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FireBlox-1 Control Module Developer`s Guide

1. MATING DONE VIA SCREW CLAMP Table 19 J4 Digital Output Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 DO00 DIGTIAL OUT 0 2 DO01 DIGTIAL OUT 1 3 DO02 DIGTIAL OUT 2 4 DO03 DIGTIAL OUT 3 5 DO04 DIGTIAL OUT 4 6 DO05 DIGTIAL OUT 5 7 DO06 DIGTIAL OUT 6 8 DO07 DIGTIAL OUT 7 9 DOVCC DIGITAL OUT VOLTAGE 10 DOGND DIGITAL OUT VOLTAGE RET MATING DONE VIA SCREW CLAMP Table 20 30 Analog Output Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 AO00 ANALOG OUT 0 2 AO01 ANALOG OUT 1 3 AVCC ANALOG VOLTAGE 4 AGND ANALOG VOLTAGE RET MATING DONE VIA SCREW CLAMP Adept FireBlox 1 Control Module Developer s Guide Rev A Page 51 of 61 Table 21 J31 Analog Input Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 100 ANALOG INPUT CHANNEL 0 2 101 ANALOG INPUT CHANNEL 1 3 102 ANALOG INPUT CHANNEL 2 4 Al03 ANALOG INPUT CHANNEL 3 5 104 ANALOG INPUT CHANNEL 3 6 105 ANALOG INPUT CHANNEL 5 7 106 ANALOG INPUT CHANNEL 6 8 107 ANALOG INPUT CHANNEL 7 9 AVCC 5VDC OUTPUT 10 DGND ANALOG RETURN MATING DONE VIA SCREW CLAMP Table 22 J33 PWM Output Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 PWMO PWM OUTPUT 0 2 PWM1 PWM OUTPUT 1 3 VDCLED PWM VOLTAGE 4 LEDRET PWM VOLTAGE RET MATING DONE VIA SCREW CLAMP Ta
2. MATING CONN 511 10 0850 P Molex CONNECTOR PIN PN 430 30 0009 C Molex Table 27 5 External Encoder Power optional PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 24VDC EXTERNAL DC POWER 2 24VRET EXT POWER RETURN MATING CONN Adept FireBlox 1 Control Module Developer s Guide Rev A Page 53 of 61 Channels Table 28 P2 Terminal Strip Digital Output Channels Table 29 P5 Terminal Strip Digital Input Channels Table 30 P6 Terminal Strip Analog I O Channels Page 54 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Appendix A Tuning Motors Introduction Knowing how to tune a motor online while it is in the machine is a tremendously valuable skill to have It does require some understanding of control theory to be successful at it Before You Begin Before you begin you will need to understand The basics of PID control Response Characteristics and System Configurations of Control Systems o Transient Responses o Steady State Response o Steady State Error o Open Loop Systems o Closed Loop Systems Unit Step Response Stability This background will help you understand the underlying principles of what will be discussed in this application note To review these topics consult your favorite controls text One such text is Norman 5 Nise Control Systems Engineering 2 Ed The Benjamin Cummings Publishing Company
3. 60 pin ribbon cable 300 mm 12 in to connect to J2 of FireBlox 1 Control Module 30 ribbon cable 300 mm 12 in to connect to J1 of FireBlox 1 Control Module The Termination Board Kit also provides easy field wiring with screw type headers for all I O and easy mounting with four symmetrical mounting holes See chapter 3 for more details FireBlox 1 Development Kit System developers will need to have a FireBlox 1 Development Kit available The FireBlox 1 Development Kit presents the required software drivers utility program and the FireBlox controller in an out of the box package which can be used as is or as a basis for machine integration See 4 for more details on the FireBlox 1 Development Kit 1 2 SmartController and PC Based Systems The Adept FireBlox 1 Control Module can be installed as part of an Adept SmartController system or part of a PC based system Although the hardware installation is similar for both systems please note the following differences Unique Amp Enable circuit for each type of system see page 15 for details The FireBlox 1 IEEE 1394 port is connected to the Adept SmartServo network when used as part of a SmartController system see page DA for details Software configuration and development is different for the two systems Page 8 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A See Chapter 5 for details on PC based systems See Chapter 6 for details on A
4. CA 1995 Adept FireBlox 1 Control Module Developer s Guide Rev A Page 59 of 61 Page 60 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A cda adept technology inc 3011 Triad Drive Livermore CA 94550 02600 000 Rev A 925 245 3400 Adept rirebiox 1 Veveloper s Rev A Page 61 of 61
5. Function Pin Motor DC out Motor DC out Motor High Voltage Motor Chassis Ground Motor Voltage Return O NI O gt Page 18 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev 2 0 A Fuse Fast Acting max rating Motor High Voltage VDC_MOT 43VDC max MOTOR_DC FireBlox 1 MOTOR_DC N C MOT_CHS_GND MOT_RET Motor Voltage 7 Motor Chassis Return Ground Figure 11 Wiring a DC Brushed Motor Motor cable specifications include twisted shielded conductors to minimize PWM noise coupling to other circuits The cable shield should connect to the motor frame and machine chassis ground For noise immunity use shielded twisted pair cabling with the cable shield tied to the motor frame ground and the machine chassis ground Mating connectors for P2 and P3 are Molex part number 43025 0600 Motors with Brakes A general purpose digital output channel can be used as a Brake Output to drive a user supplied relay which releases a motor brake if present when high power is applied to the motor When high power is removed from the motor the relay opens and the brake engages The brake output can be used to release brakes on both motors If a digital output channel is used as a Brake Output the signal number must be specified in the BloxView software Connect Motor Encoders The FireBlox 1 control loop is closed with encoder feedback The A B and Z index qu
6. Termination Board Schematic Page 27 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev The figure above shows a termination board schematic 3 5 Connecting Items to the Termination Board User Supplied Power The following user supplied power connects to the Termination Board e Digital Outputs are generally powered from 24V DOVCC and are often driven using the same supply as for the PWM drivers This power connects to the P2 screw terminal e While encoder power 5VDC can be derived from the IEEE 1394 network if several FireBlox 1 Control Modules are used on the same system it may be necessary to provide encoder power from an external supply External encoder power AVCC is connected to the P5 screw terminal When external encoder power is provided verify the setting of SW2 Ext Enc Pwr SW2 Int Enc Pwr Figure 21 Switch 1 SW1 and Switch 2 SW2 NOTE Reliable operation of the FireBlox 1 in an industrial environment requires proper design of power and grounding of the system Although the FireBlox 1 circuitry is very versatile and robust poor power and ground design can be detrimental to system performance NOTE Motor Power and power for the PWM drivers is also user provided but connects directly to the FireBlox 1 Control Module Analog AVCC and Digital DVCC voltages are generated internally Proper Grounding Proper grounding is critical for achieving a good design To preve
7. 2 VDCMTR1 MOTOR HIGH VOLTAGE 3 PWMB MOTOR DRIVE PHASE B 4 CHSGND MOTOR CHASSIS GND 5 PWMC MOTOR DRIVE PHASE C 6 VDC RTN MOTOR VOLTAGE RET MATING CONNECTOR Molex 43025 0600 PIN Molex 43030 0010 Table 16 Motor 1 Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 PWMD MOTOR DRIVE PHASE D 2 VDCMTR2 MOTOR HIGH VOLTAGE 3 PWME MOTOR DRIVE PHASE E 4 CHSGND MOTOR CHASSIS GND 5 PWMF MOTOR DRIVE PHASE F 6 VDC_RTN MOTOR VOLTAGE RET MATING CONNECTOR Page 50 of 61 Molex 43025 0600 PIN Molex 43030 0010 Adept FireBlox 1 Control Module Developer s Guide Rev A Table 17 P4 PWM and Error Loop Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 LEDA LED PWM OUT A 2 VDCLED PWM OUT POWER 3 LEDB LED PWM OUT B 4 CHASSIS CHASSIS GND 5 AMP_FLT AMP FAULT OUTPUT 6 VDCRET PWM OUT POWER RET 7 AMP ENABLE INPUT 8 ENABLE INPUT MATING CONNECTOR Molex 43025 0800 PIN Molex 43030 0010 8 2 Development Kit Connector Pin Locations Table 18 Digital Input Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 DI00 DIGTIAL IN 0 2 DI01 DIGTIAL IN 1 3 DI02 DIGTIAL IN 2 4 DI03 DIGTIAL IN 3 5 DI04 DIGTIAL IN 4 6 DI05 DIGTIAL IN 5 7 DI06 DIGTIAL IN 6 8 DI07 DIGTIAL IN 7 9 DOVCC DIGITAL OUT VOLTAGE 10 DI_COMMON EXT INT NPN PNP CONN
8. Figure 16 Digital Output Schematic Before the digital output channels can be accessed from an Adept SmartController they must be mapped See Mapping the Digital I O Channels page 43 for details PWM Outputs Two opto isolated 24V high current 2A peak PWM channels provide open loop or PID loop control for external peripherals such as heaters or illumination devices Control software provided allows the user to set PID variables for loop control and monitor closed loop parameters NOTE Access to the PWM output channels from a SmartController is not yet available Adept FireBlox 1 Control Module Developer s Guide Rev A Page 23 of 61 Connect the external supply to VDCLED and VDCLEDRET on the P4 connector Connect the load between DO and VDCLEDRET VDCLED High Side Switch VDCLED DVCC gt DO gt Y DCLEDRET LEDORIVER_SIGNAL VDCLEDRET Figure 17 PMW Output Schematic 2 9 Connect IEEE 1394 Interface The FireBlox 1 Control Module uses a three port IEEE 1394 interface to provide high speed deterministic communication between nodes peer to peer and the control system Adept SmartController or PC based system This allows multiple FireBlox to communicate directly with the control system real time event control and processing Ports 6 pin Figure 18 IEEE 1394 Ports FireBlox derives power from the host controller Adept SmartController or PC Based system via the IEEE 1394 connection
9. Redwood City CA TJ213 N497 ISBN 0 8053 5424 7 1995 What You Will Learn We will take you through the basics in order to explain how to tune a motor In this paper you will learn How to set up your BloxView software to do unit step responses Howto tune a PID motion controller on your FIREBLOX using BloxView Adept FireBlox 1 Control Module Developer s Guide Rev Page 55 of 61 B Setting Up BloxView Please open up BloxView and follow procedures to set up a motor If you do not know how to do this do not proceed and consult the BloxView user s manual Otherwise open the Motor form of the BloxView and set up the motor Setting Up the Motor Some limitations to the motor and the motion must be relaxed in order to fully exercise the PID controller A step response may be performed when the normal constraints are relaxed To do so go to the Motor Servo Tuning form and follow these instructions Setting Up Parameters In The Limits Tab First establish a range of motion where there is sufficient room for overshoot and enough travel to achieve maximum current possible Set your initial and final points in the Tuning Points right below the Enable button In the Limits tab set the envelope error sufficiently large enough such that the envelope error exceeds the range of motion Set the minimum and maximum travel to allow for the range of motion also In the In Position Limits portion of the Lim
10. Using Adept SmartController as Control System Using a 6 pin IEEE 1394 cable connect the FireBlox 1 IEEE 1394 port to the Adept SmartController s SmartServo network The FireBlox 1 Control Module can be connected in series with other SmartServo compatible devices such as the Adept SmartAmp sMI6 sDIO etc Using a PC Based Control System Using a 6 pin IEEE 1394 cable connect the FireBlox 1 IEEE 1394 port to the IEEE 1394 port on the PC based system Page 24 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 3 Using the Termination Kit 3 1 Overview of the Termination Kit The Termination Kit provides a convenient method of accessing I O channels encoder signals and motor power connections from the FireBlox 1 Control Module This assembly includes the following Termination Board with screw type terminals Qty 1 60 pin ribbon cable 300 mm 12 in Qty 1 30 ribbon cable 300 mm 12 in Qty 1 Motor power cable with fused VDC motor power line 450 mm 18 in Qty 2 PWM Amp Enable Cable 450 mm 18 in Qty 1 This assembly provides the following functionality Easy field wiring with screw type right angle headers for all I O Easy mounting with four symmetrical mounting holes Encoder power can be supplied by the FireBlox 1 or user supplied An on board voltage regulator circuit converts user supplied 12 14VDC into 5VDC for encoder power configurable with SW2 User configurable for single e
11. beyond that distance users must install an IEEE 1394 repeater to amplify the signals at 15 foot increments up to 225 feet The following table lists items for the FireBlox 1 Development Kit Table 10 Spare Items for FireBlox 1 Development Kit Part Number Description 02314 000 FireBlox 1 Control Module 02601 000 Blox 1 Development Kit with 2 motors 1 Pittman 3 phase amp 1 Faulhaber servo motor includes FireBlox 1 Control Module 10410 01030 1394a cable 6 6 pin 3 meter 30 pin Ribbon cable for Analog I O channels included with 02593 000 60 pin Ribbon cable for Digital I O channels included with 02593 000 Motor 0 PWM drive cable BloxView utility software Adept FireBlox 1 Control Module Developer s Guide Rev A Page 45 of 61 8 Technical Specifications 8 1 FireBlox 1 Control Module Specifications The following table provides the specifications for the FireBlox Table 11 FireBlox Specifications ITEM PARAMETER T EST CONDITIONS MIN TYP UNITS GENERAL 1 IEEE 1394 POWER SUPPLY 8 12 33 VDC 2 OPERATING TEMERATURE 85 3 NODE POWER 3 5 w MOTOR AMPLIFIERS Can drive either 3 brushless or servomotors 1 NUMBER OF CHANNELS 2 2 OUTPUT CURRENT PEAK 4 A 3 CONTINUOUS CURRENT 2 A QUE E I He 5 PWM OUTPUT FREQUENCY 20 kHz 6 MOTOR VOLTAGE SUPPLY 12 43 7 E Stop SHUTDOWN TIME 1 mSEC DIGITAL OU
12. by displaying the position of the robot in mm or degrees on the Manual Control Pendant MCP This information can also be view from the monitor window by issuing a WHERE 1 command This is a continuous display that updates as the axes are moved manually To exit from this display press C SPEC Utility Diagnostics The SPEC utility allows the user to display the actual encoder counts being returned from the encoders To access the diagnostics page load the SPEC V2 file and execute the a spec program From the main menu select Perform hardware diagnostics Error Messages from V Information for this section will be added to the next revision Page 44 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 7 4 Spare Parts The following table lists items for the FireBlox 1 Control Module and the Termination Board Kit Table 9 Spare Items for FireBlox 1 Control Module and Termination Board Part Number Description 02882 100 FireBlox 1 Control Module 02593 000 Blox 1 Termination Board use to connect I O and PWM devices to P N 9050 10410 01030 IEEE 1394 cable 6 pin 3 meter 02106 000 30 pin Ribbon cable 300 mm 12 in included with 02593 000 02103 000 60 pin Ribbon cable 300 mm 12 in included with 02593 000 N A Unterminated cables for Motor 0 Motor 1 and PWM connectors NOTE The IEEE 1394 specification limits the range for devices to 4 5m 15 feet between nodes For applications
13. details see chapterB IEEE 1394 Cable 24V Power Dev Kit Assembly FireBlox 1 Control Module DIO Cable AlOCable E Stop Cable Motor Input Encoder 0 3 Phase Motor Encoder 1 Motor Input DC Motor Figure 23 Development Kit Connection Diagram Adept FireBlox 1 Control Module Developer s Guide Rev A Page 31 of 61 The illustration below shows the layout of the Development Kit External Motor Power Motor Brake Power Power Optional J35 Output J34 Switch SW1 Connector ud 900500 O Go 5 p3 8 FIREBLOX 1 5 DEVELOPMENT KIT PWM Output sp 55 Channels 33 oz 9 Analog Input FireBlox 1 Channels J31 Control Module Nia 7 Analog Output Channels J30 SEE BACK SIDE OF BOARD FOR JUMPER CONFIGURATION Digital Input 9 Channels J 55555555 gm DDDDDOOOOD DDDOOOOOOO al L Digital Output Channels J4 2 L Amp Enable IEEE 1394 Motor 1 Motor 2 Switch SW4 Ports Figure 24 Development Kit Layout E E C EE 1 I Anal
14. for the motor cable to this pin and to the p motor case This pin is connected internally in FireBlox to the heatsink Chassis Ground Tie the shield for the LEDA LEDB cable to this pin This pin is CHASSIS Input pest connected internally in FireBlox to the heatsink Nye mout Analog input signals These signals are referenced to AGND and must be p isolated the same as the FWRET signal AOxx Output Analog output signals These signals are referenced to AGND Dixx Input Digital input signals The return current path is the DI_COM pin DOxx Output Digital output signals The output current is supplied by the DOVCC pin Digital input mode sets the polarity for the digital inputs For active high PNP DI_MODE Input inputs tie DI MODE to OVDC e g DOGND For active low NPN inputs connect DI_MODE to 24VDC e g DOVCC 13 A1 A2 A2 B1 Quadrature encoder differential inputs The differential signals are indicated by B1 2 2 21 Z1 Input and A and B signals are in quadrature Z is the index signal that indicates Z2 Z2 the home motor position Motor phase outputs For 3 phase brushless motors connect the motor lines to cure PM up PWMA PWMB PWMC or PWMD PWME PWMF For 2 wire Servo motors i connect the motor lines to PWMA PWMB or PWMD PWME LEDA LEDB LEDC Output PWM outputs can be used to drive heaters and illumination AMP_ENABLE_ Input Amp Enable Input channel FireBlox will be disabled if the power is removed A
15. input power connection to protect external circuits from any failure of the FireBlox motor amplifiers used on each of the motor power connections See page 4 8 for wiring examples CAUTION Fuses with a maximum rating of 4A fast acting should be 2 5 Amp Enable The FireBlox 1 Control Module has an Amp Enable channel This channel provides a way to disable the FireBlox from hardware When power is applied to this channel the FireBlox can then be enabled from software and motor power is switched on When power is removed from the Amp Enable channel the FireBlox cannot be enabled If power is removed from the Amp Enable channel while motor power is on the FireBlox will be disabled and motor power will be switched off Amp Enable with External Switch Figure 6 illustrates how to apply power to the Amp Enable channel Also shown is an external switch SW1 and a visual indicator LED optional FireBlox 1 User Supplied LOOP A L CURRENT R103 Y AEN PIN7 ENABLE 2 i de LED kami N U3 A 1 4 PIN8 AMP ENABLE XERROR LOOP IN lt lt 2 to DSP 3 5 to DSP 74 NOTA P4 24V RET U4 XERROR LOOP OK penp MAX4372T to DSP Figure 6 Amp Enable with External Switch and Indicator Adept FireBlox 1 Control Module Developer s Guide Rev Page 15 of 61 Amp Enable with Multiple FireBlox Figure 7 illust
16. menu item Change robot options and motor configuration When asked if you want to change this configuration answer Y yes For most configurations it is not necessary to change the robot bits Enter the number of joints axes for this robot Each joint for this robot will now be configured Follow the instructions on the screen Map the FireBlox from DC_SETUP V2 If a robot includes an axis driven from a SmartAmp SmartModules or Servo Kit configuration should be done using the DC_SETUP utility Following the instructions below Load DC_SETUP V2 and Execute the a dc_setup program From the main DC_SETUP menu select Configure SmartModules Servo Kits Hybrid From the sub menu select SmartModules hybrid quick setup Information will be displayed on the screen describing the setup When asked for the general robot configuration enter the robot configuration For example if a 3 axis XYZ robot is being configured enter XYZ If a 4 axis XYZ Theta robot is being configured enter XYZT Follow the directions displayed on the screen for configuring the individual motors axes Be sure to configure the correct motor to the appropriate axis When configuring axes using a SmartAmp you will be asked to load data from a file The following options are provided SmartAmp Joint File Data for individual SmartAmps axes SmartModules or Servo Kits can be loaded from data files for these products Standard Spec data file A Spec data fil
17. 7 Proceed with Application Development See page 43 For steps 2 3 the FireBlox 1 Control Module will be connected to a PC with BloxView installed via IEEE 1394 For the remaining steps the FireBlox 1 Control Module will be connected to an Adept SmartController via the SmartServo network oa 2 o System Software Requirements e V version 16 0 edit C2 or later e System Utilities accompany V 6 2 Verifying Motor Setup Parameters in BloxView Verify that the motors were configured properly using the BloxView software The axes should be operational before proceeding See or details 6 3 Configure the FireBlox 1 Control Module Configuration of the FireBlox axes depends upon the robot configuration A robot can include a combination of axes driven by FireBlox SmartAmps and the sMI6 The following utilities should be used to configure the FireBlox SPEC V2 should be used when a robot includes axes driven from a FireBlox and or sMI6 SETUP V2 should be used when a robot includes axes driven from a FireBlox and or sMI6 in addition to SmartAmps Page 38 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Map the FireBlox from SPEC V2 Connect the FireBlox 1394 cable to the Adept SmartController SmartServo Network and power up the controller To verify the presence of the FireBlox Control Module on the SmartServo network issue a SRV NET command Load SPEC V2 and Execute the a spec program Select
18. Adept FireBlox 1 Control Module Developer s Guide 02600 000 Rev A May 2003 e ceni Es 3011 Triad Drive Livermore CA 94551 Phone 925 245 3400 Fax 925 960 0452 adept technology inc Copyright Notice The information contained herein is the property of Adept Technology Inc and shall not be reproduced in whole or in part without prior written approval of Adept Technology Inc The information herein is subject to change without notice and should not be construed as a commitment by Adept Technology Inc This manual is periodically reviewed and revised Adept Technology Inc assumes no responsibility for any errors or omissions in this document Critical evaluation of this manual by the user is welcomed Your comments assist us in preparation of future documentation Please email your comments to techpubs Qadept com Copyright 2003 by Adept Technology Inc All rights reserved The Adept logo CHAD the CHAD logo and Soft Machines are registered trademarks of Adept Technology Inc ActiveV Adept Adept 1060 Adept 1060 Adept 1850 Adept 1850 XP Adept 540 Adept 560 Adept C40 Adept C60 Adept CC Adept CHADIQ Adept CHADIQh Adept CHADIQt Adept Cobra 550 Adept Cobra 550 CleanRoom Adept Cobra 600 Adept Cobra 800 Adept DeskTop Adept Digital Workcell Adept FFE Adept FlexFeeder 250 Adept IC Adept Impulse Feeder Adept LineVision Adept MC Adept MV Adept MV 10 Adept MV 19 Adept MV4 A
19. Analog Input Channels The FireBlox 1 Control Module provides eight channels of single ended 0 10V analog input with 10 bits of ADC resolution These inputs are designed to read thermocouples vacuum sensors flow meters and similar devices Analog inputs are referenced to AGND and are not isolated Therefore the analog ground must NOT be connected to the motor or digital grounds NOTE Access to analog input channels from a SmartController requires a V sub routine provided by Adept Contact Applications Support for details Analog Output Channels The FireBlox 1 Control Module provides two channels of 0 10V analog output with 10 bits of resolution and 100Hz bandwidth Analog outputs are referenced to AGND and are not isolated therefore the analog ground must NOT be connected to the motor or digital grounds Adept FireBlox 1 Control Module Developer s Guide Rev A Page 21 of 61 AQ SIGNAL AQ ne 2 AEND Figure 14 Analog Output Schematic NOTE Access to analog output channels from a SmartController requires a V sub routine provided by Adept Contact Applications Support for details Digital Input Channels The FireBlox 1 Control Module provides eight channels of opto isolated input channels and can be used to read sensors interlocks or other similar devices The input channels incorporate low pass filters to reduce bouncing These channels can also be used to generate a system interr
20. CH 4 08 0005 DIGITAL OUTPUT 5 0006 DIGITAL OUTPUT CH 6 DO07 DIGITAL OUTPUT CH 7 DOVCC DIGITAL OUT VCC typ 24V DOVCC DIGITAL OUT VCC typ 24V DOVCC DIGITAL OUT VCC typ 24V DOVCC DIGITAL OUT VCC typ 24V DOVCC DIGITAL OUT VCC typ 24V DOVCC DIGITAL OUT VCC typ 24V mo por permanere D s oos x pera ro nes pomene 33 DIO6 DIGITAL INPUT CH 6 DIO7 DIGITAL INPUT CH 7 Adept FireBlox 1 Control Module Developer s Guide Rev Page 49 of 61 85 NC NO CONNECTION 36 NC NO CONNECTION 37 NC NO CONNECTION 38 NC NO CONNECTION 39 NC NO CONNECTION 40 NC NO CONNECTION 41 NC NO CONNECTION 42 NC NO CONNECTION 43 AVCC 5VDC OUTPUT 44 DGND DIGITAL RETURN 45 A1 CH1 ENCODER A 46 At CH1 ENCODER A 47 B1 CH1 ENCODER B 48 1 CH1 ENCODER 49 Z1 CH1 ENCODER Z 50 71 CH1 ENCODER 7 51 A2 CH2 ENCODER A 52 A2 CH2 ENCODER A 53 B2 CH2 ENCODER B 54 B2 CH2 ENCODER B 55 22 2 ENCODER 2 56 Z2 CH2 ENCODER Z 57 DVCC 3 3VDC OUTPUT 58 AGND 5VDC RETURN 59 DOVCC DIGITAL OUT VCC typ 24V 60 DOVCC DIGITAL OUT VCC typ 24V MATING CONNECTOR AMP 1 111196 2 RIBBON CABLE AMP 2 57013 0 Table 15 P2 Motor 0 Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 PWMA MOTOR DRIVE PHASE A
21. Control Module Developer s Guide Rev A Tuning the Motors The motors must now be tuned for the application See Appendix A Tuning Motors Specifying Motor Calibration Select the Homing tab on the Motor control panel There are three options for calibration the motors 1 Calibrate to the nearest index select Index 2 Calibrate to a sensor connected to a Digital Input channel then find the nearest index select Digital Input When this option is selected the Input ID input channel must also be specified 3 Calibrate to a hardstop select Motor Stall The Homing Polarity specifies the direction of travel during the calibration Velocity is specified as a percentage of Max Velocity set in General parameters Offset From Home specifies the number of encoder counts from the home position to the zero index position To test the motor calibration click on the Home button 5 4 Verifying System Operation To verify system operation the following items should be checked Motor and encoder operation Use the Enable Power button on the Motor Servo Tuning control panel to switch on motor power Define two positions and select the Move Once or Move Continuous button to initiate motion Digital Inputs and Digital Outputs Verify proper wiring of the Digital Input channels by selecting the Digital Input control panel This panel monitors input devices and can be used to verify operation Use the Digital Output control pa
22. Kp is between 50 and 1000 Please increase the bit shift so that the Kp is within this range Setting The Kd Enable the motor and press the Move Once button Observe the Results Graph and take note the frequency and the rate of decay The rate of decay should be very little and the motor should oscillate about the set point and you should get a nulling error Increase Kd and try again Repeat this process until the motor settles down such that there is an initial overshoot then undershoot and then settles to the set point The unloaded motor PID controller is limited to 2 A of current which means that in some instances there will not be enough current to drive your motor during the step response You must keep this in mind as you observe the performance of your motor on the results graph If adjusting the Kp and Kd results in no performance increases it can be that the controller is railing You can check this by setting the Results Graph view settings to command from Position Actual After you finish the results graph should look similar to the following figure Position Actual m Position enc Figure 27 Typical Results Graph for a Properly Tuned Motor NOTE If the motor does not have an undershoot the dip seen here you increased Kd too much Setting The Integrator The steady state error can be improved by adding an integrator or the compensator Nominal Integrator S
23. MP ENABLE Input Return line for Amp Enable Input channel Page 48 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Connector Pin Locations Table 13 J1 Analog I O Connector SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 100 ANALOG INPUT CHANNEL 0 2 101 ANALOG INPUT CHANNEL 1 3 102 ANALOG INPUT CHANNEL 2 4 Al03 ANALOG INPUT CHANNEL 3 5 DGND ANALOG RETURN 6 DGND ANALOG RETURN 7 104 ANALOG INPUT CHANNEL 4 8 105 ANALOG INPUT CHANNEL 5 9 106 ANALOG INPUT CHANNEL 6 10 107 ANALOG INPUT CHANNEL 7 11 DGND ANALOG RETURN 12 DGND ANALOG RETURN 13 NC NO CONNECTIONION 14 NC NO CONNECTIONION 15 NC NO CONNECTIONION 16 NC NO CONNECTIONION 17 DGND ANALOG RETURN 18 DGND ANALOG RETURN 19 NC NO CONNECTIONION 20 NC NO CONNECTIONION 21 NC NO CONNECTIONION 22 NC NO CONNECTIONION 23 AGND ANALOG OUTPUT RETURN 24 AGND ANALOG OUTPUT RETURN 25 000 ANALOG OUTPUT CH 0 26 01 ANALOG OUT CH 1 27 NC NO CONNECTIONION 28 NC NO CONNECTIONION 29 FWVCC FIREWIRE SUPPLY OUT 30 FWRET FIREWIRE RETURN MATING CONNECTOR AMP 1 111196 7 RIBBON CABLE AMP 1 57013 5 Table 14 J2 Digital and Encoder Connector ITEM SYMBOL FUNCTION ITEM SYMBOL FUNCTION DO00 DIGITAL OUTPUT CH 0 DO01 DIGITAL OUTPUT CH 1 DO02 DIGITAL OUTPUT CH 2 DO03 DIGITAL OUTPUT CH 3 DOVCC DIGITAL OUT VCC 24v 6 bovcc DIGITAL OUT VCC typ 24V 0004 DIGITAL OUTPUT
24. NELS 1 2 INPUT CURRENT 5 16 mA 3 VOLTAGE DROP 0 5 V ENCODERS 1 NUMBER OF CHANNELS 2 2 TYPE 5V DIFFERENTIAL A B Z 3 OPERATING FREQUENCY 30 MHz Adept FireBlox 1 Control Module Developer s Guide Rev A Page 47 of 61 Pin Definitions The following table provides the pin definitions for the FireBlox connector tables Table 12 FireBlox Pin Definitions Name Direction Description User provided power supply for the digital outputs Tie all DOVCC lines together DOVCC Input on an external connector board and to the external supply DOGND Input Ground pin for the digital output power supply VDCMTR1 VDCMTR2 Input Power supply for the motor amplifier These pins are independent and can be tied together VDC_RTN1 VDC_RTN2 Input Ground pin for the motor power supply VDCLED Input Power supply for the PWM outputs for LEDA amp LEDB VDCRET Input Ground pin for the LED output driver EWRET Input FireWire ground reference Ground connection for the IEEE 1394bus Must be p isolated from DOGND VDC_RTN VDCRET CHSGND and CHASSIS DGND Input Fireblox digital ground Connected internally in FireBlox to FWRET AVCC Output Fireblox 5VDC Output voltage derived from the IEEE 1394 bus Can be used to supply power to motor encoders AGND Input Fireblox analog ground Connected internally in FireBlox to FWRET CHSGND input Motor Chassis Ground Tie the shield
25. TPUTS 1 NUMBER OF CHANNELS 8 Opto isolated current sourcing 2 TYPE MOSFET high side output 3 EXTERNAL SUPPLY DOVCC 12 24 26 VDC DOVCC 24VDC RL 10kQ 4 OUTPUT RISE TIME 4 1 5 uSEC 5 OUTPUT FALL TIME 1 5 SEC 6 OUTPUT CURRENT DOVCC 24VDC 050 A 7 PEAK OUTPUT CURENT DOVCC 24VDC 20msec 2 DIGITAL INPUTS 1 NUMBER OF CHANNELS 8 2 TYPE Opto isolated POLARITY 2 4 INPUT VOLTAGE 15 24 VDC 5 LOGIC HIGH VOLTAGE 10 VDC 6 LOGIC LOW VOLTAGE 2 7 INPUT DELAY TIME Vin 150 uSEC 8 INPUT DELAY TIME V 50 uSEC Page 46 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A PWM OUTPUTS 1 NUMBER OF CHANNELS 2 2 OUTPUT TYPE PWM High Side 3 INTERFACE SUPPLY 15 24 29 VDC 4 OUTPUT RISE FALL TIME PWMVCC 24VDC RL 25Q 0 8 5 FREQUENCY 20 kHz 6 OUTPUT CURRENT PEAK PWMVCC 24VDC 2 A ANALOG INPUTS 1 NUMBER OF CHANNELS 8 2 me i 3 INPUT VOLTAGE 0 10 VDC 4 ADC INPUT RESOLUTION 10 BITS 5 FULL SCALE ADC REFERENCE 0 496 VDC 6 LPF CUTOFF FREQ Fc 500 Hz 7 INPUT IMPEDANCE 115 KQ ANALOG OUTPUTS 1 NUMBER OF CHANNELS 2 2 TYPE Single ended not isolated 3 OUTPUT VOLTAGE 0 10 VDC 4 OUTPUT RESOLUTION 10 BITS 5 BANDWIDTH 135 IN PHASE 100 Hz 6 OUTPUT IMPEDANCE 100 Q AMP ENABLE INPUT 1 NUMBER OF CHAN
26. Table 1 lists the internally isolated ground signals Table 1 Isolated Ground Signals Name Type Connector Pin DOGND Digital output ground J2 Pin 25 VDC RTN1 VDC 2 Motor power supply ground P2 amp P3 Pin 6 CHSGND Motor chassis ground P2 amp P3 Pin 4 VDCRET LED output driver ground Pin 6 Grounded from Mounting CHASSIS FireBlox case ground Tabs and P4 Pin 4 1 Connect internally isolated ground signals to the power supply ground s for the current return path The signals can also be tied together and or grounded to the machine chassis CAUTION signals DGND AGND FWGND are connected to FireBlox internally and must not connect to the other grounds When designing your system be sure to use a VOM meter to verify that these grounds are not connected to the device grounds listed above 2 Connect all cable shields to the machine frame ground e To minimize the effects of current flow between the PWM outputs and the motor cable shield on other circuits connect the motor cable shield to ground e To minimize electrical noise connect the cable shield for the motor encoder signals to ground minimize PWM noise coupling into other circuits connect the cable shield for the PWM LED outputs to ground Page 14 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 2 4 Install Fusing Protect Circuits and Motors Install an external fuse on the
27. adrature encoding provides a means of measuring direction and distance of travel Encoder input for the FireBlox 1 can be any of the following types of incremental encoders 1 Single ended with A B and Z Index channels 2 Open collector A B and Z Index channels 3 Differential with A A B B and Z Z Index channels Adept FireBlox 1 Control Module Developer s Guide Rev A Page 19 of 61 The Z Z Index channel is supported and can be used to home the motor position but is not required This section assumes the use of the FireBlox Termination board For wiring encoders directly to the FireBlox 1 Control Module see 2 Digital VO and Encoder Connector on page 49 While encoder power 5VDC can be derived from the IEEE 1394 network if several FireBlox 1 Control Modules are used on the same system it may be necessary to provide this power from an external supply External encoder power AVCC is connected to the P5 screw terminal on the Termination Board when used When the Termination Board is not used AVCC is connected directly to the encoder An internal fault circuit detects an open closed or shorted encoder cable interface and provides fault indication through a status LED and software 1 Connect the encoder outputs to the Termination Board via the P3 and P4 screw terminals P7 and P10 if the 8 pin connectors are used 2 If external encoder power is provided set SW2 on the Termination Board accordingly as described i
28. ayout and Dimensions 3 3 Connecting the Termination Board to the FireBlox 1 The Termination Board is connected to the FireBlox 1 Control Module using the two ribbon cables supplied with the Termination Board Kit The table below lists the connections Table 4 Connecting the Termination Board to the FireBlox 1 Cable Termination Board EB M ORIS Module 30 pin Ribbon Cable J1 J1 60 pin Ribbon Cable J2 J2 Page 26 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 33M0d09N3 M3M0d2N3 1olo uuoo reu amp iq 183AnQOWdWYNIdOS or DOOOOOODOODDOOOODDODDDDODOOODOODODOOD DOOODOODOOODOOOOOODOOOODOODOOOODOOOOOD 3 4 Termination Board Schematic SJepoous JO 440 suonlsod LMS L v 9lH Y v LIM MES Y L 81 EANNI AC 8 5 Y 1 2 B lH Lv v S43002N3 J0joeuuo 6oleuV AMA ANGORNGHVNIAOE oooooooooooo0o0o00 oOoooooooooooooo IVNINH31 AdHOS QN9Y lL AOZ VL ADY G GL92W1 ASt ou leuuelx3 Ieuuelul 101702512 ZNS 83M0d9N3 AS Ls Ls Sd QN9Y anda IIAV 39400 d TVYNINH3L MIYOS TVYNINH3L MAHOS DAMS Figure 20
29. ble 23 J35 Motor Power Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 24V 24VDC POWER SUPPLY 2 24VRET 24VDC SUPPLY RETURN 3 24V 24VDC POWER SUPPLY 4 24VRET 24VDC SUPPLY RETURN MATING DONE VIA SCREW CLAMP Page 52 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 8 3 Termination Board The J1 and J2 connectors on the Termination Board are the same as J1 and J2 on the FireBlox 1 Control Module Encoder Signals Table 24 P3 Terminal Strip Encoder 1 Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 FWPWR FireWire POWER 2 FWRET FireWire RETURN 3 ENCPWR ENCODER POWER 4 1 ECODER 1 5 1 ENCODER 1 6 1 ENCODER B1 7 1 ENCODER 1 8 21 ENCODER 21 9 21 ENCODER 21 10 AGND ANALOG RETURN MATING DONE VIA SCREW CLAMP Table 25 P4 Terminal Strip Encoder 2 Connector PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 ENCPWR ENCODER POWER 2 A2 ENCODER A2 3 A2 ENCODER A2 4 B2 ECODER B2 5 B2 ENCODER B2 6 Z2 ENCODER Z2 7 22 ENCODER 22 8 AGND ANALOG RETURN MATING DONE VIA SCREW CLAMP Table 26 P10 and P7 Alternate Encoder Connectors PIN SYMBOL FUNCTION PIN SYMBOL FUNCTION 1 ENCPWR ENCODER POWER 2 AGND ANALOG RETURN 3 A ENCODER A 4 A ENCODER A 5 B ENCODER B 6 B ENCODER B 7 2 ENCODER Z 8 2 ENCODER 2
30. brushless and servo motors Supplies 2 5 A RMS continuous 4 A peak at up to 43 Volts per channel Incremental encoder feedback A B Z provide position velocity and digital sine commutation Motor Protection Safety current loop over temperature sensor brake control output Real Time Control Embedded DSP runs up to 8 kHz servo loop Adept FireBlox 1 Control Module Developer s Guide Rev A Page 7 of 61 Reliability The IEEE 1394 serial bus uses differential signaling and is isolated from the I O signals Digital I O 8 Inputs 8 Outputs opto isolated rated at 0 5A continuous 24 VDC Analog I O 8 analog input channels 0 10 VDC 10 bit resolution 2 Analog output channels 0 10 VDC channels 10 bit resolution High current PWM outputs 2 outputs with 8 bit resolution for driving LED Lamp illumination heaters etc Outputs are rated for 2A 24VDC Adept SmartServo Compatible The FireBlox 1 Control Module is compatible with Adept s SmartServo distributed control platform FireBlox 1 Termination Board Kit The FireBlox 1 Termination Board provides a convenient method of accessing I O and encoder signals from the FireBlox 1 Control Module Adept recommends that one Termination Board Kit be ordered for use with each FireBlox 1 Control Module The assembly includes the following Termination Board with screw type terminals and configuration switches for differential single ended and open collector encoders
31. channels by displaying the input channels on the screen issue the IO 1 command The display updates and shows the state of input channels Digital Outputs Verify proper wiring of the Digital Output channels by switching the channels ON and OFF using the SIG command For example the SIG 65 command turns output channel 65 ON while the SIG 65 command turns it OFF 6 6 Application Development Applications development for SmartController systems is done using the V programming language or the AIM application software Refer to the V Language User s Guide or the AIM MotionWare User s Guide Adept FireBlox 1 Control Module Developer s Guide Rev A Page 43 of 61 7 Service 7 1 Status Indicators LED status indicators 7 provide visible feedback for power FireWire activity reset encoder cable fault and diagnostics For the location of the LEDs on the FireBlox 1 Control Module see Figure 13 The following table provides a description of each indicator Table 8 Status Indicator Descriptions Indicator Description DIAGNOSTIC LEDs TBD RESET Encoder cable fault FW OK FireWire activity rest PWR OK Power on 7 2 Troubleshooting PC Based Systems BloxView Diagnostics See Verifying System Operation Error Codes from PC Based Systems Information for this section will be added to the next revision 7 3 Troubleshooting SmartController Systems Encoder Feedback Encoder feedback can be verified
32. configured in a variety of ways AsaField Test Unit Set up similarly to the development tool style the Kit may be used for Field Application Engineers to perform quick comprehensive testing of FireBlox in the field Chapter 8 details mating connectors and contacts Page 30 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 4 2 Development Kit Features The FireBlox Development Kit provides the following features Motion The Development Kit comes with one Pittman 3 phase brushless DC motor connected as Motor 0 and a Faulhaber MicroMo brushed DC connected as Motor 1 Digital Inputs Output Channels Outputs 8 opto isolated 24 Voc 0 25A continuous channels Inputs 8 opto isolated 24V pc channels The digital I O channels are configurable for loop back self test or external interface Analog Inputs Output Channels Outputs Two 0 10 10 bit channels Inputs Eight 0 10 Voc 10 bit channels The analog I O channels are configurable for loop back self test or external interface PWM power outputs The PWM channels with onboard LED indicators are configurable for driving external signals or for simple functional testing PWMs dual 0 24Vpc 1A channels BloxView utility software This PC software is used for configuration servo tuning and evaluation testing 4 3 Development Kit Connections The diagram below provides an overview of the connections for the Development Kit For connector pin
33. d click Next The Choose Destination Location dialog is displayed By default the software is installed into the subdirectory 4 C Program Files MetaControls BloxView Adept FireBlox 1 Control Module Developer s Guide Rev Page 35 of 61 5 onthe hard drive of your PC You can click Browse to specify a different directory if desired 6 Click Next to accept the default location The Select Program Folder dialog is displayed This dialog allows you to specify the program folder where the BloxView startup entry and icon will be stored 7 Click Next to accept the default location The software is installed in the selected directory After installation has completed the Microsoft Data Access Components License Agreement dialog displays 8 After reviewing the terms of the license agreement select the I accept all of the terms of the preceding license agreement checkbox and then click Next to proceed 9 The installer scans the PC system to verify shared components and then displays the Installing the Software dialog 10 Click Finish to complete the MDAC software installation After the software installation has completed a Setup is Complete dialog is displayed 11 Click Close to close the dialog and complete the MDAC software installation The InstallShield Wizard Setup Complete dialog is displayed 12 Click Finish to close the Setup Complete dialog 5 3 Configuring the Motors and Encoders For complete details for us
34. data should be loaded into SPEC While it is not required that FireBlox data be loaded into SPEC for runtime it is recommended that the comprehensive data be stored to a disk file Select Read Write to Adept FireBlox from the main SPEC menu Select Read Parameters from FireBlox Repeat this step for both joints then exit to the main menu Select Save robot specifications to a disk file Exit the SPEC utility Page 42 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 6 4 Mapping the Digital I O Channels Configure the Block Load DC_SETUP V2 and Execute the a dc_setup program Select the Configure RIO input output blocks menu If block number 16 is selected for input and output signals are automatically assigned as follows e V input signals 1033 1040 e V output signals 33 40 If a block number other than 16 is selected the I O numbers need to be assigned Proceed to the next section Assign IO Signal Numbers Load CONFIG C V2 and Execute the a config c program Select V System Configuration Data from the main menu Select EDIT system CONFIGURATION Follow the instructions from the CONFIG C utility Also see Configuring a RIO Device in V from Knowledge Express 6 5 VOrmnng System Operation Motor and encoder operation Use the Manual Control Pendant MCP to enable robot power With robot power on select the joint and move it using the MCP Digital Inputs Verify proper wiring of the Digital Input
35. dept MV 5 Adept MV 8 Adept NanoBonder EBS Adept NanoBonder LWS Adept NanoCell Adept NanoStage L1P2 Adept NanoStage L3 Adept NanoStage L3P2 Adept OC Adept SmartAmp Adept SmartAxis Adept SmartController CS Adept SmartController CX Adept SmartModule Adept SMIF EZ AdeptAlign 650 AdeptAtlas AdeptCartesian AdeptForce AdeptFTP AdeptGEM AdeptModules AdeptMotion AdeptMotion Servo AdeptMotion VME AdeptNet AdeptNFS AdeptOne AdeptOne MV AdeptOne XL AdeptRAPID AdeptSix 300 AdeptSix 300CL AdeptTCP IP AdeptThree AdeptThree MV AdeptThree XL AdeptTwo AdeptVicron AdeptVicron 3005 AdeptVicron 310D AdeptVision AdeptVision AVI AdeptVision AGS AdeptVision GV AdeptVision 1 AdeptVision AdeptVision VME AdeptVision VXL AdeptVision XGS AdeptVision XGS II AdeptWindows AdeptWindows Controller AdeptWindows DDE AdeptWindows Offline Editor AdeptWindows PC AIM AIM Command Server AIM Dispense AIM PCB AIM VisionWare A Series AutoCal AutoTune AutoWidth CCM CCMII CGM CHAD ACM CHAD ACT CHAD AF CHAD AutoClinchMaster CHAD BLT CHAD CH CHAD ClinchMaster CHAD ClinchMaster Il CHAD CS CHAD CSII CHAD ECA CHAD GuideMaster CHAD HT CHAD LGM CHAD LLG CHAD MGE CHAD MixTech CHAD MTM CHAD OFM CHAD PIE CHAD QCB CHAD RC CHAD SGE CHAD TM CHAD VT CimStation CimStation Robotics FireBlox FlexFeedWare HexSight HyperDrive Microenvironment MicroV MotionWare ObjectFinder ObjectFinder 2000 PackOne PalletWare Pro
36. dept SmartController systems 1 3 Warnings Cautions and Notes This documentation uses four levels of special alert notation In descending order of importance they are DANGER Indicates an imminently hazardous situation that if not avoided will result in death or serious injury A WARNING _ Indicates a potentially hazardous situation that if not avoided could result in serious injury or major damage to the equipment CAUTION Indicates a situation that if not avoided could result in minor injury or damage to the equipment NOTE Provides supplementary information emphasizes a point or procedure or gives a tip for easier operation 1 4 How Can Get Help Refer to the How to Get Help Resource Guidd Adept P N 00961 00700 for details on getting assistance with your Adept software and hardware Additionally you can access the following information sources on Adept s corporate web site e For Contact information ttp Mwww adept com main contact index html e For Product Support information http www adept com main services index asp e For general information about Adept Technology Inc ttp www adept com Adept FireBlox 1 Control Module Developer s Guide Rev A Page 9 of 61 2 Installation 2 1 Installation Overview This chapter outlines the FireBlox 1 Control Module installation process which includes the following steps Mount the FireBlox 1 Control Module Ensure proper grounding Install fus
37. duction PILOT SILMA CellFLEX SILMA CellPRO SILMA PaintPRO SILMA PressPRO SILMA SpotPRO SMIF C SMIF EZX SMIF Z SMIF ZX SoftAssembly S Series UltraOne V V and VisionTeach are trademarks of Adept Technology Inc Any trademarks from other companies used in this publication are the property of those respective companies Printed in the United States of America Page 2 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Table of Contents Adept FireBlox 1 Control Module Developer s Guide Rev Page 3 of 61 Page 4 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev Adept FireBlox 1 Control Module Developer s Guide Rev Page 5 of 61 3 Page 6 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev 1 Introduction 1 1 Product Overview Adept FireBlox 1 Control Module The Adept FireBlox 1 Control Module is an IEEE 1394a FireWire based dual axis servo motor controller amplifier with peripheral I O It is capable of driving both 3 phase brushless motors and DC brushed motors The FireBlox 1 Control Module contains a powerful Digital Signal Processor DSP 3 IEEE 1394 ports motor controller amplifier and I O Because of the high density of its electronics several control modules can often replace a conventional VME or industrial computer chassis Because of its small size and mass the FireBlox 1 Control Module can be mounted on moving axes close to the motors
38. e FireBlox 1 typically operate with a transformer isolated unregulated DC power supply The DC power supply should be sized so that the maximum output voltage under high line and no load conditions does not exceed the amplifiers maximum voltage rating Complete Motor Phase Wiring NOTE The two motor circuits are independent and can operate at different voltages Do not exceed the current and voltage specifications Adept FireBlox 1 Control Module Developer s Guide Rev Page 17 of 61 Three phase motor wiring varies by motor manufacturer and is usually labeled ABC UVW RST or 123 Three phase motors should be connected to P2 or P3 on the FireBlox 1 as follows 1 Connect three phase motors to P2 or P3 on the FireBlox 1 as shown in Table 2 and Figure 10 Table 2 Wiring 3 Phase Brushless Motors Function Pin Motor Winding A Motor Winding B Motor Winding C Motor High Voltage Motor Chassis Ground Motor Voltage Return O a O 2 0 A Fuse Fast Acting max rating Motor High Voltage VDC MOT 43VDC max Motor Drive Phase A FireBlox 1 Motor Drive Phase B Motor Drive Phase C MOT_CHS_GND MOT_RET Motor Voltage 7 Motor Chassis Return Ground Figure 10 Wiring a 3 Phase Brushless Motor NOTE Three phase motor wiring varies by motor manufacturer and is usually labeled UVW ABC RST 123 2 Connect two wire DC motors to P2 or P3 as follows Table3 Wiring 2 Wire DC Motors
39. e contains data from a previously configured system This is useful when configuring multiple systems or recovering from a FireBlox replacement Adept FireBlox 1 Control Module Developer s Guide Rev A Page 39 of 61 After the configuration is completed the robot configuration is displayed An example is shown below 21515 Current Configuration You have configured a 4 axis XYZT robot which consists of the following components Joint 1 Motor 1 Servo Kit Motor 3750 module Joint 2 Motor 2 VM module 300 mm Joint 3 Motor 3 Unknown module Joint 4 Motor 4 Unknown module Robot Option Bits Bit TESIS 1413 I25L1510 82 285 T 46 35 NA 582 220 2 Veneno 05 XD Ab 0 SD Motor Mapping Data Joint Axis Type Motor Bus Chn 1 1 Primary 1 N3 sal 2 2 Primary 2 N2 CL 3 3 Primary 3 3FF NO cl 4 4 Primary 4 3FF ND C2 Press ENTER to continue Figure 26 Typical Robot Configuration Shown from SPEC V2 Follow the instructions displayed on the screen to calibrate SmartModules axes and Servo Kit axes that calibrate to a hard stop The absolute encoder position on these axes must be reset This is accomplished by driving the axes to a hard stop then resetting the absolute encoder to zero FireBlox axes have incremental encoders and do not require this step during system setup Page 40 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Configure Calibration f
40. ed add a disturbance by nudging the motor if it is a linear motor a gentle twist if it is a rotary motor when it is enabled If the motor starts to oscillate DISABLE the motor and reduce Kp Keep doing this until the motor no longer goes into oscillation Conversely if it does not go into oscillation increase Kp until it does Once you have gotten it to immediately go into oscillation reduce Kp until the motor is stable when the enable button is pressed Once the motor is no longer oscillating when it becomes enabled add a disturbance by nudging the motor if it is a linear motor a gentle twist if it is a rotary motor when it is enabled If the motor starts to oscillate DISABLE the motor and reduce Kp Keep doing this until the motor no longer goes into oscillation NOTE If you do not have enough resolution in Kp you can increase the BIT SHIFT which is a mechanism that shifts the results of the sum of products in the accumulator in the DSP For each bit shift the sum of products gets divided by two For example a bit shift of 3 will divide the sum of products by 8 a bit shift of 5 will divide the sum of products by 32 Adept FireBlox 1 Control Module Developer s Guide Rev Page 57 of 61 If you increase the bit shift please remember to multiply the Kp value by however many multiples of 2 This ensures that you have the same magnitude for Kp when you transition from one bit shift level to another Typical range of values for
41. er system is powered up All other calibration parameters must be entered from the SPEC utility From the main SPEC menu select Edit robot specifications Select Edit motor calibration parameters and select the appropriate motor number Adjust the calibration parameters for each motor The Calibration Group must be specified for each axis The exes are calibrated sequentially based upon the Calibration Group setting For example axes with group 1 specified are calibrated first then axes with group 2 are calibrated Specify Calibration Routine Different calibration routines are provided to calibrate the robot For systems with multiple robots each robot uses a calibration routine The calibration routine selected depends upon the node types used to make up the robot The calibration routines are standard cal To be used when a robot is comprised of FireBlox 1 and or sMI6 axes smartmod cal To be used when a robot is comprised of SmartAmp axes SmartModules and or Servo Kits Adept FireBlox 1 Control Module Developer s Guide Rev A Page 41 of 61 hybmod cal To be used when a robot is comprised of SmartAmp axes SmartModules and or Servo Kits in addition to FireBlox 1 and or sMI6 axes NOTE If the system was configured from the SETUP utility the correct calibration routine should be selected automatically To specify the calibration routine select Edit robot specifications from the main SPEC menu From the sub menu selec
42. ettings The integral gain Ki is 30 or less of the Kp gain setting and nominal values are usually 10 of the Kp So set your Ki to 10 of Kp Hunting for Integrator Settings Enable the motor and press Move Once and note the shape of the waveform Adjust the bit shift such that the waveform looks similar to If you increase the bit shift please Page 58 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A remember to multiply the Kp and Kd values by however many multiples of 2 If you decrease the bit shift please remember to DIVIDE the Kp and Kd values by however many multiples of 2 This ensures that you have the same magnitudes for Kp and Kd when you transition from one bit shift level to another Each time set the Ki value to 10 of Kp Finishing Up Now that you have coarsely tuned the motor you should now fine tune it by making small adjustments to the Kp Ki and Kd values If you have increased the bit shift there will be more resolution for Kp and Kd and you should revisit the section on tuning them remember to set the Ki to zero again Save your gain settings and remember to reset the following parameters to their previous values Maximum Acceleration Maximum Velocity Maximum Windup Command Ramp Minimum Travel Maximum Travel Envelope Error Time In Position Nulling Window In Position Count 1 Nise Norman S Control Systems Engineering 27 ed Benjamin Cummings Redwood City
43. he amplifier The Amp Fault Output can be accessed from pins 4 and 5 of the P4 connector When the FireBlox is enabled the Amp Fault output is on closed When the FireBlox is in a fault state the Amp Fault output is off open The Amp Fault output is rated to 40VDC and 50 mA FireBlox 1 LOOP a CURRENT T bns FAULT OUT PS2805 4 R34 NV SHUTDOWN 330 2 15 from DSP PIN4 FAULT_RETURN P4 DGND U5 A is rated at 50 mA Figure 9 Amp Fault Output 2 7 Connect 3 Party Motors and Encoders The FireBlox 1 Control Module provides the following e Two Amplifier Channels compatible with most brushed and brushless motors including linear rotary voice coil 3 phase brushless and DC motors e Motor Voltage 12 to 43 Volts DC e Current 2 5A continuous 4 0A peak e Motor current feedback to increase performance and efficiency e DSP to implement closed loop torque position control based on user defined set points interfaced through the control system Adept SmartController or PC based system NOTE The selection of qualified 3 party motors must completed prior to installation For details contact Adept Applications Support and request the Adept FireBlox 1 Applications Note Guidelines for Selecting Motors document and the list of qualified 2 party motors NOTE FireBlox 1 uses sine wave commutation It does not use or support Hall Effect commutation Connect the Motor Power Supply Motors connected to th
44. ing BloxView software refer to the online help Start the BloxView software and select the view tab associated with the FireBlox 1 Control Module Selecting the Motors Select the Motor control panel Double click on the Motor 0 or Motor 1 Control This will bring up the Motor Servo parameters Data can be loaded from the BloxView database imported from a compatible data file bvt or entered from the Motor control panel If the desired motor has been qualified by Adept data can be loaded from the database or imported from a bvt data file NOTE The FireBlox 1 Control Module is pre configured when shipped as part of the Development Kit If the desired motor has not been qualified by Adept contact Applications support After a cursory check of the motor parameters to ensure compatibility with the FireBlox 1 data can be entered from the Motor control panel Select the Motor Setup tab The Motor Servo parameters must be entered or verified For a list of parameters and a view of the control panels see the Motors Servos section in the BloxView online help NOTE If the FireBlox 1 Control Module is to be used with SmartController system the joint limits specified in BloxView must be wider than the actual joint limits specified in the SPEC utility That is specify large limits specified in encoder counts from BloxView and specify the actual joint limits specified in mm or deg from the SPEC utility Page 36 of 61 Adept FireBlox 1
45. ing to protect circuits and motors Connect the Amp Enable circuit Connect 3rd party motors and encoders Connect peripheral I O devices Oa F WN gt Connect the IEEE 1394 line to the control system User Supplied Power The following power is user supplied e Motor power may be connected to a range of voltages not to exceed 43VDC Motor power connects to P2 and P3 of the FireBlox 1 Control Module e Digital Outputs are typically powered from 24V DOVCC and are often driven using the same supply as for the PWM drivers This power connects to the J2 connector on the FireBlox 1 Control Module or to the P2 screw terminal on the optional Termination Board e Power for the PWM drivers is typically 24V The power connects to P4 of the FireBlox 1 Control Module e Encoder power 5VDC can be derived from the IEEE 1394 network However when several FireBlox 1 Control Modules are used on the same system it may be necessary to provide this power from an external supply External encoder power AVCC is connected to the P5 screw terminal on the Termination Board When the Termination Board is not used AVCC is connected directly to the encoder NOTE Reliable operation of the FireBlox 1 in an industrial environment requires proper design of power and grounding of the system Although the FireBlox 1 circuitry is very versatile and robust poor power and ground design can be very detrimental to system performance Page 10 of 61 Adept Fi
46. ink Encosure Figure 3 Mounting Dimensions Isometric View Page 12 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Cooling is achieved through conduction from the cover to the mounting surface FireBlox must be mounted to a metal panel or machine chassis to achieve the specified motor ratings In order to maximize heat dissipation at heavy motor currents mount the enclosure to a base that is capable of dissipating heat CAUTION Do not open the FireBlox 1 Control Module It does not contain any user serviceable parts Opening the enclosure for any reason voids all warranties Figure 4 below shows the connector locations Figure 5 shows the location of pin 1 for these connectors Analog I O PWM Amp Enable J2 Digital Figure 4 Connector Locations J Figure5 Pin 1 Locations Adept FireBlox 1 Control Module Developer s Guide Rev A Page 13 of 61 2 3 Ensure Proper Grounding The FireBlox 1 internal chassis ground is connected to the external enclosure Machine wiring should connect the enclosure to machine chassis ground To provide greater flexibility in selecting power supplies the FireBlox 1 provides several ground signals for the various circuits A single common power supply can be used or multiple supplies can be selected either isolated or grounded to the machine chassis
47. its tab set the Time In Position to 200 msec Set the In Position Count to 5 encoder counts Set the Nulling Window to 300 msec These settings will allow free travel of the motor without generating errors while performing the Unit Step Response Setting Up Parameters In The General Tab First set the Max Acceleration to a value higher than what the motor can achieve Second set the Max Velocity to a value higher than what the motor can achieve Set the Max Windup to 32767 encoder counts Set the Command Ramp to 1 If the motor that you are trying to tune is a three phase motor set the Max Command to 866 PWM counts If itis a brushed DC motor set it to 1732 These settings will remove all restraints of the controller while performing the Unit Step Response Setting Up PID Coefficients Set the tuning parameters as in the following table Gains Kp 80 Ki 0 Kd 0 Feed Forward Gains Kv 0 Ka 0 Bit Shift 3 NOTE Make sure that current feedback is disabled Page 56 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Setting Up The Results Graph Verify that the Results Graph checkbox is checked In the drop down menu select Position Actual Test Settings Make sure that all the power is on Turn the motor to verify proper encoder operation and that the motor can freely move throughout the range of motion specified by Minimum and Maximum po
48. n chapter B FireBlox 1 Termination Board User Supplied Voltage Regulator 24V Circuit A aon C ena 5VDC out Encoder Power Optional V7 24V RET PIN43 ENCPWR fi PIN45 PIN 4 46 PIN 5 PIN 47 PIN 6 En a PIN 48 PIN 7 Encoder Assembly PIN 49 PIN 50 Figure 12 Differential Encoder with Termination Board Page 20 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A If single ended or open collector encoders are used the SW1 on the Termination Board must be set to configure the unused A B and Z channels see chapter 3 for details Figure 12 below illustrates connecting single ended or open collector encoders This figure also shows the use of internal encoder power ENCPWR FireBlox 1 Termination Board User Supplied ENCPWR Ji Encoder Assembly Figure 13 Single Ended Encoder Inputs to Termination Board For noise immunity use shielded twisted pair cabling with the shield tied to machine chassis ground 2 8 Connect Input and Output Devices Connections to input and output channels are made through connectors J1 J2 and P4 These connectors provide access for analog I O digital I O and PWM outputs respectively See the figures below for connector locations and pin 1 location on each connector For pin descriptions see Connector Pin Locations jon page 49
49. nded or differential encoders configurable with SW1 Encoder termination using screw down headers or 2 eight pin 2mm high density connectors User supplied Digital Output VCC DOVCC is fused on board Easy connectivity On Board Fuses The Termination Board has two fixed resetable fuses to protect the FireBlox 1 The Termination Board can be configured to provide encoder power 5VDC from the IEEE 1394 network F1 protects the IEEE 1394 network and the FireBlox if a short occurs on the ENCPOWER F1 is not field replaceable but will reset when the short condition is corrected The VCC for Digital Output channels DOVCC must be user supplied F2 a 2 0 amp PTC fuse protects the FireBlox 1 if an over current condition occurs on a digital output channel This fuse is not field replaceable but will reset when the over current condition is corrected and the DOVCC is removed from P2 Adept FireBlox 1 Control Module Developer s Guide Rev A Page 25 of 61 3 2 Mounting the Termination Board The figure below shows the termination board layout and dimensions for mounting ADEPT TECHNOLOGY INC Blox 1 Termination qQooooooo00 000000000000000000000000000000 OO00000000000000000000000000000 O000000000000000 e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e e 20 0 mm Ribbon Cables to FireBlox 12 4 mm Figure 19 Termination Board L
50. nel to turn on the output devices and verify operation Analog Inputs and Analog Outputs Verify proper wiring of the Analog Input channels by selecting the Analog Input control panel Switch the input device on and off to verify operation Use the Analog Output control panel to set the output voltage level and verify operation PWM Outputs Verify proper wiring of the PWM output channels by selecting the PWM Output control panel to set the output voltage level and verify operation 5 5 Application Development If this FireBlox 1 Control Module will be used as part of an Adept SmartController system proceed to chapter 6 To develop application software for a PC based system refer to the Sequencer section of the BloxView online help Adept FireBlox 1 Control Module Developer s Guide Rev Page 37 of 61 6 Software Configuration SmartController Systems 6 1 Overview After installing the FireBlox 1 Control Module it must be configured before proceeding with the application development This is accomplished by completing the following steps 1 Installing the BloxView software See Installing the BloxView page 35 Configuring Motors and Encoders BloxView See Configuring the Motors and Encoders on page 36 Tuning Motors BloxView See Appendix A Configure the FireBlox 1 Control Module SPEC V2 or DC SETUP See Mapping Digital MO channels DC SETUP See page 43 Verify system operation See page
51. nput will register either a logic high or logic low depending on which I O mode the Development Kit is configured for see below External I O Mode Pin 2 3 jumpered on J5 J12 The user has access to each individual input and output channel through screw terminals J3 and J4 The pinout for each connector as well as the locations for DOVCC DOGND and DI_MODE are detailed in chapter Input Modes Active High or Low The Development Kit may be used with either PNP active low or current sourcing type inputs or NPN active high or current sinking type inputs This is accomplished by setting the DI MODE labeled on the board as DI COMMON jumpers J14 and J15 There are three modes for DI MODE 1 External J15 is jumpered between pins 2 and 3 the J14 setting is irrelevant DI MODE is controlled externally using DI MODE pin 10 on J3 as an input 2 Internal NPN J15 is jumpered between pins 1 and 2 and J14 is jumpered between pins 1 and 2 3 Internal PNP J15 is jumpered between pins 1 and 2 and J14 is jumpered between pins 2 and 3 Adept FireBlox 1 Control Module Developer s Guide Rev A Page 33 of 61 Analog Input Output Channels The Analog I O channels may be operated in one of two modes loop back self test or external I O user accessible Configuration is done using jumpers J22 29 Loop Back Mode J22 J29 jumpered between pins 1 and 2 Analog Inputs 00 03 100 AIO3 will be connected to Analog O
52. nt ground loops in the system grounds should be star wired or connected only one point Additionally all cable shields should be connected directly to machine chassis ground NOTE Incorrect grounding can result in increased EMI IEEE 1394 unplug conditions inaccurate encoder read back and increased noise on Analog Inputs Analog Input Channels Analog input channels may be used with a thermistor to measure motor temperature providing Page 28 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev an extra degree of safety in the system Analog input devices connect to the P6 screw terminal Analog Output Channels The analog output channels may be used to drive a variety of analog signaled devices Analog output devices connect to the P6 screw terminal Digital Input Channels Digital input channels connect to the P5 screw terminal The input channels can be configured for NPN current sinking or PNP current sourcing polarity by setting the DI MODE signal Connecting the DI_MODE line to DOGND will result in NPN function while connecting it to DOVCC will result in PNP function Digital Output Channels Digital output channels connect to the P2 screw terminal The digital output voltage DOVCC is user supplied Encoder Inputs Encoder inputs connect to the P3 and P4 screw terminals or to the P7 and P10 plug in type connectors Set Switch 1 for the type of encoder used see Figure 21 on page The two enc
53. oder input channels can be configured independently For example encoder 1 can be a differential encoder while encoder 2 is a single ended encoder When single ended or open collector encoders are used there is no connection on the A B and Z encoder input channels Table 5 Switch 1 SW1 Settings Configured as Selene e Single Encoded or Channel Differential Open Collector Pos 1 2 3 OFF OPEN Pos 1 2 3 ON CLOSED Pos 4 5 6 OFF OPEN Pos 4 5 6 ON CLOSED Adept FireBlox 1 Control Module Developer s Guide Rev A Page 29 of 61 4 Using the Development Kit 4 1 Overview of the Development Kit FireBlox Development Kit presents the FireBlox Controller in an out of the box package which can be used as is or as a basis for machine integration 5 lt lt uw gt m FOR JUUPER Figure 22 The FireBlox 1 Development Kit Possible uses of the Development Kit include As a development tool for verifying the functionality of the FireBlox The Kit provides all power supplies loads and circuitry necessary to test all functionality of the FireBlox Controller when connected via IEEE 1394 cable to a user provided PC As a prototyping tool Existing cable assemblies motors and devices may be easily connected by means of the screw lock connectors on the kit Motors and digital I O channels may be powered either internally or externally and I O connections may be
54. og I O i Digital O I 1 qr 222 29 qm 1 12 1 1 Input Channels wrap Output Channels 2 Outputs as follows 2 pooo Doo7 wrap d 3L Aloo AIO3 00 31 to Inputs 0100 007 104 AIO7 01 i 1 i 15 12 1 15 5272 Input Channels 1 i 2 ADO 107 connect 2 2100 Dior and i 31 ta extemal devi 3 Output Channels i i Parna devices 0000 DO07 connect i to external devices 1 DI_MODE 1 Power 1 labeled as DI COMMON I I J15 I 1 i MED 1f 332 1 DI COMMON i Internal 2 _ Internal 1 2 controlled 1 3 povcc 31 VDCLED 3L externally 1 1 1 I 314 J15 i 1 1 s J13 15 J32 i 1 DI00 DIO7 1 2 External 2 External 1 2 Functionin I 3 JDOVCC 31 VDCLED al ll Active HI mode 1 I I J14 J15 1 1 0100 DIO7 1 l 2 Functionin 11 Active LO mode jc away ce pa ka li crt et Ol Figure 25 Jumper Settings Jumper configurations are also detailed on the bottom side of the Development Kit PCA Page 32 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 4 4 Development Kit Operation Power Both DOVCC and VDCLED may be powered internally or externally by setting Jumpers J13 and J32 When the jumper on J13 is connected between pins 1 and 2 the in
55. ompanying DLLs provide tools for configuration servo tuning automatic script execution and diagnostic testing of the system Operation of the BloxView software is discussed in the online documentation which can be accessed through the BloxView interface The steps to complete software configuration and tuning are outlined below Installing the BloxView Software See below Configuring the Motors and Encoders BloxView See page 86 Tuning the Motors BloxView See Appendix A on page 55 Verifying system operation See page ak WN Proceeding with Application Development See page 5 2 Installing the BloxView Software This section describes how to install the BloxView software on the PC System Requirements e Microsoft Window 2000 or higher e 128 Mb of RAM e 10 Mb of available storage space Installation The BloxView software for the PC is distributed on CD ROM The media contains an installation program to properly install the software on the PC After installation the BloxView software can be started from the Start menu bar in Windows Install the BloxView Software 1 Insert the CD ROM into the CD ROM drive of your PC If Autoplay is enabled the InstallShield Wizard begins and displays the Welcome window If Autoplay is disabled you will need to manually start the CD ROM 2 Choose Next to start the installation process The InstallShield Wizard displays the Setup Type dialog 3 Select Full an
56. or FireBlox Axes Edit Calibration Parameters There are six options for calibrating FireBlox axes Table 6 Options for Calibrating the Motors Calibration Method Notes The sensor must be connected to a FireBlox digital input channel and the channel must be specified in BloxView The sensor must be configured as Search for a home sensor described above then find nearest index mark The Index Spacing parameter must be specified in BloxView Search for a home sensor Search for a hard stop Search for a hard stop then The Index Spacing parameter must find nearest index mark be specified in BloxView Stay at current Position Stay at current Position then The Index Spacing parameter must find nearest index mark be specified in BloxView NOTE Ifa motor is calibrated to a home sensor switch the digital input channel must be specified from the Motor control panel in BloxView select Homing tab The input signal must transition from low to high as the sensor is made Failure to configure the digital input channel properly will result with a Calibration sensor failure Mtr x If the motor is calibrated to an index mark the Index Spacing parameter must also be set in BloxView select Motor Setup tab This parameter specifies the number of encoder counts between index marks The digital input channel and the Index Spacing parameters are stored to the FireBlox and are loaded when the SmartControll
57. rates how to connect the Amp Enable channel when multiple FireBlox 1 Control Modules are used in the same system 24V AMP_ENABLE_ SW1 FireBlox 1 P4 FireBlox 1 P4 FireBlox 1 P4 7 424V RET Figure 7 Amp Enable with Multiple FireBlox 1 Control Modules Connecting the Amp Enable Channel to a SmartController Figure 8 illustrates how to connected the Amp Enable channel to a SmartController system Adept recommends the Amp Enable Loop be connected to the XUSER connector on the SmartController The ES1 contact via pins 7 and 20 of XUSER provides a means of removing power from the Amp Enable channel when the SmartController system experiences an E Stop condition For complete details on the SmartController system E Stop circuitry see the SmartController User s Guide With this approach power is applied to the Amp Enable channel when the SmartController E Stop is closed When the E Stop is opened power is removed from the Amp Enable channel This implementation provides Category 1 CAT 1 safety functionality User Supplied SmartController XUSER connector 24V PIN7 AMP_ENABLE_ FireBlox 1 PIN8 AMP ENABLE 24V RET ES2 Channel can also be used Figure 8 Amp Enable Loop with SmartController E Stop Page 16 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 2 6 Amp Fault The FireBlox 1 provides an Amp Fault Output which indicates the state of t
58. reBlox 1 Control Module Developer s Guide Rev SmartServo IEEE 1394 akg wanana FireBlox 1 Amp Enable Channel for details see the Amp Enable section SmartController CS Y 24VDC Power from Customer Supplied Power Supply to Controller XFP to Controller XDC1 Front Panel XFP FA ff N Customer Supplied e Power Supply age Front Panel Manual Control Pendant not shown External E Stop circuit for SmartController not shown Motors connecting to FireBlox 1 not shown For complete SmartController wiring diagram see the Adept SmartController User s Guide Figure1 FireBlox Connected to Adept SmartController System NOTE Adept recommends the use of a Termination Board Kit for easier connection of encoders and I O devices to the FireBlox 1 Control Module See Chapter 6 for details Adept FireBlox 1 Control Module Developer s Guide Rev Page 11 of 61 2 2 Mount the FireBlox 1 Control Module FireBlox mounting dimensions are shown in the figures below When sizing the mounting area allow room for connector access and cable routing 21 IEEE 1394 Ports 4 31 this side 99 88 107 5 CD a Bottom View Figure 2 Mounting Dimensions Bottom View ko S DIN Rail Mount 6 Groove i Heats
59. sensors and actuators which minimizes cabling Often large cable harnesses are reduced to a single IEEE 1394 cable and power cable Systems can be expanded by plugging additional control modules into the IEEE 1394 network Multiple machines can be coordinated by connecting the control modules through a network to the same host controller The FireBlox 1 Control Module is compatible with Adept s SmartServo distributed control platform This includes the line of Adept SmartController based systems By connecting to Adept SmartController systems the FireBlox 1 Control Module can benefit from advanced motion control features such as coordinated motion and kinematics device modules The FireBlox 1 Control Module can also be controlled from a PC based only control system Product Features IEEE 1394a FireWire serial bus Provides a 400 megabit second synchronized control network designed for multi axis motion control and machine vision applications A High performance network protocol allows both motion controllers and digital cameras to attach to the same serial bus Distributed and modular control Connect up to 63 distributed control modules for building large control systems Real time events are processed locally and do not load down the host processor Multiple machines can be connected to the same IEEE 1394 serial bus Dual axis Controller with Digital Motor Amplifiers Two built in MOSFET motor power amplifiers Drives 3 phase
60. sitions under the Limits tab Make sure that the E STOP is not set Also it is very important that the motor position is within the range specified in the Tuning Positions CAUTION These step response settings allow for maximum current to be passed through the BLOX1 Improperly loading the motor may result in damage to the motor power supply and the BLOX1 unit Please make sure there are no obstructions Make sure to use a properly rated in line fuse to limit the current to 2 Amps Also please make sure that your motor power supply is able to supply enough current for your specific application You are now ready to conduct a step response C Tuning the Motor Aiming for Critically Damped Setting the Kp and Kd In this section you will independently tune the Kp and the Kd of the PID motor controller There should be as little load on the motor as possible to get a baseline of how the motor behaves We first approach the PID controller by simply adjusting the gain Kp and then the derivative controller Kd The transient responses unattainable by a simple gain adjustment can be obtained by augmenting the system s poles and zeros with an ideal derivative compensator Setting The Kp To begin ENABLE the motor Observe the motor If it immediately goes into oscillation DISABLE the motor and reduce Kp Repeat this until the motor is stable when the enable button is pressed Once the motor is no longer oscillating when it becomes enabl
61. t Edit robot initialization specs From the sub menu select Calibration file name Exit to the main menu and select Save ALL specifications to system disk NOTE Failure to specify the correct calibration routine will result in a Not configured as accessed error message while attempting to calibrate the robot Edit General Parameters The general parameters listed in the table below should be verified from the SPEC utility Table7 Editing General Parameters in SPEC Parameter Main Menu Sub Menu Encoder scale factor Edit robot specs Edit motor enc specs Joint Motion Specifications Edit robot specs Edit joint motion specs Cartesian Motion Specifications Edit robot specs lom moton Edit robot specs Edit general motion specs optional NOTE When editing the Joint Motion parameters in SPEC verify that the joint limits specified in mm or deg are inside the limits specified in BloxView specified in encoder counts If the SPEC joint limits are outside the BloxView limits an Overtravel Limit error message will be reported when driving the axis from the SmartController Backup Robot Specifications After editing the calibration and general parameters it is necessary to save the SPEC data to the system disk From the main SPEC menu select Save ALL specifications to system disk It is recommended that a separate backup of the data be stored to a disk file Before this is done the FireBlox
62. ternal 24VDC power supply provides power for Digital Output Voltage DOVCC If the jumper is connected between pins 2 and 3 power for DOVCC must be supplied externally through the screw terminals When the jumper on J32 is connected between pins 1 and 2 the internal 24VDC power supply provides power for PWM voltage VDCLED If the jumper is connected between pins 2 and 3 power for VDCLED must be supplied externally through the screw terminals Amp Enable The Amp Enable switch SW4 controls the presence of the Amp Enable current loop When the current loop is broken switch is set to OFF an error signal disables the motor amplifiers and notifies the node of the fault The current loop must be present for the motors to work a green LED indicates loop closure a red LED indicated an open loop The Amp Enable circuit may also be accessed using a direct connection to the FireBlox P4 for testing external circuitry Digital Input Output Channels Feedback Mode The digital Input and output channels may be operated in one of two modes loop back self test or external I O user accessible This mode is selected by setting jumpers J5 12 located adjacent to the DI O LEDs Loop Back Mode Pin 1 2 jumpered on J5 J12 Each digital output channel is wrapped internally to the corresponding digital input channel when the digital output is triggered either by software or by the user the corresponding LED will illuminate and the digital i
63. upt based upon the condition of a desired input The input channels can be configured for NPN current sinking or PNP current sourcing polarity by setting the DI MODE signal Connecting the DI MODE line to DOGND will result in NPN function while connecting it to DOVCC will result in PNP function DVCC DI gt DI_SIGNAL DI GOMMON DGND Figure 15 Digital Input Schematic The digital input channels can also be used to read home calibration sensors and limit switches The same input channel can be used as a home and a limit sensor If a digital input channel is used for a home sensor and or a limit switch it cannot also be used as a general purpose input Before the general purpose input channels can be accessed from an Adept SmartController they must be mapped See Mapping the Digital I O Channels on page 43 for details Page 22 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A Digital Output Channels The FireBlox 1 provides the following digital output capability e Channels 8 e Max voltage user supplied 24VDC e Max current 0 5A e Response time PC Based hardware TBD e Response time SmartController 4 to 16 ms default is 16 ms based on trajectory rate e Minimum load impendence 10kO Connect the external supply to DOVCC and DOGND on the J2 connector Connect the load between DO and DOGND DOVCC High Side Switch DOVCC DYCC DO_SIGNAL DO DOGND
64. utput 00 00 Analog Inputs 04 07 104 107 will be connected to Analog Output 00 01 External I O Mode J22 J29 jumpered between pins 2 3 The user has access to each individual input and output channel via screw terminals J30 and J31 The pinout for each connector as well as the locations for DGND and AGND are detailed in chapterB land labeled on the Development Kit PCA PWM Output Drivers The two PWM drivers are connected directly to LEDs The PWM output drivers may be used for driving external devices such as fans LED illumination arrays heaters etc The PWM drivers are accessible through screw terminal J33 Although there is no internal feedback of the PWM signals it is possible to wrap them externally to an Analog Input channel Motor and Encoders The Development Kit comes with two motor assemblies installed Pittman 3 phase brushless DC motor connected to Motor 0 This motor has a single ended encoder Faulhaber MicroMo brushed DC connected to Motor 1 This motor has a differential encoder Page 34 of 61 Adept FireBlox 1 Control Module Developer s Guide Rev A 5 Software Configuration PC Based Systems 5 1 Configuration Overview After installation the FireBlox 1 Control Module must be configured before proceeding with the application development This is accomplished by connecting the FireBlox 1 to a host PC via IEEE 1394 that is running BloxView software The BloxView software and acc

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