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Red Drive Manual

1. Red Drive File View Edit System Help alele C Hale eea 4 gt l Stitt O A Lele Resources used Unknown board disconnected File H WORK IN PROGRESS Red Drive RedDrive Cd Tutorial4 fle Using this method of repeating sequences the program memory has been reduced from 14 to a much smaller 4 This technique saved memory and has resulted in a simpler easier to follow program Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 51 Tel 44 0 1460 72000 www rotalink com Tutorial 5 Using Home Calibrate Home Reset Home Home is an important concept when making use of a Red Drive controller Systems requiring fixed positional accuracy make most use of the Calibrate Home block Relative positional systems make use of the Reset Home block This tutorial will first look at methods for setting up the hardware of a Calibration point and then the basics of using the Calibrate Home block to ensure accuracy Use of Reset Home will be discussed highlighting its particular usage for rotary systems Using Home Home is an important and useful tool when used with Red Drive Whilst the encoder keeps track of the position of the system this information is lost if there is a power cut and can be disrupted by high levels of electrical noise in the surrounding area These problems can be managed with the use of a home position At its simplest the home position is set up with a switc
2. PID proportional integral derivative is a mathematical system used by Red Drive to accurately maintain the desired speed The proportional term looks at the current error the integral term at past errors and the derivative term forecasts future errors These 3 terms combine to produce a quick reacting accurate system In most cases the default settings will be adequate however as PID is a compromise between response time and smoothness it can be tuned to better suit particular applications The Program parameters PID tab provides control over this function x Standard PID PID kp fi od ki 2 kd fi 5 PID update time fi 0 000 Derivative count 5 Kp Sets up how much of an effect the proportional term has in the PID calculation ki Sets up the integral term in the PID calculation kd Sets up the derivative term in the PID calculation PID update time How often 10 000 every 1mS 1 000 every 100uS the PID system is run Decreasing this value will improve the response time of the system at the expense of smoothness Derivative count DCxA How often the derivative element is calculated In the above window the derivative element is calculated once every ten PI calculations Pulses for speed timing BLDCxA How many pulses the speed measurement is taken over more pulses gives smoother but slower reacting output Page 24 Red Drive User Manual Rotalink Limited Cropmead Crewkerne
3. ow SS Both as op Digital oo ol Both Digital OD n ie wo O Both Digital oO N Both Digital O n wo 00 Both Digital Page 14 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Connecting Encoders Please see DC10A information above page 11 Timing The BLDC10A makes use of an accurate crystal to control it s timing rather than the resonator featured in the DC1A controller The crystal has an accuracy greater than 0 00005 As explained in the DC1A Timing section page 9 there are several other factors which will affect the accuracy of Red Drive particularly when the motor is running and tests should be taken to confirm suitability for a given project Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 15 Tel 44 0 1460 72000 www rotalink com Connection to PC Flowchart programs can be written without the Red Drive controller being connected to a PC This is useful for early design layout and for adjusting sequences Care should be taken when working this way as it becomes easy to make errors which could then cause damage to the users product For example an incorrect distance calculation could cause an overshoot resulting in a linear system crashing into an end stop It is always best to build up Sequences slowly testing every change that is made This does require the u
4. 232 serial port it is possible to operate from a USB port via a USB to Serial Adapter For obvious reasons we cannot confirm that every adapter will work successfully with Red Drive however Rotalink can supply tested adapters if required Page 58 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Compiler Errors If a flowchart program fails to compile a new window will appear in the lower half of the screen ed D File View Edit System Help ale m oaae elea Resources used Unknown board disconnected File ROTALINKO1 users IanR WORK IN PROGRESS Red Drive RedDrive Cd Tutorial6 flc A textual list of the failures will be listed under the Build tab A list of common errors and their fixes are described below This window can be closed using the x in the top left corner Warning Xxxxxxxxx Speed value set xx conflicts with value required Speed value xxxx required The initial soeed set in an Accel or Decel block does not match the speed set in a preceding block Clicking on these lines highlights with a red box the offending block Either the Accel Decel or preceding block needs to have a modified speed value entered Error No start element found A start block is required to indicate the first block to be run by the flowchart program Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 59 Tel
5. i e Could just restart wait for the user to press a switch before restarting or light a maintenance LED Error codes logged in Variable 1 Description of error i ia Global external Reset See Below 2s Position more than 44 million revs Position counter overrun a Position less than 20 revs Position counter under run 4 The controler cannot turn the motor f speed feedback on _ 5 Flowchart call stack overiow Seepage 62 PB Power failed switched off High current draw MOTOR AND GEARBOX TO A LIMITED EXTENT IF THE GEARBOX DRIVES AT HIGH SPEED INTO A BLOCKAGE THE RED DRIVE CONTROLLER OFFERS NO PROTECTION CAUTION THESE RESETS WILL ONLY PROTECT THE Global external reset The Red Drive controller features a user definable global fail safe input on Pin 13 This is set up in the Program Parameters window see page 22 and can be disabled if not required Pin 13 can then be used as a standard I O pin The reset condition can be set to either HIGH 5V or LOW OV When the required reset voltage is placed on pin 13 the system will freeze This reset condition will remain until the voltage is removed from Pin 13 at which point operation commences from the Start block Page 32 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Ensuring Inputs only switch when required Bouncing switches Switches are rarely pressed cleanl
6. 44 0 1460 72000 www rotalink com Error Block not connected at bottom All blocks except the End block require a line indicating the direction of program flow after the block has run This line should be drawn from the bottom of the block Error Choice not connected at bottom A choice block purple diamond does not have a line indicating direction of program flow from its Y option This line should be drawn from the bottom of the block Error Choice not connected at right A choice block purple diamond does not have a line indicating direction of program flow from its N option This line should be drawn from the right hand side of the block Error Unconnected line A direction flow line has been drawn from a block but has not been connected Without this connect the flowchart program does not know which block should be run next Error End can t be used to end a sub chart An End block has been used to end a subroutine this should be replaced by an End sub block Error xxx bytes used is gt xxx available The completed flowchart is too large to be fitted within the Red Drive controller memory Either reduce the memory usage using sub routines or Check Var commands to repeat blocks or contact Rotalink for availability of a Red Drive controller with a greater memory capacity Warning Wait time limited to xxx seconds A wait has been entered which is longer than Red Drive can manage If a very long wait
7. Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Flowchart Blocks Left clicking and holding over the block in the new block area allows it to be dragged into the editing area release the left button to place When the block is placed in the editing area right clicking opens a short menu from where the block can be deleted or the properties accessed Double clicking on the block also displays the properties window Start This is required to indicate the starting position of the program Com the block connected beneath this is the first command to be run End This indicates the end position of the program Upon reaching the End block the unit will return to run from the Start An end block is not always required as the flowchart can also end with a loop For example ending with a Stop can be achieved by looping around a Stop block as shown A flowchart may feature more than one end block Start Sub Indicates the start of a subroutine Each subroutine must be Com given a name this can be set by right clicking on the block and clicking on Properties Enter the name for the subroutine into the lower box Subroutines are useful in reducing the amount of memory used by the program and also to reduce design time by allowing blocks to be reused See page 31 End Sub From here the Red Drive will return to run the block following the Call which referenced the subroutine If a subroutine has been cr
8. be 4ms long Using this method most short noise spikes will be ignored by the Red Drive controller Saving amp Loading Programs can be saved and loaded at any time using either the File menu in the Control area or the save load icons also in the control area The current file name and location is always displayed at the bottom of the main window under the editing area Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 33 Tel 44 0 1460 72000 www rotalink com Show block hints A useful feature found under the view menu control area is show block hints If you hover over a block the block information will be displayed in a pop up at the system font size This is particularly useful when using the software with a zoom setting which makes the text within a block difficult to read Program Size There is a limit to the size of program the Red Drive hardware can contain After a Controller has been connected to the PC and its setup information downloaded see Programming the hardware the software will keep a running total of the resources used as the flowchart is created This information is displayed in the bottom left hand corner of the main window just below the New block area Resources used 19 File O Enginee This text remains green when the flowchart is well within the memory of the Red Drive unit yellow when approaching the limit and red if the memory r
9. in a smoother system It should also be noted that the faster the motor is moving the steadier the output speed This is the result of more encoder pulses per second giving rise to more opportunities to measure and to correct the speed Switching Speed Feedback on also has the benefit of providing an extra fault detection mode See fail safe page 32 If the unit is blocked for any reason the Controller will detect the lack of movement and restart This helos protects the motor from overheating and the possibility of damage to the users machine This feature will not protect the gearbox from breaking under shock loads EEPROM The Red Drive controller is able to save 64 Variables into EERROM memory This special area of memory is retained when the power is switched off and is useful for monitoring product usage over time and for keeping track of variables which need to be monitored despite power cycling The EEPROM doesn t last forever a limited number of writes can be performed Red Drive employs a sharing technique across the EEPROM memory to improve this life Red Drive makes use of 128 EEPROM cells each cell has a life of a minimum 100K writes due to the cell sharing this results in a minimum life of up to 12 million writes The worst case is 64 variables being written to EEPROM equally resulting in a minimum write life of 200K writes By looking at how many variables are being saved to EEPROM it should be possible to pred
10. often be a micro switch at one extreme of travel for a rotary system we recommend an optical sensor and slotted disk or pin on the last rotary device this may be the output shaft of the gearbox or perhaps a secondary pulley It is necessary on all systems where absolute positioning E g 100 mm from the gear case 5 output revolutions from horizontal is required for the unit to move to a known point on start up This ensures that any interrupted programs power cuts etc will always start from the correct position Rotary systems which only require relative positioning e g rotating 1 more revolution may not require this calibration point If there is any doubt Rotalink will be happy to help If a calibration point is present it is good practice to calibrate the home position as often as possible This ensures the most accurate positioning is always available The Move Home block requires that this calibration point is fitted to Pin 14 in the same way as a standard switch see page 8 Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 17 Tel 44 0 1460 72000 www rotalink com Positioning System While Red Drive can be used in either a relative or absolute positioning system all distances used by Red Drive are in the form of absolute positions That is every distance to move to is quoted as a distance from home All clockwise movements are in a positive direction and counter cl
11. will also require the use of a stop block see also Positional Accuracy page 30 If use distance is unchecked the unit will set the speed and then move directly onto the next block This is useful when followed by a wait block to provide motion for a set time This causes the motor to stop moving In Properties a time to wait is set in seconds If the block previous to this left the motor rotating then the motor will continue rotating during this wait A Stop block is required prior to a wait to provide a timed pause in motion Calibrate Home Motor will follow the user defined speed and direction until the Red Drive controller receives an input on the home pin Pin 14 At this point the next block will be run often a stop This command is used to ensure the correct positioning of the Red Drive output after start uo and during operation Good practice would dictate that a Calibrate Home block should be the first movement block following the Start Page 26 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Reset Home This block resets the position counter This is particularly useful when the Red Drive controller is being used in a relative positioning system Issuing this command will reset the position counter allowing a basic move 1 rev block to be repeated causing the output to move in 1 rev st
12. Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 If the Board Information window does not appear please check the power to the controller and the connection between the controller and PC An answer of No to the board being programmable may indicate that you require a later version of either the Red Drive software or controller firmware Upgrades will be made available from the rotalink website www rotalink com Ei The Compile button F should now be usable This will ready the flowchart for download to the Red Drive controller If there are any errors see Compiler Errors page 59 a window will appear in the lower section of the screen If this window is open a cross in the top left can be used to close the window successful compiles will be indicated here rather than in a pop up Message If the compile was successful the Download button can be used to send the program to the Red Drive Controller A window will appear indicating if the download was successful If so switching the power off removing the serial adapter and then connecting the motor leaves the system ready to start for further programming the motor may remain connected Switching power on to the Red Drive controller will begin the downloaded flowchart program Note The power to the Red Drive controller must be switched off and then on again before any flowchart programs will run Without cycling the power supply the unit will remain i
13. be done in a similar manner as with the Accel block Open the properties window for this block Dece xi Commen m Parameter Direction CLOCKWISE x Type FINAL POSITION gt Speed feedback Iv Initial speed rpm 3788 Final speed rpm jo To distance revs from home ooo Time seconds fo100 As with the acceleration block the direction of rotation should match that of the move it is associated with first move is clockwise so this deceleration will also be in a clockwise direction As with the accel block you can choose from two types TIME and FINAL POSITION This example is decelerating to a position so the type should be set to FINAL POSITION Speed feedback is left on and the initial soeed should be the same as the previous move 37 88 rom To achieve the best accuracy on the final stop the final soeed should be set as slow as possible i e as slow as the motor can move without stalling For our SP2902 unit 2 rom is a good speed to use We wish to end this decel block after 1 rev so To distance revs from home should be set to 1 Time can be set to 0 1 seconds Revising move The initial clockwise move ends at a position of 1 rev from home if we left the flowchart as it is this move would run to 1 rev and then the deceleration block would be looked at The deceleration would be run but because the position counter had already moved beyond 1 rev the unit would quickly skip onto the next block the unit would con
14. deleted and a loop run from this point up to the Calibrate Home block This ensures Check IP is only run once each time the power is switched on Without this loop the system would wait for a user input before beginning each cycle The same switch is being used twice so a wait is required after the Check IP command to ensure that setting this switch does not also cause the unit to calibrate home lajxi File View Edt System Help Check IP mm Resources used Unknown board disconnected Fie H WORK IN PROGRESS Red Drive RedDrive Cd Tutorial6 fle Compiling and then downloading this flowchart program should result in the system waiting until the optical switch is blocked a piece of card or paper can be used The unit will then wait for a further 2 seconds before calibrating the home position and starting its CW and CCW sequences Set OP When an output is attached to Red Drive and its relevant I O pin set up in the Program Parameters window it can be controlled using the Set OP block In the block properties window the Pin can be selected and then set as either HIGH 5V or LOW OV This can then be used to switch LEDs on off set relays or send signals to other Red Drive Controllers Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 55 Tel 44 0 1460 72000 www rotalink com Troubleshooting Unit is drawing much more current than expected Some motors are unsui
15. options The first option to set is whether the calculation is against a value or variable right hand box we want to create a counter so value should be selected Looking at the main calculation line Variable is just a marker indicating where the data will be stored Variable 1 is set aside for error logging see page 32 so we will use variable 2 This block is being used as a counter so the Operation needs to be this is changed using the drop down menu Value should be set to 1 to ensure that the Variable increments by only 1 each time 2 would see an increment of 2 We don t need this data on power on so leave Save result to EEPROM unticked Check Var Red Drive User Manual Page 49 www rotalink com Page 50 Red Drive User Manual www rotalink com A delay of 5 seconds is required after 5 counts have occurred to know if this has happened use of the Check Var decision block is required This block should be placed directly above the End block with the Y being connected to the End In Properties there are again several options which take the same format as the Set Var block The data to be checked was set up in Variable 2 so this must be checked with the Check Var block The value should be set to 5 ensuring the selection to the right hand side is value to check if the CW CCW motion has been run 5 times The Operation is either equal or greater than gt or less than lt In this case
16. other Red Drive units 31 Fail Safe a2 Ensuring Inputs only switch when required oo Saving amp Loading 33 Show block hints 34 Program Size 34 Zoom and scroll functions 34 Cut Copy amp Paste 35 Undo Redo 36 Printing 36 Upgrading the Controller 36 Page 4 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Tutorials 3 Tutorial 1 Start End Move Wait Stop 37 Tutorial 2 Accelerate Decelerate Position control 43 Tutorial 3 Start Sub End Sub Call 47 Tutorial 4 Check Var Var Calc 49 Tutorial 5 Using Home Calibrate Home Reset Home 52 Tutorial 6 Check IP Set OP 54 Troubleshooting 56 Unit is drawing much more current than expected 56 Irregular speed using speed feedback 56 Unit restarts part way through a cycle 56 Unit accelerates to maximum speed and then restarts 57 Skipping of blocks flowchart block fails to run org Unit fails to start 57 Unit fails to carry out programmed function 57 Working out Motor Gearbox direction 58 Failed to connect to board 58 USB 58 Compiler Errors 59 Warning XXXXXXXXXx Speed value set xx conflicts with value required 59 Speed value xxxx required 59 Error No start element found 59 Error Block not connected at bottom 60 Error Choice not connected at bottom 60 Error Choice not connected at right 60 Error Unconnected line 60 Error End can t be used to end a sub chart 60 Error xxx bytes used is gt
17. position for Single Channel systems Brushless motors can use a Dual Channel encoder or if a low accuracy is acceptable their inbuilt hall effect sensors Red Drive has been designed for encoders with an output of 48 pulses per rev Fewer pulses will result in a lower accuracy both in speed and position Page 18 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Running the Software To run the software double click on the Red Drive icon BA The following screen will appear w Red Drive File View Edit S jystem Help Elem Of sale Ql _ S Slee 2 8 xI aP New Block area Control area Editing area Note On some machines a COM port error may occur This can be ignored until programming and is dealt with in the Programming the Hardware section of this manual There are three areas to the Red Drive window The new block area control area and the editing area New Block Area Down the left hand side a pallet holds all the various blocks from Start to Set OP These are placed in the editing area by clicking and dragging as required Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 19 Tel 44 0 1460 72000 www rotalink com Control Area This area controls the entire flowchart files can be saved and loaded the flowchart zoom level can be changed blocks can
18. we want to wait for 5 seconds when Variable 2 5 Therefore the Operation is equal Is Variable 2 5 If the result is yes then Variable 2 is equal to 5 and the delay must be run A Wait block Set to 5 seconds should be inserted between the Check Var block and the End block Following from the N a link should be made skipping the wait block Check variable x Comment Check counter Check counter Var2 5 Parameters Variable Operation Value Variable 2 X E fo Value Variable Compiling and running this program will see the CW CCW motion run 5 times then there will be a delay of 5 seconds before the system runs the CW CCW motion again However the unit will not run this delay for another 250 motions Variable counters reset at 255 The system will keep checking Variable 2 however it becomes equal to 6 then 7 8 9 10 The delay is only run when the Variable is equal to 5 To provide the required operation Variable 2 must be reset to O This is done using a further Var Calc block Using the Properties window the Parameters are set to Variable 2 Operation Value O When this block is run Variable 2 will become to O With the flowchart program as below the system will carry out 5 CW CCW motions delay for an extra 5 seconds and then carry out a further 5 CW CCW motions repeating this sequence Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Tel 44 0 1460 72000
19. 00 Gearbox opposite a Motor direction COUNTER CLOCKWISE 7 Encoder Home Global reset Pin 13 E Channels DUAL 7 Home position output revolutions jo Reset when Lowo gt Pulses per revolution jas OK Cancel The available pins are listed either under Inouts or Outputs Pin 14 should have been set as an input in Tutorial 5 in order to use Calibrate Home If Pin 14 is listed as an output move to the input column as per tutorial 5 Check IP Often it s not appropriate to have the motor running as soon as the power is switched on rather the system should wait for a user input before beginning the flowchart program This is particularly useful for responding to any system errors in a fail safe manner See page 32 To function as a user start switch a Check IP block will be required at the very beginning of the flowchart with the N looping back into the Check IP block a check input m Parameter Fin State Pin14 to HIGHS OF Cancel Page 54 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 The properties window lists 2 Parameters Pin and State Pin 14 is the only input with a switch connected This should be selected from the drop down menu State follows the same principle as used for Calibrate Home discussed in Tutorial 5 this should be set to HIGH 5V The End block will need to be
20. CxA 7 Gear ratio 408 221 2539 Output shaft load torque mNm o o 177 4 Motor stall torque mNm Erase Die eel ite No load speed rpm e1 oo Gearbox opposite a Motor direction COUNTER CLOCKWISE 7 Encoder Home Global reset Pin 13 E Channels DUAL Home position output revolutions jo Reset when Low av x Pulses per revolution 48 OK Cancel Since the Program Parameters ax will generally be the same for any Sein 5 Fesdwe ca ek system using this motor and gearbox combination the output load may change it may be useful to save the empty program as a template Fiename SP2302 SSCS Once the Program Parameters Ssveastye fowr _ Cancel have been set work can begin on drawing a flowchart program Start The first command for any flowchart program is Start this tells the Red Drive controller where to begin Click and drag this block from the new block area into the editing area as shown below w Red Drive File View Edit System Help alelm Of sale ea 2 Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 39 Tel 44 0 1460 72000 www rotalink com Move As stated at the beginning of this tutorial the first task of this flowchart is to move the gearbox shaft 1 revolution clockwise To do this a Move block should be placed underneath the Start block This is done in the same way as with the Start block Dou
21. Drive controller Please ensure that all unused I O pins are set as outputs in the Program Parameters window see page 22 Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 57 Tel 44 0 1460 72000 www rotalink com Working out Motor Gearbox direction If this information is not available it can be calculated Set up a program to run the motor for 1 revolution CW it is best to switch off soeed feedback for this test and then stop see M GBtest flc Set all known Program Parameters leaving motor direction as CCW and Gearbox reverse blank Run the motor e Output is CW unit runs for just 1 rev the system is set up correctly e Output ran CCW for 1 rev Gearbox is reversing tick in Program Parameters e Output CW did not stop after one rev motor direction is wrong set to CW and tick the gearbox reverse e Output CCW and did not stop set motor direction to CW Failed to connect to board This error indicated a communication problem between the Red Drive controller and the PC Things to check are 1 Red Drive board is powered 2 Serial Adapter was connected to Red Drive before it was powered Cycle the power just to check 3 Correct Com port selected System gt Set Com Port should be safe to use trial and error 4 If using a USB to Serial adapter has the correct driver been installed USB Whilst the Red Drive controller is designed to be programmed via an RS
22. E POWER IS CONNECTED INCORRECTLY Connecting Motors ae ee ES a Positive motor connection wire usually red Negative motor connection wire usually black Connecting Inputs and Outputs Please see DC1A information above page 7 Timing Please see DC1A information above page 9 SSS K K lt _ GE lt KE amp amp amp Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Page 12 Red Drive User Manual www rotalink com Tel 44 0 1460 72000 BLDC10A Controller 4x 3mm holes Input Output a E E Nf ra io o DODOODVDOOD j a c Hall Sensors Motor Power Continuous Current 10A Voltage Range 12 30 V Motors may draw larger currents for short periods of time however extended use above 10A may result in damage to the Red Drive controller CAUTION IN OPERATION THE COMPONENTS AND SURFACE OF THE BOARD MAY BECOME HOT Connecting Power Hall effect sensors and Motor HA HB HC 5v GND M1 M2 MS Vpop Vss Vss Supply Ground OV DC Vp Supply Positive voltage 12 to 30 V DC M1 Motor Phase 1 M2 Motor Phase 2 M3 Motor Phase 3 HA Hall effect A HB Hall effect B HC Hall effect C 5V 5 volt supply for Hall effects GND Ground OV DC for Hall effe
23. Input Output 1 6 Motor 55 Continuous Current 2A A heat sink is attached to the side of the DC2A In all other ways this unit is functionally identical to the DC1A CAUTION IN OPERATION THE HEAT SINK FITTED TO THE RED DRIVE DC2A MAY BECOME HOT e Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Tel 44 0 1460 72000 Page 10 Red Drive User Manual www rotalink com DC10A Controller 18 5 3 2 approx ar 68 5 f 13 me DS acre Component pins z g 2 4x 3mm holes oO a Encoder Continuous Current 10A Voltage Range 15 30 V Motors may draw larger currents for short periods of time however extended use above 10A may result in damage to the Red Drive controller CAUTION IN OPERATION THE COMPONENTS AND SURFACE OF THE DC10A MAY BECOME HOT Connecting Encoders i 1 2 3 4 Connector shown from above Pin 1 Encoder Ground 0 V Pin Encoder A Pitt Encoder B unconnected for use with Single Channel encoder Pin 4 Encoder Supply 5 V CAUTION IF THESE CONNECTIONS ARE INCORRECT IRREPARABLE DAMAGE MAY OCCUR TO THE ENCODER AND RED DRIVE CONTROLLER Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 11 Tel 44 0 1460 72000 www rotalink com Connecting Power Lee Vss VoD Vss Supply Ground O V DC Vpop Supply Positive voltage 15 to 30 V DC CAUTION DAMAGE WILL OCCUR TO THE RED DRIVE CONTROLLER IF TH
24. M on each calculation If the power is interrupted these variables will be reloaded This is useful to resume sequences after a power failure Variables 65 128 can not be saved at power on these variables are set to O Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 27 Tel 44 0 1460 72000 www rotalink com Set OP Allows the user to set an output pin to either HIGH 5 V or LOW O V Analogue Move Provides a simple follower system Required speed and distance limits are entered Analogue voltage is taken from selected pin and motor moves between the distance limits For example voltage set to 2 5V 50 on a standard potentiometer motor will move in either direction to a position halfway between the min and max positions A standard setup would see the two outside leads of a potentiometer connected to OV and 5V with the wiper usually the middle lead connected to a suitable Analogue Input pin See page 7 or 14 Analogue Input ea Looks at the voltage on the selected pin loads a value in the range 0 255 into the selected variable i e 3V 153 BLDCxA uses an extended range 0 1023 Comparisons can then be made on this value using the Var Calc block described above The result can be saved to EEPROM by using the Var Calc Block Analogue inputs are very subseptable to noise and care should to taken when using analogue inputs it may be nessasary to progr
25. Programmable DC Motor Controller Rotalink Miniature Motors Transmission and Control WWW rotal N k Com Protection Against Electrostatic Discharge Electrostatic discharges ESD can harm the electronic components used within the Red Drive controller Conditions can occur where an electrostatic charge will build up on the user or other object and then discharge into another object such as the Red Drive controller To prevent damage from these ESD events you should discharge electricity from your body prior to contact with the Red Drive unit You can protect against ESD by using a conductive wrist strap or other method of grounding Please contact Rotalink for further information and advice CE Marking The Red Drive Controller is designed to be a component incorporated within equipment manufactured by our customers and is not sutiable for use by an end user As such it is not CE marked The method of installation for the Red Drive Controller and its associated motor will have a large impact on any CE test results as will the selection of the motor We will be pleased to advise our customers on ways to ensure their equipment complies with any relevant directives Issue 2 0 Page 2 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Introduction The Red Drive Controller is a compact yet powerful motor driver and controller In combination w
26. am averaging or unexpected value disregard fuctions Linking Blocks Directional links between the blocks are required to control which blocks activate when The blocks can only be linked from top and bottom except decisions As is common with other flowcharts these are represented by drawing lines between the relevant blocks To do this move the mouse cursor over the block to link from and when a cross hair appears click and drag into the next block and release Loops can be formed with the use of Check Var Check IP blocks A node black dot is drawn when required indicating the connected loop Paths can also cross without the program flow joining This is shown by the absence of a node Page 28 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Speed Feedback By ticking Speed Feedback the Red Drive controller will constantly monitor the speed of the motor and using the PID system automatically adjust the power to ensure the correct operating speed To reduce any initial acceleration caused by the actual speed being less than the required speed it is important that the output shaft load torque is entered in the program parameters window Entering O will still produce a working system however this value is used to calculate the initial starting soeed A value closer to the actual load will reduce any initial acceleration resulting
27. as with the move End The final block to be added should be an End block This tells the Red Drive Controller that the sequence of blocks has finished and the unit should return to run from the start block This return function provides the repeat loop required for this flowchart program Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 41 Tel 44 0 1460 72000 www rotalink com Linking Finally all the blocks should be joined together Place the mouse pointer just below the Start block so a cross hair appears click and then drag the pointer into the End block The flowchart should look as below w Red Drive File View Edit System Help alele olele aea m J Qa a Check Var Check IP 4 esources used Unknown board disconnected File ROTALINKO1 users IanR WORK IN PROGRESS Red Drive RedDrive Cd Tutorialt flc Downloading and Running All that remains now is for the flowchart program to be downloaded onto the Red Drive controller The section Connecting to PC page 16 details the physical process of connecting programming the hardware page 20 runs through the downloading stage Once the Programming successful window has been displayed the Red Drive controller can be switched off the Serial Adapter removed and the motor plugged In Switching the power supply back on should start the motor in its sequence of clockwise and counter clock
28. be copied and pasted Red Drive parameters are set and the flowchart downloaded to the controller Editing Area This is where the program flowchart is built Programming the Hardware The first steo to downloading a flowchart program to the Red Drive controller is to connect it to a PC This is done via the Serial Port also Known as an RS 232 port A suitable cable must be plugged into this port and into the Serial Adapter board see page 16 This board must then be connected to the Red Drive unit via its 14 Pin I O connector see the Hardware section of this manual for the location of this connector If the PC features more than one serial port or is using a USB serial adapter it may be necessary to configure the correct serial port Under the System heading in the Control area the menu Set Com Port can be selected This will produce a window with a drop down menu indicating all available Com Ports After selecting the relevant Com port it is safe to use trial and error clicking OK confirms the change Only after this has been completed can power be applied to the Red Drive Unit via its power connector Clicking the Connect button ER will cause the Red Drive software to connect to the unit and report its status x l programmable Yez Clock speed 20MH Memory available 1754 bytes Start address jooosogH O Firmware version foor o Serial number 1 007 00788 Page 20 Red Drive User Manual Rotalink Limited Cropmead
29. ble click the block shows a Name dialogue beneath the familiar Comment dialogue A name must be given to the subroutine here Stop Wait 1s seems appropriate The Stop and Wait blocks can then be moved beneath the start sub by holding the Shift key and dragging into place End Sub Finally a End Sub block should be added and the three blocks joined Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 47 Tel 44 0 1460 72000 www rotalink com The subroutine has now been created all that remains for this subroutine to be used are some Call blocks The First Call block should be located in place of the moved Stop and Wait blocks The Properties window is similar to that of Start Sub Clicking on the down arrow in the Chart to Call section produces a drop down menu of all the subroutines created so far Stop Wait 1s should be selected Cs x The second Stop and Wait blocks should also be deleted right click and the Call block copied in place Compiling downloading and running should see the motor move as before By using subroutines the program is now neater and easier to follow and expand in future lo x File View Edit System Help elele odale eeo S Baler AII LAA PERR Resources used Unknown board disconnected File ROTALINKO1 users IanR WORK IN PROGRESS Red Drive RedDrive Cd Tutorial3 flc Page 48 Red Drive User Manual Rotalink Limit
30. ble clicking on this Move block displays the Properties window for the block The comment box can be used to enter a brief description of the block Move 1 rev clockwise is appropriate in this case The direction is correct at Clockwise Speed Feedback should be left ticked to allow the Red Drive controller to monitor and ensure the correct running speed Resting the mouse pointer over the Speed rom text entry box causes a pop up to be displayed This shows the minimum and maximum speed at which the gearbox can move To move as fast as possible the maximum speed should be entered for the SP2902 unit this will be 37 88 rom The output shaft needs to rotate by 1 revolution Use distance needs to be ticked to allow a distance of 1 to be entered into the To distance revs from home box Note When a system is switched on the home position is set to the value contained in the Program Parameters To move 1 rev clockwise the number entered into the To distance revs from home field should be 1 greater than the home position If the home position is 0 to move one revolution the To distance value should be 1 If the home position is 5 the To distance should be set to 6 Move Comment Move 1 rev clockwise Parameters Direction clockwise x Speed feedback m Speed rpm 37 sg Use distance m To distance revs from home fi 0000 Page 40 Red Drive User Manual Rotalink Limited Cropmead Crewkern
31. cts Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 13 Tel 44 0 1460 72000 www rotalink com Connecting Inputs and Outputs The I O function in the same way as on the DC1A see page 7 The BLDC10A offers an extra 26 way 13x2 IDC header and pins 15 40 can be found here Functionally of the full 40 pins are listed below 16 18 20 22 24 26 28 30 32 34 36 38 40 15 17 19 21 23 25 27 29 31 33 35 37 39 Connector show Pull up Resistor Special feature Pin Number Input Output Analogue Digital input 12 19 1 5 Volts 7 8 23 24 28 31 32 39 40 OV GND Both Analogue Digital Both Analogue Digital Both Analogue Digital Both Analogue Digital Both Analogue Digital O Pin Number InpuvOutput 121516 5vots s feh a o fen so feh e feh e fen o fen no fen 2 o fen so feh o fen azo o fen gs o feh o fen fen an fen 2 ee a fen 2 fe a fen fen s feon E ESE E s feon ESE ESE Both Analogue Digital Both Analogue Digital NO Both as n Analogue Digital wo Both Digital Global Reset Home Input D Both as op Digital Both Digital Both Digital oO Both Digital NO O Both Digital MN Both Digital NO Nh Both Digital Nh oO Both Digital NO O Both as n io Digital NO NI Both Digital MN Both Digital ce O Both Digital wo Se Both Digital
32. d Drive SA1 serial adapter must be connected when the power supply is switched on This instructs the Red Drive controller to enter Programming rather than run mode Note Pins 1 11 MUST NOT all be high 5 V when the unit is switched on This will place the Red Drive controller into programming mode during which downloaded flowcharts are NOT run Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 7 Tel 44 0 1460 72000 www rotalink com Outputs Maximum current sunk by all I O pins 200 mA Maximum output current sunk by any one I O pin 25 mA All outputs operate at 5 V other voltages or current requirements will need to be managed with additional external circuitry such as an optocoupler CAUTION FAILURE TO LIMIT THE MAXIMUM CURRENT OR VOLTAGE TO THE ABOVE LEVELS MAY RESULT IN IRREPARABLE DAMAGE Inputs Internal pull up resistors make pins 5 9 11 13 and 14 ideal for use with simple switches identified in the Red Drive software with a In this configuration the switch is simply fitted between the pin and ground 0 V Other inputs will require an external pull up resistor 10K Ohm to ensure the pin is held at either O V or 5 V Both examples are shown below 5 Volts Pin with internal Pullup resistor External Pullup resistor required 65 9 11 13 14 3 4 6 10 12 Pin Pin switch NO switch NO In the above configurations a normally open swi
33. e Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Click on OK to confirm the values entered This move block will now instruct the motor to move the gearbox output shaft 1 revolution clockwise Stop After ending the move block the motor will continue to turn unless told otherwise The next block required is a Stop The only parameters available for a Stop are a comment This can be left blank Wait Because a stop has no parameters a method is required to produce a stop which lasts for 1 second Placing a wait block beneath the stop will do this Double click on the wait and enter 1 into the Time to wait seconds box Move A counter clockwise move back to the start position needs to take place next Press and hold the control key often labelled Ctrl on a PC Keyboard click on the first move and drag to beneath the wait block This will copy the first move reducing the amount of data needing to be entered The comment box should be changed to Move back to home the direction is counter clockwise and the To distance revs from home should be set to O Note Red Drive operates an absolute positioning system All distances are given as positions so a move of 1 rev counter clockwise CCW from position 5 revs would be To distance 4 revs A move of 1 rev CCW from position 1 rev would be To distance 0 revs Stop Wait Following this move a stop and wait should be added these can be copied using the Ctrl key
34. e Rotalink encoder motor data sheet 48 pulses is normal for our dual channel encoder Gearbox Gear Ratio The ratio is entered in its 150 3 form gt Note Gear ratios must be entered in their full form A gear ratio of 472 3 could be described as 160 1 However entering this approximate ratio would result in incorrect output distance and speed Output shaft load torque mNm This value is not critical however a value closer to the actual load will produce a more accurate and smoother running system Note If Speed feedback is switched off then this feature is important to ensure actual speed is as close to the required speed as possible Gearbox opposite Tick if the gearbox shaft rotates in the opposite direction to that of the motor This information is available on the gearbox label SA same OP opposite See Working out Motor Gearbox direction page 58 Home Home position output revolutions Normally left at O output revolutions alternative values may be required depending on position of the home calibration inout Further information can be found in the Positioning System section page 18 CAUTION PROGRAM PARAMETERS MUST BE SETUP BEFORE PROGRAMMING ANY INCORRECT PARAMETERS MAY LEAD TO UNFORESEEN AND POTENTIALLY DAMAGING MOTION Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 23 Tel 44 0 1460 72000 www rotalink com PID
35. e units communicating with each other For example one Red Drive unit cannot tell another where it needs to move data cannot be sent but it can tell it to move a pulse can be sent which must then be interpreted by the second Red Drive controller At any given time there are likely to be only a small subset of possible movements Clever use of the various I O pins and design of the flowchart programs can allow a large amount of interaction to take place Care needs to be taken with electrical noise when connecting 2 units together for distances greater than 30cms differential signals may reduce false signals At greater distances in noisy environiments an isolated signal may be required to stop damage to the Red Drive unit CAUTION LINKING RED DRIVES OVER LONG DISTANCES WITHOUT ADITIONAL PROTECTION COULD LEAD TO UNEXPECTED AND PERMAMENTLY DAMAGING EVENTS Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 31 Tel 44 0 1460 72000 www rotalink com Fail Safe The Red Drive controller features two types of fail safe Internal computation the controller decides an error has occurred and also a external global fail safe An external system alerts Red Drive to an error Both of these cause the Controller to reset with operation commencing from the programmed flow charts Start block An error code will be logged in Variable 1 which can then be used to provide different start up options
36. eated this block is used to run the blocks within the Start Sub End Sub In the Properties window is a drop down menu from which the relevant subroutine can be selected Calls can be used within subroutines but this is limited to a chain of 6 calls See page 62 Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 25 Tel 44 0 1460 72000 www rotalink com Check Var With this block a variable can be compared to either a set value clas or to a second variable Either a Yes or a No path can be taken The variable can be checked for being either equal less than lt or greater than gt the given value As with all blocks these options are defined in the Properties window accessed by right clicking on the selected block Red Drive supports the use of up to 128 Individual variables each one of which can hold a value from O to 255 Variables are identified by their variable number Variable 1 is set aside for error logging See page 32 Check IP O As with the Check Var block this provides two paths that can vema be taken Any of the 10 I O pins that have been configured as inputs can be checked and the user is free to define either following Y if the pin is LOW O Volts or if the pin is HIGH 5 V 4 Move Using the properties window this block gives the user the ability to move at a set speed for a set distance Stopping the motor
37. ed Croomead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Tutorial 4 Check Var Var Calc Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Tel 44 0 1460 72000 Variables can be very useful in reducing the amount of flowchart that has to be written to complete a given task As with subroutines they have a dual purpose of reducing the time spent writing a flowchart and also in saving memory The flowchart program written so far in these tutorials is going to be modified again Rather than simply moving clockwise and then counter clockwise endlessly every 5 cycles CW amp CCW motion a delay of 5 seconds will be added This could easily be achieved by copying all the blocks 5 times and then adding a delay of 5 seconds before the End block Writing in this way takes a lot of time and wastes memory If the flowchart was written in this way 14 of the Red Drive DC1A controllers memory would have been used A better way is to use Check Var and Var Calc blocks Var Calc In order to count the number of times the system runs through a CW CCW motion a counting block is required Var Calc is used for this purpose Insert a Var calc block just below the Start block Open its Properties window ariable calculation x Commen Increment counted Parameter Variable Variable Operation Value 2 2 gt fi Value Save result to EEPROM J Variable In the Parameters section are several
38. eleration time is too short for Red Drive to control A larger time value should be used A very quick acceleration or deceleration as quick as motor can manage is achieved by removing the accel decel block and simply starting with a Move or stopping with a stop block Error Accel decel Processed initial and final speeds both xxx Both Initial and Final soeed in an Accel or Decel block are the same there is no acceleration or deceleration taking place Warning Speed gear ratio and encoder pulse formula limited to 65535 Speed is set too slow for Red Drive to control Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 61 Tel 44 0 1460 72000 www rotalink com Warning Distance and encoder formula limited to 4294967295 A distance has been set which is beyond the range Red Drive can manage Error Calibrate Home requires pin 14 to be input it is currently an output Pin 14 should be selected as output in program parameters Error Torques Output shaft xxx gt motor stall xxx gear ratio xxx The torque being moved is greater than the torque the motor can produce Error Stack Overflow lt gt There is a limit of 6 nested J subroutines within the Red Drive Gk system Calling a 7th subroutine CD will result in a Stack Overflow error The Flowchart will need to be re ordered to ensure only 6 subroutines are nested Warning Disass
39. embly problem Please confirm the latest version of the Red Drive software is in use If error continues please contact Rotalink Error default in CompileFlowChart Please confirm the latest version of the Red Drive software is in use If error continues please contact Rotalink Page 62 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Conversion Formula Torque Conversion factors If you need to convert 24 oz in into mNm for use with the Red Drive software take the known unit 24 oz in and multiply by the mNm conversion factor 0 142 e g 24 oz in x 0 142 3 408 mNm Lead screw Conversion formula If you are using a lead screw the following formula will be useful Distance Output shaft revolutions x lead screw pitch linear distance e g 3 5 revolutions x 80 mm pitch 280 mm Speed Output shaft soeed x lead screw pitch linear speed e g 500 rom x 80 mm pitch 40000 mm per minute 666 mm per second R Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 63 Tel 44 0 1460 72000 www rotalink com www rotalink com info rotalink com T 44 0 1460 72000 F 44 0 1460 74278 Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ UK www rotalink com
40. eps Accel Red Drive employs a fairly basic straight line approximation Ea acceleration and deceleration Using the Properties window the start speed end speed time and final position can be defined Final position selected via the drop down menu only ensures the final position accuracy it does not control the position during the Acceleration Using this function after the acceleration time has been run the unit will continue to move at the final speed until the final position is met only then will Red Drive move on to the next block See page 30 for further description Note Acceleration blocks control speed not position If an acceleration is attempted which the motor cannot match position control will be reduced Decel E As per acceleration but for deceleration Var Calc Variable calculations provide for a greater program complexity Ea where required Generally used for program loops carrying out a sequence x number of times they can also be used to process an analogue input or for a range of other uses Addition subtraction multiplication and setting either to an integer or to a second variable are all catered for Variables roll over when they reach 256 65536 for BLDCxA If variable 5 is already equal to 250 and you add 100 variable 5 will become equal to 94 Variable 1 is used for error logging see page 32 therefore the value of this variable on start up is unknown Variables 2 64 can be saved into EEPRO
41. es a D3857 2490 motor dual channel encoder and 230 gearbox This unit is designed to be run from 24 Volts These tutorials are designed to be followed sequentially as each builds upon the program created in the last The flowcharts are saved on the Red Drive CD Tutoriall flc for example is the flowchart produced when Tutorial 1 is completed Note Care must be taken when following these tutorials with a different motor gearbox or supply voltage It is important to ensure that the correct Program Parameters data is used Output speeds may also need to be altered for the tutorials to work as intended Tutorial 1 Start End Move Wait Stop This tutorial will introduce the initial setup of a motor and gearbox system using the program parameters window The Start End Move Wait and Stop blocks will be used and the distance concept will be explored The aim of this tutorial is to have the gearbox turning clockwise one revolution stopping and waiting for 1 second and then moving counter clockwise back to the start position stopping and waiting for 1 second This sequence will then be repeated Program Parameters The first step to producing any flowchart program is always to setup the constraints of the system the speeds and torques available from the motor the gear ratios and normal directions of rotation Without these correctly set up at best any flowchart programs won t work as expected at worst the user may break either or both
42. esources of the Red Drive controller are exceeded Reviewing the flowchart program for repeated block combinations and replacing them with Call blocks and subroutines can often dramatically reduce the resources used It would take a very large and complex program to fill the memory of the Red Drive however Red Drive variants with expanded memory capabilities may be available Contact Rotalink if this is an issue Zoom and scroll functions As well as using the zoom buttons in the Control Area and the standard scroll bars if the PC is fitted with a scroll wheel mouse this can also be used to control zooming and scrolling of the Editing area e Moving the scroll wheel backwards and forwards zooms in and out e Pressing the Alt key and scrolling moves the Editing area left right e Pressing the Ctrl or Shift keys and scrolling moves the Editing area up down Page 34 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Cut Copy amp Paste The Red Drive software allows the user to copy or cut large sections of flowchart The Control area of the main window features the following four icons D faeci l Cut Clicking on the select icon allows the user to click and drag a grey area over a group of blocks in the editing area This selection can then be Cut or Copied using the above icons as required Clicking on the Paste icon then allows the u
43. gain selected to suit the system being controlled This gap is to allow for inertial differences in manufactured systems The lower the speed at the end of the deceleration the more accurate the final rest position of the motor will be The deceleration block has a Type Final Position feature that provides this method of control in a single block Page 30 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Making use of Calls Calls are best used to save memory with often repeated sequences of blocks In order to use a call the Subroutine to be called must first be setup The blocks to be called should be placed between a Start Sub and End Sub block The block Properties menu should then be used to give the subroutine a name The Call block will be placed in the main flowchart and using the block Properties of the Call the subroutine name can be chosen from the drop down menu The illustration shows the subroutine Move O CCW being called by the first call block in the main flowchart It is worth noting that due to the memory used to process a call you should not package any single blocks except acceleration blocks Doing so will result in more memory being used Interacting with other Red Drive units While sharing data with other Red Drive units is not currently available using the I O system it is possible to hav
44. h When the unit reaches and activates this switch it is deemed to have reached home The SP2902 unit features a Optical switch This should be connected to Pin 14 as shown in the Connecting Inputs and Outputs section of the manual page 7 or 14 Each time the pin on the output shaft passes though the optical switch a signal is sent to the Red Drive controller which can then be used to calibrate the home position Pin 14 also needs to be setup as an input This is done in the Program parameters window Program parameters R x Standard PID Pin set up Motor Gearbox Inputs Outputs Motor and board type Brushed Motor DCA 7 Gear ratio 408 221 2539 Output shaft load torque mNm joo fi 774 Motor stall torque mNm seal ciate ite No load speed rpm E1 00 Gearbox opposite E Motor direction COUNTER CLOCKWISE Encoder Home Global reset Pin 13 E Channels DUAL x Home position output revolutions jo Reset when Lowo Pulses per revolution jas OK Cancel All available pins are listed either under Inputs or Outputs The home calibration switch is on Pin 14 This must be defined as an Input in this window If Pin 14 is currently defined as an output it can be moved by clicking on Pin 14 and then clicking on the bottom arrow Pin 14 should then be listed under Inputs Page 52 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Some
45. heating CAUTION BOTH VERTICALLY MOUNTED COMPONENTS GENERATE HEAT IN OPERATION THESE COMPONENTS MAY BECOME HOT Connecting Motors 1 2 3 4 5 6 Connector shown from above Pin 1 Connection to Motor Pin Connection to Motor PINS Encoder Ground 0 V Pin 4 Encoder A Pino Encoder B unconnected for use with Single Channel encoder Pin 6 Encoder Supply 5 V CAUTION IF THESE CONNECTIONS ARE INCORRECT IRREPARABLE DAMAGE MAY OCCUR TO THE ENCODER AND RED DRIVE CONTROLLER Page 6 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Connecting Inputs and Outputs 4 6 8 10 12 14 1 3 5 7 9 11 18 Connector shown from above Red Drive features a standard 14 Way 7 x 2 IDC header Two 5 Volt and two O Volt pins are provided alongside 9 user definable input or output pins with one input only pin Pin 14 is also used as the home input see page 17 Pin 13 can be set as the global reset pin see page 32 All Pins epee at 5 volt TTL levels 5 Pins also support ana ene s ooo o ww o o C C or C ows id frewow pow w few o C Cr C C or C C eon e ve Global Reset Home Input Note Any pins not used should be set as outputs via the Program Parameters window Where this is not possible i e Pin 6 connect to O V QO The 14 Way header is also used as the programming connector For programming to take place the Re
46. his is used to define any parameters that have an effect on the entire program These only need to be setup once for each program and are saved along with the rest of the flowchart information Pin set up This section sets the I O Pins as either inputs or outputs Unused pins should be set to outputs Select the required pin and use the arrows to move their definition An next to the pin number indicates an internal pull up Note Pin 14 must be set to input if the Calibrate Home block is to be used Global reset Pin 13 Should be set to use the global reset function Reset when indicates if there should be a reset on a HIGH 5V or LOW OV See page 32 Motor Motor and board type Select between Brushless motor BLDCxA and Brushed motor DCxA Motor stall torque mNm This is available from the Rotalink motor data sheet and has a value in mNm Take care to enter the value for the correct Red Drive supply voltage No load speed rpm Also available from the Rotalink motor data sheet Page 22 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Motor direction The normal direction of motor rotation shown on the Rotalink data sheet See also the Working out Motor Gearbox direction section page 58 Encoder Channels Single Dual or Hall effect depending upon encoder and board type Number of pulses Available from th
47. hout causing a reset The flowchart created in Tutorial 1 can be modified to include a soft start To do so an Accel block should be added between the start block and the first move block This can be achieved by moving the mouse pointer over the move block until a hand appears Click and hold the left mouse button and drag downwards into the next space A gap will have opened up and an Accel block can then be taken from the new block area and directly placed over the linking line This will automatically connect it into the main flowchart Double clicking on the Accel block will open up the properties window for this block x Commen m Parameter Direction CLOCKWISE x Type TIME 7 Speed feedback v Initial speed rpm fo 00 Final speed rpm Time seconds fo 0o OK Cancel Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 43 Tel 44 0 1460 72000 www rotalink com The direction of the first move is clockwise and it follows that the output shaft should also be turning clockwise through this acceleration There are two types of acceleration Those which are purely based on TIME accelerate from 500 rom to 100 rom in 1 second and also those which are to a FINAL POSITION accelerate from 500 rom to 100 rom in 1 second and then move to 2 revs from home In this example an acceleration based on TIME is sufficient Speed feedback is left on and the i
48. ict the minimum EEPROM life expected in a given application Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 29 Tel 44 0 1460 72000 www rotalink com Positional accuracy Whilst the Red Drive controller has a high level of accuracy it does require use of good programming techniques to maintain this As an example driving the motor at full soeed and expecting it to stop exactly where required is simply unobtainable the systems inertia will act to cause the unit to overshoot This can be improved upon by stopping the motor before the final rest position and as long as each system has the same inertia a consistent stop will be achieved however it should be noted that as a DC motor heats up its breaking potential changes System inertia is however unlikely to be consistent and where possible this should be overcome by driving the motor to its rest position To do so accurately requires the motor to be driven slowly and deceleration blocks should be used to achieve this slower speed before requesting the motor to stop The diagram below shows this in more detail start of deceleration end of deceleration Distance The distance between the start of the deceleration and the end of the deceleration in time should be selected to complement the system being controlled Positional overshoot will occur if this time is set too short The distance between the end of deceleration and the stop is a
49. is required successive waits should be used Warning Speed xxx gt no load speed xxx gear ratio XXX A speed has been entered which is greater than the maximum speed available with the system as defined in the Program Parameters window Page 60 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Warning Initial soeed xxx gt no load speed xxx gear ratio Xxx The Initial soeed set up in an accelerate or decelerate block has been entered as a value greater than the maximum speed available with the system as defined in the Program Parameters window Warning Final speed xxx gt no load speed xxx gear ratio Xxx The Final speed set up in an accelerate or decelerate block has been entered as a value greater than the maximum speed available with the system as defined in the Program Parameters window Warning Speed and torque formula limited to 4294967295 Acceleration deceleration time is too long for Red Drive to control If a very long acceleration or deceleration is required Successive accel decel blocks should be used Warning Speed and torque formula restricted DP limited to 4294967295 Acceleration deceleration time is too long for Red Drive to control If a very long acceleration or deceleration is required Successive accel decel blocks should be used Warning Speed and torque formula restricted DP limited to 0 Acceleration dec
50. ith the supplied software and Serial Adapter unit it allows the user to specify how and when their motor will move Full control is available over speeds distances O 44 million output revolutions and direction The unit is able to interact with switches LEDs buzzers and other user defined inputs and outputs It is even possible to interact with other Red Drive controllers The Red Drive software provides the user with an incredibly easy to use interface for defining all aspects of the controller No complex programming is required just a simple drag and drop flowchart style interface which uses real world values such as rom and seconds Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 3 Tel 44 0 1460 72000 www rotalink com Contents Introduction 3 Hardware 6 DC1A Controller 6 Connecting Motors 6 Connecting Inouts and Outputs 7 Connecting Power 9 Timing 9 DC2A Controller 10 DC10A Controller 11 Connecting Encoders 11 Connecting Power 12 Connecting Motors 12 Connecting Inputs and Outputs 12 Timing 12 BLDC10A Controller 13 Connection to PC 16 Software 17 Installation 17 Concept 17 Calibration 17 Positioning System 16 Selecting an Encoder 18 Running the Software 19 Programming the Hardware 20 Fast Communications 21 Program Parameters 2a PID 24 Flowchart Blocks 25 Linking Blocks 28 Speed Feedback 29 EEPROM 29 Positional accuracy 30 Making use of Calls 31 Interacting with
51. mNm A 23 8 13 1 177 4 5 83 PH IS Performance characteristics and general specification are measured from sample motor From the Label attached to the side of the gearbox the Gear ratio can be read For this unit the Gear ratio is 408221 2535 An OP on the label indicates that the Gearbox has an opposite direction of rotation to the motor an SA would indicate that the rotation is the same as that of the motor These tutorials will be undertaken with a unloaded gearbox so the Output shaft load torque is O mNm Information regarding the encoder can be taken from our encoder data sheet As shown below the encoder is dual channel featuring 48 pulses per revolution General Specification Number of Channels 2 Pulses per Motor rev 48 Output CMOS TTL Supply Voltage 5 Vde Supply Current lt 30mA Wiring Colour Code 5V Brown Ground Blue Channel A Yellow Page 38 Red Drive User Manual www rotalink com Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Tel 44 0 1460 72000 The home position indicates the position value to be taken by the Red Drive controller when the unit calibrates This is done both on start up and if the user issues a reset home block O should be entered here After completing these stages the Program Parameters window should look as below x Standard PID Pin set up Motor Gearbox Inputs Outputs Motor and board type Brushed Motor D
52. n programming mode CAUTION SWITCHING ON THE POWER TO THE RED DRIVE CONTROLLER WITHOUT A SA1 SERIAL ADAPTER WILL RESULT IN RED DRIVE STARTING THE FLOWCHART PROGRAM IF THE FIRST BLOCK IS A MOVE THE UNIT WILL IMMEDIATELY START MOVING Fast Communications Under the same menu as Set Com Port see Programming the Hardware above is a Fast Communications option Selecting this causes the PC to download flowcharts to the Red Drive controller at a faster speed Unfortunately this option does not function successfully with all PCs if you experience communication problems please deselect this option Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 21 Tel 44 0 1460 72000 www rotalink com Program Parameters Selecting the System menu in the Control area and then Program parameters results in the following window being displayed Program parameters j x Standard PID m Pin set up Motor Gearbox Inputs Outputs Motor and board type Brushed Motor DCxA 7 Gear ratio 408 221 2 539 Output shaft load torque mNm foo 177 4 Motor stall torque mNm noo aps ite No load speed rpm 6 1 oo Gearbox opposite E Motor direction COUNTER CLOCKWISE Encoder Home Peta tlh E E Channels DUAL Home position output revolutions fo Reset when Lowo Pulses per revolution 48 OK Cancel T
53. ng and starting around the home position regardless of the start position Reset Home Reset Home is useful for applications where relative positioning is required If a rotation of 1 rev is needed for driving a pump driving to 1 rev first cycle and then to 2 revs from home second cycle may not be suitable If there was an over pump with the first movement an under pump to move to 2 revs from home might not be wanted rather another attempt to pump for 1 revolution In this instance use of a Reset Home block at the beginning of each movement would cause the unit to forget any previous error and simply move a further 1 revolution The motion would be Start Reset Home Move 1 rev End Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 53 Tel 44 0 1460 72000 www rotalink com Tutorial 6 Check IP Set OP This tutorial will introduce the use of inputs and outputs within the Red Drive system how they are set up and how they are used The easiest way to introduce inputs IP is to use the home calibration switch as an input Setting up Inputs and Outputs All inputs and Outputs are setup in the Program parameters window x Standard PID Pin set up Motor Gearbox Inputs Outputs Motor and board type Brushed Motor DCA Gear ratio 408 221 gt 12 539 Output shaft load torque mNm o o fi 77 4 Motor stall torque mNm T unknown ite No load speed rpm E1
54. nit to be connected to a PC OV iV Power Supply SA1 Serial Adapter The serial adapter must be connected to the Red Drive controller before switching the power on Otherwise the unit will not enter programming mode Page 16 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Software Installation The Red Drive software can be found on the supplied CD It does not require installation first run may require administrator rights and can be run direct from this disk If required the Red Drive program can be installed onto a PC by copying the file RedDrive exe to the desired location This software can also be downloaded from the Rotalink website at www rotalink com Concept The Red Drive software has been designed to be as easy to use as possible The system is designed around a flowchart concept with blocks for moves waits and other commands Blocks can be easily moved added and deleted with just clicks and drags Any values needed are in easy to understand revolutions per minute of the gearbox output shaft and number of revolutions There s no need to continually calculate gear ratios and times are all in seconds Programs can be saved or printed at any stage for later completion or review Calibration It is recommended that all systems feature a calibration point home position on their final movement output For a lead screw this would
55. nitial soeed should be set to O rom The final soeed should be set to the same speed as the move 87 88 rom Time in seconds should be set to produce a smooth start to the motor 0 1 seconds has been shown to be a good value to try The user may wish to vary this value to suit their impression of a good and clean start Downloading this program and then running should demonstrate a noticeable difference in smoothness of start comparing the clockwise rotation with the counter clockwise movement This Accel block should be copied and placed before the CCW move Ctrl click drag can be used to copy the block The direction must be changed to CCW Note It is important to make sure that the appropriate direction is inserted into an acceleration or deceleration block unexpected motion can result if this is not correct Position Control As described in the section Positional Accuracy page 30 running a motor at full soeed and then expecting it to stop exactly where required is impossible By using Decel blocks the rest position can be more accurately controlled A soft stop as shown below will now be added to the flowchart program start of deceleration end of deceleration Distance Page 44 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Decel A Decel block can be added between the first move block and the stop block This can
56. ockwise movements are in a negative direction For example moving 2 revs CW a further 8 revs CW and then 10 revs CCW would be written Move CW at x rpm to distance 2 revs Move CW at x rpm to distance 10 revs Move CCW at x rpm to distance 0 revs At power on the home position will default to the customer set value in the Home section of the Program Parameters window see page 22 Negative numbers are not allowed to move counter clockwise beyond the home position requires the home position to be set as a positive number in the Program Parameters window see Program Parameters page 22 If the first move is to be CCW the home position should be set equal to the largest total movement for example Home position set to 10 revs in Program Parameters window Move CCW at x rpm to distance 8 revs Move CCW at x rpm to distance 0 revs Move CW at x rpm to distance 10 revs Relative positioning move another 2 revolutions is possible by using the Reset Home block described on page 27 CAUTION FAILURE TO ENSURE ALL DISTANCES GIVEN ARE RELATIVE TO THE HOME POSITION CAN RESULT IN UNFORESEEN AND POTENTIALLY DAMAGING MOTION Selecting an Encoder When using Red Drive with Brushed motors two encoder are available Single and Dual Channel Dual channel encoders provide information on direction distance and speed single channel encoders only provide distance and speed information The lack of direction information results in a small loss of
57. rces used Unknown board disconnected File H iWORK IN PROGRESS Red Drive RedDrive Cd Tutorial2 fle Compiling downloading and running this flowchart will result in the output shaft completing exactly one revolution before waiting and then reversing The CCW deceleration will see the unit returning to its starting point Page 46 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Tutorial 3 Start Sub End Sub Call Start Sub End Sub and Call blocks are the building blocks of subroutines this tutorial will introduce what they are for and how to use them Subroutines are mini flowcharts used to contain often used blocks A pointer Call to this mini flowchart can be used in place of the blocks When the flowchart reaches this Call the mini flowchart will run and then the main chart will continue This is useful in two ways e Writing programs is quicker and involves less typing e Programs featuring subroutines can be more efficient allowing more complex flowchart programs to fit within the Red Drive memory Tutorial 2 used Stop and Wait blocks to end each movement In a more complex program these blocks could be used many times To make programming easier and to save memory a Subroutine should be used Start Sub Each subroutine must begin with a Start Sub block Click and drag to place a Start Sub to the right of the Start block The Properties window dou
58. rinting Printing is available under the File menu in the control area Using the Single page Multiple pages options and the Page size selector bar flowcharts can be printed at almost any scale The Settings tab allow the page borders to be modified as well as providing dialogue boxes for Header and Footer information The following control codes can be added into the Header and Footer dialogue n Prints the page number N Prints the total number of pages to be printed f Prints the file name without path F Prints the file name with full path q Prints the current date D Prints the date of the last flowchart modification t Prints the current time T Prints the time of the last flowchart modification followed by any other character causes the word Error to be inserted Upgrading the Controller If any future upgrades are made to the Red Drive system these may require changes to the firmware stored within the Controller These upgrades will be distributed via our website www rotalink com and can be installed by using the System menu found in the Control area and then clicking on Firmware Download Page 36 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Tutorials All of the following tutorials will be based around our standard SP2902 unit running on a DC1A controller The SP2902 compris
59. rset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Calibrate Home The main use of calibrating the home position is to ensure the absolute position of the system when the power is switched on Therefore the Calibrate Home block should be the first block in the flowchart Opening the Calibrate Home Properties displays the following window Calibrate Home xj r Comment I ji Parameters Direction CLOCKWISE x Begin next block when home input Pin 14 is HIGHE S x Speed feedback Iv Speed 2 00 OK Cancel The direction is very important in a linear system if this is wrong the system will never find the home switch and home will never be calibrated For a rotary system movement in either direction will cause the home switch to be activated In this example the direction can be left as clockwise Begin next block when home input pin 14 is should be set to HIGH 5V This relates to how the switch is set up and how it is activated Our switch outputs O volts to Pin 14 when the detector is clear and 5 volts when the pin passes though After receiving this input the flowchart program will immediately move onto the next block To ensure accuracy the motor should pass through the optical unit slowly Setting the speed to 2 rom as used for final position accuracy in Tutorial 2 should be sufficient Downloading and running this program should see the system stoppi
60. ser to move the new block s around the editing area to the required space clicking with the left button then places the selection A small no entry sign for the cursor indicates that the blocks can not be placed this usually indicates a block or line beneath the selection which will need to be moved before the paste can take place Cut Copy amp Paste can be done between flowcharts Simply make the selection and Cut Copy then open the new flowchart and use the Paste icon here Red Drive lal x File View Edit System Help alele o aelel Sea S sil ep ats Check IP TTT OST Fe TSS OO OT a p D lt E Resources used Unknown board disconnected File ROTALINKO users lanR WORK IN PROGRESS Red Drive Development Testing Test Prog Bistart O A O S GS A Adobe tstrator orisales r Outlook A Adobe InDesign cs2 m B Red Drive _ _X_Adobe Photoshop La surfotfine Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 35 Tel 44 0 1460 72000 www rotalink com Undo Redo The Red Drive software features a simple undo redo function The undo redo buffer is constantly updated and holds a record of the last 100 actions To undo simply press the left had arrow to redo press the right hand arrow These arrows appear red when an undo redo action is possible SS tt af Bol alent gt I P
61. table to be driven by Red Drive or any other PWM controller This is due to the type of suppression fitted to the motor The only solution in this instance is to use a different motor Rotalink will be happy to assist with a new selection Irregular speed using speed feedback There are 2 causes for this Either the required speed is simply too low and the motor is constantly starting and stalling or the PID system is set too aggressive for the speed required Setting the kp ki and kd values to O will demonstrate if the required speed is physically possible with this motor If this test is Successful it should be possible to tune the PID system to improve smoothness see page 24 Unit restarts part way through a cycle Restarts are caused by the Red Drive controller experiencing a reset condition See the Fail safe section page 32 The two main causes of this failure are discussed below 1 With aDC1A DC2A if the motor has a stall current of 4 A or more it is possible to overload the system causing a reset by trying to stop or start too quickly Use of acceleration and deceleration blocks to soft start and soft stop the system should remove this overload condition 2 Matching the power supply to the selected motor and motion is critical If the power supply cannot deliver enough current quickly enough the voltage to the Red Drive controller can drop below that at which it can operate The key indication of this fault is the program res
62. tarting when starting or stopping a motor DC motors draw large amounts of current when switched on for a short period of time the stall current is required and also when stopping due to acting as a generator If these events are drawing too much current there are two options Firstly a larger power supply can be selected ideally the power supply should match the motor stall current secondly the flowchart can be modified to include soft starts By accelerating and conversely decelerating the motor to speed this initial current Surge is reduced How long this soft start needs to take is entirely dependent upon the motor load being driven and the current rating of the power supply being used Page 56 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Unit accelerates to maximum speed and then restarts If soeed feedback is switched on box ticked then this is indicative of a failed encoder The Red Drive controller is receiving no position feedback from the encoder and so increases power in an attempt to get the unit moving The motor will be accelerated to full power without the encoder sending a pulse to the Red Drive Controller causing an error within Red Drive and therefore a system reset This error will also be shown by a value of 4 being placed in Variable 1 on reset see page 32 Skipping of blocks flowchart block fails to run The Red Drive con
63. tch NO will produce a LOW 0 V when pressed A normally closed switch NC will produce a HIGH 5 V when pressed CAUTION ATTEMPTING TO USE A SWITCH WITHOUT EITHER AN INTERNAL OR EXTERNAL PULL UP RESISTOR MAY RESULT IN UNDESIRED OPERATION All inputs operate at 0 5 V other input voltages will need to be managed with additional external circuitry such as an optocoupler Page 8 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Connecting Power Vss VoD Vss Supply Ground O V DC Vpop Supply Positive voltage 9 to 30 V DC Timing The DC1A PCB features a ceramic resonator to provide timing This component has an accuracy of 0 5 Due to the nature of the microprocessor design further delays could effect the timing accuracy provided by wait blocks especially if the motor is moving Taking the worst case scenario if you were to set a wait for 24 hours 86400 seconds you should only rely on an accuracy of 14 4 minutes 864 seconds that is 1 If more accurate timings are required a external clock could be attached to the Input pins and used to trigger an event Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 9 Tel 44 0 1460 72000 www rotalink com DC2A Controller pe a U u N o 3 2 approx LO 2 Soldered Component pins 4x 3mm holes 1 13
64. their machine and motor gearbox The Program Parameters Window can be found by clicking on System in the Control area and then selecting Program Parameters This window is split into 5 sections Pin setup Motor Gearbox Encoder and Home The Pin setup section should be ignored for now this will become relevant in Tutorial 5 6 when inputs and outputs are introduced On the next page part of our D38857 2490 Data sheet is shown Running from a supply voltage of 24V the motor setup information can be copied into the Program Parameters window Stall Torque is 177 4 mNm and the Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 37 Tel 44 0 1460 72000 www rotalink com No load speed is 6100 rom The Motor Direction can be read from the drawing Assuming that the terminal next to the red dot is connected to the positive wire red wire then the direction of the arrow can be used showing that the motor rotates counter clockwise CCW VY IVIOLUILS Unit mm VHT HALUIS IVIOLUTS HAINSH HISSIIN AIU WUTILIUl D3857 2490 M3 0x0 5 tapped hole 2 places Direction of Rotation If Terminal nearest Red Mark Connected to vol Issue 02 lts Performance No Load Current A Current A Volts V Speed rpm Speed rpm 5250 Model Number D3857 2490 24 6100 0 21 0 90 Maximum Efficiency Stall Torque Output Torque Current Max Power mNm W
65. tinue to overshoot as at the end of Tutorial 1 The decel block needs to be run before a position of 1 rev from home is met This revised position should be final position 1 rev minus the distance taken to decelerate in 0 1 seconds Rotalink Limited Croomead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 45 Tel 44 0 1460 72000 www rotalink com This deceleration distance can be calculated fairly easily Because the deceleration curve is a straight line we can assume that the distance will be the same as if the unit was moving for the same length of time at the average speed Initial soeed final soeed 2 final soeed average speed 37 88 2 2 2 19 94 19 94 rom 0 33 revs per second Multiply by 0 1 seconds decelerate time 0 033 revs The inertial of the system will have an impact on this deceleration distance allowances should be made for this by increasing the value In this example a deceleration distance of 0 06 revolutions will be assumed Distance in the move block should therefore be changed to 0 94 revs CCW deceleration and move A similar process should be carried out in the CCW direction The move distance should be changed to 0 06 revs and then a copy of the CW deceleration block should be made changing the direction to CCW and the Final position to O revs The flowchart should look as below File View Edit System Help eleja Of sie aaa 4 gt Check Var Check IP Resou
66. troller considers position to be important above all other parameters If the controller is asked to complete a move which is not possible for example moving CW to position 5 when the system is already at position 6 it will assume that the command is no longer required as the system has already moved passed position 5 and skip onto the next block If the distance is correct and the block still does not appear to be running then the direction should be checked and the system checked for any over shoot from a previous block Unit fails to start Firstly check the Program Parameters If the motor normal direction is incorrect Red Drive will detect that the direction is wrong and reset Is the global reset function is being used see page 32 Check that this is set the correctly is a LOW OV signal being checked for when a HIGH 5 is required Otherwise has the controller been configured to use another I O pin to supply the ground or 5 volt signal for the global fail safe pin The global reset check operates before these pins are set up Supply for a global fail safe switch must come from the 5V pins If possible also check the motor for movement If the gear ratio is large the error may be Unit accelerates to maximum speed and then stops Unit fails to carry out programmed function This maybe an overshoot random change in direction or other strange event Usually caused by excessive electronic noise effecting the Red
67. wise movements D Note If our SP2902 unit is being used with this program the user may notice that the Red Drive controller is moving the output shaft a little over one revolution before stopping an overshoot has occurred Insuring positional accuracy will be looked at in tutorial 2 Page 42 Red Drive User Manual Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ www rotalink com Tel 44 0 1460 72000 Tutorial 2 Accelerate Decelerate Position control This tutorial will look at the use of the Accelerate Accel block and how it can be used to reduce the large start up currents common with DC motors and also Decelerate Decel blocks and how they can be used to improve the position control attained by the Red Drive Controller Accel DC motors generally have a stall current far in excess of their running current The D38657 2490 unit has a stall current of 6 25 Amps but at maximum efficiency the point at which a design should aim to run the motor only 0 84 A is consumed When the motor is switched on for a very short period of time the motor is not turning so the stall current is drawn If this period is too long or for too great a current it may cause the Red Drive controller to reset In these situations it is best to accelerate the motor up to speed Applying a lower voltage to the motor for the short period where the motor is stalled will produce a lower stall current ensuring that the motor starts wit
68. xxx available 60 Warning Wait time limited to xxx seconds 60 Warning Speed xxx gt no load speed xxx gear ratio xxx 60 Warning Initial soeed xxx gt no load speed xxx gear ratio xxx 61 Warning Final soeed xxx gt no load speed xxx gear ratio xxx 61 Warning Speed and torque formula limited to 4294967295 61 Warning Speed and torque formula restricted DP limited to 4294967295 61 Warning Speed and torque formula restricted DP limited to O 61 Error Accel decel Processed initial and final soeeds both xxx 61 Warning Speed gear ratio and encoder pulse formula limited to 65535 61 Warning Distance and encoder formula limited to 4294967295 62 Error Calibrate Home requires pin 14 to be input it is currently an output 62 Error Torques Output shaft xxx gt motor stall xxx gear ratio xxx 62 Error Stack Overflow 62 Warning Disassembly problem 62 Error default in CompileFlowChart 62 Conversion Formula 63 Torque Conversion factors 63 Lead screw Conversion formula 63 Rotalink Limited Cropmead Crewkerne Somerset TA18 7HQ Red Drive User Manual Page 5 Tel 44 0 1460 72000 www rotalink com Hardware DC1A Controller 24 3 2 approx i Soldered Component pins l i 4x 3mm holes Input Output Motor Continuous Current 1A Voltage Range 9 30 V Motors may draw larger currents for short periods of time however the unit may cut the power supplied to the motor at higher currents to protect from over
69. y It s common for a switch to make a connection several times when the user only wanted it pressed once Sometimes this is due to the user not pressing cleanly and often the contacts of the switch actually bounce To avoid counting switch inputs more than is required it is good practice to check a switch several times before accepting the result of a Check IP As shown the switch is checked if its been pressed there s a short wait before it s checked again Only if the switch is still pressed then the result accepted 0 1 seconds has been proven to work well for this however the user may wish to experiment with alternative values Electrical Noise There will always be electrical noise in our environment from mobile phones to office equipment Usually the level of this noise is small however it s always best to reduce the effect any noise may have with good design The most important rule is to keep any wiring short The shorter any wiring looms the less area an input signal has to be effected by noise The next step is to design the flowchart program to ignore noise When bouncing switches were mentioned above it was suggested that a wait block should be placed between two Check IP blocks This is important on other inputs as well The length of the wait in this case should be less than the shortest expected input pulse For example if a piece of equipment was providing a Sms pulse to instruct Red Drive to start the wait could

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