selected operating voltage Over Voltage Protection None available Voltages exceeding 55 VDC will permanently damage the driver electronics Supply inputs may require active voltage clamping for aggressive braking deceleration motions or applications with high inertial loads All applications using 34HC servos require voltage clamps Reverse Polarity Protection None available Connecting supply voltage in reverse will damage servo Current Defined by each servo drive internally See individual servo specifications datasheets Digital Inputs amp Outputs Inputs O or 5 VDC TTL level only Active low sinking Inputs 1 2 and 3 have internal 4 7K ohm pull up resistors to the 5 V Inputs 4 5 6 and 7 have an effective internal 200K ohm impedance to 5 V Outputs 0 or 5 VDC TTL level only 5 milliamps sinking or sourcing UO Over voltage Protection Each I O line is double protected with parallel MOV clamping devices followed by series over voltage limiting External Enco
71. outset of move ha lastCheck ae noened SilverMax will go the opposite direction of that indicated in the command Change direction Yes of move Toggle conditions if options selected Are Conditions met Second Check Repeated until enabled conditions are met Second Check Used for a two condition Input check Are conditions met If no conditions are enabled the check is immediately passed The checks repeat every servo cycle 120usec until the Si Yes conditions are met or the motion ends Last Check Last Check AND conditions and If no conditions are enabled the OR conditions check is immediately passed The servo decelerates to a stop Are using the Conditions acceleration met that began the move Yes Stop Motion and me Single AND Yes eege Record Condition Positi Current Semen Position SilverMax User Manual 4 01 74 Advanced Stop Conditions Table This table covers the Stop Enable Word and the Stop State Word Examples of how to use these in native SilverMax commands follow Setting a bit in the Stop Enable Word enables monitoring of that input The corresponding bit in the Stop States Word sets the condition to monitor for LAST CHECK PROCESS STOP ENABLE WORD STOP STATES WORD First Check State Toggle Toggle 2nd Check Conditions Toggle OR States Bit 15 in both words is used to toggle states of the other Checks Set this bit to invert the Se
72. provides access to all functions of the software These pull down type menus offer many selections that can bring up other menus to accomplish certain objectives Above the Menu Bar next to the QCI logo amp QuickControl name is the active filename being displayed in the QuickControl Program Window BS QuickControl QCprog1 File Edit View Programs Tools Setup Window Help File Menu New Program File Opens blank program template New Sequence File Opens blank sequence template Open Opens a saved file Close Closes the active file in QuickControl Save Saves the current file Save As Saves the current file with user set parameters Program File Properties Contains scaling password protection and user defined names Upload Program File Retrieves the current program residing in Non Volatile memory Print Prints the active QuickControl Program file to the default printer Print Setup Allows the user to change printer and paper settings All Halt Sends the All Halt command Recent Files Displays a list of files recently open in QuickControl Exit Closes the current files opened and exits QuickControl Edit Menu Cut Removes highlighted section of text or program line Copy Copies highlighted section of text or program line Paste Inserts a copied or cut section of text or program line before selected line Select All Highlights an entire program Events Events Menu Events are used to
73. same charge cycle RSM uses the same identification and checksum words for all registers RSM can store up to 10 registers in 1 5x the time needed for the RSN command Backup Power Alternatives If a complete power loss occurs just before the final resting point and SilverMax doesn t quite have time to save all pertinent information and then additional capacitance placed across the Power Bus should be adequate The SilverMax controller requires approximately 2 5W to operate When the driver is disabled by a command or a supply voltage below 10 5 SilverMax only draws power for the control circuitry Based on the energy equation for capacitance and the time needed the extra capacitance can be determined as follows W 2 5W wii 4 W At V1 Voltage setting of Low Voltage Trip Ze D rv V2 7 5V At Total time needed to save data This value gives a good estimate of the size of the extra capacitor needed However this estimate is based on the assumption that the SilverMax is the only device drawing power from the capacitor An even larger capacitor is needed if there are any other devices powered from the same line A back up power supply allows SilverMax to continuously log actual position even in the event of total power loss Given the 10 5 to 7 5 volt range between the point of driver disable and loss of circuit operation a nominal 9V battery provides an ideal backup supply When implemented with the QuickSilver voltage clamp a simple dr
74. startAdr 2900 e 94 Ending Address Directive endAdr This directive specifies the non volatile memory ending address of the Register File Array The ending address may be in decimal or hexadecimal form QuickControl will calculate the starting address for this Register File Array based on the given ending address QuickControl needs to know the number of rows and columns to find the starting address therefore the number of rows and columns must be specified before this directive Example endAdr 3000 If neither the starting address nor the ending address is specified the Register File Array starting address will be set to the default Auto memory mode In Auto memory mode QuickControl assigns the Register File Array starting address when the QCP is downloaded Data Format Directive colXFmt This directive specifies the format of the imported data When using this directive ensure that proper scaling is defined in the QCP file and saved BEFORE linking the text file to the QCP The following data formats are accepted long imports data as a 32 bit signed value hex imports data as a hexadecimal value uLong imports data as a 32 bit unsigned value pos scales value and imports with position units set in QuickControl Scaling acc scales value and imports with acceleration units set in QuickControl Scaling vel scales value and imports with velocity units set in QuickControl Scaling time number of servo ticks 120 usec 1 tick
75. strength Lower temperatures and torque speed usage in the nominal regions improves torque accuracy The power supply in use must also be taken into consideration A supply in compliance with QCI specifications is highly recommended and required to maintain the warranty Further variation in the voltage level up to 10 may vary the output torque similarly These minimum power supply requirements are meant to ensure the SilverMax can operate optimally If all four of these requirements are met SilverMax torque ripple is minimized SilverMax User Manual 4 01 126 Chapter 8 Shutdown and Recovery Techniques Automatic SilverMax Shutdown Every servo cycle 120 microseconds SilverMax performs an error check based on the settings issued in the Kill Motor Conditions KMC command If any of these SilverMax kill conditions are met the program specified by the Kill Motor Recovery KMR command is immediately loaded In addition an over voltage condition will always trigger a kill condition The program specified by KMR can then perform any operation a shutdown recovery or other technique The default SilverMax initialization files have a KMC that selects a default recovery program which repeatedly cycles the Status LED green located on the back of the SilverMax after a KMC setting is found TRUE Strategies on how to modify the recovery program based on application requirements are covered in this chapter The Low Voltage Trip LVT command
76. that line 1 2 3 Command Example program listing Move 1234 revs acc 100 pss vel 33 3 rps Stop when 1 0 1 is Falling Jump to the label START when 1 0 2 low state i Jump On Input to START l When I O 2 is LOW FALSE There are three columns in the Program Window 1 Line Number and Operation Displays the program line number and the TLA of the command 2 Label Allows the user to put in labels for branching operations in programs 3 Command Provides a brief summary of the command on that line and the parameters that are set in that specific operation of the command In this example of the Program Window there are two colors used to differentiate the lines of the program Blue is used for actual SilverMax commands and green is used for the remarks REM Remarks are not downloaded to SilverMax with the commands and are only used for adding text information to a QCP When a label is placed on a REM line in the program the line that is activated from that label in the program when downloaded is the next available command line If the label is placed ona REM line that is at the end of a program it will be the next available command line up from that REM line In the example above START is a label on line 1 a REM line The program branches to the START label from Line 4 when the I O condition is met Since line 1 is a REM line when this program is downloaded to SilverMax the START label
77. the Clear Poll CPL command Chapter 2 contains more information on the SilverMax command hierarchy and polling routines Poll POL Command The POL command is used to determine the condition of SilverMax A POL command can be executed at any time including while SilverMax is in motion Executing this command will cause SilverMax to return an ACK message if all of the bits in the word are cleared or return the word itself in hexadecimal if any of the bits are set An ACK is an Acknowledgement signal from SilverMax that indicates that the command was received correctly with no errors but no reply was required The POL command is used to access the information in the bits of the Polling Status Word These bits contain a variety of information as shown later in this section The information contained in this word is intended to be used in polling routines The Polling Status Word bits are each set to 1 when a particular condition takes place The bits are cleared to O using a Clear Poll CPL command All of the bits are latched meaning that they must be cleared manually they are not cleared when the condition they are tied to clears Clear Poll CPL Command The CPL command is used to clear the bits of the Polling Status Word This command is the only way to clear the bits in the Polling Status Word since all the bits are latched Additional conditions that occur after a POL command is issued will show up when the next POL command is
78. the Internal Status Word Parts of this status word are available through the RIO and POL command as well The RIS command returns the decimal form of the 16 bit binary number that makes up the Internal Status Word Some of the bits are latched while some are not The bits that are not latched represent the status of the condition associated with them while the latched bits function as flags to indicate that the associated condition occurred at some time after the last time the flag was cleared The meaning of each bit is explained later in this section Clear Internal Status Word CIS Command The CIS command is used to clear the latched bits of the Internal Status Word Latched bits must be cleared with this command in order to be reset This makes the CIS command an important part of a Kill Motor recovery routine since if the bits are not cleared Kill Motor will trip again As mentioned earlier Kill Motor routines are covered in detail in Chapter 8 Check Internal Status CKS Command Bit 6 of the Polling Status Word shows the CKS status This allows a host that is polling SilverMax to indirectly use the Internal Status Word just by polling The CKS command sets the conditions that will trigger the Polling Status Word bit There are 15 conditions for the CKS command to match the 15 bits used in the Internal Status Word The conditions are toggled on and off and then combined with a logical OR This means that if any of the conditions set with th
79. the defaults are accepted 4 Reboot PC Remove any diskettes and re boot the PC This can be done by selecting Start gt Shut Down Restart the Computer 5 Run QuickControl From the Start menu select Start gt Programs gt QuickControl QuickControl will come up with a blank program 6 Initialize and Program SilverMax Go to the QuickControl Help System for a detailed step by step procedure on Initializing SilverMax Programming SilverMax The QuickControl Help system is accessed through Help gt Help Topics gt Getting Started Tutorials SilverMax User Manual 4 01 14 Find SilverMax on the COM port With the SilverMax powered up start QuickControl and the polling routine should automatically find SilverMax If QuickControl is already running and the SilverMax is powered up press the Scan Network button to find SilverMax on the network If Device Not Found appears in the Device Status Monitor either the SilverMax has been configured with something other than the Factory Defaults listed in the Hardware Requirements section of this chapter or QuickControl is not set up to communicate with the SilverMax in its present communications state Some things to check if this happens are e Under Setup select Comm Port Comm Channels and ensure the baud rate and protocol are set to Factory Defaults 57600 and 8 bit ASCII respectively Also confirm the Enable checkbox is checked and the COM Channel enabled is th
80. the motor was first stopped Target position will advance to the location of Actual Position Moving Error Limit If Drag Mode were turned off the target position would increase to 10 000 counts When the flywheel is released the motor may or may not continue moving depending on how long it was held Either way once the motion has stopped the Actual Position register will not read 10 000 counts because the shaft was jammed for a period of time DRAG MODE WITH THE PMV COMMAND 11 Push the momentary switch connected to I O 5 The motor will begin to move in the opposite direction using the PMV command 12 While it is moving grab the flywheel and stop the motion Hold for a few seconds and release it Hold and release again Regardless of how long the motor was held it will eventually reach the target position of 10 000 counts The Profile Move command recalculates the trajectory for the motion parameters every servo cycle 120 microsecond so SilverMax will always reach its target position Anti Hunt Feature Digital servo systems share a common characteristic called dithering when holding a position Dithering typically occurs when the holding position is near the count transition point of the digital feedback device i e optical encoder or resolver causing the shaft to oscillate between counts For some applications dither is desirable and may even be intentionally created In other applications however any dither is
81. torque limit value within of one servo cycle 120 usec of the register update Note that writing to registers SilverMax User Manual 4 01 121 206 and 207 obtains the same result as executing the TOL command Writing directly to the registers allows real time dynamic modification active SilverMax torque limits Direct editing also allows individual limits to be adjusted without changing any of the other three limits With the TQL command all four torque limits must be specified requiring caution in certain situations Note that when writing to either register 206 or 207 the torque limits must be in Native SilverMax torque units Please see the SilverMax Torque Limits table earlier in this chapter for details Registers 206 and 207 can be updated from any internal and external source To change torque limits internally use the CLC command to move the data CLC has the ability to write to either the low word or high word of a register Thus an individual torque limit can be changed with CLC The procedure for changing torque limits using CLC is as follows First copy or write the desired torque limit value into register 10 the accumulator Be sure that the value is in Native SilverMax torque units Save this number from the Accumulator to the corresponding 16 bit half of torque limit register using CLC In the example below CLC updates the closed loop running torque limit the low word of register 206 Command Register Based Torque Control ee
82. use the SilverMax native units The five parameter types are summarized below e Raw Numbers These numbers are used in general mathematical operations An example application is setting the number of times to execute a loop Raw numbers are transmitted directly to SilverMax with no scaling When receiving a raw number from the SilverMax the number will be in hexadecimal Therefore a host may need to perform a conversion to decimal after requesting the data from SilverMax See the Appendix for details on decimal hexadecimal conversion e Position Distance The native unit of position and distance is the count The number of encoder counts in a single revolution varies depending on the resolution of the encoder All position or distance parameters transmitted to SilverMax must be in counts e Velocity The native unit of velocity is designed to give maximum resolution in speed selection It is a signed 32 bit number giving a range of 2 147 483 647 These numbers correspond directly to actual speeds of 4000 RPM To convert a velocity in RPM to SilverMax native units simply multiply by 536870 911 The fractional component can be ignored with minimal impact on accuracy Actual velocity is reported as a signed 16 bit value in the low word of register 7 To convert this to the native units multiply it by 65 536 The standard conversion to engineering units can then be applied e Acceleration Acceleration is like velocity designe
83. will actually point to line 2 the next command line after the REM line 5 Device Status Monitor The Device Status Monitor occupies the right hand portion of the main QuickControl window It provides status information on QuickControl and the attached devices Device Status The top portion of the display is used as a quick reference to the Registered Devices QuickControl uses a polling routine to check the status of these devices Five different buttons can be displayed in the status SilverMax User Manual 4 01 20 NOT ENABLED No device is registered or the communication is not set up correctly COM Port not enabled 53H 5 NOT PGM STP Polling is active and a program is NOT running in SilverMax Es salb 2 ae PGM RUN Polling is active and a program is running in SilverMax 16 0 BLED NO POL Polling is not active to the registered device NOT NOT NO COM Communication has been terminated to the device bev 3 N atal NOT NOT The status of the active SilverMax selected by pressing the button next to a bev 5 ENA bev 6 ENA 0 BLED im BLED gt displayed SilverMax is displayed anytime polling is running This includes the current position of SilverMax and the I O Channel Status If the Dev Dev 1 counts button is selected the Register Watch Tool will be launched to communicate o i Ja Ja Ja Ja fe a with that device Stop Polling Poling Scan Network Stop Polling Button Status Log Selecting the button initiates a ne
84. with no error warning For example if an application required that SilverMax 1 send its internal encoder signal as an output 2 stop motion based on an input condition and 3 enter a Kill Motor Condition based on a digital input several conflicts could occur The only I O lines capable of being used for Kill Motor inputs are lines 1 2 and 3 The raw internal encoder output signal can use lines 1 2 and 3 or the scaled internal encoder output signal can use lines 6 and 7 Finally any of the I O lines can be used for a digital input to stop motion The Kill Motor inputs would collide with the raw encoder signal outputs meaning that a scaled internal encoder signal should be sent out using I O lines 6 and 7 After assigning I O lines for these two functions the only lines left would be lines 4 and 5 so either of these could be used for the stop motion digital inputs SilverMax User Manual 4 0 107 The table below shows the UO lines used by each UO function as well as the special uses for each UO line for the high speed functions This table should be used to assign I O functions to I O lines and avoid conflicts UO Function O 1 1O 2 1 0 3 UO 4 VO 5 VO 6 UO 7 General Digital Input A A A A A A A Motion Control Input X X X X X X X Kill Motor Input A A A Modulo Trigger X General Analog Input X X X X Input Mode Analog Input X A A X General Digital Output X X X X X X
85. word indicating new move parameters have not been loaded into registers 18 and 20 23 Clearing the upper word of register 17 writing a O must be done manually ideally in a loop or the IMS operation will use the value in register 19 to stop motion and exit IMS operation Segment 2 3000 1073741824 1073742 1073741824 Ramp up to 2000 RPM velocity 2147483647 2 1073741824 using 05 acceleration 0005 2147483647 107342 for 3000 ticks 0 36seconds before looking to load a new segment or decelerate to a stop using register 19 Note that these parameters project the second set of ramping and constant velocity segments and the position parameter for this segment is never realized Time decrements down in register 18 as described above Segment 3 1000 1073741824 1073742 536870912 Ramp back down to 1000 RPM A velocity using 05 acceleration for 1000 ticks 0 12seconds before looking to load a new segment or decelerate to a stop using register 19 Note that these parameters project a set of decelerating and constant velocity segments but the time value is chosen so the next set of parameters are loaded before the constant velocity segment starts Time decrements down in register 18 as described above Segment 4 2000 92000 536871 536870912 This is the last segment of the profile Therefore define position as the desired stopping position of the profile 92000 rather than a large value to simply project the segment Since this s
86. 017 to obtain appropriate clamping resistance and connect leads to the Res 1 and Res 2 terminals on the Voltage Clamp SilverMax User Manual 4 01 The V Input connections on the Optical I O board must be connected to V of a power supply and Pwr Gnd connections must be connected to Ground of that power supply The V Fused connection must be tied to the ENA V connection to enable the Drive Enable line on SilverMax This connection can be made with the included jumper or external switching circuitry 13 Software Requirements Installing QuickControl Software Note Do not power up the SilverMax until the setup procedure specifies this action Note QuickControl can control SilverMax in real time it therefore needs full access to PC resources When installing QuickControl it is necessary to close all shared files and exit open applications It is also highly recommended that applications requiring large system demands be closed and any screen saver is disabled Background tasks can cause interference and should be reduced to minimum requirements 1 Insert the QuickControl Setup CD into the CD ROM drive If QuickControl setup automatically runs follow the instructions and go to step 5 else go to step 3 2 From the Start menu select Start gt Run 3 Type in the setup program CD Drive Letter setup Follow the instructions on the screen It is strongly recommended that Typical installation is selected and all
87. 2 300 x 5 2 301 X 7 2 302 SilverMax User Manual 4 01 93 Register File Array Import Directives Import directives for Register File Arrays are very similar to those used with Register Files Shown on the right is Reg File Adv Example txt This example is found in the Data Registers folder within the QCI Examples directory and is used with Reg File Adv Example qcp The text file shown illustrates the Register File and Register File Array formatting techniques Register File Array Import Directive NVRegArray This directive informs QuickControl that a Register File Array is to be imported The following directives define the Register File Array They need to be on the same line as the Register File Array Import directive and must be separated by commas Register File Array Name Directive name Specifies the name of the Register File Array to be imported Quotation marks optional and spaces allowed Example namez reg file array 1 Number of Columns Directive col Specifies the number of columns in the Register File Array to be imported The number of columns can be equated to the number of registers in each row of the Register File Array Data must be between 1 and 10 Example col 4 This directive is optional unless using the ending address directive Number of Rows Directive row Specifies the number of rows in the Register File Array to be imported Example row 6 This directive is o
88. 2767 User Input Dead band 15 0 to 32767 User Maximum Scale Limit 16 KE User Maximum Output Scale to 2 147 483 647 2 147 483 648 User or 17 Be hence Output Offset to 2 147 483 647 SilverMax j 18 0 to 2 147 483 647 User Output Rate of Change Limit Register 12 is the most important register since its value sets the target for each Input Mode command For PIM the target is a shaft position For VIM it is a particular shaft velocity For TIM the target is a torque The 11 bits of differential analog input resolution or 10 bits of single analog input resolution that the analog inputs can provide is usually sufficient for Velocity Input Mode or Torque Input Mode However this may not be enough resolution for position critical applications QCI recommends using another position based motion command like Profile Move PMV for precise position control More information on the Input Mode motion commands is available in the QC Command Reference and in the QCI application note on analog inputs The difference between the three Input Modes is explained below SilverMax User Manual 4 0 112 Velocity Input Mode The Velocity Input Mode VIM command is the most basic of the Input Mode motion commands The most important register used by this command or the other two Input Mode commands is register 12 which is typically tied into an analog input with the ACR command The VIM command allows that analog input to directly control the sp
89. 28 Calculation is accurate to 3C between 5C and 100C 216 Maximum driver voltage in ADC counts HW and Drive V calibrate data in ADC counts volt LW The CAI command stored in the factory memory block initializes the data in this register 217 Maximum driver temperature in ADC counts for HC series HW and Processor V Calibration for the HC series counts volt LW Data is initialized by factory block 218 Non Volatile load address for debug HW and MSTATE of command that loaded the EEPROM LW Register is intended primarily for use by QuickControl to trace errors and single step programs 219 Communication addresses HW upper byte is Group ID lower byte is Unit ID and Sequence pointer to internal RAM used by program download routines to verify that all words were received LW 228 MSTATE of the command that caused a Sequence error HW and the Pointer to the buffer location RAM where the error was observed LW Register intended for use by QuickControl for debugging 229 STEP4 HW and STEP_SHFT LW This register combined with register 230 is used to 1 configure encoder resolution 2 select maximum servo speed represented by the full scale velocity value and 3 configure the servo for different resolutions of external encoders The factory block sets these values 230 Encoder Gamm HW and Encoder Gain 2 LW See note for 229 SilverMax User Manual 4 0 180 Appendix C Conversion Data Inertia To convert fr
90. 29 133 SilverMax specifications 126 151 156 175 185 187 8 10 18 107 standalone configuration ccccee 1 2 4 start up kits i 9 10 28 38 44 57 65 80 139 status wore esseeeeeenreen neee 36 47 56 62 183 stop Commande 97 supply voltage eee 8 24 137 170 175 temperature 2 36 50 52 53 55 110 111 120 121 126 128 180 torque Control 54 120 121 123 trajectory 31 50 53 63 72 97 161 179 trajectory generator 119 120 166 178 179 tuning commands control constants 53 117 121 161 162 filter CONSTANTS ccceeeceeeeeeeeees 162 170 172 nit EE 8 24 179 velocity feedback gain Kv1 amp Kv2 164 165 171 173 velocity feedforward gain wf 173 velocity filters Fv1 amp Fv2 esee 172 velocity mode commands VMI VMP 38 63 71 Voltage n a 1 8 10 11 22 24 25 36 49 52 62 97 123 126 128 134 137 150 153 156 170 175 180 wait Commande 81 84 180 Cd le EE 18 194
91. 4 17 3 3 29 17H 3 3 29 SilverMax User Manual 4 0 185 SilverMax 23 Frame Mechanical Data All measurements listed are in inches CAD files are available from the QCI website www quicksilvercontrols com 2 22 0 745 ka GA Ge eg 0 365 7 a y 81 50 0 250 F 2 22 ai z i 0 205 THRU Dees Ge SE m See Table 2 62 Model Type Length w o shaft in 23H 1 3 25 23 3 23H 3 3 725 23 5 23H 5 4 625 SilverMax User Manual 4 0 SilverMax 34 Frame Mechanical Data All measurements listed are in inches CAD files are available from the QCI website www quicksilvercontrols com E 274 4X 275 THRU Si SEE Z oiaes e w SE vi l SS e E 2 875 0 002 E Seege S I Pes e g ae 8 3 S S dH CEH on T 345 2 econ f AN Ir SEE STATUS amp A EE x TABLE SEE TABLE oe LEDS mei J i J e Sg J 0 325 GE osd ere Length w o Shaft Shaft Diameter Keyway Width Keyway Depth modet Type in in in in 34N 1 34H 1 34HC 1 5 06 0 500 0 1250 0 0700 34HC 2 6 65 0 500 0 1250 0 0700 34HC 3 8 13 0 625 0 1875 0 1075 34HC 4 9 68 0 625 0 1875 0 1075 SilverMax User Manual 4 0 187 S
92. 5 Continuously read analog input into selected OK msec filter is used on the raw input The ACR command can E the last ACR is active be used with the input mode motion commands PIM VIM and Cancel Channel Analog Chane zl TIM to externally control motion Like the ARI commana it can read the value of any of the analog inputs the four single analog inputs the two differential inputs or the six internal channels More information on this command is available in the SilverMax Command Reference and in the QCI application note on analog inputs The QuickControl screenshot to the right shows the ACR command Description Register ll SilverMax User Manual 4 0 111 Input Mode Commands Three commands Position Input Mode PIM Velocity Input Mode VIM and Torque Input Mode TIM are used to access three special SilverMax operating modes The Input Modes use seven data registers for processing position velocity and torque information They allow SilverMax to use data from an analog input or an external host to directly control motion The most important parameter used by the Input Mode commands is the parameter held in register 12 This register sets the target value for each input mode position velocity or torque target A common use of these commands is to tie register 12 to an Analog Continuous Read ACR command allowing an analog input like a potentiometer to directly control speed position or torque An external
93. 53 06 PosMax 100000 counts j Enter the label to be used in Move count VelM Don A type command i e revs Unis count esst Fass 266666 67 cps Number of Decimal Places to Dec 2 Ee p EE See EE DN hmmm cps s Register Names and Descriptions MaxTime 10000 mSec Description L SC D Upload ha o Password 1234 Sort Programs in download order V E Run button does not save IT Update Device Status Properties Vv ES anytime this file is active If the software is polling clicking the Get CPR button will adjust the software to the resolution of the currently selected SilverMax encoder Adjusting the value in the Scale field will divide all position distance velocity and acceleration values in QuickControl by the number A simple example is to put 4000 in this box This scales the display to revolutions when using a 4000 count per revolution encoder For display purposes the string in the Units box can be changed to anything In this case revs is appropriate The first letter in the Units box is used in velocity and acceleration units The velocity unit would be scaled and changed to rps while acceleration will be changed to rps s The Dec Places box adjusts the accuracy of the scaling used in QuickControl For some applications it is convenient to scale the software to a linear unit appropriate to the system For example it could be a
94. 600 Full S Curve g Trapezoidal Motion Same Acceleration J Zero S Curve as Trap Motion 400 200 0 0 0 1 0 2 0 3 0 4 0 5 Time SilverMax User Manual 4 01 37 ii Exercise 2 1 Basic Motion Commands amp Jump Commands The purpose of this exercise to get familiar with the basic MRV JMP and JOI commands SilverMax will execute two moves depending on the state of the I O 1 switch or I O 3 switch The program runs ina continuous loop monitoring the two switches Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers 1 Make sure QuickControl is polling SilverMax Click the Scan Network button in the middle of the Device Status Monitor to start polling SilverMax if polling is stopped Select File Open Navigate to the QCI Examples Using Inputs for Move Selection folder and select the file Two Inputs Two Moves with MRV qcp Put the I O 1 switch in the up position and the I O 3 switch in the down position Verify both input are in the high state by looking at the Input status boxes just above the Scan Network button A Green box indicates the I O line in this case an input is in the HIGH state A Red box indicates a LOW state Take a moment to toggle the I O switches up amp down to see the Input status boxes change color as the inputs change state Click on the
95. 8 R Integrator 9f R Loop State HW lt gt Torque current torque value LW 10 R W Accumulator calc results reg copy save buffer indirect addressing pointer Data register contains two independent 16 bit data words R Read Only R W Read and Write R W Read and Write Write only using CLC command with Offset Target Position operation SilverMax User Manual 4 0 178 The table below provides information on dedicated data registers 200 through 233 These registers are utilized for advanced operations complex programming troubleshooting and factory specific settings Data Type Dedicated Data Register Description Register High word HW lt gt Low word LW 200 R W_ External Encoder Position total count value from external encoder signals 201 R W External Index Position count value of last external index trigger 202 Reserved 203 Reserved 204 R Trajectory Acceleration calculated internally by trajectory generator 205 R Trajectory Velocity calculated internally by trajectory generator 206 R W Closed Loop Holding Torque HW lt gt Closed Loop Moving Torque LW 207 R W Open Loop Holding Torque HW lt gt Open Loop Moving Torque LW 208 R W Error Limit moving HW lt gt Error Limit holding LW 209 R Sense Mask shaft rotation dir for data HW lt gt FLGINP I O Status Word 210
96. A o BLED Vin BLED NOT NOT Dev Hp ENA Dev 6 ENA o BLED p BLED Dev 1 E counts Input fa fafa fa fa a fe Scan Network Not Polling Status Log 01 Polling Started 02 Scanning SilverMax User Manual 4 01 28 bes Exercise 1 2 Advanced SilverMax Initialization This exercise demonstrates how to initialize SilverMax using the Initialization Wizard interview feature 1 To initialize SilverMax using the wizard begin by choosing SilverMax Initialization Wizard under the Tools pull down menu SilverMax Initialization Wizard x Press Download to initialize SilverMax or change the Exit factory default parameters using the Initialize Parameter Si Browser or Interview 5 Options Download File Se To SilverMax Interview Motor jl Type 23H 5 Initialize Parameter Browser File Communications Motor Servo Tuning Motion Error Limits Misc BilverMax Factory Default Initialization qep Open Save Save As H A A A 2 To begin a step by step run through of the initialization parameters select the Interview button Note If the Cancel button is selected the old command parameter s are reserved for all windows and the interview is stopped 3 Parameters for each command can be modified during the interview The following is a simple outline of the parameters in order of which they will appear during the interview IDT Identit
97. Analog INpuls E 110 SilverMax Analog leet 110 Using Analog Inputs for Program Flow and Data Monitoring cc ccceeeeeeeeeeenneaeeeeeeeeeeeeeenneeeeeeeeees 111 Analog Read Input ARI Command cick sccsduetdverpecncepecsened taut seted eave acundedessaeats edacedenass Ed EEN 111 Analog Read Continuous ACR Command EE 111 Input Mode Command EE 112 Input Mode Operation a aE E eE EEEa Taaa RE aE E E EEE ARE AE AREE ERRi 112 Velocity IME e TEE 113 P sition INPUT MOG Gis leccens epee dutta tes geckeg eege gedet gehen 113 Torgus TEM Oe 113 Using Encoder Signals with Digital e EE 113 Encoder Signal e 113 el ee BR Ee E UE 114 Step Up Step Down Elei EE 114 Aand B Quadrature Sigd S r a aer dats a E iets cog ec Aea e e ra a OEN Eea 115 External Encoder ale EE 115 Diret Motion Control Late 115 Dual Loop Control re e a E E R REEN 116 EASE CR 117 Raw Internal Encoder Te E 117 Scaled Internal Encoder Output Modulo Output 118 SilverMax User Manual 4 0 vi Chapter 7 Torque Control ssisccisccasccteccdinncneciacedacddnnncatuancvenaddisucsadsncvdeiddinadaddiadveneddedctaatdenivaniens 119 SilverMax Torque Ee 119 Torque Limit PSE OD GEET 119 SilverMax Units OF Torgu E 120 SilverMax e te EE dn e CET 120 Data Register Relationships essea in EE Sege eegen 121 Torque Control Methods epps a E a eaaa EE I AEEA E E 121 Chapter 8 Shutdown and Recovery Techniques eecccceeeeeeeseeeeeeeeeeeeeeeseeeeseeeeeeeeeees 127 Automatic Sil
98. B Index Modulo Output R Index alt si i Index Exe nal EENS Step alt Direction alt Index These lines can be used for A amp B quadrature step up step down or step and direction signals SilverMax User Manual 4 0 113 The external encoder input function can receive all three types of signals while the scaled internal encoder modulo output can send all of them The internal encoder output function can only send A and B quadrature signals The internal encoder output and external encoder input functions also use an index pulse line This line sends or receives one pulse every time the encoder index is found The 4000 count encoders have one index line one index pulse per revolution while the 8000 count encoders that are optional on 17 and 23 frame models and the 16 000 count encoders that are standard on 34HC models have 50 sub index lines 50 sub index pulses per revolution These also have one main index pulse per revolution These three types of signals can come from several sources The encoder monitor output function sends the raw internal encoder signals of SilverMax out through I O lines 1 2 amp 3 Modulo output functions send a scaled version of the internal encoder signal out through I O lines 6 amp 7 The external encoder input function allows SilverMax to connect to any external device capable of sending the proper signal format This source is usually an external encoder or resolver but it c
99. Buffer 200 words Serial Communications Buffer The serial communications buffer is a 10 word 10 16 bit blocks memory location used to temporarily store incoming and outgoing commands along with associated parameters and data Commands sent to SilverMax through the serial interface are temporarily stored in the buffer as the command string is being received During this time the command and its parameters are checked for proper syntax while any data is checked for proper range When the command and all necessary parameters and or data have been received program type commands are transferred to the program buffer and executed Immediate type commands are executed directly from the serial buffer Program Buffer The program buffer provides a 200 word memory array for program and command execution The buffer is used by the SilverMax to hold a single command or a series of commands a program for eventual execution Only one program can be held in the buffer at a time The buffer can be loaded with commands using the serial interface or with programs transferred from the non volatile memory The buffer will hold a command or program until overwritten or until power is removed SilverMax User Manual 4 01 39 Programs that are contained in the buffer can also be written to the non volatile memory for long term storage The following is a list of SilverMax commands that pertain to the program buffer These commands are described completely in the Silver
100. C MAT MAT Aan Edit Control Edit Filter Constants Constants C MAV MRV A See STOP 0 g Mator Dev 1 16 Test Move 1 ja Type Soa e Rev 32 4 Distance Jong counts d peii ne Acceleration 399999 9 cps s he polly sis Si i1 Velocity Dr Target Posf5000 cores ee ee Position sqq3 aen Test Move 2 Digital 1 0 red LO W sec H EEN Distance 4000 counts ja jo js a js ele Pos Euorl 3 counts Cea CCC CCC Max Error 49 eras a Acceleration 8000 1 cps s co RK SCRKKSR Tooueleo Velocity 4000 cps ES Taal Get Voltage 47 vts 1 eg Get Temp 26 2 SE Strip Chart 1 fo 212 ass 3 Click and drag the purple arrow of the Jog Tool to verify proper operation of SilverMax SilverMax will respond by moving at the velocity indicated in the direction specified by the Direction DIR command line 40 of SilverMax Factory Default Initialization By default positive velocities or positive relative positions indicate clockwise movement SilverMax User Manual 4 01 27 Exercise 1 1 Basic SilverMax Default Initialization This exercise demonstrates how to accomplish a basic initialization of SilverMax using the Factory Default Initialization File Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers 1 To initialize SilverMax using th
101. F 04 and Resistor Pack QCI CLRP 2 are included QCI Technical Document QCI TD0013 included contains more information on the Optical Interface Module The female end of the SilverMax Interface Cable The SilverMax Line Power Cable The male 15 pin connector on the SilverMax Interface Cable The RuJ 11 connector on the serial cable The 9 pin female connector on the serial cable Ne jpg attaches to the 15 pin male connector on the SilverMax 34 servo attaches to the 3 pin receptacle on SilverMax attaches to the 15 pin female connector on the Optical I O board attaches to the RJ 11 jack on the Optical I O board attaches to a standard PC COM port The red wire at the end of the SilverMax Line Power Cable is connected to the Vout 3 terminal on the Voltage Clamp The black wire connects to the Gnd 4 terminal on the Voltage Clamp The white wire connects to chassis ground of the power supply DO NOT make any other connections to the outputs on the Voltage Clamp other than to the 3 pin receptacle on the SilverMax In the case of SilverMax regenerating any added circuitry connected to Voltage Clamp outputs is not protected and could be damaged by the back EMF Connect the Vin 1 amp 5 terminals to the V of the power supply and connect Gnd 2 amp 6 terminals to the ground of the same supply Wire the resistors of QCI CLRP 2 as needed see QCI Technical Document QCI TD0
102. For SilverMax a word is defined to be a 16 bit number two bytes when used by the SilverMax processor Three special status words provide a wealth of information about the operating state of SilverMax the Polling Status Word the Internal Status Word and the I O Status Word The information contained in the 16 bits of these words can supplement information available elsewhere in SilverMax such as in the data registers or can provide information not available anywhere else Proper use of these words is critical for proper program flow when SilverMax is in the standalone or hybrid configurations and useful for almost any host application This section describes each of the three status words the meaning of each bit in each word and the commands used to read and work with the words SilverMax User Manual 4 01 47 Polling Status Word The Polling Status Word indicates the overall condition of SilverMax This word is accessible with Immediate commands given from an external host It is used to give the host a quick status update A host could be programmed to act on changes in the Polling Status Word or the word could simply be used to alert the host to changes in the operating condition of SilverMax Repeatedly checking the Polling Status Word is referred to as polling and is a common way to update an external host on the condition of SilverMax Two Immediate commands are associated with the Polling Status Word the Poll POL command and
103. If Over Temperature or Moving Error Just a wait before calling the next program Set a user register equal to 1 to indicate that the Recovery Progam has been used to Recover Biver au Delay for 500 mSec Write 1 to User 11 Register Run a system recovery program from here This following program could be a Homing routine that would recover from the error Load And Run Program Program Mam Program Example Recovery Program Command Check to see if SilverMax has just recovered from the Recovery Program Jump to RESUME When User 11 1 This would be a section of programming that would not need to be reissued after a Kill Motor Recovery Initialize data registers 20 through 24 with the appropriate parameters for the profile move Write 1000000 counts to User Profile Move Pos 20 Register Writes to the Acceleration Data Register 21 Write 20000 cps s to User Profile Move Acc 21 Register Writes to the Velocity Data Register 22 Write 60000 cps to User Profile Move Vel 22 Register Writes to the Deceleration Data Register 23 Write 80000 cps s to User Profile Move Dec 23 Register Writes to the Position Offset Data Register 24 Write 4000 counts to User Profile Move Offset 24 Register RESUME Zero Target and Position Put SilverMax into a Profile Move and use the parameters curently loaded into Regs 20 24 Any of these parameters can be modified on the fly by issuing a Write Reg
104. Line _ ZE Add Cth Edit Cnthe Note Each tab contains a specific set of commands Command numbers range from Oto est Cnt Delete Cnt 255 Detailed descriptions of each command and command parameters can be found in Programs the SilverMax Command Reference Downoad Pun 3 Ge Move tab and double click on MRV Move Relative Velocity Based Trace _ Single Step Program List 4 Enter the following values for the first MRV move Seel 0 S Distance 10000 counts i8 of 200 words used Acceleration 1000 cps s 999 62 actual Velocity 2000 cps rm Device To Program Acceleration parameters are rounded as QuickControl calculates the exact motion profile Bers Devi 16 i Type 5 Click on the Advanced button to choose the input I O line and configure the stop condition 6 Choose the Standard tab of the Edit Stop Conditions box Select I O 1 for the Condition and use HIGH TRUE as the State 7 Click the OK button twice to get back to the main QuickControl screen 8 Highlight the newly created Line 2 and choose Insert from the Program Info Toolbar This will insert a new program command into the program list before the first MRV command on Line 2 SilverMax User Manual 4 01 44 9 Choose the Move tab and double click on MRV Move Relative Velocity Based command 10 Enter the following values for the second MRV move Distance 10000 counts Acceleration 1000 cps s 999 62 actual Vel
105. M and PIM in that register 12 directly controls motion However TIM only uses registers 13 to 17 with register 12 not registers 13 to 18 Torque Input Mode is not as simple to use as Velocity or Position Input Modes While directly controlling torque is the way many traditional servo systems worked directly controlling SilverMax torque bypasses many of its capabilities requiring a SilverMax program or a host controller to replicate them Velocity Input Mode or a simpler motion command like MRV is usually a much better solution than Torque Input Mode because those motion commands allow SilverMax to use its internal control algorithm Chapter 7 covers Torque Input Mode in detail Using Encoder Signals with Digital UO In addition to the other functions covered in this chapter the SilverMax I O lines can be used for high speed I O functions external encoder input internal encoder output and scaled internal encoder modulo output All three functions have a maximum bandwidth of 1 MHz per I O line This section describes the types of signals used by the high speed I O functions their use and commands used to configure them Encoder Signal Types The SilverMax high speed digital I O functions use three types of signal formats step and direction A and B quadrature and step up step down The signals and their I O lines are shown in the table below Function Line UO 1 UO 2 UO 3 O 4 VO 5 O 6 VO 7 Internal Encoder Output A
106. MISC Start Location of User Program Load nd Run Program Servo Tuning SERVO Load and Run Program See NY Memory Location 512 SilverMax User Manual 4 01 Interview Button To begin a line by line examination of the initialization parameters select the Interview button A window will be displayed for each configurable command in the initialization file The first parameter in the interview is line 4 which is highlighted in the number line column of the Program Window To see a description of the command or parameter select the Description button of each window After any changes to the parameter s are made select OK to accept the changes and move on to the next command If the Cancel button is selected the interview process is stopped After the interview is complete save the changes to a new initialization file by selecting Save As and give the new initialization file a descriptive name Please see the SilverMax Command Reference for more details on any of the following commands IDT Identity Line 4 Each SilverMax needs to have a unique unit identity or address to establish communication to a single drive Values between 1 and 254 may be chosen for these identities Multiple SilverMax may have the same Group identity or address to communicate with multiple drives at once The group identity must be different from any individual SilverMax identity on the network PRO Protocol Line 6 Select
107. Max The next 15 registers 10 24 are available for user applications but have special functions if the Calculation CLC Profile Move PMV PMC PMO PMX or Input Mode PIM VIM TIM commands are used Registers 25 42 are available for user data without restriction The remaining registers numbered 200 233 are dedicated special purpose registers SilverMax Status Registers 0 9 These registers are not available for general use as they are dedicated to reporting the internal status of the servomotor They are updated internally every servo cycle 120 microseconds and are available to a host using the Read Register RRG command Registers 0 and 1 can be modified by the Calculation CLC command and registers 2 4 and 5 can be modified using the internal or host Write Register WRP WRI commands The rest of the status registers are read only Reg Type Description 0 R W Current Target value Requested Position R W Current Position Actual Position R W Last Index Position Position of last detected index pulse R Internal Status Word upper word lt gt Current Process State lower word R W Last Input Position Position when last input was found R W Delay counter value Ticks left on the DELAY counter Max Error value upper word lt gt Most recent Error value lower word Once filtered Velocity upper word lt gt Twice filtered Velocity lower word Integrator value Loop State upper word lt gt Servo
108. Max Command Reference Clear Program CLP Clears the contents of the program buffer Start Download SDL Puts SilverMax into download mode Store Program SPR Stores the currently loaded program into non volatile memory Run Program RUN Executes the currently loaded program Load Program LPR Loads a program from non volatile memory into the program buffer Load and Run Program LRP Loads a program from non volatile memory to the program buffer then executes the program Data Registers Data Registers are used as data storage locations that may be used and modified by a host controller or by SilverMax internal functions There are a number of 32 bit data registers available within SilverMax They provide data storage for the parameters of register based commands They can also be used by the Calculation CLC command as data variables for more complex calculations Some registers contain two separate pieces of data These values are stored as two 16 bit numbers one in the upper 16 bits of the register and one in the lower 16 bits This type of stored data can be separated using the operations in the Calculation CLC that reference the 16 bit words of each register separately Please see the application note on the CLC command and the Register Watch tool in QuickControl There are 77 registers available to an application program The first 10 data registers 0 9 are dedicated to reporting the current status of Silver
109. Max ID the command number being responded to and a NAK code The NAK code is an explanation for the rejection of the command packet The following table describes the codes NAK ar epee fn The device received a command number it did not recognize If you are sure the command number is correct ensure that the servo has the latest 1 Bad Command firmware revision A table of commands verses firmware revisions can be found at the end of the Command Reference The current revision can be found in the SilverMax Control Panel The Device is actively executing a previous command or internal program 2 Device Busy The received command cannot be executed at this time See the SilverMax Command Reference under Command Types for details Reserved for back compatibility with pre E series units Reserved for back compatibility with pre E series units Bad Format Command number and number of parameters is not consistent Buffer Full The device s program buffer is full Too many bytes were sent to the device for its available program buffer space RAM An address used in a command was out of range This includes trying to 7 Bad Address BCCESS Data Registers that do not exist accessing registers not available to the command accessing command buffer that does not exist negative or larger than buffer or trying to read or write zero words of data The requested return data was too large for one packet The serial communications buffer c
110. Max will resist any external force on the shaft with a tunable amount of torque and will not fly back to its original position when the external force is removed e Ifthe shaft were jammed the actual position would not change since the shaft would be stuck Drag Mode would freeze the target position until the jam was cleared preventing the target position SilverMax User Manual 4 01 56 from running away The target position would freeze a number of counts away from the actual position equal to the holding error limit e Ifthe Trajectory Generator were commanding a move that was too fast for the motor to physically keep up with due to excessive load or insufficient torque Drag Mode would limit the target position runaway to a number of counts equal to the moving error limit e H SilverMax were holding a position and the shaft was moved outside of the holding error limit Drag Mode would drag the holding target position along as the shaft was moved preventing a rapid move back to the original position when the shaft is released SilverMax would only move the shaft back a number of counts equal to the holding error limit A significant point when using Drag Mode is that the original target position is modified This can cause the final position to fall far short of the original target position if one of the basic move commands is used MRV MRT MAV or MAT Profile Move Commands discussed in Chapter 5 eliminate this problem and the or
111. Moving Torque SilverMax has two motion states moving and holding It is always in one of these two states The holding and moving states are defined by the status of the Trajectory Generator when the Trajectory Generator is active SilverMax is in the moving state when the Trajectory Generator is inactive SilverMax is in the holding state When a motion command is running the Trajectory Generator changes the target position velocity and acceleration values every servo cycle and sends them to the control algorithm After the motion command ends the Trajectory Generator stays active for a short time as defined by the ERL command The state active inactive of the Trajectory Generator is shown in the I O Status Word It is possible for SilverMax to actually be moving while in the holding state e g turning the flywheel by hand or not moving while in the moving state e g if the shaft were jammed The moving and holding states are used only for control purposes and are not related to the actual state of the shaft When in the moving state SilverMax applies moving torque and commutates the motor in response to changes in the target position velocity and acceleration made by the Trajectory Generator When in the holding state the Trajectory Generator is inactive not changing any target values and SilverMax applies holding torque in order to maintain the position of the shaft The moving torque limit is usually set higher than the holding torqu
112. REM The Kill Motor Recovery program softly decelerates the motor to a stop Then the SilverMax re homes to encoder index Finally the back and forth motion commands are re issued Use the Kill Enable Drivers to allow Guer au to leave 2 REM the motor drivers enabled during motor shutdown i e allow continued operation SKED Kill Enable Drivers ADEM Enable Multi Tasking operation so that a Motion can E continue even when the Kill Recovery program is called 5 EMT Enable Multi Tasking EREM Set the conditions on which the SilyerMax should automatically shut down Kill Motor Conditions Peele If 1 0 3 is LOW Define the Kill Motor Recovery process that will be 8 REM used In this case a Recovery Program will be call to ae deal with the error Kill Motor Recovery 3 KMR Load and Run Program Fault Recovery 10 REM 4 simple move back and forth loop The SilverMax will Seel continue its motion until the Kill Motor Conditions are met Move 10 revs IMRT 2 FOREVER ramp time 235 92 mSec oa total time 750 24 mSec Move 8 4 revs 12 MRT ramp time 157 32 mSec total time 1100 16 mSec 13 JMP Jump to FOREWER Controlled Shutdown Initialization Program SilverMax User Manual 4 01 133 Line Oper Label Command fault has occurred 1 REM Motor drivers are sill enabled so the SilverMax can perform a controlled deceleration Velocity Mode 24MP ban pss vel 0 rps REM Re set the K
113. Run button in the Program Info Toolbar Once the program is downloaded click on the OK button The program is now running Toggle I O 1 switch LOW then back to High SilverMax will execute a simple move Toggle I O 3 switch LOW then back to High SilverMax will execute a different move Experiment with the I O switches and notice the SilverMax motion When finished close the active program Question If BOTH switches are LOW which move gets executed Why bes Exercise 2 2 Basic Velocity Mode This exercise demonstrates the basic Velocity Mode Program Mode VMP command It illustrates how simple it is to have SilverMax operate in a set velocity mode amp stop on an Input trigger Select File Open Navigate to the QCl Examples Moves basic folder and select the file Velocity Mode Program Mode ocp Click the Run button to download and begin execution of the program Once the program is downloaded click on the OK button SilverMax is now running in Velocity Mode Notice the position counter window increasing the revolution count value as SilverMax moves Push the I O 5 momentary switch to stop motion Click on the Reboot button to run again When finished close the active program This program contains only one command It has all the parameters needed for simple motion control SilverMax User Manual 4 01 38 SilverMax Memory Model Before programming SilverMax it is important to understand how t
114. SB PCMCIA or internal ISA PCI type cards These devices can also sometimes provide RS 485 ports OCI ACCESSORIES AND RS 485 TERMINATION Many of the communication accessories available from OC include the basic termination resistors built in The QCI RS 232 to RS 485 converter provides both active and passive termination selectable by jumpers With smaller networks this may be all the termination required For larger networks the OC Optical Isolation Module and Training Network Breakout provide optional connected by jumper or solder blobs node termination SilverMax User Manual 4 01 156 Chapter 10 Tuning SilverMax Servomotors Control System Overview The SilverMax factory default servo loop parameters have been optimized for a nominal load range inertial mismatch up to 10 1 for each servomotor Given a fairly tight coupling SilverMax meets the performance requirements of most systems Generally 9 out of 10 applications can use the factory default tuning parameters Some applications require servo loop tuning to match the target system One of the biggest challenges for a servo system is maintaining stable control in spite of a large mismatch between the servomotor s rotor inertia and the load inertia of the system The SilverMax PVIA servo control algorithm can be tuned to provide stable operation over a very broad range In addition it can be tuned for precise control with mismatch ratios greater than 100 1 This chapter c
115. Se E SE z SE SE GE GE ee ee S o GE WEE es hes EE pies eee E ae E E SE S SE 2 SE Ss Ss SE SE S Gel E SE E E Lat ee E D EE F SE EE 2 amp Se SE Soa SE SE Se EE See E Sc SH SE 25 e lt E ee Se ee E EE SE o SE S S SE SC E S5 S S SS S SN Se S SE is es SC ZS ee eee SE SE SS SS E SE SE E EE E SE E SS SS SN oe Sonus SRSA os SE SE SS ie se SC oe GE E E Ee Ss m SE E SE SE SE SE 3 SE Se EEN EE ee Ss ee SE SE Ss SS d oe SS SE e e E SS SE SS Se SS E geg 5 2800 00 SS Fe S Se Se E SE ec E 2 Be S a SE Sc Se S e S 3 Be SH SE SH S Ges ee f SE E SS Hie EE EE SS Ss E S SE SE SE A e SC SC S Ss ee se 4 GE i Se SC SE SC SE S S S SE E SS SS E SE SE SE pi E aB ZU e ae Se E SE SE Kp 10 Kv2 1 The Kv2 parameter has a significant damping effect on the system Setting Kv2 to 3 will provide even more damping SS SS SE i E 3 SE SE E SE sta EE e e E SE D SE 4875 00 E SE E S E E S ie 2 Se SS E SE E E Se E SC Ss S SE eed SS EE oe SE EE s 3 e Se e EE E E D S 5 S S ee es SESE CORON SE SS GO
116. SilverMax User Manual Revision 4 01 January 2003 QuickSilver Controls Inc www quicksilvercontrols com SilverMax User Manual 4 01 SilverMax User Manual 4 01 Introduction to the SilverMax User Manual The SilverMax User Manual is a technical reference designed to aid users in the operation and programming of SilverMax servomotors The companion publication SilverMax Command Reference provides details on all SilverMax commands This user manual frequently references the commands and discusses their operation For this reason both publications are needed to understand SilverMax The User Manual material is arranged in a textbook format It begins with the fundamentals of SilverMax use and progresses into advanced topics that are application oriented Any new SilverMax user can follow the material in a natural progression of product usage In addition there are exercises throughout the text that provide users a hands on approach toward understanding the topics better The manual is thorough but not exhaustive Users that explore this material fully and complete the exercises should gain the ability to operate program and prototype any SilverMax servomotor into working applications Performing Exercises Bes The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers For First Time Users T
117. SilverMax to start end or select programs using different I O combinations Special commands have been designed into SilverMax that can use I O inputs for performing motion and program flow control See the section below on programming SilverMax for more details Host amp Standalone Combined Hybrid There are times where features from both configurations are required in the system design This type of configuration is called hybrid A homing routine using over travel sensors is a good example In this type of setup using a PLC to detect over travel and stop the SilverMax introduces a significant time delay due to transmission time This time delay would allow SilverMax to travel past the switches an undesirable situation Attempting to monitor multiple SilverMax is difficult In these cases SilverMax can perform the complex motion programs while the PLC is monitoring the process and initiating the desired motions An implementation that solves this problem involves a hybrid solution A homing program is stored in one or more SilverMax The PLC starts these programs at the appropriate time using the digital I O or the serial interface The homing program moves the motors towards their home positions monitoring the I O lines tied directly to SilverMax The motion is ended as soon as the signals are detected without the delay of communication from the PLC The PLC could use a polling routine to determine when all SilverMax have reached their home pos
118. VDC 100mA power supply 4 70 3 14 e us I O lines 4 thru 7 each have a 200k Ohm effective pull E Ge Ge up impedance to the internal 5 VDC power supply 15 VO 7 DB 3 Connector This high current connector is found on most 34 frame SilverMax E series servomotors It connects an external power source to the control electronics and the servo drive DB 3 power cables are offered by OCL allowing easy connection to power sources DB 3 Plug Layout TECHNICAL DETAILS DB 3W3 Front View on SilverMax 3 contact D subminiature Socket w plugs type gender Size 20 solder cup contacts Max wire guage is 12 AWG Rated at 20 Amps per contact Shell size is std DB 15 O O DB 3 Plug to Signal Assignments 34N amp 34H Series Comments Pin _ Signal Description Power amp Chassis Grounds are internally A1 Chassis Ground connected A1 amp A3 are shorted A2 V Power Input 12 to 48 VDC A3 Power Ground Input V Input Power and Power Ground are not reverse hias nrotected SilverMax User Manual 4 0 190 SilverMax 34HC Connector Data SilverMax 34HC servomotors are designed with two connectors a DB 15 for controller signals and a DB 3 for input driver power Both are used when operating SilverMax 34HC servos DB 15 Connector This connector is found on all SilverMax E series servomotors On the 34HC series it provides access to I O lines serial communications controller power amp the drive enable signal It connects
119. Watch ee EE 78 Exercise 4 1 Using the Register Watch Tool 222 cccccceeccceeeeeeeeeeeeeeeeeeeeeeeeesseeeeeeeeeeeesenenseeeneeeeeeeees 78 SilverMax Register Based Motion Commande vk 79 Register MOV EE 79 Extended Register MOVES 1 sicct ctr geed a n anedd uaaa mites a aada Tiad e aasi 79 Nee 79 Registered Step and Direction HG 80 TUDE d EE EEN 80 Exercise 4 2 Simple Register Based Motion 80 Exercise 4 3 Complete Register Based Motion 80 Program RlOWweG Onl con ccocss aries e ais tte ts acd Oud onset od an a T eeae 81 PausSing Program FlOW E 81 MILITARIA EE cet cade an eee At EE 82 Branching and Looping EE 83 Other Program Flow ae 84 U Me DEE 84 Exercise 4 4 Cut Copy amp Paste bProgrammimg AAA 85 Chapter 5 Advanced Motion Operations een 87 Register EE 87 Register E 87 Linking Text Files QuickControl Programs AEN 88 Text File Format for Register Flener ei gece Ee ee edie eta 91 General Ga ele EEN 91 Register File Import Directives Formatting cccicicccecdecoscceesedecvtaves SEENEN DEE 91 Register File Detalls iiai eeina a E aa E a EAE OKEE AAE EEE S 92 SilverMax User Manual 4 0 V Register File Details Alternative esuen gsgeergge EE seceded saauceeneneee ences lode Sechadad eevee earner endian nad naberae 93 Register File Array Import Directives so c iccecdscckenesatonigdeeerkeudeceths AAEAEEEEEdEEERNE ENEE EAEEeEN 94 Register File Array Details eege tea ex chaste ee eege ege Eed eege er 95 T
120. Write To buffer data to be replaced is specified symbolically Label rather than with an actual memory location reducing the chance for error The QuickControl screenshot Command JRRV Register Move Relative Velocity Based shows the WCL dialog box used with QuickControl The parameters for both commands are the same QuickControl requires the register containing the value that will overwrite the old data the label of the line containing the command that will be modified and the command parameter that will actually be modified Parameter The WCW and WCL commands can turn many SilverMax commands into register based commands A simple command to do this with is the Velocity Mode Program Type VMP command The VMP command requires two parameters velocity and acceleration Normally these parameters are entered with the VMP command and are fixed until a second VMP command is issued However if multi tasking is enabled and a WCL is issued in the program this can change One WCL command can link the value in one 32 bit register to either the velocity or the acceleration parameter of the VMP command This means that two WCL commands could link the values in two user registers registers 30 and 31 for example to the VMP parameters Every time the VMP command is issued it will reference the user registers for the two parameters it requires Data in the user registers can be changed by a SilverMax program by an external host or by an an
121. a host controller such as a PC or PLC provides commands to SilverMax SilverMax waits for each command to be sent executes the command and then waits for the next command No internal program is running that would allow SilverMax to perform an operation by itself Most SilverMax commands are available to the host Some commands such as Jump JMP or Program Call PCL are only for use inside programs downloaded into SilverMax A host should not issue these class E commands The primary purpose of host configuration is to allow SilverMax to be a passive slave to the host controller waiting for each command before performing any operation This allows for extended operations not available in a SilverMax only network In cases where many axes of control are required a host configuration can achieve very complex or highly coordinated multi axis control A host controller can also retrieve from SilverMax registers Polling SilverMax Polling the SilverMax involves retrieving of data and the contents of appropriate registers The appropriate registers are selected based on the required information Polling can be used to check the current status of the SilverMax for data such as errors command completion and other general information A host controller can use this information to assist in motion coordination and error checking The information retrieval is implemented by a host controller periodically perform a polling routine The most basic routine
122. abalnnenties 36 Basic SilverMax Ee lun aaa hte rt a ate ea Ae ek He Bsa baa cro fo lw 36 SilverMax User Manual 4 0 iii Belzatte Mltbgtt ee Neocon decane Eege dE 36 Absolute Moun reroncene iaia E E EENS EE ENEE 36 Velocity Based M ttes eaeoe aenar anah aAa geg EAA ERARAS Pao Esaa AAA DiN qua beans seamen jecesnee ebone 37 Time e Mere DEE 37 Velocity GONG EE 37 S G rve EE 37 Exercise 2 1 Basic Motion Commands amp JUMP Commande ne 38 Exercise 2 2 Basic Velocity Mode c2 s pcciccteis etedscnedss dcsasnsnentedenivadeccukatecuely teste vatenteatelasnecsaieleepeletaa sled 38 SilverMax Memory EE Ee 39 Serial lant Me le 39 es 60 8062 Ua alm UL C2 E 39 Me EE A0 Non Volatile Memory EE 41 e geen EE 41 SilverMax Memory Management AANEREN 41 SilverMax Program EEGEN 42 elen ee Tee EE 43 Moti n COMMANGS EE 43 Flow Commands EE 43 Mode Commands resan a a AE EEE a ae Teea E deeds a AE ETA E Eaa AE eaaa aa aE nai Tei 43 Data Register Commands EE 43 Miscellaneous and Initialization COMMANGS sczcscvecesseseed cee saves adies anceedemeeiesssdadspassedeusst pent heneeervese tena peac one 43 Program Flow Controla EE 44 C nditional Program FOW ca cls acd een RG a em ce a e Sees OG ada Aaa EE OEE EAA Ea 44 Using Digital I O for Flow Control EE 44 Exercise 2 3 Creating Downloading and Running a Program in OutcktControlf 44 Exercise 2 4 Troubleshooting a QuickControl Program cceceeceeeeeeeeeeeeeeeeeeeeeeeeesenaa
123. ace displaying the available inputs and conditions Clicking OK in the command window will add the command to the program Stop conditions will be displayed in QuickControl Communications Edit MAT Move Absolute Time Based The same stop conditions presented within QuickControl are available when sending commands from a host The following is a list of the inputs and their codes Stop Enable Code Input Source Description 0 Do not Check for Input 1 Hardware UO 1 2 y UO 2 3 S UO 3 4 UO 4 5 UO 5 6 i UO 6 7 de UO 7 8 E Reserved 9 KR Internal Index 10 lt External Index 11 Internal Status Moving Error 12 d Holding Error 13 Trajectory Generator Active 14 de Delay Counter Active Stop states are setup using the following parameters Stop State Stop on the Following Condition 0 FALSE 1 TRUE 2 FALLING TRUE to FALSE Transition 3 RISING FALSE to TRUE Transition For example to issue a Velocity Mode Immediate VMI command that will stop when UO 7 is high the following string would be issued See SilverMax Command Reference for details on the VMI command 16 15 200000 100000000 7 1 lt CR gt SilverMax User Manual 4 01 72 Advanced Stop Conditions Only four inputs are available when using the advanced conditions The index and I O lines 1 2 and 3 Advanced stop is used for situations when stopp
124. algorithm the Velocity Feedback parameters Kv1 and Kv2 act as shock absorbers Velocity Feedback Kv1 amp Kv2 Velocity values are derived from the position information read every servo cycle 120 microseconds Velocity is calculated from the change in position each servo cycle Velocity data is filtered by two cascaded low pass filters providing a once filtered value Velocity 1 and a twice filtered value Velocity 2 Both velocity values have a gain setting that is used to adjust the amount of velocity feedback Velocity feedback is negative feedback used to dampen the servo control loop Setting the velocity feedback gain values to zero removes all velocity feedback from the control loop Kv1 is typically set to 0 Most applications have no need for a Kv1 greater than zero Kv1 is only necessary for high frequency response applications i e 10ms move In these situations the extra filtering done to calculate Velocity 2 does not accurately represent the load s velocity Kv2 is typically the only velocity feedback used Kv2 is analogous to a shock absorber coupled with a spring The more Kv2 increases the more damping the shock absorber provides With Kp only SilverMax would oscillate to a stop during every move Even the smallest amount of Kv2 adds noticeable damping to the system The following plot has the same settings as the previous chart except Kv2 1 SilverMax User Manual 4 01 164 E SE EE EE A SC z e
125. ally limit the maximum torque it produces With a tight torque limit there is a much smaller risk that SilverMax will break a delicate part or burst past a stop Open loop torque limits also explicitly define the level of torque output when using open loop control Torque limits are used in many ways by SilverMax and a solid understanding of them is vital to a good understanding of SilverMax itself SilverMax always operates with either closed loop control or open loop control SilverMax also always applies either holding or moving torque This gives four possible operating states for SilverMax A separate torque limit can be set for each different control state using the Torque Limits TQL command The differences between holding and moving torque and between closed loop and open loop control are very important as is the way that SilverMax uses and reports torque internally This section covers SilverMax torque limits the four different control states of SilverMax and the TQL command SilverMax User Manual 4 01 52 Open Loop and Closed Loop Control SilverMax uses software for all of its control functions This allows SilverMax or a host controller to change the control constants filter values and even the control algorithm dynamically One of the control system properties that can be changed is whether the control system uses open loop or closed loop control The difference between closed loop and open loop control can be illustrated with a t
126. alog input tz Exercise 3 4 Dynamic Speed and Acceleration Adjust This exercise uses multi tasking with Write Command Buffer Longword WCL commands to dynamically adjust the velocity and acceleration parameters of a Velocity Mode Program VMP command The parameter data is loaded into two registers directly by the user This program consists primarily of a loop that contains two WCL commands and a VMP command The WCL commands move data from register 25 and register 26 into the velocity and acceleration parameters of the VMP command respectively Using the Register watch tool both parameters of the VMP command can be modified In a real world application a host could issue Write Register Immediate Type WRI commands via serial communications to change the parameter values Additionally the Calculation CLC command can be used to modify the register data 1 Within QuickControl select File gt Open and navigate to QCI Examples Applications and select the file Dynamic speed amp accel in VMP qcp SilverMax User Manual 4 01 68 2 Click the Run button to download and execute the program The motor will NOT start moving since the default Velocity is 0 rps and the default Acceleration is 0 rps s 3 Open the Register Watch Tool Tools gt Register Watch Click the Add Register Button and select User 25 select Velocity for the Data Format and click OK Repeat again for User 26 except select Acceleration for t
127. am New Program Creates a new blank program Delete Program Deletes selected program Program Details Allows a user to name describe and modify the stored location of a program Scaling Allows a user to adjust scaling parameters and max min ranges Register Files Links register files or file arrays txt based to active QuickControl program Register Names Assigns user defined names to registers I O Names Assigns user defined names to I O lines Run Program w o Save Runs current program without storing the program to NVM Erase Application in Device Erases current program in non volatile memory Toggle Breakpoints Toggles Breakpoint at current line Clear all Breakpoints Clears all Breakpoints in all programs Tools Menu SilverMax Initialization Wizard Sets up and initializes SilverMax servos Unknown SilverMax Wizard Establishes communications with a SilverMax unknown parameters SilverMax Control Panel Tool for Jogging Tuning and Monitoring SilverMax Register Watch Change and or view data in the SilverMax data registers with this utility Data Monitor Monitor all data sent and received by SilverMax and the PC Rev 3 1 Tools Rev 3 1 Tools Menu Tools available in previous QuickControl versions Use only with Legacy Series of SilverMax DO NOT use any of these utilities as an alternative to existing utilities for any E Series SilverMax Jog SilverMax Jog utility within 3 1 Initialize SilverMax
128. an actually be any compatible signal source e g a function generator PLC or another SilverMax The maximum sustained input pulse frequency is 1 MHz per line The Select Encoder Filter SEF command sets a filter that is used with the high speed input functions The minimum pulse width for an input signal is 400 nanoseconds with the filter off and 850 nanoseconds with the filter on Step and Direction Signals A step and direction signal consists of two parts a step signal and a direction signal As the figure shows every rising edge of the step signal equals one count The direction signal is high for one Step Pulse direction and low for the other The scaled internal encoder modulo output and the external Direction Signal encoder input functions can both use a Step and direction signal Direction ce ke N oO E E St S 3 e D e O Gi O Step and Direction Signal Step Up Step Down Signals A step up step down function consists of two step signals One step signal corresponds to one count of motion in one direction while the other step signal corresponds to one count in the other direction Step Up Direction Change N m E C c bei 3 bei Q Q Q O O O The step up step down signal can be used by the modulo output function and the external encoder input function Step Down The Step Up Step Down signal type is NOT available with the internal encoder output function Ste
129. an transmit only 31 bytes at a time Break the request into multiple packets Bad Response Packet Request SilverMax Protocols 8 bit ASCII Communications SilverMax packets in the 8 bit ASCII protocol consist of standard ASCII characters A space character delimits the components of the packet Command Packets 8 Bit ASCII Command Packet Data Transmission Order Start Character ID Command Num Parameters Ending Character 1 3 1 10 bytes for 1 Byte Bytes 1 3 Bytes each parameter 1 Byte lt CR gt START CHARACTER For the 8 Bit ASCII command packets the start character is the symbol Any characters sent before the are ignored including responses from other units or communication between other devices Following the symbol one or more space characters may be inserted but are not required SilverMax User Manual 4 01 143 SILVERMAX ID The target ID is transmitted as the ASCII representation of the number For example to transmit the default unit address of 16 transmit the ASCII code for 1 followed by the ASCII code for 6 COMMAND NUMBER The command number is transmitted in the same fashion as the ID The ASCII space character must be transmitted between the ID and command number PARAMETERS Any parameters are transmitted in the same fashion as the ID and command number The ASCII space character must be transmitted between the command number and the first parameter A space must also
130. and Holding ERL LW 209 The direction Sense Mask HW defines the direction of shaft rotation clockwise or counter clockwise in relation to positive data parameters of position and velocity The low word FLGINP contains the I O Status Word used with all motion commands I O jump commands and wait commands 211 May be used to determine the cause of a triggered Kill Motor operation These registers are written internally whenever the Kill Motor operation is activated They may be overwritten to zero to make conditional testing of a triggering event easier Kill Conditions HW and Kill States LW 212 Contains the filtered ADC readings for Analog Input1 HW and Analog Input 2 LW Allows these inputs to be monitored from the serial port without program involvement or stopping program operation 213 Same as 212 but for Analog Input 3 HW and Analog Input 4 LW 214 Contains the filtered ADC readings for the Main V drive voltage HW and the Controller Processor temperature LW Temperature data is in a raw format and requires scaling for degree C output 215 Contains filtered ADC readings for HC processor voltage HW and HC driver temperature LW Note that the calibration for the processor power is different than that for the driver power The HC driver temperature does not follow the same scaling equation as for the processor temperature The HC driver temperature can be approximated using Temp centigrade ADC value 2230 2
131. ange of commands to the SilverMax and can read SilverMax internal states like temperature and position Recommended Setup A typical external host configuration using recommended parts is shown below In this configuration the SilverMax servomotor is connected to a QCI breakout module and the breakout module is connected to the external host and the SilverMax power supply Any network connections or I O points used in the system are connected to the external host not the SilverMax The host controls all motion by issuing commands to the SilverMax using the serial connection between them 1 0 QCI Network Breakout Host Configuration Recommended Parts List SilverMax servomotor QCI breakout module 12 to 48 VDC power supply Host device PC PLC HMI Vision System etc SilverMax cable Serial communications cable Power supply wires NO OAO Na Generic Host Setup As with a standalone configuration SilverMax can be configured for host operation without using a breakout module or QCI cables the QCI equipment is recommended because it usually reduces installation problems and makes troubleshooting easier The most generic setup possible for SilverMax in host mode is connecting the SilverMax to the external host and then connecting the host to power and to any other system connections necessary UO points network connections etc This type of setup can be simpler than the one recommended by QCI but has the possible disadvanta
132. arded SilverMax User Manual 4 01 66 e Shift Reg Right w o Sign Extend This command is identical to Shift Reg Right w Sign Extend except that a zero is placed in bit 31 of the selected register e Sub i e Acc Acc Reg This command subtracts the value in the selected register from the value in the accumulator and stores the result in the accumulator e Sub Target Position i e Targ Reg Pos Reg This command subtracts the value in the selected register from the Target Position and Actual Position registers registers 0 and 1 For additional details on the CLC command refer to the QCI application note on the CLC command and to the SilverMax Command Reference D Exercise 3 3 Calculation Example This exercise demonstrates the use of several different functions of the Calculation CLC command It begins with a long move calculates half the distance moved and moves back that amount It is strictly a demonstration of the CLC command The Wait on Bit State WBS command serves to pause the program Pushing and releasing the momentary I O 5 switch will cause the program to pause then move 1 Power up the SilverMax and start QuickControl Start polling the motor and verify that the system is operating properly 2 In QuickControl select File gt Open Navigate fo OC Examples Data Register Calculations and select the file Register Moves by half with Calculation qcp 3 Click the Run button to download and run
133. aw ram address HW lt i gt MSTATE loading command when error occurs LW QuickControl use 229 R W STEP4 lt gt STEP_SHFT Used to configure Encoder resolution Directly affects servo operation Set by Factory block 230 R W ENC_GAIN1 lt gt ENC_GAIN2 Used to configure Encoder resolution Directly affects servo operation Set by Factory block 231 R W Factory configuration information Do not write Set by Factory block 232 R O_PHASE lt gt C_PHASE Used for servo calibration Set by Factory block 233 R Used for servo calibration Set by Factory block T Data register contains two independent 16 bit data words R Read Only R W Read and Write Note Use caution when writing to 200 level data registers as some retain factory specific data Changing the data in specific registers may cause operation problems with SilverMax SilverMax User Manual 4 0 179 Detailed Descriptions of Specific Data Registers 206 amp 207 Provide an alternate way to set the servo torque at any time from the Serial Interface These may be altered within a program while a motion is in progress if multitasking has been enabled Reg 206 has closed loop data 207 open loop data Holding torque HW and moving torque LW for both registers 208 Provides an alternate way to set the error limits from the Serial Interface or from within a program while a motion is in progress if multitasking has been enabled Moving ERL HW
134. be included between multiple parameters ENDING CHARACTER The final character is an ASCII Carriage Return represented in examples as lt CR gt The carriage return signals the end of the Command Packet SilverMax will begin processing the command once this character is received A space may be included between the final parameter and lt CR gt but is not required Example Send a Read Register RRG command Command RRG Command Number 12 ID 5 Data Register 1 Fields with data shown in ASCII Start Char ID Cmd Data Register End Char lt CR gt dec 13 5 12 1 Byte stream with data shown as an ASCII String 5 12 1 lt CR gt Example Send a MOVE RELATIVE TIME BASED MRT command Command MRT Command Number 177 ID 16 Distance 4000 counts Ramp Time 833 ticks 1 tick 120us Total Time 8333 ticks No stop conditions Fields with data shown in ASCII Ramp Total Stop Stop Start Char ID Cmd Distance Time Time Enable State End Char 16 177 4000 833 8333 0 0 lt CR gt Byte stream with data shown as an ASCII string 16 177 4000 833 8333 0 0 lt CR gt SilverMax User Manual 4 01 144 POLL COMMAND The Poll POL command number 0 command is the most commonly transmitted command A special packet may be used in place of the standard POL packet The command number is dropped to make the packet shorter and he
135. bit ASCII for Choose 9 bit Binary for an easy to implement protocol time critical communications non time critical communications error checking for electrically noisy minimal programming requirements environments human interpretable data Consistent data length transmission compatibility with most devices drivers time The choice between RS 232 and RS 485 is dictated primarily by system size and environment RS 232 is generally only suitable for systems with less than five nodes and less than 50 feet of total cable RS 232 has the advantage of being easy to set up requiring only three wires to each SilverMax RS 485 is capable of connecting up to 64 servos and up to 1000 foot cable runs RS 485 also improves the noise immunity of the system making it the suitable choice for operation in electrically noisy environments OC SilverMax User Manual 4 01 141 also has several additional hardware components available for electrically noisy environments RS 485 usually requires extra communications hardware such as converters or termination SilverMax Communications Communication Port Settings Successful communication with SilverMax requires that both the host and SilverMax serial ports have matching settings The host must be configured for 1 start bit and 1 5 or 2 stop bits 2 being preferable as this improves the robustness of communications This setting is fixed within SilverMax The baud rates of SilverMax and the host must also be set to
136. ble The table below lists all ten 10 user adjustable tuning parameters in the PVIA algorithm These parameters are used in the calculations of the PVIA algorithm that controls the position of the SilverMax when in motion or stopped Each parameter has its own individual influence on SilverMax operation but most of the parameters work in conjunction with one another For example velocity and acceleration feedback filters have a frequency setting for rolling off high frequencies that may cause system instabilities and noise In addition velocity and acceleration feedforward parameters are used to SilverMax User Manual 4 01 161 compensate for position lag effects of the velocity and acceleration feedback gains All of these parameters can be manipulated in order to configure or tune the SilverMax to minimize motion error and overshoot SilverMax Tuning Parameters QuickControl Variables Typical Parameter Range Proportional Gain 40 400 Velocity 1 Feedback Gain 0 Velocity 2 Feedback Gain 5 50 Velocity Feedforward Gain 5 50 Acceleration Feedback Gain 0 200 Acceleration Feedforward Gain 0 200 Integrator Gain i 0 2000 Velocity 1 Feedback Filter 50Hz 200Hz Velocity 2 Feedback Filter 70Hz 400Hz Acceleration Feedback Filter 30Hz 2000Hz User Adjustable SilverMax Tuning Parameters Proportional Gain Kp Proportional gain Kp is the simplest component of the servo loop Pos
137. bugging tools to support SilverMax programming Four powerful tools are available to the user Single Step Trace Breakpoints and Test Line NOTES The default QCI Examples folder is located at C Program Files QuickControl QCI Examples The Red Stop Hand Icon on the Main Icon Toolbar will allow the user to quit operation of any Tool SINGLE STEP 1 Using the File menu open the following qcp program QCI Examples Moves basic Move Examples qcp 2 Click the Single Step button on the Program Info Toolbar This will initiate the execution of the first command found in the program 3 Continue to click Single Step until the end of the program file Click on the Red Stop Hand Icon TRACE Use the Trace tool on the same QuickControl program file SilverMax User Manual 4 01 45 1 Click on the first line of the program and then click the Trace button once This will initiate an automatic step by step execution of the program commands one line at a time 2 The Trace tool will continue through the program until it reaches either a Breakpoint a program error or the end of the program When complete click on the Red Stop Hand Icon BREAKPOINTS Breakpoints are set on lines by highlighting the desired line and selecting Toggle Breakpoint from the Programs menu The line should change color to Red The function key F9 is a shortcut to toggle breakpoints on amp off 1 Seta breakpoint on line 6 and select Trace from the Program I
138. cific function like a loop counter can be named as such just like the Input Mode registers and the Profile Move registers If the QCP file does not use Profile Move or Input Mode functionality these registers can have descriptive names set as desired Access the Register Names dialog window from the Programs pull down menu or from within the Scaling dialog window found in the Program Info Toolbar 90 Text File Format for Register File Import An integral feature of the Register File System is its ability to dynamically link text files containing data to a QCP file that uses the data These text files must reside in the same Windows directory as the QCP file that calls upon them In addition the text files must be formatted in such a way that allows QuickControl to read the data and reallocate it to SilverMax non volatile memory This is achieved through Import Directives and Details Subtle differences exist between the Import Directives and Details of a Register File and a Register File Array Alternative detail methods are also shown for different programming styles and efficient memory use General Formatting The two formatting parameters listed below are used in Register Files as well as Register File Arrays Comments Any line preceded with a semi colon is considered a comment and is ignored Example Comment File Include lnclude A File Include may be placed anywhere in the file and incorporates the listed file name as if
139. comes the drive enable signal line 10 O 5 WEN 5 TO 6 In this configuration it has a 4 7k Ohm pull down resistor 15 VO 7 connected to the internal logic ground SilverMax User Manual 4 0 189 SilverMax 34N amp 34H Connector Data SilverMax 34N and 34H servomotors are designed with two connectors a DB 15 for controller signals and a DB 3 for input power Both are used when operating SilverMax 34N amp 34H servos DB 15 High Density Connector This connector is found on all SilverMax E series servomotors On the 34N amp 34H series it permits access to I O lines serial communications and the drive enable signal It mates to all SilverMax DB 15 SMI cables for easy connection to many QCI Accessory Products TECHNICAL DETAILS DB 15HD 15 pin High Density D subminiature Plug w pins type gender Crimp type contacts Rated at 5 Amps per contact Max wire gauge is 20 AWG Shell size is a std DB 9 DB 15 Pin Layout Front View on SilverMax DB 15 Pin to Signal N amp H series Pin Signal Description 6 NC No Connect Signal Comments 1 Drive Enable 11 NC Drive Enable operates from a DC voltage range of 10 z ae BEE to 48 to enable the servomotor drive It is commonly S 232 Tx e EE connected to the V driver power supply when not used 8 Logic Ground independently 3 5 VDC Supply 100mA max 13 70 1 I O lines 1 2 amp 3 each have a 4 7k Ohm pull up resistor 9 VO 2 connected to the internal 5
140. cond Set this bit to invert the Last They are both triggered if the Check Conditions if the First Check conditions if the First First Check Conditions are met Check Conditions are met Check conditions are met First Check Conditions Bit 14 Input 3 enabled Input 3 State These three bits are used to set Bit 13 Input 2 enabled Input 2 State the conditions Bit 12 Input 1 enabled Input 1 State Second Check d Se E SilverMax moves to its programmed location if the Second Check Conditions are never met Last Check e Sen A If both types of conditions are enabled both sets must be met to stop the servo i Ee GE If the Last Check conditions are met SilverMax will stop and register 4 is updated SilverMax User Manual 4 01 75 Advanced Stop Parameters The input values that are used as parameters in an advanced stop condition take a little work to create Inside SilverMax the values are in binary form Both the 16 bit words must be specified as part of the command Each of the bits is evaluated individually to determine how the inputs will be used to control a motion The previous table shows the meaning of each bit in the words The process begins by choosing which bits need to be set and to what value Setting a bit to 1 in the Stop Enable Word selects that input for use Setting the corresponding bit to 1 in the Stop States Word sets the condition as logic high 5 volts on the input Setting a bit in
141. core the JMP command to loop through the number of desired iterations A register is used for the loop counter and the Calculation CLC command has a decrement option that can be used to subtract one from any data register SilverMax User Manual 4 01 Et THEN Command This is an example of an JE THEN ELSE statement d the a number is Positive move Clockwise Else if the number is i Negative move Counter Clockwise If the Number is Zero i don t move User Data Register 11 is a data value to be tested Copying i Register 11 in the accumulator Accumulator 1 DI User 11 Jump to ELSE If Last Calc was not Positive Move Clockwise Move 4000 counts ramp time 99 96 mSec total time 999 96 mer Jump to END IF If Last Calc was not Negative Move Counter Clockwise Move 4000 counts ramp time 99 96 mSec total time 999 96 mSec ND IF End Program Command NEX am END This is an example of a FOR NEXT loop Loop a program 10 times using Data Register 11 as the loop counter When the count 0 end the program User Data Register 11 is a data value for the counter Write 10 to User 11 Register Copying Register 11 in the accumulator 10 will test for gM Accumulator 10 User 11 Jump to END If Last Calc was Zero Cause 1 0 line 1 to go Low Clear Output Bit 1 Delay for 500 mSec Cause 1 0 Line 1 to go High Se
142. ct Support Office before modifying the K factor FLC Filter Constants Line 33 These constants select the cutoff frequency for the velocity and acceleration tuning filters These filters help minimize high frequency noise The SilverMax default values can be changed by unchecking the Use Default For SilverMax checkbox These values are modified when using the QuickControl Control Panel for tuning See Chapter 10 for a complete discussion on tuning SilverMax SilverMax User Manual 4 01 24 CTC Control Constants Line 35 This command sets the various servo loop gains used for tuning the SilverMax Variations of these constants allow oscillations and error to be minimized See description and Command Reference for definitions These values are modified when using the QuickControl Tuning Tool See Chapter 10 for a complete discussion on tuning SilverMax GOC Gravity Offset Constants Line 37 This command sets a custom gravity offset term in the servo control loop for vertical load applications The gravity offset value increases torque by the given amount for moving loads against gravity and decreases torque by the given value for moving loads with gravity DIR Direction Line 40 Select which direction that will correspond to positive motion values Viewing SilverMax from the shaft end references the direction This command can only be issued once do not issue again in a user program TQL Torque Limits Line 50 This command cha
143. ction scheme supplied by an external power source If the wire gauge is sufficient to carry the required current the entire SilverMax network can be supplied with power from a single pair wire buss networked to each servomotor For example a standard 23 frame SilverMax has a peak operating current of 2 5 Amps In a network of three such servos a total of 7 5 Amps is required if all units will be operating at peak power The power wires connectors and power source should be reliable and rated for the application In this example assuming total network cable length is less then 10 ft 16 to 18 gauge stranded wire can be used for power lines A heavier gauge supply wire for long lengths will reduce voltage loss that can decrease high speed power output from SilverMax Example Wiring Diagrams RS 232 This interface can be directly connected to SilverMax The wiring is called a null modem configuration because the Tx line of the host is connected to the Rx line of the servo and vice versa RS 232 Communications Host PC or PLC Power V Gnd Rx Tx Power Supply 12 to 48 Volts SilverMax SilverMax User Manual 4 01 153 RS 232 Network Up to five SilverMax can be connected on a single network This is available from the advanced communication chip within SilverMax To implement this mode use the ACK Delay ACK command with a non zero value typically 2 3 msec This causes SilverMax to tri state its transmit line when not in use
144. d for maximum resolution It is an unsigned 30 bit number giving a range of 0 to 1 073 741 824 The maximum value corresponds to 277 777 rps s This value is not physically attainable with values at one percent of this value or less being typical e Time SilverMax is measured in servo cycle clock ticks The clock is 8 33 kHz and therefore a tick is equal to one servo cycle or 120us It generally takes one servo cycle to execute one command All time parameters must be integer multiples of ticks SilverMax User Manual 4 01 32 When working with SilverMax native units it is generally simplest to transmit native units directly from the host However use of the Calculation CLC command allows SilverMax to make the scaling corrections internally The CLC command is covered in Chapter 3 and an Application Note Scaling Engineering Units in QuickControl The QuickControl software provides automatic scaling to normal engineering units It also makes command and parameter generation a simple point and click process By default distance is displayed in counts velocity in counts per second acceleration in cps sec and time in milliseconds The basic distance unit can be adjusted by clicking the Scaling button This brings up the Program File Properties window Program File Properties ee EE x Scale equals counts position unit Scale i fc MA he reo Encoder Counts Rev CPR Acc IER Bee Min H 00000 counts 4000 7 _GecPR vel 80
145. d the ways SilverMax responds to different motion commands when multi tasking is enabled SilverMax Servo Cycle SilverMax uses a 120 microsecond period for its digital control calculations This period is called the servo cycle All SilverMax functions including command execution are synchronized by the servo cycle When multi tasking is enabled with a few exceptions such as a delay or wait command a command ina SilverMax program takes one servo cycle to execute When multi tasking is disabled SilverMax still performs its regular functions like servo calculations and communications every servo cycle but does not execute program commands if a move operation is still underway i e the Trajectory Generator is active The tasks SilverMax completes during each cycle are shown below Notice that the serial communications task is completed three times per servo cycle Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Serial Every 120 Communications Program Motion Update Status Command Command Words and Execution Execution I O Error Checking Serial Servo Control Communications Loop Serial Communications SilverMax User Manual 4 01 61 Task 1 Serial Communications SilverMax checks for serial communications every 40 microseconds or three times per servo cycle During each 40 microsecond period SilverMax can send or receive one ASCII character if using the ASCII communications protocol or eight bits of
146. data if using the binary protocol Chapter 9 covers serial communications in detail Task 2 Servo Control Loop If set to closed loop control SilverMax updates the output of the control algorithm every servo cycle When using open loop control the control loop is bypassed Task 3 Program Command Execution If a SilverMax program is running the program buffer will have at least one command in it If multi tasking is disabled SilverMax will execute the next command in the program buffer only if the last command has finished executing If multi tasking is enabled SilverMax will generally execute a new command from the program buffer every servo cycle although there are exceptions The way SilverMax treats different motion commands when multi tasking is explained in the next part of this section Task 4 Motion Command Execution When SilverMax receives a motion command either by reading the next command in the command buffer or by receiving an Immediate command from an external host the Trajectory Generator goes active and the move starts If multi tasking is disabled SilverMax will not execute the next command in the program buffer until the move is complete If multi tasking is enabled the next command in the program buffer will be executed as soon as the Trajectory Generator goes active and the move starts Task 5 Update Status Words and I O SilverMax updates each bit of the three status words and checks or changes the I O sta
147. data stored in native units 2624 2 310 2626 2 320 2628 2 330 SilverMax User Manual 4 01 96 Techniques for Stopping Motion When using dynamic systems to control complex motion provisions for stopping movement and exiting those operations must be addressed SilverMax has the functionality to accomplish this through software or through hardware on some models via the Drive Enable option Software Stop Options The commands described below are the software stop options available to stop SilverMax motion All of these options are part of the SilverMax Command Set and can be used as interrupts to stop motion as described below Some commands initiate immediate stops while others allow for a predetermined deceleration profile Immediate stops use maximum acceleration available and consequentially maximum current available to stop SilverMax as quickly as possible immediate stop options generate a significant amount of back EMF that could damage the driver circuitry or motor windings of SilverMax Technical Document QCI TDO0006 contains more information regarding QCI voltage clamp modules that dissipate dangerous back EMF When designing a stop for SilverMax motion consider the move velocity load inertia available back EMF protection and importance of the stop condition The Stop STP command not only stops the present motion but also exits the current program and puts SilverMax into a holding state once stopped The STP c
148. der Inputs Maximum Bandwidth 1 MHz per I O line Analog Inputs Analog inputs 1 to 4 are mapped to share digital I O lines 4 to 7 Input Signal Range 0 to 5 VDC Resolution ADC 10 bit single channel 11 bit differential channel Each input has an effective internal 200K ohm impedance to 5 VDC Analog signals are read every servo cycle 120 usec and the converted analog data is processed through a5 ms filter to reduce noise amp transients The filtered digital data is updated every 120 usec Communication Specifications Serial Communications Hardware Interfaces RS 232 RS 232 multi drop or RS 485 multi drop software selectable Protocols 8 bit ASCII or 9 bit binary software selectable Communication Line Protection Each line is protected with MOV clamping devices Hardware Configuration Settings Available Baud Rates 2400 4800 9600 19 2k 28 8k 57 6k 115 2k or 230 4k Data Bits 8 Stop Bits 1 50r2 Parity Bit None SilverMax User Manual 4 0 175 Servo Control Specifications Encoding Resolution Internal 4000 counts rev 0 09 deg count Standard on all 17 17H 23 23H 34H 1 and 34N 1 servos 16000 counts rev 0 0225 deg count Standard on all 34HC servos 8000 counts rev 0 045 deg count Optional for 17 and 23 frame servos EA option Servo Cycle Rate 120 microseconds 8 33 kHz Software Torque Control Signed 16 bit control 1 part in 32767 Internal Memory Serial Communications Bu
149. djusted to cm based on the actual system output The Min Max section on the right sets minimum and maximum values for all parameters entered into QuickControl Typical values are supplied by default and can be changed at any time These are provided strictly as a convenience to keep parameters from exceeding the maximum allowable values Other Features of the Program File Properties Window There are several other settings unrelated to scaling available in the Program File Properties window The program upload feature available in QuickControl includes encrypted password protection The desired password is set in the Upload Password box the default is 1234 There are also buttons available to create custom names for registers and I O lines For more information on register and I O names see Chapter 4 All contents of the Program File Properties window are stored as part of the qcp file SilverMax User Manual 4 01 33 Operating SilverMax in Host and Standalone Configuration SilverMax can operate in two distinct configurations host and standalone each of which meet different system design needs A host configuration involves an external controller governing each operation of the SilverMax Standalone configuration is when the servo is operating completely independent of any other controller These configurations can be combined in a number of different ways to form a hybrid system design Host Configuration In this configuration
150. down menu This brings up the same window displayed when a new program is created On the right side of this window is the Memory Management section This shows the NV memory storage address assigned to this program automatically by QuickControl and the total NV memory size of the SilverMax To override the automatic NV memory assignment check the Manually Set Address checkbox and enter a NV memory address into the Store Program into box If automatic memory management is not used then the NV addresses must be independently tracked to prevent programs from overwriting each other or otherwise interfering with themselves the Initialization program or stored data Overwritten programs and data may result in a SilverMax fault condition which will stop program execution If the Initialization program is overwritten SilverMax may be unable to operate Unless the system operation requires manual memory control it is best to let QuickControl manage the NV memory storage Program Details Se i E Cancel Manually Set Address E Check to enable manual addressing Program Name r Memory Management Description Store Program into Non Volatile 512 Memory starting at Non Volatile Memory Size 3833 Percent Used jo Program Description Specify address to store program SilverMax Program Execution SilverMax programs are constructed from a series of program type comman
151. ds Programs enable SilverMax to execute complex operations independent of any external controller Programs can consist of commands from the following categories Initialization Motion Program Flow I O Data Register and Miscellaneous Programs can be created and edited using QuickControl SilverMax User Manual 4 01 42 Creating programs involves combining a series of commands together in the desired order downloading the series of commands into the SilverMax and optionally storing the series of commands the program in the non volatile memory Only program type commands can be stored as part of aprogram See the Program Types section earlier in this chapter How Programs Operate Programs execute commands sequentially starting at the first line and continuing until the end of the program or until a command with override capability is issued from a host See the SilverMax Command Reference for details on command classes and which classes can override executing programs Programs can perform conditional branching providing the ability to modify their behavior or start a different program Program lines typically execute the command each servo cycle 120 usec If a command requires only one servo cycle to execute the next program line will execute on the next servo cycle Some commands block pause the process of executing the next line program execution while the command completes Commands from different categories influence program execu
152. ducing the chance of invalid data errors Each command dialog box also includes a description of the command for easy reference Troubleshooting The most painstaking part of almost any development project is troubleshooting the prototype QuickControl not only has many of the common tools for debugging such as trace and single line execution but also includes several tools that allow access to registers and to the command and data packets that are actually transmitted and received by the SilverMax Tuning SilverMax can be tuned for very high inertial mismatches and for systems with difficult plants such as systems that include a highly elastic element like a belt QuickControl includes tools designed to make the tuning process as efficient and effective as possible including a built in strip chart tool that can track position velocity torque and error Housekeeping QuickControl includes several tools to manage simple tasks like saving and loading programs and cutting and pasting commands between and within programs as well as more advanced tools like a program upload retrieving a program from a SilverMax tool and a firmware upgrade wizard SilverMax User Manual 4 01 6 Getting Started with QCI Start up Kits The following pages are designed to be a quick start up guide for new SilverMax users Most of the information applies to QCI Start up Kits and will take a user who is unfamiliar with SilverMax through the process of putting togeth
153. e Mark data 1 5 VDC min 1 5 VDC min A gt B 15 VDC max 5 VDC max A gt B Input Level Minimum 3 VDC 0 2 VDC difference 500 mA Output Current Note driver ICs normally used 250 mA in PCs are limited to 10 mA 1 SilverMax supports multiple units up to 5 with RS 232 when an ACK delay greater than 0 is set Space data 0 RS 485 specifications allow for 32 nodes devices with full load receivers per network SilverMax uses 1 2 load receivers and allows up to 64 nodes devices per network 3 Actual transmission speed limited to the SilverMax baud rate See the Additional Information and Troubleshooting section of this chapter SilverMax User Manual 4 01 151 Choosing RS 232 or RS 485 Simplicity The simplicity of setting up RS 232 makes it the default choice for most applications It is recommended unless RS 485 is required for one of the following reasons Nodes RS 232 can support at most five nodes in one network Further this size can only be achieved with a high quality host serial port and cabling An RS 485 SilverMax network will support up to 64 nodes with standard equipment Large networks require RS 485 Cable Length RS 232 will support up to 50 foot cable runs at 19 2k baud and 10 foot runs at 57 6k baud This also requires high quality equipment RS 485 will support up to 4000 feet making it the choice for geographically large networks Noise RS 232 provides very little n
154. e SS SE E E E SE SE E S E SE SE SE SS E SE SE E SE SS SS CH iei ee z S E e SS S E SE ES ss B E SE SC SE E 8 200095 SE E SE SE SE es E aes S e GE SE SS SE S SE EE SE Ce SC Sa SE EE EE E SE as E S Se 3 EE E ee es E SS S SE SE SE SE o ae oe See SE SE EE 163 SilverMax User Manual 4 01 Although less error is required to generate sufficient torque SilverMax overshoots once SilverMax gets moving SilverMax does not come back until enough negative torque is generated Increasing Kp will continue to have this effect Strip Chart Y Minj Y Maxf5200 Sample ms 200 POR Select Channels Cancel slala la Em ae SPANO deiere Kp 10 Using the spring analogy again by increasing Kp the spring stiffness is increased Typically Kp is increased to achieve the desired stiffness and reduce position error Although SilverMax is moving to the target in a timely manner there is noticeable overshoot Thus if Kp is large SilverMax will start vibrating as it overcompensates for small errors This is the same principle as a car with no shock absorbers The springs work fine but every time the car hits a bump the car bounces several times To eliminate the bounce shock absorbers are added to the car In the PVIA
155. e CKS are true bit 6 on the Polling Status Word will be set The purpose of this is to add functionality to the Polling Status Word by allowing one or more conditions of the Internal Status Word to be flagged If a host detects that bit 6 on the Polling Status Word is set the host could then check the Internal Status Word the host essentially checks the Internal Status Word and Polling Status Word using just the Polling Status Word Edit CKS Check Internal Status EN Select which conditions to check Press the buttons to F change state or here for more help Cancel Index Found Disable Moving Error From Error Limit Disable Last Calculation Was Zero Disable Holding Error From Error Limit Disable Last Calculation Was Positive Disable Halt Command Was Sent Disable Last Calculation Was Negative Disable Input Found On Last Move Disable 170 1 Disable Wait Delay Count Exhausted Disable 170 2 Disable Over Voltage Disable UU H Disable Low Voltage Disable ul Bes Bes Bes Bes Bes Dhe Bes hte Over Temperature Disable SilverMax User Manual 4 01 51 Internal Status Word Description The meaning of each bit in the Internal Status Word is explained in the table below The description for each bit except Bit 7 indicates the SilverMax condition indicated by a 1 in that bit Bit Latched Definition Description 15 Reserved Reserved bit 14 Yes Low Voltage Low voltage error has occurred
156. e Data column of the User 26 Register Enter the value 100 into the cell and push the Enter key on the keyboard Toggle I O 3 switch LOW then back to High 8 Experiment with different values for the registers used in this position control example 9 When finished close the active program Question What type of applications can this program work in iz Exercise 4 3 Complete Register Based Motion The purpose of this exercise to get familiar with the basic XRV JMP and JOI commands SilverMax will execute two moves depending on the state of the I O 1 switch or I O 3 switch The program runs ina continuous loop monitoring the two switches The complete motion profile of each move can be changed if data in the User Registers is modified 1 Select File gt Open Navigate to the QCI Examples Using Inputs for Move Selection folder and select the file Two Inputs Two Moves with XRV qcp SilverMax User Manual 4 01 80 2 Open the Register Watch Tool Tools gt Register Watch Delete all listed Data Registers Click the Add Register Button select User 25 select Position for the Data Format and click OK Click the Add Register Button again select User 26 select Acceleration for the Data Format and click OK Click the Add Register Button again select User 27 select Velocity for the Data Format and click OK 3 Click the Add Register Button select User 28 select Position for the Data F
157. e PVIA control algorithm The SLC command puts SilverMax back in its default state of using the internal encoder for all control purposes Command details are available in the SilverMax Command Reference There are two applications where dual loop control using an external encoder is very useful e High Resolution Feedback Some applications require very high resolution feedback especially for positioning The SilverMax external encoder input function can use encoding resolutions higher than 100 000 counts per revolution Some serious issues must be considered when using high resolution encoders First motor commutation and phasing is still done using the internal encoder so the highest available internal encoder resolution available should be chosen Second the feedback control action is position error based so the control loop gains must be adjusted inversely to the increase in encoder resolution This is especially important for Kp If the default gain values were used with an external encoder that had a resolution five times higher than the internal SilverMax encoder the control loop would be five times more sensitive than normal and might be unstable without proper tuning Chapter 10 covers the control constants and system tuning e Local Feedback For some applications the motor shaft position is not the best measure of the state of the machine Loose couplings elastic components like belts gear backlash or simply metal flexure in the mac
158. e Word The jump will only occur if the specified condition is met Jump on Inputs ANDed JAN This jump command operates on the entire I O State Word The jump will only occur if ALL selected input conditions are met Jump on Inputs NANDed JNA This jump command also operates on the entire I O State Word The NAND jump will occur if ANY of the specified conditions are NOT met Jump on Inputs ORed JOR This jump also operates on the entire I O State Word The OR jump will occur if ANY of the specified conditions are met Jump on Register Equal JRE This jump will occur if the contents of the specified register are exactly equal to the specified value Jump on Register Not Equal JNE This jump will occur if the register contents do not equal the specified value Jump on Register Less Than JLT This jump occurs if the register contents are less than but not equal to the specified value Jump on Register Greater Than or Equal JGE This jump occurs if the register contents are greater than or exactly equal to the specified value SilverMax User Manual 4 01 82 Branching and Looping Branching and looping in a SilverMax program use standard logic structures This is accomplished using the various jump commands IW Then Eise This example demonstrates using the JMP command to build an If Then Else statement This example is available in the QCI Examples folder For Next The For Next loop again uses at its
159. e acted upon but no response packet will be sent See the section on networking later in this chapter Command Number Each SilverMax command has a unique number in the range of 0 to 255 The command number follows the ID in the packet Refer to the SilverMax Command Reference for command numbers Parameters Many SilverMax commands require parameters such as distance or I O state These parameters are numerical values that are included in a command packet following the command number Response Packet Response packets are sent from SilverMax in response to command packets They have three forms that differ significantly depending on the circumstances The three types of response packets are acknowledgement ACK data and negative acknowledgement NAK ACK RESPONSE ACK packets contain only the ID of the responding servo indicating that a command was successfully received These packets are as short as possible since they are the most commonly transmitted DATA RESPONSE Data packets are issued in response to commands requesting information from SilverMax They include the ID of the responding servo the command number being responded to and the data itself SilverMax User Manual 4 01 142 NAK RESPONSE NAK packets are issued in response to command packets that contain invalid information This can be due to a variety of reasons such as improper command parameters perhaps induced by communication errors NAK packets include the Silver
160. e also several internal signals available as stop conditions More complex control of a motion is possible using the advanced stop conditions allowing precise positioning The SilverMax registers can be adjusted by either an external host or an internal program The registers in turn can be used by various motion commands to adjust parameters at execution time This allows a program to react to real time input and to be extremely flexible Use of the registers also makes many advanced motion commands available such as Profile Move or Input Modes These are discussed in Chapters 5 and 6 The QuickControl software package provides an easy way to implement these commands The Register Watch tool in QuickControl gives easy access to the QuickControl registers This allows emulation of a serial host while allowing use of the powerful tools in the QuickControl software Program flow can be controlled by either registers or the digital O These commands alter the standard line by line program flow Proper use creates standard IF and LOOP type structures These structures while powerful require careful design to maintain proper program flow Using Inputs to Stop Motion All basic SilverMax motion commands as well as the input mode and velocity mode commands have integrated stop conditions as of SilverMax firmware revision 38 There are seven digital inputs available for evaluation as well as six other signals tabled below Digital inputs can be
161. e available Anti Hunt Settings Experiment with the Anti Hunt settings to optimize operation The typical Open to Closed value of 10 counts and Closed to Open value of 4 counts are a good start If normal operation involves overcoming the motor torque by hand or with a load such as would happen with a gripper or going against a hard stop then set up the SilverMax to check holding currents before going into Anti Hunt Mode This makes the transition into and out of Anti Hunt Mode smoother Checking holding currents forces the closed loop torque to be less than the open loop torque setting before SilverMax enters Anti Hunt Mode Checking holding currents also forces the error to be less than the magnitude of the limit before Anti Hunt Mode begins This usually requires the load to settle down on its own as even a slight error will cause the torque command to go to its limits when the integrator is on This makes SilverMax go to zero error before the torque is reduced meaning that SilverMax must delay entering Anti Hunt Mode until the load has settled Turning off the holding currents check bypasses the torque test allowing the transition to Anti Hunt Mode to be based solely on position error See Chapter 3 Special Step and Direction Tuning For systems using step and direction inputs the anti hunt delay setting will delay the transition into the holding state to a time that is consistent with the step rate For example if the minimum step rate is
162. e limit so the moving to holding delay set by the ERL command allows SilverMax a little more time to reach the target position with full torque before transitioning to holding torque and a lower torque limit Torque Limits Command TQL The control choices of open loop and closed loop control and holding and moving torque lead to four possible on control states for SilverMax Each state has a different Maximum BE torque limit associated with it The Torque Limits TOL Closed Loop Holding 75 o uN _Deseinion command is used to change the torque limits of each control state Torque limits have broad uses including e protecting machine parts at hard stops web tensioning allowing the shaft to free wheel and reducing power o EE consumption by SilverMax and hence its temperature Ee eae when holding position How SilverMax handles torque is ae Normal Open Loop Moving max key to understanding how to use torque limits C Native SilverMax User Manual 4 01 53 SilverMax Torque Control States The four torque control states are explained below Each torque limit can be set separately by the TQL command The difference between the four torque states centers on the information SilverMax uses to calculate how to move the shaft When in the closed loop moving state SilverMax moves the shaft based on a motion command and on error feedback When in the closed loop holding state SilverMax moves the shaft based on
163. e lower tones i e bass For a typical system the first velocity filter Fv1 is placed at the lowest frequency The second filter Fv2 is 2 to 5 times higher with 3 times higher being typical These tuned filters help reduce the high frequency resonance modes of widely mismatched systems 20 1 to 200 1 A good rule of thumb is to set the cutoff frequency just above the system s primary harmonic frequency For example to move a large flywheel setting these filters at 1000Hz is unreasonable There is nothing of importance happening in a 1 millisecond or less time frame Since the flywheel cannot not move that fast setting these filters down below 100Hz is more appropriate SilverMax User Manual 4 01 169 Acceleration Filter Fa Like the Velocity Feedback terms the Acceleration Feedback terms also have a low pass filter that reduces undesired high frequency noise Fa is typically set to about 5 times Fv1 When Ka has been increased Fa should be set just above the resonance frequency of the system See the tuning notes for belt drive systems at the end of this chapter for an example SilverMax Voltage Dependant Parameters SilverMax has several control loop parameters in the Motor Constants MCT command that depend solely on voltage level of the external power supply Thus these parameters must be configured for the correct operating voltage of the SilverMax Incorrect initialization or power supply voltage level deviation can cause uns
164. e one SilverMax is connected to e Under Setup select Register Devices and ensure all six devices have the Auto Reg checkbox checked e If networking multiple SilverMax QuickControl can register six at a time for viewing e f networking multiple SilverMax each has to be initialized with the SilverMax Initialization Wizard with a unique ID e Under Setup select Options and make sure the Autoscan ID range encompasses the ID of the SilverMax units desired Troubleshooting SilverMax Communication There are two indicator light emitting diodes LED on the back of every SilverMax servo one red and one green These LED indicators provide the user some basic information about the current operational state of the SilverMax When SilverMax is powered up the green and red LEDs should both be on The red LED is the SilverMax communication indicator If the red LED is on solid dim glow then no program is running in the SilverMax is not communicating When SilverMax receives the start of a transmission the red LED will shine extra bright When the transmission is processed the red LED will return to its original state Sending SilverMax a number of commands in succession e g the QuickControl polling routine will induce a flickering of the red LED This flickering can occur in regular intervals or as random blinks depending on the communication scheme If the red LED is out completely then a program is running from the internal nonvolatile memor
165. e setting must be set to TRUE in the KMC command because the Drive Enable bit is tied to the Over Temperature bit in the Internal Status Word Profile Move Operation The Profile Move commands add a new dimension to SilverMax by allowing the move parameters to be changed on the fly This gives SilverMax the ability to create just about any shape of move that is required Profile Move commands can perform very complex motion profiles by allowing the move parameters to be changed dynamically Move parameters stored in Data Registers can be changed by an external Host controller or by an internal program There are two Profile Move commands 1 For a single move use the Profile Move PMV command to execute a single move where the command ends when the target position is reached 2 For a continuous move use the Profile Move Continuous PMC command to execute a move that does not stop when the target position is reached Once in position this operation will wait until the position parameter is changed so there is no need to reissue a move command Multi Tasking must be enabled for PMC to function properly This continuous move can be terminated with a Stop on Input condition or the stop techniques mentioned previously Both Profile Move commands use Data Registers 20 to 24 for parameter storage The Profile Move commands use linear acceleration and deceleration parameters where a separate deceleration parameter is provided for different acc
166. e wizard begin by choosing SilverMax Initialization Wizard under the Tools pull down menu SilverMax Initialization Wizard xl Press Download to initialize SilverMax or change the Exit factory default parameters using the Initialize Parameter _ Browser or Interview S Options Download File To SilverMax Interview Motor 1 Ea Type S23H 5 Initialize Parameter Browser File Communications Motor Servo Tuning Motion Error Limits Misc A A A BiverMax Factory Default Initialization gep Open Save Save s EC D N Verify the filename SilverMax Factory Default Initialization qcp is listed in the File box 3 Select the Download File To SilverMax button to have the default SilverMax initialization file parameters downloaded to SilverMax The motor will automatically reboot and the parameters will then become active on each successive power up and motor reboot cycle Program Downloaded 4 The Program Downloaded screen will appear when downloading is complete Click on the OR button to clear the message screen 5 To exit the SilverMax Initialization Wizard select the Exit button on the screen 6 If polling is stopped click on the Scan Network button to verify proper communications and polling of the SilverMax Device Status Monitor 23H_5 NOT Dev 1 ba Dev 2 ENA 16 0 BLED NOT NOT Dev 3 ENA Dev 4 EN
167. echniques for Stopping Motion EE 97 S ftware STOP OPI EE 97 Hardware Stop Drive EE EE 98 Profile Moye eene 98 Related Profile Move Commande 27 caacsiecieleisotcazeletsints decke EENS NEE 99 Ieren eege e eren ee 100 Registers Used with Interpolated Motion ccccccccessseeeeneeeeeeeeeeeeeeeeneeeeeeeeseaaeeeaeeeeeeeenesseeeensaeeeetens 100 Examiple orlmierpolated RO 102 Interpolated Motion Host Based Control xi 2 cho ncesied cleus Se oat ee ees as ees 103 Chapter 6 Input and Output FUNCTIONS cceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeseeeeeeeeeees 105 Input nd Kei je Vim ele en serie i Cir ee E e e er ere 105 SilverMax V O EE 105 SilverMax V O PUNCHONS EE 106 Digital Inputs and Outputs E E 106 Analog Ir EE 107 High Speed VO Ree 107 eet E 107 BY gle Klee 108 General Digital Puts aieeaa nE e E Eaa aaa aE AE AEA A EEE RE AEE A EARR Et 108 Motion Control INputS ga 8o ed ose Stee cteaacctitsaset wxctua es coteans ccna incc cae pecan acene so atc cok ce sepioateagedcesee nts enon aeantmenan mee 109 Kill Motor on ne EE EE 109 iu tere re Trigger Lee EE 109 C nfig re VO CIO eC ONIN EE 109 Digital Input Filter DIF Command iice sc ccccecetcczateceasaihedeatsccrtadeaeksberancktu econ disdaatedankeneedelennelaguacidbens deat 109 Using Digital fue CEET E a a 109 General Digital e EE 109 Configure VO CIO Command WE 110 Set Output Bit SOB Comman disagree 110 Clear Output Bit COB Command EE 110 Using
168. ed DO Clear Internal Status This move will stop is a Moving Error is detected Move 4000 counts ramp time 99 96 mSec total time 999 96 mSec Stop when Moving Error is HIGH TRUE If it was a jam this gets rid of the position error Target to Position Delay for 200 mSec Continue the DO loop if the WHILE condition is met vagy e Jump to DO WHILE if No Mavis Error END End Program d 4 4 ij 4 1 Other Program Flow Commands The Program Call PCL and Program Return PRT commands can use the Internal Status Word as a condition like the basic JMP The commands Program Call on Input PCI and Program Return on Input PRI operate in the same fashion but use the I O Status Word like JOI The call commands operate in the same fashion as a jump command The difference is that a return command can be issued to send the program back to the line immediately following the call command Handshaking The digital I O lines in SilverMax allow it to engage in handshaking routines with other SilverMax or control devices The wait commands can pause program execution until an external source triggers an I O line Conversely the output commands can be used within a program to trigger other devices Placing the entire routine in a loop allows a set of devices to repeat the same
169. ed from the motion 9 Kp x 2 To decrease the Position Error double the Position Gain Test the move Some oscillation may begin to occur Bring up the Strip Chart and chart the position error and torque Kp can be increased more if the position error is too great but watch the torque If the torque saturates no amount of tuning will allow SilverMax to provide more torque 10 Set Ki and Reduce Kp Kv2 Kvff by 25 A good starting place for Ki is a value that keeps the product of Ki and Kp the same as the factory default In other words if Kp is twice the default Kp then start with Ki at half its default value Set the Integrator Gain and reduce all gains by 25 to provide system stability Increasing Ki will make the system stiffer when holding a position Increasing Ki too much will cause oscillation during motion Test the move The move should be stable If excessive oscillation occurs reduce Ki 11 Save Results Record the results Then download all the new control and filter constants to SilverMax Reboot and test SilverMax again to verify that the correct parameters are being used SilverMax User Manual 4 01 172 Tuning Notes Proper tuning depends on the specific properties of the system Tuning SilverMax a certain way for one system may not work for another system In order to help facilitate the tuning of different systems several application specific recommendations are provided These suggestions are meant to be a starting p
170. ed if an I O line is reconfigured as an output and then needs to be used an input again More information on the ClO command is available in the SilverMax Command Reference Digital Input Filter DIF Command The DIF command sets up a filter time for any of the seven I O lines used as a digital input The filter time affects how long a digital input state must be held for SilverMax to see the given state This filter is useful for noisy systems or for de bouncing switches because it causes SilverMax to wait for the specified number of servo cycles 120 usec before recognizing a change in the state of the input Using Digital Outputs SilverMax digital outputs are used as signaling or control outputs They can be used to indicate the internal status of SilverMax to an external device like a PLC or used to control another device like a relay or another SilverMax The main commands used for this function are Configure I O CIO Set Output Bit SOB and Clear Output Bit COB General Digital Outputs SilverMax can use any of its I O lines as digital outputs by either setting or clearing the output state of that line SilverMax can use a digital output to communicate with external devices including a PLC an HMI a switch or indicator light or even another SilverMax SilverMax cannot send commands via serial connection only receive commands and reply with an ACK or with data so digital outputs are the only way SilverMax can initiate communication w
171. edefined condition in SilverMax The status words are integral to the operation of any polling routine including the one used by QuickControl e Torque Limits Torque limits control the maximum torque SilverMax will produce SilverMax has four torque limit settings closed loop moving closed loop holding open loop moving and open loop holding e Error Limits Error limits define the maximum acceptable deviation from a target position before SilverMax sets a flag SilverMax has separate settings for maximum moving error and maximum holding error e Anti Hunt Mode Anti Hunt Mode is a special operating mode that SilverMax can enter to eliminate dither When holding a position SilverMax transitions from closed loop control to open loop control based on the Anti Hunt settings e Multi Tasking With multi tasking disabled SilverMax executes every command sequentially This means that program flow stops until each command has completely finished executing Enabling multi tasking allows SilverMax to execute commands sequentially as normal while also executing a command that takes several servo cycles to finish like a motion command e Specialty Commands The Calculation CLC Write Command Buffer Word WCW and Write Command Buffer Longword WCL commands are very useful for some applications Properly using them requires a solid understanding of binary numbers but accesses some very powerful features of SilverMax SilverMax Status Words
172. eed of SilverMax When using VIM data from an analog input or from a host can be used to control velocity A filter parameter is used to filter the incoming data Filter values range from a zero no filtering to 32767 no data gets through This is the same type of low pass filter used with the Filter Constants FLC command Filter constants are covered in Chapter 10 Before using the VIM command registers 12 through 18 must be loaded with appropriate values If an analog input is used to feed a value into register 12 it can be set up first but the RLM or RLN command must then be used to set the other registers to acceptable values for use with the VIM command Position Input Mode The Position Input Mode PIM command is usually used with a simple application like a joystick It is used to directly control shaft position The PIM command can work well in an application like that because it is so simple It is set up exactly like the VIM command so registers 12 through 18 control the motion profile Like VIM an analog input can be used to control motion if it is tied into register 12 although it would control shaft position not shaft velocity The precision of Position Input Mode is limited so if a precise position based move is required the more powerful SilverMax motion commands like Profile Move PMV will work better Torque Input Mode Torque Input Mode is configured with the Torque Input Mode TIM command It is very similar to VI
173. eeeeeeeeeeeeeneeees 45 Chapter 3 Unique Features and Commands ccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeeeeeeeeeseeeeees 47 SilVerMax StatUS Words EE A EE ETE E T 47 elt Te EE e DEE 48 cco xs OU a gig ac Ug 6 EE 48 Clear Pol CPL Command BEE 48 Polling Status Word Description xc cxceniciscteecenrutseekudinnianaslaneelenyesl Edel 49 e SVU e DEE 49 Read l O States RIO Command EE 50 JUMP and Motion Command E 50 VO Status Wore Description EE 50 at GE EE EE 51 Read Internal Status Word RIS Commande 51 Clear Internal Status Word CIS Commande 51 Check Internal Status CKS Command vrsccssacenytecevacctedeversseuened deed gd eege Eegen ee 51 Internal Status Word Eege ci seceded E desea eceetiay eh hetero Meena eae ogee 52 PORN nn EE 52 Open Loop and Closed Loop Control s cciecccedecneleetacediainatesevtarnncadecdioehiausctsnctg dastedandeatranienbelanaaneabels Masten 53 Holding Torque and Moving Bt te EE 53 Torque Limits Command TE nennen nerne mae 53 SilverMax Torque Control eeng eege Eege EE eege 54 SilverMax Torg E 54 Error Limits and Drag ModE eiiicecrei nanan eds Glee idr E a laa da eae ede 55 Drag Ne EE 56 Exercise 3 1 ERL and Drag Mode Operation with MAV and PMV n ssssssssessssessssernsserrnnreerrnrssrrrrssrrrnee 57 AE wl Tu E 58 LISI E elt LEE 58 A tiH nt Operationen a a a a A a a a a a a e 59 SilverMax User Manual 4 0 iv Antic Hunt Commands eeraa n eves voecde cededvedaswdedeveceeew yess EE se de
174. egment decelerates to a stop define velocity as the starting velocity of the segment 536870912 rather then the ending velocity Note that the purpose of this segment is to decrease the deceleration to 025 536871 Time decrements down in register 18 as described above Final Segment 0 92000 536871 536870912 Feed one additional segment to the IMS operation with a 0 for the time parameter prompting an exit from IMS operation Repeat position acceleration and velocity parameters as they should have no effect on the profile the profile was physically completed with the previous segment Segment 4 This segment takes effectively one servo cycle to execute the 0 for time is copied to register 18 and is decremented instantly exiting IMS operation SilverMax User Manual 4 01 102 Interpolated Motion Host Based Control Rather than using the register based queue and writing the reference number of the first of four registers to register 17 write a O to the lower word of register 17 indicating to the IMS operation to use the Interpolated Move Queue A host can be programmed to control Interpolated Movement via this queue The host must utilize two commands to accomplish this Interpolated Move Queue Clear IMQ and Interpolated Move Write Queue IMW The IMQ command is sent through the serial interface and clears any residual data that may have been left in the Interpolated Move Queue This queue is a software FIFO first
175. eleration and deceleration profiles The S Curve Factor SCF command does not work with the Profile Move command Profile Move commands also use an offset parameter which causes SilverMax to move an offset distance after a Stop on Input condition is met see Chapter 4 for stopping on inputs User Data oe Register Number Description Comment 20 Position Absolute destination value 21 Acceleration Sets the acceleration rate that is used when increasing the move speed 22 Velocity The maximum speed that is allowed during a move 23 Deceleration Sets the deceleration rate that is used when decreasing the move speed When a stop condition is met this value is added to the current position 24 Offset and copied to Register 20 for a profiled stop If set to zero only the deceleration values is used to ramp down to a stop SilverMax User Manual 4 01 98 Advanced Dynamic Motion Control 1600 4 1400 1200 Velocity RPM 0 00 0 50 1 00 1 50 2 00 2 50 3 00 Distance revs Using both the Enable Multi Tasking EMT and Calculation CLC commands with the PMV and PMC commands allows the functionality to create custom motion profiles similar to the one shown see Chapter 3 for a discussion on EMT and CLC In the following example program a PMV command is automatically updated The velocity register is being incremented by the CLC command which increases the vel
176. er a functioning system Achieving a perfectly functioning system on the first try is not always applicable This section addresses hardware and software issues that some first time users encounter as well as troubleshooting strategies to overcome these obstacles Before Using SilverMax Servomotors e Turn Off ALL Power Supplies and Switches e Read All Setup Instructions for Specific SilverMax Model and Start Up Kit e Double check ALL Intended Connections for Shorts or Unwanted Grounding These setup instructions are designed to help configure a SilverMax servo and the QuickControl Software Carefully follow the setup procedure for the applicable SilverMax Start Up Kit and the system should be operating within minutes WARNING Do Not Hot Plug The Servomotor When a SilverMax is powered and plugged in or unplugged anywhere along the 15 pin signal cable this is defined as Hot Plugging When this occurs the residual current in the power circuitry motor windings power supply voltage clamp 5 Volt supply communication power attempts to find the path of least resistance to ground before the proper ground connection is established In most cases this path is through the communication lines but is not limited to communication failure The available protection devices are not rated for high transient power spikes or repeated spikes Repeated spikes can weaken communication slowly to the point of failure In some cases total communicati
177. er data registers by default These read write registers can be used by all SilverMax commands that are associated with user data registers When SilverMax is programmed to operate in an Input Mode registers 12 through 18 become dedicated to the Input Mode operation When Profile Move commands are implemented registers 20 through 24 become dedicated to the Profile Move operation Registers 11 19 and 25 through 42 are always available for user data React Type Default Use PE a ahs Dedicated Use Description 11 R W User Data 12 R W User Data Input Mode Input Source Data 13 R W User Data Input Mode Input Offset 14 R W User Data Input Mode Input Dead band 15 R W User Data Input Mode Maximum Scale Limit 16 R W User Data Input Mode Maximum Output Scale 17 R W User Data Input Mode Output Offset 18 R W User Data Input Mode Output Rate of Change Limit 19 R W User Data 20 R W User Data Profile Move Absolute Position 21 R W User Data Profile Move Acceleration 22 R W User Data Profile Move Velocity 23 R W User Data Profile Move Deceleration 24 R W User Data Profile Move Offset pos from input stop 25 R W User Data thru R W User Data 42 R W User Data R W Read and Write Registers for Optional Dedicated Command Use Input Modes Position Input Mode PIM Velocity Input Mode TIM and Torque Input Mode TIM Profile
178. er is counting down If the closed loop torque condition see below is enabled the timer will not start until the closed loop torque being used drops below the open loop torque limit e Moving status optional When the Anti Hunt Mode AHM command is set to its default value SilverMax only enters Anti Hunt after the end of a move when it is holding a position The end of a move occurs when the Trajectory Generator goes inactive In this default setting SilverMax uses closed loop control throughout the move When the AHM command is set to the non default value SilverMax can enter Anti Hunt at any time moving or stopped This allows SilverMax to use open loop control during a move if the other Anti Hunt conditions are met e Closed loop torque optional If the AHC command is set to its default state SilverMax compares the torque being used during closed loop operation with the open loop torque limit the open loop moving limit during a move the open loop holding limit while holding position If the closed loop torque exceeds the open loop torque limit SilverMax will not enter Anti Hunt and switch to open loop control This extra condition can be disabled with the AHC command SilverMax User Manual 4 01 59 Anti Hunt Commands Five different commands are important to Anti Hunt operation Anti Hunt Constants AHC Anti Hunt Delay AHD Anti Hunt Mode AHM Torque Limits TQL and Error Limits ERL The AHC and AHD commands set the co
179. er sources DB 3 Plug Layout TECHNICAL DETAILS DB 3W3 Front View on SilverMax 3 contact D subminiature Socket w plugs type gender Size 20 solder cup contacts Max wire guage is 12 AWG Rated at 20 Amps per contact Shell size is std DB 15 DB 3 Plug to Signal Assignments z t34HC Series Comments Pin Signal Description A1 Chassis Ground t Power Ground A3 amp Chassis Ground A1 are TOO not internally shorted together A2 V Power Input 12 to 48 VDC A3 Power Ground Input t V Input Power and Power Ground are not reverse bias protected SilverMax User Manual 4 0 191 SilverMax User Manual 4 0 192 Index acceleration feedback gain Ka 53 59 161 167 acceleration feedforward gain Kaff 161 acceleration filter Fa 160 ACK e e 148 analog INPUTS sees aes ease 105 107 110 112 lun E 110 WELT GE 112 SIG EN 111 Lat Ei e ln e 60 173 EEN ee ee ee eT 173 dithering EE 58 DESEN ca adeeb 60 calculations oeenn 40 61 67 101 161 commands 33 39 40 47 52 65 68 83 99 122 124 128 178 closed loop 25 47 52 54 58 63 106 116 119 123 125 157 160 161 173 180 command packet 142 148 146 149 151 ending character a e 145 communication 2 8 9 15 16 18 21 24 27 30 36 43 77 100 103 109 141 146 150 156 9 bit binary protocol 141 146 183 bardware ccc ceeecceceeeeeceeceeeeeeeceeaeeseeeaaeeeenes 150
180. error feedback only When in the open loop moving state SilverMax moves the shaft based only on the parameters of the motion command Finally when in the open loop holding state SilverMax does not move the shaft at all The characteristics of each control state are explained below e Closed Loop Moving Control SilverMax is most commonly used as a servomotor By definition a servomotor is able to move from one position to another reacting to feedback to minimize error This is exactly what SilverMax does when operating in the closed loop moving state While in this state SilverMax acts on a motion command from a host or an internal program to move the shaft SilverMax uses the parameters of the motion command and feedback from its encoder or an external feedback device for the move using closed loop control to minimize moving error Torque during the move is limited by the Closed Loop Moving torque limit set with the TQL command e Closed Loop Holding Control The end of a move is defined by the motion command that started it As soon as the move ends the Trajectory Generator goes inactive SilverMax switches from applying moving torque to applying holding torque after the Delay to Holding time delay set with the ERL command expires If Anti Hunt has not been activated see the section on Anti Hunt later in this chapter SilverMax will use closed loop control to hold position This means that SilverMax will move the shaft in response to posit
181. es by eut Disable ZE MM utga Das pressing on the Input e button Togde OR Staen ZJAND Stop whenboih D Dieable Last Check ofthe chosen inputs are S in the indicated states z S e Saena NCR This option Sch virks oR Require the following veth two inputs at a bme input states to be Input 1 Disable C AND TRUE belos evaluating lhe Last Input 2 S RECORD Recodthe C RECJAD i Chack This enables a mator s position when Two State stop pap am of the inputs are in condon ind the indicated sate OK Cancel f Aray Help First Check Direction Toggle This check operates in exactly in same way as the serial command Select the conditions to be ORed and if the Last Check conditions are to be toggled if the First Check is met The Toggle Second Check Conditions bit is not available within QuickControl Second Check This check functions in exactly the same fashion as under serial communications Last Check Selecting RECORD causes SilverMax to record its position at the time of input trigger but does not halt This is used rather than specifically enabling a single condition with AND This window also does not allow the use of AND and OR conditions simultaneously SilverMax User Manual 4 01 77 Register Watch Tool The Register Watch Tool is a powerful tool within QuickControl for monitoring and adjusting the contents of SilverMax
182. es register 12 even while other commands or the programs are executed SilverMax then calculates the torque output based on the Input Mode registers Register 13 specifies an offset value of anything between 0 and 32 767 Register 14 allows a zero point deadband Register 15 holds the scaling value The scaling value limits the total input value and scales the input value down This new number is multiplied by the output scale value in register 16 Finally any value in register 17 is added to the final value SilverMax User Manual 4 01 123 Analog Input Mode Torque single input Analog input scale f Oto 5Y 0 to 15 Torque 3 000 STUs Continuously Read the Analog inpul into Reg 12 Analog Continuous Read User Input Source Data 12 Analog Channel 1 Reg 13 Offset No offset for torque since for this application OVolts O torque Write 0 to User Input Oftset 13 Register Reg 14 Deadband Add a smal deadband at value called zero helps minimize effect of noise about zero port White 500 to User Input Dead Band 14 Register Reg 15 Max Input amp Scale Allow the full scale value of the 5 VDC input Write 32767 to User Maximum ScalelLimil 15 Register Reg 16 Max Output Scale Make the full scale value 3 000 Siveshiax Torque Units STUs 3 000 STUs 15 Torque Write 3000 to User Maximum Output Scale 16 Register Reg 17 Oulput Offse
183. eseeeseeeeeeeeeeeeees 171 Tuning Ter 173 Appendix As Fonnen aa aeh o aaa e anaa aa aae eaei aaa ae oaaae aaea eao oaaae aE antaa a ELSE 175 Appendix A SilverMax E Series Gpeclcatons 175 Electrical Specifications E 175 Eegen leger EE 175 Eege Ee Le 176 Fenneng 176 Appendix B SilverMax Data Hegleters 177 Appendix C Conversion Date ze08eteskugeug telansoteanalesaatadascsiavnedd nddaeuandensdh cna dacs Punk EES EE 181 Appendix D Binary Hexadecimal and Decimal Conversions 183 Appendix E SilverMax Mechanical Dimenslong sss sss sssssserisesitesntterttsritrintnnitnnitsnntnnntornrnrrennrennnt 185 SilverMax 17 Frame Mechanical Eet edd gege geieg iere eeneg atic piel Eege 185 SilverMax 23 Frame Mechanical Data ives cnc ce ier fGen ded reieneetes DS eege oa Sonn eae 186 SilverMax 34 Frame Mechanical Data cscne sletet ccc inntecdetetsitnewsdudt Maar gedoe ieren EE ege 187 Appendix F SilverMax Connector Specifications cccccsesessescsssseccssssesccceresecnsseressesescensseseceeserees 189 SilverMax 17 17H 23 and 23H Connector Data 189 SilverMax 34N amp 34H Connector Data 190 SilverMax 34HC Connector RE 191 WINGO E 193 SilverMax User Manual 4 0 viii Chapter 1 Using SilverMax and QCI Start up Kits Introduction to Using SilverMax This section describes the common configurations for SilverMax systems standalone host and hybrid It summarizes some of the ways multiple SilverMax motors can be used t
184. est and evaluate 17 and 23 frame SilverMax servomotors The SilverMax interface cable is provided to connect the SilverMax servo to the Optical Interface Module QCI Technical Document QCI TD0013 included contains more information on the Optical Interface Module The female 15 pin connector on the SilverMax Interface Cable attaches to the 15 pin male connector on the 17 23 frame SilverMax zg attaches to the 15 pin The male 15 pin connector on the SilverMax Interface Cable female connector on the Optical I O board The RuJ 11 connector on the serial cable attaches to the RJ 11 jack on the Optical I O board attaches to a standard PC COM port The V Input connections on the Optical I O board must be connected to the V terminal of a power supply 10 48VDC and the Pwr Gnd connections must be connected to the ground of that power supply The 9 pin female connector of the serial cable SilverMax D15 Connect to SilverMax and tighten thumbscrews 15 pin Interface Cable Connect to Optical I O Module RJ 11 Cable Connects to RJ 11 port on Optical I O Module to PC COM port Power Supply Connectors V Input to V of power supply and Pwr Gnd to Ground SilverMax User Manual 4 01 12 Setup QCI SKOM FC v Start Up Kit The setup for this kit is the same as the setup described above for the QCI SKOM 34 V Start Up Kit except a Clamp Module QCI CLC
185. existing Register File Arrays before Importing File Register File Import An alternative way to define Register Files and the only way to define Register File Arrays is with Register File Import A properly formatted text file can be imported and will store Register Files and or Register File Arrays to non volatile memory Register File Import is accessible only in QuickControl through the Program menu by selecting Register Files and then the Import Register Files from Text File button Following a successful import the Register Files and or Register File Arrays and their names will be available to use when creating programs for the current QCP The user can choose to import the text file once or each time the current QCP is downloaded SilverMax User Manual 4 01 xl Register File Name Cancel RN SS Number of Registers Rename ik J Delete Memory Mode I Auto C Manual Non Volatile Memory Location Edit Initialization Data Edit Register File Initial Data Cancel Edit initial data for Register File Register File Example Initial Daa Units 0 Edit Register File Initial Data Register File Initial Data facilitates storing data into a Register File before program execution This is to avoid checksum errors that occur when reading from uninitialized non volatile memory locations From the Edit Register File dialog press the Edit Initialization Data button The initial data wil
186. ffer Size 10 words 20 bytes Program Buffer Size 200 words 400 bytes Non Volatile Memory Size 8K bytes 4K words Standard on all 17 17H 23 23H 34H 1 and 34N 1 servos 32K bytes 16K words Standard on all 34HC servos 32K byte memory option Available on 17 17H 23 and 23H servos Environmental Specifications Temperature Operational 10 C to 80 C for the electronics section 105 C for the motor winding section Operation in environments with temperatures outside this range is possible if the electronics section in kept above 10C and below 80C during motion Storage 40 C to 85 C Humidity Continuous specification is 95 RH non condensing Shock Limitation is approximately 50g 11ms SilverMax User Manual 4 0 176 Appendix B SilverMax Data Registers Data registers can be dedicated to a specific purpose optionally dedicated or continuously available for user data They can be designated as Read Only or Read amp Write Data registers are 32 bits in length long word and numbered from 0 to 233 Many are designed to operate as two independent 16 bit data registers with each 16 bit word containing discrete data Data is refreshed internally every servo cycle 120 usec It can be sent or retrieved serially through a host controller or used internally by programs downloaded into SilverMax User Data Registers and Optionally Dedicated Data Registers Data registers 11 through 42 are defined as us
187. final TIM output torque can never be greater than this torque limit Second register 18 has no effect on TIM In the other two input modes Position and Velocity register 18 controls the output rate of change This is not the case with TIM Register 18 could be set to zero yet the TIM torque output would continue to change at a constant rate Third the integral low pass filtering in the TIM command has a tradeoff associated with it A low cutoff frequency of 20Hz or less causes both a hysteresis and a slightly lower than expected output This is the result of cutting off the numerical resolution in the digital filter However noisy inputs work best with a very low cutoff frequency typically 1Hz Therefore this tradeoff must be considered for each TIM application Fourth a SilverMax cannot exceed its specified maximum speed of 4000 RPM Therefore TIM cannot cause SilverMax to output such a torque that the maximum speed is exceeded Thus SilverMax torque output will automatically be limited before SilverMax goes beyond the max speed The next example is included to clarify how TIM works For a detailed description of the Input Mode refer to Chapter 9 In this example an external 0 5V analog signal is used to vary the SilverMax torque output from 0 15 of the continuous torque rating First the Analog Continuous Read ACR executes This command sets up a register to be updated with an analog voltage input Now every servo cycle SilverMax updat
188. fine basic stop conditions for example stop motion if I O 3 goes HIGH Using inputs for program flow and motion control is discussed in depth in Chapter 4 UO Status Word Description The meaning of each bit in the I O Status Word is explained in the table below The description for each bit except Bit 7 indicates the SilverMax condition indicated by a 1 in that bit Bit Latched Definition Description 15 No UO 7 Status of I O line 7 normally high low when triggered 14 No I O 6 Status of I O line 6 normally high low when triggered 13 No UO 5 Status of I O line 5 normally high low when triggered 12 No I O 4 Status of I O line 4 normally high low when triggered 11 No Reserved Reserved bit 10 No Delay Counter Status of the Delay Counter High when counting down low Active when count is expired Holding error limit set by the Error Limits ERL command mo OIG SHO has been exceeded with SilverMax in a holding control state g No Novina Error Moving error limit set by the ERL command has been H exceeded with SilverMax in a moving control state Internal sensor determines over temperature condition and 7 No Over Temperature clears this bit when true Bitis shared by drive enable lines on 34 frame servos disable high enable low 6 No UO 3 Status of I O line 3 normally high low when triggered 5 No I O 2 Status of I O line 2 n
189. g data gt lt row 2 1st reg data gt lt row 2 2nd reg data lt row 2 last reg data gt lt last row 1st reg data gt lt last row 2nd reg data lt last row last reg data gt If there is no Register File Array data and the rows and columns are defined QuickControl will define the array and allocate memory for it but will not write to memory SilverMax User Manual 4 01 95 Example NVRegArray name reg file array 1 col 4 row 3 startAdr 2600 coloFmt time 100 110 120 130 200 210 220 230 300 310 320 330 If an imported text file contained the above example it would create a Register File Array named reg file array 1 The first row of this array would start at memory location 2600 followed in memory by the other rows of the array After the import non volatile memory starting with address 2600 would be configured as follows pened of words Stored Elements 2600 9 length of reg file array 1 first row 84 checksum of reg file array 1 first row 2601 1 0 2602 2 100 time data stored in native units 2604 2 110 2606 2 120 2608 2 130 2610 9 length of reg file array 1 second row 228 checksum of reg file array 1 Second row 2611 1 0 2612 2 200 time data stored in native units 2614 2 210 2616 2 220 2618 2 230 2620 9 length of reg file array 1 third row 113 checksum of reg file array 1 third row 2621 1 0 2622 2 300 time
190. ge of requiring a greater understanding of SilverMax wiring requirements than a setup using QCI parts SilverMax User Manual 4 01 2 Hybrid Configuration A hybrid configuration utilizes a SilverMax operating such that is directed by an external controller executing internal programs and using its internal I O points This configuration is more versatile than either a pure standalone or pure host controlled configuration SilverMax can use its standalone abilities to execute internal programs and interact with the system through its I O points also an external host can issue commands or interact with SilverMax programs For example a PLC could direct the SilverMax to switch tasks or stop motion in response to a digital input from the PLC Recommended Setup A typical hybrid configuration using recommended parts is shown below In this configuration SilverMax is connected to a OC breakout module the breakout module is then connected to the power supply any UO devices needed to interface to the SilverMax and the host device The host can also be connected to I O devices a network or anything else it is capable of interfacing with Note that the host can also interface with the SilverMax when some of the SilverMax I O lines are connected to the host System I O 5 OC Breakout 2 Hybrid Configuration Recommended Parts List SilverMax servomotor QCI breakout module 12 48 VDC power supply Host device PC PLC HMI V
191. gisters that cycle through Time Position Acceleration and Velocity data to control motion These registers define constant acceleration segments that ramp up or down to a desired velocity or move at a constant velocity over a period of time By streaming data through these registers the Interpolated Move Start IMS command can interpolate the points in each velocity segment as well as between velocity segments to create a continuous complex motion profile The cycling of data can be accomplished by either a host that streams the data to SilverMax via serial communication or by a standalone program Registers Used with Interpolated Motion There can be up to eleven data registers used by the Interpolated Movement operation at any time three operational registers used to control the Interpolated Movement process four user defined registers where velocity segment data is cycled and four Profile Move registers 20 to 23 where current velocity segment parameters are copied to just prior to execution of that segment Although the user has no control over the final four registers and one of the operational registers Register 18 it should be noted that these registers should not be used by any other part of a program that plans to incorporate Interpolated Movement these registers are written to automatically by the interpolated move process Any use of these registers 18 and 20 23 while in an IMS operation could cause a program or movement error
192. gnal and simply record it ina data register A host connected to SilverMax could read the register holding the value at a regular time interval and save the value to a file In an application like this SilverMax would be acting as a data acquisition device This might be useful in an application that needed a servomotor but also needed to record temperature for example Analog Read Input ARI Command The ARI command reads the value of the selected analog input and stores that value in the selected data register The ARI command only reads the value of the analog input once This command can be used for several purposes To read the value Cancel F of any of the four analog inputs when read as a single input to Channel V Main Buss Voltage g Den read the value of one of the differential inputs I O 4 and I O 5 or I O 6 and I O 7 or to read the value of one of the internal Register Accumulator 10 analog channels The QuickControl screenshot on the right shows the two parameters of the ARI command More information on the analog channels available with this command is available in the QCI application note on analog inputs More information the ARI command itself is available in the SilverMax Command Reference Analog Read Continuous ACR Command The ACR command reads the value of the selected analog input and stores the value in the selected register That register is updated every servo cycle 120 usec although a
193. gram buffer 39 40 41 62 68 143 176 motion commands 36 43 47 50 61 64 71 79 106 109 111 113 116 128 160 180 absolute 36 58 65 67 134 135 BASIC a r a 32 36 160 R I E 161 register based EE 79 relative nn 36 44 65 76 146 147 150 MUIti tASKING 0 cceseeeeeeeeeeeeee 47 61 65 68 97 NAK TESPONS aen eer SEA n e Eege 149 networking 4 15 141 142 150 151 non volatile memory 5 18 19 26 31 39 43 49 87 88 91 96 112 129 134 135 176 indirect addressing eeeeeeeeeeeceeeeeeeeeeees 178 long term storage ue 25 39 43 98 open loop 25 47 52 54 58 62 116 119 122 161 173 180 over voltage E 175 poll command packet 147 polling 15 18 20 21 28 30 31 33 34 36 38 47 48 51 57 62 65 67 78 79 139 140 polling status word 2028 ddecceeeeonu wee 34 e Ee TEE 8 PYOCOSSOM EE 7 8 31 47 180 profile Move COMMANAG cceceeeeeeeeeeneees 63 program i 5 6 14 22 25 26 31 34 36 51 54 58 61 65 67 69 71 72 78 80 85 87 88 93 97 100 105 106 108 109 111 113 119 121 127 129 130 131 133 135 136 138 140 143 150 161 179 180 creating ME 5 downloading ccceeeceeeceeeeeeeeeeeeees 28 42 45 193 program flow 5 36 43 44 47 50 62 63 71 81 106 108 111 139 Wait Commande sooennnoonennsoenrerenenne 81 84 180 program troubleshooting
194. he Data Format Both should have 0 values listed 4 Click once in the data column of the User 25 entry Enter a value of 5 rps for the velocity be aware of the scaling being used and press enter Select the data field of User 26 and enter a value of 2 rps s into the cell Note If no units are shown in the right column double click on the units field of the Register Watch Tool and choose the appropriate type Velocity for Reg 25 ros amp Acceleration for Reg 26 rps s 5 Experiment with other values in these registers and note the effect on the motor operation Try starting with a very slow Acceleration rate 0 5 rps and a Velocity rate of 30 rps After motion begins increase the Velocity rate to 1 rps then 5 rps and then 10 rps Notice the dynamic Acceleration change SilverMax User Manual 4 01 69 SilverMax User Manual 4 0 70 Chapter 4 Motion Control Using Inputs and Registers SilverMax has two primary methods for interfacing with external devices The methods can be used to stop motions modify motion parameters at execution time and control program flow The two methods are the I O and internal data registers See Chapter 6 for more information on the physical properties and setup of the I O Most SilverMax motion commands have built in stop conditions These additional parameters are issued with a motion command to prematurely end the programmed motion based on the condition of the digital UO There ar
195. he Getting Started section of Chapter 1 provides information about using QCI Startup Kits It gives step by step instructions on the hardware setup and first time SilverMax operation It details the SilverMax Initialization process and the particular programs used in the Initialization to setup SilverMax for operation Application Related Information Detailed application programming examples are available with the QuickControl software They are found in a subfolder of the main QuickControl install folder named OCT Examples QuickControl can be downloaded from the QCI website at the following web addresses www silvermax us www qcontrol com or www quicksilvercontrols com The website also contains OC Application Notes that offer the user details of SilverMax operation in specific applications Warnings SilverMax shall not be used for Life Support applications without explicit written permission from the President of QuickSilver Controls Inc SilverMax is a high performance motion system As with any motion system it is capable of producing sufficient mechanical output to cause bodily injury and or equipment damage if it is improperly operated or if it malfunctions The user shall not attach SilverMax to any mechanism until its operation is fully understood Furthermore the user shall provide sufficient safety means and measures to protect any operator from misuse or malfunction of the motion system The user assumes all liability for it
196. he SilverMax and start QuickControl Start polling the motor and verify that the system is operating properly 2 Select File Open Navigate to QCI Examples Profile Moves and select the file Absolute and Profile Move with Drag Mode qcp 3 Notice the error limits set with the ERL command in line 3 Also note that Drag Mode is enabled with this command 4 Edit the TQL command in Line 5 Set the Closed Loop Moving and Open Loop Moving torque limits to 30 Click OK when done 5 Select Tools Register Watch Click Add Register select Target Position 0 and Position data format Click OK when done 6 Repeat Step 5 but add Actual Position 1 and User Profile Move Position 20 Choose Position for the data format for both 7 Edit the Absolute Location data of Line 8 MAV to read 10 000 counts Click OK when done 8 Edit the Data value in Line 12 WRP to read 10 000 counts Click OK when done SilverMax User Manual 4 01 57 DRAG MODE WITH THE MAV COMMAND 9 Click Run to download and start the program The motor will begin a slow MAV move to the absolute location of 10 000 counts The Target Position register and Actual Position register begin incrementing to 10 000 counts 10 While the motor is in motion grab the flywheel on the motor shaft Physically stop it from rotating until the move command completes its trajectory Notice that the Actual Position Register stops counting up and reports the location where
197. he absolute value of the accumulator subtracted from the value in register 25 If the result of this calculation is negative the new move distance will be less than the value in register 25 and the program will reset the position to 30 000 counts SilverMax User Manual 4 01 67 WCW and WCL Commands The Write Command Word WCW and Write Command Word Long WCL commands are two of the most powerful SilverMax commands available They allow a SilverMax program to modify itself by overwriting data in the program buffer These two commands can effectively make any command requiring a parameter a register based command SilverMax does not do any error checking on the data that is changed potentially making these commands very dangerous QuickControl however does check for errors by keeping track of which line in the program buffer will be modified and by querying for the parameter to be changed rather than blindly changing data QCI highly recommends that QuickControl be used to implement the WCW and WCL commands Both the WCW and the WCL commands work the same way The difference between them is that the WCW command is used for 16 bit parameters and the WCL command is used for 32 bit numbers When Register E either of the commands is issued in a program ery SilverMax replaces part of the data in the program om Description buffer with the data in the register the WCW or WCL command specifies With QuickControl the program Command to
198. he memory operates for storing and executing programs There are five types of memory available The Serial Communications Buffer static s The Program Buffer static e The Data Registers static e The Non Volatile Memory permanent e SilverMax Firmware permanent When receiving commands through the serial interface a Serial Communications Buffer is used to temporarily store the commands parameters and data received For executing commands and programs there is a Program Buffer used for temporary storage of the executing command or program The program buffer uses a static type memory cell that can be written any number of times and only maintains information while power is present The Data Registers are used to process and store numerical values inside SilverMax Values in registers are used to store parameters or results for many SilverMax command The Calculation CLC command in particular makes extensive use of data registers For long term storage of programs and data use the Non Volatile Memory Non volatile memory uses an EEPROM type memory cell that can be written to at least 100 000 times and retains the data even when power is lost SilverMax Firmware is a separate piece of memory not directly accessible This memory uses special flash type of memory that can only be updated using the SilverMax Firmware Download Wizard within QuickControl Serial Interface Serial Comm Buffer 10 Words Non Volatile Memory Program
199. he start of a packet All values are transmitted in hexadecimal form in this protocol Command packet 9 Bit Binary Command Packet Data Transmission Order ID Length Command Parameters Checksum 1 Byte 9th bitset 1 Byte 1 Byte 2 or 4 Bytes each 1 Byte SILVERMAX ID The target ID is the first byte transmitted in the 9 bit protocol The parity bit is set or mark for this byte only This indicates that it is the start of acommand packet SilverMax will ignore any transmission prior to the byte with the parity bit set LENGTH The second byte is the length The length is defined as the number of bytes from the command number up to but not including the checksum Put another way it is one the command number plus the number of bytes used by all parameters This value of the length is limited to the range 0 31 COMMAND NUMBER The command number is the next byte in hexadecimal form PARAMETERS Command parameters are also sent in hexadecimal form 16 bit parameters must be transmitted as two bytes and 32 bit parameters as four That is all the bytes must be transmitted even if a small value would only require a single byte The size of a parameter is listed in the SilverMax Command Reference SilverMax User Manual 4 01 146 CHECKSUM The final byte of the packet is the checksum This is used to verify that the rest of the packet arrived intact The checksum is the 2 s complement 1 s compleme
200. hine can add unacceptable inaccuracy to feedback measurements taken at the internal encoder For these applications using a feedback device placed on or near the critical machine part is better than relying on SilverMax for feedback information The same considerations that apply to high resolution external encoders apply to locally placed feedback devices Some of these devices might have a lower resolution than the internal SilverMax encoder so the control loop gains must be scaled up rather than down Encoder Outputs SilverMax can use its I O lines to send a raw and a scaled version of its internal encoder signal The main reason to use this feature is for an electronic gearing or following application This feature is useful for multi axis SilverMax systems that must move in unison the two SilverMax would not be truly synchronized however because of the unavoidable processing lag between the lead and following unit so high precision systems should be coordinated with an external controller like a PLC The raw internal encoder output function is just that a buffered copy of the A and B quadrature signal that SilverMax uses for internal control purposes This encoder output is not scalable The scaled internal encoder output or modulo output is fully scalable and can be output in any of the three signal formats SilverMax uses step and direction step up step down or A and B quadrature Several commands are used with the raw and scaled inte
201. host could also change the value of register 12 over a serial connection Input Mode Operation Registers 12 through 18 are used for the three Input Mode commands These registers must be loaded with the correct data before any of these commands are issued The registers can be loaded by an external host with the Write Register Immediate WRI command by a host or SilverMax program using the Register Load Multiple RLM or Register Load from Non Volatile RLN commands or by a SilverMax program using the Write Register Program Type WRP command If the RLM or RLN commands are used the correct parameters must first be stored to non volatile memory using the Register Store Multiple RSM or Register Store to Non Volatile RSN commands Once the registers have been loaded the Input Mode move can start The move will follow the target value position velocity or torque in register 12 If register 12 is tied to an analog input the analog input value will directly control motion If an external host can change the value in register 12 that host directly controls motion The table below shows the registers used by the Input Mode motion commands and their functions Data Data A f Register Data Range Source Data Register Function 12 2 147 483 648 User or Input Source Data Data can be placed here to 2 147 483 647 SilverMax by Analog or Data Register commands 13 ea hearer te User Input Offset to 2 147 483 647 14 0 to 3
202. ialization settings as well as default settings for some of the advanced SilverMax functions User programs contain the instructions SilverMax follows while operating in standalone or hybrid configuration e Initialization program The initialization program starts at the first memory location in non volatile memory address 0 After a SilverMax powers up it automatically executes the program that starts at the first memory location This program must contain initialization instructions for the SilverMax or it will not operate properly Every SilverMax comes from the factory with a default initialization in the proper memory location QuickControl has several tools for safely changing the default initialization The last command in the default initialization program is a command to load and run the program that starts at memory address 512 This is the default location for the start of the first user program e User programs User programs give SilverMax much of its true power and allow it to act as a truly intelligent servomotor User programs are integral to the standalone and hybrid configurations since in those configurations the logic and control load is entirely or partially shifted to the SilverMax User programs are formed by linking commands together The SilverMax command set includes commands for program flow logic and math functions memory manipulation as well as numerous commands to control the motion of the SilverMax QuickControl incl
203. ical jam When the jam is released and the shaft is free to move again the position error BEE Cancel can be huge and the servo might spin at a very high speed to DETR catch up The high speed Gen ete ice of the basic Ip ee Dee torque position error Kp calculation that virtually all Holding Error Limit Sr servomotors including SilverMax perform as part of their 20 counts p control sequence If position error is very large then so is the PEL torque response The most common way to prevent this Delay to Holding 9 oes response is to shut down the servomotor This may be fine if esd msee H f Native the shutdown is due to a jam but there are cases where a shutdown is not acceptable An alternative to shutdown would be to limit this position error so it never becomes large enough to cause a problem SilverMax Drag Mode allows the control algorithm to forgive excessive position error and prevents extreme motion Drag Mode is enabled with the ERL command In Drag Mode when an error limit is reached moving or holding SilverMax adjusts the target position so that it differs from the actual position by no more than the error limit Some examples of Drag Mode are e SilverMax can be configured to emulate a mechanical slip clutch For this application the ERL command is used to set the error limits and enable Drag Mode and the Control Constants CTC command is used to tune the response When configured for this operation Silver
204. ificant difference between QuickControl Program files QCP and the programs residing in the QCP files QCP files may contain many programs QCP files store program information like scaling parameters register names I O names and data stored in the register file system QCP files are saved to a computer s hard disk while programs are downloaded to SilverMax non volatile NV memory Only native command data is stored into SilverMax Remarks and program information are not downloaded Managing both QCP files on the PC and programs in SilverMax is necessary Program Size Limits The size of a program is shown in a small window in the middle of Program Info Toolbar when the program is displayed in QuickControl Size is listed as the number of words used in the program buffer e g 18 of 200 words used The SilverMax program buffer is 400 bytes long limiting the length of executing programs to 200 words QuickControl automatically places an End Program END command to the end of all programs reducing the maximum user length to 199 words If a program exceeds 200 words SilverMax will not allow it to download The solution is to create multiple programs of less than 200 words each that work together QCP files can contain an unlimited number of programs that can link to each other using the Load amp Run Program LRP command SilverMax User Manual 4 01 41 Multiple Programs in QCP Files From the QuickControl main menu select Programs then
205. iginal target is achieved even with Drag Mode enabled This compatibility with Drag Mode is one of the benefits of using Profile Move commands Ui Exercise 3 1 ERL and Drag Mode Operation with MAV and PMV This exercise demonstrates the effects Drag Mode has on motion from the Move Absolute Velocity Based MAV and Profile Move PMV commands Drag Mode adjusts the target position to keep it within a certain number of counts of the actual position The number of counts is determined by the Moving Error Limit parameter of the ERL command For example if the Moving Error Limit is 500 and the motor jams at position 2000 while moving in the positive direction the target position will not exceed 2500 regardless of what the original target was The entire motion profile of the MAV command is pre calculated by SilverMax It only moves the calculated time of the motion profile so SilverMax will stop short of the target position In contrast PMV will not stop short because it is recalculated every servo cycle Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers This exercise requires the user to manually stop the motion of the shaft A small flywheel attached to the shaft makes this task easier The torque limits must be set low so it will not be difficult to stop the shaft Please use caution 1 Power up t
206. ile move commands the Registered Step and Direction RSD and Scaled Step and Direction SSD commands do not pre calculate their moves They can be overridden by other RSD and SSD commands by VMP and VMI commands or by the PMO HSM STP and HLT commands Step and direction moves are covered in Chapter 6 Input Mode Commands The Velocity Input Mode VIM Torque Input Mode TIM and Position Input Mode PIM commands allow SilverMax to respond directly to the values in registers 12 through 18 Like the last three motion commands they do not pre calculate their moves The input mode commands can be overridden by VMP and VMI commands or by the PMO HSM STP and HLT commands Input mode moves can also be changed on the fly by changing the values in register 12 to 18 and are covered in Chapter 6 Hard Stop Move HSM Command The HSM command immediately stops a move started by any motion command Stop STP Command The STP command immediately exits the current program and stops any active move Halt HLT Command The HLT command immediately stops any motion sets the halt bit in the Internal Status Word and calls the Kill Motor Recovery program When multi tasking is enabled the motor drivers will remain active during the Kill Motor routine if the Kill Enable Driver KED command has been issued With multi tasking disabled the motor drivers are always disabled during a Kill Motor routine regardless of whether or not a KED command was is
207. ill Motor Conditions This is required if after this recovery routine normal operation is restored Kill Motor Conditions 4 KMC If Moving Error 5 REM A short wait before calling the next program This is not necessary but does allow time for things to settle 6 DLY Delay for 500 mSec Run a system recovery program from here This following 7 REM program could be a Homing routine that would recover from the error 8 LAP Load and Run Program Home the Give au Controlled Shutdown Recovery Program Power Loss Management and Recovery SilverMax needs a constant voltage source in order to function Unfortunately power can be interrupted so there are built in functions to help deal with this At approximately 10 5V lower for some HC SilverMax SilverMax disables the driver circuit The DSP is still functioning but the SilverMax no longer applies torque to the shaft Disabling the drivers prevents any erratic movement by the SilverMax at low voltages If the voltage drops below 7 5V the control electronics start shutting down All data stored in the volatile memory RAM is lost Upon the voltage rising above this lower limit the SilverMax essentially powers back on and goes through its default initialization When the voltage drops below 7 5V the SilverMax loses its position information The internal encoder contained in the SilverMax is not an absolute encoder Without power the SilverMax cannot monitor its position If any movement
208. ilter z Constants Constants C MAV MRAV Motor Dey 1 16 Test Move 1 Zero STOP REE Type S23H 3 Rev 32 4 Distance E counts Serial fea Acceleration 299999 9 cps s m Device Status Velocity 40000 cps Target Pos 5000 counts p Inputs Outputs Postion 5003 counts Test Move 2 Digital 1 0 red L0w Sg e geeteg wn JE Ja JE Ja Pos Error 3 counts aan a en ee ee Max Errorl4g aoe Acceleration 8000 1 cps s o KEE Toouelen Velocity 4000 cps TE nalog Inputs voltage Get Voltage ff 47 volts Get Temp 262 SE Stip Chat IS TE T af SilverMax User Manual 4 01 170 Example 10 1 Tuning a 100 1 Inertial Mismatch High resolution fast following applications require maximum bandwidth and gain but no oscillations A simple procedure for tuning SilverMax with a non frictional 100 1 inertial load mismatch using the Control Panel in QuickControl is shown below When tuning SilverMax it is important to keep the Velocity Feedforward Kvff term equal to the sum of the two velocity feedback terms Kv1 amp Kv2 The Acceleration Feedforward Kaff and feedback terms Ka should also be equal 1 Determine Motion Profile To Be Tuned Before beginning to tune SilverMax determine the motion profile for the system Absolute moves may be used to produce a fast move in one direction and a slow move in the other while helping to ensure that hard stops are not hit
209. ilverMax User Manual 4 0 188 Appendix F SilverMax Connector Specifications SilverMax 17 17H 23 and 23H Connector Data SilverMax 17 17H 23 amp 23H servomotors w o IP65 ratings are designed with one high density DB 15 connector for all controller signals and source power DB 15 High Density Connector This connector is found on all non IP65 rated SilverMax E series servomotors On 17 amp 23 frame size servos it permits access to I O lines serial communications and the power supply inputs It mates to all SilverMax DB15HD SMI cables for easy connection to many QCI products Technical Details DB 15HD 15 pin High Density D subminiature Plug w pins type gender Crimp type contacts Rated at 5 Amps per contact Max wire gauge is 20 AWG Shell size is a std DB 9 DB 15HD Pin Layout Front View on SilverMax DB 15HD Pin to Signal 17 23 non IP65 Signal Comments Pin Signal Description g 6 Power Ground V Input Power and Power Ground lines 1 7 6 and 11 1 V Input Power are not reverse bias protected 11 Power Ground SEN Poe x I O lines 1 2 amp 3 each have a 4 7k ohm pull up resistor 12 RS485 B RS232 Rx connected to the internal 5 VDC 100mA supply 8 Logic Ground 3 5 VDC Supply 100mA max I O lines 4 thru 7 each have a 200k ohm effective pull up 13 UO 1 impedance to the internal 5 VDC supply 9 O 2 4 0 8 A Drive Enable option is available on 17 and 23 series 14 ae servos I O line 3 be
210. ilverMax is being polled If Drag Mode is enabled then the position error will never exceed the limits and these conditions are not useful as Kill Conditions See Chapter 3 for more information on the Error Limits Command Enable Multi Tasking EMT Enables SilverMax Multi Tasking operation which allows motion to occur while executing a program in the background Multi Tasking is required when using the Kill Enable Drivers Command KED See the Command Reference for details on this command Enable Motor Driver EMD Enables the SilverMax driver The driver is enabled by default so this command is only required if the driver has been disabled by either the Disable Motor Driver DMD command or a kill condition Recovering or Restarting After a Kill Motor Condition Simple Shutdown Routine This program selects KMC settings but selects no recovery program Note that if the SilverMax shuts down a host would need to poll the SilverMax in order to determine that shutdown occurred This situation requires constant outside monitoring and intervention if immediate post fault action is needed For most applications the next method would be more applicable In addition this program can be used to shutdown SilverMax indefinitely until an operator resets manually Line Oper Label Command This program allows the motor shutdown routine to be tested Host intervention must be used to bring the motor 1 REM back up and running Move back a
211. imit Disable Last Calculation Was Zero Disable Holding Error From Error Limit Disable Last Calculation Was Positive Disable Halt Command was Sent Disable Last Calculation Was Negative Disable Input Found On Last Move Disable LA HI Disable Wat Delay Count Exhausted Disable LA 2 Disable Over Voltage Disable OD LU 87 Disable Low Voltage Disable baak Over Temperature TRUE Kill Motor Conditions Edit Window Index Found The internal encoder within SilverMax can trigger a kill condition since this condition resides within the ISW and the ISW is the basis for KMC This condition is available but is not necessarily useful as a SilverMax shutdown condition If a an external encoder has been setup its index signal will also trip this condition SilverMax User Manual 4 01 127 Last Calculation Was Zero Positive or Negative When a calculation takes place Using the CLC command the result of the calculation will be one of the above This allows SilverMax shutdown to occur based on the result of a calculation If for example a calculated position parameter should never be negative setting the Last Calculation Was Negative to TRUE will kill the SilverMax when this situation is encountered O 1 2 and 3 Used for E Stop conditions Three of the seven digital Inputs are available as kill conditions They are probably most useful when developing an emergency stop E Stop signal When using the controlled shutdown
212. in first out buffer capable of holding up to four interpolated motion parameters 1 segment The IMW command writes data to the Interpolated Move Queue through the serial interface If the data is able to fit within the queue it is accepted and the communication is positively acknowledged ACK If the queue is full the request is answered with a NAK Full response This NAK is to be expected it indicates the host is successfully keeping the queue filled The same data should be sent repeatedly until it is positively acknowledged ACK The host is still responsible for updating the upper word of register 17 as well Every time move parameters are copied from the Interpolated Move queue to registers 18 and 20 23 a 1 is set in the upper word of register 17 just as in standalone operation This 1 must be cleared set to O so the next set of move parameters can be used rather then the deceleration value in register 19 which will stop the profile and exit IMS operation SilverMax User Manual 4 01 103 SilverMax User Manual 4 0 104 Chapter 6 Input and Output Functions One of the most important features of SilverMax is the input output capability SilverMax has seven multi purpose I O lines These seven lines can be independently software configured for a variety of functions This chapter covers the basic operation of all SilverMax I O lines as well as their different uses There are four kinds of SilverMax I O functions
213. ine A and B The resistance between A and B is referred to as passive termination The pull up down resistors are active termination 1 2 KQ 150 Q Ser __ 485 LINEA 4 485 Line B Logic Ground Cable Shield not connected to SilverMax RS 485 Network Last SilverMax on RS 485 Network Additional information and Troubleshooting Communications is a complex topic and systems can require careful design A great deal of documentation on both the RS 232 and RS 485 standard is available on the Internet This section attempts to cover some commonly needed details in setting up communication systems RS 422 This is the 5 wire full duplex version of RS 485 The four data lines have two naming conventions and are usually labeled as follows Tx or TxA Tx or TXB Rx or RxA Rx or RxB Tie the Tx and Rx lines together to create the RS 485 A channel and the Tx and Rx to create the B channel RS 232 COMPATIBLE Many devices including many laptop computers have serial ports listed as RS 232 compatible These ports typically use low power signals that may or may not meet the RS 232 specifications As noted in the spec charts the ports can sometimes supply as little as 10mA which is insufficient to communicate with many industrial devices such as SilverMax There are accessories available for laptops and other devices to provide industrial quality serial ports These are usually available as conversions from other ports such as U
214. ined torque limit until the error decreases to lower levels This torque limit setting can be an advantage in tightening applications To avoid over tightening decrease the closed loop moving torque limit to the required amount However if the limit is set too low SilverMax might be unable to complete the motion profile correctly because of the low torque limit Data Register Relationships The real time torque output value from SilverMax resides in the low word of register 9 and updated every servo cycle 120 usec In closed loop control the torque value can be anything between plus or minus the torque limit setting The torque value during open loop control will be the exact value in the TQL command This is a read only data register The other data registers relating to torque are registers 206 and 207 These registers contain the four torque limits of SilverMax are available for both read and write The values listed in 206 amp 207 reflect the last TQL command executed SilverMax will update these registers anytime a TQL command is executed either in a program or sent from a host For more information see Register Control under the Control Methods section in this chapter Torque Control Methods Three methods actively control torque in SilverMax Torque limits set the maximum available torque output during any operation and are readily available via specific registers Torque limit registers can be dynamically modified from any source in
215. ing on a combination of inputs is required The advanced method can alter the direction of a move based on an input s starting condition toggle the final check values accordingly and perform two ordered checks Instead of a single number two complete 16 bit words are passed to SilverMax the Input Enable Word and the Input State Word A complete table of these words follows the descriptions First Check Used to toggle the starting direction of a motion The upper four bits of the Input Enable Word and Input State Word parameters are used to determine the initial direction of a move based on the selected states of the enabled inputs If any of the input conditions are met when the move begins the motion will be in the opposite direction of that indicated in the command There are two more bits one in each word These bits cause parameters in the other two Checks to change if First Check has reversed the direction If the Toggle Second Check Conditions bit is set all enabled Second Check conditions will be inverted This allows SilverMax to look for the opposite edge of a sensor flag if motion begins on the sensor If the Toggle OR States bit is set all enabled Last Check OR conditions will be inverted This check is only performed as the motion begins and the system immediately moves on to the Second Check Second Check Used to do a Two State input check The Second Check does a preliminary test of the inputs The Second Check condi
216. inue when power is restored a Register Store Non Volatile RSN command should be added to the Power Low Recovery program This command will store the data from the Actual Position 1 register to some Non Volatile memory location Download the Initialization File to SilverMax Select the Download File To SilverMax button to have the initialization file parameters become active on power up and SilverMax reboot This will downloaded the file to SilverMax and reboots the system to ensure the new parameters take affect To exit the SilverMax Initialization Wizard select the Exit button SilverMax User Manual 4 01 22 The following illustration is a listing of the SilverMax Factory Default Initialization qcp file SERVO Filter Constants Filter Contants Using Default Settings These programs contains the SilverMax s initialization SERVO Control Constants commands It can be edited directly or through Control Constants e DES 8 Using Default Settings Tools gt SilverMax Initialization Wizard z ERVO Gravity Offset Constant Download the program at the end of the wizard or by pressing the Download button in the Program Info Toolbar Reboot the SilverMax See the description in Scaling for more details MOTION Direction ez Communications COMM Direction cw Do Phase Align COMM Identity Open Loop Phase Identity Torque Ramp Up Unit ID 16 Group ID 20 Final Torque
217. ion error only not in response to changing target position since the Trajectory Generator is inactive SilverMax calculates the torque to apply but is limited by the Closed Loop Holding torque limit set with the TQL command In this control state SilverMax uses full servo control to correct for position error just as it does when in the closed loop moving torque state Full servo control can lead to dither as explained in the section on Anti Hunt e Open Loop Moving Control SilverMax has the ability to ignore the servo feedback while calculating motion Positioning is still achieved from the encoder feedback SilverMax is essentially emulating a stepper type of drive when operating like this When SilverMax is using open loop control and the Trajectory Generator is active SilverMax moves the shaft based only on the changing target position from the Trajectory Generator When operating this way SilverMax applies maximum allowable torque as set by the Open Loop Moving torque limit set with the TQL command The SilverMax Anti Hunt feature occasionally uses this control state e Open Loop Holding Control When in the open loop holding control state SilverMax does not move the shaft at all SilverMax ignores any position error and applies open loop holding torque to hold position This control state can be very useful in eliminating servo dither and is used for Anti Hunt Anti Hunt eliminates servo dither but can increase servo heating if the Open Lo
218. ional to current but heat is proportional to the square of current Therefore decreasing the torque setting by 25 will generally decrease the heat generated by almost 50 The Anti Hunt feature default operation switches SilverMax into open loop mode temporarily and uses the open loop torque limit when motion ends as SilverMax begins holding If the SilverMax is configured for open loop operation SilverMax torque control acts very much like a stepper drive Again the open loop holding limit specifies the exact torque SilverMax uses to hold the rotor at any point Open loop mode disables torque feedback so the SilverMax no longer servos Therefore use of the open loop mode with the Go Open Loop GOL command is not recommended Refer to the Open Loop and Closed Loop Control section of Chapter 3 for more detail on open loop mode operation Open Loop Moving SilverMax only implements the open loop moving torque limit if two conditions are met The SilverMax must be switched over to open loop control with the GOL command and a motion command must be executed Because this motion has no feedback it is not controlled and may not end up at the commanded position as expected Operating in this mode should be avoided unless the user is familiar enough with SilverMax to use it properly This control state is also reached when the Anti Hunt Mode AHM is set to 1 causing SilverMax to move in open loop mode Good for very slow applications Closed Loo
219. is set to 20 30 Normally the Closed Loop Holding torque limit is set about 10 higher than the Open Loop Holding torque limit Open Loop Moving torque rarely ever comes into play so this setting is rarely edited Control Loop Mode CLM The CLM command closes the control loop around position or around velocity When the servo loop is closed around motor velocity rather than motor position the proportional gain Kp is ignored and therefore is disabled and the integrator acts on the difference in velocities between the target velocity and the actual SilverMax User Manual 4 01 160 velocity These changes allow the SilverMax to smoothly recover from a motion stoppage without overrunning the target velocity Single Loop Control SLC The SLC command configures SilverMax to run in a single feedback control loop All information for commutation position velocity and acceleration control is derived from the internal encoder If a motion is running the Trajectory Generator must be shut down before executing this command When entering single loop control SilverMax sets the current target position to the actual position SilverMax uses single loop control by default The Dual Control Loop command is used for cases where external encoder position control is required Switching between Single Loop and Dual Loop control usually requires changing the control loop tuning Dual Loop Control DLC The DLC command configures SilverMax to run in a dua
220. ision System etc SilverMax inputs and or outputs application specific SilverMax cable I O wires application specific Power supply wires Serial communications cable O0 NO Or Ps G0 Generic Hybrid Setup The QCl recommended configuration is often easier for new users and more reliable for experienced users but systems using custom built cables or slightly different configurations can work just as well A generic hybrid configuration would be a combination of the generic standalone and host configurations with custom cables providing connections between the host and the SilverMax the SilverMax and a power supply and the SilverMax and any I O devices the system required SilverMax User Manual 4 01 3 Multiple SilverMax Configurations SilverMax can be part of small RS 232 or larger RS 485 networks Two or more SilverMax can also be interconnected by using their I O lines The possible configurations for multiple SilverMax systems are seemingly endless although all of the configurations are just combinations of the two basic configurations listed in this section Many of the advanced applications for SilverMax use this capability RS 232 or RS 485 SilverMax Network Network SE Power Supply This drawing shows three SilverMax configured on an RS 232 or RS 485 network The external host can communicate with each SilverMax individually or with all of them as a group Each SilverMax can have its own I O lines connec
221. issued even if those bits have been cleared by an intervening CPL command i e the data is double buffered and the bits cannot be cleared until they have been read The CPL requires one parameter the decimal form of any bits in the Polling Status Word that need to be cleared If bit 0 of the word is set the decimal form of the word would be 1 0000 0000 0000 0001 Issuing the CPL command with a 1 parameter would clear bit 0 If bit 0 bit 2 and bit 5 were set the decimal form of the word would be 21 0000 0000 0001 0101 The CPL parameter to clear just bits 0 and 2 would be 5 The parameter to clear all three bits would be 21 To clear all bits in the Polling Status Word the parameter for the CPL command needs to be 65535 because this is the decimal equivalent of a 16 bit number consisting of all 1 s Binary numbers and binary number arithmetic are covered in the appendix SilverMax User Manual 4 01 48 Polling Status Word Description The meaning of each bit in the Polling Status Word is explained in the table below The description for each bit describes the SilverMax condition indicated by a 1 in that bit Bit Latched Definition Description 15 Yes EE An immediate command finished executing There was a checksum error while reading data from 14 Yes NVM Checksum Error non volatile memory All commands active in the Program B
222. ister Immediate command WRI to the desired register with the new data parameter All Position data is for ABSOLUTE POSITIONS with the PROFILE MOVE command Profile Move Stop when 1 0 1 is LOW FALSE Enter remark here Example Main Program SilverMax User Manual 4 01 138 Kill Motor Conditions as an Interrupt Since SilverMax checks the status of the KMC settings every servo cycle one or a combination of settings could be used as an interrupt to break the flow of a program and run the recovery program In this case the recovery program could be triggered by an I O state intentionally by the operator and the main program could be set up to restore program flow to the location interrupted Usually a register is used to keep track of the currently executing line This register is checked when the main program is loaded to determine where to begin execution i Exercise 8 1 Using an Input to Trigger a Kill Motor Shutdown This exercise demonstrates a simple automatic shutdown of the SilverMax driver circuit using a single input to trigger the shutdown Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers 9 Re initialize the SilverMax Make sure QuickControl is polling the SilverMax and that I O 3 on the training block is in the HIGH position 10 Click on the New Program ico
223. ith an external device Because of this digital outputs can be extremely useful for communicating the state of SilverMax to an external device or to a user Digital outputs are one of the features that give SilverMax the most flexibility For example a SilverMax program could include branching logic that would jump to one of two sections of code based on an input One section of code would start a rapid move while the other section of code would start a slower move The section of code for the rapid move could also set I O 2 high That output could connect to an input on a PLC The section of code for the slow move could set I O 3 high and that SilverMax User Manual 4 0 109 output could trigger another input to the PLC With this setup the PLC could monitor a critical state of SilverMax With a similar setup the SilverMax with the two move speeds could use its two digital outputs to interface with two digital inputs on a second SilverMax The second SilverMax could be programmed to respond in one way if the first SilverMax were moving at the fast speed and in another way if the first SilverMax were moving at the slow speed Interlocked SilverMax programs like this can be very useful on multi axis machines Configure I O CIO Command The ClO command discussed in the previous section configures the seven I O lines By default all SilverMax I O lines are configured as inputs The ClO command can reconfigure any of the lines as a digital ou
224. ition Mode Target Delta Proportional al Position Daag ee E Mode CLM Integrator se Gain a a y gt j w x Ee Limiter gt Tmax lt X lt Tmax Limited Intearat uerg S Se K E Velocity LA Mode CLM ga Te this cycle S Encoder Delta _ this cycle E 4 y Summation Bock ES SE j L J Ce Unit Delay Block 120 usec per tick SilverMax PVIA Block Diagram SilverMax User Manual 4 01 159 Gain Block Limiter 16 bits Limiter Block Block Diagram Legend 2 15 lt X lt 215 1 Torque Output o gt SilverMax Tuning Commands Primary Commands The following two commands set the SilverMax primary tuning parameters See the SilverMax Command Reference for the specific details of each command Control Constants CTC This command specifies values for the seven SilverMax servo loop gain constants Proportional Kp Velocity 1 Feedback Kv1 Velocity 2 Feedback Kv2 Velocity Feedforward Kvff Acceleration Feedback Ka Acceleration Feedforward Kaff Integrator Ki Filter Constants FLC This command selects the cutoff frequency for the velocity and acceleration filters Velocity 1 Feedback Filter Fv1 Velocity 2 Feedback Filter Fv2 Acceleration Feedback Filter Fa Associated Commands The following commands set parameters associated with tuning Anti Hunt Constants AHC The Anti
225. ition error feedback enters the servo loop and Kp scales the error The product of the error and Kp produces a torque that minimizes error This concept is the basis of most servomechanisms Thus the larger the error grows the more torque SilverMax produces For general SilverMax motion torque output is not directly proportional to position error due to the effect of the control parameters Kv1 Kv2 Kvff Ka Kaff and Ki However the product of Kp and position error does provide a good approximate of SilverMax average torque output Torque Kp Target Position Actual Position or Torque Kp X Position _ Error The best analogy to Kp is a simple spring If SilverMax were to be replaced by a spring Kp would be the spring s stiffness If the shaft were rotated the spring would be winding or unwinding The more the shaft was rotated the more the spring would fight back The next Strip Chart plot from the QuickControl Control Panel demonstrates the effects of Kp The filter constants are set at their default values and the control constants are set as follows Kp Kvi Kv2 Kvff Ka Kaff Ki O O O O O O SilverMax User Manual 4 01 162 The Strip Chart plots a 4000 count 100 millisecond ms move with a 25 ms ramp time MAT command d is Suppose here the shaft ition is w The channels plotted are Position and Target Position The Target Pos IS ion is w to be and the Pos SS E SE SS
226. itions See Chapter 4 for using I O and the serial interface to control motion Basic SilverMax Motion Commands There are four basic motion commands that are used to create simple motion profiles These commands follow the same motion rules but require different motion parameters The result is a similar type of motion The differences between the commands allow motion to be defined by relative or absolute distance using velocity or time as the base The commands pre calculate the motion profile into a standard trapezoidal motion The motion profile is subject to the maximum acceleration and velocity of the servomotor A motion profile that SilverMax cannot accomplish will cause a command error and the motion will not be executed Execution of complex motion profiles is covered primarily in Chapters 4 and 5 Relative Motion The Move Relative Velocity Based MRV and Move Relative Time Based MRT commands are both relative moves Relative motion is distance based meaning that the first parameter is the overall distance to move The current position when the motion begins is irrelevant and the shaft will simply rotate the specified number of counts Absolute Motion The Move Absolute Velocity Based MAV and Move Absolute Time Based MAT commands are absolute moves As long as SilverMax is powered it keeps track of its current location based on the zero SilverMax User Manual 4 01 36 point The absolute position to move to is also based
227. ivedsevesseveuyeisevvayevees HENNEN EEN 60 Anti Hunt Constants AHC Comtmanmgl Gieu t Ree eekeEde EE SEENEAEEN EAR een 60 Anti Hunt Delay AHD Command WEE 60 Anti Hunt EERSTEN gert Sew se Sancy stees ueeahaecactasanee teen oapsiceds ed 60 Error Limits ERL and Torque Limits TQL Commande sssssneesseernsereeneersnnersrrrrnsrtrnnnrnnrnssrrrnnerrnne 61 Multi SKIING E 61 M lti Tasking Eege 61 silverMax Servo ee TEE 61 Multi Tasking Operation TEE 62 Exercise 3 2 Multi Tasking for Advanced I O Control 65 GLE WGL and WCW Command naeia a a a AE Een 65 Calculation CLC Omni an ME 65 Exercise 3 3 Calculation Example c c ceiscsctecensachedeetyccrtageeoeaanesenkercuaglotacssdandeneeezcnsdelanvaciabens daeceraadiend 67 WCW and WCL ee unt ue EE 68 Exercise 3 4 Dynamic Speed and Acceleration Adiust e 68 Chapter 4 Motion Control Using Inputs and Registers csscssseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneees 71 Using aleet 71 Standard Stop Conditions QUICKCONTIOL kA 72 Standard Stop Conditions Serial Communmicatons cece eeeeete ee ee cette eee teee eee eeeeeeeeeeeeaaeeeeetenaaeeeenee 72 Advanced Stop Conditions EE EE 73 Advanced Stop Conditions EE 74 Advanced Stop Conditions Table oeugeeugdeskerEgegiegued dee code udandepeieshalueessniiadeuedandsceeusniat ENEE 75 EALE ee R E eege E 75 Second Check rele Eeoa aaa Eegen ettlech eps 75 EE 75 Advanced Stop EE 76 Advanced Stop Conditions QuickControl AAA 77 Register
228. k term Ka Normally Kaff is set equal to Ka although it may be set slightly higher than Ka to assist with the acceleration of high inertial loads SilverMax User Manual 4 01 167 Integrator Gain Ki The integrator parameter is the most important term for controlling steady state position error The integrator works over time to eliminate position error The longer there is position error the larger the effect of Ki to get rid of the error This term is commonly referred to as the I term in the traditional PID control loop Unlike a PID servo the PVIA integrator term can be increased greatly without causing hunting or oscillation This is because the PVIA loop clips the accumulated error to reduce the effects of the windup caused by the integrator The integrator gain should be set to zero when tuning the motor This allows the true steady state response to be seen This chart shows a 500 count move run with Kp set to 7 all other gains set to 0 Strip Chart Dis x Y Min O Y Mayf600 Sample ms 3000 EBR Select Channels Cancel sjala amp S EH my aele JS elti EI Target Position H Position Kp 7 all other K values gains 0 The shaft never gets to the target position because there is not enough torque generated by Kp to move the shaft into position By using Ki more and more torque will be added until the position error becomes zero In the next plot the integrator gain term is set to a small
229. kill occurs SilverMax leaves its motor drivers enabled allowing controlled deceleration granted there are no obstructions and inertia has been taken into account In addition with Multi Tasking enabled SilverMax finishes any motion that was in progress at the time of the kill This motion will continue to completion unless it is overridden by a command in the KMR program SilverMax Shutdown Commands The details of the following commands are available in the SilverMax Command Reference Kill Motor Conditions KMC The KMC command allows the user to select what conditions will allow a controlled shutdown of the SilverMax unit The Condition Enable Word selects which bits in the Internal Status Word will be evaluated Conditions are enabled by setting a 1 in the desired bit position of the Condition Enable Word The Condition State Word allows the user to specify the state of the selected conditions that will cause SilverMax to do a controlled shutdown Kill Motor Recovery KMR The KMR command sets up options for recovery from a SilverMax shut down The KMC command establishes conditions that will cause SilverMax to shut down Using the KMR command SilverMax can perform a standard or user defined process for re initializing the SilverMax User programs can be executed that have been previously stored in the non volatile memory of SilverMax Kill Enable Driver KED Causes SilverMax to leave the servo drivers enabled when a KMC setting is
230. l execute two moves depending on the state of the I O 1 switch or I O 3 switch The program runs ina continuous loop monitoring the two switches If data in the User Registers is modified the motion profiles of the moves can be changed Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers 1 Select File gt Open Navigate to the QCI Examples Using Inputs for Move Selection folder and select the file Two Inputs Two Moves with RRV qcp 2 Open the Register Watch Tool Tools gt Register Watch Click the Add Register Button select User 25 select Position for the Data Format and click OK Click the Add Register Button again select User 26 select Position for the Data Format and click OK 3 Click the Run button to download and begin execution of the program Once the program is downloaded click on the OK button 4 Notice the values placed in the selected Data Registers by the program Toggle I O 1 switch LOW then back to High SilverMax will execute a simple move 5 Toggle I O 3 switch LOW then back to High SilverMax will execute a different move 6 Click once in the Data column of the User 25 Register Enter the value 10 into the cell and push the Enter key on the keyboard Toggle I O 1 switch LOW then back to High 7 Click once in th
231. l be displayed and may be edited The units for initial data can be set by double clicking in the units column 89 Edit RLM Register Load Multiple x Register File Name Cance Profile Ode to Joy Description Edit Register File Indirect JV Addressing Mode Select the Starting Register User 30 Number of Registers E Memory Location FE Fe Note When using indirect addressing the accumulator must be loaded with non volatile memory address See WRF Mode Ge Normal Native WRF Command Write Register File The WRF command is very useful for loading the accumulator with the proper address when utilizing indirect addressing Besides the starting address for the Register File Array the WRF command can also load the number of columns in the array the number of rows in the array the ending address of the array and the address increment Using the address increment along with the starting address the starting address of any of the array rows can be found and loaded into the accumulator for indirect addressing Register Name E x Cancel Edit Selected Register Name Input Mode Registers 12 18 Set Names Set To e Za iiser ERC ive ames Profile Move Registers 20 24 SetTo Set Names Descrinti To User Deem ive ames Reset Selected Register Name to Default Reset All Register Names to x Default 11 User Input Source Data 12 User Input Offset 13 U
232. l feedback control loop With a dual feedback control loop SilverMax uses an external encoder signal for position info SilverMax commutation velocity and acceleration feedback information are still derived from the internal encoder however moving and holding error limit flags are also based on the external encoder for triggering the Kill Motor Conditions Anti Hunt Mode uses the position error derived from the external encoder to establish when to move in and out of open loop holding torque When precise position control is needed an external encoder allows direct position control of the device Attaching an encoder directly to the driven device avoids the backlash and flexure present in the coupling between SilverMax and the device When using a linear slider for example a linear encoder can be used for the external encoder signal When entering dual loop control SilverMax sets the current target position to the current actual position in order to prevent a sudden motion SilverMax must be configured for closed loop control for this command to take effect SilverMax uses single loop control by default but the DLC command can be placed anywhere in a user program to change SilverMax to DLC Executing a move with single loop control before entering dual loop control may be used to verify that the external encoder is connected and operational The external encoder settings must be initialized before using this command The Select External Encoder SEE
233. lete all registers on the register list amp close the Register Watch Tool Program Flow Control Basic SilverMax program flow is a straightforward line by line execution of a program Altering the flow of a program from this default requires use of the program flow commands There are two main types of flow commands wait commands which pause program flow and jump commands that change the order of command execution Jump commands that are register based allow the use of register data in determining the flow characteristics This allows a host to control program flow via serial communications In specific host based applications where all I O lines are allocated or I O lines are not used this method of flow control is necessary Pausing Program Flow There are three commands DLY WBS and WBE which pause program execution while waiting for different conditions To create a wait condition based on multiple signals use the appropriate jump command Delay DLY This command causes the program to pause for the specified time period More complex timing structures can be implemented using the Wait Delay WDL command See the SilverMax Command Reference for details SilverMax User Manual 4 01 81 Wait on Bit State WBS When SilverMax executes this command it will wait for the specified condition before executing All seven I O lines as well as several internal status bits can be conditions The second option specifies the state to wai
234. lines to be configured for three specialized functions raw internal encoder signal output scaled modulo internal encoder signal output and high speed external signal input When configured for any of these functions the I O lines used cannot be used for any other I O function The maximum reliable input or output pulse rate for any of the high speed functions is 1 pulse per usec or 1 MHz The high speed I O functions must interface with TTL circuits just like the other I O functions Due to the speed of the signals however optical isolation may not be possible the QCI website contains specifications for the maximum signal rates of the QCI optical isolation module The high speed functions use three types of signals step and direction A and B quadrature and step up step down These signal types are explained later in this chapter UO Conflicts The seven I O lines can be configured to perform many different functions These functions can compete for I O resources so care must be taken when assigning I O lines to a given function Careful and systematic design can usually eliminate problems before they occur Many of the SilverMax I O functions require the use of specific I O lines meaning that those lines are not available for other I O functions Some UO conflicts can cause fatal errors in SilverMax programs Others might not cause a fatal error but might cause serious hidden problems such as a desired Kill Motor input condition being ignored
235. lowing Move Relative Time Based MRT command SilverMax User Manual 4 01 Second byte is the length set to zero This defines the packet as the POL Command packet 147 Command MRT Command Number 177 ID 16 Distance 4000 counts Hex OxFFFFFO060 Ramp Time 833 ticks 1 tick 120us 0x00000341 Total Time 8333 ticks 0x0000208D No stop conditions Fields with data shown in hex Stop Stop Enable State 0x10 0x11 0xB1 OxFFFFF060 0x00000341 0x0000208D 0x0000 0x0000 OxEF ID Length Command Distance Ramp Time Total Time Checksum Byte stream with data shown in Hex 10 11 B1 FF FF FO 60 00 00 03 41 00 00 20 8D 00 00 00 00 EF Response Packets All of the information returned from SilverMax is in binary format The ID of the responding servo is returned as a single byte with the ninth bit set The length of the return packet is returned as a single byte All parameters are returned as bytes with 2 bytes for words 16 bit and 4 bytes for long words 32 bit The checksum is returned as a single byte There are three types of response packets Acknowledge ACK Returned Data and Negative Acknowledge NAK Each has a different form to allow them to be easily parsed by the host system ACK RESPONSE The ACK response is the positive acknowledge of the receipt of a command packet This response has also been shortened to minimize the load on the serial communications i
236. lp minimize communication overhead 5 lt CR gt shortened format Response Packets All the information in a response packet is in ASCII hexadecimal Each type of response packet has a different start character but all use the lt CR gt as the ending character ACK PACKET The ACK response uses the asterisk as the start character followed by a space the SilverMax ID in hexadecimal and the lt CR gt end character 8 Bit ASCII ACK Packet Data Transmission Order Start Character ID Hex Ending Character 1 Byte 1 2 Bytes 1 Byte lt CR gt Example Acknowledge response from SilverMax 16 which is 10 in Hexadecimal 10 lt CR gt DATA PACKET Data packets use as the start character This is followed by the ID of the responding servo the command number being responded to the actual data requested followed with the lt CR gt ending character 8 Bit ASCII Returned Data Packet Data Transmission Order Start ID Hex Command Data Fields Ending Character Number Hex Hex Character 1 Byte 2 Bytes 4 Bytes 4 Bytes each 1 Byte lt CR gt Example Poll command data response from SilverMax 27 which is 1B in Hexadecimal The actual data returned is the Polling Status Word 1B 0000 2000 lt CR gt Example Read Register command data response from SilverMax 10 0x0A in Hexadecimal the last 8 digits represent the 32 bits of data The Read Register command number
237. lverMax User Manual 4 01 166 The system responds very well with Kp 40 Strip Chart x vr Min 0 uP Max 5200 Sample ms 200 elpgleli S Kp 40 Kv2 3 Kvff 3 Acceleration Feedback Ka The acceleration feedback value is derived from the Velocity 1 post filter value The Acceleration Feedback term functions as an electronic damper improving the overall system smoothness and decreasing the system settling time Ka amplifies high rates of velocity change feedback This counteracts any rapid changes in shaft velocity Ka can be thought of as a virtual flywheel attached to the shaft The larger the value of Ka the larger the virtual flywheel becomes A larger flywheel increases the inertia of the system and resists rapid acceleration Thus Ka smoothes out the velocity ripple Excessive Ka can introduce noise into the system as the individual encoder counts are emphasized This noise often occurs as of a high frequency squeal Ka is most useful when tuning out vibrations or resonance modes induced by system components e g a belt drive To use this term effectively very stiff shaft couplings should be used See the section on tuning belt drives at the end of the chapter for an example Acceleration Feedforward Kaff The Acceleration Feedforward value is derived from the Velocity Feedforward value It functions similarly to the Velocity Feedforward term by compensating for the position lag induced by Acceleration Feedbac
238. m SilverMax User Manual 4 01 165 Velocity Feedforward Kvff SilverMax contains an internal target generator called the trajectory generator In real time SilverMax calculates the motion profile defined by a command and its parameters During each servo cycle the target position is updated in the servo control loop The trajectory generator also calculates a target velocity The target velocity value is used to compensate for lag in position that is induced by the Velocity Feedback terms Kv1 and Kv2 Velocity Feedforward is a positive value used to anticipate the velocity necessary for a given move Setting the gain value to zero eliminates the Velocity Feedforward term Usually this gain value is set equal to the sum of the Velocity 1 Feedback Kv1 and Velocity 2 Feedback Kv2 gain values Kvff 3 produces the following chart Strip Chart Y Mind Malz Sample ms 200 DE Cancel slale deed aele BUE elt Kp 10 Kv2 3 Kvff 3 The actual velocity follows the desired velocity very well To further reduce position error Kp can be increased With a dampener in place Kv2 increasing Kp should not cause the system oscillation In the next plot the value of Kp is increased For applications that require zero overshoot and faster response Kvff may be slightly reduced to force a following error This forces SilverMax to approach the commanded position from the starting side without overshooting Si
239. m Flow Conditional program flow control is essential for building complex operations in any kind of a programming environment SilverMax can use jump commands in a number of different ways to achieve traditional conditional program flow Chapter 4 provides details on program flow control Using Digital UO for Flow Control The basic flow control commands such as Jump JMP use the Internal Status Word to detect conditions There are several variations of this command that allow logical decisions to made based on the state of all seven I O lines Using these commands it is possible to create complex program flow using devices as simple as contact switches For more information on I O and flow control see Chapters 4 and 6 Bes Exercise 2 3 Creating Downloading and Running a Program in QuickControl In this exercise a new program is created in QuickControl It includes a short Move Relative Velocity Based MRV move clockwise and a similar move counter clockwise I O 1 can be triggered low to stop motion at any time Note The exercises in this manual are designed for use with one SilverMax a PC running QuickControl an acceptable power supply and a basic QCI start up kit or comparable circuitry for I O triggers CREATING A NEW PROGRAM 1 Select New Program File from the File menu to open a blank new program template 2 Choose Add from the Program Info Toolbar to place a new program command in 3 S A m Program
240. m data to IMS with the register based queue Either store all data in successive blocks of four user registers if the data profile is small enough and construct a loop that iterates the appropriate register reference number into the lower word of register 17 or import data from a register file array into the same set of user registers and leave the lower word of register 17 alone The register file array method allows for much larger data tables and higher profiling resolution Time 0 to 2 147 483 647 A value within this range indicates the number of servo cycles 120 usec time slices to count down before loading the next set of data Note that this time parameter does not influence the motion profile it acts as a time delay giving the profile enough time to develop based on the acceleration velocity and position data sent with this parameter The next set of move parameters must be loaded by the register base queue or the Interpolated Move queue before this counter decrements to zero or the deceleration value in register 19 will be used to stop the profile A 0 indicates the last set of data to be transferred and tells SilverMax to end IMS operation SilverMax User Manual 4 01 100 Position 2 147 483 648 to 2 147 483 647 Unless the segment is intended to come to a halt at a given location the position parameter is only used to project the direction of motion It should be noted that position calculations incorporate register wrap
241. mands VMP and VMI do not pre calculate their moves so program flow is not disrupted They also do not check on the busy status of the Trajectory Generator so they will override any other move that is still executing Setting the desired velocity to zero and issuing the VMP or VMI command is the best way to do a controlled stop on a move because these two commands override the other move commands and because the deceleration can be specified A VMP or VMI command can be overridden by another VMP or VMI command a PMO command or by an HSM STP or HLT command Profile Move Commands The profile move commands allow SilverMax to follow a pre defined motion profile Like VMP and VMI the Profile Move PMV and Profile Move Continuous PMC commands do not pre calculate their moves They can be overridden by other PMV and PMC commands by VMP and VMI commands or by the PMO PMX HSM STP and HLT commands Moves using profile move commands can be dynamically changed by modifying the motion parameters when multi tasking is enabled Interpolated moves using the IMS command work like profile moves with respect to multi tasking Profile amp interpolated moves are covered in Chapter 5 Step and Direction Commands The step and direction commands allow SilverMax to respond to direct motion commands from a host in a manner similar to a simple stepper motor although SilverMax can still use closed loop control unlike any stepper Like velocity mode and prof
242. me of registers and data for specific Register Files There can be multiple Register Files imported but the details of each Register File must be contained on one line of the text file The Register File details must be separated by commas and listed in the following format lt reg file name gt lt of registers gt lt 1 reg data gt lt 2 reg data gt lt last reg data gt lt reg file name gt Name of importing Register File Quotation marks are optional and spaces allowed lt of registers gt The number of registers to be stored in this Register File Range must be 1 to 10 lt 1 reg data gt lt 2 reg data gt lt last reg data gt The 32 bit data entries that are to be stored in this Register File The number of data entries should match the number of registers for this Register File Commas must separate the data entries Example Reg File 1 2 100 110 This would define a Register File named Reg File 1 that has 2 registers with data 100 and 110 Example NVReoFile startAdr 2500 col0Fmt time col2Fmt pos col4Fmt vel Reg File 1 2 100 110 Reg File 2 6 30 31 32 33 34 35 If an imported text file contained the above example it would create two Register Files named Reg File 1 and Reg File 2 Reg File 1 would start at memory location 2500 and Reg File 2 would start at memory location 2506 After importing non volatile memory starting at address 2500 is be configured as follows
243. mit is surpassed and the Kill Motor Condition is activated The driver will disable Click the Reboot button to try again What kind of malfunction would trigger this type of motor shutdown SilverMax User Manual 4 01 140 Chapter 9 Serial Communication and Networking Operating in a host configuration or accessing the SilverMax serial communications requires networking Networking SilverMax servos uses industry standard protocols and serial interfaces The serial interface selected dictates the hardware configuration while the protocol selected affects the programming necessary on the host side SilverMax supports two standard communication protocols 8 bit ASCII and 9 bit binary The default and most straightforward is the 8 bit ASCII protocol It uses packets constructed from 8 bit ASCII characters to send commands to and receive responses from SilverMax This is a common protocol supported by most PLCs HMls and other host devices However the 9 bit binary protocol provides more robust communications Each packet consists of binary values and includes packet length and checksum information The 9 bit protocol has built in error checking to determine the integrity of all commands received Two serial interfaces are also supported RS 232 and RS 485 The default RS 232 is a widely used easy to wire communication system SilverMax uses the simple three wire version of the RS 232 standard RS 485 is a more noise immune interface
244. mmand sent from an external host and through a large number of different Program commands that are available for flow and motion control in SilverMax programs When accessed by a host the I O Status Word allows the host to view information that can supplement the information available from the Polling Status Word As with that word a host could be programmed to act on changes in the I O Status Word or it could be used for monitoring The I O Status Word cannot be accessed directly by a SilverMax program but the conditions represented by the 16 bits in the I O status Word are used as the stop or jump conditions in most of the motion and jump commands SilverMax User Manual 4 01 49 Read UO States RIO Command The RIO command is similar to the Poll POL command It is issued by an external host to gain access to the I O Status Word The RIO command can be executed at any time and returns the hexadecimal form of the 16 bit binary number that makes up the I O Status Word None of the bits are latched so the number returned with the RIO command will represent current information The meaning of each bit is explained later in this section Jump and Motion Commands Most jump commands used by SilverMax programs use the I O Status Word This word is also used with motion commands for stop conditions The jump commands use the status word to define the conditions for the jump e g if I O 1 is LOW jump to line 5 The motion commands use the word to de
245. mmands JOI JOR etc allow a program to jump to another command within the program based on one or more inputs For example if an application required SilverMax to start a move if a switch were thrown the Wait on Bit State WBS command could be used This command can be tied to any I O line configured as an input and can be set to wait until the input goes high or goes low If the command were set to wait until I O 1 went high for example the program would pause at the WBS command for as long as I O 1 stayed low As soon as I O 1 went high the program would continue If a motion command immediately followed the WBS command then the start of the move would be tied to the state of I O 1 A looping structure with a jump command could be used for the same application if multitasking were enabled A loop could be set up using the Jump JMP command to repeat the loop and a Jump On Input JOI command could be inserted into the loop and tied to the state of I O 1 If I O 1 were low the loop would continue running repeatedly When I O 1 went high the JOI command would cause the program to jump out of the loop If the JOI command pointed to a motion command the start of the move would be tied to the state of I O 1 just like in the previous example The example programs that come with QuickControl illustrate both of these program flow techniques SilverMax User Manual 4 0 108 Motion Control Inputs A digital input can control motion based
246. mmands that SilverMax uses for the external encoder input function Both commands allow scaling of the input signal When these commands are used SilverMax generates a motion profile based on the incoming signal This is different from the other types of motion commands like MRV where SilverMax generates the motion profile internally The Select External Encoder SEE command must be used to configure SilverMax to receive the external encoder input signal More information on these commands is available in the SilverMax Command Reference External encoder input signals can be scaled with the SSD command or the RSD command The exact scaling procedure depends on the SilverMax internal encoder type The SSD and RSD commands scale the external encoder input signal to a 1 1 base value This base value is 1024 for 4000 count encoding 512 for 8000 count encoding and 256 for 16 000 count encoding The scaling parameter for the two commands can be set to any integer value between 1 and 32767 When the scaling parameter is set to the base value 1024 SilverMax will scale the signal at a 1 1 ratio so one external encoder count results in one count of SilverMax motion If the scaling value is greater than the base value one external encoder count will result in more than one count of SilverMax motion if the scaling parameter were set to 2048 ona SilverMax with 4000 count encoding one count from the external encoder signal would equal two counts of SilverMax mo
247. motor Torque lower word D 0 O 0O N O1 AIIN User Registers 10 42 Registers 10 through 42 are available for general use but some can have special functions under certain commands These registers are tabled with their command specific uses in the Appendix and the SilverMax Command Reference SilverMax User Manual 4 01 40 Dedicated System Registers 200 233 Registers 200 through 233 fulfill a variety of advanced application specific functions Their functionality is unique and used as needed to meet application requirements Detailed information on these Dedicated Data Registers is available in the Appendix and the SilverMax Command Reference Non Volatile Memory The non volatile memory is used for long term storage of SilverMax programs and data Information stored in the non volatile memory remains in SilverMax when power is removed It is also useful when storing multiple programs in SilverMax Each program is stored to a known memory address and loaded when needed Non volatile memory is also available for storing data When using data registers for internal data operations it is occasionally necessary to store the content of a register into the non volatile memory This is often the case when generating offset or calibration values The data register contents can be stored to non volatile memory from a single register or an array of registers When storing multiple pr
248. n Since the carriage return does not have a viewable character it is displayed as a vertical bar when ASCII strings are viewed in QuickControl 1 2 Initialize the SilverMax and click the Start Polling button to ensure functioning communication Click on Data Monitor in the Tools pull down menu and view the polling routine that QuickControl uses to report all information about SilverMax Note that SilverMax never initiates outward communication Therefore every piece of information displayed in QuickControl has to be polled out of SilverMax by this routine Check the Data Only box With this box checked the Data Monitor only displays the command strings that QuickControl sends to SilverMax and the SilverMax response to those commands With this box unchecked each data string is preceded by TX RX indicator TX for QuickControl transmissions and RX for SilverMax responses and a recycling clock time The purpose of the clock is to tell how much time has passed in between a QuickControl TX and a SilverMax RX e The TX and RX are redundant because any transmission to SilverMax is indicated with an symbol followed by the ID of the unit e g 16 e SilverMax responses are preceded with either a or character See Chapter 9 for a discussion on the individual meanings of each Check the Silent box to stop the polling routine from streaming in the Data Monitor and scroll up in the window to view the routine i
249. n the reverse direction The SilverMax internal encoder is an optical disk type encoder providing A and B quadrature signals to the internal circuitry These signals can be monitored or passed out through the digital I O for use in encoder following applications See Chapter 6 for more details on I O and the encoder SilverMax Command Types and Classes SilverMax commands are categorized in two ways by type and class These two categories determine when or if a command can be issued The factors that determine when a command can be issued include active motion execution other commands being executed and the source of the command internal or external The two command types are Immediate and Program they set the valid source for the command Immediate type commands can be issued from an external host through the serial link ONLY they cannot be part of an internal program stored into SilverMax non volatile memory Program type commands can be either issued through the serial link or stored as part of an internal program Some commands have both an immediate and a program version For example Velocity Mode has both a program type VMP and an SilverMax User Manual 4 01 31 immediate type VMI These two commands take the same parameters and cause the same motion but have different command numbers The letters A through F designate the command class The class determines under what circumstances the command can be issued Example circumstance
250. n End Program END command each time the initialization file is e downloaded This prevents SilverMax from Erase application program s automatically running programs on power up or everytime new initialization Iw reboot Programs can still be downloaded to this iiaia al tial nse location after the initialization is completed after m Erase Application which they will automatically run on reboot or power Reboot On Download up Uncheck this box to run the first user program stored in non volatile memory after the initialization Reboot SilverMax everytime Vv process completes new parameters are downloaded REBOOT ON DOWNLOAD OPTION This option selects whether SilverMax is to be rebooted automatically after each initialization file download In order for any changes in the initialization file to take affect SilverMax must be rebooted SilverMax can be manually rebooted by selecting the Reboot button in the Program Info Toolbar or by power cycling the SilverMax SilverMax User Manual 4 01 26 SilverMax Power Up Sequence At power up and before the Initialization Program is executed SilverMax is first set to the 9 Bit Binary protocol for 120 milliseconds then switches to the 8 Bit protocol for 120 milliseconds In addition during this time the Baud Rate is set to 57600 and the Serial Interface is set to RS 485 and then RS 232 This power up procedure allows a host controller to establish communication with SilverMax
251. n detail or check the Log to File box and click on the Log to File button to select a specific location and text file to log this routine to Note the commands used in the basic polling routine look them up by command number in the SilverMax Command Reference if necessary and the data registers that are queried e 16 12 1 lt CR gt This Read Register command queries the Actual Position 1 register e Actual Position is displayed in the Device Status Monitor and is updated due to this line of the polling routine Click on Register Watch in the Tools menu and Add Register when the Register Watch utility appears Choose Accumulator 10 or a register that is not being polled by the basic polling routine and select long format to view values as signed decimal numbers e Uncheck the Silent box in the Data Monitor and note that Accumulator 10 is now being queried by the polling routine Type a 50 into the data box of the added register and press enter Quickly check the Silent box and scroll up in the Data Monitor log to view the transmission e 16 11 10 50 lt CR gt This Write Register command writes a 50 into the Accumulator 1 0 register e This string was issued by QuickControl as soon as data was typed into Register Watch and Enter was pressed Move to the Custom Transmit section of the Data Monitor Type 16 11 10 100 in place of Test Packet Add the final carriage return character with the Add CR to End button and
252. n or select File New Program File 11 Select Add from Program Info Tool bar choose the INIT tab and select the command Kill Motor Conditions KMC 12 Click on the Over Temperature button until it reads True 13 Click on the I O 3 button until it reads Low 14 Click the OK button Run the one line program 15 Try moving SilverMax shaft by hand Notice that the SilverMax servos back to its holding position 16 Switch I O 3 to the LOW position Again try moving SilverMax shaft by hand NOTE Notice that the SilverMax no longer has any active holding torque Watch the encoder counts in QuickControl change as the shaft is rotated SilverMax control circuitry remains active and communicating even when a Kill Motor Condition occurs 17 Switch UO 3 back to the HIGH position Notice the SilverMax drive is still disabled 18 Power the SilverMax off then on again to reboot the motor 19 Try rotating shaft and notice that SilverMax servos back to position as before 20 Open the Control Panel Tool in QuickControl and click on the Reboot button 21 Monitor the Device Status area of the Control Panel lower left while the shaft of the SilverMax is turned Note the changing torque value while turning the shaft and at rest 22 Watch the status boxes and repeat step 8 Note any changes in the status boxes What type of motor shutdown does this exercise illustrate SilverMax User Manual 4 01 139 bk Exercise 8 2
253. ncorporated into standard QCI cables but could be SSC overlooked when manufacturing custom cabling Shielding l O and communication lines are susceptible to noise in many industrial environments e Grounding SilverMax has logic processor power and chassis grounds that must be wired correctly e Null modem connections the transmit line on SilverMax is connected to the receive line ona serial port and vise versa for the receive line on SilverMax RS 232 e Sound electrical junctions it may be beneficial to use crimp style connectors rather then the solder tail type to avoid unintentional solder bridging across adjacent pins Lines with poor electrical junctions could cause intermittent contacts that could effectively Hot Plug SilverMax and disable communications e Wire gage ensure lines meet the specified current requirements SilverMax User Manual 4 01 8 QCI Start Up Kits Overview QCI SK Start Up Kit SilverMax personal computer and power supply not included provide a simple and inexpensive means for testing and evaluating a SilverMax servomotor With a standard PC serial COM port anda power supply any SilverMax servo can be fully programmed and operated with the RS 232 communication protocol The SilverMax Training Breakout Module is included in each kit to connect a SilverMax to a PC a power supply and to breakout I O Also included are the QuickControl Software the SilverMax User Manual and the SilverMax Command
254. nd This Program sets up the Power Low Recovery to Load the previous Position stored at power down This store the motor position and direction when power is is loaded from NY Memory address 1000 lost When power is restored it takes that position and 10 REM direction and goes from there Make sure a Data Register value has been previously stored at this address or the Program will Stop To make this work right a position value must be Register Load Non olatile 1 REM previously stored into the NY Memory location used In 11 RLN Load User 11 this case do this by selecting the Prower Low from Non Yolatile Memory Address 1000 Recovery program and doing a Test Line on line 4 The following three commands take the saved position LHE 12 REM and restore it as the actual position SilverM ax does not have a single command that does this So to complete In order to execute this program cycle power to the this task a roundabout method must be used motor Then verify that the actual position and direction 13 REM Zero out the Accumulator 2REM Set torque to some reasonable values 14 CLC Clear Accurnulator 1 0 Torque Limits i Subtract the actual position retrieved from NY memory Closed Loop Holding 3000 15 REM from the Accumulator in order to make it the opposite 3 TOL Closed Loop Moving 151000 value of what it is Open Loop Holding 3000 a Ge Ge dech 15000 16 CLC Ee 0 Accumulator u sa 1 a Pe R 7 ubtract the pre
255. nd 9 Bit Binary communications The Unknown SilverMax Wizard sends out a continuous stream of Stop commands through the COM port stopping execution of the initialization file and preventing SilverMax from reaching an unknown communications state The wizard will then prompt for communication configuration of SilverMax These settings should match how QuickControl is configured Note that the protocol 8 bit SilverMax User Manual 4 01 15 ASCII or 9 bit Binary is determined by the settings under Comm Port in the Setup menu of QuickControl to ensure that the protocol matches QuickControl Upon completion of the wizard the SilverMax will be successfully communicating See SilverMax Power Up Sequence later in this chapter for a detailed explanation of how this is achieved and how to manually implement this routine in a host system It is also good to verify that the Windows PC can communicate through the serial port without QuickControl Programs like HyperTerminal can accomplish this Follow the QCI application note QCI013AN PLC emulation with HyperTerminal for the correct setup If communication is successful with the third party terminal program then QuickControl should be able to operate correctly QuickControl Interface The main QuickControl screen offers the user an easy to use programming interface with the ability to monitor the communications status of all active SilverMax units connected to the PC Host An active status log is a
256. nd forth until Motion Error occurs and SilverMax shuts down on this Kill Motor Condition 2 REM Set torque values low The values are set low to allow the g shaft or flywheel to be manually stopped by the hand Torque Limits Closed Loop Holding 15 3 TGL Closed Loop Moving 9 Open Loop Holding 15 Open Loop Moving 9 APEM Set up the Error Limits that establish the amount of error G which will cause the motor shutdown Error Limts Moving Limit 200 counts Holding Limit 100 counts Delay to Holding 100 ticks Set the conditions on which the SilverMax should automatically shut down Kill Motor Conditions 7 KMC If Over Temperature or Moving Error A simple move back and forth loop The SilverMax will continue its motion until the Kill Motor Conditions are met Move 2 revs SMART FOREVER ramp time 500 04 mSec total time 2000 04 mSec Move 2 revs 5 ERL 6 REM 8 REM 10 MAT ramp time 500 04 mSec total time 2000 04 mSec 11 JMP Jump to FOREVER Basic SilverMax Shutdown Program SilverMax User Manual 4 01 130 To return the SilverMax to operation a host must send either of the following command string s RESTART RST SilverMax acts as though it was just powered on by resetting itself and jumping to the default program in NV memory This will clear all registers including the current position ASCII example 16 4 lt CR gt OR To maintain
257. nditions under which SilverMax enters and exits Anti Hunt while the AHM command sets the type of anti hunt operation SilverMax uses The AHC AHD and AHM commands are covered below The TQL and ERL commands as explained earlier are also important to Anti Hunt operation Anti Hunt Constants AHC Command ee ae xi The AHC command sets the conditions for SilverMax to enter AntiHunt disabled when both parameters 0 and exit Anti Hunt The AHC command uses three SEH Cancel _ parameters Closed to Open error Open to Closed error and e tod sat gs lcs TS the Check Holding Currents flag Dereon fo counts Units The Closed to Open error parameter sets the point at which a Normal SilverMax can enter Anti Hunt and transition to open loop EE EE control SilverMax can enter Anti Hunt once position error is Amount of error required to go into equal to or less than this value Position error is the Geier difference between the target shaft position and the actual if aoe Check shaft position measured in encoder counts a a The Open to Closed error parameter establishes the point at which SilverMax exits Anti Hunt and returns to closed loop control If position error ever equals or exceeds this value when SilverMax is in Anti Hunt SilverMax immediately exits Anti Hunt switching to closed loop control to correct the position error Setting the Closed to Open and the Open to Closed parameters to zero disables Anti Hunt
258. ndows 9x NT ME 2000 or XP based PC connected to a SilverMax servomotor using one of the PC s serial ports QuickControl is designed to make programming SilverMax easy and efficient Programming SilverMax and using its advanced features is the topic of most of this manual and QuickControl is used in nearly all of the examples It is also the only SilverMax programming interface fully supported by QCI and is always required to change the SilverMax factory default initialization program SilverMax Programming Overview The SilverMax command set is accessible by any device capable of communicating over an RS 232 or RS 485 serial connection This means that almost all host controllers HMI PLC Vision and PC systems can be used to communicate with and control SilverMax Many applications require commands to be sent from the host directly to SilverMax This type of control is usually prototyped and tested more efficiently using QuickControl For example an application might require a custom program written in C running on a PC to dynamically issue a series of commands to a SilverMax connected to the PC SilverMax operation could be setup for this application without the use of QuickControl but the development and prototyping of the application is easier faster and more accurate if done with QuickControl SilverMax programs are made up of two components the initialization program and user programs The initialization program contains all the init
259. nfo Toolbar QuickControl will step through the program and then stop at the selected breakpoint TEST LINE The Test Line tool allows any one line in a program list to be executed It only Tests executes the selected line command and does NOT run the entire program 1 Click the Red Stop Hand Icon 2 Using the same open qcp program file click on Line 4 to highlight the line MAT Move Absolute Time Based and then click Test Line on the Program Info Toolbar 3 QuickControl should have executed the chosen command without executing other commands SilverMax User Manual 4 01 46 Chapter 3 Unique Features and Commands The last two chapters covered the hardware setup basic programming techniques and motion commands necessary to get SilverMax moving This chapter describes additional commands and features needed to use SilverMax in a basic application Later chapters deal with advanced features like data registers I O functions SilverMax networks and system tuning A solid understanding of this chapter and the previous chapters will greatly reduce the learning curve for the material in the rest of the manual This chapter contains six sections each dealing with a different feature or group of commands e Status Words SilverMax uses three 16 bit status words that are integral to its operation the Polling Status Word the Internal Status Word and the I O Status Word Each bit of these status words indicates the state of a pr
260. nges the torque limit settings for the different control states of SilverMax The limit caps the maximum value the SilverMax may use Specify the limit as a percent or check the Maximum box next to each slider to maximize the parameter at 150 AHC Anti Hunt Constant Line 52 Anti Hunt mode is an open loop mode that allows the SilverMax to eliminate dither The AHC command sets the thresholds used to determine if the position is sufficiently close to the target to allow the SilverMax to go into and to stay in Anti hunt mode AHD Anti Hunt Delay Line 54 Set the Anti Hunt time delays of closed loop to open loop at the end of a motion and from open loop to closed loop at the beginning of motion Creates a very stable operation when the SilverMax is at rest SCF S Curve Factor Line 56 Choose the S curve characteristics in the acceleration portion of motion profiles The SCF command uses a sixteen bit value 0 32767 to correspond to a Trapezoidal profile to a full S curve LVT Low Voltage Trip Line 59 Allows for a low voltage threshold to cause SilverMax to stop operation or load and run a program defined by the POWER LOW RECOVERY PLR command This allows for proper shut down when power is lost or for data storage in power loss situations OVT Over Voltage Trip Line 61 Like LVT except for this command sets the max voltage that will cause the SilverMax to kill or shut down OVT is tied to the Kill Motor Conditions to se
261. nless a servo shutdown is what you really want to do SilverMax has a unique feature in that a low voltage condition can be used to trigger a special recovery routine that can be use to exit SilverMax operation before power is totally lost Use the Power Low Recovery PLR command to set up SilverMax User Manual 4 01 128 this operation The under voltage threshold can be set using the Low Voltage Trip LVT command This option is provided for backward compatibility reasons If any one or more of the preceding conditions are enabled and found to be TRUE the SilverMax will execute a process defined by the recovery program The recovery program can do nothing disable SilverMax and wait as the default recovery process does or execute a program at a specified location in the non volatile memory SilverMax Kill Process The kill process can be carried out two different ways depending on the initialization settings The SilverMax default kill process ends any motion and or program that is currently executing and disables the motor drivers which cuts off torque to the shaft This causes SilverMax to come an uncontrolled stop This uncontrolled kill provides no deceleration control with only friction to slow SilverMax to a stop SilverMax executes the actions specified by the KMR program The second shutdown method leaves SilverMax operating and calls a specified recovery program This allows SilverMax to do a controlled shutdown if required When a
262. nnecessary to specify a velocity PMX uses the deceleration register for Profiled Moves Register 23 to slow to a stop Soft Stop Limits SSL can also be used to stop any type of move This command defines two data registers as end of travel limits Once values are stored in these registers any motion affecting the target is limited to keep the target position more than the first register value and less than the second Motion that exceeds a limit is hard stopped see HSM at the point that the limit is encountered so no ramping occurs SilverMax User Manual 4 01 97 Hardware Stop Drive Enable feature A hardware driver enable disable feature is available as an additional option for the 17 and 23 frame SilverMax and is standard on the 34 frame SilverMax This feature allows the motor driver circuit to be disabled via a solid state switch Disabling the motor driver cuts off torque while the DSP control electronics remain active to track position and respond to commands With the absence of torque the load inertia will cause SilverMax to coast to an uncontrolled stop Upon power cutoff to the drive enable line SilverMax enters the Kill Motor Recovery routine provided appropriate settings in the Kill Motor Conditions KMC command are met For the 17 and 23 frame SilverMax the UO 3 setting must be low in the KMC command because the drive enable option dedicates UO 3 as the drive enable line On the 34 frame SilverMax the Over Temperatur
263. nt 1 of the sum of the rest of the previous bytes In other words add up all bytes from the ID through the final parameter and take the 2 s complement Example Calculate the following Read Register RRG command Address 16 0x10 ignore 9th bit Length 03 0x03 Command RRG Command Number 12 0x0C Data Register 1 0x0001 Add up all the bytes all numbers shown in hex 0x10 0x03 Ox0C 0x00 0x01 0x20 1 s Complement invert Invert 0x20 OxDF Add 1 OxDF 0x1 OxEO Checksum 0xEO POL Command Packet The POL command packet is a special command packet that has been shortened to minimize communications overhead as this is probably the most frequently sent packet 9 Bit Binary POL Command Packet Data Transmission Order Address Length Checksum 1 Byte 9th bit set 1 Byte 0x00 1 Byte First byte is the ID with the ninth bit set Since the data count is zero no command or parameters are included Third byte is the Checksum Example POL command to SilverMax ID 10 Hex Ox0A byte stream in hex 0A 00 F6 Example Send a Read Register RRG command with the following Command RRG Command Number 12 ID 16 Hex 0x10 Data Register 1 Fields with data shown in hex ID Length Command Data Register Checksum 0x10 0x03 0x0C 0x0001 OxE0 Byte stream with data shown in hex 10 03 0C 00 01 E0 Example Send the fol
264. nterface as it is the most common response of SilverMax It contains only the ID and a special code in the length slot to indicate an ACK 9 Bit Binary ACK Response Packet data transmission order ID Length ACK Code Checksum 1 Byte 9th bit set 1 Byte 0x80 1 Byte e The first byte is the ID of the responding SilverMax with the ninth bit set e The second byte is the length value of zero plus the eighth bit set to indicate an ACK 128 0x80 This is the equivalent of a length value of 128 e The third byte is the checksum This is calculated in the same fashion as a command packet Example ACK response from SilverMax 16 shown in hex 10 80 70 SilverMax User Manual 4 01 148 RETURNED DATA RESPONSE The returned data packet is sent when SilverMax receives a properly formatted command requesting data The format is as follows 9 Bit Binary ACK Response Packet data transmission order Address Length Command Number Data fields Checksum 1 Byte 9th bit set 1 Bytes 1 Byte 2 or 4 Bytes each 1 Byte The first byte the address with the ninth bit set The second byte is the length which is the number of bytes starting with the command number and including all the data fields The third byte is the command number that is being responded to The requested data fields are next 16 bit words are sent one byte at a time upper byte first 32 bit long words are also sent
265. number rather than a value The value in the register at the time of execution is used to generate motion Extended Register Moves XRV XRT XAV XAT The extended register version of the standard motion commands take only a single register as a parameter The specified register is used as the position distance parameter The following two registers are used for the second two parameters SilverMax has other register based motion types They are even more powerful with changes in register values being applied on the fly These commands are covered in detail in other chapters Profile Moves All Profile Move commands PMV PMC PMO PMX use the contents of registers 20 24 as parameters See chapter 5 for more information on Profile Moves SilverMax User Manual 4 01 79 Registered Step and Direction RSD This command is operationally the same as Scaled Step and Direction SSD but the scale factor is retrieved from the specified register to allow dynamic scaling See chapter 6 for details on Step and Direction commands Input Modes SilverMax has three input modes position velocity and torque PIM VIM TIM Each of these modes uses registers 12 18 as scaling parameters All registers must be specified before entering these modes See Chapter 6 for more information on Input Modes ti Exercise 4 2 Simple Register Based Motion The purpose of this exercise to get familiar with the basic RRV JMP and JOI commands SilverMax wil
266. o SilverMax using the external encoder input function and then scaled appropriately Any device capable of sending a properly formatted signal can send the camming profile signal Dual Loop Control In addition to simple encoder following control the external encoder input function can be used ina position feedback configuration This Dual Loop Control operation uses the external encoder signal count to replace the position portion of the SilverMax internal encoder feedback in the PVIA control algorithm The internal encoder position signal is still used for motor commutation and phase information SilverMax positions itself according to the external encoder source This feature is very useful for two applications high resolution feedback applications and applications requiring feedback directly from a machine or machine part rather than from the SilverMax shaft The input signal from the external feedback device can be in any of the three signal formats discussed in this section step and direction step up step down or A and B quadrature SilverMax User Manual 4 0 116 The Select External Encoder SEE the Dual Loop Control DLC and the Single Loop Control SLC commands are used for this feature The SEE command is used to configure SilverMax to receive the external encoder input signal just like when the signal is used for direct motion control The DLC command configures SilverMax to use the external encoder signal for position feedback in th
267. occurs during a powered down period the SilverMax will need to re establish its current position by some method such as re homing A back up power supply provides an alternative by keeping the internal circuitry active Note that only the voltage dropping below the threshold will cause this information to be accidentally lost The drivers being disabled for any reason will not clear the position information Power Low Recovery Commands Low Voltage Trip LVT Used in conjunction with the Power Low Recovery command this command sets the input voltage that will trigger a Low Voltage status Bit 14 in the Internal Status Word When a Low Voltage Trip occurs SilverMax will stop immediately then load and run the program defined by the PLR command This command allows the user to shut down SilverMax properly when power is lost The current position of SilverMax could be stored to non volatile memory for pseudo absolute encoder functionality The LVT trip setting should by set as high as possible for any given power supply A higher setting causes the SilverMax to trip sooner giving it more time to write data to the Non Volatile memory Power Low Recovery PLR If the input voltage drops below a set value see Low Voltage Trip a user program can be called that can perform a power loss exit routine This command selects what to do in case of power loss A Load and Run Program is issued which runs the power loss exit routine from a specified NV Memory
268. ocity 2000 cps 11 Click on the Advanced button choose the input I O line and configure the stop condition 12 Choose the Standard tab of the Edit Stop Conditions box Select I O 1 for the Condition and use LOW FALSE as the State 13 Click the OK button twice to get back to the main QuickControl screen DOWNLOADING AND RUNNING THE PROGRAM 14 Before running the program put SW1 of the training module to the up position 15 Choose Run from the Program Info Toolbar This function will Download the program into the NV memory reboot the servomotor amp run the program in standalone mode THE PROGRAM WILL ONLY RUN ONCE PER REBOOT 16 While the program is running trigger I O 1 to stop the move before the motion completes Click on the Reboot button to run the program again SAVING THE NEW QCP FILE 1 Using the File menu choose File gt Save As This will open a standard file browser window where the program can be named and saved to the computer Note The browser window opened by default will be the last active folder accessed in QuickControl 2 Choose a unique name for the new program and click on Save button b Exercise 2 4 Troubleshooting a QuickControl Program This exercise is an introduction to the program troubleshooting capabilities of QuickControl These functions provide a powerful means to check the operation of a program and understand how individual commands execute QuickControl contains de
269. ocity every 2 seconds Geng Label Command 1 EMT Enable Multi Tasking r Write 200 rev to 2WRP User Profile Move Pos 20 Register f Write 0 5 rps s to 3WRP User Profile Move Acc 21 Register f Write 1 rps to 4 WAP User Profile Move Vel 22 Register y Write 40 rps s to WP User Profile Move Dec 23 Register S Write 0 rev to Kap User Profile Move Offset 24 Register 7 PMY Profile Move 8 DLY LOOP Delay for 2000 mSec FELIC Increment User Profile Move Vel 22 10 JMP Jump to LOOP Related Profile Move Commands The Profile Move Override PMO command will override any other motion currently in progress and execute a PMV command using the parameters loaded into the Profile Move registers 20 to 24 When this command follows a PMC command the PMC operation will end when the target position is reached effectively changing the functionality of PMC command to act like the simpler PMV command Normally the PMC command will not end unless explicitly stopped by a stop condition Using the PMO command after a standard PMV command will have no effect PMO will also override other modes if Multi Tasking is enabled e g Step and Direction The Profile Move Exit PMX command will stop any profile move currently executing bringing SilverMax to a halt using the Profile Move deceleration register 23 SilverMax User Manual 4 01 99 Interpolated Motion Control Interpolated movement allows SilverMax to use Data Re
270. ogether provides an overview of SilverMax programming and introduces QuickControl QCI s Windows based software interface for SilverMax Instructions for setting up the connections shown in each SilverMax configuration are given later in this chapter Each configuration drawing shows the connections for a 17 or 23 frame servomotor The connections for 34 frame servos used in similar configurations are slightly different and detailed later the addition of a voltage clamp module between the power supply and the servomotor is the most important difference Recommended setup including parts list is shown for each of the three common configurations A description of a generic setup is also given for each configuration Standalone Configuration SilverMax is capable of operating as a system level controller without any input from a master controller or user interface When set up like this SilverMax is pre programmed to control the motion correctly and to respond to any sensors or other inputs in the system System I O 4 PCwith OC QuickControl Breakout i 5 s 2 tae aS Sle ae ei Power Supply 3 Standalone Configuration Recommended Setup A typical standalone configuration is shown above In this configuration the SilverMax servomotor is connected to a OC breakout module the breakout module is connected to any I O devices and the power supply The breakout module allows easy access to the serial
271. ograms or register values to the non volatile memory locations and organization is taken care of by the register file system See Chapter 5 for more information or the register file system When storing programs or registers SilverMax automatically adds length and checksum values in the first memory location This is used when loading to find the correct number of words to load and to verify the integrity of the data After the length and checksum word a 0 is stored as a NULL word This prevents SilverMax from trying to execute data as a program By default QuickControl will organize all programs and data to be stored into the non volatile memory If this organization is performed manually it is essential that no overlap occur If SilverMax attempts to retrieve information that has been overwritten it will shutdown and cease executing any commands or programs SilverMax Firmware The SilverMax firmware is stored in a separate section of flash memory that not user accessible It translates all instructions into the actual machine code that controls motion and all other operations Upgrades to the firmware are available from time to time from the factory and can be installed in the field using the QuickControl software These upgrades improve and increase the capabilities and functionality of SilverMax For instructions on upgrading firmware see the QCI Instruction Document on firmware upgrades SilverMax Memory Management There is a sign
272. oint None of these recommendations are an end all solution because all systems are truly unique Inertial ratios up to 5 1 For a load inertia to motor inertia ratio of 1 1 to 5 1 the default tuning parameters should be sufficient These have been optimized for each SilverMax for this nominal load range assuming a relatively tight coupling servo class coupler or a stiff belt Aramid type Higher Inertia Ratios SilverMax can be tuned to handle huge inertial loads with mismatches of 1000 1 or even 3000 1 category The limiting factor is not the control loop but the electric motor s maximum torque At some point the electric motor will just not have enough torque to move the mass in the desired time frame For high inertia loads the load inertia will dominate the response Therefore the velocity estimator should have a lower bandwidth low Fv2 because fast variations seen at the servo are not good estimates of the actual load response Reducing Fv2 reduces the high frequency gain of the system This suppresses the high frequency resonance modes allowing Kv2 to be increased to improve the low frequency damping of the system Torque Saturation Use QuickControl s Control Panel to chart torque while doing both very fast and very slow moves If the fast moves are causing the torque to saturate reduce the acceleration Trying to stop faster than the torque of the motor allows will cause overshoot Tuning cannot increase the maximum torqu
273. oise immunity In applications with significant electro magnetic interference EMI such as welding or other high energy machinery RS 232 communications will most likely be disrupted In these applications the noise immunity provided by RS 485 may be required QCI has additional filters available to improve the noise immunity of any system Industrial Standard Many industrial devices support RS 485 but do not support RS 232 usually for the above reasons Obviously in these cases RS 485 must be used Implementing a SilverMax Communications Network General requirements Unit Group Global ID Each SilverMax on a network must have a different Unit ID This is set by the Identity IDT command The command also sets the Group ID SilverMax will react but not transmit a response packet to this ID Multiple servos can share a group ID A Group ID would typically be used to initiate coordinated action of several but not all servos in a system i e via a Run Program RUN command The Global ID fixed at 255 is a reserved value to which all SilverMax units will respond SilverMax servos will not send response packets when the Global ID is used The Global ID is typically used to stop all motions on a multi axis system simultaneously or to initialize a SilverMax with an unknown ID Shielding Cable shielding is required for many technical reasons commonly noise reduction in systems or environments where EMI is heavy Typically the supply power
274. olling program flow Motion Control Digital Input All I O lines can be used as input stop conditions for motion 1 7 commands pa Three UO lines can be used as Kill Motor Conditions allowing KSN Motor Manal npu for immediate shutdown based on input is ee I O 1 can be used as a special digital input to trigger enable Meguro Trigger E or disable the modulo output function d All I O lines can be used as general purpose digital outputs General Digital Digital Output allowing SilverMax to control on off devices such as valves and 1 7 Output H put switches An output can also be connected to an I O line on another SilverMax and used as an input General Analog Four I O lines can receive 0 to 5 V analog signals These p Input Analog input signals can be used within SilverMax programs KSE Input Mode An analog signal received on one of these UO lines can be used p Analog Input Anag Input directly for motion control ner Internal High Speed Three I O lines can send the raw signal from the internal 1 3 Encoder Output Output encoder as an output High Speed Two I O lines can send a scaled signal from the internal encoder g ModulorQuipet Output as an output while I O 1 can toggle the function on and off Ee Three I O lines can receive a position feedback signal from an external encoder or another feedback device like a resolver External High Speed This signal can be used for closed loop control instead of the 234 6 Encoder Input Input inte
275. oltage Clamp The white wire connects to chassis ground of the power supply DO NOT make any other connections to the outputs on the Voltage Clamp other than to the 3 pin receptacle on SilverMax In the case of SilverMax regenerating any added circuitry connected to Voltage Clamp outputs is not protected and could be damaged by the back EMF The SilverMax Line Power Cable Connect the Vin 1 amp 5 Wire the resistors of QCI CLRP 2 as terminals to the V of the N needed see QCI Technical power supply and connect Document QCI TD0017 to obtain Gnd 2 amp 6 terminals to the _ appropriate clamping resistance and ground of the same supply pa t connect leads to the Res 1 and Res 2 terminals on the Voltage Clamp attaches female on the The male end of the SilverMax Interface Cable to the 15 pin _ receptacle 3 attaches to a standard 9 pin PC COM port The female end of the Communications Cable The male end of the Communications Cable attaches to the 9 pin female receptacle 4 on the Training Breakout Apply a connection for input voltage 12 to 48 VDC to the terminal labeled Vin on the Main Terminal Block 1 of the Training Breakout Module and apply a connection for input supply ground to the terminal labeled PGND SilverMax User Manual 4 01 11 Setup QCI SKOM FS v Start Up Kit This Start Up Kit with Optical Interface Module QCI OPTM V provides a comprehensive solution to t
276. om A to B multiply by the constant in table A B oz in oz in s Ib in Ib in s N m s g cm kom kgf m s oz in 1 2 59 10 6 25 10 1 6188 10 1 8289 10 182 9 1 8289 10 1 86 10 oz in s 386 09 1 24 131 6 25 10 7 0612 10 7 0612 10 7 0612 10 7 2 10 Ib in 16 4 1441 10 1 2 5901 10 2 9262 10 2926 2 2 9262 10 2 9839 10 Ib in s 6177 16 386 09 1 0 11298 1 1298 10 0 11298 1 1521 10 N m s 5 4678 10f 141 62 3417 4 8 8512 1 1107 1 0 10197 g cm 5 4678 10 1 4162 10 3 4174 10f 8 8512 107 1 107 1 1 107 1 0197 10 kom 5 4678 10 141 62 3417 4 8 8512 1 i 1 0 10197 kgf m s 5 3621 10 1388 8 3 3513 10 86 801 9 8067 9 8067 10 9 8067 1 Power To convert from A to B multiply by the constant in table A B Watt HP N m RPS in oz RPM_ ft Ilb RPM_ ft lb sec N m sec Watt 1 1 341 10 0 1592 1352 7 042 0 7375 1 HP 745 7 1 118 7 1 0083 10 5251 4 549 93 745 7 N m RPS 6 283 8 426 10 1 8496 44 25 4 634 6 283 in oz RPM 7 396 10 9 918 107 1 177 10 1 5 208 10 5 454 10 7 396 10 ft lb RPM 0 142 1 904 10 2 26 10 192 1 0 1047 0 142 ft Ib sec 1 356 1 818 10 0 2158 1833 9 549 1 1 356 N m sec 1 1 341 10 0 1592 1352 7 0423 0 7375 1 Torque To convert from A to B multiply by the constant in table A B ft lb in lb in oz N m kgf m kgf cm gf cm ft lb 1 12 192 1 3558 0 13825 13 825 1 3825 104 in lb 8 333 10 1 16 0 113 1 1521 10 1 1521 1152 1 in oz 5 2083 10 6 25 10 1 7 0615 10 7 2006 10 7 2006 10 72
277. ommand can be formatted to use a specific deceleration use the current move s acceleration parameter to decelerate to a stop or use maximum deceleration to achieve an immediate stop where the target position is set to the present position EI The red stop hand button in the QuickControl Icon Bar is issues an all stop command It sends the Stop STP command to address 255 and all SilverMax connected to the PC will stop The Halt HLT command stops the execution of any command program and motion in progress It also disables the servo drive which allows the shaft to spin freely and starts the Kill Motor Recovery routine where the recovery method can be programmed the KMC command is covered in Chapter 8 The Hard Stop Move HSM command provides a means to execute a hard stop while multi tasking A hard stop immediately disables the Trajectory Generator stopping any movement and exiting any move operation e g Step amp Direction This causes an abrupt stop which in many cases will cause SilverMax to overshoot the stop position and oscillate until settled More controlled stops can be accomplished by using the Velocity Mode VMP or VMI command which allows a predetermined deceleration profile to stop SilverMax Use this command to specify a deceleration to zero velocity stopping SilverMax The Profile Move Exit PMX works much like the VMP stop and will be discussed in the Profile Move section of this chapter With this syntax it is u
278. on failure can occur in the first and only instance of Hot Plugging In applications this can be overcome by connecting chassis ground a lug on the servomotor body to the power supply ground With this direct ground implemented the path of least resistance for residual power is through the added chassis ground In applications where chassis ground must be isolated from power ground take EXTREME care not to Hot Plug Contact QCI if necessary Hardware requirements e Personal computer with a Pentium at least 133 MHz or higher processor running Windows 9x NT Me 2000 or XP SilverMax Servo 12 to 48 VDC Regulated Power Supply See Technical Document QCI TD002 for details Startup Kit which includes CD with QuickControl Software version 3 2 and higher SilverMax User Manual this document SilverMax Command Reference Cabling NOTE Procedures in this chapter require a SilverMax Start Up Kit to perform the setup and initialization SilverMax User Manual 4 01 7 SilverMax Factory Defaults When shipped from the factory the SilverMax servo and QuickControl software are configured with default values that are used to establish initial communications between SilverMax and a PC These default values can be changed to different settings during the initialization procedure SilverMax Unit ID address 16 SilverMax Supply Voltage 48VDC Serial Communications Protocol 8 Bit ASCII Serial Interface RS 232 Baud Rate 57600
279. on the zero point The zero point can be reset using the Zero Target and Position ZTP command Absolute motion is position based where the first parameter specified is the position to move to The actual distance moved is the difference between the current position and the position specified in the command Velocity Based Motion The MRV and MAV commands are velocity based The second and third parameters are velocity and acceleration The SilverMax will use the specified acceleration to achieve the velocity and the same acceleration to bring SilverMax to a halt If the acceleration is not sufficient to reach the specified velocity before deceleration must begin the profile will be triangular Time Based Motion The MRT and MAT commands use time based parameters to create a motion profile The second and third parameters are ramp time and total time The total time specifies how fast the move is to be completed The ramp time sets the time to accelerate to velocity and the time to decelerate to a halt The total time must be at least twice the ramp time or errors will result The move will not be executed Velocity Control If an application requires only velocity control and no position designation the Velocity Mode VMP or VMI commands should be implemented VMP is the program type command and VMI is the immediate type The Velocity Mode commands provide a never ending motion If no outside conditions interfere the servomotor will con
280. ontains information necessary to properly tune SilverMax control systems It covers the PVIA servo control loop SilverMax commands associated with tuning control loop parameters and the effects of each parameter on SilverMax motion A tuning exercise is included that explains how to tune a SilverMax with an inertial mismatch of 100 1 The chapter concludes with a section that provides tuning recommendations for specific applications SilverMax PVIA Servo Algorithm Internal to SilverMax is a unique servo loop algorithm called Position Velocity Feedback Feedforward Integral and Acceleration Feedback Feedforward PVIA In the PVIA algorithm position information is used to perform closed loop control of rotor position by detecting and correcting for errors in actual position versus the target position Velocity and acceleration are calculated from the time history data of rotor position Current position velocity and acceleration data are passed in real time to the PVIA algorithm along with target position target velocity and target acceleration data See diagram on following page These variables are used in calculating the motor torque needed to correct any motor position error SilverMax User Manual 4 01 157 The exact transfer function when not limiting is Torque _ _1 1 kF Kvi x512 y re 1 F dr Kvaxsia h Aa x Position 32 Lat ch Kuff XT arget Velocity only upper word _used 1 KF 1 AF Kax512 Ma ee
281. ontrol Interface deeg 16 ER dE OR 17 PA WGI EE 19 3 Program INTO TOGIDAN gedeien egene Gebeier 19 A Program IIIe EE Eeer eege a a ido adea i 20 5 Device Status MOITO ieren E E ERE A ed 20 Using QuickControl To Configure Skrerklargg Aeee e eEeEe EE 21 SilverMax Initialization Wizard EE 21 silverMax Initialization EE 22 SilverMax Power Up Sequence EE 27 Silve rMax Contr l EE 27 Exercise 1 1 Basic SilverMax Default Initialization cece cee eeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaaeeeeeeneeeenenaees 28 Exercise 1 2 Advanced SilverMax InitialiZation cccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeesecaeeeseeneeeenenaees 29 Exercise 1 3 QuickControl WINGS c cessasreecesersecnecs psc oidessteu sneered ewdeddessvatepessededtis Hiaus i svenpecucapees enedeeuedeants 30 Chapter 2 Basic Motion and Programming Fundamentals cccccceeseeeseeeeeeeeeeeeeeeees 31 Ee EE 31 SilverMax Command Types and Classes 31 CC elegin ee GET EE 32 Parameter SCAG EE 32 Scaling Engineering Units in QuICKControl cccccscscssesssesesscsesssescsssecscscssesscesestesscitassescnssetatacstanseneees 33 Operating SilverMax in Host and Standalone Configuration ccccccsssesssssssssesecesessssssesentesesecseassenenss 34 FOS EGON ICAU ONY EE 34 Polling SilverMaX E 34 Standalone Configuratii N EE 36 Host amp Standalone Combined Hybrid wc i cc2i cee asnceaeashat oes teach ceaaeieee sama yanienaiaidoeeeencidvaeeenbi
282. op Holding torque limit is set too high SilverMax Torque The high pole count motor designed into SilverMax is one of its distinguishing features SilverMax can produce a relatively large amount of torque for its size at lower speeds However at moderate to high speeds the available torque drops off quickly and nonlinearly due to the electrical characteristics of its high pole count motor Operating SilverMax from higher voltages up to 48 VDC allows it to attain higher speeds and greater output torque Understanding the SilverMax torque speed relationship is extremely important to properly using and sizing SilverMax Chapter 7 covers using torque control with SilverMax and goes into detail about SilverMax torque As with some of the other important physical parameters like distance time velocity and acceleration SilverMax uses special units for torque For most SilverMax models 30 000 SilverMax units of torque is the maximum peak amount of torque SilverMax can apply Unlike the other physical parameters SilverMax User Manual 4 01 54 SilverMax uses however SilverMax torque units are relative units and do not directly correlate to a physical unit like ounce inches because the torque speed relationship changes as the speed changes This relative definition of torque in SilverMax leads to the use of percentage torque An important aspect of SilverMax torque is the percentage torque representation used in OC documentation and by QuickCon
283. op in solution is created A customer supplied charger maintains the charge on the battery which immediately provides power when the main power is lost Internal diodes in the voltage clamp are biased to ensure that the main power doesn t drive the 9V battery QCI Voltage Clamp Example Backup Power Circuit SilverMax User Manual 4 01 137 Using the Kill Motor Process for Program Flow The issue of resuming program execution from the line where the KMC setting was tripped may be desirable in some applications If the program structure is simple enough the recovery program can be written to jump back to a predetermined location in the main program when completed with the recovery process or whatever task it is designed for The recovery program will have to WRP a specific value to a user register and LRP the main program The first line of the main program will recognize that the system has recovered from the recovery program based on the register set by the WRP command using the Jump on Register Equals JRE or a similar command Command fault has occurred By default SilverMax automatically zeros the Torque Limits and Disables the Motor Driver Give the motor a little time to stop This can be increased if needed Velocity Mode acc 8000 cps s vel 0 cps Delay for 500 mSec Re set the Kill Motor Conditions This is required if after this recovery routine normal operation is restored Kill Motor Conditions
284. operates similar to the KMC command except that it is triggered by one condition low voltage and it loads the program specified by the Power Low Recovery PLR command The default SilverMax initialization files are set up to run a Power Low Recovery program that disables the servo driver whenever the LVT setting is tripped voltage drops below specified value This distinction between interrupts adds the functionality of choosing a recovery process based on whether the SilverMax has found error conditions relating to normal machine operation KMC settings or if power has been cut off to the servo LVT settings Such conditions most often are used for emergency stops halting on mechanism jams hard stop homing routines program interrupts and power down scenarios Servo Error Conditions Kill Motor Conditions Fifteen different conditions are available to shutdown SilverMax Each of these conditions can be independently enabled When enabled the state TRUE or FALSE that will trigger the kill condition is also set The conditions are derived from the Internal Status Word ISW that is used by SilverMax in a variety of commands such as the JUMP command The reserved bit is used to detect an over voltage and is always enabled as a kill condition Edit KMC Kill Motor Conditions Select which conditions will Kill the motor Press the buttons to f Y change state or here for more help Cancel Indes Found Disable Moving Error From Error L
285. operation of SilverMax This can be accomplished through the Wizard in two ways the Interview utility or the Initialize Parameter Browser window The Interview utility takes the user through a step by step process or Interview of all the commands and parameters in the SilverMax User Manual 4 01 21 SilverMax Initialization File The Browser permits direct access to all commands via a categorized selection tree This selection tree has expanding line branches to the individual commands that can be selected for editing SilverMax Initialization Files It is good practice to save a record of the specific power up changes made to each SilverMax as a unique SilverMax Initialization file This file should contain all the command settings for any particular SilverMax in a specific application These commands include SilverMax specific settings like Motor Constants and Phase Constants that work with a specific type of SilverMax servo at a fixed operating voltage The initialization file also contains application parameters such as the SilverMax Identity Serial Interface Baud Rate Kill Motor Conditions Error Limits tuning parameters etc There should be one initialization file per axis on any multi axis machine The Open button can open a different SilverMax initialization file When using the SilverMax Initialization Wizard for the first time the SilverMax Factory Default Initialization qcp file is automatically opened in the Wizard File window
286. or Limits Operation SilverMax applies moving torque whenever the Trajectory Generator is active While the Trajectory Generator is active SilverMax compares the position error with the moving error limit Position error is calculated by subtracting the target position set by the Trajectory Generator from the actual position read from the encoder or external feedback device If the magnitude of the position error exceeds the moving error limit the moving error bit in the three status words is set The bit in the Internal Status Word may be used to automatically shutdown the motor see Chapter 8 on Kill Motor Conditions while the bit in the Polling Status Word and I O status Word can alert an external host to the error condition if SilverMax is being polled At the end of a move the Trajectory Generator goes inactive and stops changing the target position When this happens SilverMax starts the Delay to Holding timer set up with the ERL command Until this timer expires SilverMax continues using the moving torque limits and checking the moving error limit After it expires SilverMax applies holding torque and uses the Holding Error Limit to check for a position error while holding position Holding error is reported using a holding error bit in the three status words Drag Mode Servo systems can suffer from a problem called position wind up This condition occurs when a servomotor cannot keep up with a move or is stalled by a mechan
287. ormally high low when triggered 4 No UO 1 Status of I O line 1 normally high low when triggered 3 No Trajectory Generator When the Trajectory Generator is active SilverMax is Active calculating motion i e a move is in progress 2 No External Index An index mark on an external encoder has been detected 1 No Internal Index An index mark on an internal encoder has been detected 0 No Index Multiplexed An index mark has been detected on the selected encoder SilverMax User Manual 4 01 50 Internal Status Word The Internal Status Word provides supplemental information to SilverMax programs or external hosts that check the Polling and I O Status Words The Internal Status Word is available in a data register upper word of register 3 making it very useful for troubleshooting An external host can use this status word in several ways A host can use the Read Internal Status Word RIS and Clear Internal Status Word CIS commands to work directly with the Internal Status Word A host checking the Polling Status Word can access the Internal Status Word by using the Check Internal Status CKS command Finally a SilverMax program can use the Internal Status Word by checking a data register This status word is also integral to the Kill Motor function which is explained in chapter 8 Read Internal Status Word RIS Command The RIS command is similar to the RIO and POL commande It is issued by an external host to gain access to
288. ormat and click OK Click the Add Register Button again select User 29 select Acceleration for the Data Format and click OK Click the Add Register Button again select User 30 select Velocity for the Data Format and click OK 4 Click the Run button to download and begin execution of the program Once the program is downloaded click on the OK button 5 Notice the values placed in the selected Data Registers by the program Toggle I O 1 switch LOW then back to High SilverMax will execute a simple move 6 Toggle I O 3 switch LOW then back to High SilverMax will execute a different move 7 Click once in the Data column of the User 25 Register Enter the position value 100 revs into the cell and push the Enter key on the keyboard 8 Click once in the Data column of the User 26 Register Enter the acceleration value 150 rps s into the cell and push the Enter key on the keyboard 9 Click once in the Data column of the User 27 Register Enter the velocity value 25 rps into the cell and push the Enter key on the keyboard Toggle I O 1 switch LOW then back to High Note Acceleration Range is 0 to 277 78 rps s Velocity Range is 0 to 66 66 rps 4000 rpm 10 Modify the Position User 28 Acceleration User 29 amp Velocity User 30 data for the second move Toggle I O 3 switch LOW then back to High 11 Experiment with different values 12 When finished close the active program de
289. ormation presented in this chapter QCI has published an application note about analog inputs available on the QCI website SilverMax Analog Inputs SilverMax analog inputs have a range of 0 to 5 V Passive external circuitry can convert the common industrial input signal types including 10 to 10 V 0 to 10 V and 4 to 20 mA into the 0 to 5 V signal SilverMax requires More information about converting signal levels is available in the QCI application note on analog inputs That application note also goes into detail about the twelve analog channels SilverMax uses Only six of these channels are actually used with the I O lines The other six channels are used internally but can also be used by programs or by host controllers Of the six channels that are used with the I O lines four are linked directly to the four I O lines used for analog inputs I O lines 4 5 6 and 7 while two more are available as differential channels I O lines 4 and 5 can be used together as a single differential analog input I O lines 6 and 7 can also be used together The Analog Read Input ARI and Analog Read Continuous ACR commands are used to read information from the analog inputs The analog to digital converter ADC used in SilverMax has 10 bit resolution 4 88 mV per division Any analog input using only one I O line single analog input has this 10 bit resolution When two I O lines are used to form one differential analog input that input has 11 bit
290. p Holding SilverMax closed loop holding limit comes into effect in three instances The first case occurs when the SilverMax finishes a motion and the trajectory generator goes inactive The Anti Hunt Delay AHD SilverMax User Manual 4 01 120 command sets an amount of time SilverMax waits after the trajectory goes inactive before Anti Hunt is triggered During this Anti Hunt delay period SilverMax uses the closed loop holding limit only if the delay to holding defined in the Error Limits ERL command value has passed Once the Anti Hunt delay and the delay to holding passes SilverMax enters Anti Hunt open loop control and uses the previously mentioned open loop holding torque limit The limit is also used if SilverMax is holding in Anti Hunt but is forced out of position This torque limit is used while the system servos back into position If Anti Hunt is disabled this torque limit is used anytime the motor is holding which occurs after the Delay to Holding Closed Loop Moving Most all SilverMax motion is governed by the closed loop moving torque limit Whenever a motion command is executed SilverMax increases torque to decrease servo error More error equates to higher torque output Most of this error and increased torque output occurs during the acceleration and deceleration periods of a motion profile However this torque output will only increase up to the closed loop moving torque limit The output torque will remain at the def
291. p Up Step Down Signal SilverMax User Manual 4 0 114 A and B Quadrature Signals The A and B quadrature format consists of two step like signals that are 90 out of phase with each other Every rising or falling edge of each signal corresponds to a count Direction is determined by which phase is leading and which is lagging SilverMax operates from the A and B quadrature signals generated by its internal encoder The internal encoder output modulo output and external encoder input functions of SilverMax can be configured to use this type of signal Change S Z D O O Direction Phase A Phase B A amp B Quadrature Signal The preferred encoder input and output signal is A B quadrature The alternative formats of step up step down and step and direction transmit one pulse per encoder count and become subject to the bandwidth limit more rapidly For example during a 1000 count per second move the step formats require 1000 pulses per second on a single line A B quadrature uses two signals and therefore requires only 250 pulses per second on each line to transmit the same information A B quadrature signals have a lower frequency than the other two types of encoder signals This is an advantage when operating in electrically noisy environments SilverMax has a 1 MHz per line frequency limit so A B quadrature signals can transmit a higher control rate than the other formats available External Encoder Inputs Sil
292. p difficult Wherever possible this section offers suggestions on avoiding these problems RS 232 RS 232 is the default setting of the servo This is a widely used standard for serial communication between devices It is simple to set up requiring only three wires but is more susceptible to noise and has limited networking capabilities RS 485 RS 485 is a more robust serial interface with powerful networking capabilities These capabilities require a more complicated setup including termination and software configuration The extra effort is rewarded with support for bigger networks and better noise immunity Comparing RS 485 and RS 232 The following terms need to be defined to compare the two standards Balance Signals can be either balanced or unbalanced Unbalanced interfaces use a voltage level on a single wire to transmit either a 1 ora 0 This level is in reference to the required ground wire Balanced interfaces use two wires to transmit a signal The state of the bit is defined by which line is at a higher voltage This scheme is also called a differential signal A balanced signal provides better noise immunity and longer transmission distance than an unbalanced one Slave Device SilverMax servos are slave devices meaning that they do not initiate communication on their own They only respond after receiving a command SilverMax User Manual 4 01 150 Half Full Duplex Full duplex systems can transmit and receive data
293. ponds to a faster maximum rate of current torque change and slower for a lower K factor By default K factor is set to 0 1 or 0 2 depending on the SilverMax type The K factor can be set as high as 1 0 or as low as 0 02 To access the K factor open the SilverMax Initialization Wizard tool in QuickControl In the Edit MCT Motor Constants window click Manual under the Mode option Then click the Advanced button Another window titled Edit K Factor appears Clicking the arrow expands the table of available K factors ranging from 0 02 to 1 A lower K factor may help in stabilizing high inertia loads or systems with backlash The lower rate of torque change helps minimize the rate of change of acceleration or jerk allowed in the control loop Edit MCT Motor Constants Current Vokage ar Update Edit K Factor Moda C Aulo defaut eier e read voltage Seen Selecta aay e ua SE vollage _ Advanced Edk Nabve Siveitiax Ed Parameters Torque Saturation Torque saturation is another common issue encountered while tuning Common signs of saturation are SilverMax being unable to complete a motion in the required time or accruing excessive amounts of error Saturation can occur because of two limits Either the required SilverMax torque exceeds the software based torque limits or SilverMax cannot output sufficient torque due to physical constraints such as the actual maximum torque output In the case of soft
294. portant to some applications the Calculation CLC Write Command Word WCW and Write Command Word Long WCL commands The CLC command actually accesses a few dozen sub commands The CLC command is used for almost every math or logic function SilverMax can do as well as some binary number operations useful for data registers The WCW and WCL commands are extremely powerful commands that should not be used until fully understood but which can add a new degree of flexibility to SilverMax programs or host applications They turn any command that requires a data parameter into a register based command This section covers the operation and usage of these three commands Calculation CLC Command The CLC command provides basic math and logic functions While not required for some programs z many complex programs require these operations to cce modify values stored in data registers manipulate Register Accumulator 10 Description binary numbers or aid in programs using loops Three different kinds of operations are accessible Operation Decrement fie Reg Reg 1 zi with the CLC command The first group of operations is basic math functions These include add subtract multiply divide absolute value increment and decrement functions The second group contains binary logic and number manipulation functions which include the bitwise AND OR and XOR functions as well as several bit shift functions The third group contains data
295. press Transmit e Notice that Register Watch is immediately updated by the polling routine e Note how the Data Monitor and Register Watch tools can be used to emulate a PLC HMI or other host that sends data serially to SilverMax SilverMax User Manual 4 01 30 Chapter 2 Basic Motion and Programming Fundamentals In order to successfully implement a SilverMax application it is critical to understand the basic operational concepts of the servo system This chapter lays the basic groundwork needed for using SilverMax It also provides essential information that is needed to comprehend other topics in this manual The core of SilverMax is the patented PVIA servo control loop All SilverMax motion is controlled by this servo loop that executes SilverMax commands The commands themselves have a particular format shown in detail in the SilverMax Command Reference The basics of command parameters and how they are scaled are covered later in this chapter The QuickControl software simplifies the entire process of command generation by providing a user friendly interface that can scale all units to typical engineering values When operating SilverMax in host mode it is good practice to provide the host with the capability to monitor the servomotor A standard method is a polling routine A fully developed polling routine provides a wealth of information about the servo allowing for detailed control by the external host In standalone mode
296. process repeatedly A similar routine can be implemented using the registers in SilverMax SilverMax User Manual 4 01 84 ii Exercise 4 4 Cut Copy amp Paste Programming This exercise provides the user a technique for building up an entire motion profile Several QCI Example programs are opened up and the entire list of command is copied into a New program 1 Select File gt Open Navigate to the QCI Examples Homing folder and select the file Homing against a hard stop qcp Select File gt Save As Enter the filename testfile qcp 2 Select Programs gt Program Details Edit the program name to be home 3 Select Programs gt New Program Enter the program name move Repeat again using the program name tune 4 Verify all three 3 programs are in the Program List of the Program Info Toolbar Click on the small down arrow button to see the list contents If all three are listed save the file again If all programs are not listed repeat Step 3 then save the file 5 Select File gt Open Navigate to the QCI Examples Stopping Moves folder and select the file Stop Move Using Input 1 qcp Select Edit gt Select All Select Edit gt Copy 6 Select Window gt testfile qcp From the Program List choose the move 1 program a Select Edit gt paste Highlight the last line of the program b Click on Add choose the Flow tab double click on the LRP command click on
297. ptional unless using the ending address directive Starting Address Directive startAdr This directive specifies the non volatile memory starting address of the Register File Array The starting address may be in decimal or hexadecimal form Example startAdr 2500 SilverMax User Manual 4 01 A Reg File Ady Example Notepad File Edit Format Help Non Volative Register File lol x GNVRegFile name lt reg file name gt numRegs lt num of reg 1 10 gt lt lt data regl data reg2 data regn data gt gt NOTE S Quotes around Reg file name are optional 4 initial data is optional G nNVRegFile name My Reg File numRegs 4 data 300 301 302 303 Non volatile Register File Array H GNVReg rray name Array Name Number of rows and cols is automatically determined G nvRegarray name profilel 1000 0 3000 4000 1001 1 2001 4001 1002 0 2002 4007 1003 1 2002 4002 1004 0 3004 4004 1005 1 3005 4005 1006 0 3006 4006 1007 1 3007 4007 1008 0 3008 4008 1009 1 3009 4009 NvRegFile ProfilerInterval 1 8333 Include other file NvRegarray name profile2 row 8 col 2 Include Reg File Adv Example Include csv Quotation marks are optional Extra commas are ignored nvRegFile reg file 1 2 100 101 reg file 2 3 2147483647 2147483646 2147483645 nvRegFile startAdr 2000 reg file 3 4 300 301 302 303 reg file 4 3 400 401 402 nVRegFile reg file 5
298. rated by the servo loop is limited to a program specified percent By default all motion occurs with torque being constantly adjusted by the servo loop This is referred to as closed loop mode and allows the SilverMax to use only as much torque as required for any given move It is also possible to operate SilverMax without the benefits of the PVIA servo loop In this open loop mode SilverMax has no feedback and constantly applies the torque specified by the programmed limit There are several methods for controlling the immediate torque output of the SilverMax Each of these methods is outlined in the second half of this chapter Torque Limit Operation SilverMax operates in one of four different control states at any time Refer to Chapter 3 for more information on SilverMax control states While in any of the control states the maximum torque output of the SilverMax is limited However these limits are easily varied and can extend well beyond the continuous torque rating of SilverMax Thus if no true limiting is desired the torque limit specific to an operating state of SilverMax should be increased to the highest allowable limit The highest limit or torque is about referred to as Max Torque All torque limits for each control state are part of one command Torque Limits TQL In a simple application the torque limits are edited as part of the QuickControl SilverMax Initialization Wizard However it is perfectly acceptable to vary torque
299. re buffered when the second MRV command is Move 10 reve encountered the program stalls until the first MRV 2MAY s GE command is finished executing before starting the Lo ZE Wee d Move 5 revs second MRV and continuing with the program AM aco l Var a vel 5 Ips App E Example 3 Multi Tasking Motion Command Transitioning In this next program SilverMax begins the MRV move and then delays for 3000 msec before continuing with the rest of the program After the delay time SilverMax executes the VMP command in line 4 As explained previously the VMP command overrides all other motion commands so this command prematurely ends the move from line 2 and accelerates the motor to turn at 20 revolutions per second nee Label Command 1 EMT Enable Multi Tasking Move 10 revs 2 MRY acc 1 rps s vel 5 rps 3 DLY Wait for 3000 mSec Velocity Mode 4 VMP ace 5 i vel 20 rps 4 End Program SilverMax User Manual 4 01 64 t Exercise 3 2 Multi Tasking for Advanced I O Control GEZ This example shows multi tasking use with inputs and outputs during motion The program executes one of two Register Move Relative Velocity Based RRV commands depending on the state of I O 1 and 5 The values stored in registers 25 and 26 are used as parameters for the RRV move commands The loop is comprised of Jump JMP commands in an infinite loop that execute continuously until one of the inputs is triggered
300. red dynamically either by a SilverMax program or by an external host This section covers the functions that the I O lines can be used for the operation of the I O lines and the conflicts that can occur between different I O functions SilverMax UO Lines The I O lines on SilverMax are TTL level TTL signals are 0 or 5 V and are not capable of driving much current QCI offers an optical isolation module designed to work with the SilverMax I O lines that provide input and output optical isolation and can handle larger currents I O lines 1 through 7 can be used as digital inputs or digital outputs I O lines 4 through 7 can be used as digital inputs or outputs but can also be used as analog inputs When used as analog inputs they must receive a 0 to 5 V signal An understanding of the electrical characteristics and requirements of the seven I O lines is essential to properly using the SilverMax I O SilverMax User Manual 4 0 105 SilverMax UO Functions The seven I O lines used by SilverMax can be used for many different functions The table below lists the SilverMax I O functions their type their description and the I O lines they use ws 1 0 Lines Function Type Description Used All I O lines can be used as general purpose digital inputs The General Digital Digital Input inputs can be used for a number of uses within a SilverMax 1 7 Input H R program including loading new programs and contr
301. register and accumulator manipulation functions These operations are used to move data to and from the accumulator register and to load store and manipulate data in the data registers Operations of the CLC command are accessed from a pull down list SilverMax User Manual 4 01 65 Operations of the CLC Command Absolute Value i e Reg Abs Reg This command replaces the value in the selected register with a positive value of the same magnitude Add i e Acc Acc Reg This command adds the value in the accumulator to the value in the selected register and stores the result in the accumulator Bitwise AND i e Acc Acc AND Reg This command performs a bitwise AND on the value in the accumulator with the value in the selected register The result of the operation is placed in the accumulator Bitwise OR i e Acc Acc OR Reg This command performs a bitwise OR on the value in the accumulator with the value in the selected register The result of the operation is placed in the accumulator Bitwise XOR i e Acc Acc XOR Reg This command performs a bitwise XOR or exclusive or on the value in the accumulator with the value in the selected register The result of the operation is placed in the accumulator Clear i e Reg 0 This command sets the selected register equal to zero Copy i e Acc Reg This command copies the value of the selected register into the accumulator Copy from Reg Ref i e Acc reg reg Val
302. register is a specialized register that is automatically decremented each servo cycle As demonstrated here QuickControl is also constantly reading registers and reporting their contents in the register watch tool while polling 5 The register watch tool can be very powerful if applied well Repeat the steps to add register 5 to the tool again but select Time in the format window Register Watch Delay Count 5 Delay Count 5 6 The tool now displays register 5 twice Data entered in either of the data fields will be transmitted to SilverMax On the next QuickControl polling cycle the other field will be updated and contain a scaled version of the edited field This provides a convenient method for monitoring both SilverMax native units and the QuickControl scaled engineering units SilverMax Register Based Motion Commands The standard motion commands MRV MRT MAV MAT all have corresponding register and extended register versions The trajectory for each of these moves is entirely pre calculated the contents of the register s are checked only once when the command is issued Changing the value of the register s has no impact on a move already in progress All values stored in the registers used by these commands must be in native SilverMax units Register Moves RRV RRT RAV RAT These register commands are the same as their standard counterparts except that the first parameter position distance is a register
303. registers This tool allows QuickControl to simulate a host allowing an application developer to adjust register values while a program is running within SilverMax The tool also has the QuickControl scaling capabilities described in Chapter 2 Exercise 4 1 Using the Register Watch Tool This exercise explores the operation and use of the Register Watch Tool 1 QuickControl must be polling for the tool to function If the word none appears at any time in the data section of the Register Watch Tool then polling is not active to establish polling press Scan Network The Register Watch Tool is started by selecting Tools gt Register Watch By default no registers are displayed Register Watch Add Register Device ID 16 Dev 1 Register Data Units 2 To add a register to the display click the Add Register button This brings up the Select Register window Select the register to monitor modify from the scrolling list Some are combo registers where the upper 16 bits and lower 16 bits contain separate pieces of information These registers are named by default high word low word For example register 7 contains two velocity values and is named Velocity 1 Velocity 2 To view only one half of register select either Upper Word or Lower Word from the Display section Select Register Cancel Register Target Position 0 Display Actual Position 1 Register La
304. renthesis and separated by commas Example data 300 301 302 303 If a data directive is not given and the number of registers is defined QuickControl will allocate memory for the Register File but will not save any data to memory Example NVReoFile name reg file 1 numRegs 3 If an imported text file contained the above example it would create a Register File named reg file 1 This Register File would be assigned a non volatile memory location by QuickControl but that memory location would not be written to at program download The following examples use the above directives NVReoFile name reg file 1 numRegs 3 startAdr 2800 coloFmt time data 300 301 302 If an imported text file contained the above example it would create a Register File named reg file 1 which would be stored to non volatile memory location 2800 as follows Memory Address of words Stored Elements 2800 1 7 length lower byte 215 checksum upper byte 2801 1 0 2803 2 2499 time data stored in native units 2805 2 301 2807 2 302 NVReoFile name reg file 1 data 300 301 302 If an imported text file contained the above example it would create a Register File named reg file 1 stored to a non volatile memory location assigned by QuickControl at program download Memory Address of words Stored Elements Xx 1 7 length lower byte 118 checksum upper byte x 1 1 0 X 3
305. resolution In addition to having twice the resolution of a single analog input differential analog inputs have the advantage of noise rejection since two simultaneous signals are subtracted from one another eliminating much of the noise common to both lines Analog inputs are always 10 bit or 11 bit resolution but SilverMax scales them internally up to 16 bit SilverMax User Manual 4 0 110 numbers A single analog input can be from 0 to 32767 in SilverMax units while a differential analog input can be from 32768 to 32767 Using Analog Inputs for Program Flow and Data Monitoring The analog inputs can be used just like the analog inputs on a PLC or other industrial controller When used this way they can provide a great deal of flexibility to a SilverMax application Two simple applications for the analog inputs are program flow and data acquisition SilverMax analog inputs can be used to trigger events like digital outputs or program calls A SilverMax program could use analog inputs within a loop For example one of the tasks performed in a loop could be an analog input read The value of the analog input could be subtracted from a pre defined value and an action triggered based on the result e g a branch condition inside the loop could call a subroutine If the analog input value were to fall below a certain value for example a digital output could be set high Another use for an analog input would be for SilverMax to read an analog si
306. rminal Block Terminal labeled PGND The female end of the SilverMax Interface Cable attaches to the 15 pin male connector on SilverMax The male end of the SilverMax Interface Cable attaches to the 15 pin female receptacle 3 on the Training Breakout attaches to a standard 9 pin PC COM port The female end of the Communications Cable The male end of the Communications Cable attaches to the 9 pin female receptacle 4 on the Training Breakout Or Apply a connection for input voltage 12 to 48 VDC to the terminal labeled Vin on the Main Terminal Block 1 of the Training Breakout Module and apply a connection for input Supply ground to the terminal labeled PGND SilverMax User Manual 4 01 10 Setup QCI SK fc Start Up Kit The setup for this kit is the same as the setup described above for the QCI SK 34 Start Up Kit except a Clamp Module QCI CLCF 04 and Resistor Pack QCI CLRP 2 are included This kit is to be used with 34 frame SilverMax servomotors GER OBRRIO The female end of the attaches to the 15 pin SilverMax Interface male connector on the i Cable SilverMax 34N H servo e i KEE e Ei attaches to the aa 3 pin receptacle E on the SilverMax i WE 34N H servo i The red wire at the end of the SilverMax Line Power Cable is connected to Vout 3 terminal on the Voltage Clamp The black wire connects to the Gnd 4 terminal on the V
307. rnal encoder output functions the Enable Encoder Monitor EEM command the Disable Encoder Monitor DEM command the Modulo Set MDS command the Modulo Clear MDC command and the Modulo Trigger MDT command Raw Internal Encoder Output SilverMax can output its raw internal encoder signal through specific I O lines This signal is the same A and B quadrature and index pulse signal that SilverMax uses for internal control and motor commutation purposes The A signal is output on I O line 1 the B signal on I O line 2 and the index signal on I O line 3 This function has the advantage of being simple to use but the disadvantages of not being very flexible it is only available in A and B quadrature and not scalable and using I O lines 1 through 3 The first three I O lines are the only lines available for use as Kill Motor inputs a commonly used I O function For simple applications or for applications that specifically require the raw encoder signal this I O function can be very useful Only one command is needed to send the raw internal encoder signal to the I O lines Enable Encoder Monitor EEM This command requires no parameters and is essentially an on button for this SilverMax User Manual 4 0 117 function The Disable Encoder Monitor DEM command is the off button I O lines 1 to 3 must be configured as inputs before this function is used in order to avoid an error as explained previously Scaled Internal Encoder Output Modulo O
308. rnal encoder signal or for special applications like camming SR and electronic gearing The main signal can be formatted in several ways and use several combinations of I O lines Digital Inputs and Outputs The SilverMax I O lines are designed to interface with either totem pole or open collector TTL circuits when used as digital inputs or outputs I O lines 1 2 and 3 have an internal 4 7 KQ pull up resistor making them ideal as digital inputs for interfacing with open collector circuits I O lines 4 5 6 and 7 have an effective internal impedance of approximately 200 kQ but no pull up resistors so these lines may require an external pull up resistor if they are used as inputs with open collector circuits All seven I O lines work equally well as inputs with totem pole TTL circuits The pull up resistors on I O lines 1 2 and 3 hold those lines high when they are inactive When I O lines 4 5 6 and 7 are inactive they float between 0 and 5 V because they are not held high As digital outputs the I O lines can sink or source up to 5 mA A 5 VDC regulated power supply capable of supplying 100 mA is available from SilverMax This power supply is intended for use with external sensors or switches QCI recommends using the OC optical isolation module to optically isolate the I O lines when they are used as digital inputs or digital outputs In addition to the circuit protection gained from optical isolation the QCI optical isolation module
309. rque Max Torque Any 17 or 23 34N 1 34H 1 Any 34HC SilverMax Torque Units in Native Format SilverMax Torque Settings There are four SilverMax control states as described in detail in Chapter 3 Each of these states has an associated torque limit all of which can be adjusted by the methods described below If the 100 torque setting is insufficient the Max Torque selection can be used subject to certain restrictions The primary difficulty with the Max Torque setting is servomotor overheating Short duty cycles less than 25 at Max Torque can usually be used without restriction The exact time depends entirely on the operating environment If sufficient external cooling is provided SilverMax can operate at the Max setting indefinitely A slight amount of air movement over SilverMax can have a significant effect on temperature Open Loop Holding This torque setting is frequently referred to as the Anti Hunt torque This is an open loop mode so the current required to generate the torque specified is always flowing through the windings This current flow generates heat increasing the temperature of SilverMax If SilverMax is experiencing excessive heating while at rest lowering this value can decrease the amount of heat generated Excessive holding current contributes solely to the heating of the SilverMax so remember that less torque means less current decreasing the operating temperature In addition torque is proport
310. s are if a command is already being executed if a motion is running or if a program is executing Class D commands such as the ones for basic motion described later in this chapter can only be executed from a host when SilverMax is idle no command no motion or program executing Class A commands such as the status commands can be executed at any time even while a motion is executing The SilverMax Command Reference provides a complete description of each command class Command Parameters SilverMax commands all have the same fundamental structure Each command has an assigned command number which may be followed by parameters The number of parameters varies by command and each command is described in detail in the SilverMax Command Reference The parameters also have unique scaling and special formatting Use care when generating command parameters as incorrect values will result in execution errors QuickControl is designed to perform all parameter generation in an easy to understand graphical interface Serial commands are covered in Chapter 9 of this manual Parameter Scaling Parameters fall into five basic categories that will be discussed in detail below Raw Numbers Position Distance Velocity Acceleration and Time Parameters have fixed internal units called SilverMax native units The QuickControl software package displays all values in typical engineering units but basic communications from a separate host such as a PLC must
311. s to correct the existing error do this using a Target to Position TTP command This removes any Position Error that may exist Next issue the CIS and CPL commands to clear the error conditions in the Internal and Poling Status Words Then reissue the KMC and KMR command to reset the KMC and KMR operation Restoring operation After a shutdown the system can be restarted automatically by adding a few extra steps to the Recovery Program If a homing routine is to follow the Torque Limits could be set to a lower value required for homing Next the servo drivers must be re enabled using the EMD command SilverMax firmware version 21 and older required issuing the Motor Constants command SilverMax is now ready for operation From here a homing or other corrective action Program can be executed putting the system back into service SilverMax User Manual 4 01 131 Uncontrolled Shutdown Recovery Program continued SilverMax User Manual 4 01 This pragram performs an Lncontrolled shutdown of the Silvervax SilverMax immediately shorts the wincings on the mo or upon a motor shutdown condition Then the recovery program re enable the drives and returns the Silver ax to readiness Set the conditions on which the Gier au shoulc automatically shut down Kill Molor Conditions If 140 3 is LOW Define the Kill Motor Recovery process that wil be used In this case SilverMax calls a Recovery Program to deal with the error
312. s use Trademarks SilverMax QuickControl Anti Hunt and PVIA are trademarks and property of QuickSilver Controls Inc All other names and trademarks cited are property of their respective owners 2003 Copyright The SilverMax embedded software SilverMax electronic circuit board designs SilverMax embedded CPLD logic and this SilverMax User Manual are Copyright 1996 2003 by QuickSilver Controls Inc SilverMax User Manual 4 0 i SilverMax User Manual 4 0 Table of Contents Introduction to the SilverMax User Manual s ssssssssssesssssssssssscsesessssssssrerensesesesseseatareneesenes i Chapter 1 Using SilverMax and OC Start up Kits sscssesssssssssssssesesesssssseseersesessssenesearenes 1 Introduction to Using lV GMX E 1 DANG Mee ne IIe EE 1 PHOS COMMON AUOM EE 2 PLY PIC C ue TEE 3 Multiple SilverMax Configurations tic mae fae fata ks tai he welt atta teh aN 4 RS 232 or RS 485 SilverMax Network NENNEN EESEERRS SNE EEN dE 4 Master Slave E EE 4 QuickControl and SilverMax Proc arn eh geesde EE 5 SilverMax Programming Overview ree eege 5 Feat res SEI eet EE 6 Getting Started with QCI Start Up TE 7 ene EE TEE E ER 7 SilverMax Factory Details EE 8 Neel 8 MAUNA WEE 8 OC Start Up Kits Overview EE 9 Setup QCI SK fs Stat up EE 10 Setup QCI SK fc Start Up EE 11 ee Mee Eu Ee Te EEN 12 Setup QCI SKOm FC v Start Up EE 13 S ftware Requirements EE 14 Troubleshooting SilverMax Communication 15 QuickC
313. seconds to complete the program will wait and do nothing for twenty seconds With multi tasking enabled the move command will execute normally but the rest of the program will also continue to run Disabling multi tasking makes the logic of a SilverMax program much simpler and prevents some common programming errors This is why multi tasking is disabled by default Some applications however require multi tasking and a good understanding of how SilverMax multi tasking works is essential for these applications This section explains how multi tasking operates describes how to properly use multi tasking and gives some examples of the effects of multi tasking on a SilverMax program written with QuickControl Multi Tasking Operation Multi tasking enables SilverMax to continue executing a program while a motion is in progress With multi tasking disabled when SilverMax executes a motion command the program stops execution until the move is complete i e the Trajectory Generator is inactive or until a stop condition is met With multi tasking enabled the program continues to run during the move allowing much greater versatility in the program The Enable Multi Tasking EMT command enables multi tasking and the Disable Multi Tasking DMT command disables it Using multi tasking correctly requires a firm understanding of how SilverMax controls program timing the system tasks that SilverMax executes in the background along with program commands an
314. ser Input Dead Band DA User Maximum ScalelLimit 15 User Maximum Output Scale 16 User Output Offset 17 User Output Rate of Change 18 User 19 User Profile Move Pos 20 User Profile Move Acc 21 User Profile Move Vel 22 User Profile Move Dec 23 Profile Move Offset 24 5 SilverMax User Manual 4 01 Indirect Addressing Indirect addressing is the best way to utilize Register File Array Data With indirect addressing the address of the Register File or the row of the Register File Array to be accessed is loaded into the accumulator using the WRF command before the Register File command is executed Each of the Register File Commands RLN RLM RSN and RSM has a check box for indirect addressing When the indirect addressing box is checked the address in the accumulator will direct SilverMax to the Register File or Register File Array row that is to be accessed Edit Write Register File q x OK Cancel Register File Name D Register File Arrays Register Files Description il Write To Register Accumulator 10 Register File Property to Write Start Address v Editing Register Names QuickControl 4 0 allows for editing the names of registers 11 through 40 user registers Any user registers used in a QCP file can be descriptively named to add physical meaning to the program code Data registers being used for a spe
315. specified with each command and calculates the entire trajectory for the move before sending the calculated trajectory to the Trajectory Generator and actually starting the move During this calculation period SilverMax does not execute the next command in the program buffer even if multi tasking is enabled This calculation period is a little less than two milliseconds for the time based moves and a little less than four milliseconds for velocity based moves The Pre Calculate move commands PCM and PCG allow some control over this delay period and can be useful for some applications The SilverMax Command Reference has more information on these two commands Velocity and Time Based Motion Commands When SilverMax executes a time or velocity based motion command it checks to see if the Trajectory Generator is busy active If another move is still SilverMax User Manual 4 01 62 running SilverMax will queue the time or velocity based motion command and pause program execution This effectively disables multi tasking although no error is generated Once the first move finishes multi tasking begins working as expected again This is one of the most common errors encountered when using multi tasking Some other commands can override the first motion command and unblock the program The velocity and time based motion commands can be overridden by the VMP VMI HSM HLT STP PMO or PMX commands Velocity Mode Motion Commands The velocity mode com
316. st Index 2 C Targ Status Word Reserved 3 Upper Word Input Trig Position 4 C Lower Word Max Position Error Current Position Error 6 Sort zi E Alphabetically Velocity 1 Velocity 2 7 3 Select register 5 Delay Count and Register to view the timer register Click OK to bring up the format window Select the desired data format Long and ULong display the exact contents of the register with no units This is useful for inputting basic numbers or for viewing SilverMax native units The Hex option translates the contents from decimal to hexadecimal This format allows easier analysis of individual register bits Position Acceleration Velocity and Time options all scale the register value using the current QuickControl units For information on native units and QuickControl scaling see chapter 2 Select Long to display register 5 in native units SilverMax User Manual 4 01 Select Data Format Select the format you with to display the data in E pe Cancel hon a C Hex C ULong Acceleration Time ong C Position Velocity EE 78 4 Clicking OK a final time places the register into the tool Click on the data box of register 5 which currently contains a zero Enter a numeric value of 10 000 or greater Once the value has been typed press enter At that moment the value typed in will be transmitted to the SilverMax and immediately begins decreasing The Delay Count
317. state with no torque applied to shaft By enabling this condition the SilverMax could process an error recovery routine or re initialize itself without host intervention Sensor Found on Last Move Used for Hard Limit shutdown All motion commands can be stopped using a digital input or other bit state conditions When an input stops a motion command this condition is set If the input was an end of travel sensor SilverMax could also shutdown in order to halt motion Wait Delay Count Exhausted Used for a Watch Dog timer The Delay counter can be pre set with a time value that will count down automatically When the counter reaches zero this condition is set Setting the Delay counter and enabling this condition prior to an operation that should complete in a given time allows a Timeout function If the operation does not complete before this condition is disabled disabled by issuing another KMC command a shutdown will occur Over Voltage Used for handling Over Voltage conditions Over Voltage will always cause the SilverMax to shutdown regardless of the KMC command settings However if some type of error recovery is desired setting this condition will allow SilverMax to continue operation after the Over Voltage This is useful when the over voltage is due to heavy deceleration and control of the load must be regained Under Voltage Don t use this use the Power Low Recovery instead Don t use this u
318. sued The Kill Motor routine is covered in Chapter 8 End Program END Command If multi tasking is enabled and an END command is issued SilverMax will finish the current move if a motion command is active and then end the program SilverMax User Manual 4 01 63 Multi Tasking Examples The following examples illustrate how multi tasking works with SilverMax programs Example 1 I O Control During a Move Command Enable Multi Tasking Move 10 revs acc 1 pss vel 5 rps Wait for 1000 mSec Clear Output Bit 1 Wait for 50 mSec Set Output Bit 1 Wait On Bit State Until Trajectory Active is LOW FALSE Clear Output Bit 2 End Program This program starts a 10 revolution MRV move waits for a 1000 msec delay then toggles I O bit 1 for 50 msec while the move is still in progress The WBS command in line 7 causes the program to wait on that command until the move command is complete The move completes before bit 2 is cleared in line 8 This program sends an output signal when the move is finished but also allows other commands to be executed before the WBS command holds the program while the move finishes Several non motion commands could be inserted between lines 2 and 7 that would all execute during the MRV move Example 2 Multi Tasking Motion Command Buffering Multi tasking will have no effect in this program rae Label Command Since time and velocity based motion commands f1 EMT Enable Mule T asking a
319. t Offset a Mile to place slight torque on shaft at al times Write 20 to User Output Difset 17 Register Reg 18 Rate of change for PIM and VIM Oriy imis the Rate that Position and Velocity would chan ge Does not effect rate of change of Torque Outpy Write 0 to User Output Rate of Change 18f Register Enter Torque Input Mode Stop if Inout 5 viggers LOW A fiter value of 20 Hz c less wil add hysteresis to the inp Torque Input Mode Stop when 1 0 5 is LOW FALSE Torque Input Mode Example Program The TIM equation is shown below The gt symbol indicates the limiting effect of register 15 jee lt 12 14 13 lt 15 14 Torque 40r 15 14 17 if abs 12 13 lt 14 ko 17 if abs 12 13 14 Any other process that writes to register 12 could replace the analog input of this example For a serial host remove the ACR command and use the WRI command directly from the host Program commands such as Calculation CLC and Write Register Program mode WRP could also fulfill this function SilverMax User Manual 4 01 124 Tuning Issues SilverMax varies torque by changing the current fed to the windings The rate at which SilverMax changes current is controlled by the K factor This factor can be denoted by the term di dt or rate of current change per unit change of time While the K factor isn t specified in units increasing K factor s magnitude corres
320. t Check Direction Toggle Enable Second Check Last Check Last Check Enable AND Inputs Enable OR Inputs Enable if io 9 sai7 6 5 43 2 11 0 Po CT oC Toft tof oftototfototofofoftoto tis ee e Sa LS Deeg Stop Enable Word 0x1001 in hexadecimal form Hexadecimal 0x1001 4097 decimal SilverMax User Manual 4 01 76 The table below shows how the value of 36865 was derived First Check Direction Toggle Second Check State Last Check Last Check AND Inputs State OR Inputs State Toggle OR States Bit 15 Stop State Word 0x9001 in hexadecimal form Hexadecimal 0x9001 36865 decimal The binary values must be converted to either decimal or hexadecimal depending on the communication protocol used for use in SilverMax commands See Chapter 9 for more details on protocols and Appendix for information on converting between binary decimal and hex Advanced Stop Conditions QuickControl Most of the capabilities available in serial mode are also available within QuickControl To access these options in QuickControl click the Advanced tab in the Edit Stop Conditions window Edit Stop Conditions x Standard Advanced First Check lt Last Check Reverse Starting The Last Check can do Direction when any of Input 1 HIGH one of three things Input BI 17 the following inputs are inthe indicated state Input 3 Disable 109 top wien am dl MPR Disable Change siev
321. t Output Bit 1 Delay for 500 mSec This is where Register 11 the counter is decremented by 1 Vi Decrement User 11 Jump to FOR 11 10 T0 1 End Program 83 While The While loop is a portion of code as long Label Command as a specified condition is true The first JMP in this program skips the entire loop if the conditions I O 1 low 3 high are true These are called exit conditions since they dictate when the loop will not run The second JMP is 1 0 Line 2 will toggle waiting an unconditional jump back to the first JMP for the inputs Jump On AND to END WHILE If1 0 1 LOW and 1 0 3 HIGH Cause 1 0 line 1 to go Low Clear Output Bit 2 Delay for 200 mSec Cause 1 0 Line 2 to go High Set Output Bit 2 Delay for 200 mSec Always Jump back to the WHILE condition Jump to WHILE END End Program This is an example of a WHILE loop The Program will Loop until 1 0 Line 1 and 3 are set to there desired states Do While The Do While loop functions similarly to a while loop with one exception This loop will always execute at least once before exiting It requires only a single JMP at the end that jumps back to the start of the loop Label Command This is an example of aDO WHILE loop The Program will Loop until a Moving Error is detected The Internal Status Word must be clear to remove any error that may have previously exist
322. t for This command is affected by the Digital Input Filter DIF command See the SilverMax Command Reference for details Wait on Bit Edge WBE This command operates similarly to WBS pausing execution of the program However rather than waiting for a particular state high or low the condition is met when the transition occurs The condition can be either rising low to high transition or falling high to low Edge triggered commands require careful timing and analysis This command is not affected by the DIF command Jump Commands There are many variations on the basic jump command Each provides a different logical operation on either inputs or register values All jump commands have the same basic structure a set of conditions and a location to jump to specified by a label If the conditions are not met then the jump will not occur and the program will continue to the next line The label to jump to must exist when the program is downloaded Click in the label column of a QuickControl program and use the keyboard to create labels Jump JMP This is the most basic jump command It is used to create unconditional jumps those that occur every time they are executed The bits of the Internal Status Word are available to set conditions but are provided primarily for backwards compatibility Other jump commands are specialized to operate on many conditions Jump on Input JOI This jump command operates on a single bit of the I O Stat
323. table operation QuickControl takes care of most of the work During SilverMax initialization QuickControl polls SilverMax for the current voltage level QuickControl then sets the voltage dependant parameters based on the voltage sensed by the SilverMax If the SilverMax will be operated at a different voltage than the current supply voltage the Motor Constants voltage setting should be manually set to the expected operating voltage This forces QuickControl to use the manually set voltage when configuring the Motor Constants rather than the detected voltage SilverMax Control Panel The Control Panel is a tool in QuickControl that provides access to several important features of SilverMax The Control Panel makes it possible to jog SilverMax at scalable velocities while monitoring the condition of SilverMax in the Device Status area The panel also provides the means to interactively tune the SilverMax servo loop Test moves can be issued to the SilverMax after changing control and filter constants and a strip chart can be displayed to show motion data while tuning This strip chart function was used to create the illustrations in the previous section SilverMax Control Panel EN r Initialization File Tuning Exit SilverMax Factory Default Cycle Initialization qcp Use Wizard to Download and or 1 Cycles Ir Reboot O forever delay Change Initialization File Ger as Initialization Wizard Move Type 7 it Fj C MAT C MAT Edit Control Edit F
324. ted to external devices or to each other as described below and can execute programs independent of the rest of the network just like a hybrid configuration Master SilverMax Slave SilverMax Master Slave SilverMax Breakout UO Line 4 Connection Breakout This figure shows two SilverMax configured to work together in what amounts to a host configuration for one and a standalone configuration for the other The two SilverMax are only interconnected through their I O lines This interconnection allows the master SilverMax to coordinate motion with the slave SilverMax Advanced details on master slave operation and SilverMax networking are described later in the manual SilverMax User Manual 4 01 4 QuickControl and SilverMax Programming SilverMax has an extensive command set that allows it to be programmed for a wide variety of complex applications SilverMax needs to be pre programmed if it is to be used in a standalone or hybrid configuration In host configuration the host issues commands directly to the servo for execution and no user program is stored in the SilverMax non volatile memory SilverMax is programmed from a series of commands issued through a serial communications link The most practical way to program SilverMax is to issue these commands from the QuickControl software running on a PC QuickControl is QCI s Windows based software interface for SilverMax It can run on Wi
325. termination if the stubs are short Other wiring examples are listed but termination schemes must be devised on a case by case basis Backbone with OM Very workable avoid long stubs Backbone with Stars or Clusters Avoid E h g Star Network OK for short runs avoid long runs Daisy cee Best tough to wire Ring Avoid Source Biasing Termination Source termination involves the use of resistors between various wires in the communication system A source biasing resistor of 120 ohms is connected between line A and line B at the host serial port connection Some RS 485 serial devices have internal jumpers available to add this biasing resistor If the device does not have this internal setting the developer must add this resistor A standard 1 8 Watt 120 ohm resistor with 5 tolerance is optimal RS 485 Network RS 485 Line A a RS 485 Line B Logic Ground Cable Shield RS 485 Host Device SilverMax User Manual 4 01 155 End Node Termination A properly biased RS 485 network will have line voltage levels and transmission characteristics that allow all devices on the network to communicate correctly This RS 485 serial configuration is designed from standard line levels and is flexible to accommodate the range of RS 485 serial devices available The following resistor configuration should be implemented on the last connector node of the RS 485 network This will correctly bias the differential voltage between l
326. ternal or external Besides simply limiting torque SilverMax torque can be controlled using an Input Mode These two options are discussed further in the Input Mode section Lastly varying SilverMax control constants changes the way SilverMax develops torque output Adjusting these constants is called tuning and is discussed in detail in Chapter 10 Tuning is often used to compensate for instabilities or performance problems in the overall system Although SilverMax is a powerful servomotor system the SilverMax is not intended for use as a precision torque sensor The accuracy of the SilverMax torque data is often better than 10 However the accuracy can vary with speed operating temperature and power supply drift SilverMax position velocity and acceleration control have a higher precision than direct torque control Specifying these parameters along with torque control will yield better overall performance Register Control SilverMax torque limits are defined by four 16 bit words in two data registers Register 206 contains both the closed loop holding torque limit the upper word and the closed loop moving torque limit the lower word Register 207 contains the two open loop torque limits holding in the upper word and moving in the lower word Both registers are read write capable For more information on registers see Chapter 2 The torque limit data can be updated at any time via these registers SilverMax will begin using the new
327. ters that are used by the dynamic move operations Functionality to exit these operations and stop SilverMax motion is also addressed Register File System The Register File System facilitates storing data to non volatile memory and the subsequent loading of data from non volatile memory for program use A useful example would be storing position offset values during a calibration routine and later loading these values for use in the main program It also serves as the basis for any type of standalone motion profiling where a complex profile is known before the move starts The motion data parameters are stored in SilverMax non volatile memory and the Register File System allows the sending of data to a dynamic move operation like Profile Move or Interpolated Move as the move executes Register Files A Register File contains data from specified data registers stored in non volatile memory beginning at a defined memory address This data may be stored from a single register or an array of sequential registers One Register File may contain data from up to ten registers Register Files may be created using the following commands RSN Register Store Non Volatile single register store RSM Register Store Multiple multiple register store The first memory address of the Register File always contains the Length and Checksum of the Register File which is automatically calculated and stored by SilverMax SilverMax uses the length and checksum
328. terview process and modify the initialization command parameters directly use the Initialize Parameter Browser box Scroll down in the lower right window to find the desired parameter category Press the sign the left of the category name to see the parameters under that category Double click on parameter name that is to be changed A separate window will pop up for the selected parameter Make changes as needed and press the OK button SilverMax Initialization Wizard Options The Options button in the SilverMax Initialization Wizard provides access to a secondary options window Select specific options for the SilverMax initialization procedure in this window APPLICATION STARTING ADDRESS OPTION The starting address location where a user program will be stored in the SilverMax Non Volatile memory The default value is 512 This option is available for advanced users that know the exact size of their initialization file and the starting location of their QuickControl program Changing this address is not Cancel recommended by QCI See Chapter 2 SilyerMax Initialization Wizard Options m Default Start Address ERASE APPLICATION OPTION Default starting address for The non volatile memory of SilverMax has no true new programs erase function only the ability to overwrite This initialization option will cause the first location of non 512 volatile memory where the stored program begins to be overwritten with a
329. th 0 05 to 0 025 and stop acceleration 0 6 0 8 Time sec SilverMax User Manual 4 01 101 Example of Interpolated Move In the following move there are four velocity segments two segments that ramp up to speed and two decelerating segments Note that each segment is projected off to an unattainable position 1 073 741 824 because the time parameter determines where the next segment starts Time Position Velocity Acceleration Segment1 4000 1073741824 1073742 536870912 Ramp up to 1000 RPM 1 4 velocity 2147483647 4 53687091 2 with 05 acceleration 0005 2147483647 107342 and project that motion for 4000 ticks 48 seconds before looking to load a new segment or decelerate to a stop using register 19 Note that these parameters project the initial ramping and constant velocity segments and the position parameter for this segment is never realized The position parameter is intended to define direction of motion while allowing acceleration and velocity parameters to define the shape of the profile The 4000 ticks of time data are copied to register 18 just before this segment s execution This count is decremented every servo cycle 120 usec until it reaches 0 Before the counter decrements to 0 the lower word of register 17 should contain the register reference number of the first register out of four user registers to load data from for the next segment In addition register 17 still has a 1 in the upper
330. th byte is the NAK error code The code is 16 bit word that indicates the error The codes are tabled at the beginning of this section e The fifth byte is the command number of the command that caused the NAK Command numbers above 128 will be returned with the most significant bit removed For example Identity IDT command number 155 would be returned as 27 e The final byte is the checksum Example NAK response for a Read Register RRG Command Number 0x0C from SilverMax 10 Ox0A with an invalid Data Register parameter OA 04 FF 00 07 OC E0 Example NAK response for a Move Relative Time Based MRT Command Number 0xB1 if SilverMax 16 0x10 is already in motion The SilverMax will NAK back Device Busy as follows 10 03 FF 00 02 B1 3B Serial Interface SilverMax has two communication hardware configurations available RS 485 or RS 232 The serial interface is selected by the Serial Interface SIF command The serial lines are used to program the servo issue instructions to SilverMax or query SilverMax for data Choosing between the two available standards is a matter of application requirements and system complexity This section covers the two protocols their requirements and how to choose between them When working with serial communications it is important to remember that RS stands for Recommended Standard There can be a great deal of variation between manufacturers sometimes making communication setu
331. that supports more devices on a single network The tradeoff for this improvement is increased wiring complexity This chapter covers the details of both protocols and interfaces and offers some guidance in choosing between them Suggested hardware configurations and trouble shooting tips are provided for building systems In addition to this document there is a great deal of information on standard protocols and interfaces available on the Internet Selecting a Protocol and Interface The SilverMax default protocol is 8 bit ASCII In this protocol packets are made up of standard ASCII characters This protocol is supported by most equipment manufacturers and is easy to generate in a PC host The 8 bit ASCII protocol is recommended for most applications The 9 bit binary protocol supplies error checking capabilities built into each packet This makes the protocol suitable for environments where interference and transmission errors are likely or expected The 9 bit protocol is also faster because it requires fewer bytes to transmit a given packet This protocol is more complex and requires greater control over the host serial port to implement The ninth bit is the parity bit and is used only at the start of packets and not to establish parity It should be set high for the start of a packet and low for other bytes in the packet If this type of control of the parity bit is not available then the 9 bit protocol cannot be implemented Choose 8
332. the Stop States word to 0 sets the desired state value to logic low 0 volts on the input Example of Advanced Stop Conditions This example shows a Move Relative Velocity Based MRV move that will change the direction of the move based on the beginning condition of input 1 the motion will then be stopped using the same input 1 This is a simple system with a single sensor supplying the signal to I O 1 In scenario A the starting position is off the sensor SilverMax will move clockwise to the sensor edge and then stop The First Check has no impact as I O 1 is low when motion begins Once the sensor is reached I O 1 is high and SilverMax decelerates In scenario B the starting position is on the sensor In this scenario the First Check will trigger because I O 1 is high This causes the motion to begin in the opposite direction of that commanded The Toggle Last Check bit is also set so the conditions to end the move are inverted In this case SilverMax moving off the sensor and UO 1 going low will stop the motion Using this single setup the final position will always be on the same edge of the sensor The command example is shown in the 8 bit ASCII protocol Address Stop Enable Stop States Word Word 40000 1000000 100000 4097 36865 See Chapter 2 for the distance acceleration and velocity values The table below shows how the value of 4097 was derived Toggle Second Check Conditions Bit 15 Firs
333. the button and choose the tune program Select File gt Save 7 Select File gt Open Navigate to the QCl Examples Miscellaneous folder and select the file Ode To Joy qcp Select Edit gt Select All Select Edit gt Copy 8 Select Window gt testfile qcp From the Program List choose the tune 2 program a Select Edit gt paste Highlight the last line of the program b Click on Add choose the Flow tab double click on the LRP command click on the button and choose the home program Select File gt Save c Click once in the Label column of the new LRP command Enter the text home and push the Enter key on the keyboard Put another label on the first line of the program Name the label tune Now highlight the last line of the program d Click on Insert choose the Flow tab and double click on the JOI command Choose HOME from the Program List Click on the Conditions button choose I O 3 from the Condition list and Low FALSE as the State Click OK twice to get back to the program e Highlight the last line of the program Click on Insert choose the Flow tab and double click on the JMP command Choose TUNE from the Program List Click OK to return Select File gt Save 9 From the Program List choose the home 0 program Highlight the last line of the program a Click on Add choose the Flow tab double click on the LRP command click on the b
334. the current position and other internal data TARGET TO POSITION TTP Clear the accumulated error CLEAR INTERNAL STATUS CIS Clear the moving error bit in the ISW that triggered kill CLEAR POLL CPL Clear the moving error in the PSW as well KILL MOTOR CONDITIONS KMC Reset SilverMax shutdown conditions ENABLE MOTOR DRIVERS EMD Re enable the servo drivers so the SilverMax can begin motion ASCII example 16 146 lt CR gt 16 167 256 256 lt CR gt 16 227 lt CR gt Kill Motor Recovery from Uncontrolled Shutdown Handling the Shutdown SilverMax shutdown may occur while in motion If this is true there may be a period of time required to allow SilverMax to come to a complete stop Fault Recovery Program The simplest way to deal with this is to wait using the Delay DLY command Set a delay sufficient to allow the system to come to a halt This depends on the system implementation the needed time delay will vary greatly Once SilverMax has stopped the error processing can begin Processing the Error Condition Depending on the shutdown condition enabled there may be a number of different things that must be done to clear the error continue operation or simply alert the system or operator of an error Alerting the system or operator may involve toggling a Digital Output Line The program example shows a Moving Error triggered recovery that will allow SilverMax to re home and continue with operation The first operation i
335. the program The motor will begin its first move of 30 000 counts 4 Select Tools gt Register Watch to open the Register Watch tool Click the Add Register button and select User 25 Select Position for the Data Format and click OK Repeat for Accumulator 10 Actual Position 1 and User 30 Choose Position format for each register The value in register 25 is how small the move position will be allowed to become before restarting Raising this will make the cycle time shorter Register 30 contains the beginning position for the move The accumulator is used with most of the CLC operations in a similar manner to how the accumulator is used in an assembly program In this exercise the accumulator s value is not used directly by the motion command The value in the actual position register should be User 30 User 25 at the end of each move 5 With the Register Watch tool still open push and release the button connected to I O 5 This will start the calculations The program will pause before each move The calculation process is reasonably simple using a few math operations to accomplish its task Any data in the accumulator is first cleared and then the actual position is subtracted from the accumulator This results in a negative position value After this the binary value in the accumulator is bit shifted right which is the binary equivalent of dividing by two This value is placed in the register used by the move After this t
336. tinue to move at the specified velocity forever This command requires two parameters velocity and acceleration SilverMax will achieve the specified velocity using the given acceleration and remain at that velocity until commanded otherwise In a multitasking environment this command can override any other motion currently in progress This provides an easy transition to a controlled deceleration to slow down or stop the servomotor See Chapter 3 for more information on multitasking S Curve Factor This action set by the S Curve Factor SCF command alters the motion profiles of the four basic move commands MRV MRT MAV MAT by introducing an s curve into the acceleration A full s curve will minimize the rate of change of acceleration or jerk for a trapezoidal motion In a full s curve time based move the actual acceleration used is double that of a pure trapezoidal zero s curve motion In a velocity based move the time to complete the move increases proportionally to the amount of s curve specified In order to have the full s curve move complete in the same time as the trapezoidal move the acceleration parameter must be doubled The following chart shows a velocity based move with zero s curve trapezoidal full s curve and full s curve with the specified acceleration doubled Velocity Based Motion and S Curve 1200 Full S Curve We 2 x Acceleration as Trap Motion 800 S
337. tion Likewise if the scaling value were set to 512 on the same SilverMax two counts from the external encoder signal would equal one SilverMax count Common applications for the direct motion control use of the external encoder input function include e Stepper Motor Replacement One common and straightforward use for this feature is replacing a stepper motor in an existing machine design with SilverMax Many stepper motor drives receive a step signal that controls the step motion SilverMax can be programmed to act directly on these types of step signals allowing SilverMax to be used in the existing design with no other design changes This allows SilverMax a servomotor that uses closed loop position control to replace a traditional open loop stepper motor with minimal design overhead e Electronic Gearing Following SilverMax can be set up to follow a signal from an external source This source could be the signal from the encoder on a non QCI motor the internal encoder from another SilverMax or the signal from some other type of device like a linear encoder on a slide With the scaling feature of the SSD and RSD commands SilverMax can follow the external signal with a wide variety of motion ratios A common use for this feature is on multi axis SilverMax systems e Camming An external encoder input is one of several ways SilverMax can be used in a camming application An elliptical or other type of irregular motion profile can be sent t
338. tion in different ways The multitasking capability of SilverMax alters the impact of motion commands allowing them to execute in the background Commands from other categories can then be executed while a motion is in progress See Chapter 3 for additional details The following descriptions are for non multitasking applications Motion Commands Motion commands stop program progress when they are executed This means that no other program type command can be issued neither the next command in the program nor program commands received from the serial interface Immediate commands from the serial interface will still be processed Motion commands may also have stop conditions specified which will cause both motion and command execution to terminate Chapter 4 contains more information on stop conditions Flow Commands There are two types of flow commands those that alter program flow and those that cause pauses in execution The jump commands cause SilverMax to execute a specific line next not necessarily the next one The Wait commands such as Wait Delay WDL and Wait on Bit State WBS operate similarly to motion commands by suspending program execution while waiting for a condition to be met One exception to this is the Delay DLY command that has an option to set up a delay counter to run in the background and allows program execution to continue These commands are explained in detail in the later section on program flow Mode Commands
339. tions must be met for the input checking process to continue If the conditions are never met the move will continue until it reaches it s programmed end This in combination with the Last Check allows a motion to only stop only on an ordered condition of inputs This would be used for example in a homing routine to first find a sensor and then stop on its far edge This provides repeatable highly accurate positioning independent of starting location The detection of the far edge would occur in the Last Check Last Check This stops the move The Last Check has several options based on the AND and OR logical operations e OR only if any of the enabled conditions are met the motion will stop e AND only e More than one condition if all enabled conditions are met the motion will stop e Only one condition enabled if the single condition is met the position will be recorded as normal but the motion will not stop e AND and OR both sets of conditions are evaluated and the logical results are ANDed together If the net condition is met the motion will stop SilverMax User Manual 4 01 73 Input Checking Flow Diagram If the Toggle Second Check Conditions bit is set the Second plist Check Dsedte Check conditions are inverted toggle the starting First Check direction of a move Direction toggle iine rogge Or EE If any of the enabled input done only at set any active OR conditions in conditions are met then the
340. to all SilverMax DB 15 SMI cables for easy connection to many OC Accessory Products TECHNICAL DETAILS DB 15HD DB 15 Pin Layout 15 pin High Density D subminiature Plug w pins type gender Front View on SilverMax Crimp type contacts Rated at 5 Amps per contact Max wire gauge is 20 AWG Shell size is a std DB 9 Signal Comments DB 15 Pin to Signal 84HC series Drive Enable operates from a DC voltage range of 10 to 48 to enable the servomotor drive It is Pin Signal Description commonly connected to the V driver power supply E 6 Controller Power Ground when not used independently 1 Drive Enable 11 Controller Power Ground Controller V Power pin 7 and both Controller T Controller V Power 8 to 48 V 2 RS 485 A RS 232 Tx 12 RS 485 B RS 232 Rx 8 Logic Ground 3 5 VDC Supply 100mA max Power Grounds pins 6 amp 11 must connect respectively to the V and ground terminals of a 8V to 48V DC supply 13 10 1 I O lines 1 2 amp 3 each have a 4 7k ohm pull up 9 70 2 resistor connected to the internal 5 VDC 100mA 4 IO 3 ly 14 VO 4 oe 10 O 5 5 1O 6 I O lines 4 thru 7 each have a 200k ohm effective JE Ge pull up impedance to the internal 5 VDC supply DB 3 Connector This high current connector is found on most 34 frame SilverMax E series servomotors It connects an external power source to the servo drive only DB 3 power cables are offered by OC allowing easy connection to pow
341. tput and set the default state for the output high or low Set Output Bit SOB Command The SOB command configures the selected I O line as a digital output and sets it high If the I O line was in use as a digital or an analog input this command will reconfigure the line as a digital output If the I O line was in use for a high speed I O function however an error may occur In either case care must be taken to prevent I O functions from using the same I O lines Clear Output Bit COB Command The COB command does the same thing as the SOB command but sets the output low As with the SOB command and all of the I O functions I O functions should not be assigned to the same I O line in order to avoid conflicts Using Analog Inputs Analog inputs are another way to use the SilverMax I O lines An analog input could be a potentiometer a Hall effect joystick a temperature sensor or a pressure transducer A 5 V power supply is available from one of the SilverMax pins that can provide up to 100 mA for sensors and other peripherals These features give SilverMax added power and flexibility The analog inputs can be used for traditional PLC tasks like event triggering or data monitoring or they can be used for direct motion control SilverMax also has three motion modes can directly control movement based on an analog input This section covers the different functions of analog inputs and the commands used to set them up In addition to the inf
342. trol QuickControl can represent torque in native SilverMax units or in percentage form with 100 torque corresponding to 20 000 SilverMax units and Maximum torque corresponding to 30 000 units for most models The QuickControl screenshot shown previously for the TQL command shows this Representing torque this way can be very useful since 20 000 SilverMax units of torque really is 100 torque as reported in the QCI torque speed curves for each motor The torque limits can be set higher but this can result in the motor overheating depending on the required duty cycle For most applications 20 000 SilverMax units of torque is considered 100 torque It represents the torque produced at the maximum continuous power level SilverMax can handle For continuous duty applications the maximum torque level may be lower than 100 depending on ventilation ambient temperature and speed A typical SilverMax torque speed curve is shown below When the 34HC 2 SilverMax is operating at 48 VDC 30 000 SilverMax units of torque corresponds to 1650 oz in at 0 RPM However 30 000 SilverMax units of torque also corresponds to 780 oz in at 1000 RPM and is exactly the same as 20 000 units of torque at higher speeds This speed dependant torque relationship is a result of the design of the motor used in SilverMax It is important because the torque limits set with the TQL command limit the relative torque SilverMax will apply not the actual torque The relative na
343. tup a kill enable when the voltage is exceeded ERL Error Limits Line 63 Choose the application error limits for Moving Error Holding Error and the Delay to Hold time Enable Drag mode operation by checking the Drag Mode box Values are tied to the Kill Motor Conditions KMC command to setup a kill whenever an error limit is exceeded KMC Kill Motor Conditions Line 68 Enable options to kill SilverMax under certain conditions To select the conditions press the button next to the desired option until it matches the desired state i e Disable TRUE of FALSE After tripping an enabled condition in the KMC a Kill Motor Recovery KMR routine can be setup and called automatically SilverMax User Manual 4 01 25 DIF Digital Input Filter Line 72 Select a time constant for any or all of the seven digital inputs The time filter ensures valid I O states by ignoring noise and spikes on the signal lines that could trigger a state change if the I O line was to react instantaneously Select individual UO lines or all lines to set the filter constant LRP Load and Run Program Line 76 Specify the next Non Volatile address to load and run a user program The default is Non Volatile address 512 the first open location after the initialization Download the first user program into this location and the Initialization program will load and run it automatically Modifying the Initialization Parameters Directly To skip the In
344. ture of the SilverMax torque representation must be considered on applications with critical maximum torque requirements SilverMax 34HC 2 Torque vs Speed Data 1800 1600 48V MAX 48V 100 1400 36V 100 1200 MN 24V 100 12V 100 1000 800 Torque in oz 600 400 200 0 500 1000 1500 2000 2500 Speed rpm Error Limits and Drag Mode This section describes the uses of the Error Limits ERL command and the special operating mode set up with this command Drag Mode The ERL command is used to change four SilverMax settings It sets the moving and holding error limit conditions it sets the delay time for switching from moving torque to holding torque and it enables or disables a special operating mode called Drag Mode Drag Mode helps eliminate servo wind up and allows SilverMax to emulate a mechanical slip clutch SilverMax User Manual 4 01 55 Error Limits Command Parameters The Moving Error Limit Holding Error Limit and Delay to Holding time are all set by the ERL command They determine the conditions under which SilverMax reports a moving or holding error SilverMax reports a holding or moving error by setting a bit in the Internal Status Word the I O Status Word and the Polling Status Word There is a separate bit in each status word for moving and holding error The QuickControl screenshot below shows the three parameters of the ERL command Err
345. tus every servo cycle The analog input digital input and digital output capabilities of SilverMax are covered in Chapter 6 The status words are used internally by SilverMax as explained earlier in this chapter and are integral to the polling routines used with external hosts as explained in Chapter 2 Task 6 Error Checking SilverMax checks for errors once every servo cycle Some of the errors it checks for are user defined such as position error and Kill Motor Conditions while others are preset such as over voltage errors Kill Motor Conditions are covered in Chapter 8 Multi Tasking Operation Rules The purpose of multi tasking is to allow SilverMax to continue to execute commands while a motion command is running The ideal way for this to happen would be for the Trajectory Generator to go active as soon as a motion command is issued and for the next command in the program buffer to be executed the next servo cycle In some cases this is exactly what happens but some motion commands still stop program flow right after they are issued just like a delay or wait command Different types of motion commands also work differently when multi tasking is enabled These multi tasking exceptions and special cases are explained below Delays with Motion Commands The time and velocity based motion commands MRV MRT MAV MAT RRV RRT RAV RAT XRV XRT XAV and XAT are all pre calculated This means that SilverMax uses the motion parameters
346. twork scan for active SilverMax servos It will scan SilverMax identities that are within the Autoscan ID Range which is adjustable in the Setup Options menu The Polling Status field next to the button will display the current polling state The label on this button will display Scan Network when polling is stopped and Stop Polling while polling is on Status Log This area of the Device Status Monitor provides information on the operation of QuickControl and SilverMax Using QuickControl To Configure SilverMax QuickControl has a specific tool designed to configure the SilverMax operating characteristics on power up QCI recommends using this tool to set up the initialization commands required by SilverMax When the initialization is completed the initialization file can be saved for future use SilverMax Initialization Wizard The SilverMax Initialization Wizard is launched from the Tools pull down menu SilyerMax Initialization Wizard Press Download to initialize SilyerMax or change the factory default parameters using the Initialize Parameter Browser or Interview Download File Motor Select Device To SilverMax Interview Type IR Initialize Parameter Browser File E Communications H Motor Silvers ax Factory Default Initialization qep E Servo Tuning H Motion Open Save Save s Error Limits Misc It allows for changes in the power up
347. udes tools to aid in creating programs as well as an on line description of each command SilverMax User Manual 4 01 5 Features of QuickControl QuickControl contains a wide array of tools and features designed to make using and programming SilverMax easier These tools are all available through the QuickControl interface although learning how to access them and what each one is used for can take some practice A full listing of all of QuickControl s features is too long to list here but some of QuickControl s tools and features are summarized below Getting started with QuickControl is covered later in this chapter and many of its features are illustrated throughout this manual QuickControl also has an extensive on line help library Communications QuickControl includes several tools to make establishing and monitoring communications between the PC and SilverMax easier These tools monitor the status of SilverMax connected to the PC Initialization QuickControl must be used if the factory default initialization program needs to be changed SilverMax can be run in a host configuration with no internal user programs running but the initialization program always runs when SilverMax first powers up Programming QuickControl is designed to make writing new SilverMax programs as easy as possible Every command added to a program using QuickControl is done so with a dialog box that prompts the programmer for each required parameter thus re
348. ue of Reg This command reads the value of the selected register and then loads the value stored in the register number that matches the value of the selected register into the accumulator Decrement i e Reg Reg 1 This command subtracts one from the value stored in the selected register and replaces the old value with the new decremented value Div Signed 32 16 bit i e Acc Acc Reg This command divides the value stored in the accumulator by the lower word bits 0 15 of the value stored in the selected register and stores the result in the accumulator Increment i e Reg Reg 1 This command adds one to the value stored in the selected register and replaces the old value with the new incremented value Load H Word Sign Extend i e Acc Reg H Word This command copies the most significant word bits 16 31 or high word of the selected register into the least significant word bits 0 15 or low word of the accumulator Load L Word Sign Extend i e Acc Reg L Word This command copies the least significant word bits 0 15 or low word of the selected register into the least significant word of the accumulator Modulo 32 16 Bit i e Acc Reg L Word This command divides the value stored in the accumulator by the lower word bits 0 15 of the value stored in the selected register and stores the remainder of the division in the accumulator Mult Signed 32 32 bit i e Acc Acc Reg This command multiplies the value
349. uffer finished 13 Yes Commands Done executing There was an error associated with the command 12 Yes Command Error execution 11 Yes Move Stopped on Input A move stopped due to a stop on input condition 10 Yes Low Over Voltage A low or over voltage error occurred f Holding error limit set by the Error Limits ERL gt TES Podno Eor command was exceeded during a holding control state g Yes Moving Error Moving error limit set with the ERL command was 9 exceeded with SilverMax in a moving control state 7 Yes Receiver Overflow The SilverMax serial receiver buffer overflowed y One of the conditions set with the Check Internal Status 6 Yes CKS Condition Met CKS command was met 5 Yes Message Too Long The received message was longer than 31 bytes 4 Yes Framing Error There was a packet framing error in a received byte SilverMax was shut down due to one or more conditions S EE SEN set with the Kill Motor Condition KMC command eg A soft stop limit was reached as set by the Soft Stop Sr aes Son Limit Limit SSL command Yes Rassivecheckeun Ener The 9 bit checksum received did not match the checksum sent the packet was ignored There was a data error or a new packet was received S ARR ADONE EACE before the last packet was complete UO Status Word The I O Status Word indicates the states of the SilverMax I O lines as well as several specific internal conditions This word is accessible in two ways with the Read I O States RIO Immediate co
350. utput In addition to the raw encoder signal SilverMax can output a scaled version of its internal encoder signal with the modulo output function This function can also be used to output an external encoder signal if required SilverMax can only scale the modulo output signal down The modulo output function is essential for synchronized multi axis SilverMax applications since it allows the master SilverMax to output its encoder signal for the other SilverMax to follow The modulo encoder output function can use all three SilverMax high speed I O function signal formats step and direction step up step down and A amp B quadrature The output signal is scaled using the modulo scaling parameter which can be set to any integer value between 1 and 256 The output signal is different for the three signal formats For the step and direction and step up step down signal formats with the scaling parameter set to 1 the 4000 counts per revolution internal encoder signal is output as a 2000 pulses per revolution signal For A amp B quadrature format and a 1 scaling parameter 4000 counts per revolution from the internal encoder is output as a 1000 pulses per revolution If an A amp B signal is sent to another SilverMax the decoding circuitry in the second SilverMax will turn the 1000 pulses per revolution back into a 4000 counts per revolution signal A scaling parameter other than 1 will scale the modulo output signal down by the scaling
351. utton and choose the move program Select File gt Save 10 Toggle all I O switches to be in the HIGH state 11 Click the Run button to download and begin execution of the program Once the program is downloaded click on the OK button Review The program begins by running the homing to hard stop program from Exercise 3 5 the next program is run with motion stopping on I O 1 Low followed by the Ode to Joy tune program The tune will continue to run until I O 3 Low then the entire process repeats Click on the Red Stop Hand Icon to end SilverMax User Manual 4 01 85 SilverMax User Manual 4 0 86 Chapter 5 Advanced Motion Operations This chapter covers the techniques and commands for programming advanced motion with SilverMax The more advanced move operations like Profile Move and Interpolated Move require multiple motion parameters that are user defined over time to create a complex motion profile Along with this advanced functionality comes advanced complexity A host or standalone program must be implemented to stream motion parameters to these operations This chapter will not address host systems in detail See Chapters 4 and 9 It will suggest host strategies to implement with these operations and discuss the QuickControl Register File System which allows for standalone motion profiling by storing data to the non volatile memory of SilverMax and subsequently loading the data to the appropriate data regis
352. vailable for viewing the status information the active SilverMax are sending to the host In addition any device connected to the host can be selected in order to view current position and the active I O states The Main QuickControl Screen is divided into five major sections The Menu Bar contains pull down menus with all the functions of QuickControl The Icon Bar contains the most often used menu items as shortcuts The Program Info Toolbar displays programming and program information The Program Window displays the active program The Device Status Monitor provides information about all connected SilverMax JELG 2 3 4 5 RNN ontrol QCpri g1 A E File Edit Yiew Progra Tools Sey Window Help WW oles slale se amp 2 Program Info Toolbar Program Info Toolbar Toolbar peri zH bov i A Fr 16 0 amp r Program Line Add Cnitl _Edt CntE Edit Cte Cntl E bev 8 a 4 A _Insert CntH Cnt _Insert CntH Delete Gott Delete Gott 0 BLED in BLED Pee Devas ENA Dev e ENA b BLED b BLED Download Run __ Sealing TestLine_ Dev fo counts Scaling Test Line Ee Trace Single Step vo pa Ja Ja Ja fa a a Program List aa Program Name 0 Stop Polling ing Status Log fo of 200 words used r Device To Program Reboot Desc Dev HUT 16 Type For Help press F1 SilverMax User Manual 4 01 16 1 Menu Bar The QuickControl Menu Bar
353. value Ki 5 SilverMax User Manual 4 01 168 Strip Chart Bisi E Y Minj EI Target Position E Position Kp 7 Ki 5 The integrator gain greatly reduced the steady state error The product of Ki and Kp generally sets the steady state accuracy of a system In other words if Kp is doubled halving the Ki value achieves approximately the same amount of steady state error A good starting point for determining the ideal Ki for a system is to take a look at the default Kp and Ki values For example if a custom tuned system has Kp 200 and the default tuning parameters had Kp 100 and Ki 1000 a good starting value for Ki would be 500 Velocity Filters Fv1 and Fv2 Both Velocity Feedback values are filtered using two low pass filters The first one cascades into the second providing a steeper frequency roll off on the output of the second filter By adding this filtering the velocity gains can be increased for greater damping capacity In applications with large inertial mismatches 100 1 gt the velocity gains are increased greatly The filters provide a means to stabilize the high gain servo control loop A good example of this technique is the application of an equalizer to an audio system If the upper half of the frequency range is reduced to minimum levels reducing the high notes a low pass filter has effectively been introduced into the system The only sounds allowed to pass through the audio system would be th
354. verMax ShUtdOWN EE 127 Servo Error Conditions Kill Motor Condttons 127 e E TRIE ee 129 SilverMax reen Reen un ae EE 129 Other Relevant Commands ene Egeter 130 Recovering or Restarting After a Kill Motor Condition eeeseeeseeeeeeeeceeseneeeeeeeeeseeeeeseeeeeseeeeesneeeeees 130 Simple Shutdown Routine eelere eens eames eioteedh ana EENS 130 Kill Motor Recovery from Uncontrolled Shutdown cccccceeeeeeeeeeeeeeeneeeeeeeeeeeeeeeneeeeeeeseaeeeeessnaeeeeneaas 131 Kill Motor Recovery from Controlled Shutdown ccccccccceeeeeeneeeeeeeeeeeeeeeceeeeeeeeneeeeeeseaeeeeesseaaeeeeneaas 133 Power Loss Management and Recovery ccecccceeeseeeeeceneeeeeeeseseeeeeseeeeeeeeeessseeeeeeeeeeeeseeseeneeeeneeeeeneees 134 Power Low Recovery Commands EE 134 Other Related Commands esere y E E A A E RERE OEE 135 Recovering and Processing Saved Intomatton AEN 135 Power Low Recovery and Restoration of Direction and Position e esseeseeeeeeeerrrieessrrrrrrrresssrrrreens 135 Time Needed For Saving to NV Memory AANEREN 137 Backup Power E 137 Using the Kill Motor Process for Program FIOWS a eeeetegeeKEEEAE case cocessbcntineoatncncensanti ENNEN cbidhatntenaoeneniedass 138 Kill Motor Conditions as an Interrupts sc ceveiseccaztscztedednecesaazesctcecsanshtnkenntacetaede vanderenentandebeaenamalsahaceasdeede 139 Exercise 8 1 Using an Input to Trigger a Kill Motor Shutdown eee eee eeeeeeeeeeeeeneeeeeeteeaaeeeeneees 139 Exercise 8 2
355. verMax uses the external encoder input function for two purposes to accept direct motion control signals from external devices and to accept position feedback signals from an external feedback device such as an encoder When used for direct motion control this function allows SilverMax to be used in several specialized applications including electronic gearing camming stepper motor replacement and flying knife applications When used for external position feedback this function allows SilverMax to use a high resolution feedback device or to receive feedback from a device mounted on a critical machine component Several commands are used with this I O function the Select External Encoder SEE command the Scaled Step and Direction SSD command the Registered Step and Direction RSD command the Dual Loop Control DLC command and the Single Loop Control SLC command Direct Motion Control Inputs The external encoder input function allows SilverMax to accept a step signal from an external source This feature is usually used with an external optical encoder or magnetic resolver but can actually be used with SilverMax User Manual 4 0 115 any kind of device that can produce the appropriate signals The three signal types that can be used step and direction step up step down and A and B quadrature were covered earlier in this section The Scaled Step and Direction SSD and Registered Step and Direction RSD commands are the motion co
356. vious Position value for the curren 4 REM ee and postion registers before recaling Target and Position This will force the current a position to be at the position when power was lost The 5 2TP Zero Target and Position 17 REM subtract command is the only command that modifies Set the minimum voltage limit for the Power Low both the Actual and Target position at the same time Recovery program to be executed Note extra This is the reason why the number in the accumulator EREM capacitors may need to be placed across the power needs to be the oppsite of the true walue from NY leads Without the additional capacitance the motor 18 CLC Targ Accumulator 10 Pos Accurnulator 1 0 lies not eg die time e save its position and Now that the actual position is restored the SilverMax EEN ection before all power ts lost 19 REM must determine which direction it was moving last The LVT Low Woltage Trip 24 volts following four commands perform this task SREM Configure SilverMax to call the Power Low Recovery PEN Load the direction flag from NY memory back into S Program on low voltage trip S register 31 i Power Low Condition Register Load Non Yolatile 3 PLR Load and Run Program Program Low Recovery 21 ALN Load User 31 SilverMax User Manual 4 01 135 example program continued Zero the accumulator register Clear Accumulator 10 Perform a calculation to determine last direction Calculation will be positive if
357. ware 1 9 10 11 12 1 Create a New Program 4 Save the Active Program 7 Copy Selection in Program 8 Paste Selection in Program 10 About QuickControl 11 Help on Selected Item 2 Open an Existing File 3 Close the Active Program 5 SilverMax Initialization Wizard 6 Cut Selection From Program 9 Print Active Program 12 All Stop STOP EI The All Stop Icon is the most widely used of the icons It serves to stop all command execution and programs running in all SilverMax servos connected to the PC It can also be used to verify communications to any SilverMax as the Red LED blinks briefly when issued 3 Program Info Toolbar The Program Info Toolbar is located on the left side of the main QuickControl Screen This toolbar allows the user to create edit download and debug programs It also offers information about programs and the current SilverMax being programmed PROGRAM LINE Add Ctrl A Adds a new line to the end of a program Edit Ctrl E Edits the selected line in a program Insert Ctrl l Inserts a line above a selected line in a program Delete Ctrl D Deletes the selected line in a program Program Info Toolbar Program Line re Add Cntl 4 Edit Cnitl E Insert Cntl 1 Delete Cnt D Pogas PROGRAMS Download Run Scaling Test Line Trace Single Step Program List m Device To Program Reboot Desc no name 16 0x10 Download
358. ware limited torque the TQL command can be edited to increase the limits If the SilverMax is limited by physical constraints then the torque cannot be increased in any manner No amount of tuning or varying of parameters can change the physical amount of torque SilverMax can output In this case a SilverMax with higher torque capabilities should be obtained An example of SilverMax torque saturating taken with the Strip Chart tool is shown below The torque saturation is a result of the closed loop moving torque limit set to 25 Notice how the position error deviates significantly from the near zero values when the torque saturates at the 5000 mark 5000 SilverMax torque units 25 rated torque As this example shows torque saturation greatly hinders the precision control Thus an overhead of torque should always be included when selecting a SilverMax SilverMax User Manual 4 01 125 Strip Chart SilverMax Torque Accuracy SilverMax torque accuracy is better than 10 if several conditions are met If a SilverMax is operated in its nominal torque speed and temperature range unit to unit torque accuracy is around 8 The nominal torque range is from 20 to 80 of the torque rating The nominal speed range lies on the torque plateau at the lower speed end of the SilverMax torque curves This is the area of the torque curve where the torque remains roughly constant as the speed increases Temperature has a slight effect on the rotor magnetic
359. wired to sensors switches or digital I O from a PLC or other host Whatever the hardware connected SilverMax I O can be used either alone or in conjunction to affect the operation of motion commands When a move is stopped using an input the servo decelerates to a stop using the acceleration parameter given in the move command Because the deceleration begins at the moment the I O is detected SilverMax will come to rest some distance past the sensor depending on velocity and acceleration To compensate for this overshoot register four is loaded with the exact position at which the input was triggered This register value can be used to move back to the exact position where the input was triggered SilverMax commands can be entered in either their native form or scaled within QuickControl The native form is used when commanding the SilverMax from a host controller such as a PC QuickControl is recommended for any standalone application because it generates the entire command string from a simple graphical interface SilverMax User Manual 4 01 71 Standard Stop Conditions QuickControl Stop conditions for any move can be edited by pressing the Advanced button in the command window Absolute Location age D 10 ey This brings up the standard Edit Stop Conditions window GE Seet 108 mSec aee input is inthe Total Time be wer SSES Standard Stop Conditions Serial This window presents a simple interf
360. wires do not need shielding However communication lines are generally shielded to insure reliable data transmissions Shielding the communication lines amp I O lines will also provide some protection from stray external electro static discharge ESD that can possibly harm the host controller or SilverMax Analog inputs to SilverMax have a 4 88 mV per step increment These lines require shielding to retain stability and accurate resolution SilverMax digital inputs may also require shielding in applications with long wire lengths and or electrically noisy environments Most cable shields are connected to the source and not connected at the other end of the cable This will reduce the likelihood of ground loop problems developing SilverMax User Manual 4 01 152 Logic Ground The logic or communication ground of all devices on a communications network should be connected For RS 232 this connection is required to achieve communications while strongly recommended under RS 485 A logic ground connection prevents the development of large voltages across communication lines a potentially dangerous situation Termination RS 485 termination can be difficult to calculate for system designers not familiar with the interface The wiring diagram section and the additional information section provide details on implementing termination in standard SilverMax networks Power DC power must be routed to the SilverMax network nodes using a two wire conne
361. witches to closed loop control and exits Anti Hunt The Anti Hunt deadband can be a different width depending on whether SilverMax is entering Anti Hunt or exiting it For example by default SilverMax will start to enter Anti Hunt when position error becomes equal to or less than four counts and exit Anti Hunt when position error becomes ten or more counts SilverMax checks only one condition to exit Anti Hunt position error As soon as position error exceeds the Open to Closed value set with the AHC command SilverMax switches to closed loop control in order to correct the error It then operates in closed loop control until conditions to enter Anti Hunt are met again SilverMax checks several conditions before entering Anti Hunt The conditions SilverMax checks before entering Anti Hunt are e Position error SilverMax compares position error to the Closed to Open value set with the AHC command If the position error the difference between actual position in Register 1 and target position in Register 0 is less than or equal to the AHC value this condition is met and SilverMax can enter Anti Hunt e Anti Hunt delay timer Once the position error is low enough SilverMax starts the Anti Hunt delay timer The time delay is set with the Anti Hunt Delay AHD command SilverMax uses closed loop control and does not enter Anti Hunt until the timer expires The timer resets if position error exceeds the limit set with the AHC command while the tim
362. without knowing what protocol Baud Rate or serial interface is specified in the Initialization Program A Halt command can be sent repeatedly during power up When SilverMax recognizes the command it will Halt and remain in the mode it was in at the point the Halt command was received From this point SilverMax is now ina known state and can be initialized to the desired settings The unit will usually recognize RS 232 levels even when in RS 485 mode although it cannot properly respond If operating in RS 232 mode explicitly command SilverMax to RS 485 if the power up sequence has been stopped via a Halt command SilverMax Control Panel The Control Panel is a Tool in QuickControl that provides access to several important features It allows the jogging of SilverMax at scalable velocities while monitoring the condition of SilverMax in the Device Status area of the Control Panel In addition the Panel provides the means to interactively tune the SilverMax servo loop Test moves are available for tuning the system when prototyping A strip chart can be displayed to show various motion parameters and is useful while tuning SilverMax Control Panel Ea m Initialization File Tuning Jog Vel Eat SilverMax Factory Default Cycl Jare Initialization qep es Use Wizard to Download and or 1 Cycles ms Reboot Change Initialization File forever delay pres SilverMazx Initialization Wizard Move Type ST Zero i t Ej
363. y Communications Troubles Know the PC hardware and what port is physically connecting to the SilverMax In QuickControl verify the Communication Port is enabled and is the actual port being used to connect to SilverMax Verify there are no other programs using the port only one program can control a COM Port at any given time These can include other motion control drivers or programs used for communication devices e g Palm Pilot HyperTerminal etc If these programs do not relinquish control of the port QuickControl will report Could Not Open select COM Port and Access is denied errors in the Status Log After verifying the integrity of the COM Port and making any necessary changes try a quick communication test Stop the QuickControl polling routine if it is running and click on the red hand icon button on the QC toolbar The red LED on the back of SilverMax should flash briefly as it receives and processes the Halt command sent to it This simple test can be done at any time to verify that SilverMax is receiving commands If the SilverMax is in an unknown communication state there is no way to explicitly configure QuickControl to establish communications The Unknown SilverMax Wizard located under the Tools menu is designed to overcome this obstacle Before the initialization file executes when SilverMax is first powered up it automatically comes up configured for 57600 Baud and toggles momentarily between 8 Bit ASCII a
364. y AHC Anti Hunt Constant PRO Protocol AHD Anti Hunt Delay SIF Serial Interface SCF S Curve Factor BRT Baud Rate LVT Low Voltage Trip ADL ACK Delay OVT Over Voltage Trip MCT Motor Constants MTT Maximum Temperature Trip FLC Filter Constants ERL Error Limits CTC Control Constants KMC Kill Motor Conditions GOC Gravity Offset Constants DIF Digital Input Filter DIR Direction LRP Load And Run Program TQL Torque Limits Note To see a description of the command or parameter select the Description button of each window 4 After any changes to the parameter s are made select OK to save the changes and move on to the next command 5 Once the wizard is completed QuickControl will be back at the main SilverMax Initialization Wizard screen 6 Select the Download File To SilverMax button to have the initialization file parameters become active on power up and motor reboot The file will be downloaded to SilverMax and the motor will be rebooted To exit the SilverMax Initialization Wizard select the Exit button SilverMax User Manual 4 01 29 Bes Exercise 1 3 QuickControl Utilities This exercise demonstrates two of the most widely used utilities within QuickControl in an effort to show their usefulness in prototyping as well as troubleshooting Upon completion of this exercise an understanding of how QuickControl interfaces with SilverMax should be developed lt CR gt carriage retur
365. ypical passenger car The driver is the controller in the driver vehicle system When the driver s eyes are open the driver receives feedback about the position speed acceleration and direction of the vehicle and can correct for errors like drifting out of a lane or going the wrong way If the driver s eyes were shut the vehicle would still be moving and the driver could still operate the vehicle but the driver would not receive any feedback and would not be able to drive safely The driver vehicle system is using closed loop control when the driver is looking at the road and open loop control when the driver s eyes are shut SilverMax receives position feedback from its internal encoder or from an external feedback device It also receives velocity and acceleration feedback from its internal encoder These feedback devices act as eyes When operating with closed loop control the SilverMax controls the motor driver based on a target from the Trajectory Generator and based on feedback from the feedback device When operating with open loop control with its eyes shut SilverMax controls the motor driver based on the target position from the Trajectory Generator only 100 encoder counts from the Trajectory Generator results in a single 100 count move command to the motor driver If the shaft hits a jam or overshoots the target SilverMax ignores the position error and finishes processing the command as if nothing had happened Holding Torque and

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