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1. SilverMax D15 Connect to SilverMax Be sure to tighten thumbscrews SilverMax Line Power Cable Connect to SilverMax Be sure to tighten thumbscrews Power Supply Flying leads Required for Driver Enable Power Supply Flying leads Connect to user supplied power supply Red to V black to Ground and White to Chassis Ground RS 232 D9 Connect to 9 Pin RS 232 COM1 or COM2 on PC Breakout Module Pin out Pin Signal 1 I 01 2 102 3 1 03 4 1 04 5 105 6 106 7 107 8 LOGIC GND 9 5V OUTPUT SilverMax User Manual 13 Revision 3 22 QCI SKO FS v Start Up Kit Setup The SilverMax interface cable is provided to connect the SilverMax motor to the Optical I O Module QCI OPTOC For more information on the Optical I O Module see QCI Technical Document QCI TD0010 included The female 15 pin connector of the interface cable attaches to the 15 pin male connector on the SilverMax motor The male 15 pin connector of the interface cable attaches to the 15 pin female connector on the optical I O board attaches to the RJ 11 connector on the Optical I O board The phone jack like connector of the RJ 11 serial cable The 9 pin female Comm connector of the RJ 11 serial cable connects to your PC The V Input connection on the Optical I O board must be connected to V of a power supply and Pwr Gnd connection must be connected to Ground of that power
2. 512 1 z Kv1 G Fv1 C 512 Oz Kv2 G Fv1 G Fv2 C 512 1 2 Kvff R 512 Oz Ka G Fa C 512 DS Kaff G Fv1 C See below for a description of the terms i e Ki Kp SilverMax User Manual 97 Revision 3 22 Position y from motor d A shaft 4000 rev D Acceleration Feedback Low Pass Filter AF Fa 215 Acceleration Filtered A Acceleration First Velocity Feeback Low Pass Filter KF Fv1 2M5 1 0 o Velocity Once Filtered VF Fv2 2115 Velocity Twice Filtered Second Velocity Feedback Low Pass Filter Target Acceleration z Target Velocit Trajectory S y Generator Target Position gt Position Error Target Acceleration and Target Velocity are scaled such that the maximum values of each are represented by 2115 1 SilverMax PVIA Block Diagram SilverMax User Manual Acceleration Feedback Gain Velocity 1 Feedback Gain ui gt Velocity 2 Feedback gt Gain 5 Kv2 gt Acceleration Feedfoward Gain Velocity Feedforward Gain b Kutt Limiter 16 bits 2 2M5 lt X lt 25 1 Limiter 16 bits Tmax lt X lt Tmax Sum of Non Integral Terms 98 J Limiter 1 Tmax lt X lt Tmax Limited Integrator Torque Output Z Position mode EE D oe e Gain Limiter 16 bits KS e JS 2 2M5 lt X lt
3. 147 3 SilverMax User Manual 62 Command This Program reads the current V power supply voltage converts it 4 ito a usable value and stores it in User Data Register 11 b R ead in the raw V voltage value into the accumulator Read Ma Main Buss Voltage Into Accumulator 10 Read the Va scaling factor form Non Volatile memory and store it in User Data Register 11 Read Ma Scale Factor Into User 11 Divide the V raw value by the scaling factor to give a reading in Volts Accumulator 10 ccumulator 10 DIV16 User 11 Write the calibrated voltage value to Data Register 11 User 11 Accumulator 10 Command This Program reads the motor temperature On the Controller Board converts the value to degrees C and stores it in User Data Register 2411 j Read Temperature Into Accumulator 1 0 The following value written to Data Register 11 is the 0 degree offset for the temperature circuit Write 9011 to User 11 Accumulator 10 Accumulator 10 User 11 The following value written to 11 is the scaling factor that converts ADC counts to degrees C Write 147 to User 11 Accumulator 10 Accumulator 10 DIV16 User 11 The following value written to 11 is a small number for compensating for a temperature offset in the electronics Write 3 to User 11 Accumulator 10 4ccumulator 10 User 11 User 11 4ccumulator 1 0 Revision 3 22 UO CONFLICTS The seven digital
4. 30 866 4 x 4 40 0 17 Deep Front View of SilverMax 17 Frame DB 15 Connector Power Ground RS 485 A RS 232 Tx RS 485 B RS 232 Rx Logic Ground 5 Volts 100mA SilverMax User Manual 15 Pin HD D Sub Connector 2 000 0 240 0 790 E FLAT 0 177 I 1 890 0 590 0 080 2 980 Model Number Overall Length 17 1 amp 17H 1 2 14 17 38 17H 3 3 29 Notes Inputs 1 2 and 3 have a 4 7K pull up to 5 Volts Revision 3 22 129 SilverMax 23 Frame 0 270 Male 9 Pin D Connector 1 500 2 220 1 500 0 177 Dia 4 Places ken See Table EE R1 312 0 36 Typ Model Number Overall Length Front View of SilverMax 23 3 3 69 23 Frame DB 15 Connector 23 5 4 55 23H 1 3 22 Power Ground 23H 3 3 72 23H 5 4 65 RS 485 A RS 232 Tx RS 485 B RS 232 Rx Logic Ground 5 Volts 100mA Notes Inputs 1 2 and 3 have a 4 7K pull up to 5 Volts Signal SilverMax User Manual 130 Revision 3 22 SilverMax 34N 1 34H 1 amp 34H 2 Frame 4X Y 218 THRU EQUALLY SPACED 0 88 ON A Y 3 875 B C 2 875 0 002 0 0000 0 500 o 0005 0 125 KEYWAY 1 25 High Density DB 15 Model Number Overall Length Connector 34N 1 5 13 34H 1 5 13 6 NC 34H 2 6 65 Driver Enable 2 RS 485 A RS 232 Tx Notes 12 RS 485 B RS 232 Rx 8 Logic Ground Driver Enable must
5. or electronic damper improving the overall system smoothness and decreasing the system settling time It does this by providing a high frequency phase gain boost that counters any PVIA changes is shaft velocity Ka can be thought of as a large virtual flywheel a dampener attached to the back of the motor through a viscous clutch Ka would then be the product of the damper viscosity damping factor and the damper inertia Increasing Ka will increase the amount of damping injected into the control loop The larger the Ka the larger the flywheel and the stiffer the viscous clutch Bring up Ka if additional mid range damping is needed Excessive Ka will first sound gritty as the individual encoder counts are emphasized or may cause a high frequency squeal Ka is most useful when trying to tune out vibrations resonance modes induced by system components i e a belt drive To use this term effectively motor shaft couplings with very low torsional compliance are normally required See the section on tuning belt drives at the end of the chapter for an example Acceleration Feedforward Kaff The Acceleration Feedforward value is derived from the Velocity Feedforward value It functions similar to the Velocity Feedforward term by compensating the position lag induced by Acceleration Feedback term Normally the Acceleration Feedforward gain term is set to equal the Acceleration Feedback gain term Although it
6. Limit 32767 lt 5000 gt 32767 5000 Scale 6000 32767 0 1526 Step 4 Scale for output by multiplying by 16 0 1526 x 4000 610 Step 5 Offset output by subtracting 17 610 0 610 The Result from Step 5 is used for the motor Target position Target 610 Step 6 Limit the Velocity of the move using 18 In this case the Velocity is limited to 100 RPM Process is repeated every Servo Cycle SilverMax User Manual Zero Target and Position Data 12 Reg 13 Offset Reg 14 Deadband No deadband required Write 100 to User Input Dead Band 1 4 Reg 15 Max Input amp Scale Allow the full scale value Write 32767 to User Maximum ScalelLimit 15 Reg 16 Max Output Scale Make the full scale value up to 4000 counts Write 4000 to User Maximum Output Scale 16 Reg 17 Output Offset No Output offset Write O to User Output Offset 17 Reg 18 Rate Limit the Velocity to 100 RPM Write 53687100 to User Output Rate of Change 18 Enter Position Input Mode Position Input Mode Stop when I O 1 is LOW FALSE Continuously Read the Analog input into Reg 12 Continuously Read Analog Channel 1 2 Into User Input Source Analog Input Mode Positioning Scale the analog input for 0 54 2000 to 2000 counts Analog inputs 1 amp 2 are used differentially u Read the current position of the Joystick and store it into Reg 13 Read Analog Channel 1 2
7. commands add a new dimension to SilverMax by allowing the move parameters to be changed on the fly This gives the ability to create just about any shape of move that is required Profile Move commands perform very complex profile shapes by allowing the move parameters to be changed dynamically Move parameters stored in Data Registers can be changed by an external Host controller or by an internal program Profile Move commands come in two flavors 1 Single Move using the Profile Move command where the command ends when the Position is reached 2 Continuous Move using Profile Move command where the command doesn t end when the position is reached The Continuous Move puts SilverMax into a move that even when at the Target Position will move again when the Position parameter changes there is no need to issue the move command again The Continuous Move can be terminated with a Stop on Input Halt Stop Velocity Mode or Hard Stop Move command Added with these commands is a separate Deceleration parameter for providing different acceleration and deceleration profiles Also added is an Offset parameter which causes SilverMax to move an offset distance after a Stop on Input condition is met Profile Move commands use ONLY Linear acceleration and deceleration All Profile Move commands use Data Registers for parameter storage The Profile Move commands use five parameters stored in registers 20 to 24 for al
8. e CD with QuickControl Software version 3 2 and higher e SilverMax User Manual this document e SilverMax Command Reference e Cabling NOTE The following setup procedures require the usage of a SilverMax Start Up Kit in order to perform the setup and initialization If you did not have a Startup Kit contact your distributor or QuickSilver Controls SilverMax Factory Defaults When shipped from the factory the SilverMax motor and Quicksilver software are configured with default values that are used to establish initial communications between the motor and your computer These default values can be changed re initialized to different settings during the Setup procedure if desired SilverMax Unit ID 16 SilverMax Supply Voltage 48VDC Serial Communications Protocol 8 bit ASCII Serial Interface RS 232 SilverMax User Manual 10 Revision 3 22 Start Up Kits Overview The QCI SK1 Start Up Kits SilverMax motor personal computer and power supply not included provide a simple and inexpensive means for testing and evaluation of a SilverMax motor With a standard PC serial COM port and a user supplied power supply any SilverMax motor can be fully programmed and operated with RS 232 communication protocol The SilverMax Y evaluation cable is included in each kit to connect your SilverMax motor to a PC a power supply and a 9 Pin I O breakout module Also included are the QuickControl Software the Si
9. 00 1 Byte e The first character is the Address with the 9th bit set e The second character the Length is set to zero This defines the packet as the Poll Command packet Since the data count is zero no Command or Parameters are included e The third character is the Checksum Poll Command Example Shown with as Binary Data in Hexadecimal format Sends Poll command to SilverMax 16 10 00 FO SilverMax User Manual 121 Revision 3 22 Response Packets All of the information returned from the SilverMax is in Binary Format The Address is returned as a single byte with the 9 bit set The Length is returned as a single byte All Data is returned as bytes with 2 byte for Words 16 bit and 4 bytes for Long Words 32 bit The Checksum is returned as a single byte There are three types of response packets Acknowledge ACK Returned Data and Negative Acknowledge NAK Each has a different form to allow them to be easily parsed by the Host system ACK Response The ACK response is the positive acknowledge of the receipt of a Command Packet This response has also been shortened to minimize the load on the Serial Communications Interface as it is the most common response of the SilverMax 9 Bit Binary ACK Response Packet data transmission order Address Length ACK Code Checksum 1 Byte 9th bit set 1 Byte 1 Byte e The first byte is the Address with the 9th
10. 10 05 OC 00 00 OF AO 30 SilverMax User Manual 123 Revision 3 22 NAK Response The NAK response packet is sent when the Command issued is not a valid command When the Command Packet is improperly formatted or when the Parameters are invalid or a Command is sent at the wrong time such as requesting a motion when the motor is already busy 9 Bit Binary NAK Response Packet data transmission order Address Length NAK Response Command NAK Error Checksum Code Code Code 1 Byte 9th 1 Bytes 1 Byte 1 Byte 2 Bytes 1 Byte bit set 255 0xFF e The first byte is the Address with the 9th bit set e The second byte is the Length This is defined as the number of bytes starting with the NAK Response Code and including the two bytes for the NAK Error Code e The third byte is the NAK Response Code A value of 255 OxFF indicates this is a NAK Response Packet e The forth byte is the Command Code of the command that failed e The fifth byte is the NAK Error Code The code is 16 Bit word that indicated the NAK Error e The final byte is the Checksum Example NAK response for a Read Register RRG Command Code 0x0C from SilverMax 10 0x0A with an invalid Data Register parameter 0A 04 FF 0C 00 07 E0 Example NAK response for a Move Relative Time Based MRT Command Code 0xB1 if SilverMax 16 0x10 is already in motion The SilverMax will NAK back Device Busy as follows 10 0
11. Kp to move the motor into position By using Ki more and more torque will be added until the Position Error is zero The following plot is with Ki 5 lel Es ES EE SE E SE EE E 3 SE EE ne SS EE a S SE E Target E 3 shea SE EE Position EE EE EE EE SE HB Position Ge I SE SE vi E SC EE SE E E SE Ss gt SE Increase Ki by a factor of 2 or 3 each time until a low frequency oscillation or excessive overshoot is obvious then reduce by a factor of 2 or 3 SilverMax User Manual 107 Revision 3 22 The product of Ki and Kp generally sets the stiffness of a system In other words if you double Kp you will have to half Ki to get the same steady state error A good starting place for Ki can be derived from the default tuning parameters For example if your custom tuned system has Kp 200 and the default tuning parameters had Kp 100 and Ki 1000 a good starting place for Ki would be 500 Velocity Filters Fv1 amp Fv2 The Velocity Feedback values are filtered by a low pass filter Two filters are used with the first one cascading into the second for a steeper roll off on the output of the second filter See the SilverMax PVIA Diagram Filtering the velocity values allows the velocity gain to be increased for greater damping control of the load In cases where large inertial mismatches are present the filters aide in stabilizing the servo control loop to allow greater velocity feed
12. Kvff Velocity Feedforward Kvff SilverMax contains an internal target generator called the Trajectory Generator In real time SilverMax calculates the motion profile defined by a given command and it s parameters On each servo cycle the target value is updated in the servo control loop Similar to the Velocity Feedback value a Target Velocity value is calculated from the target value instead of the position value This target value is used to compensate a lag in position that is induced by the Velocity Feedback term The Velocity Feedforward gain value is set to adjust the required amount of the Velocity Feedforward term Velocity Feedforward is a positive feedback value used to anticipate the velocity needs for the servo control loop Setting the gain value to zero prevents the Velocity Feedforward term from being used Usually this gain value is set equal to the sum of the Velocity 1 Feedback Kv1 and Velocity 2 Feedback Kv2 gain values Setting Kvff 3 in our system produces the following chart SilverMax User Manual 104 Revision 3 22 EE E aed SC ee cee oe e SS Ge SS Ze SS ee do E E E SE SS ES CS SS 2 E SE ee es oe S Ze S a 7 S SS ee pene Ss SC SS SC E Goes SS Ss Ss S SE S SS SE oe SC Sc z z E os eat ah SE E SE WE EE EE SE oa P Of US ES FS PES O De Ee E Be S
13. Loads a program from Non Volatile Memory LOAD AND RUN PROGRAM Loads a program from Non Volatile Memory then executes the program Non Volatile Memory The Non Volatile Memory is used for long term storage of SilverMax programs and Data This type of Memory is used when a program or Data needs to remain in the SilverMax even when power is removed This is also useful when multiple programs must be stored in the SilverMax Each program can be stored at a known memory address and loaded when needed Non Volatile Memory is also available for storing Data When using Data Registers for internal data manipulation and usage there are times when the content of these Data Register needs to be stored This is often the case when generating Position offset or Calibration values The Data Register value can be stored to Non Volatile memory from a single register or an array of registers When storing multiple programs or Data Register values to the Non Volatile Memory care must be taken to keep track of the storage addresses If an improper address is used for loading the loading process will fail SilverMax does not keep track of where programs or Data are stored When storing programs or Data Registers SilverMax automatically adds a Length amp Checksum value at the first memory location This is used when loading to know the correct number of words to load and to verify the integrity of the data When storing Data Registers a 0
14. These two checks may be used together for stopping a motion while the AND condition is used alone for motor position recording Motor Position Revision 3 22 Motion Profile Input Options Table Last Check Process Bit in Stop Enables Stop States word Word Word First Check State Toggle Toggle Preliminary Toggle OR States Bit 15 in both words is used to States toggle the states of the Set this bit to toggle Set this bit to toggle OR Preliminary and OR conditions Preliminary input state input state bits This happens if Direction toggle bits conditions are TRUE Direction Toggle Conditions Bit 14 Input 3 enabled Input 3 State These three bits are used to Bit 13 Input 2 enabled Input 2 State toggle direction before the motor Input 1 enabled Input 1 State begins to move H any condition is TRUE the motor will reverse direction Second Check Preliminary Conditions Bit 11 Index enabled 1 if index is enabled This is the next condition it is Bit 10 Input 3 enabled Input 3 State now checked every cycle This is Input 2 enabled Input 2 State used so that a sensor can be checked for Two State conditions Input 1 enabled Input 1 State If the Preliminary conditions are not met checking stops here Last Check Final conditions AND Conditions Index enabled 4 if index is enabled This will now allow you to check Input 3 enabled Input 3 State eet input 2 enabled Input 2 State with the OR
15. 120 microseconds after receiving the last character in a command packet This is sometimes too fast for the host PC or PLC when running on an RS 485 or RS 232 network SilverMax may be sending its acknowledge packet before the host has switched out of transmit mode This condition will cause a loss of characters Setting the ACK Delay will allow SilverMax to delay a SilverMax User Manual 25 Revision 3 22 specified period before the acknowledge packet is sent NOTE A non zero ACK Delay puts a SilverMax using RS 232 into RS 232 Multi Drop mode See the Command Reference for details In Auto QuickControl will set the ACK Delay to 2 4ms 20 120uSec ticks if the SilverMax is in RS 485 or RS 232 Multi Drop mode and to Oms if it is in straight RS 232 mode Startup Error Conditions ae Startup Error Conditions At power up or if the initialization routine is called SilverMax will verify that the input voltage and the motor A special Startup Kill Motor Recover program is used for only a short time temperature are at an acceptable level before during initialization It allows the motor H H initial i to come up to a point where it can proceeding with the motor initialization If the voltage or a Ae Ah aret haci temperature is out of range the Startup Recovery gets shut down by an existing error program will be executed that will aide in the diagnosis kiaii ofa startup problem The rooma romane sep a ij minimum set of error conditions
16. 20db per decade 60Hz is approximately 6db down The ADC is internally referenced to the 5 Volt power supply When designing analog sources the 5 Volt power supply can be used for power requirements that are less then 100 milliamps Using the 5 Volt power supply implements a design that minimizes effects from power supply variation Analog inputs need to be driven from a low impedance source 10 ohm or less or with a capacitance across the input A minimum 0 01ufd can be used at the input to provide the low impedance source Typical capacitor values can range from 0 01ufd to 0 1ufd An internal 200K ohm pullup resistor is connected to the 5 Volt power supply and will give a slight bias on the input The 200K ohm value must be considered in circuit designs that are high impedance or passive The Input Mode commands can use Analog inputs for Position Velocity and Torque control When using these modes Calibration of the input can be done internally without requiring external circuitry This allows devices such as Joysticks to be directly connected to SilverMax without external interface circuitry See Analog Input Mode below in this manual Selecting Analog Inputs Single Channel Inputs Single Channel Input is the simplest way to read an analog signal into SilverMax For single channel usage the analog signal is referenced to the SilverMax logic ground Electrical noise can be a problem therefore an input capacitor may be required No
17. 232 RS 232 multi drop or RS 485 multi drop Baud Rates 2400 4800 9600 19 2k 28 8k 57 6k 115 2K or 230 4K Data Bits 8 Stop Bits 1 5 or 2 Parity bit None Protocols 9 Bit Binary or 8 Bit ASCII Digital UO Outputs TTL level 0 to 5 Volts 5 milliamps Sinking or Sourcing Inputs TTL level Inputs 1 2 and 3 have an internal 4 7K ohm pull up resistor tied to 5 Volts Inputs 4 5 6 and 7 have an internal 220K ohm pull up resistor tied to 5 Volts Over Voltage Protection All I O is doubly protected with parallel MOV clamping followed by series over voltage limiting to protect the internal circuitry Analog Inputs 0 to 5 Volt input Analog Inputs 1 to 4 share Digital Inputs 4 5 6 and 7 Each input has an internal 200K ohm pull up resistor tied to 5 Volts Input Power 12v to 48v Motor must be initialized for selected voltage 34HC 15v to 48v Maximum current See individual motor specifications in data sheets There is no over voltage protection for the supply input Voltages exceeding 55 volts will permanently damage the motor electronics Supply input may require an active voltage clamp for aggressive braking deceleration or with high inertial loads Maximum Operating Temperatures 40 Cto 70 C storage 10 C to 70 C operation 100 C on the motor section The motor can run at a higher temperature if the Electronics section in kept below 70 C Serial Communications Buf
18. 70 Connecting Analog Inputs 90 Control Constants CTC 99 Control System Overview 97 Controlled Shutdown 82 Creating Programs Overview 69 CTC 99 D Data Register Commands 70 Data Register Operations 96 default 10 Default Start Address 19 Differential Analog Input Example Using a Joystick 92 Differential Channel Inputs 61 Digital UO 33 127 Direction Toggle Conditions 48 Dithering 76 Do While 71 Done Status 59 Download 23 Download Process 73 Downloading Programs Without QuickControl 73 Drag Mode Like a Mechanical Clutch 80 E 8 bit ASCII 114 8 Bit ASCII Communications 115 Enable Multi Tasking 82 Encoder Output 59 Ending Character 116 Error Limits 29 Execute Immediate Type Commands 87 External Trajectory Control 42 F Fa 100 108 Filter Constants FLC 99 First Check Used to toggle the starting direction of motor 45 Revision 3 22 F FLC 99 For Next 71 Fv1 100 108 Fv2 100 108 G Getting Started 10 H Host 66 Host 8 Standalone Mode Combined 66 Host Mode 64 How Do Edit the Initialization Parameters 19 How Programs Operate 69 How to Create the Input Values Native SilverMax only 49 AND Inputs State 49 OR Inputs State 49 I O Conflicts 63 If Then Else 70 Input amp Output Functions 55 Input Checking Process for Motion Commands 45 Input Mode Data Processing Diagram 94 Input Mode Descriptio
19. Chart and observe the position error incurred from the motion 9 Kp x2 To decrease the Position Error increase the Position Gain by 2X TEST the move Some ringing may begin to occur Bring up the Strip Chart and chart the Position Error and Torque Kp can be increased more if Position Error is too great but watch the torque If the torque saturates you are asking too much out of the motor and no amount of tuning will give you more torque 10 Ki 100 and Reduce Kp Kv2 Kvff x75 SilverMax User Manual 111 Revision 3 22 Set the Integrator Gain Ki to 100 and reduce all gains K values by 25 to provide overhead in system operation Increasing Ki will make the system stiffer when holding a position Increasing Ki too much will cause oscillation during moves Keep creeping Ki up until the system feels stiff enough for you TEST the move The move should still be stable If excess oscillations are occurring reduce Ki 11 Save Results Record and save the results then download to the motor reboot and test Tuning Notes Inertial ratios up to 5 1 For a load inertia to motor inertia ratio of 1 1 to 5 1 the default tuning parameters should be sufficient These have been optimized for each motor for this nominal load range given a fairly tight coupling servo class coupler or a stiff belt Aramid type Higher Inertia Ratios SilverMax can be tuned to handle huge inertial loads with mismatches in 1000 1 or even 3000 1
20. Comm LEDS s ecceeeceeeeeeeeeee cece eeeeeeeeeaeee sees en seneeaeeeseeeeaaeeaeseaeeeseseeeeeesenened 18 UPGRADING FROM QUICKCONTROL 3 1 TO 32 ees 19 What is New oc ees an ticle ett Sik ee ee EE 19 SilverMax Initialization Ward 19 Where Do l Set Motor Voltage cocioosioccoiniacar accident 19 How Do Edit the Initialization Parameters ccccccececeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeseseseseseseseeeseeeees 19 Can Still Use My Old Initialization Files 0 cece eect eeeneee eee e eee eaeee ee eeeeeeteeeeeeeieeeeeeieeeeeeaa 19 Default Stat Address ica e dE EE dee hates it 19 silverMax Control Panel a Ee ee deen a a aaa REE REA RAAR 20 Single Giep lfraceiBrezakpooint nn nn nnnnnnn nano nn nn nn nnnnnnnnnnnnnnnnnnrnnannnnnnnnnnnnns 20 QuickKGontrolRev 3 1 TodlS EE 21 SILVERMAX INITIALIZATION 0 ccoo id di 22 SilverMax Factory Default Inittaltzatton ocp ke 22 SilverMax Initialization TC Ir EEN 22 SilverMax Factory Default Initialization File Detailed cccccceessseneeeseeeeeeeseeneeeeseeneeenseeneeensseeeenees 24 Ma i 25 COMMUNICAIONS EE A E EE 25 startup eigene te EE 26 le TEE 27 A le DEE 27 lee 28 Motor Encoder Alignment Route 28 O een Ee teed 30 OVERVIEW Seeche eee Aled a te ce eee ees ete lee el et EE A ee te he alas 31 SilverMax User Manual 2 Revision 3 22 SilverMax Block Diag rans iana a centeceescasecteecanaessecasecnyccasecgusneaheess casesnyansveeendcasauedeas
21. Curve 2 x Acceleration As Linear Ramp Full S Curve Same Acceleration Linear as Linear Ramp Acceleration 0 000 0 050 0 100 0 150 0 200 0 250 0 300 0 350 0 400 Time seconds SilverMax User Manual 36 Revision 3 22 Relative Move Commands Relative Move commands will cause SilverMax to move a specified distance from its current position This is a relative position command meaning it will always move the specified distance away from its current position Move Relative commands come in following types Move Relative Velocity Based MRV Three parameters are entered Distance Acceleration amp Velocity This is the most straightforward command type Register Move Relative Velocity Based RRV Three parameters are entered Data Register Acceleration amp Velocity The Distance parameter is the number of a special internal register called a Data Register The Data Register is used for the distance value The value entered in the Data Register is still in counts The other parameters are the same as the MRV command This command allows the user to modify the distance value without having to change the command when used as part of a program Extended Register Move Velocity Based XRV One parameter is entered the Starting Data Register Only the Distance register location is sent as a parameter the Acceleration amp Velocity must be stored in two successive Regist
22. Example Send a Read Register RRG command as follows Command RRG Command Code 12 Address 16 Data Register 1 Fields with data shown in ASCII Start Char Adr Cmd Data Register End Char 16 12 1 lt CR gt Dec 13 Byte stream with data shown as an ASCII String 16 12 1 lt CR gt Example Send a MOVE RELATIVE TIME BASED MRT command to SilverMax as follows Command MRT Command Code 177 Address 16 Distance 4000 counts Ramp Time 833 ticks 1 tick 120us Total Time 8333 ticks No stop conditions Fields with data shown in ASCII Start Char Adr Cmd Distance Ramp Time Total Time Stop Enable Stop State End Char 16 177 4000 833 8333 0 0 lt CR gt Byte stream with data shown as an ASCII string 16 177 4000 833 8333 0 0 lt CR gt SilverMax User Manual 116 Revision 3 22 Poll Command Packet The Poll Command Packet is a special Command packet that has a shortened form to minimize the communications overhead as this is probably the most frequently sent packet The Poll command may be formatted as any other command as described above or the command portion may be omitted and the SilverMax will interpret the shortened form as a Poll command Example if addressing the command to SilverMax 5 5 lt CR gt shortened format or 5 0 lt CR gt normal command format Response Pa
23. Filter o Constants Constants C May MRY Motor Dev 1 16 Test Move 1 Zero STOP Type QCI 23H 3 Rev 32 4 Distance 8000 ES pied Acceleration 239999 9 cps s r Device Status 8 Velocity 40000 cps Target Pos 5000 counts H p Inputs Outputs Position 5003 counts Test Move 2 Digital 1 0 red LO w a e e el TT J Pos Error 3 counts Cea CT CCC CCC Max Error 49 Gr Acceleration 8000 1 cps s co 999099900 Torque sg bs Velocity 4000 cps i Get Voltage 47 La IS Get Temp 26 2 PE Strip Chart 1021 2f495 3fo ab Tuning Example 100x1 Inertial Miss Match High resolution fast following is all about maximizing bandwidth and gain of the system while keeping the damping reasonable to prevent ringing Below is a simple procedure for tuning SilverMax with a non frictional 100 1 all inertia load using the tuning tool in QuickControl When tuning SilverMax it is important to keep the Velocity Feedforward Kvff term equal the sum of the two velocity feedback terms Kv1 amp Kv2 In addition the Acceleration Feedforward Kaff and feedback terms Ka should also be equal 1 Determine Motion Profile To Be Tuned Before beginning to tune SilverMax determine the motion profile to be tuned using the example moves in the QuickControl Control Panel Absolute moves may be used to produce a fast move in one
24. I O lines can be configured to perform a number of different functions In many cases these functions compete for the I O resources Care and thought must be taken when choosing which I O lines to use for a given function The most flexible is the General Input and Output This can be configured on any I O line and therefore the selected lines should be chosen last Sometimes no mater how the I O is used there will be conflicts The following lists the different functions that will conflict with one another NOTE Before using any Input Functions make sure the I O lines have been configured as Input using the CONFIGURE I O command or the appropriate CLEAR or DISABLE commands When using Motion Conditional or Kill Motor Inputs Any function that configures an I O line for Output will conflict with these functions Motion and Conditional commands that use I O for control do not configure the I O for input If an I O line is configured for Output these commands will read the current state of the line this may cause very unpredictable results When using Step and Direction Input or External Encoder Input Depending on the SELECT EXTERNAL ENCODER setup either I O 2 amp 3 or I O 4 amp 5 will be used for Step and Direction input The ENABLE ENCODER MONITOR can conflict with I O 2 amp 3 usage General Output can conflict with any I O line used When using Analog Input Analog signals can be used on I O lines 4 5
25. Loop Moving Torque In this example the SilverMax will go into Anti Hunt operation when the motion is complete and the position error is less then 4 the required Torque is less than the Torque Limit usually means the position error must be near O and after the Anti Hunt Delay has expired There may be a brief period where the Open Loop Moving torque is applied helping to pull the position error to zero The Delay to Holding affects both Open Loop and Closed Loop operation Snap and hold Example Command Settings Anti Hunt Constants Anti Hunt Delay Torque Limits Error Limits Open to Closed 10 Delay Count 416 Closed Loop Moving Error 100 Closed to Open 4 0 msec Holding 10000 Holding Error 20 Closed Loop Delay to Holding 833 Moving 20000 100 msec Open Loop Holding 5000 Open Loop Moving 20000 SilverMax User Manual 78 Revision 3 22 Anti Hunt Process Assuming the SilverMax is executing a motion this is the beginning Wait for no motion Stay Closed Loop NOTE The Torque Limit value being used by SilverMax depends on the Delay parameter in the Error Limits command Is Moving The Motion must complete before Anti Hunt can This works to pull the begin position error in very tight before going to Is Error Anti Hunt lt P2 Parameter 2 sets Yes when to ENTER Anti Hunt Wait for Torque to No Is P2 be lt Torque Limit
26. Parameter Browser Mode auto Read from SilverMax Double Click on browser will Modify GG Edit Selected Parameter Reboot On Download q Reboot SilverMax everytime Vv new parameters are downloaded Start Interview at Selected Parameter SilverMax Control Panel The rev 3 1 Motion Tuning and Jog SilverMax screens have been replaced with the SilverMax Control Panel See QuickControl Help System for a detailed description of this screen SilverMax Control Panel EN Initialization Fie 2p Tuning ext SilverMax Factory Default Cycle Initialization qcp E Use Wizard to Download and or fi Cycles ms Reboot Change Initialization File O forever delay s SilverMax Initialization Wizard Move yn gt Zero C MAT C MAT Edit Control Edit Filter Ilene z lol Constants Constants eq 8 C MAV E MAY STOP o Motor Axis 16 Test Move 1 Typef Q0 23 3 Rev 324 Distance 8000 counts ERT ee senate ene Acceleration f399999 3 cps s 7 Device Status gt Target Posf counts ace bag GE APA Dr Pasitionls counts Test Move 2 Digital 1 0 red L0 w ea ene Distance 4000 counts ja a la a is la a Pos Error 5 counts Clear ft tt Max Error 46 prey Acceleration 8000 1 cps s St Ce CC eS Get Temp 139 6 PE Torque 25 Velocity 4000 ec Get Analog Inpu
27. Program SPR or Clear Program CLP commands Step 3 Program Type commands are sent to the SilverMax When in the download mode a number of commands can be sent to the buffer one at a time The buffer is limited to 200 words and therefore care must be taken to limit the program size Step 4 End the download with the desired operation Typically one of two things can be done If the program is to be stored into Non Volatile Memory the Store Program SPR command is sent Doing this will cause the Program Buffer contents to be saved into the on board Non Volatile Memory The Store Program SPR command designates a memory location to which the program will be stored When storing the program SilverMax will calculate the length of words that are to be stored and will place that value at the beginning of the memory location designated SilverMax later uses the length value to know how many words to load from the Non Volatile Memory when a Load Program LPR or a Load and SilverMax User Manual 73 Revision 3 22 Run Program LRP command is sent If the program is intended for immediate execution the Run Program RUN command can be used This will cause SilverMax to execute the program that is contained in the program Buffer When the execution is completed the buffer can be over written with a new Program Program Download Example The following example shows a small 2 line program designed for downloading into the SilverMax Non Volatile Mem
28. QuickControl is usually installed in C Program Files QuickControl Rename to C Program Files QuickControlOld 2 Insert QuickControl Setup CD into your CD ROM drive 3 From the Start menu select Start gt Run 4 Type in the setup program lt CD Drive Letter gt setup Follow the instructions on the screen It is strongly recommended that you select Typical installation and accept all the defaults 5 Reboot PC Remove all diskettes from your floppy drives and re boot your PC This can be done by selecting Start gt Shut Down Restart the Computer 6 Run QuickControl From the Start menu select Start gt Programs gt QuickControl QuickControl will come up with a blank program SilverMax User Manual 17 Revision 3 22 7 Initialize and Program SilverMax Go to the QuickControl Help System for a detailed step by step procedure on Initializing SilverMax Programming SilverMax The QuickControl Help system is accessed through Help gt Help Topics gt Getting Started Tutorials SilverMax Status and Comm LEDs There are two LEDs on the back of the SilverMax motor that are used for motor status and communications indication The Red LED indicates in four ways 1 A Short Flicker Successful communications to the motor 2 Bright ON Incomplete transmission 3 Y Bright ON Motor in Idle state 4 OFF A program is running The Green LED indicates two ways 1 ON Power is present and D
29. QuickSilver Controls as part of SilverMax Startup Kits or can be downloaded from the QuickSilver web site www qcontrol com Fora detailed step by step explanation on creating a program in QuickControl see the QuickControl Help system tutorial Creating programs involves combining a series of commands together in the desired order downloading the series of commands into the SilverMax and optionally storing the series of commands the program in the on board Non Volatile Memory Command Types Required There are two different Types of commands that SilverMax accepts Immediate Type and Program Type Immediate type commands can only be issued from a Host controller using the Serial Interface They CANNOT be used as part of a program or stored in Non Volatile Memory The Program Type commands can be used in a program or issued Real time using the Serial Interface For more information see Command Types in the SilverMax Command Reference How Programs Operate Programs execute commands sequentially starting at the first line and continuing until the end of the program is reached or until an Over ride command is issued from a Host controller Programs can perform conditional branching providing the ability to modify their behavior or even start a different program Program lines typically perform their command each servo cycle 120 usec If a command requires only one servo cycle to execute the next program line will execute on th
30. Status This move will stop is a Moving Error is detected Move 4000 counts ramp time 99 96 mSec total time 999 96 mSec Stop when Moving Error is HIGH TRUE If it was a jam this gets rid of the position error Target to Position Wait for 200 mSec Continue the DO loop if the WHILE condition is met Jump to DO If No Motion Error End Program Revision 3 22 Using Digital I O for Flow Control The JUMP PROGRAM CALL and PROGRAM RETURN commands are designed to use the Internal Status Word and Digital I O for conditional processing Digital I O provides an external method for controlling program execution Using all seven of the I O inputs it is possible to set up many different combinations for conditional control This enables complex system control by simply using Switches to setup input conditions SilverMax User Manual 72 Revision 3 22 Downloading Programs Without QuickControl Downloading a program into a SilverMax allows the execution of complex operations without external input or control Although using QuickControl to download programs requires simple press a button the actual process is a little more complicated The following information is intended to be used by those developers wanting to download programs without using QuickControl i e Use a PC to download a program from a custom C program Program downloading requires a procedure that loads the series of commands into the Program Buffer for
31. These inputs are tied to an internal Analog to Digital Converter ADC that converts the analog signals to numeric values that can be used by the SilverMax DSP controller The ADC is a 10 Bit version which mean that the full range input provides a number from 0 to 1023 The inputs can accept a voltage range of 0 to 5 volts Doing a little math this means that 1 ADC count represents 0 00488 volts 5 millivolts Internally the SilverMax scales the number so that a maximum count of 1023 is converted to 32767 15 Bits Analog Read Methods There are two methods for reading in analog information One method is to do a single read using the Analog Read Input command This command does a single reading of a selected analog input and places the value in a selected Data Register The second method is to do continuous readings of a selected analog channel using the Analog Continuous Read command This command puts SilverMax into a continuous read cycle that takes an analog reading every servo cycle 120 usec When in analog continuous read the analog value is place in the selected Data Register after each reading every 120 usec This provides continuous update of the analog signal that allows for better tracking Connecting Analog Inputs Analog inputs can be use in two different ways Single channel or Differential Channel The method used depends on the system requirements Single Channel Input is the
32. This type of motor provides for the use of a special anti hunting mode in which the motor windings are driven to hold the motor at the desired position without hunting Position Feedback The Position Feedback furnishes the control system with precise information about the motor position and velocity The Position Feedback can resolve position information of 4000 8000 and 16000 on some models counts per revolution The position feedback also provides an index pulse for each revolution of the motor SilverMax User Manual 34 Revision 3 22 SILVERMAX MOTION COMMANDS SilverMax can operate using different motion commands that provide options to meet a variety of motion control needs SilverMax can be controlled internally or externally depending on the system requirements and can operate in different modes depending on the type of motion needed Internal Control Standard Motion Trapezoidal Velocity Mode Profile Move Any Shape Internal Control Uses Trajectory Generator Uses the SilverMax internal calculation machine to perform the motion External Control Step amp Direction Mode Analog Input Mode Velocity amp Position External Control Uses External Controller Uses an External Controller or signal source for motion control SilverMax User Manual 35 Revision 3 22 Standard Motion amp Profile Move Commands Internal Trajectory Control Built into SilverMax is a full featured trajectory contro
33. Uncontrolled Shutdown ii ede Aedes A ee eile ee i eee 81 Controlled Show oo acia A el ed A de ee 82 Kill Motor Conditions ecien ad adan 83 Kill Motor Condition Edit screen from QuickControl cococcccconncccononacocannnonacnnonorc cnn arc cnn rca 83 Kill Motor Recovery Program Uncontrolled Shutdown oooonooccccnnnncccononocccino nono canonorcc cnn nc cnn rc 85 Kill Motor Recovery Program Controlled Shutdown ooococccnnncccccnonocccinnnonocano nono cano noc cc rra cnn rar rncnnnnnn 86 Multi Tasking Operation ooo es 87 The Primary Benefit of Multi Tasking nc n cnn non r canon nnn rr rra rra rra 87 Other Benefits Mego 1 od 87 Intelligent Motor but ewwft Aessen ee EE E 87 Analog Input Modes Velocity Position and Torque ccccessesceseseeeeseseeeeeeeeeeeseeeeneeseneesneeseseenenenseenaees 90 Analog Input RESOlUtION het depen ete ease bak tee eebe ee EE ee deeg ia 90 Analog Read Meos esera E EEA AE AEE AEE dEe ERR gea dee 90 Connecting Analog MEN 90 Analog Input Mode Example Using a Potentiometer A 91 Input Mode Description ccccceceeecceececeeeee cece eeeeceeeeeeeseaanaeceeeeeeeecansaeaeeeeeeeeesacneaeeeeeseseseeaaeeeeeeeseeeees 93 Input Mode Data Processing Diagram ooononccccnnocccccononnccccnnoncnnnnnoncncnnnoncnn nano nc cn nano nn cnn nan nn cr EEE EAA FERA ERKEERE AE 94 CalculationS cioiniiin iaa ii ii Eaa 95 Math Operations cee iniae a ga 95 Bitwise Opera a agree ele 95 Data Register Operations iii 96 S
34. address and is the start of a packet At this point the SilverMax processes the Address as explained in the 8 Bit ASCII protocol section Length The second byte is the Length The Length is defined as number of bytes from the Command Code up to but not including the Checksum This is limited to the range of 0 31 so only the lower 5 bits may be non zero 119 Revision 3 22 Command Code The third byte is the Command Code It indicates the desired function The Command Codes can be obtained from the SilverMax Command Reference Parameters Following the Command Code are any Parameters associated with the Command The SilverMax knows the total count of data from the Length character The number of data characters is also checked with the command type for consistency 16 Bit words are sent one byte at a time upper byte first 32 Bit Long words are sent a byte at a time upper byte first Checksum The final byte of the packet is the Checksum This is used to verify that the rest of the packet arrived intact The Checksum is the 2 s complement 1 s complement 1 of the sum of the rest of the previous bytes In other words add up all bytes from the Address through the final parameter and take the 2 s complement Example To calculate the following Read Register RRG command Address 16 0x10 ignore 9 bit Length 03 0x03 Command RRG Command Code 12 0x0C Data Register 1 0x0001 Add up all the bytes al
35. any time to switch to a different channel or redirect the data to a different Data Register SilverMax User Manual 61 Revision 3 22 Reading and Calibrating the V Analog Input The V SilverMax Power Supply input can be read using the Single Read or the Continuous Read command In the example shown a single reading of the input is taken and placed in the accumulator Reg 10 A single reading of the voltage calibration factor is also taken and placed in Data Register 11 The accumulator is divided by Register 11 to achieve a calibrated voltage value This is stored in Data Register 11 for future use Voltage Calibration equation RV Raw V voltage reading CF V calibration factor V RV CF Reading and Calibrating the Temperature Analog Input The SilverMax Internal Temperature input can be read using the Single Read or the Continuous Read command In the example shown a single reading of the input is taken and placed in the accumulator Reg 10 A temperature offset is placed in Data Register 11 and then subtracted from the accumulator The accumulator is divided by a cal factor placed in Register 11 Finally an offset value is placed in Register 11 and subtracted from the accumulator The result is stored in Data Register 11 for future use Temperature calibration equation RT Raw Temperature reading 9011 0 offset 147 Counts to Degrees C factor 3 Temperature offset Temp in C RT 9011
36. are used to output Step and Direction from the motor Using the Modulo commands the output can be scaled down 1 to 256 from the Internal Encoder or from an External Encoder When the output is Step amp Direction or Step Up amp Step Down the step pulse rate is always one half the Encoder Count rate with a modulo of 1 The Step and Direction outputs are found on I O lines 6 amp 7 Step amp Direction Output provides a 50 duty cycle Pulse for the Step Pulse output This gives a minimum pulse width of 3 75 micro seconds at the maximum speed of 4000 RPM The SilverMax Internal Encoder puts out 4000 counts per revolution With a modulo of 1 the maximum pulse count is 2000 pulses per revolution The Direction signal changes state depending on the direction that the Encoder is moving The Direction signal can change only on the falling edge of the Step pulse Count 1 Count 2 Count 3 Count 4 Direction Change Phase A Internal Encoder Phase B Step Pulse Step 1 Step 2 Step amp Direction Output Direction Signal Direction Signal Changes Only on Step Pulse Falling Edge Step amp Direction Output mode Step Pulse changes state with each edge of Phase A or Phase B This causes the Step rate to be one half the count rate 2 Counts 1 Step Count 1 Count 2 Count 3 Count 4 Phase A Internal Encoder Phase B Step Up Step Up amp Dn Output
37. be used in the application manually set these commands to the application s voltage These commands can also be edited from the SilverMax Motor Voltage field of the SilverMax Initialization Wizard s Option screen Servo Tuning LC Filter Constants CTC Control Constants SERVO Filter Constants The SilverMax PVIA servo control loop is set up with yea ee default parameters which will allow the motor to operate a Se under most conditions We have found that the factory Control Constants values work well over 80 of the time If not these a values can be modified using QuickControl to establish Ge Ae Offset Constant the desired operational control see Tuning SilverMax for details GOC Gravity Offset default 0 Gravity offset is a constant torque injected after the servo loop A none zero value will compensate for gravity on vertical loads See Command Reference for details SilverMax User Manual 27 Revision 3 22 Motion This section contains parameters affecting general SilverMax motion They are all editable from both the SilverMax Initialization Wizard or from the program file directly i e double click on the command DIR Direction TQL Torque Limits AHC Anti Hunt Constants AHD Anti Hunt Delay SCF S Curve Factor For details on these commands see the Command Reference Motor Encoder Alignment Routine Before the SilverMax can be put into closed loop mode an alignment between the motor rotor an
38. best fit your system design Use these guidelines or consult the factory for more information Use 8 Bit ASCII if Use 9 Bit Binary if Highly coordinated moves are not e You need deterministic communications required e You require highly coordinated motions You want an easy to use protocol You want to do minimal programming You are using a PLC e You have strong programming skills e You need reliable communications ney Features of 8 bit ASCII Uses Standard ASCII characters Works with all types of serial communications ports Typically no special software driver is required Human readable data Works with terminal programs Key Features of 9 Bit Binary Consistent Data Length Typically higher data transmission rate Error Checking Data length and Checksum Compact Binary data Deterministic Transmission time consistent Works well with highly coordinated multi axis moves Requires ability to Set Clear Parity Bit on any single byte SilverMax User Manual 114 Revision 3 22 8 BiT ASCII COMMUNICATIONS An Easy to use 8 Bit ASCII Protocol for SilverMax The following section describes the 8 Bit ASCII protocol that is used for communications to the SilverMax This protocol defines the Command Packet that is used to send command messages to the SilverMax and the Response Packet with which the SilverMax responds The 8 bit ASCII protocol requires only the Address Command Code and Parameters to be sent it does NOT include a Che
39. bit set e The second byte is the Length with a value of zero plus the 8th bit set to indicate an ACK 128 0x80 e The third byte is the Checksum Example ACK response from SilverMax 16 shown in hex 10 80 70 SilverMax User Manual 122 Revision 3 22 Returned Data Response The Returned Data packet is sent when a properly formatted Command for data is received by a SilverMax Its format is as follows 9 Bit Binary ACK Response Packet data transmission order Address Length Command Code Data fields Checksum 1 Byte 9th bit set 1 Bytes 1 Byte 2 or 4 Bytes each 1 Byte e The first byte the Address with the 9th bit set e The second byte is the Length which is the number of bytes starting at the Command Code and including all the data fields e The third byte is the Command Code that is being responded to e The requested Data Fields are next 16 Bit words are sent one byte at a time upper byte first 32 Bit Long words are sent a byte at a time upper byte first e The Final byte is the Checksum Example Send a Read Register RRG command and receive the following response packet Command RRG Command Code 12 Address 16 Data Register 1 Response Packet with field data shown in Hex Adr Len Cmd Value of Register 1 Checksum 10 03 UC O0000FAO 30 Byte stream with data shown in Hex
40. both the AND and the OR inputs are disabled motions cannot be stopped using inputs 3 Ifthe AND inputs are used both the AND condition and the OR condition must be TRUE to stop the motion When rule number 3 is used the inputs are logically anded to each other and then tested for TRUE If the input conditions are met the motor shaft position when the input condition became TRUE is stored to the Sensor Found Data Register and the Sensor Found Bit is set in the Internal Status Word The move underway is set to decelerate to zero using the acceleration parameters that began the motion Recording Sensor Found Position If the OR inputs are disabled and the AND inputs are enabled only the motor position will be recorded When the AND input conditions become TRUE the current motor position is stored to the Sensor Found Data Register and the motion is allowed to continue T he Sensor Found status bit in the Internal Status Word is also set NOTE Stop Enable Word and the Stop State Word processing is the same for all Motion Profile Commands SilverMax User Manual 46 Revision 3 22 First Check Used to toggle the starting direction of Motor The upper nibble of the Input Enable Word and Input State word parameters are used to determine the initial direction of a move based on the selected states of the enabled inputs If any of the enabled input conditions are TRUE then the motor will go the opposite direction otherwise indicat
41. category The limiting factor is not the control loop but the motor s max torque At some point the SilverMax will just not have enough torque to move the mass in a reasonable time frame For higher inertia loads the load inertia will dominate the response and therefore the velocity estimator should have a lower bandwidth low Fv2 for fast variations seen at the motor are not a good estimate of what the load is doing Reducing Fv2 reduces the high frequency gain of the system to suppress the high frequency resonance modes allowing Kv2 to be increased to improve the low frequency damping of the system Torque Saturation Use QuickControl s Control Panel to chart Torque while doing both fast and hard moves as well as very slow moves If the fast moves are causing the torque to saturate reduce the acceleration of the move command or your tuning effort may be frustrated Trying to stop faster than the torque of the motor allows will cause overshoot SilverMax cannot stop fast enough and tuning is not going to increase the motor torque Anti Hunt Settings Experiment with the anti hunt values to optimize your operation The typical 10 4 values are a good start If normal operation involves overcoming the motor torque by hand or by a load such as would happen with a gripper or going against a hard stop then setting the second term to a negative value of the same magnitude i e 4 makes the feeling of the transition into and out of anti
42. conditions Normally all sensors are ORed with each Input 1 enabled Input 1 State other OR Conditions E OA If the Final conditions are met the motor will STOP SilverMax User Manual 48 Revision 3 22 How to Create the Input Values Native SilverMax only The input values that are used as parameters in a motion command take a little work to create Inside SilverMax the values are used in Binary form In this case both values are used as a 16 bit binary word Each of the bits is evaluated individually to determine how the inputs will be used to control a motion The table above shows the meaning of each bit in the word The user must first decide which bits need to be set and to what value Setting a bit to 1 either Enables a function or sets the desired State value to a logic high 5 volts on the input Setting a bit to 0 disables a function or sets the desired State value to logic low 0 volts on the input The table below shows settings for the State word that will toggle the OR states and the move direction if Input 1 is logic high 1 at the beginning of a motion It also shows the state value of the OR input 1 logic high 1 that would be used to stop the motion Toggle OR Direction Toggle Preliminary Inputs AND Inputs State OR Inputs State 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Pt jojoj 1lfofo o_offofojo_offofojo 1 Binary Word 1001000000000001 After the tab
43. conditions for any move can be edited by pressing the Advanced button on the move For example to edit the following command press Advanced Edit MAT Move Absolute Time Based Press the Advanced tab to edit the Advanced stop conditions The above Change Direction and Stop on Input example above would be as follows Edit Stop Conditions SilverMax User Manual 53 Revision 3 22 USING THE DIGITAL I O SilverMax has seven fully programmable digital I O lines Each line is software configurable to be a digital input a digital output or dedicated to a special function The configuration can be done on the fly Digital outputs can be configured for tri state mode allowing the lines to be used as both an output and an input at the same time In addition to the digital I O SilverMax accepts four analog inputs The four analog inputs share four digital I O lines and will accept a voltage range 0 to 5 volts Analog inputs can be used for control of the motor s position velocity torque or other software programmable operations Using a variety of dedicated modes the Digital I O lines can accept external encoder input for electronic gearing or camming operations Inputs can be Step and Direction A B quadrature or Step up down An external encoder input is provided for dual control loops that enable position control of external mechanisms using a second encoder The E series can also output Step and Direction A B
44. direction and a slow move in the other and will help insure your hard stops are not hit NOTE Make sure the move is within the SilverMax s torque limits One of biggest problems with tuning a high inertial mismatch system is the undersized motor The SilverMax is trying SilverMax User Manual 109 Revision 3 22 to move a very large load 100x times the rotor inertia Keep an eye on the motor s torque to make sure it does not max out 2 Disable Anti Hunt and Drag Mode Turn off the Anti hunt feature and any Error Limit Drag Mode settings This will allow the user to see the true response of control system enable them after tuning This is done in Tools gt SilverMax Initialization Wizard The modes are changed in the Anti Hunt Constants AHC and Error Limits ERL commands AHC can be accessed by way of the Initialization Parameter Browser s Motion branch ERL is accessed by way of the Error Limits branch SilyerM ax Initialization Wizard CO Communications H Motor H Servo Tuning H Motion o Error Limits Mer Edit AHC Ant Hunt Constant Edit ERL Error Limits 3 Start With Defaults Start with the default tuning parameters for your motor 4 Ki 0 Start tuning with the integrator term set to zero Ki 0 Once a stable system with adequate phase margins has been established then the integrator value can be turned up SilverMax User Manual 110 Revisio
45. execution or for storage into the internal Non Volatile Memory Key Notes SilverMax can only execute a program pre loaded into its 200 word Program Buffer SilverMax has internal Non Volatile Memory that can store 3839 words of information Commands loaded into the Program Buffer can be stored into Non Volatile Memory A program can be loaded into the Program Buffer in two ways 1 Through the Serial Interface 2 By loading a previously stored program from Non Volatile Memory Only Program Type commands can be downloaded into the Program Buffer Certain Program Type commands should only be executed from within the Program Buffer For Example the JUMP and WAIT DELAY commands Download Process There are four steps to the download process that must be followed in the correct order to complete properly Step 1 Clear out the Program Buffer Use the Clear Program CLP command to clear the contents of the Program Buffer Step 2 Put SilverMax in the download mode Use the Start Download SDL command to set the SilverMax into download mode In this mode Program Type commands are stored into the Program Buffer rather then being executed most Program Type commands can be executed in an immediate mode All Program Type commands downloaded after the Start Download SDL command will be downloaded into the Program Buffer until the download mode is terminated The download mode is terminated by one of the following Run Program RUN Store
46. input pulses The input can be multiplied by up to 32 times or divided by up to 1024 Position Input Mode When the Position Input Mode PIM command is used SilverMax will take Target desired position information from a predefined Data Register and track the value contained in it This is done every servo cycle 120 usec providing an 8K Hz update rate The Target Register can be loaded from many sources including the Serial Interface or the Analog Inputs Using the Serial Interface a Host controller can stream Target information to the SilverMax using the Write Register Immediate Type WRI command The Serial Interface can run ata BAUD rate of up to 230K bits per second which allows sending new data at approximately 500 times per second This assumes continuous data feed to the Serial Interface Using the Analog Inputs an Analog signal can be used to send the Target information to the predefined Data Register The Analog Input is converted using an Analog to Digital Converter ADC to a 10 Bit digital number The number is filtered to eliminate noise then scaled to a 16 Bit value and placed in the Data Register This is done at the 8K Hz update rate of the servo system See ANALOG CONTINUOUS READ command for more information Both Input sources are put through a data processing algorithm to allow Offsetting Limiting and Scaling of the data source See Using Input Modes in the SilverMax Command Reference for more informati
47. is stored after the Length amp Checksum as a NULL word This prevents SilverMax from trying to execute Data as a program Program Storage Memory Usage Example Data Storage Memory Usage Example Starting at Address 150 Starting at Address 170 of Memory Stored Elements of Memory Stored Elements Words Address Words Address 1 150 Length amp Checksum 1 170 Length amp Checksum 9 151 Command amp Parameters 1 171 NULL WORD 0 Move Relative Velocity z Based MRV 2 173 Data Register 12 1 160 Command amp Parameters 2 175 Data Register 13 Zero Target amp Position 2 177 Data Register 14 5 ZTP TEF 2 179 Data Register 15 omman arameters A Move Absolute Velocity 2 169 Data Register 210 Based MAV 2 183 Data Register 17 20 170 Next 2 185 Data Register 18 Words available 16 187 Next Total Address Words available Total Address SilverMax User Manual 68 Revision 3 22 Creating Programs Overview SilverMax programs are constructed from a series of Program Type commands Programs enable SilverMax to execute complex operations independent of any external controller Programs can consist of Initialization Motion Program Flow I O Data Register and Miscellaneous commands Programs can be created and edited using QuickControl a Windows software application designed as support tool for the SilverMax motor line QuickControl is available from
48. loop operation The second parameter is the maximum error allowed to enter the Anti Hunt mode See the SilverMax Command Reference for details S Curve Factor SCF Using this command the shape of motion profile acceleration can be set from Linear to full S curve All motion profile commands use the current setting This command can be set at any time except for during a motion allowing each motion profile to be tailored for the best shape See the SilverMax Command Reference for details Torque Limits TQL This command specifies the torque limits for the different operating modes of SilverMax The two modes are Open Loop and Closed Loop with each mode having a Moving or Holding condition being active The four parameters for the SilverMax torque limits are as follows Closed Loop Holding Closed Loop Moving Open Loop Holding and Open Loop Moving SilverMax operates in Moving mode whenever the trajectory velocity is non zero It will continue to use the Moving torque limits until the Delay to Holding time expires after the last non zero SilverMax User Manual 99 Revision 3 22 trajectory velocity is calculated This allows a higher Moving torque limit to persist up to seven seconds after the last motion or motion step of the Step and Direction command Following this period which power up defaults to zero the Holding torque levels are used The Open Loop Holding value is used by the Anti Hunt mode for the current level that will
49. motion in process by shutting down the motor The trajectory generator can be fed a step and direction input to permit interfacing a SilverMax with an external indexer Servo Control Loop The Servo Control loop implements a Patented Control Algorithm that includes filtering on the Velocity amp Acceleration terms This allows Lead Lag compensation to be employed for higher performance loops Also included are a Velocity feed forward term and an additional Acceleration Feed Forward term for active damping term The control algorithm provides gain terms for each of the control parameters and filter time constants for velocity and acceleration feedback filters SilverMax User Manual 33 Revision 3 22 Motor Driver Commutation The motor driver is matched to the selected motor and power supply voltage by using motor setup parameters that are pre set at the factory This means that there is usually no work required by the user to prepare the motor for operation The parameters have been optimized to produce maximum performance under a wide range of conditions Motor commutation is accomplished using the internal encoder for motor phase information Sine and Cosine signals are used to drive the two phases of the motor thus producing a quiet low cogging motor output Brushless Motor The Brushless Motor is a high pole count Permanent Magnet AC Synchronous Motor The magnetic gearing of a high pole count motor yields high torque in a small package
50. move back into Servo Control Mode and again actively control the rotor position Two commands can be used to put the SilverMax into Anti Hunt mode They are Anti Hunt Constants AHC and Anti Hunt Mode AHM See the SilverMax Command Reference for details These commands use the following two parameters Parameter 1 Open to Closed Error establishes the point at which SilverMax will EXIT anti hunt operation and return to full Closed Loop operation Servo Control If for example this parameter was set to 10 when the position error absolute value of Target position Actual position exceeded 10 counts SilverMax would transition from Open Loop to Closed Loop operation Parameter 2 Closed to Open Error establishes the point at which the SilverMax will ENTER anti hunt operation and operate in an Open Loop Locked Rotor fashion If for example this parameter was set to 4 when the position error absolute value of Target position Actual position was less than 4 counts SilverMax would transition from Closed Loop to Open Loop operation The motor torque required to move to position must be less than the Torque Limit setting before Anti Hunt will begin An additional feature with this parameter is that setting it to a negative value will create a dead band area where no matter what Anti Hunt will begin when the position error is less than the parameter 2 setting See Anti Hunt Process below for more d
51. parameters Other Benefits Include Buffer Motion Commands When executing a Motion command a second Motion command when sent using the serial interface is buffered and will be executed when the previous command is complete Intelligent Motor Shutdown Kill Motor conditions provide programmed hard shutdown protection Specific applications require controlled conditions for shutdown SilverMax can be preprogrammed to shutdown a motion gracefully without destroying vital components Execute Immediate Type Commands During specific motions or Programs Immediate Commands can be executed with no time delay by sending to the serial communication buffer The current program will branch and perform the immediate command and then branch back to the next sequential command of its current program Multi Tasking enables SilverMax to perform six 6 different tasks each SilverMax Time Slice 120 microseconds The SilverMax Time Slice is an interrupt driven time period of 120 microseconds that is used to keep all motor activity on a very consistent time schedule Each of the six tasks is operated on during this time with the exception of the Serial communications with is operated on 3 times each slice Task 1 Serial Communications The Serial Communications task runs 3 times every 40 microseconds each Time Slice During each 40 microsecond period the Serial Communications can receive or transmit a serial character This enables Sil
52. quadrature or Step up down from its internal encoder Below is a table showing the available Digital Input and Output functions SilverMax E Series I O Configuration Table Output Functions es 11071 111 Conditional Motion Program h Modulo Done Stop On Flow i Output Output Status Input x x x A se reo x ee Indicates I O that can be configured in one of three ways 1 A 8 B Quadrature 2 Step Up amp Step Down 3 Step amp Direction NOTES Alternate I O selections are indicated with alt Alternate I O is selected using configuration commands UO 4 5 6 or 7 must be configured for input when using analog signals on the input pins SilverMax User Manual 54 Revision 3 22 Input amp Output Functions Inputs Conditional Motion Program Flow Kill Motor Step amp Direction Analog Inputs External Encoder Outputs Output Set Clear VO 1 General Output Encoder Output Modulo Output Done Status Description Used to cause a motion to ramp down and stop May also be used for changing the move direction All inputs can be used in Standard mode by using a negative number for the I O line selections All inputs can be used for conditional branching The inputs can be decoded such that many conditional branches can be taken using only a few inputs For example three inputs can be decoded to command SilverMax to run 1 of 7 programs Inputs
53. required 2 Restart the SilverMax by executing the Initialization Program 3 Execute a User Defined Program Even though all are allowed option 3 is the one that should be used SilverMax User Manual Enable Multi Tasking Kill Enable Drivers Shutdown Condition is met Leave Motor Drivers Enabled Process User Defined Recovery Program 82 Prior to motor operation or added to a startup program these two commands enable SilverMax to continue operation while processing a Kill Motor Condition After the shutdown conditions are met the SilverMax will continue any motion in process and leave the drivers enabled If a Program is executing it will End and the User Defined Recovery Program will be executed Option 3 is used in the Kill Motor Recovery command Revision 3 22 Kill Motor Conditions Kill Motor Condition Edit screen from QuickControl Edit Conditions xl 15 Different conditions are d T IA available that can be used to Select which conditions wil Kil the motor Press the buttons to OK Shutdown the motor Each of change state or here for these conditions can be more help Cancel independently enabled When enabled the State TRUE or FALSE that will trigger the Kill Index Found Disable Motion Error From Error Limit Disable condition is also set Last Calculation Was Zero Disable Holding Error Fro
54. result Incrementing adds a 1 to the a Data Register This is often used for creating counters Counters can be used in FOR NEXT loops Decrementing subtracts a 1 from the Data Register This is also used for counters that count down Absolute Value finds the positive value of the Data Register This is very useful when testing for the magnitude of a number Modulo finds the remainder of the Data Register after being divided by the 16 Bit operand For example 17 modulo 16 1 Bitwise Operations These operations perform Bitwise processing on the Data Registers This is designed for detecting bit patterns in Data Registers AND ing ANDs each bit of the Data Register to each bit of the Accumulator This is done on all 32 Bits Both bits AND ed must be a 1 for the result to be 1 OR ing ORs each bit of the Data Register to each bit of the Accumulator This is done on all 32 Bits Any bit OR ed that is a 1 will result in a 1 SilverMax User Manual 95 Revision 3 22 XOR ing XORs each bit of the Data Register to each bit of the Accumulator This is done on all 32 Bits If both bits XOR ed are 1 the result will be O If one of the Bits is a 1 and the other is a 0 the result will be a 1 If both Bits are 0 the result is 0 Shift Left Right Shift the bits in the Data Register left or right one position Data Register Operations These ope
55. simplest way to connect to SilverMax the example below shows a single channel input connection to a potentiometer In the single channel approach the analog signal is referenced to the SilverMax logic ground Electrical noise can be problem therefore an input capacitor may be required Normally an input capacitor should be used if the source impedance is high Differential Channel Input has an added advantage of giving noise rejection of low frequency electrical signals Using differential channel input will also double the resolution of the ADC input from 10 Bit to 11 Bit The value read by the Analog input commands will range for 32767 to 32767 0 to 5 volts SilverMax User Manual 90 Revision 3 22 Analog Input Mode Example Power Grourd Using a Potentiometer This example shows connecting a 5K ohm Analog Potentiometer potentiometer to input 1 The 5 volt output Linear Taper gt from the SilverMax is used for the voltage ogc Ground 8 reference This provides a 0 to 5 volt signal to Ns 3 the Analog Input HA IO 4 Analog I O 4 4 as Analog 2 I O 5 0 Example Program Description EE 5 Velocity Input Mode Data is continuously read in from Analog SilverMex 17 amp 23 Frame Input 1 The Raw ADC value is placed deer DES into Data Register 12 every 120usec Analog Input Mode Velocity qcp Process Example Assume 12 24000 DOE to 0 1uF Step 1 13 is subtracted from 12 24000 1
56. system with the motion trajectory controller motor driver electronics position encoder and motor all contained in one unit It requires less space than conventional controllers and simplifies the integration of your system The incorporated design requires just power and communications to be up and running The work of integrating a full vector controlled servo system has already been done for you Smooth quiet operation with high performance motion control is ready to go SilverMax connects to a standard PC using RS 232 or RS 485 and an 8 Bit ASCII or 9 bit Binary protocol It is designed for master slave communications and can be connected with other devices such as sensors and data collectors from a single communications port SilverMax provides closed loop servo control using 32 bit calculations High resolution position control delivers precise executions every time It produces smooth motion profiles with minimal noise and vibration SilverMax can store blocks of motion profiles for execution with a single command The available QuickControl software package makes rapid application development easy And it contains a fully featured command set that provides SilverMax set up and complex motion control Optional C and Basic communications examples are available for integration into your source code Warnings SilverMax shall not be used for Life Support applications without explicit written permission from QuickSilver Controls Inc Si
57. that can use I O inputs for performing Motion and program flow control Host amp Standalone Mode Combined There are times where both modes are required in the system design This may be when a PLC is used for system control A PLC typically is not the best at motion control when very critical timing or motion coordination is being implemented In these cases SilverMax can perform the complex motion programs while the PLC is monitoring the process and initiating the desired programs An example of this is having a homing program and the motion program stored in one or more SilverMax then using the PLC to initiate these programs at the appropriate time The PLC can initiate the programs using the I O or the Serial Interface Shown below is block diagram of a PLC using the Serial Interface to initiate programs stored in SilverMax This is a Multi drop serial communications setup that can be accomplished using RS 485 or RS 232 unique to SilverMax Serial Interface PLC as a Host controller Store Homing and Motion programs for SilverMax 1 here SilverMax 1 Put Main Control Program here Run SilverMax Programs by issuing the LOAD amp RUN PROGRAM command using the Serial Interface Store Homing and Motion programs for SilverMax 2 here SilverMax 2 In the above example the PLC can perform the Polling Routine to check status
58. the number of counts or distance required to move to the specified position If the position given in the command is the same as the current position SilverMax will not move since it is already at the specified position Using this command helps prevent over travel when a command is sent twice by mistake This command is also useful in setting up Registered positions that can be referenced from the Dedicated or Data Registers Move Absolute commands come in following types Move Absolute Velocity Based MAV Three parameters are entered Position Acceleration amp Velocity This is the basic command type for absolute moves Register Move Absolute Velocity Based RAV Three parameters are entered Data Register Acceleration amp Velocity The Data Register parameter is the Data Register that is used to fill in the position value The value entered in the Data Register remains in counts The other parameters are the same as the MAV command This command allows the user to modify the position value without having to change the command when used as part of a program Extended Register Move Absolute Velocity Based XAV One parameter is entered the Starting Data Register Only the Position register location is sent as a parameter the Acceleration amp Velocity must be stored in two successive Data Registers Move Absolute Time Based MAT Three parameters are entered Position Acceleration Time amp Total Time This command
59. use internal Conditional Jumps at a low level to User Data Register 11 is a data value to be tested Copying build IF commands 2 Accumulator 10 User 11 Jump to ELSE If Last Calc was not Positive Move Clockwise Move 4000 counts ramp time 99 96 mSec total time 999 96 mSec Jump to END IF If Last Cale was not Negative Move Counter Clockwise Move 4000 counts ramp time 99 96 mSec total time 999 96 mSec END IF End Program SilverMax User Manual 70 Revision 3 22 For Next The For Next loop again uses at its core the JUMP command to loop through the number of desired iterations In addition a Data Register is used for the loop counter The CALCULATION command has a Decrement option that can be used to subtract 1 from any Data Register While Loop The While loop is typically a conditional loop that can exit when entering the loop or at any pass If the conditions for exiting the loop are TRUE when entering the While loop will not be executed In this example two different Jump commands are used The first jump is a special version that looks for the ANDed condition of selected digital Inputs The second jump at the end of the loop acts like a GOTO by doing an unconditional jump back to the beginning Do While The Do While loop works a little different from the While by allowing the loop to execute at least one time before exiting This loop requi
60. 000 DO Phase A yey Internal Encoder PhaseB A Output A amp B Quadrature Output i B Output A amp B Quadrature Output mode A amp B outputs change state with the edge of Phase A or Phase B This causes the Step rate to be one to one with the count rate 1 Count 1 Step Special UO There are a couple of I O functions that serve special purposes Encoder Output A amp B Quatrature Provides a typical Encoder style output When used with a modulo of 1 it is identical to the Internal Encoder signals The minimum pulse width is 7 5 micro seconds at the maximum speed of 4000 RPM The SilverMax Internal Encoder puts out 4000 counts per revolution With a modulo of 1 the maximum pulse count is 1000 pulses per revolution Using a decoding circuit the A amp B Quatrature signals can be converted to 4000 pulses per revolution The Internal Encoder can be viewed directly by issuing the ENABLE ENCODER MONITOR command In this mode SilverMax simply passes through the Internal Encoder A B and Index signals Done Status The Done Status is a special output function that indicates with an output High 1 when the motor is executing a motion or has a Position Error status When a motion profile is executing the Trajectory Generator calculates the move profile The calculation is done on a cycle by cycle basis until the entire motion is complete When a mo
61. 22 Calculations Calculations may be one of the subtlest commands in SilverMax This command has many different operations that range from integer math to moving data This command is found in the Program FLOW section of the command set because when a Calculation operation takes place Calculation Flags are set Calculation flags Last Result Was Positive Last Result Was Negative and Last Result Was Zero can be used by the JUMP command to control program flow Calculations are done on Data Registers which are all designed for 32 Bit storage Data Registers are used as parameters in a number of SilverMax commands Some of the following operations are not available on older firmware revisions Contact your distributor for a firmware upgrade Math Operations All math operations are Integer Data Register 10 acts as an accumulator where results are placed after an operation Addition and Subtraction can be done on 32 Bit numbers with the result being 32 Bit SilverMax does not keep track of overflow and therefore data can be lost Signed Multiplication is done can be done on Signed 32 Bit operands with a Signed 32 Bit result The user is responsible for handling overflow conditions That is make sure the two 32 bit numbers product will not be larger than 2147483647 or data will be lost Unsigned Multiplication is done using on 32 Bit operands with a 32 Bit result Signed Division uses a 32 Bit dividend and a 16 Bit divisor with a 32 Bit
62. 2M5 1 DKMSA Velocity mode Target delta This cycle Encoder delta This cycle f 7 Summation Block x Gain Block L J Proportional Gain Position mode Limiter 16 bits ko e Unit Delay 25 lt X lt 25 1 7 P i Block e a Velocity mode 120 usec per tick Limiter Block l 4 Block Diagram Legend Revision 3 22 SilverMax Tuning Commands Primary Commands The following two commands set the primary tuning parameters Control Constants CTC This command sets the various SilverMax servo loop gain constants See the SilverMax Command Reference for details Proportional Kp Velocity 1 Feedback Kv1 Velocity 2 Feedback Kv2 Velocity Feedforward Kff Acceleration Feedback Ka Acceleration Feedforward Kaff Integrator Ki Filter Constants FLC Filter Constants selects the cutoff frequency for the velocity and acceleration filters See the SilverMax Command Reference for details Velocity 1 Feedback Filter Fv1 Velocity 2 Feedback Filter Fv2 Acceleration Feedback Filter Fa Associated Commands The following commands set parameters associated with tuning Anti Hunt Constants AHC Anti Hunt Constants set the thresholds used to determine if the position is sufficiently close to the target to allow the motor to go into and to stay in Anti hunt mode The first parameter is the maximum error in counts allowed in the Anti Hunt mode before the unit will revert to normal closed
63. 3 FF 02 B1 3B NAK codes defined below SilverMax User Manual 124 Revision 3 22 PROTOCOL DEFINITIONS SilverMax Negative Acknowledge NAK Codes The following are the strings for the above NAK error codes as they will appear in the NAK Response Packet Error Description Code Bad Command The device received a command command number it did not recognize If you are sure the ere number is a check the firmware revision to make sure the command was implemented A table of commands verses firmware revisions can be found at the end of the Command Reference Device Busy The Device is actively executing a previous command The new command cannot be executed at this time Some commands cannot be executed while SilverMax is executing a previous command See Commands for details 3 Reserved Reserved for back compatibility from pre E series units This response included the expected count which required a more sophisticated error response parsing code This error code was replaced with error code 5 which only indicates the error Reserved for back compatibility with pre E series units 5 Bad Format Command number and number of parameters is not consistent EE Full The device s Command Buffer is full Too many bytes were sent to the device for its available Command Buffer space RAM _ Address An address used in a command was out of range This includes trying to access a Data Register that does exist writing to a read o
64. 30 Revision 3 22 OVERVIEW The SilverMax Motion Control System integrates all of the traditional modules for motion control needed to provide rotary position and velocity control in one single mechanical package SilverMax Block Diagram Non Volatile Memory 8K Byte 32K Option Serial Communications RS 232 or RS 485 Program Buffer 200 Words Command Processor TI DSP 7 Digital I O amp 4 Analog inputs Servo High Pole Motor D Trajectory Control e ees Count Generator Loop Sine Cosine Brushless Motor SilverMax elements include Position Feedback 4K 16K Count Optical Encoder Serial Communications Command Processor Digital I O amp Analog Input Non Volatile Memory Trajectory Generator Servo Control Loop Motor Driver Commutation Brushless Motor Position Feedback All of these elements work together to form an easy to use system that requires only DC power for full operation SilverMax User Manual 31 Revision 3 22 Serial Communications The serial communications furnish SilverMax with an RS 485 multi drop or RS 232 communications capability at a selectable baud rate default 57 6K baud Two different communications protocols are available depending on the system design needs The serial communications are used to initialize the SilverMax in both network and stand alone operations SilverMax s companion product Quic
65. 6 and 7 The MODULO SET command uses l O 6 amp 7 for modulo output and will over write the I O bit usage even if the Inputs are being used General Output can conflict with any I O line used NOTE Before using Output Functions make sure the I O lines have been configured as Inputs using the CONFIGURE I O command or the appropriate CLEAR or DISABLE commands When using Modulo Output General Output is the only function that can conflict with the Modulo function Configure I O lines 6 or 7 to input before using the MODULE SET command Use MODULO CLEAR to configure I O back to input before General Output can be used When using Encoder Monitor Before ENABLE ENCODER MONITOR can be used I O lines 1 2 and 3 must be configured for Input If I O Line 1 is configured as an Output the ENABLE ENCODER MONITOR will simply Set I O line 1 High 1 and not enable Encoder viewing DISABLE ENCODER MONITOR will Clear I O Line 1 to low 0 This is a legacy from the original SilverMax design When using Done Bit I O Line 1 must be configured for Input before this function can be used Attempting an ENABLE ENCODER MONITOR or a CONFIGURE I O will cause a command failure Use the ENABLE DONE BIT and DISABLE DONE BIT to use this function SilverMax User Manual 63 Revision 3 22 OPERATING IN HOST AND STANDALONE MODE SilverMax can operate in two distinct modes that each meet different system design needs H
66. 6383 xxx Command Analog Input Mode Velocity Scale the analog input for 0 54 1000 to 1000 RPM Step 2 Remove deadband value 14 Beete sign ABS 6000 100 Zero Target and Position 5000 Continuously Read the Analog input into Reg 12 Continuously Read Analog Channel 1 Into User Input Source Data 12 Reg 13 Offset Offset the input to 1 2 full scale Middle of Potentiometer 0 RPM Step 3 Limit and Scale using 15 Because the result is less than 32767 it won t be limited Limit 32767 lt 5000 gt 32767 5000 Scale 6000 32767 0 1526 Write 16383 to User Input Offset 13 Reg 14 Deadband Add a small deadband so that Zero Velocity can occur Write 500 to User Input Dead Band 14 Reg 15 Max Input amp Scale Allow the full scale value Write 32767 to User Maximum ScalelLimit 15 Reg 16 Max Dutput Scale Make the full scale value 1000 RPM Write 536871000 to User Maximum Output Scale 16 Reg 17 Output Offset No caput offset write User Ge Offset 1 7 Reg 18 Rate Limit the Acceleration Write 100000 to User Output Rate of Change 18 Enter Velocity Input Mode Velocity Input Mode Stop when 1 0 1 is LOW FALSE Step 4 Scale for output by multiplying by 16 0 1526 x 4000 610 Step 5 Offset output by subtracting 17 610 0 610 The Result from Step 5 is used for the motor Target position Target 610 Step 6 Limit the Vel
67. ALED STEP amp DIRECTION SSD REGISTERED STEP amp DIRECTION RSD SELECT EXTERNAL ENCODER SEE ANALOG CONTINUOUS READ ACR ANALOG READ INPUT ARI ALL INPUT MODE COMMANDS SELECT EXTERNAL ENCODER SEE DUAL LOOP CONTROL DLC Associated Commands CONFIGURE I O CIO ENABLE ENCODER MONITOR EEM CONFIGURE I O CIO SET OUTPUT BIT SOB CLEAR OUTPUT BIT COB ENABLE ENCODER MONITOR EEM DISABLE ENCODER MONITOR DEM MODULO SET MDS MODULO CLEAR MDC MODULO TRIGGER MDT ENABLE DONE BIT EDB DISABLE DONE BIT DDB NOTE Some I O functions are not compatible SilverMax will indicate a command error in the Polling Status Word when incompatible modes are attempted See I O Conflicts below All I O is doubly protected with parallel MOV clamping followed by series over voltage limiting to protect the internal circuitry SilverMax User Manual 55 Revision 3 22 See CONFIGURE I O CIO SET OUTPUT BIT SOB amp CLEAR OUTPUT BIT COB commands Basic Digital Inputs amp Outputs The digital Inputs and Outputs on SilverMax are TTL level with no optical isolation TTL level signals are O to 5 volts with low current drive capability I O lines are over voltage and ESD protected to prevent failure from improper connections e All seven I O lines can be configured for Input or Output e When in Output configuration the I O lines can both Source and Sink 8 milliamps of current e I O lin
68. Into User Input Offset 13 92 Revision 3 22 Input Mode Description Input mode is designed to use Data Registers for processing Position Velocity or Torque information for the given modes This allows SilverMax to input data from an Analog Input or the Serial Interface for operating in the selected modes The Data Registers are used to perform processing on the input data so that the output will give the desired results If for example the input is an analog data source from a Joystick the processing can serve to calibrate the Joystick for the desired motion on the SilverMax This can be done for almost any kind of data source including data that is sent directly from the Serial Interface All Input Mode commands use the same dedicated Data Registers for data storage and manipulation When SilverMax is placed into one of the input modes Velocity Position or Torque 7 data registers starting at 12 are automatically assigned for use in the data processing The appropriate Data Registers must be initialized before the input modes will work properly This can be done in two different ways The Data Registers may be initialized using the Serial Interface by sending data directly to the registers using the Write Register Immediate type command This method requires that a Host controller be connected to the Serial Interface during initialization Another method is to use data that has been previously stored in the Non volatile memory Using t
69. Over Temperature must always be enabled so that the SilverMax can halt operation if it gets too hot The over temperature is actually a combination of the motor driver thermal sensor not settable and the internal electronics temperature sensor Settable using the Maximum Temperature Trip command Either of the two can cause this condition Internal Temperature can be read back using the Analog Read Input command Motion and Holding Errors Most Commonly used In any servo system the most common cause of motor shutdown is when the moving or holding position error exceeds a set limit Using the Error Limits command the amount of acceptable error can be set for both the Moving Error and the Holding Error When the error exceeds the limit these flags will be triggered Typically the Moving Error is set to a larger value because of the dynamic conditions encountered during a move One or both of these conditions can be used for shutdown it just depends on the needs of the system SilverMax User Manual 83 Revision 3 22 Halt Command was sent Use to re initialize the motor after a Halt The Halt command when sent from a Host system will cause the SilverMax to shutdown This leaves the SilverMax in a disabled state with no power applied to motor If this condition is enabled the SilverMax could process an error recovery routine or re initialize itself without Host intervention Sensor Found on Last Move Used for Hard Limit shutdown Al
70. P EE Ey AE E S L E ES Eh A sf SE Sr E ee Raa E A SS SE EE E E 7 SE SE EE SE Bae E SC Ges Eo Going back to our spring analogy by increasing Kp we have created a stiffer spring Although it is moving to target in a timely manner it is also bouncing around a lot or ringing This is the SilverMax User Manual 102 Revision 3 22 same thing as a car without shocks The springs are still working fine but every time you hit a bump the car bounces a few times To eliminate the bounce we need some shocks In PVIA the Velocity Feedbacks Kv1 and Kv2 are the shocks Typically Kp is increased to get the desired stiffness and response reduce Position Error If Kp gets too high the SilverMax will start vibrating as it overcompensates for small errors Velocity Feedback Kv1 amp Kv2 Velocity values are derived from the position information that is read every servo cycle 120 usec Velocity values are calculated from the change in position that at each servo cycle The velocity data is filtered by two cascaded low pass filters that provide at their output the filtered Velocity 1 and Velocity 2 values Both Velocity values have a gain setting that is used to adjust the amount of velocity feedback that is required Velocity is a negative feedback value that is used to Damp the servo control loop Setting the gain values at 0 prevents any velocity feedback from b
71. S ES E E E E Si S S 8 ce Sch i SS E oe S E SC E E g S E SE S EE E SE SE i EE Se Soe E y SE E S SE 4 E Bes See E SE SE z 2 GE D Kp 10 Kv2 3 Kvff 3 Notice how well the velocity is now tracking To further improve the system response reduce Position Error Kp can be increased With our dampener in place Kv2 increasing Kp should not cause the system to ring Notice how well the system behaves with Kp 40 IES welt Y Mayf5200 Sample ms 200 COKE Select Channels Cancel JS E della SE EE E SE es Dene S GE EE e S EE SE E EE EE SE SS E E E E E eg RE E SE E SE E S Se D EE SE SS a pan EE SE EE See See SE EH EE SS SE DEE SS SE a Se GE SS Ge 3 7 SE SE Ze S E E EE O E gon SE Gs SS EE ZE DE SE 2 E SS SE SE PE E ZE GE EE Bees SE E Ges E E GE E EE E SE SE EE Kp 40 Kv2 3 Kvff 3 Note For applications that require NO overshoot and fast response Kvff may be slightly reduced to force a following error such that the response approaches from starting side without overshooting even in the presence of minimal ringing SilverMax User Manual 105 Revision 3 22 Acceleration Feedback Ka The Acceleration value is derived from the Velocity 1 Post Filter value See SilverMax PVIA Diagram The Acceleration Feedback term functions as an virtual
72. SP is active on the Motor 2 Blinking There was a fault at power up SilverMax User Manual 18 Revision 3 22 UPGRADING FROM QUICKCONTROL 3 1 TO 3 2 What is New SilverMax Initialization Wizard Rev 3 1 s Initialize SilverMax screen has been replaced with the much simpler SilverMax Initialization Wizard Initialization files have been upgraded to standard program Files QCP See SilverMax Initialization for details SilverMax Initialization Wizard x Press Download to initialize SilverMax or change the Exit factory default parameters using the Initialize Parameter Browser or Interview 7 SSES Options Motor Aas 16 E Interview Type QCI 23 3 Initialize Parameter Browser File Communications r Gemen E Motor Silvers ax Factory Default Initialization qcp Br Servo Tuning H Motion Open Save Save s Error Limits W Misc Where Do I Set Motor Voltage You no longer have to manually set the motor s supply voltage QuickControl automatically reads the voltage from the SilverMax and modifies the Initialization file for you The motor voltage can still be set manually by pressing the Options button How Do Edit the Initialization Parameters The initialization parameters are accessed through the Initialization Parameter Browser Can Still Use My Old Initialization Files Although existing initialization files can still be used by way of the Rev 3 1 Tools menu it
73. SiverMax User Manual Revision 3 22 September 2001 SilverMax QuickControl and PVIA are trademarks of QuickSilver Controls Inc The SilverMax embedded software SilverMax electronic circuit board designs and the embedded logic in the contained CPLDs as well as this SilverMax User Manual are Copyright 1996 2001 by QuickSilver Controls Inc SilverMax User Manual 1 Revision 3 22 TABLE OF CONTENTS INTRODUCTIONS EE 8 WarningS E T N e id ia in de ia 8 What is contained in this User Manual oooocccnnnonionoccncnocnnnnnnccnnnnccnnnnnnnnnonnnn seen rnnnnn nn cn cnn eran creen 9 GETTING STARTED 00 A A A A ege 10 Start Up Kits OVervieWi iooociocncooninnnnasicotac artritis 11 Start Up EA O 12 QCI SK1 FS 1 Start Up Kit Setup ooooococcocococcccnccccononononcnnncccnnnnnnonnnncnncnnnnnnnn nn nn nn nr nn nan nnnn nn nn rn nr rnanannnnnnnnns 12 QCI SK1 34 1 Start Up Kit Getunp cece a a cece oa A E aa E TE A Eaa i E E 13 QCI SKO FS v Start Up Kit SetUP reina RAAE TRAA REAR TREA AEREA R TARRA 14 QCI SKO 34 v Start Up Kit Setup cece ceecccececeeeccceae cece ee eee ee ceaaaeceeeeeeesecacaeeeeeeeseesecceceeeeeeeeessnesaeeeeeess 15 QCI SKO 34 65 v Start Up Kit Getup cece cece cece cece ee ee eee ae ance sete tees ceaeaeeeeeeeseseccaeaeeeeeeeseesenseneeeeeees 16 Installing QuickControl Software ceeeeteeeeeee en eeeeeeeeeeeneeeeeneeeeeseseseeeseseseeeseseeeeeseeseeeeeseseeeeeseseeeseeneeenens 17 SilverMax Status and
74. Step 1 Step 2 Direction Change Step Down Step Up amp Step Down Output mode Step Pulse changes state with each edge of Phase A or Phase B This causes the Step rate to be one half the count rate 2 Counts 1 Step SilverMax User Manual 58 Step Up amp Step Down Output provides a 50 duty cycle Pulse for the Step Pulse outputs This gives a minimum pulse width of 3 75 micro seconds at the maximum speed of 4000 RPM The SilverMax Internal Encoder puts out 4000 counts per revolution With a modulo of 1 the maximum pulse count is 2000 pulses per revolution The Step Up pulses for one direction that the Encoder is moving the Step Down pulses for the other direction Both Step outputs must be low before one can be used this prevents the Step outputs from both being high at the same time Revision 3 22 The best type output to use for Step and Direction is the A amp B Quadrature When interconnecting two SilverMax units this is the ideal method since SilverMax can both output and input A amp B Quatrature A amp B Quatrature operates with lower Frequency signals while maintaining all the needed information This type is the most noise immune when proper decoding circuitry is used This type does require the inputting device to have decoding circuitry in order to use the full resolution of the output E NO Su e 50 t i OC 333353 oo EE SS 0
75. The Torque value can be set for the desired amount under all types of move commands If a pure torque mode is required the Velocity Mode commands can be set so that the SilverMax will attempt to run at desired maximum speed Full speed 4000 RPM The ERROR LIMITS command must be used as mentioned above to prevent excessive wind up Torque can then be set using the Torque Limits command to a desired value giving a constant torque output on the motor shaft SilverMax User Manual 41 Revision 3 22 External Trajectory Control If the need arises for external control of a motion profile SilverMax can be placed in optional modes which will accept external control input Scaled Step and Direction Electronic Gearing Step and Direction mode allows input of external signals that can be designed to provide the desired motion control profiles In this mode two digital input lines are used to input a step pulse and direction state into the SilverMax A B Quadrature is also allowed SilverMax has an internal counter that keeps track of the number of step pulses If the direction state is a 1 the counter counts up if the state is a 0 the counter counts down Every 120us SilverMax checks the counter value and updates its target value with the latest counter value In this way SilverMax tracks the step count so that its position will match the desired count A scaling factor allows the user to scale the input pulses by multiplying or dividing the
76. alog signals Analog inputs can be used for control of the motor s position velocity torque or other software programmable operations Non Volatile Memory SilverMax includes on board Non Volatile Memory The Non Volatile Memory is used to permanently store SilverMax programs and data The stored programs can then be used for power on initialization or for user defined autonomous operation programs that are stored in Non Volatile Memory can be recalled by SilverMax for execution even after power has been removed Stored programs can be recalled and executed using the Serial Communications or Digital Inputs At power on the program stored in the first memory location 0 is automatically re called and executed This feature allows a SilverMax to operate autonomously or from a Host controlling device Trajectory Generator The trajectory generator is a significant component of SilverMax It enables trapezoidal and S Curve shaped moves that are defined by either the Relative distance to move or the Absolute position Motion profiles can be defined either by acceleration and velocity or by the total motion time plus the ramp time The generator can also stop motions by using a complex Stop on digital input algorithm The generator monitors both the running position error value and the holding position error value and will automatically set a status bit when an error limit is exceeded The running and holding error status bits can optionally halt a
77. am if special processing is required on a Power Low condition For example the user may want to save the SilverMax s current position SilverMax User Manual 24 Revision 3 22 Main Init 0 The Main Initialization program is broken up into the following sections Each section editable by the SilverMax Initialization Wizard is a branch on the wizard s Browser Please refer to the Command Reference for a detailed description of the individual commands Communications At the very beginning of power up the most vital thing to do is establish serial communications with SilverMax Without this the user may be unable to communicate with SilverMax which will make diagnosing a problem or configuring the motor difficult This section is the first to execute IDT Identity default 16 The motor Identity command must be the first command in the first program If it is not present no initialization will take place This is to prevent an non initialized motor from attempting to initialize from blank non volatile memory PRO Protocol default 8 Bit ASCII 8 Bit ASCII is the most common protocol used and the easiest to communicate with SilverMax using a standard serial UART SIF Serial Interface default Auto SilverMax can operate using either RS 232 or RS 485 In Auto QuickControl will query SilverMax on its current SIF and set this command to match This command can also be edited from the Serial Interface field of the S
78. and Error conditions on the SilverMax units attached to the serial network see above for more information on Polling SilverMax User Manual 66 Revision 3 22 PROGRAMMING SILVERMAX SilverMax Memory Model Before programming the SilverMax it is important to understand how the memory for storing and executing programs is set up There are three types of memory available in the unit When receiving commands through the Serial Interface a Serial Communications Buffer is used to temporarily store the Commands Parameters and Data for the Serial Interface For executing commands and programs there is a Program Buffer for temporary storage of the executing command or program The Program Buffer uses a Static type memory cell that can be written any number of times and only maintains information while power is present For long term storage of programs and data use the Non Volatile Memory Non Volatile Memory uses a EEPROM type memory cell that can be written to a large number of times and retains the data even when power is lost Serial Interface Serial Comm Buffer 10 Words Non Volatile Memory Program Buffer 200 words Serial Communications Buffer The Serial Communications Buffer is a 10 Word memory location used to temporarily store in coming and out going Commands Parameters and Data When sending a Command from a Host system to the SilverMax using the Serial Interface SilverMax will temporarily store the inform
79. and Example Command Settings Anti Hunt Constants Anti Hunt Delay Torque Limits Error Limits Open to Closed 10 Delay Count 0 Closed Loop Moving Error 100 Closed to Open 10 0 msec Holding 10000 Holding Error 20 Closed Loop Delay to Holding 833 Moving 20000 100 msec Open Loop Holding 5000 Open Loop Moving 20000 SilverMax User Manual 77 Revision 3 22 Minimize Position Error Pulls position error in tight before Anti Hunt In this example the SilverMax will go into Anti Hunt operation when the motion is complete and the position error is less then 4 the required Torque is less than the Torque Limit usually means the position error must be near O and after the Anti Hunt Delay has expired There may be a brief period where the Open Loop Moving torque is applied helping to pull the position error to zero The Delay to Holding affects both Open Loop and Closed Loop operation Minimize position Error Example Command Settings Anti Hunt Constants Anti Hunt Delay Torque Limits Error Limits Open to Closed 10 Delay Count 416 Closed Loop Moving Error 100 Closed to Open 4 0 msec Holding 20000 Holding Error 20 Closed Loop Delay to Holding 833 This gives Moving 20000 100 msec SilverMax more Open Loop Closed Loop Holding 5000 settling time Open Loop Moving 5000 Snap and hold Pulls position error in tight before Anti Hunt using high Open
80. ar configure the Startup Kill Motor KMR Kill Motor Recovery Recovery to be run in the event of an D D r existing error Run Startup Recovery program if a Kill Motor E T Condition occurs Load and Run Program Startup nn HECOVEIY Kill Motor Conditions KMC Kill Motor Conditions Over owes H rror Limts Set KMC to over temp only over voltage is always an me erc ticari active KMC If an over temperature or over voltage Holding Limit 0 counts condition exist the SilverMax will now execute the Ge iert Biu z J A Startup Power Low Recovery Startup Recovery program This is simular to the above explained Startup Kill Motor Recovery SE Power Low Condition ERL Error Limits Load and Run Program Startup ae Recovery Disable error limits at startup to suppress nuisance error Fead the faciar sel ADC calibration messages Until the motor has torque it will probably data from NV memory Athe analog command reads the calibration data from NY memory and calibrates the ADC PLR Power Low Recovery Calibrate Analog Input from Run Startup Recovery program if a low power i Non Volatile have movement errors inputs are factory calibrated This condition occurs H Phase Align torque limits Torque Limits Closed Loop Holding 0 CAI Calibrate Analog Input Closed Loop Moving 0 a Open Loop Holding 0 Calibrate analog input channels using factory stored Open Loop Moving 0 scale factor sto
81. ation in the buffer as the command is being received During this time the Command and Parameters are checked for proper syntax and data range When the entire Command and Parameters have been received they are either executed directly or transferred to the Program Buffer and executed Immediate Type commands are executed directly from the serial Buffer Program Type commands are first transferred to the Program Buffer before execution Program Buffer The Program Buffer provides a 200 Word memory array for program and Command execution The buffer is used by the SilverMax to hold a single Command or a series of Commands a program for eventual execution Only one program can be held in the buffer at a time The buffer can be loaded with Commands using the Serial Interface or from the Non Volatile Memory The buffer will hold a Command or series of Commands until over written or until power is removed SilverMax User Manual 67 Revision 3 22 Programs that are contained in the buffer can also be written to the Non Volatile Memory for long term storage The following is a list of SilverMax Commands that pertain to the Program Buffer e Clear Program CLP Clears the contents of the Program Buffer Start Download SDL Puts SilverMax into Download mode using Serial Interface Store Program SPR Stores the currently loaded program into Non Volatile Memory Run Program RUN Executes the currently loaded program Load Program LPR
82. atus a td ai 59 USING ANALOG INPUTS cuco iris 60 SilverMax User Manual 4 Revision 3 22 Selecting Analog ll UE 60 Single Channel le e EE 60 Differential Channel IBU geiergert dee dese deed 61 Reading Analog In e 61 Reading and Calibrating the V Analog Input 62 Reading and Calibrating the Temperature Analog Input 62 VO CONFLICTS riai n iian E AE pi 63 OPERATING IN HOST AND STANDALONE MODE ccessseeeeeseeeeeeeeeeeneeeeseeneeeeseeneeeaseeneeenseeeneeenseeneeenas 64 ak e EE 64 Polling SilverMax Using the Poll Commande 64 Standalone Moda saaa a A A A A A A A A A A E 66 Host amp Standalone Mode Combined sss ussssnunssunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn KEEN 66 PROGRAMMING SILVERMAX wisiiecicccvct cas ceesecteecvsncnesestuctenedeiceeceusbaceesestuetencd dd RE 67 SilverMax Memory Model cccccceseccceeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeseeeeeeaseeeeesaseeeeesaseeneeseaseaeeeeaseneeeaseaeeenees 67 Serial Communications Butter 67 Program Buffer eege A dt nen 67 Non Volatile Memory coi ENEE 68 Creating Programs Overview ci iccciiceccesesscecesisscuceceisncensisscecencesccectetssaceasiaecuceresscceesisidudestisaceteteneeesiares 69 Command Types Required ug Brett rear aa dee e dee ee Ed ebe 69 Hows Programs e 69 Motion Commands ET 69 Wait ul Le 69 Mode Commands ET 69 Data Register Commands esiin a E cccunbided reacia 70 Allother commands custodia iaa atada tata 70 P
83. ax User Manual 64 Revision 3 22 Example 8 Bit ASCII Code Send an initial Poll command 16 0 CR Poll Clear Entire Status Word 16 1 65535 CR Clear Poll Actual Poll command 16 0 CR Poll SilverMax Response 10 0000 2000 CR Command Complete NOTE 8192 in decimal equals 2000 in hexadecimal Clear Only Bit 13 16 1 8192 CR Clear Poll SilverMax User Manual Polling Routine Begin Polling Routine Send Poll Command Send Clear Poll Command Send Poll Command Receive Response Check for Command Completion Polling must be initialized by first doing a Poll then a Clear Poll Polling Routine repeat loop This can be done at any rate that the Serial Interface can support Send Clear Poll Command Exit Polling Routine 65 Revision 3 22 Standalone Mode A common mode of SilverMax operation is to download programs in the SilverMax and allow it to run totally independent of any other controller This is referred to as a Standalone mode because the SilverMax can actually stand alone in a system with only a power supply connection This enables SilverMax to take on PLC like qualities for operating a small system Often in this mode the Digital I O is used to initiate the required operations by programming the SilverMax to Start programs End programs or Select programs using different I O combinations Special commands have been designed into SilverMax
84. back gain Think of a stereo with an equalizer If you were to zero out the upper half of the frequency slides reduce the high notes you would have effectively introduced a low pass into your stereo The only thing passing through your stereo would be the low bass notes For a typical system the first velocity filter Fv1 is placed at the lowest frequency the second filter Fv2 is typically a factor of 2 to 5 times higher with 3 being typical This allows Fv1 to roll off gain in the velocity estimator before Fv2 introduces significant phase lag The two filters together help reduce the higher frequency torsional resonance modes of the widely mismatched systems 20 1 to 200 1 A good rule of thumb is to set these just above your system s reasonable frequency response For example if your are trying to move a large flywheel having these filters up at 1000Hz is unreasonable There is nothing happening of interest in the 1ms time frame The flywheel just cannot not move that fast Putting these filters down under 100Hz is more reasonable Note The modes above the roll off frequencies of the velocity estimators are not just ignored but they are passively damped by the patented drive technique that effectively shorts the windings to signals at frequencies higher than the velocity filters Acceleration Filter Fa As with the Velocity Feedback term the Acceleration Feedback term has a low pass filter used to filter out unwanted high fr
85. be connected to the V power 3 5 Volts 100mA supply to enable the motor driver circuitry 13 VO 1 3 E UO lines 1 2 and 3 have an internal 4 7K ohm 14 VO 4 resistor connected to the internal 5 Volt power supply 10 VO 5 5 VO 6 15 VO 7 pi Back View of 34 Frame motors in Signal showing connector placement DB 3 Power Connector A1 Chassis Ground A2 V Power 12 to 48 Volts A3 Power Ground Power amp Chassis Ground are internally connected SilverMax User Manual 131 Revision 3 22 SilverMax 34H 3 amp 34H 4 Frame 4X Y 218 THRU EQUALLY SPACED 0 88 ON A 3 875 B C 2 875 0 002 3 35 0 500 0 0000 0 0005 0 125 KEYWAY AAA ke 2 72 See Table 1 25 Model Number Overall Length 34N 1 5 13 34H 1 5 13 6 NC 34H 2 6 65 Driver Enable 2 RS 485 A RS 232 Tx Notes 12 RS 485 B RS 232 Rx 8 Logic Ground Driver Enable must be connected to the V power 3 5 Volts 100mA supply to enable the motor driver circuitry 13 VO 1 9 1 0 2 e 4 10 3 I O lines 1 2 and 3 have an internal 4 7K ohm 14 VO 4 resistor connected to the internal 5 Volt power supply 10 VO 5 5 VO 6 15 VO 7 A l Back View of 34 Frame motors Pin Signal E showing connector placement O DB 3 Power Connector A1 Chassis Ground Comm amp I O DB 15 A2 V Power 12 to 48 Volts A3 Power Ground Power amp Chassis Ground are O internally conne
86. be used to prevent hunting This is only used when the ANTI HUNT CONSTANTS are set to a value greater than geht Overview of the Control System Parameters A good understanding of the parameters and settings is useful when figuring what changes should be made to give the desired results QCI recommends that all users are educated on the parameter descriptions and functions they provide in the control system before tuning the SilverMax The typical parameter range listed in the above table represents values that have been implemented in working applications and are to be utilized as a guide range for user applications Some applications may have values outside the typical range There are TEN tuning parameters that the user can set in the PVIA algorithm The following parameters are calculated in the PVIA algorithm and support the position control of the motor when it is moving and stopped Velocity and acceleration feedback filters have a Frequency setting for rolling off high frequencies that may cause system instabilities Velocity and acceleration feedforward parameters are used to compensate for the position lag effects of the velocity and acceleration feedback gains SilverMax Tuning E STEE QuickControl Variables Typical Parameter Range Proportional Gain Kp 40 400 Velocity 1 Feedback Gain Kv1 0 Velocity 2 Feedback Gain Kv2 5 50 Velocity Feedforward Gain Kvff 5 50 Acce
87. ce that requires constant updating The memory can be Read any number of times One advantage of using the Non Volatile Memory for program storage is that more than one program can be stored Depending on the size as few as 19 programs can be stored or as many as 1900 Temporary storage can only hold one program at a time QuickControl downloads programs into Long Term storage SilverMax User Manual 75 Revision 3 22 SPECIAL MODES amp OPERATIONS Anti Hunt Operation Eliminates Dithering Digital servo systems share a common characteristic of dithering when holding at position Dithering typically occurs when the holding position is near the count transition point of a digital feedback device i e Optical encoder or resolver This results in a small oscillation of the motor shaft 1 count which in some cases may not be acceptable to the system performance In more severe cases it can cause a greater oscillation in the total system SilverMax has a unique ability to eliminate dithering by transitioning from Closed Loop mode Servo Control to Open Loop mode when holding position When the motor s rotor has been moved to the Target position within a pre defined limit the motor will drop out of Servo control and operate in Anti Hunt mode In the Anti Hunt mode active control of the motor s rotor position is suspended until the position error exceeds a different pre defined limit If the limit is exceeded SilverMax will
88. ckets All of the information returned from the SilverMax is in ASCII Hexadecimal The Address is returned as a 2 digit Hexadecimal characters while any Data returned is returned as 4 hexadecimal characters for each Data Field Long Word data 32 bit is returned as two Data fields 8 total characters There are three types of response packets Acknowledge ACK Returned Data and Negative Acknowledge NAK Each has a different form to allow them to be easily parsed by the Host system Acknowledge ACK Response The ACK response is the positive acknowledge of the receipt of a Command Packet This response has also been shortened to minimize the load on the Serial Communications Interface as it is the most common response of the SilverMax 8 Bit ASCII ACK Response Packet data transmission order Start Character Address Hex Ending Character 1 Byte 1 2 Bytes 1 Byte Carriage Return The Acknowledge response starts with an followed by a space character then the SilverMax Address in Hexadecimal and finally a Carriage Return lt CR gt to end the packet Example Acknowledge response from SilverMax 16 which is 10 in Hexadecimal 10 lt CR gt Returned Data Response The Returned Data packet is sent when a properly formatted request for data is received by a SilverMax lts format is as follows The Returned Data Packet starts with the character to indicate a numeric respons
89. cksum or character count as the 9 bit protocol does SilverMax checks each character for proper framing and valid characters proper syntax and number of parameters Command Packets All communications originate with a Command Packet from a Host controller SilverMax does not initiate communications it only responds when a Command is sent 8 Bit ASCII Command Packet data transmission order Start Character Address Command Code Parameters Ending Character 1 Byte 1 3 Bytes 1 3 Bytes 1 10 bytes for 1 Byte Carriage Return each parameter Start Character The first character of the Command Packet is a Start Character For the 8 Bit ASCII Command Packets this is an character Any characters sent before the are ignored including the responses from other units that are traversing the same communications lines In the case of RS 485 Following the symbol one or more spaces characters may be inserted but are not required Address The destination Address character is sent as one to three digits in the range of 1 to 255 The SilverMax checks to see if the address received corresponds to the Identity Group or Global address Packets not containing one of these addresses are ignored Packets addressed to a Group or Global address will be acted upon but no response will be sent The Address is delimited with one or more space characters The Global address 255 is a reserved addr
90. cted SilverMax User Manual 132 Revision 3 22 INDEX A A 8 B Quatrature 59 Absolute Move Commands 38 Acceleration Feedback Ka 106 Acceleration Feedforward Kaff 106 Acceleration Filter Fa 108 ACK Response 122 Acknowledge ACK Response 117 Address 115 119 Advanced Usage Native SilverMax 45 Advanced Usage QuickControl 53 All other commands 70 Analog Input Mode Example Using a Potentiometer 91 Analog Input Modes Velocity Position and Torque 90 Analog Input Resolution 90 Analog Inputs 33 127 Analog Read Methods 90 Anti Hunt Constants AHC 99 Anti Hunt Delays 77 Anti Hunt Examples 77 Anti Hunt Operation Eliminates Dithering 76 Anti Hunt Process 79 Anti Hunt Torque Settings 76 B Basic Digital Inputs amp Outputs 56 Basic Stop on Input AND Inputs State 51 OR Inputs State 51 Bitwise Operations 95 Breakpoint 20 Brushless Motor 34 Buffer Motion Commands 87 C Calculations 95 Can I Still Use My Old Initialization Files 19 Change Direction and Stop on Input AND Inputs State 52 OR Inputs State 52 Checksum 120 Choosing Which Protocol to Use 114 Closed to Open Error 76 Closed Loop mode 76 Command Code 115 120 Command Packets 115 119 Command Processor 32 SilverMax User Manual C Command Types Required 69 Communication Hardware 32 Communication Protocols 32 communications 10 Communications 25 Conditional Program Flow
91. d Now re enable the motor driver Form here on the motor will have continue operation or simply alert the system power oie E A D nable Motor Driver or operator of an error Alerting the system Just a wait before calling the next program or operator may involve toggling a Digital Wait for 500 mSec Output Line Run a system recovery program from here This following program could be a Homing routine that would recover from the error Load and Run Program Home the Give ax The program example shows a Moving error recovery that will allow the motor to Re Home and continue on with operation The first operation is to remove the error this is done using a Target to Position command This removes any Position error that may exist Next the Kill Motor Conditions command is issued again This is required if normal operation is to resume because the Kill Motor Recovery disables the conditions command Restoring operation After a shutdown the system can be restarted automatically by adding a few extra steps to the Recovery program Since the Torque Limits were zeroed out at shutdown they must be re initialized to the desired values If a homing routine is to follow the Torque Limits could be set to a lower value required for homing Next the motor drivers must be re enabled using the Enable Motor Driver command Previous versions of SilverMax required issuing the Motor Constants command The SilverMax is now read
92. d the Encoder must be established This is done using one of two different algorithms that will automatically perform this task Standard alignment is selected when very low residual torque is on the motor at startup and low torque lt 5 of Max is required to move the load at low speed lt 1 RPM The Complex alignment is used with high residual torque or when high breakaway torque stiction is present during startup Standard alignment Factory Default MOTION Direction Direction Cw Do Phase Align Dpen Loop Phase Torque Ramp Up Final Torque 100 Increment 25 Move 20 counts acc 10348 cps s vel 683 cps Move 20 counts acc 10348 cps s vel 683 cps Move 20 counts acc 10348 cps s vel 683 cps Delay for 200 mSec Go Closed Loop Go back to zero Move to 0 counts ramp time 20 mSec total time 50 mSec MOTION Torque Limits Torque Limits Closed Loop Holding 75 Closed Loop Moving 100 Open Loop Holding 50 Open Loop Moving max MOTION Anti Hunt Constants Anti Hunt Constants Anti Hunt Disabled MOTION Anti Hunt Delay Anti Hunt Delay 10 mSec MOTION Set S Curve Factor S Curve Factor 0 The standard alignment routine simply fixes a known vector phase value in the stator windings clears the encoder count register then puts the motor into closed loop mode This is typically done using a high winding current to ensure that the motor rotor aligns itself to the encoder This
93. dows 95 or Windows NT The Calculator is found in Programs Accessories from the Start menu If the calculator does not look like the one at the right go to the View menu and change it to Scientific Put the calculator into Hex input mode by clicking the Hex button Now enter the Hexadecimal number into the calculator A to F is used in Hex mode The Hexadecimal number can now be converted to Decimal by simply clicking the Dec button Decimal Number 36865 This number can now be used in an ASCII string SilverMax User Manual im Calculator Edit View Help 9001 mes amp Dwad C Wod C Byte Ce Cu lf TI Back ce c sm ref 0 9 mef z efo 1 ned ag me amf oo 0 un ef sf e N orf x son inf xy ton el aS e 3 usaf ua wef of a wef tal f zl nf al 9 sl af of cf of ef Hei Dec C Oct Bin im Calculator BBE Edit View Help 36865 C He Deg C Oct Bin Deg Rad Grad ESUSS Sal el el Owi f ef s e wal aal al m wl af 5 ef or xor x9 wl wel 112 a Jul nal lol wl AE del ol af 6 cl oj el e 50 Revision 3 22 Using Inputs Examples Basic Stop on Input This example shows a MOVE RELATIVE VELOCITY BASED move that stops using input 1 In this example the motor will spin at least 10 revolutions looking for an input If the input occurs before the distance i
94. e 76 Operating in Host and Standalone Mode 64 Other Benefits Include 87 Outputs 55 Overview 31 Overview of the Control System Parameters 100 P Poll Command Packet 116 121 Polling SilverMax Using the Poll Command 64 Revision 3 22 P Polling Status Word 126 Position Feedback 34 Position Input Mode 42 Primary Commands 99 Profile Moves 40 Program Buffer 67 Program Buffer Size 127 Program Download Example 74 Program Flow Control 70 Programming SilverMax 67 Proportional Gain Kp 100 Protocol Definitions 125 PVIA 97 Q QCI SK1 Start Up Kits 11 QCI SK1 34 1 Start Up Kit Setup 13 QCI SK1 FS 1 Start Up Kit Setup 12 QCI SKO Start Up Kits 11 QCI SKO 34 65 v Start Up Kit Setup 16 QCI SKO 34 v Start Up Kit Setup 15 QCI SKO FS v Start Up Kit Setup 14 QuickControl 17 QuickControl Rev 3 1 Tools 21 R RAT 38 RAV 38 Reading Analog Inputs 61 Reading and Calibrating the Temperature Analog Input 62 Reading and Calibrating the V analog Input 62 Recording Sensor Found Position 46 Relative Move Commands 37 Response Packets 117 122 Returned Data Response 117 123 RRT 37 RRV 37 RS 232 32 RS 232 Multi Drop 32 RS 485 Multi Drop 32 S Scaled Step and Direction Electronic Gearing 42 S Curve Factor SCF 99 Second Check Used to do a Two State input check 45 Selecting Analog Inputs 60 Serial Communications 32 127 Serial Communications Buffer 67 Ser
95. e it is followed by a space character then the Command Code in Hexadecimal followed by the data again in Hexadecimal If the response data is larger than a 16 bit response the response is split into two 16 Bit fields four hexadecimal characters with the two fields separated by a space SilverMax User Manual 117 Revision 3 22 The packet is ended with a carriage return 8 Bit ASCII Returned Data Packet data transmission order Start Address Command Code Data Fields Ending Character Character Hex Hex Hex 1 Byte FP 2 Bytes 4 Bytes 4 Bytes each 1 Byte Carriage Return Example Poll command Returned Data from SilverMax 27 which is 1B in Hexadecimal The actual Returned Data is the Polling Status Word 1B 0000 2000 lt CR gt Example Read Register command Returned Data from SilverMax 10 which is OA in Hexadecimal the last 8 digits represent the 32 bits of data The Read Register command code is 12 which is OC in Hexadecimal OA 000C 0005 06A3 lt CR gt NAK Response The NAK response packet is sent when the Command issued is not a valid command When the Command Packet is improperly formatted or when the Parameters are invalid or a Command is sent at the wrong time such as requesting a motion when the motor is already busy The NAK response begins with the character followed by a space character Next are the Address the Command Code and f
96. e back tothe 4 per revolution location In this example line s absolute position the motor was at when the encoder Index was 7 uses a Registered Move Absolute e Velocity Based RAV command The Torque Limits Data Register is set to 2 Last Index 7 Move a linie ia then 1 revolution so that the Index will be A 3 3 t which is the location of the motor the last rT time the Index was encountered The ace 1 ips s b 5 vel 2 rps previous move command allowed the Stop when Current Index is HIGH TRUE motor to find the Index before it stopped This move is a Registered Absolute that moves to the location S recorded when the encoder index last occured Move to location stored in The RAV command will cause the motor to Last Index Register 2 move directly to the Last Index position reido without having to do any extra calculations 7 PEE EE Torque Limits Zero Target and Position SilverMax s Extended Register Move commands give the user access to all of the move parameters as Data Registers With this not only the Position or Distance parameters can be changed outside the command Acceleration and Velocity can also be modified as Data Register values This gives the ability to modify these parameters based on system needs prior to their use in a program SilverMax User Manual 39 Revision 3 22 See Profile Move Commands in the SilverMax Command Reference for more information Profile Moves The Profile Move
97. e next servo cycle Some commands block program execution while the command is completing its operation Since commands behave differently the following gives more information on how different commands effect program execution NOTE The following assumes the SilverMax is not in Multi Tasking mode Multi Tasking is an advanced topic detailed latter in this document Motion Commands Motion commands stop program progress when they are executed When a motion command is issued to SilverMax it transfers all effort into performing the motion profile during this time Program execution is suspended This means that no other Program Type command can be issued while a motion command is in process This is true for both programs and issuing commands from the Serial Interface remember Immediate Types commands can still be used Wait Commands Wait commands such as WAIT DELAY and WAIT ON BIT STATE operate similar to Motion commands by suspending program execution while waiting for a Condition to be met One exception to this is the DELAY command that can be used to set up a delay counter for future use and continue program execution Mode Commands Mode commands such as VELOCITY MODE and SCALED STEP amp DIRECTION completely suspend program execution until an I O condition is met or an Over ride command is sent from a Host Controller When using this type of command the intention would be to put SilverMax into the SilverMax User Manual 69 Revisi
98. ectenetsases 31 Serial COMMUNICATIONS occ ceseedieccucetes dlaeeevesteceteesccuantesduaseevescucstevsuacedvestuacevedacstevstaservescs 32 COMMUNICATION Be Ee 32 RSB MODOM onae a aa diia 32 EEA AP E E E E E E E E E AT Merged T EE S 32 EEE AE DI a 2 0 E E E A id 32 Communication Frott S arier sistas artesa a aR Aa i AL A EASES SAA OA Eaa aAA aA ake 32 G mmand Process ON iii a 32 Digital MO AAA A 33 Analog Os a ets 33 Non Volatile Memory ta 33 Trajectory Generado iii ii A 33 SETVO CONTFOMEDO P ecc A ET 33 Motor Driver CommMutation ccccceeseneeeseeeeeeeeeneeeeeeeeeeseeeseeeseeeseeeseseseeeseseseeaeseeeseaesesesaesesesaesesseeeseeesans 34 Brushless Motor ees Eege aaa aa o 34 Position Feedba k oeaan A A AAAA E AA EER AAAS AA aAA EERS PAA TE AAA SAAS AAL AAA NOAA SEE AERIS A TSENT ASIAA 34 SILVERMAX MOTION COMMANDS c coooocccccococccccnnncnncnnn cnn 35 Standard Motion amp Profile Move COMMAnNdS ccccssccceseeeeeeeseeneeeeeeeenseeeseeeseseseenseseseanseeessenseeeseenseeees 36 Internal Trajectory Control omcoioiiaiiaanit ia anaana ana daag annan Nidaa N EEan ri iaai 36 Standard Motion Profiles iii dd Naaa NENA a ad ida 36 Standard Motion commands come in three flavors ooonnocncnnnnociconacocnnnnocannn oran cnn rca ran r nana rca 36 Relative Move Commande 37 Move Relative Velocity Based MV 37 Register Move Relative Velocity Based RRV 37 Extended Register Move Velocity Based RV 37 Move Re
99. ed in the command First Check Direction toggle amp State toggle DONE ONLY ONCE Are Conditions met No Second Check Preliminary Input conditions Check for Inputs Again This is Are done every Conditions 120usec met Yes This is done every Last Check servo cycle 120usec AND conditions until the conditions are amp met or the motion ends OR conditions Check for Inputs Again This is Are done every Conditions This uses the 120usec met acceleration parameter that began Yes the motion to decelerate Stop Motion OR the motor to a amp Enabled What s stop Enabled Record Motor Position SilverMax User Manual 47 AND Enabled OR Disabled Record Input Checking Flow If the Toggle Preliminary State bit is set the Preliminary input state bits are complemented If the Toggle Or State bit is set the OR input state bits are complemented Change direction of move Toggle settings of state bits Second Check Used to do a two condition Input check The Second Check is done if inputs are enabled to find a two state condition of the inputs Last Check The last check can do two different things The most common is to stop the motor and record the motor position when an input TRUE condition is detected The second is to just record the motor position Two different checks are done at this time the AND conditions and the OR conditions
100. ed to the SilverMax logic ground care should be taken to minimize ground noise and ground loops Analog input 5 is the differential reading of inputs 1 amp 2 This analog input is designed for external analog input readings and can be used for all analog input functions Analog input 6 is the differential reading of inputs 3 amp 4 This analog input is designed for external analog input readings and can be used for all analog input functions Reading Analog Inputs There are two methods for reading in analog information One method is to do a single read using the Analog Read Input command This command does a single reading of a selected analog input and places the value in a selected Data Register The second method is to do continuous readings of a selected analog channel using the Analog Continuous Read command This command puts SilverMax into a continuous read cycle that takes an analog reading every servo cycle 120 usec Putting SilverMax into Analog Continuous Read has no effect on other operations the readings are done in a foreground routine that is designed to work without effecting the controller performance When in Analog Continuous Read the analog value is placed in the selected Data Register after each reading every 120 usec This provides continuous update of the analog signal that allows for better tracking Analog Continuous Read can only be set up for 1 channel at a time The setting can be modified at
101. eet DEES d veer EEN 117 NAK Ee EE 118 9 BIT BINARY COMMUNICATIONS coccccoocoococccccccnnnnnnnnnnnnncncnnnnnnnnnncn cnn cnn eens eeaeeeseeeeeseasseaeeaeeeseeeseseeeeneneesees 119 Command Packets E 119 Lieler 119 Rue Un E 119 Beil E Ile Kee TEE 120 attert ees ge De ee EE 120 A Bee eege es os e eege a eek hak cs Mea es eege ease eebe 120 EXAM ples coria ind 120 Poll Command Packet cocoa tic EERSTEN EN eege 121 Response Packet iia Seet EESAE EES 122 AAG IGIRESPONSC ae etc Eech 122 Returned Data Response eee enaeeeeeeeeecgeaeaenaeceeeeesageaanaeceseeeseeneaceeeeeeeesaeineaeeeeeens 123 NA RESPONSES ioe tek cater ee at ales ta dead 124 PROTOCOL DEFINITIONS cuasi ise 125 SilverMax Negative Acknowledge NAK Codes ccccmoomccconnonncccnnonncccninanrcnnnn erre ercer 125 SilverMax Polling Status Codes Polling Status Word oooonmccoconicccnnnseccnnsscnnnn serca 126 SPECIFICATIONS enee ees nor cde eates EENS ser 127 Digtal geg een li ic 127 Analog Be TEEN 127 Mechanical Specifications ci sida 129 SilverMax Tf Tu 129 silverMax 23 Brame EE 130 SilverMax 34N 1 34H 1 8 34H 2 Frame oooocccnccccccoconoconennnncnonononcrnnononononnnrnnoncnnnnonnrnnranencnonnnanernnanannnnos 131 SilverMax 34H 3 amp 34H 4 Frame cece eeeee ee ceaaaeceeeeeeesecneaeceeeeeeeseccacaeeeeeeeeeeessnaeees 132 IDEA Ee EES 133 SilverMax User Manual 7 Revision 3 22 INTRODUCTION SilverMax from QuickSilver Controls Inc is a fully integrated motion control
102. eing used Kv1 is typically set to 0 Kv1 is only needed in rare high frequency response applications i e 10ms move In these situations the extra filtering done to calculate Velocity 2 causes it to not accurately represent the load s velocity Kv2 is typically the only Velocity Feedback used Kv2 is analogous to a shock absorber added to our spring The larger the Kv2 the more damped the shock With Kp only our SilverMax spring would oscillate to a stop every time it was moved Even the smallest amount of Kv2 i e Kv2 1 will add noticeable dampening Let us see what a shock absorber does to our bouncy system The following plot is the same as above except Kv2 1 Strip Chart Y Minfo Y Max 5200 Sample ms 200 al Select Channels Cancel slala a EH my elele BUE aet Kp 10 Kv2 1 Notice what a significant damping effect Kv2 has on the system Let us make Kv2 3 SilverMax User Manual 103 Revision 3 22 Strip Chart Y Minfo Y Max 5200 Sample ms 200 Cor Select Channels Cancel leit mu aolen EBE 2 7 lus Kp 10 Kv2 3 Although the system is more damped it appears to be having a little trouble matching the velocity of the target Velocity feedback means substracting some component of the velocity Kv2 x velocity from the torque As Kv2 increases the velocity feedback will cause a greater velocity error in our system To compensate for this we need to add some Velocity Feedforward
103. em it is suggested you create new ones with the new wizard The old files do not have access to any of the new initialization commands that have been developed compare all the parameters in the browser to what you use to have Default Start Address The Default Start Address is the place in non volatile memory where the first program gets stored In other words this is the address the initialization program runs when it is finished In Rev 3 1 this was set to 110 In Rev 3 2 this has been increased to 512 do to all the new initialization options we have added If you upgrade to the SilverMax Initialization Wizard this will be transparent to you and all your old programs will work just fine If you choose to continue to use the older initialization files you will have to set the Default Starting Address to 110 This can be done by pressing the Options button and entering 110 into the Default Starting Address field Exit out of the SilverMax Initialization Wizard and use your old Initialization files from the rev 3 1 Tools menu SilverMax User Manual 19 Revision 3 22 SilverMax Initialization Wizard Options Cancel OK m SilverMax Motor Voltage p Default Start Address a Mode Auto Read from SilverMax Default starting address for iy Erase Application IA Erase application program s Modify J fio everytime new initialization Vv 110 z parameters are downloaded r Serial Interface Initialize
104. ep amp Direction Input Encoder Input 57 Step amp Direction Output Modulo Output 58 Step Up amp Step Down 58 Stopping a Motion on Input 46 Supply Voltage 10 T Temporary Storage in Program Buffer 74 Temporary Vs Long Term Storage 74 The Primary Benefit of Multi Tasking 87 Torque Control Using Velocity Mode 41 Revision 3 22 T Torque Control Limit 128 Torque Limits TQL 99 Trace 20 Trajectory Generator 33 Tuning Example 100x1 Inertial Miss Match 109 Tuning Notes 112 Tuning SilverMax 97 U Uncontrolled Shutdown 81 Unit ID 10 Upgrading 17 Upgrading From QuickControl 3 1 to 3 2 19 Using Analog Inputs 60 Using Digital I O for Flow Control 72 Using Inputs Examples 51 Using Inputs to Stop Motions 43 Using the Digital I O 54 V Velocity and Torque Input Modes 42 Velocity Feedback Kv1 amp Kv2 103 Velocity Feedforward Kvff 104 Velocity Filters Fv1 amp Fv2 108 Velocity Mode Control 41 W Wait Commands 69 Warnings 8 What is contained in this User Manual 9 What is New 19 Where Do Set Motor Voltage 19 While Loop 71 SilverMax User Manual 136 Revision 3 22
105. equency data Fa is typically set at about 5x Fv1 this produces the greatest phase boost while minimizing the high frequency noise amplification The peak phase boost enhancement is at the geometrical mean of the Fv1 and Fa square root of the product of these frequencies When Ka has been increased to produce a virtual dampener see the section on Ka for details Fa should be set just above the resonance frequency of the system See the Belt Driver tuning notes at the end of this chapter for an example SilverMax User Manual 108 Revision 3 22 SilverMax Control Panel This Control Panel in QuickControl provides the user access to several important features of operation It allows the user to JOG SilverMax at scalable velocities while monitoring the condition of the motor in the Device Status area of the Control Panel In addition the Panel provides the means to interactively tune the SilverMax servo loop Test Moves are available to prototype specific application operations for making the tuning capabilities more realistic A strip chart can be displayed to show various motion parameters while tuning SilverMax Control Panel EN Initialization Fle j p Tuning l Exit SilverMax Factory Default Cycle Initialization qcp z Cycles ms Reboot Use Wizard to Download and or 1 V 0 dl Rebool Change Initialization File SilverM ax Initialization Wizard Move Type gt il it Fil MAT C MAT Edit Control Edit
106. er of 32 and a maximum divisor of 1024 The inputs for Step and Direction can be one of three different types A B quadrature Encoder Direct Step and Direction or Step up down I O lines 2 amp 3 or Lines 4 amp 5 are used for input Examples of the three different Input types 1 O Lines 4 amp 5 Only Count 1 Count 2 Count 3 Count 4 Direction Change A Input Each falling and rising ee edge of the A amp B 1 O Lines 2 A 8 B Quadrature inputs equal 1 count Input in the internal counter B Input seapail l Step amp Direction EE E Minimum Pulse width for I O Lines 4 amp 5 Only In the step inputs is 400ns put P KEE Shorter pulses ma Direction Signal ES y cause erratic behavior l Each Rising Edge Step Up III equals 1 count in Step Up amp Dn A i the internal counter Input prea Step Down Each step input causes an internal counter in the SilverMax to increment or decrement depending on the Direction The internal counter is scaled to provide the Electronic Gearing ratios The Scaled Step and Direction command uses the Step and Direction inputs SilverMax User Manual 57 Revision 3 22 See MODULE SET MDS MODULO CLEAR MDC MODULO TRIGGER MDT amp SELECT EXTERNAL ENCODER SEE Step amp Direction Output Modulo Output Step and Direction output works slightly different than the input The Modulo commands
107. ers Move Relative Time Based MRT Three parameters are entered Distance Acceleration Time amp Total Time This command makes doing time critical profiles easy When the desired time to make the move is fixed using this command will cause SilverMax to make the move no matter the distance within limits in the exact time specified This is very useful when a number of different axes must be precisely coordinated in time Register Move Relative Time Based RRT Three parameters are entered Data Register Acceleration Time amp Total Time This combines the RRV and MRT types parameters together Extended Register Move Relative Time Based XRT One parameter is entered the Starting Data Register Only the Distance register location is sent as a parameter the Acceleration Time and Total Time must be stored in two successive Registers SilverMax User Manual 37 Revision 3 22 Absolute Move Commands Absolute Move commands will cause SilverMax to move to a specified position from its current position This is different from the Relative commands that move a given distance rather than to a specific position SilverMax keeps track of its current position as indicated in counts by continuously monitoring its Internal Encoder When SilverMax moves the current position is updated by the number of Encoder counts negative or positive encountered during the move When a Move Absolute command is used SilverMax calculates
108. es 1 2 amp 3 are internally pulled up to 5 volts using a 4 7K ohm resistor e UO lines 4 through 7 are internally pulled up to 5 volts using a 220 K ohm resistor When used as Input I O lines 4 through 7 may require lower value resistor pull ups to reduce possible noise issues e All special UO modes have the same output drive and input constraints e Some special purpose outputs such as Step amp Direction require high speed circuitry e A 5 Volt 100ma power supply is available from the motor to power optical proximity or Hall effect switches Example of High Speed Opto Isolated output circuit This could be used for the Step output that has a minimum 3 5 micro second pulse width signal 24 Volts External VCC Power Ground SilverMax 17 amp 23 Frame High Density DB15 Example of Low Speed Opto Isolated output circuit This could be used for general input from a PLC Use the CONFIGURE I O command to set I O line to Input or Output mode Use the SET OUTPUT BIT command to set an I O line High 1 use CLEAR OUTPUT BIT command to clear an I O line to Low 0 SilverMax User Manual 56 Revision 3 22 See SCALED STEP AND DIRECTION amp SELECT EXTERNAL ENCODER SEE Step amp Direction Input Encoder Input SilverMax can input Step and Direction signals in a number of different forms The Step and Direction input is designed to be a scalable mode with a maximum multipli
109. ess to which all SilverMax units will respond lt is typically used to stop all motions simultaneously or to initialize an unknown SilverMax Group addresses are user selected addresses that are assigned as a secondary address to a subset of the SilverMax units on a communications network A Group address would typically be used to initiate a coordinated move of several axes i e a Run Program command after the wanted motions had been downloaded to each axis individually The units execute commands sent to a Group address but they do not reply with a Response Packet SilverMax User Manual 115 Revision 3 22 Command Code The Command Code is the unique number associated with each command Refer to the SilverMax Command Reference for Command Codes If the command has no parameters associated with it the command may be initiated with a Carriage Return lt CR gt which completes the packet See final character below The Command is delimited with one or more space characters Parameters If the Command has Parameters associated with it then each Parameter is sent with one or more space lt SP gt character s used to separate the parameters Typically the number of Parameters can range from one to five Each Parameter must be delimited with one or more space characters Ending Character The final Ending Character is a Carriage Return lt CR gt Hex 0D Decimal 13 The carriage return signals the end of the Command Packet Examples
110. etail on ENTERING and EXITING Anti Hunt Operation Anti Hunt Torque Settings Anti Hunt operation works using additional torque settings that establish the desired force needed to hold position The Torque Limits command has two extra parameters Open Loop Moving and Open Loop Holding that are used when entering Anti Hunt operation Typically these parameters are set to a lower value than the Closed Loop Moving parameter PLEASE NOTE When in Anti Hunt operation the Open Loop Torque Limit setting reflects the actual current being applied to the motor windings This may cause significant heating of the motor For Example If the Open Loop Holding Torque limit is set to 10 000 which is 50 of the maximum motor torque setting the motor current will be fixed at 50 of the maximum current This will cause a greater amount of motor heating The Torque Limit setting should be set just high enough to hold the SilverMax User Manual 76 Revision 3 22 desired position to prevent over heating Anti Hunt Delays There are two delay settings that effect when Anti Hunt operation is entered and what Torque Limit value is used The Anti Hunt Delay command sets when after the position error has become less then parameter 2 Anti Hunt operation can begin This allows SilverMax to move into holding position using Closed Loop mode before switching to Open Loop The Error Limits command has a Delay parameter that sets when the SilverMax will switch from the Moving To
111. etting Motor POSITION voii e dat 96 TUNING SILVERMAX oiea A di 97 VS ell el e Ee EE 97 SilverMax PVIA Servo Algorithm ccccceesecc cesses eeeeeneeeeeeceeeeeeseeneeenseeeeeeaseeeeesaseaeeeeaseeneeeaseeneeenaeeneeneas 97 SilverMax Tuning COMMANOS oommcccnnnonnnnnnnnnnnnnnnrrrn rr 99 Primary Commande cuco lla 99 Associated Commande cit td db td ltd ld 99 Overview of the Control System Parameters oonnmmncicnnncccnnnncnnnecnrcrn recrea 100 Tuning Example 100x1 Inertial Miss Match ccccssessesseeeeeeeeeeeeeeeeeseeeeneesaeeeseeeeeseseeeseseseeesnneeeees 109 TUNING Note caia 112 SILVERMAX 8 BIT AND 9 BIT COMMUNICATIONS PROTOCOLS cccccseseeeeeseeeeeesseneeeeeseenenseeeseenes 114 Choosing Which Protocol to USE icic ccc ccesscccctvecteceescesteceessceccesdezcacecesanccaesstanceesdensececarsencesesssnceeseeseceets 114 Key Features of 8 bit AE Ugen a EAR 114 Key Features of 9 Bit Binary oia e dd 114 SilverMax User Manual 6 Revision 3 22 8 BIT ASCII COMMUNICATIONS oooococccccooccnonccncnnaconinan nana c cnn cananea 115 Command Packet ico ra ea 115 ege E Te 115 ele 115 Reuler 116 ParaMeters e ee Eege eebe Mee EEN 116 Ending GhataGteris24 cee ceei les Pees teed sitesi Ass Ai eters ee 116 EXIM PGS ee a tal escead fete cede a octave dE 116 Poll Command Paketa ne ceca vce cee eee EEN 117 Response Packs ar 117 Acknowledge ACK Reetotee eeh EENEG 117 Returned Data RESPONSE iaa scare agereechten ogege CR ege Gr
112. fer Size 10 Words Program Buffer Size 200 Words Non Volatile Memory Size 4K Words 8K Bytes Optional 16K Words 32K Bytes SilverMax User Manual 127 Revision 3 22 Motion Parameters Position Resolution 4000 counts per revolution 09 degrees 17 23 Frame Option 8000 counts per revolution 045 degrees 34 Frame Option 16000 counts per revolution 0 0225 degrees Position range 32 bits 2 147 483 648 to 2 147 483 647 536 870 Revolutions 3370000 radians Velocity Resolution 0 000000031 Revolutions Second or approximately 1 Revolution per year 195e 9 radians Sec Velocity Range 31 bits 1 073 741 824 to 1 073 741 823 In Velocity Mode 31 bits O to 2 147 483 647 In Motion or Profile Move Modes 4000 RPM 66 6 Revolutions per Second Maximum velocity 32 counts 120 microseconds 4000 RPM 66 6 Revolutions per Second 418 9 radians per Second Acceleration Resolution 0 000000031 counts 120uS 120uS 1 03 counts sec sec 1 62e 3 radians Sec Sec Maximum Acceleration s w 16 counts 120uS 120uS 0 to full speed in 240 microseconds actual acceleration limited by motor torque motor load inertia Maximum Acceleration Time when using Time Based Commands 65 568 120 microseconds 7 86 Seconds Torque Control Limit 1 part in 32768 Servo Sample Rate 120 microseconds 8 33kHz SilverMax User Manual 128 Revision 3 22 Mechanical Specifications SilverMax 17 Frame
113. for unreasonable values Bit 11 Input Found Within The move ended when the selected exit stop condition was met Motion Command found The value in Register 4 has been updated with the sensor found position Note set as soon as the sensor has been found the motion may take some additional time to come to a stop must return to normal for this to clear Error Limits exceeded while holding stopped Set by Error Limits ERL command Error Limits exceeded while Moving Set by Error Limits ERL command SilverMax serial receive UART buffer overflowed Bit 6 CKS Condition Met A condition was met while executing the command CHECK INTERNAL STATUS CKS See SilverMax Command Reference for details This is a user controlled status bit Message Too Long The received message was greater than 31 bytes Bit 4 Framing Error A received byte had an error during reception This is triggered when no stop bit is detected lt may be caused by noise on the serial channel or an improperly biased 485 network Also may be triggered by an incorrect baud rate Shut Down SilverMax shut down due to something set by the KMC command Soft Limit Soft stop limit reached set by SSL command Receive Checksum 9 bit checksum did not match with sent checksum Packet ignored Error Aborted packet Data errors or new packet received before the last was complete SilverMax User Manual 126 Revision 3 22 SPECIFICATIONS Serial Communications Hardware RS
114. from the 8 Bit ASCII protocol The 9th bit is actually the Parity bit of a standard 8 bit serial byte Using the Parity bit in this way allows the protocol to easily distinguish the Address byte from all others When the SilverMax receives a byte with the 9th bit set it knows that it is the Address and the beginning of the Command Packet Setting parity is called Mark Parity and clearing parity is called Space Parity 8 Bit serial byte bit pattern As sent from a standard UART Bit 1 2 3 4 5 6 7 8 9 10 11 12 Period Desc Start Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Bit 9 Stop Stop Bit LSB MSB Parity Bit Bit All communications originate from a Host system using the Serial Communication Interface SilverMax units do not and cannot initiate communications they only respond to commands Command Packets 9 Bit Binary Command Packet data transmission order Address Length Command Code Parameters Checksum 1 Byte 9th bit set 1 Byte 1 Byte 2 or 4 Bytes each 1 Byte SilverMax User Manual The following gives a description of the Command Packet Address The first byte is the Address that contains the Identity Group or Global address to which the SilverMax the command is being sent The Parity bit bit 9 of the serial byte is set to 1 Mark Parity to indicate that this byte is an
115. g it anything else will squash your circles by forcing a velocity dependent following if the feedforward is less or leading if the feedforward is greater than the sum of the other two error For a clockwise circle with following error this appears as an ellipse with the major axis at 45 degrees Belt Driven Positioning Tables Direct Drive SilverMax s high torque coupled with its PVIA servo technology is ideal for direct drive belt applications i e belt driven slides and tables Direct drive belt applications have two challenges high inertial mismatch and resonance modes vibration caused by the belt We recommend tuning for high inertial mismatch first described earlier then knock out the resonance modes You will find it easier to tune for high inertial mismatches if you pick a move that does not induce a resonance mode in the belt Once the high inertial mismatch is taken care of find the move that is causing the resonance mode and implement PVIA s Viscous Inertial Dampener This is done by increasing Ka typically x5 to x10 and increasing Fa to above the belt resonance typically 1500 to 2000Hz See the Acceleration Feedback Ka section for more details SilverMax User Manual 113 Revision 3 22 SILVERMAX 8 BIT AND 9 BIT COMMUNICATIONS PROTOCOLS Choosing Which Protocol to Use The choice of a protocol depends on several system design issues Below is a list that will aid you in determining the protocol that will
116. ge Trip sets the point at which the motor will execute the Power Low Recovery program Low Yoltage Trip 10 volts LIMITS Over Voltage Trip Over Voltage Trip sets the point at which the motor will set the Dvervoltage flag If this flag is enabled in Kill Motor Conditions KMA the Kill Motor Recovery program will be called Over Yoltage Trip 51 volts LIMITS Maximum Temperature Trip Maximum Temperature Trip 70 C LIMITS Error Limits Error Limts Moving Limit 500 counts Holding Limit 200 counts Delay to Holding 125 mSec Kill Disable Drivers Setup Final Kill Motor Conditions Kill Motor Recovery and Power Low Recovery Kill Motor Recovery Load and Run Program Kill Motor Recovery LIMITS Kill Motor Conditions Kill Motor Conditions If Over Temperature Power Low Condition Load and Run Program Power Low Recovery Run the program Kill Motor Recovery any time a Kill Motor Condition occurs KMC Kill Motor Conditions default Kill only on over temp Set KMC to over temp only over voltage is always an active KMC If an over temperature or over voltage condition exist the SilverMax will now execute the Kill Motor Recovery program PLR Power Low Recovery Run the Power Low Recovery program if a low power condition occurs SilverMax User Manual 29 Revision 3 22 Misc DIF Digital Input Filter en eee 4 MISC Set Digital Input Filters defau 1t 1 Oms i Di
117. ges accessed through the Initialization made here can be saved to the file by Parameter Browser Editing the pressing the Save or Save As button commands through the browser is the A new file can be opened by pressing same as editing them in the QCP file the Open button SilverMax User Manual 22 Revision 3 22 The wizard provides a friendly way of editing the initialization program file i e SilverMax Factory Default Initialization qcp Note when the wizard is launched the initialization file is opened in the background and stays open after the wizard is closed Editing a SilverMax command in the wizard is the same as editing it in the QCP file If the factory defaults are acceptable described below turn the SilverMax on and press the Download button to initialize the attached SilverMax When the Download Complete message appears close the wizard and start using your SilverMax Detailed Description of Download Steps When the Download button is pressed the wizard will do the following steps 1 Check if the selected SilverMax is present by asking it for its firmware revision If successful go to step 5 2 Check if any registered device is present If successful go to step 5 3 Scan network for any SilverMax If a SilverMax is found go to step 5 4 Run Unknown SilverMax Wizard to find a device If the previous steps could not find a SilverMax it might be that the SilverMax is running a different Serial Inte
118. gital Input Filter DIF is a digital filter on all input lines de bounce Alt Lines 10 mSec This only affects the basic digital inputs and does ee Done Bi affect the analog inputs external encoder signals or i e MISC Start Location of User step and direction signals EPA i Program Load and Run Program NY Memory Location 512 DDB Disable Done Bit MDC Modulo Clear Special output modes set to their default states See the Command Reference for details LRP Load and Run Program default 512 After the initialization is complete SilverMax can begin execution of a user defined program User programs can be created using QuickControl s program editor ACP This command can also be edited from the Default Starting Address of the SilverMax Initialization Wizards Option screen The SilverMax Initialization Wizard requires this line to exist in all init program files If your application does not require a user program Check the Erase Application box of the SilverMax Initialization Wizard s Option screen Tools gt SilverMax Initialization Wizard 0Options gt Erase Application This will write a single line program at the Default Starting Address 512 consisting of the END Program End command When SilverMax reboots it will execute its initialization program and them load and run the program at 512 which will be an END command SilverMax will now be in host mode awaiting commands over the serial port SilverMax User Manual
119. he Drag Mode box is checked Moving Error Limit Dm punks Description The Delay to Holding effects when the two different parameters are used In this case the i Holding Error will be used 100msec after a oa de Ae M Drag Mode motion is complete Trajectory Generator is 20 ae ZS inactive S Delay to Holding Normal C Native fi 00 mSec E NOTE Drag mode used in conjunction with the PROFILE MOVE commands will allow SilverMax to slip if an over load or a jam occurs but still complete the move when the over load or jam is removed Standard move commands will fall short of the target under the same conditions This is used to prevent run away when a motor shutdown is not the desired method to deal with over loads or jams SilverMax User Manual 80 Revision 3 22 Motor Shutdown Kill Motor Conditions SilverMax is able to detect a number of conditions that can be enabled to Shutdown the motor operation One of the Tasks that is performed every servo tick every 120 microseconds is to check a set of Kill Motor Conditions that may be used to stop the motor operation If any one of these conditions are Enabled and found to be TRUE the SilverMax will execute a process as defined by the Kill Motor Recovery The recovery process can do Nothing Kill the motor and wait execute a program beginning at address location O or execute a program at a specified location Mo
120. he Register Load Multiple command all the Data Registers can be initialized at one time The Register Load from Non Volatile can also be used but requires each register to be loaded one at a time If the register load method is used the data must be stored in Non Volatile Memory ahead of time using either the Register Store Multiple or the Register Store to Non Volatile commands The following is a description of the Data Registers used and their functions Data Register Data Range Data Source Data Register Function 12 2 147 483 648 to SilverMax or Input Source Data Data can be placed here 2 147 483 647 User by Analog or Data Register commands 2 147 483 648 to 13 2 147 483 647 User Input Offset 14 0 to 32767 User Input Deadband 15 0 to 32767 User Maximum Scale Limit 2 147 483 648 to 16 2 147 483 647 User Maximum Output Scale 2 147 483 648 to User or SC 2 147 483 647 SilverMax Outpubonset 0 to Ki 18 2 147 483 647 User Output Rate of Change Limit The diagram on the next page shows the data operations and data flow used for the Input Modes SilverMax User Manual 93 Revision 3 22 Input Mode Data Processing Diagram The Input Offset value is loaded here using a Write Register command or is Data Input SEET b loaded from NV Memory using a To SE S LOAD REGISTER command All data Reg 12 Analog Input or direct from the Serial Interface using the Write Regis
121. he move For example to edit the following command press Advanced SilverMax User Manual Edit MAT Move Absolute Time Based LOW FALSE HIGH TRUE Falling Rising 44 Edit Stop Conditions Revision 3 22 Advanced Usage Native SilverMax Only four inputs are available with the Advanced usage The Index and I O lines 1 2 and 3 Advanced usage is for the times when complex stopping using inputs is required The advanced method can alter the direction of a move based on an input s starting condition toggle the State values that are being checked and evaluate combinations of input conditions A NOTE for QuickControl Users Using the Programming interface the motion Stop conditions can easily be set up using the Motion Command setup screens Input Checking Process for Motion Commands First Check Used to toggle the starting direction of motor The upper nibble of the Input Enable Word and Input State Word parameters are used to determine the initial direction of a move based on the selected states of the selected inputs If any of the selected input conditions are TRUE the motor will move in the opposite direction indicated in the command Additionally if the Toggle first state bit is set the bits representing the desired input that were enabled in the Input Enable Word will cause the corresponding bits in the Input State Word of the Preliminary inputs to be complemented This allows the mo
122. hunt feel more natural A positive value requires the closed loop torque to be less than the open loop torque as well as the error to be less than the magnitude of the limit This usually requires the load to be settling down on its own as even a slight error will cause the torque command to go to its limits when the integrator is on This makes the motor go to zero error before the torque is reduced This mode cause the anti hunt to delay until the motor load has settled down enough for the anti hunt to hold it Using a negative value bypasses the torque test allowing the transition between modes to be only based on position error Adjust the closed loop hold torque as well as both open loop torques to reasonable values Remember that using anti hunt requires motor current heat even if no load is present The heat SilverMax User Manual 112 Revision 3 22 generated is to the square of the torque current so reducing the holding torque to 25 reduces the heating by a factor of 16 Special Step and Direction Tuning For systems using step and direction camming inputs the anti hunt delay ADH setting will delay the transition into hold mode to a time that is consistent with your step rate For example if the minimum step rate is 100 Hz then the delay should be at least 10 or 20 ms to keep the system from transitioning between the modes while running The Velocity Feedforward term must equal the sum of the two velocity feedback terms Makin
123. ial Communications Buffer Size 127 Serial Interface 10 SilverMax User Manual 135 S Servo 97 Servo Control Loop 33 Servo Sample Rate 128 Servo Tuning 27 Setting Motor Position 96 SilverMax Status and Comm LEDs 18 SilverMax 23 Frame 130 SilverMax 34H 3 8 34H 4 Frame 132 SilverMax 34N 1 34H 1 8 34H 2 Frame 131 SilverMax 8 bit and 9 bit Communications Protocols 114 SilverMax Block Diagram 31 SilverMax Control Panel 20 109 SilverMax E Series l O Configuration Table 54 SilverMax Factory Default Initialization File Detailed 24 SilverMax Factory Default Initialization qcp 22 SilverMax Initialization 22 SilverMax Initialization Wizard 19 22 SilverMax Memory Model 67 SilverMax Motion Commands 35 SilverMax Negative Acknowledge NAK Codes 125 SilverMax Polling Status Codes Polling Status Word 126 SilverMax Tuning Commands 99 Single Channel Inputs 60 Single Step 20 Single Step Trace Breakpoint 20 Software 17 Special I O 59 Special Modes amp Operations 76 Specifications 127 Standalone 66 Standalone Mode 66 Standard Motion amp Profile Move Commands 36 Standard Motion commands come in three flavors 36 Standard Motion Profiles 36 Standard Usage Native SilverMax 43 Standard Usage QuickControl 44 Start Character 115 Startup Error Conditions 26 Start Up Kit Hardware Setup 12 Start Up Kits Overview 11 Step amp Direction 58 St
124. ilverMax Initialization Wizard s Option screen BRT Baud Rate default 57 6K Command These programs contains the SilverMax s initialization commands lt can be edited directly or through i Tools gt SilverMax Initialization izard Download the program at the end of the wizard or by pressing the Download button in the Program Info Toolbar Reboot the SilverMax E See the description in Scaling ng for more details COMM Identity Identity Unit ID 16 Group ID 10 COMM Protocol Protocol 8 Bit ASCII COMM Serial Interface Serial Interface Auto COMM Baud Rate Baud Rate 57 6K COMM ACK Delay ACK Delay Auto The serial communications baud rate can be set to lower values such as 9600 or 19200 baud for slower host communications ports or to higher values such as 115200 or 230400 for high speed systems 57 6K is recommended for RS 232 and RS 485 while 19 2K is recommended for RS 232 multi drop Please note this command has no affect on the PC s baud rate If you download an initialization program with a different baud rate than your PC you will loose communications with the SilverMax as soon as the SilverMax reboots To re establish communications change the PC s baud rate to match the new SilverMax baud rate Setup Comm Channels ADL ACK Delay default Auto Normally SilverMax will immediately acknowledge a received command It can do this within
125. ilverMax User Manual 32 Revision 3 22 Digital I O To give the SilverMax more PLC like features there are seven fully programmable digital I O lines Each line is software configurable to be a digital input a digital output or dedicated to a special function These lines can be configured on the fly Digital outputs can be set into tri state mode allowing the lines to be used as both an output and input at the same time Using a variety of dedicated modes these I O lines can also be used for external encoder input for electronic gearing or camming operations Inputs can be Step and Direction A B quadrature or Step up down An external encoder input is provided for dual control loops that enable position control of external mechanisms using a second encoder The E Series can also output Step and Direction A B quadrature or Step up down from its internal encoder To supplement the serial communications digital inputs can also provide simple control over SilverMax operation SilverMax programs that use the digital inputs for program flow control can be written and downloaded into the motor Using the digital inputs the SilverMax can operate independent of any other controlling device Home or position sensors can also be connected to the inputs allowing end of travel control Analog Inputs In addition to the digital I O SilverMax motors accept analog input Four analog inputs share four digital I O lines and will accept O to 5 volt an
126. inally the NAK code all in hexadecimal and delimited with spaces The packet is ended with a carriage return 8 Bit ASCII NAK Response Packet data transmission order Start Character Address Command Code NAK Code Ending Character 1 Byte 2 Bytes 4 Bytes 4 Bytes 1 Byte Carriage Return Example NAK response for a Read Register RRG Command Code 0x0C from SilverMax 10 Ox0A with an invalid Data Register parameter 0A 000C 0007 lt CR gt Example NAK response for a Move Relative Time Based MRT Command Code 0xB1 if SilverMax 16 0x10 is already in motion The SilverMax will NAK back Device Busy as follows 10 00B1 0002 lt CR gt See NAK codes below SilverMax User Manual 118 Revision 3 22 9 BIT BINARY COMMUNICATIONS Advanced 9 Bit Protocol for SilverMax The following section describes the advanced 9 Bit protocol that is used for communications to the SilverMax This protocol defines the Serial Communications packets that are used to send Commands to the SilverMax and to receive SilverMax Responses The protocol provides both Addressing and error checking of the Command Packet to ensure proper delivery The SilverMax checks each command packet for proper syntax length and for a correct checksum before responding to the command The same is used for the Response Packets from the SilverMax The use of an extra 9th bit is one of the main differences
127. kControl may be used to quickly prototype motions initialize and program SilverMax using the serial communications Communication Hardware SilverMax is programmable with two different hardware interfaces for serial communications RS 485 or RS 232 is selectable by initializing the SilverMax for the desired hardware interface RS 485 Multi Drop RS 485 is a two wire serial communications hardware interface By design RS 485 can connect up to 32 serial devices in parallel on the same two wires This provides the ability to network a number of SilverMax units together on a common serial connection SilverMax is designed to work on a network with its individual addressing and communications protocol This offers greater simplicity in harnessing and communicating to a number of SilverMax units on a system If a host controller is used that only supports RS 232 an RS 232 to RS 485 converter can be used that will allow the host to communicate with a SilverMax RS 485 network RS 232 RS 232 offers the easiest way to connect SilverMax to a host computer Through appropriate cabling a SilverMax can be directly connected to an RS 232 serial communications port A drawback of RS 232 is that typically only one SilverMax can be connected to the serial port at a time If a network is required the RS 485 version with a converter board RS 232 to RS 485 can be used RS 232 Multi Drop SilverMax is also able to work on an RS 232 multi drop network with a li
128. l generator The generator can algorithmically calculate and create S Curve and trapezoidal motion profiles The motion profiles are built from parameters such as distance acceleration and velocity provided by the user The following is a discussion on the various command types that provides the user with a number of different techniques for creating a motion profile Standard Motion Profiles Standard Motion commands provide a basic Acceleration Velocity Deceleration Trapezoidal shaped move that goes a given Relative Distance or to a defined Absolute Position Standard motions use both Linear and S Curve acceleration and deceleration for the excellent control of the load under all conditions Once initiated these moves cannot be altered dynamically Standard Motion commands come in three flavors e Parameterized Where all parameters are sent with the command e Registered Where the Distance or Position parameters are located in a Data Register e Extended Registered Where all of the move parameters except for the Stop Conditions are located in Data Registers Each flavor has two different parameter types 1200 1000 800 Velocity RPM E O 8 8 N o o 0 Absolute or Relative The move runs to a given Absolute Position or a Relative Distance Velocity or Time The motion profile uses Acceleration and Velocity or Acceleration Time and Total Time for the speed parameters SilverMax Standard Motions Full S
129. l motion commands can be stopped using a digital input or other bit state conditions When a motion command is stopped using inputs this condition is set If the input was an end of travel sensor SilverMax could also shutdown to turn off power to the motor Wait Delay Count Exhausted Sometimes used for a Watch Dog timer The Delay counter can be pre set with a time value that will count down automatically When the counter reaches 0 this condition is set Setting the Delay counter and enabling this condition prior to an operation that should complete in a given time allows a Timeout function If the operation does not complete before this condition is disabled issue another Kill Motor Condition command a shutdown will occur Over Voltage Can be used for handling a Over Voltage condition Over Voltage will always cause the motor to shutdown regardless of the Kill Motor Condition settings However if some type of error recovery is desired setting this condition will allow SilverMax to continue operation after the Over Voltage This is useful when the over voltage is due to heavy deceleration and it is required to regain control of the load Under Voltage Don t use this use the Power Low Recovery instead Don t use this unless a motor shutdown is what you really want to do SilverMax has a unique feature in that a low voltage condition can be used to trigger a special recovery routine that can be use to exit
130. l moves e Position Data Register 20 e Acceleration Data Register 21 e Velocity Data Register 22 e Deceleration Data Register 23 e Offset Data Register 24 Advanced Dynamic Motion Control 1600 1400 1200 a 1000 E 800 D o 600 Oo e 400 gt 200 0 T T T T 0 00 0 50 1 00 1 50 2 00 2 50 3 00 Distance revs SilverMax User Manual 40 Revision 3 22 Velocity Mode Control From a Host Controller or using an internal program Velocity profiles can be created on SilverMax using the Velocity Mode Immediate Type command Host Controller or the Velocity Mode program Type Internal program that will allow changes in velocity at desired time intervals This allows the creation of a complex shaped profile where different velocities are required at different times during the move In this mode distances cannot be controlled precisely therefore other operations such as a final MOVE ABSOLUTE command must be used for precise positioning Use the Profile Move commands for complex position control Velocity control can be set so that the SilverMax runs at a constant velocity for an indefinite period of time The ERROR LIMITS command may be used in conjunction with this command to prevent excessive wind up under conditions where the velocity cannot be maintained See Error Limits Command for more details also see Drag Operation below Torque Control Using Velocity Mode
131. l numbers shown in hex 10 03 OC 00 01 20 1 s Complement invert Invert 20 DF Add 1 DF 1 E0 Checksum E0 Examples Example Send a Read Register RRG command as follows Command RRG Command Code 12 Address 16 Hex 0x10 Data Register 1 Fields with data shown in Hex Adr Len Cmd Data Register Checksum 10 03 OC 0001 EO Byte stream with data shown in Hex 10 03 0C 00 01 E0 Example Send a MOVE RELATIVE TIME BASED MRT command to SilverMax as follows SilverMax User Manual 120 Revision 3 22 Command MRT Command Code 177 Address 16 Distance 4000 counts Hex 0x00000FA0 Ramp Time 833 ticks 1 tick 120us 0x00000341 Total Time 8333 ticks 0x0000208D No stop conditions Fields with data shown in Hex Adr Len Cmd Distance Ramp Time Total Time Stop Enable Stop State Checksum 10 11 B1 00000 FAO 00000341 0000208D 0000 0000 8E Byte stream with data shown in Hex 10 11 B1 00 00 OF AO 00 00 03 41 00 00 20 8D 00 00 00 00 8E Poll Command Packet The Poll Command Packet is a special command packet that has been shortened to minimize the communications overhead as this is probably the most frequently sent packet 9 Bit Binary Poll Command Packet data transmission order Address Length Checksum 1 Byte 9th bit set 1 Byte
132. lative Time Based MRT 37 Register Move Relative Time Based RR Dooicicnnnnccccnonacocinnnoccccnnnorcccnn non cnnn nar ncn rra rn rr 37 Extended Register Move Relative Time Based RT 37 Absolute Move Commands iersinii e a deb 38 Move Absolute Velocity Based MAN 38 Register Move Absolute Velocity Based RAN 38 Extended Register Move Absolute Velocity Based AV 38 Move Absolute Time Based MAT 38 Register Move Absolute Time Based RAT nn cnn narrar rr 38 Extended Register Move Absolute Time Based AT 38 Moves Using Data Register 39 Profile MOVES dee 40 Velocity Mode Control ee EENS EAE AAS ATASATA dada 41 Torque Control Using Velocity Mode A 41 External Trajectory Control inoan aA AETA A A AA AETA AA AE A AEA AAAA 42 SilverMax User Manual 3 Revision 3 22 Scaled Step and Direction Electronic Gesang 42 Position p tt Mode otitis ER A ee dE ee td 42 Velocity and Torque Input Modes Annen eent nn nenene ent 42 USING INPUTS TO STOP MOTIONS wscccecccctctececcendeeceesecenceustereceesecenssueveceeeeustereceeveceessvenceeeeeveccresenveceessoaete 43 Standard Usage Native SilverMax ccccccsscceeeseeeeeeeeeneeeeeeeneeeeeeneeeesaeeeeesseeneeseseeeeesaseeneeenseeeeeensenneeenees 43 Standard Usage QUiCkControl eeeeceeeeeeenneeeeeee seen ence seen sense eeseee rr 44 Advanced Usage Native SilverMaX ccccssescseseeeseeeeeeeseeeeeeeeeseeneeseseeeeeseeeeeeeeseseenee
133. le is filled out the next step is to convert the Binary number into a Hexadecimal number We do this by first grouping the Binary values into sets of 4 this is call a Nibble In Hexadecimal a Nibble can represent a value of O to 15 The letters A B C D E F are used in place of 10 11 12 13 14 15 This gives a numbering system as shown in the following set 0 1 2 3 4 5 6 7 8 9 A B C D E F Binary Nibbles are converted to a number by adding up the value of each binary digit The table below shows the value of each bit in a nibble If a bit is set to 1 its associated value is added into the nibble Remember to convert the numbers 10 15 to A F for Hexadecimal notation 4 2 4 2 1 4 2 1 4 2 1 Bit Values P 1 1 Binary word j a f o Jo Nibbles SilverMax User Manual 49 Revision 3 22 The nibbles are now joined together to form the Hexadecimal word Hexadecimal Word When working in Hexadecimal programmers use a Ox notation at the beginning of the number to identify it as Hexadecimal T his avoids any confusion as to the base system of the number Hexadecimal Word 0x9001 Hexadecimal is great for programmers who are writing software in Basic Visual Basic C or C but for those who are trying to put together ASCII strings on a PLC or other simple controller the number needs to be converted to Decimal The easiest way to do this is to use the Scientific Calculator application in Win
134. leration Feedback Gain Ka 0 200 Acceleration Feedforward Gain Kaff 0 200 Integrator Gain Ki 0 2000 Velocity 1 Feedback Filter Fv1 50 200Hz Velocity 2 Feedback Filter Fv2 70 400Hz Acceleration Feedback Filter Fa 30 2000Hz User Accessible SilverMax Tuning Parameters Proportional Gain Kp Of all parameters this is the most straight forward to understand and use The position error of the motor provides the most basic information to the algorithm about the state of the motor It is calculated from the motor s actual position and calculated target position Torque output is controlled proportionally to the amount of position error detected By adding in a gain value the error is amplified providing an appropriate torque output depending on the load and desired stiffness Higher gain settings increase the motor position holding stiffness and reduce position error Torque Kp Target Position Actual Position Torque Kp Position Error The best analogy to Kp is a simple spring If SilverMax were to be replaced by a spring Kp would be the spring s stiffness If you were to rotate the shaft you would be either winding or unwinding the spring The more you rotated the shaft the more the spring would fight you SilverMax User Manual 100 Revision 3 22 1 Kv1 0 0 0 Kv2 0 Kvff 0 Kaff 0 Ki Ka Kp positions of the motor respectively That is the Target Position is where the motor is su
135. ll eight Digital Inputs plus a few internal conditions are available with Standard usage Input checking is done on only ONE selected input By using a negative number in the Stop Enable parameter the motion commands can look at a single Digital Input or Internal Status Condition to stop a motion This is the simplest usage for stopping on Input The following is a list of possible inputs Stop Enable Code Input Source Description 0 Do not Check for Input 1 Hardware IO 1 2 1 0 2 3 7 1 0 3 4 UO 4 5 7 1 0 5 6 k IO 6 7 S IO 7 Current Index Sensor 8 Future implementation use 9 or 10 9 E Internal Index Sensor 10 s External Index Sensor 11 Internal Status Moving Error Status 12 S Holding Error Status 13 S Trajectory Generator Active 14 S Delay Counter Active SilverMax User Manual 43 Revision 3 22 The Stop State is set as follows Stop Description State Stop When Stop Enable Condition is 0 FALSE 1 TRUE 2 FALLING TRUE to FALSE Transition 3 RISING FALSE to TRUE Transition The value entered is used to evaluate the TRUE condition for stopping If for example a motion needs to stop with input 4 in logic high 5 volts on input a 1 should be used for the Stop State Standard Usage QuickControl The stop conditions for any move can be edited by pressing the Advanced button on t
136. lverMax User Manual and the SilverMax Command Reference ES Wick bar Feiner ree The QCI SKO Start Up Kits SilverMax motor personal computer and power supply not included provide a means for testing and evaluation of a SilverMax motor through an Optical I O board With a standard PC serial COM port and SilverMax a user supplied power supply any SilverMax motor can be o fully programmed and operated through an Optical I O d User Manual board with RS 232 communication protocol gt The SilverMax Interface cable is included in each kit to connect your SilverMax motor to the Optical I O board An additional cable is provided for the connection of the I O board and a personal computer Also included are the QuickControl Software the SilverMax User Manual and the SilverMax Command Reference SilverMax User Manual 11 Revision 3 22 Start Up Kit Hardware Setup NOTE Set up differs slightly between kits so read entire set up section of manual before connecting anything to your motor QCI SK1 FS 1 Start Up Kit Setup The SilverMax RS 232 Y evaluation cable supplied with Kit 1 has three connectors The center 15 pin attaches to the 15 pin Female connector male connector on the D15 High Density SilverMax motor The 9 pin female connects to I O connector the supplied Shorter leg with a breakout D9 connector module The 9 pin female Comm connector longer leg with a D9 connector connects
137. lverMax is a high performance motion system As with any motion system it is capable of producing sufficient mechanical output to cause bodily injury and or equipment damage if it is improperly operated or if it malfunctions The user shall not attach SilverMax to any mechanism until its operation is fully understood Furthermore the user shall provide sufficient safety means and measures to protect any operator from misuse or malfunction of the motion system The user assumes all liability for its use SilverMax User Manual 8 Revision 3 22 What is contained in this User Manual This SilverMax User Manual is a reference manual design to aid the user in the operation and programming of the SilverMax Servomotor family A companion publication the SilverMax Command Reference has the detailed description of the SilverMax command set Many times this manual will discuss or reference the commands detailed in the Command Reference For this reason both publications are needed for a full understanding of SilverMax operation and programming The User Manual is laid out to take the user through a natural progression of product usage Getting Started is where to begin since using a Startup Kit is probably the user s first experience with trying to setup and operate a SilverMax motor SilverMax Initialization is next and goes though the Initialization and Initialization programs used to setup SilverMax for a specific application SilverMax Ove
138. m Error Limit Disable The conditions are derived from the Internal Status Word that Last Calculation Was Positive TRUE Halt Command Was Sent Disable is used by SilverMax in a variety of commands such as Last Calculation Was Negative TRUE Sensor Found On Last Move Disable the JUMP command Index Found Rarely i Disable Wat Deby CountExhausted Ier Sine these ctatus Disable Over Voltage Disable word Internal Status R E Woe II Disable Under Vag ege different commands in SilverMax this condition is available but is not necessarily useful as a Over Temperature motor shutdown condition Last Calculation Was Zero Positive or Negative These are rarely used When a calculation takes place Using the CALCULATION command the result of the calculation will be one of the above This allows motor shutdown to occur based on the results of a calculation If for example a Position move parameter should never be Negative when calculating a move internally enabling the Last Calculation Was Negative to TRUE will shutdown the motor UO 1 2 and 3 Used for E Stop conditions Three of the seven digital Inputs are available as shutdown conditions They are probably most useful when needing an emergency stop E Stop using hardware inputs When using the controlled shutdown method these inputs can be used to redirect motor or program operation Over Temperature Always Used
139. makes doing time critical profiles easy When the desired time to make the move is fixed using this command will cause SilverMax to make the move no matter the position within limits in the exact time specified This is very useful where a number of different axes must be precisely coordinated in time Register Move Absolute Time Based RAT Three parameters are entered Data Register Acceleration Time amp Total Time The Data Register specified holds the Position parameter The other two parameters are the same as MAT Extended Register Move Absolute Time Based XAT One parameter is entered The Starting Data Register Only the Position register location is sent as a parameter the Acceleration Time and Total Time must be stored in two successive Data Registers SilverMax User Manual 38 Revision 3 22 Moves Using Data Registers A number of the Standard Motion commands can use data registers for their parameter information This allows SilverMax and the user more flexibility in programming a Motion The most common is when Motion commands are used as part of a program and the parameters need to change depending on operating conditions Homing to Encoder Index qcp The Example at the Right shows a homing program that uses the Internal Index Command i The motor will move until it hits the encoder Index Since it cannot 4 sensor to stop the motor at a precise once p stop immediately the motor will overshoot then mov
140. mand Continuing Operation Continuing on is less complicated in that the motor does not have to be re initialized This may be as simple as doing a Load and Run Program of the corrective action program SilverMax User Manual 86 FOREVER Startup Program Begins at power up Command i Move back and forth until Motion Error occurs and runs Kill Motor Recovery i Use the Kill Enable Drivers to allow SilverMax to leave the motor 3 drivers enabled during motor shutdown Kill Enable Drivers Enable Multi Tasking operation so that a Motion can continue even when the Kill Recovery program is called Enable Multi Tasking Set up the Error Limits that establish the amount of error which will cause the motor shutdown Error Limits Enable the Motion Error condition for motor shutdown Kill Motor Conditions If Motion Error Define the Kill Motor Recovery process that will be used In this case a Recovery Program will ba call to deal with the error On Kill Motor Condition Load and Run Program Fault Recovery Move the motor back and forth waiting for a User induced Motion error Move 10 revs ramp time 199 92 mSec total time 2000 04 mSec Move 10 revs ramp time 199 92 mSec total time 2000 04 mSec Jump to FOREVER Command A fault has occurred E By default SilverMax automatically zeros the Torque Limits and Disables the Motor Driver 3 Give the motor a little time to
141. may be set slightly higher to assist with the acceleration of high inertial loads Integrator Gain Ki The integrator parameter is the most important term for controlling steady state position error The integrator works over time to bring the motor to zero error when the target position and the actual position differ The longer there is position error the harder Ki will work to get rid of it This term is commonly referred to as the I term in the traditional PID control loop Unlike a PID servo the PVIA integrator term can be set very high without causing hunting This is because PVIA automatically clips the accumulated error to reduce the effects of integrator windup Running SilverMax with 0 integrator gain is a valid condition when tuning or where steady state position error is not a critical concern The best way to see the effects of Ki is to start with Kp 7 and plot a short move The following is a 500 count move SilverMax User Manual 106 Revision 3 22 SS SE SS SE LIS an DEE Ss EE GE EE EE GE EE gt hdg E un a TEE EIERE SERS DEES GEET EE BEE E ZE j EE SE O Position If Ty E 1 e SR LEE s Fi AA E ES IR e SG S SS E EE al ee EE SE D SC EE E E ae SE SE SE E Kp 5 all other K s 0 Notice how the motor never actually gets to the target There is not enough torque generated by
142. mited number of nodes The number of nodes is limited by the communications drivers and cabling requirements typically no more than 5 This is a great way of attaching multiple SilverMax to a standard or PLC serial port i e COM1 Communication Protocols A simple 9 bit protocol can be used where systems require high data rates deterministic operation and robust error checking The 9 bit protocol transmits data in binary form which minimizes the number of bytes required fora command An 8 bit ASCII protocol can be used where generic serial communications is required and speed or determinism of transmission is not critical SilverMax E Series motors are shipped from the factory with both protocols available The desired protocol is selected when first initializing a SilverMax unit For more information see the 9 Bit Binary Communications and the 8 Bit ASCII Communications sections below Command Processor The Command Processor interprets each command sent to the SilverMax using the serial communications and then initiates the desired operation The Command Processor checks each received command to verify that proper syntax is used If a command is complete the Command Processor will perform all the necessary functions required to set up and execute the command Ifa command is incorrect the Command Processor will issue an error code through the serial communications The Command Processor uses a Command Buffer to store and execute commands S
143. motor operation before power is totally lost Use the Power Low Recovery command to set up this operation The under voltage threshold can be set using the Low Voltage Trip command SilverMax User Manual 84 Revision 3 22 Kill Motor Recovery Program Uncontrolled Shutdown Handling the Shutdown The motor Fault Recovery Program shutdown may occur while the motor is in motion If this is true there may be a period of time required to allow the motor to come toa complete stop The simplest way to deal with Command A fault has occurred E By default Silver ax automatically zeros the Torque Limits and this is to wait using a time delay for a period Disables the Motor Driver of time required until it is believed that the ke SES e a E 3 Give the motor a little time to stop This can be increased if needed motor has stopped This depends on the Wait for 500 mSec system implementation therefore the time Now that the motor is stopped set the Target to the Position delay would vary greatly When the motor has ere CES stopped the error processing can begin Re set the Kill Motor Conditions This is required if after this recovery routine normal operation is restored S LAG ill Mot tions Processing the Error Condition Geo Sage Depending on the shutdown condition Because the Torque Limits were set to zero they need to be enabled there may be a number of different E Unk things that must be done to clear the error an
144. n 93 Input Power 127 Inputs 55 Installing QuickControl Software 17 Integrator Gain Ki 106 Intelligent Motor Shutdown 87 Internal Trajectory Control 36 Introduction 8 K Ka 100 106 Kaff 100 106 Key Features of 8 bit ASCII 114 Key Features of 9 bit Binary 114 Ki 100 106 Kill Enable Driver 82 Kill Motor Conditions 81 83 Kill Motor Recovery 81 Kill Motor Recovery Program Controlled Shutdown 86 Kill Motor Recovery Program Uncontrolled Shutdown 85 Kp 100 Kv1 100 103 Kv2 100 103 Kvff 100 104 SilverMax User Manual L Last Check This may now stop the motor 45 Length 119 Long Term Storage in Non Volatile Memory 75 Main Init 0 25 MAT 38 Math Operations 95 MAV 38 Maximum Acceleration Time when using Time Based Commands 128 Maximum Operating Temperatures 127 Mechanical Clutch 80 Mechanical Specifications 129 Misc 30 Mode Commands 69 Motion 28 Motion Commands 69 Motion Parameters 128 Motion Profile Input Options Table 48 Motor 27 Motor Driver Commutation 34 Motor Shutdown Kill Motor Conditions 81 Motor Encoder Alignment Routine 28 Moves Using Data Registers 39 MRT 37 MRV 37 Multi Tasking Operation 87 N 9 Bit Binary 114 9 Bit Binary Communications 119 NAK 125 NAK Response 118 124 Negative Acknowledge 125 Non Volatile Memory 33 68 Non Volatile Memory Size 127 O Open to Closed Error 76 Open Loop mod
145. n 3 22 TEST the move Note any changes in the operation or sound in motion 5 Increase Kv2 and Kvff Increase both velocity terms to 10 times 10X the default values TEST the move Note any changes in the operation or sound in motion If a high frequency screech occurs in a low inertia system lower the Kv2 and Kvff until the sounds subside If excessive overshoot occurs increase Kv2 and Kvff Typical adjustments are by a factor of 2 i e either divide by 2 or multiply by 2 Typically Kv2 and Kvff are adjusted until there is some screech during the move but not at rest 6 Reduce Fv1 and Fv2 Reduce Fv1 by 3X 1 3 and make Fv2 3xFv1 Example Default Fv1 209 Fv2 209 Change to Fv1 70 Fv2 210 This helps reduce the high frequency noise in the system TEST the move Most noise should be gone and the overshoot at minimum Keep decreasing the velocity filters until the noise goes away Remember to keep Fv2 3xFv1 Typically Fv2 should be well above the system highest velocity For example if a 100ms is as fast as the SilverMax can 100ms 10Hz then you might set Fv2 at 100Hz 7 Iterate Kv2 and Kvff Fv1 Fv2 With noise gone or greatly reduce try increasing Kv1 and Kvff to increase the damping decrease the overshoot When you have minimum noise and overshoot go to the next step 8 Kv2 and Kvff x 90 Decrease both velocity terms by 10 to loosen up the system TEST the move Bring up the Strip
146. n Flag Flag Edge t H _ Input 1 0 gt Input 1 1 gt The A scenario will move the motor clockwise to the Flag edge and then stop In scenario B the motor will move counter clockwise and then stop at the Flag edge The B scenario causes the motor to reverse direction before the move and toggles the State of the OR input 1 Toggling the State of input 1 allows the motor to stop when the sensor moves off of the flag The Command example is shown in the 8 bit ASCII protocol form Address Input Enables 36865 16 135 40000 1000000 100000 4097 The table below shows how the value of 4097 was derived Toggle Pre Direction Toggle Preliminary Inputs States Enable Enable Bit 15 Bit 14141142 44 Ho EA a AA a J CEA EEE IAEA CALDERAS E OPS DEE So EAN APA ee VAR AND Inputs Enable OR Inputs Enable Input Enable Word 0x1001 in Word Hexadecimal form Hexadecimal 0x1001 4097 Decimal Input Enable Word 4097 in Decimal form The table below shows how the value of 36865 was derived deere Direction Toggle Preliminary Inputs AND Inputs State OR Inputs State Bit 15 10 9 8 7 6 5 4 3 2 1 0 1 0 1 1 Ao o Input State Word 0x9001 in Word Hexadecimal form Hexadecimal 0x9001 36865 Decimal Input State Word 36865 in Decimal form SilverMax User Manual 52 Revision 3 22 Advanced Usage QuickControl The stop
147. negative Wait for Anti Hunt Delay to count down Torque lt Limit Go Open Loop Is Delay Torque Torque count 0 Limit Parameter 1 sets when to EXIT Anti Hunt and go back to Closed Loop Is Error gt P1 Go into Closed Loop Operation No Ge SilverMax User Manual 79 Revision 3 22 Drag Mode Like a Mechanical Clutch Most Servo systems can suffer from a problem called wind up This condition occurs when a servomotor cannot keep up with a move or is stalled by a mechanism jam If the jam is released or whatever is holding back the motor goes away the motor can spin at very high speed to catch up Commonly the way to prevent this is to simply shutdown the motor It many cases this is fine especially if it is due to a jam but there are case where shutdown is not acceptable A different method would be to somehow forgive the error like a mechanical clutch does For a mechanical clutch when the torque exceeds the clutch limit it will slip allowing the motor to continue to move and preventing wind up SilverMax has a feature that allows it to do essentially the same thing Drag mode is set in the Error Limits ERL command see the Command Set Reference for details Example Use QuickControl to set the drag so LETS Si SI TS LS that it will begin when the Moving Error is greater than 100 or when the Holding Error is greater than 20 set the following error limits Cancel Note t
148. nly register reading or writing a multiple register block into out of non volatile memory when the registers are not in the user block 10 40 Also trying to directly read or write to the buffer to an invalid address negative or larger than the buffer or trying to read or write zero words of data Also get one from the Download command if the magic word is incorrect Bad Response The requested return data was too large for one packet The serial Packet Request communications buffer is can transmit only 31 bytes at a time Break the request into multiple packets SilverMax User Manual 125 Revision 3 22 SilverMax Polling Status Codes Polling Status Word See Poll command under Status Commands section Also see Polling SilverMax Using the Poll Command above Word Description Bit Bit 15 Immediate Command A foreground command that was requested from the immediate mode has completed such as Non Volatile Memory Storing operations Also set if multitasking is enabled no additional commands are waiting in the buffer and a motion command completes Bit 14 Non Volatile Memory A checksum error occurred while trying to read some data or a Checksum Error program from non volatile memory Commands such as LRP RLN and RLM can cause this error Bit 13 Program Command The commands in the Command Buffer just completed Note If Done multi tasking is enabled this will not be set until all motions have also finished Check parameters
149. ocity of the move using 18 In this case the Velocity is limited to 100 RPM SilverMax User Manual 91 Revision 3 22 5 Volt supply df Differential Analog Input pe Example Using a Joystick This example uses a Joystick that has an internal voltage divider to provide a voltage Power Ground 1 i KC 7 RS 485 A RS 232 Tx__ 2 RS 485 B RS 232 Rx_12 Analog JoyStick Logic Ground 8 reference This method minimizes effects from ee e power supply variation and electrical noise e EES VO 3 4 Analog 1 1 0 4_14 Analog 2 I O 5 _10 Analog 3 VO 6 5 O Analog 4 1 0 7 15 Example Program Description Position Input Mode Data is continuously read in differentially from Analog Inputs 1 amp 2 Raw ADC value is placed into Data Register 12 SilverMax 17 amp 23 Frame High Density DB15 every 120usec A Single differential data read is done from Analog Inputs 1 amp 2 This is dynamic offset data from the Joystick that is placed Capacitors used to lower input impedance Two Analog Inputs are used in differential mode to minimize noise in Data Register 13 Analog Input Mode Positioning qcp Process Example Assume 12 10000 Assume 13 16000 Step 1 13 is subtracted from 12 16000 10000 6000 Step 2 Remove deadband value 14 sign ABS 6000 100 5000 Limit and Scale using 15 Because the result is less then 32767 it won t be limited
150. on Velocity and Torque Input Modes The Velocity Input Mode VIM and Torque Input Mode TIM commands use the same input sources and techniques as the Position Input Mode PIM VIM and TIM will use the Target Register for Velocity and Torque respectively SilverMax User Manual 42 Revision 3 22 USING INPUTS TO STOP MOTIONS Commands that use inputs to stop their operation can use a Standard or Advanced process in detecting desired input stop conditions Eight Digital Inputs are available for evaluation One of the inputs is a dedicated internal input that is tied to the Internal Encoder Index sensor The index sensor is able to detect a single count position out of the 4000 in one revolution one count in one revolution This input is referred to as the Index The other seven inputs are user configurable These inputs can be Home sensors End of Travel sensors or even digital inputs from a PLC or Master Controller Whatever the inputs are they can be used either alone or together to affect the operation of the motion commands The following shows the process that is used for sensor detection and utilization SilverMax commands can be entered in either their native form or from QuickControl The native form is required when commanding the SilverMax from a host controller such as a PC or PLC QuickControl would be used for any stand alone application Both interfaces are described below Standard Usage Native SilverMax A
151. on 3 22 desired mode for continued use Data Register Commands Data Register commands that write data to Non Volatile Memory will suspend program execution during the storing process The Non Volatile Memory takes a certain amount of time to complete a Write Cycle due to the physical characteristics of the Non Volatile Memory storage cells All other commands All other commands execute within a single servo cycle and therefore do not effectively block program execution Program Flow Control Programs do not just sequence from one line to the next Branching both conditional and non conditional can be performed at any time Using the JUMP PROGRAM CALL PROGRAM RETURN and LOAD AND RUN PROGRAM commands very complex program flow control can be accomplished Using the Program Flow commands common conditional program flow techniques can be created Conditional Program Flow Conditional program flow control is essential for building complex operations in any kind of a programming environment SilverMax can use a JUMP command in a number of different ways to achieve traditional conditional program flow If Then Else The example shown demonstrates This is an example of an IF THEN ELSE statement using the JUMP command to build an d the a number is Positive move Clockwise Else if the number is IF THEN ELSE statement All Negative move Counter Clockwise If the Number is Zero don t j imove programming languages
152. onstantly modified Long Term storage is typically used when SilverMax is running in Standalone mode or the programs are changing only on occasion Temporary Storage in Program Buffer Temporary storage is actually the first step toward Long Term storage The same procedure is used for downloading the program into the SilverMax Program Buffer as described above The only SilverMax User Manual 74 Revision 3 22 difference is that the final command Store Program SPR is not sent Instead the Run Program RUN command is used which will immediately execute the program The program will remain in the Program Buffer until over written or power to the SilverMax is removed Long Term Storage in Non Volatile Memory Long Term Storage of programs in Non Volatile Memory enables SilverMax to Keep programs on board even after power is lost Storing the program Long Term is simply the final step of the downloading process Using the Store Program SPR command the program currently loaded into the Program Buffer can be transferred into the Non Volatile Memory This process takes a bit of time to do approximately 120usec for every 10 words so typically it is done off line The memory cells used for Long Term storage are a type that Wear Out with usage being written to The current devices used can be written approximately 100 000 times before the cells become unreliable For this reason Non Volatile Memory should not be used for data variable spa
153. ory NOTE Example shows command syntax using the 8 Bit ASCII Protocol The following shows the Download sequence 1 A Clear Program CLP command clears any data out of the Program Buffer 16 8 CR 2 A Start Download SDL command puts SilverMax into the download mode Remember as long as this mode is active further commands sent to the SilverMax will be downloaded to the Program Buffer In other words they will be stored not executed 16 9 CR 3 Program Line 1 A MOVE RELATIVE VELOCITY BASED MRV command is sent that will be the first command in the program Remember because we are in Download Mode the SilverMax will not move when it gets this command It will store it at the beginning of the Program Buffer 16 135 80000 10000 53687100 0 0 CR 4 Program Line 2 A SET OUTPUT BIT SOB command is sent to set output 1 HIGH 16 205 1 CR 5 A Store Program SPR command is used to terminate the download process and store the contents of the command buffer into non volatile memory The memory address used in this case is 140 If another program or Data is stored at this address it will be over written by this command SilverMax does not check memory for what is previously stored 16 13 140 CR Temporary Vs Long Term Storage Programs can be stored on the SilverMax in a Temporary or Long Term manner Temporary storing can be used when programs are being downloaded by a Host system and their behavior is being c
154. ost mode is typically when an external computer based controller is governing each operation of the SilverMax Standalone mode is when the motor is operating completely independent of any other computer based controller These modes can be combined in a number of different ways to form a hybrid system design Host Mode Host mode is when SilverMax is connected using the Serial Interface to a Hosting computer such a Desktop Computer PC or PLC In this mode the SilverMax waits for each command to be sent executes the command and then waits for the next command In this mode no internal program is running that would allow the unit to perform an operation by itself In Host mode most of the SilverMax commands are available to execute on an Immediate basis Some commands such as the JUMP or PROGRAM CALL are designed to only be used inside programs downloaded into the motor Certain commands such as the Motion Profile Commands can only be executed when the motor is Idle These are called program Type because they are intended to be used in SilverMax programs A few commands such as Status Commands can be executed at any time even when a motion is executing The primary purpose of Host mode is to allow SilverMax to be a Passive Follower to the Host controller waiting for each command before doing any operation This allows a system designer to achieve many extended operations by having the Host controller and the SilverMax interacting In case
155. pply and Pwr Gnd connection must be connected to Ground of that power supply The red wire at the end of the SilverMax 34 IP 65 Cable is connected to V of the power supply The black wire connects to Ground BOTH these and the power connections on the Optical I O cable MUST be connected Power Supply Flying leads Connect to user supplied power supply Red to V and black to Ground 15 pin Interface Cable Connect to Optical I O Module Power Supply Connectors Required for Driver Enable RJ 11 Cable Connects to RJ 11 port on Optical I O Module to PC COM port SilverMax User Manual 16 Revision 3 22 Installing QuickControl Software NOTE Do not power up the SilverMax until the setup procedure specifies this action NOTE QuickControl controls the SilverMax in real time it therefore needs full access to your PC s resources When installing the QuickControl Software it will be necessary to close all shared files and exit open applications It is also highly recommended that applications requiring large system demands be closed and any screen saver disabled when running QuickControl Do not power up the SilverMax or Power Interface Box until the setup procedure specifies this action 1 Upgrading from previous versions Rename the current QuickControl directory to QuickControlOld or a name of your choice This will save your old version and allow QuickControl to install correctly
156. pposed to To demonstrate the effects of Kp the following is a Strip Chart from the QuickControl Control Panel of a motor with the Filter Constants FLC left at their default values and the Control The Strip Chart plots a 4000 count 100ms move with a 25ms ramp time MAT command The channels plotted are the Position and Target Position which represent the actual and target be The Position is where the motor actually is Constants CTC set as follows Ea GK Select Channels a ca E Sample YMinfo Y Mawf5200 ma SS SE ES E amp E 140 E 1 Kp 2 will double the torque and produces the following strip chart Notice how much error has to be developed in order to make the motor move Setting Kp Revision 3 22 101 SilverMax User Manual Strip Chart Y Milt Y Max5200 Sample ms 200 Co Select Channels Cancel E 2 0 Tus Le SC EE SE E SE SE SE SS EE E E E T de gees r A aie f a E EST EE DEEN EE SE SE DE SE eae Although less error is required to generate sufficient torque once the motor gets moving it overshoots and does not come back and until enough negative torque is generated Increasing Kp will continue to have this effect The overshoot is often called ringing See what increasing Kp to 10 does SE E E SE E SE SE e S ES SE SE z amp E a seas E Ss SU EE
157. rations perform data manipulation on the Data Registers usually preparing them for other calculations See Data Register Commands for other operations such as writing to NV Memory Loading or Copying copies the data from a Data Register into the Accumulator Any Data Register can be loaded The Load High Word loads only the Upper Word 16 Bits of the Data Register into the Accumulator Load Low Word loads only the Lower Word 16 Bits of the Data Register into the Accumulator Saving takes the contents of the Accumulator usually after a math operation and copies it into a Data Register This can only be done to writable Data Registers see Data Register Command section Clearing clears the contents of the Data Register to 0 Word Manipulation There are several operations for moving the 16 Bit words around in a Data Register Setting Motor Position Subtract from Target and Position is a special purpose operation that subtracts a value from the Target Data Register and the Position Data Register simultaneously This is used to explicitly set the SilverMax motor position to a pre determined value Subtracting a negative value is the same as adding SilverMax User Manual 96 Revision 3 22 TUNING SILVERMAX Control System Overview The SilverMax factory default servo loop parameters have been optimized for a nominal load range for each motor Given a fairly tight coupling they meet the requirements of mo
158. red in non volatile memory GOL Go Open Loop Single Loop Control TQL Torque Limits GOL Go Open Loop SLC Single Loop Control Start motor encoder alignment by setting torque to 0 and entering Open Loop and Single Loop modes see below for more detail on Motor Encoder alignment SilverMax User Manual 26 Revision 3 22 Motor These motor settings are required before the SilverMax E Ben GE can attempt any kind of move including the Motor to The commands Encoder alignment Motor Constants MCT Phase Advance PAC MCT Motor Constants are set dependent on input voltage by PAC Phase Advance Constants a factory derived fomula These t Each SilverMax is set up with unique motor parameters ge Saan EEan ec that program it for operation at a set voltage The most MOTO Motor And Phase Advance common voltages are 12 24 36 and 48 QuickSilver CS Controls provides parameters for these common voltages Phase Advance Constants in complete initialization files For other voltages contact This command is edited the same time e S A MCT is edited The edit dialog box QuickSilver Controls Product Support to obtain does both at the same time parameters for any voltage between 12 and 48 These Phase Advance Constants parameters should not be edited manually In Auto QuickControl will query SilverMax for its current voltage and set this command to match If you are programming SilverMax at a different voltage than will
159. res only one Jump command at the end This example shows a repetitive move that exits only if a Moving Error is encountered SilverMax User Manual This is an example of a FOR NEXT loop Loop a program 10 times using Data Register 11 as the loop counter when the count 0 end the program Write 10 to User 11 Copying Register 11 in the accumulator 10 will test for 0 FOR 11 10 TO 1 Accumulator 10 User 11 NEXT 411 1 END 71 WHILE END WHILE END Jump to END If Last Cale was Zero Cause 1 0 line 1 to go Low Clear Output Bit 1 Wait for 500 mSec Cause 1 0 Line 1 to go High Set Output Bit 1 Wait for 500 mSec This is where Register 11 the counter is decremented by 1 Decrement User 11 Jump to FOR 11 10 TO 1 End Program This is an example of a WHILE loop The Program will Loop until 140 Line 2 and 3 are set to there desired states dy Line 1 will toggle waiting for the inputs Jump On AND to END iF1 0 2 LOW and1 0 3 HIGH Cause 140 line 1 to go Low Clear Output Bit 1 Wait for 200 mSec Cause 140 Line 1 to go High Set Output Bit 1 Wait for 200 mSec Always Jump back to the WHILE condition Jump to WHILE End Program This is an example of a DO WHILE loop The Program will Loop until a Moving Error is detected The Internal Status Word must be clear to remove any error that E Clear Internal
160. rface see Serial Interface SIF command in SilverMax Command Reference manual or a different baud rate The Unknown SilverMax Wizard will walk the user through a procedure to establish communications with a SilverMax of unknown serial interface baud rate and ID If no SilverMax is found the wizard will notify the user that the download has failed 5 Send Stop STP command This makes it stop moving and end any programs it might be running 6 Download selected initialization file SilverMax User Manual 23 Revision 3 22 SilverMax Factory Default Initialization File Detailed The Initialization program file contains the following programs Main Init The main initialization program which contains all of the initialization commands This is described in great detail below Startup Recovery Startup Recovery is used during the factory default initialization to indicate an error has occurred The program will cause the Status LED to pulse Kill Motor Recovery This program gets called whenever a condition in the Kill Motor Recovery KMR command is met The user may modify this program if special processing is required For example if the user wanted the SilverMax to set an error output anytime it detected a jam They would first set the Moving Error in the Kill Motor Conditions KMC command and then add a Set Output Bit SOB command to the Kill Motor Recovery program Power Low Recovery The user may modify this progr
161. rmally an input capacitor should be used if the source impedance is high Analog inputs 1 to 4 share digital I O lines 4 to 7 respectively These analog inputs are designed for external analog input readings and can be use for all analog input functions Analog input 7 is the non calibrated V input A calibration factor must be applied to this in order to get a usable result See below for details Analog input 8 is the non calibrated internal temperature of the SilverMax A calibration formula must be use to get a usable result See below for details Analog input 9 this is not really an analog input it reads a voltage calibration value out of the Non Volatile Memory that is used to convert the reading from input 7 to a usable value Only the Analog Read Input command can access this value SilverMax User Manual 60 Revision 3 22 Differential Channel Inputs Differential Channel Input provides an added advantage of giving noise rejection of the analog signals Also the differential readings will double the resolution of the ADC reading from 10 Bit to 11 Bit The value read by the Analog inputs will range from 32767 to 32767 To achieve the full range both inputs must be active If for example inputs 1 amp 2 are used in differential mode 32767 will be read when 1 is at 5 volts and 2 is at O volts 32767 will be read when 1 is at O volts and 2 is at 5 volts The inputs used for differential readings are still referenc
162. rogram Flow Control yesir arna Gh ee iia irradia 70 Conditional Program FlOW 7 cc cschecessk ts cece etidedeg egent cheese dedieeath dg leded dea cuit agen thts ledaduedeeeet add 70 Ees WGN yan EE 70 STEE E TE 71 While LOOP tii in ii bid 71 DO A A NN 71 Using Digital1 O Tor Flow Control socia 72 Downloading Programs Without QuickControl oooommnccconiccnnnonanncncnnannncnnnnnnnncrnnnnnnrrnnnnn nr rra 73 Ren le Nee EE 73 Program Download Example see secs deed Anite alte dite 74 Temporary Vs Long Term Storage ooccconnoccccnnnocccccononcncnanonnncnnnno cnn c canon nn r ran rn rr nan a rr ran nr aA rre 74 Temporary Storage in Program Buffer ooooocccnnnnccccnnnacccccnnnoncccnn noc cn nono n cnn norris 74 Long Term Storage in Non Volatile Memory oooononcccnononiccnnnaniccnononcnononnncnn nano nn nr nano nn rro rra 75 SPECIAL MODES 8 OPERATIONS cccoiionccroicconionacacarin nda ed 76 Anti Hunt Operation Eliminates Dithering cccccseseeeeseseeeeeeeeeeeseeeeeeeeseseeneeseseeeeesesesneeseseeeeesensenenens 76 Anti Hunt Torque Setting ii ieed ceded cteedtas ahead abe db Ad did 76 SilverMax User Manual 5 Revision 3 22 Anti Hunt Dela Scene d 77 AnticHunt Exam plesics cox cciiterete EE 77 ue Hu ee 79 Drag Mode Like a Mechanical Clutch c ccccesseeceseseeeeeeeeeeeeeeeseeeeeeneeeeeseseeneeseseseeeseseeneesesesseeesessenens 80 Motor Shutdown Kill Motor ConditiONS oommcooconccconnccoosnaoseccconn rre 81
163. routine always takes a pre determined period of time Complex alignment SilverMax Factory Complex Initialization qcp For loads that have a very high frictional content the complex alignment routine offers a more accurate system of aligning the encoder to the motor The complex routine spends more time to make sure that the rotor and encoder are aligned before going into closed loop mode The timing can vary and therefore the SilverMax should be polled for Program Complete before attempting to operate the motor SilverMax User Manual 28 Revision 3 22 Error Limits Good practice requires that operational limits and error conditions be set up prior to motor operation Setting up these parameters can provide safer operation or may prevent damage to the motor and system LVT Low Voltage Trip default 10V Set point at which SilverMax will execute the Power Low Recovery program OVT Over Voltage Trip default 51V MTT Maximum Temperature Trip default 70C Set points at which SilverMax will disable its driver and execute the Kill Motor Recovery program ERL Error Limits default no limits The difference between the Actual Position and the Target Position can trigger an error flag or Kill the motor The acceptable limits are set here KDD Kill Disable Drivers Drivers will be disabled when a Kill Motor Condition occurs KMR Kill Motor Recovery LIMITS Low Voltage Trip Low Volta
164. rque Limit to the Holding Torque limit after a motion has completed This provides SilverMax with a Settling Period after a motion that can keep the Torque Limits at a higher value until all movement has ended Anti Hunt Examples Dead Band This creates a zone where no Torque is applied In this example the SilverMax will go into Anti Hunt operation when the motion is complete and the position error is less than 10 When in Anti Hunt NO Torque will be applied Open Loop Torque settings are 0 This creates an area where the motor can move freely The Delay to Holding only effects Closed Loop operation Dead Band Example Command Settings Anti Hunt Constants Anti Hunt Delay Torque Limits Error Limits Open to Closed 10 Delay Count 0 Closed Loop Holding Moving Error 100 Closed to Open 10 10000 Holding Error 20 Closed Loop Delay to Holding 833 Moving 20000 100 msec Open Loop Holding 0 Open Loop Moving 0 Live Band A zone is created when a defined level of holding Torque is applied In this example the SilverMax will go into Anti Hunt operation when the motion is complete and the position error is less then 10 When in Anti Hunt a defined amount of Torque will be applied There may be a brief period where the Open Loop Moving torque is applied helping to pull the position error to zero The Delay to Holding affects both Open Loop and Closed Loop operation Live B
165. rt out the windings and set the Torque Limits to 0 If the motor is spinning this will cause an abrupt stop of the motion in process Any program that is executing will also End Revision 3 22 Controlled Shutdown This requires a few extra initialization settings to enable the capability Normally SilverMax cannot process a Kill Motor Recovery without shutting down any move and or program in process However when Multi Tasking Operation is enabled a move can continue while the recovery process is taking place Adding the Enable Multi Tasking command to the initialization process enables Multi Tasking Operation Even with this the motor driver will still be disabled a Kill Enable Driver command must also be added to over ride this default Finally the Kill Motor Recovery must be set to process a User defined Recovery program that can contain the desired shutdown operations This Recovery program must be written by the user and stored in the SilverMax Non Volatile memory at a known address specified in the Kill Motor Recovery option parameter Initialize with These Kill Motor Conditions The Programmed shutdown condition is met Conditions are checked every 120 usec Each Servo cycle The Kill Motor Conditions command is used to set the shutdown conditions Over Temperature is enabled by default Kill Motor Recovery There are three options 1 Do Nothing Host intervention
166. rview gives the user some basic knowledge of what is inside of SilverMax from a features point of view SilverMax Motion Commands typically are at the top of the list of things to know about so they are covered right away From there the manual goes through a number of important topics that give the basics of SilverMax operation and programming This manual is not exhaustive It would bore the user and waste everyone s time Detailed information for specific applications can be found in QuickSilver Controls application example files found in the QuickControl directory under QC Examples and on QuickSilver Controls website at www QuickSilverControls com or www qcontrol com where Application notes are updated periodically SilverMax User Manual 9 Revision 3 22 GETTING STARTED BEFORE USING A SilverMax Motor e Turn Off ALL Power Supplies and Switches e Read All Set Up Instructions for Your Specific Motor or Start Up Kit e Double check ALL Intended Connections for Shorts or Unwanted Grounding These setup instructions are designed to help you configure your SilverMax motor and QuickControl Software If you carefully follow the setup procedure for your specific SilverMax Start Up Kit your motor should be operating within minutes Equipment required e Personal computer with a 586 at least 133 MHz or higher processor running Windows 9x NT 4 0 2000 or Me e SilverMax Motor e Startup Kit SK1 or SKO which includes
167. s reached the motion will stop A point to remember is that when the input condition is met this begins the deceleration of the motor The position that is actually reached will be the deceleration distance that was required to stop the motion Slower deceleration rates set by the Acceleration parameter will cause greater stopping distances from the edge of detection The Command example is shown in the 8 bit ASCII protocol form Input Enables ert 135 S 1000000 100000 The table below shows how the value of 1 was derived Toggle Pre Direction Preliminary Inputs States Toggle Enable Enable AND Inputs Enable OR Inputs Enable Bit 15 Input Enable Word 0x0001 in Word Hexadecimal form Hexadecimal 0x0001 1 Decimal Input Enable Word 1 in Decimal form The table below shows how the value of 1 was derived Toggle OR Direction Preliminary Inputs States Togo le State State Bit 15 AND Inputs State OR Inputs State Input State Word 0x0001 in Word Hexadecimal form Hexadecimal 0x0001 1 Decimal Input State Word 1 in Decimal form SilverMax User Manual 51 Revision 3 22 Change Direction and Stop on Input This example shows a MOVE RELATIVE VELOCITY BASED move that will change the direction of the move based on the beginning condition of input 1 the motion will then be stopped using the same input 1 A Sensor B Sensor Starts Off Flag E Starts O
168. s where many axes of control are required the Host configuration can achieve very complex or highly coordinated multi axis control When a Host controller is used a great deal of information can be retrieved from a unit This can be done using the Status Commands or the Read Register Commands The following is a discussion on using the Poll command Polling SilverMax Using the Poll Command Polling the SilverMax is a process sending the Poll command and receiving back the Polling Status Word Polling is used to check the current status of the SilverMax for item such as errors command completion and general information A Host controller can use this information to assist in motion coordination and error checking Polling is typically implemented by having the Host controller periodically perform a Polling routine This routine consists of Polling the Motor using the Poll Command reading back the status word checking the word for the desired condition and then clearing the Polling Status Word see diagram below If the condition is not TRUE the Polling operation can be repeated using a loop that continues to check the condition until it is TRUE Repeat loops delays can vary depending on the desired polling rate and the communications baud rates Below is an example of a Polling Routine that can be used to retrieve status on command execution This may be used for waiting until a motion completes before sending the next command SilverM
169. se to an error condition The Kill Motor Conditions are part of this checking so that error conditions can immediately shutdown a motor SilverMax User Manual 88 Revision 3 22 SilverMax Multi Tasking Diagram Checking Motor OOOOOO Error Shutdown conditions Task 5 Task 6 Check Input states UO Start and End on Status a 120 usec time slice Task 4 Move Program 1 instruction each 120 usec time slice Task 3 Flow Task 2 Servo Loop every 120 Calculate usec Task 1 Serial Comm Every 40 usec Time Slice 120 usec Revision 3 22 89 SilverMax User Manual Analog Input Modes Velocity Position and Torque The Analog input modes provide all the basic motor control that can be achieved using the various move commands using an analog signal for the control input Be aware that internally SilverMax does all moves using 32 Bit values that give very high resolution for Position or Velocity Analog inputs cannot come close to this level of resolution because of being limited to 10 Bits Typically this is OK for Velocity or Torque modes but may not be enough resolution for Position mode 32 Bit values range from 0 to 4294967295 2 147 483 648 to 2 147 483 647 10 Bit values range form 0 to 1023 512 to 511 Analog Input Resolution SilverMax has four analog input channels as part of its input design
170. seseeneesesesnansnneeeenens 45 Input Checking Process for Motion Commandes 45 First Check Used to toggle the starting direction Of motor cece ee eete eect entree eeetaeeeeetnaeeeeeeaas 45 Second Check Used to do a Two State input checkt 45 Last Check This may now stop the motor tees nano ncnc cano nn nc canon rr rnnnn rn rra 45 Stopping a Motion ON INpPUt ua ls a earls oi os AA eal 46 Recording Sensor Found Poeton ano nn rro nn rra rr rra 46 Motion Profile Input Options Table ooooooooccnnncnnnococcconncccconnonnnncnnnnncnnnnnnnnnnnnnnnnnnnnnn nn nn cnnnnn anar nnnnnnnnnnanannes 48 Direction Toggle Conditions eege waned aie dE dee ere eege 48 How to Create the Input Values Native SilverMax on 49 AND Inputs EE 49 OR el 49 Using Inputs EE 51 Seel e El 51 Lt ebe 51 ORMANPUIS Stale as ee eelere 51 Change Direction and Stop On Input 52 AND AN ei 52 SIEA EE 52 Advanced Usage QuickControl commoccccinnicncnnnnncccinnencnninnennn nine rre 53 USING THE DIGITAL WO uu ad A ia 54 SilverMax E Series I O Configuration Table 54 Input Output a Te EE 55 ele LEE 55 LEIDER cages et ap ates Pata aad o cn nets et ere iit sacas 55 Basic Digital Inputs amp Outputs iia 56 Step amp Direction Input Encoder Input coconmonncccconcnicnnncnnccncnonenonnnnnonncnnnncnnnnnnnnncn cnn nn nr nenes 57 Step amp Direction Output Modulo Output ee 58 Step Ree 58 TT e i 59 Special YO EE 59 ENCON o cars 59 Done St
171. st systems It has been our experience that 9 out of 10 applications can use the factory defaults Other applications will require servo loop tuning to fit the target system One of the biggest challenges for servo motors is having stable control with a large mismatch between motor s rotor inertia and the load inertia of the system The SilverMax PVIA Servo Control algorithm can be tuned to provide stable operation over a very broad range and can be tuned for stable control with large mismatch ratios i e 100 1 SilverMax PVIA Servo Algorithm SilverMax has a unique servo loop algorithm called Position Velocity Feedback Feedforward Integral and Acceleration Feedback Feedforward PVIA In the PVIA algorithm position information is used to perform closed loop control of rotor position by detecting and correcting for error in position versus the defined target position Velocity and acceleration are calculated from time history data of the precise rotor position Current position velocity and acceleration data are passed on real time to the PVIA algorithm with target position target velocity and target acceleration data Following the control law these parameters are used in calculating the motor torque needed to correct any motor position errors The exact transfer function when not limiting is C Actual Position R Target Position 1 x 32768 G X 1 xz 32768 Torque 1 Ki 32768 1 2
172. stop This can be increased if needed Velocity Mode acc 200 rps s vel 0 rps Wait for 500 mSec Re set the Kill Motor Conditions This is required if after this recovery routine normal operation is restored Kill Motor Conditions If Motion Error Just a wait before calling the next program Wait for 500 mSec Run a system recovery program from here This following program could be a Homing routine that would recover from the error Load and Run Program Home the SilverMax Revision 3 22 See Enable Multi Tasking and Disable Multi Tasking commands in the SilverMax Command Reference Multi Tasking Operation Multi Tasking operation allows SilverMax to perform a Motion while executing a program By default SilverMax does not continue internal program execution when performing a motion command or while executing in Velocity Mode Step and Direction Mode or Input Mode Enabling Multi Tasking causes SilverMax to continue program execution after a motion or mode has been started The Primary Benefit of Multi Tasking Is to allow Programs amp Motions to run at same time The DSP and internal state machine code permits simultaneous Task operation allowing alteration of motion parameters before after or during actual motion events The following complex operations are typical Modify Profile Moves On The Fly Create ramps for Electronic Gearing Set amp Clear I O during Motions Monitor torque or other
173. supply SilverMax D15 Connect to SilverMax Be sure to tighten thumbscrews 15 pin Interface Cable Connect to Optical I O Module RJ 11 Cable Connects to RJ 11 port on Optical I O Module to PC COM port Power Supply Connectors V Input to V of power supply and Pwr Gnd to Ground SilverMax User Manual 14 Revision 3 22 QCI SKO 34 v Start Up Kit Setup The Setup for this kit is the same as the setup described above for the QCI SKO FS v Start Up Kit except a SilverMax Line Power Cable is Included For more information on the Optical I O Module see QCI Technical Document QCI TD0010 included attaches to the 15 pin male connector on the SilverMax motor The female 15 pin connector of the interface cable attaches to the 15 pin female connector on the optical I O board The male 15 pin connector of the interface cable attaches to the RJ 11 connector on the Optical I O board The phone jack like connector of the RJ 11 serial cable The V Input connection on the Optical I O board must be connected to V of a power supply and Pwr Gnd connection must be connected to Ground of that power supply The 9 pin female Comm connector y of the RJ 11 serial cable connects to your PC connects to the power connector on the 34 frame SilverMax motor The 3 pin female connector on the SilverMax Line Power Cable The red wire at the end of the SilverMax Line Power Cable is connected
174. ter Immediate Type command ue T Input Offset is subtracted from 0 ET the input value This may provide offsetting of a Joystick input is loaded in the same fashion Input Offset Data Reg 13 Dead band value causes input S to be 0 when input is j deeg ee Band to GES SE SE between Dead band value nput data loaded here and 0 Limit amp Scale works by first limiting the Limit Scale value is loaded here Limit Scale ni input negative or positive to the Limit amp l Data api Se S Limit Scale value then scaling it by Reg 15 dividing the Input by the same Limit Scale value This now scales the data for Scale data for Output Scale Output Scale output by multiplying by the Output Data value is output scale value Reg 16 loaded here Adds an offset value to the data for output This can also be used as a direct data input by placing the input value into Register 17 Output Offset value is loaded here Don t let the output data change faster then the Rate Limit value When in Velocity mode this acts like Acceleration When in Position mode this acts like a velocity limit Rate Limit Data Reg 18 Rate Limit is loaded here Limit Rate of Change Send data to selected mode Data is finally sent to the selected mode Velocity Position or Torque mode SilverMax User Manual 94 Revision 3
175. that are not shown in the Initialize tool Typically this file should be saved to a different name after it is edited or used for initializing a motor The wizard can be accessed by selecting Tools gt SilverMax Initialization Wizard SilverMax Initialization Wizard Begins the Download process that loads Press Exit to exit and stores the initialization into the the wizard Your SilverMax s Non Volatile Memory By changes will be default the motor will automatically reboot automatically saved See the QuickControl after the download to allow the new to the selected file Help system for details on parameters to take affect Options SilverM ax Initialization Wizard Press Download to initialize SilverMax or change the factory default parameters using the Initialize Parameter Exit Browser or Interview Options Motor Axis 16 i Type QCI 23 3 Initialize Parameter Browser Hec Communications Press Interview to have QuickControl walk you through every initialization parameter Note as each command is presented its location in the initialization file is highlighted SilverMax Factory Default Initialization qcp o Game Turi Press the Cancel button on any as ral unng command to stop the interview Open Save Save As Error Limits Misc D DA All the parameters are stored in the The initialization parameters are displayed initialization file Chan
176. tion is complete and the Settling Time is expired the Done Status will output a low 0 indicating the SilverMax is Idle and no position error exists The Done Status does not indicate whether the motor is Moving or Holding position Itis a status of what it should be doing Moving Error and Holding Error Limits must be set using the ERROR LIMITS command to use the Done Status to indicate motion complete and in position SilverMax User Manual 59 Revision 3 22 See ANALOG CONTINOUS READ ACR amp ANALOG READ INPUT ARI commands Also see Input Mode commands USING ANALOG INPUTS Analog inputs are designed for analog signals with a range of 0 to 5 Volts The internal Analog to Digital Converter ADC has 10 Bit resolution that reads 0 00488 volts per count When an input is used Single Ended the 10 Bit resolution is achieved When two inputs are used in a Differential fashion an 11 Bit resolution is achieved Analog inputs 1 2 3 and 4 share Digital I O lines 4 5 6 and 7 respectively All single channel ADC readings are scaled to a 15 Bit value before being stored in a selected Data Register Single channel readings range from 0 to 32767 counts with a 0 to 5 volt input Differential channel readings are converted to 16 Bit values with a range from 32767 to 32767 counts ADC readings taken using the Analog Continuous Read command are filtered with a simple roll off filter The filter knee is at 30Hz rolling off at
177. to V of the power supply The black wire connects to Ground The white wire connects to chassis ground of the power supply SilverMax Line Power Cable Connect to SilverMax SilverMax D15 Connect to SilverMax Be sure to tighten thumbscrews 15 pin Interface Cable Connect to Optical I O Module N RJ 11 Cable Power Supply va Connects to RJ 11 Connectors V Input to V N port on Optical I O of power supply and Pwr ent Module to PC COM Gnd to Ground port Power Supply Connectors Required for Driver Enable SilverMax User Manual 15 Revision 3 22 QCI SKO 34 65 v Start Up Kit Setup The Setup for this kit is similar to previously described setups except the QCI SK1 34 65 Start Up Kit contains a SilverMax 34 IP 65 Cable and no Silver Max Line Power Cable For more information on the Optical I O Module see QCI Technical Document QCI TD0010 included to the male round connector on the 34 frame SilverMax motor Connect the female round IP 65 connector of the SilverMax connects to the supplied Optical I O module The 15 pin male connector on the SilverMax 34 IP 65 Cable attaches to the RJ 11 connector on the optical UO board The phone jack like connector of the RJ 11 serial cable The 9 pin female Comm connector of the RJ 11 serial cable connects to your PC The V Input connection on the optical UO board must be connected to V of a power su
178. to the Internal Status Word may be enabled in the Kill Motor command to cause the motion system to shut down and execute an error routine SilverMax can input Step and Direction signals in a number of different forms The Step and Direction input is designed to be scalable with a maximum multiplier of 32 and a maximum divisor of 1024 Inputs may be used for internal Analog to Digital for conversion Analog signals can control Velocity Position or Torque The external encoder input gives the user greater flexibility for inputting digital signals When using the Step and Direction commands the external encoder input gives a variety of input styles Description This is a left over from the original SilverMax design and is available for Legacy designs It should not be used when implementing a new E Series design Allows I O lines to be set high 1 or low 0 if enabled Outputs the Internal Encoder signals Divided down output of the Internal Encoder or External Encoder used for an output to other devices A program or Single command has completed and motion is within the indicated error limits Associated Commands ALL MOTION COMMANDS VELOCITY MODE PROGRAM TYPE VMP Velocity Mode Immediate Type VMI ALL INPUT MODE COMMANDS ALL JUMP COMMANDS All PROGRAM CALL AND RETURN COMMANDS WAIT ON BIT STATE WBE WAIT ON BIT EDGE WBS KILL MOTOR CONDITIONS KMC SC
179. to your PC and has flying leads for power supply connection SilverMax D15 Connect to SilverMax Be sure to tighten thumbscrews UO D9 Connect to breakout module UO Breakout Module Pin out Pin Signal 1 1 0 1 1 0 2 1 0 3 1 0 4 1 0 5 1 0 6 VO7 LOGIC GND 5V OUTPUT 100ma max RS 232 D9 Connect to 9 Pin RS 232 COM1 or COM2 on PC OMANDOAKRWNDY Power Supply Flying leads Connect to user supplied power supply Red to V and black to Ground SilverMax User Manual 12 Revision 3 22 QCI SK1 34 1 Start Up Kit Setup The Setup for this kit is the same as the setup described above for the QCI SK1 FS 1 Start Up Kit except a SilverMax Line Power Cable is Included The center 15 pin attaches to the 15 pin Female connector male connector on the D15 High Density SilverMax motor The 9 pin female connects to I O connector the supplied of the evaluation breakout Cable module The 9 pin female Comm connector of the evaluation cable connects to your PC and has flying leads for power supply connection connects to the power connector on the 34 frame SilverMax motor The 3 pin female connector on the SilverMax Line Power Cable The red wire at the end of the SilverMax Line Power Cable is connected to V of the power supply The black wire connects to Ground The white wire connects to chassis ground of the power supply
180. tor Shutdown can be done in two different ways depending on the initialization settings The default shutdown turns off the motor drivers shorts the windings which will cause the motor to come to a rapid uncontrolled shutdown The second way will leave the motor operating and Jump to the specified recovery program This allows the motor to do a controlled shutdown if required Uncontrolled Shutdown This is the default that is set in the factory initialization When a Kill Motor Condition is met SilverMax will immediately disable the motor drivers set the Torque Limits to 0 then execute the operation as defined by the Kill Motor Recovery No settings are required other than the Kill Motor Condition Kill Motor Conditions The Programmed shutdown condition is met Conditions are checked every 120 usec Each Servo cycle The Kill Motor Conditions command is used to set the shutdown conditions Over Temperature is enabled by default Kill Motor Recovery There are three options 1 Do Nothing Host intervention required 2 Restart the SilverMax by executing the Initialization Program 3 Execute a User Defined program Do Nothing is the default SilverMax User Manual Shutdown Condition is met Turn Off Driver Set Torque limits to O Process the Recovery option selected 81 After the shutdown conditions are met the SilverMax will turn off the motor drivers sho
181. tor to look for the opposite edge of a sensor flag if that flag is already activated A similar operation is performed to the Input State Word bits corresponding to the OR inputs if the Toggle Or State bit is set Second Check Used to do a Two State input check The Second Check does a preliminary test of the inputs If the Preliminary inputs are enabled the Input conditions must be TRUE for the input checking process to continue This allows a motion to find a Two State condition of the inputs This would be useful for example in a motor homing routine to first find a sensor covered and then wait for it to be uncovered If the input conditions are not met at this check the checking process will not continue and the motion will not be stopped Last Check This may now stop the motor The last check can do two different things The most common is to stop the motor and record the motor position when an input TRUE condition is detected The second is to just record the motor position Two different checks are done at this time the AND conditions and the OR conditions These two checks may be used together for stopping a motion while the AND condition is used alone for motor position recording SilverMax User Manual 45 Revision 3 22 Stopping a Motion on Input The AND and the OR conditions are used together in order to stop the motion The following are rules for usage 1 Ifthe AND inputs are disabled only the OR inputs are used 2 If
182. ts voltage Get Voltage WA Strip Chart 1fa os 23 29 3f3 25 4J3 3i The major additions include Device Status Voltage actual voltage measured by SilverMax Device Status Temperature actual temperature measured by SilverMax Inputs Outputs Analog Inputs actual voltage measured by SilverMax Single Step Trace Breakpoint Two new buttons have been added to the program Info Toolbar Trace and Single Step Using these buttons you can now single step through your program A Breakpoint can be set on any line by selecting SilverMax User Manual 20 Revision 3 22 Programs gt Toggle Breakpoint See the QuickControl Help system for a detailed explanation of these new features QuickControl Rev 3 1 Tools All your old favorites can still be accessed by selecting Tools gt Rev 3 1 Tools SilverMax User Manual 21 Revision 3 22 SILVERMAX INITIALIZATION Each SilverMax unit contains internal Initialization Programs that set up the operational values and constants for the motor at power up By default the Initialization Programs are downloaded into the non volatile memory at location 0 User programs start at 512 SilverMax Factory Default Initialization qcp The program SilverMax Factory Default Initialization qcp is designed for use with the SilverMax Initialization Wizard tool This program sets up all motor parameters The program can also be edited manually to add more commands or modify those
183. verMax to maintain continuous serial communications using BAUD rates up to 230 000 bits per second 230K BAUD even while executing a motion Task 2 Servo Control Loop Every Time Slice the Servo Control is updated This high rate of servo update 8333 times per second is what gives SilverMax very tight motion and positioning control SilverMax User Manual 87 Revision 3 22 Task 3 Program Execution If a program is running each line of the program will execute on a Time Slice Some commands like the Delay will cause the program to remain on a line until the command is completed program execution continues even after a Motion command is encountered This allows other operations such as digital I O control to be performed while a move is running Task 4 Move An internal calculation algorithm called the Trajectory Generator typically accomplishes a move Each Time Slice the Trajectory Generator updates its calculation of the on going move In the case of a Profile Move move parameters can be changed at any time allowing the profile of the move to be dynamically changed Task 5 I O Status The SilverMax I O inputs are checked each Time Slice so that motions stopping or other program operations can act very rapidly This gives very accurate position registering when stopping on a digital input Task 6 Error Checking All internal status checking is done each Time Slice to provide the fastest possible respon
184. y for operation From here a homing or other corrective action program can be executed putting the system back into service SilverMax User Manual 85 Revision 3 22 Kill Motor Recovery Program Controlled Shutdown Initializing SilverMax for Controlled Shutdown Controlled shutdown requires adding a few extra elements to the SilverMax startup The most important is to add the Enable Multi Tasking command to the startup program Multi Tasking will allow SilverMax to continue a motion while processing the shutdown condition The second is the Kill Enable Driver command This command over rides the default setting that disables the motor drivers on shutdown Handling the Shutdown In the controlled shutdown scenario the SilverMax does not stop the motion in process instead the Kill Recovery program is called allowing the motor to stop the motion or not in a controlled manner In the example shown Fault Recovery program a Velocity Mode command is issue with a 0 velocity This will bring the motor to a controlled stop Processing the Error Condition Depending on the shutdown condition enabled there may be a number of different things that must be done to clear the error and continue operation or simply alert the system or operator of an error Alerting the system or operator may involve toggling a Digital Output Line In this example nothing was required other then re issuing the Kill Motor Conditions com

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