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DMC-1410/1411/1417 USER MANUAL

1. Description Connection ACMD Channel A MA Channel B MB Channel A MA Channel B MB Index 1 Index 1 GND 5V 5V Red Wire cH Red Connector CPS Power Supply Black Wire Motor Black Connector O 5 high volt 4 power gnd 2 motor 1 motor MSA 12 80 11 INHIBIT 4 REF IN 2 SIGNALGND Figure 2 4 System Connections with a separate amplifier MSA 12 80 This diagram shows the connections for a standard DC Servo Motor and encoder Step 7b Connect brushless motors for sinusoidal commutation DMC 1410 1417 only Please consult the factory before operating with sinusoidal commutation The sinusoidal commutation option is available only on the DMC 1410 1417 When using sinusoidal commutation the parameters for the commutation must be determined and saved in the controller non volatile memory The servo can then be tuned as described in Step 8 Step A Disable the motor amplifier Use the command MO to disable the motor amplifiers Step B Connect the motor amplifier to the controller The sinusoidal commutation amplifier requires 2 signals usually denoted as Phase A amp Phase B These inputs should be connected to the two sinusoidal signals generated by the controller The first signal is the main controller motor output ACMD The second signal utilizes the seco
2. Computer DMC 1400 Controller Encoder Figure 1 2 Elements of Servo systems Motor Amplifier Driver A motor converts current into torque which produces motion Each axis of motion requires a motor sized properly to move the load at the desired speed and acceleration Galil s Motion Component Selector software can help you calculate motor size and drive size requirements Contact Galil at 800 377 6329 if you would like this product DMC 1410 1411 1417 Series Chapter 1 Overview e 3 The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step motors the controller can control full step half step or microstep drives Amplifier Driver For each axis the power amplifier converts a 10 Volt signal from the controller into current to drive the motor The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation is required The amplifiers may be either pulse width modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 Volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 Volts should run
3. MOTOR ENCODER Figure 10 4 Functional Elements of a Motion Control System Motor Amplifier The motor amplifier may be configured in three modes 1 Voltage Drive 126 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Source The amplifier is a voltage source with a gain of Kv V V The transfer function relating the input voltage V to the motor position P is P V K K S ST 1 ST 1 where 2 T RJ K is and T L R 5 and the motor parameters and units are Kt Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m2 L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to MKS units For example consider a motor with the parameters K 14 16 oz in A 0 1 Nm A R 2Q0 J 0 0283 oz in s 2 10 4 kg m2 L 0 004H Then the corresponding time constants are Tm 0 04 sec and Te 0 002 sec Assuming that the amplifier gain is Kv 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of Ka The resulting transfer function in this case is P V K K Js2 where Kt and J are as defined previously For example a current
4. bres 109 Programmable Hardware V O enne nennen trennen eene 110 Digital Outputs pen e e p He i ae 110 Digital Inputs tite aero omete arn enero d 111 Input Interrupt Function entente nennen 111 Example Applications iaia 112 Mire Cutter ue data ioter o deo e d EHE d 112 Backlash Compensation by Dual L00p eese 113 DMC 1410 1411 1417 Series Contents e iii iv e Contents Chapter 8 Error Handling 115 troduction ici ta etr eH Te RS 115 Hardware Protection rec ee I E eie te eed e xe decus 115 Output Protection oco ertet Ue ete page e aaa oasi 115 Input Protection Lines 212 tre aD epo b Rp endi 116 S ftware ProtectiOmn i RE Rr ERROR n e RE br RA TR 116 Programmable Position Limits i 116 ita AR ELLI omaia a e Rn 117 Automatic Error 117 Limit Switch lana Lana 117 Chapter 9 Troubleshooting 119 OVERVIEW diver or eee iare debet te e o a OI OU 119 Installation e R 119 evite 120 Stability sica ae ee anes al ee beet bees 121 Operation EE 121 Chapter 10 Theory of Operation 123 wc 123 Operation of Closed Loop Systems ii 125 System Modeling eiut ia ee tdi Bei de thc ae ana 126 Mo
5. i 66 Additional Commands i tte eel riali 67 Teach Record and Play Back ss occ ert e eee eR rai t 70 Stepper Motor Operation nars ritoriale odia 71 Specifying Stepper Motor Operation i 71 DMC 1410 1411 1417 Series Using an Encoder with Stepper Motors eese eene 72 Command Summary Stepper Motor 72 Operand Summary Stepper Motor Operation ii 72 Dual Loop Auxiliary Encoder inni iena neon 73 Backlash Compensation sii iii ai te pe REI TH 73 Motion Smoothing wis 5 30 a EEE ao et alal aa E E e ei 75 Usimep the IT Cormmnand tate pe Rr p eio red 75 Hoinmg a 5 diente a atate rp e EE rana iii 76 High Speed Positi n Capture oorpore P P en E bep entera 79 Chapter 7 Application Programming 81 Introduction uere eden eG eer eate ep oc ep etes 81 Using the DMC 141X Editor to Enter Programs iii 81 Edit Mode Commands eese eene nennen nennen rennen iaia 82 Program Format aententia eB ee 82 Using Labels in Programs eese rennen enne enne nennen 83 Special L b ls eod e a d Up m 83 Commenting Programs oneness nee e m t e o t eg enge 84 Executing Programs Multitasking i 85 Debugging PrOSratns 1 4 n oe efe d ee D Re ai m ge i edem 86 Program Flow Commands enne enne enne
6. Note The DMC 1417 is only supported in Windows 98 SE NT 4 ME 2000 and XP Using DOS Using the Galil Software CD ROM go to the directory July2000 CD DMCDOS DISK1 Type INSTALL at the DOS prompt and follow the directions Using Windows 3 x 16 bit versions Explore the Galil Software CD ROM and go to the directory July2000 CD DMCWIN Run DMCWINI16 and follow the directions The Windows Servo Design Kit WSDK16 which 15 DMC 1410 1411 1417 Series Chapter 2 Getting Started e 7 useful for tuning servos and viewing useful controller information can be downloaded off the CD as well However WSDK16 is a purchase only software package and is password protected on the CD Contact Galil for purchase information Using Windows 95 or 98 First Edition The HTML page that opens automatically from the CD ROM does not contain the necessary software for Windows 95 or Windows 98 First Edition Instead Explore the CD and go to the July2000 CD folder To install the basic communications software click on DMCTERM and then run the application DMCTERM Another terminal software is called DMCWIN32 and is located under July2000 CD DMCWIN The Windows Servo Design Kit WSDK32 which is useful for tuning servos and viewing useful controller information can be downloaded off the CD as well However WSDK32 is a purchase only software package and is password protected on the CD Contact Galil for purchase information Using Windows 98 Second Edition
7. WTn Halts program execution until specified time in msec has elapsed Event Trigger Examples Event Trigger Multiple Move Sequence The AM trippoint is used to separate the two PR moves If AM is not used the controller returns a for the second PR command because a new PR cannot be given until motion is complete Instruction Interpretation TWOMOVE Label PR 2000 Position Command BG Begin Motion AM Wait for Motion Complete PR 4000 Next Position Move BG Begin 2nd move EN End program Event Trigger Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period Instruction Interpretation SETBIT Label SP 10000 Speed is 10000 PA 20000 Specify Absolute position BG Begin motion DMC 1410 1411 1417 Series Chapter 7 Application Programming e 89 AD 1000 Wait until 1000 counts SB1 Set output bit 1 EN End program Event Trigger Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR trippoint is used as shown in the next example Instruction Interpretation TRIP Label JG 50000 Specify Jog Speed BG n 0 Begin Motion REPEAT Repeat Loop AR 10000 Wait 10000 counts TP Tell Position SB1 Set output 1 WT50 Wait 50 msec Clear output 1 n n 1 Increment counter JP REPEAT n lt 5 Repeat 5 times ST Stop EN End Event Trigger Start Motion on Input Thi
8. 652 656 660 664 668 Address 672 676 680 684 688 692 696 700 704 708 712 716 720 724 732 736 740 744 748 752 756 760 764 768 776 780 784 788 792 796 800 804 808 812 DMC 1410 1411 1417 Series 144 e Appendices 816 820 824 828 832 836 840 844 848 852 856 Address 860 864 868 872 876 880 884 888 892 896 900 904 908 912 916 920 924 928 932 936 940 944 948 952 956 960 964 968 972 976 DMC 1410 1411 1417 Series Appendices e 145 1000 1004 1008 1012 1016 1020 ICM 1460 Interconnect Module Rev F The ICM 1460 Interconnect Module provides easy connections between the DMC 141X series controllers and other system elements such as amplifiers encoders and external switches The ICM 1460 accepts the 37 pin cable from the DMC 1410 and 1417 or the 40 pin to 37 pin cable from the DMC 1411 and breaks it into screw type terminals Each screw terminal is labeled for quick connection of system elements The ICM 1460 is packaged as a circuit board mounted to a metal enclosure A version of the ICM 1460 is also available with a servo amplifier see AMP 1460 Features e Breaks out 37 pin ribbon cable into individual screw type terminals e Clearly identifies all terminals e Available with on board servo drive see AMP 1460 e 10 pin IDC connectors for encoders e Amplifier enable buffer chip allowing for vario
9. E Galil DMC 17x0 Motion Controller 3 Hard disk controllers F Keyboard Monitors Mouse Network adapters gg Dther devices PCI Multimedia Audio Device cm VR mea een 9 mm Device Manager in Win 98 SE DMC 1410 1411 1417 Series Chapter 2 Getting Started e 19 Select the device from the list go to the resource tab and reassign the resources to those that match the address and interrupt IRQ jumpers on the controller see the appendix for Address Settings and Step 3 for installing jumpers Galil DMC 14x0 Motion Controller Properties A Use automate setings Basic configuration 0 Changing the Resources in Win 98 SE 20 e Chapter 2 Getting Started DMC 1410 1411 1417 Series ii DMC 1410 1411 1417 Series Edit Input Output Range 2 Enter the input output range you would like to set for this device You may either enter a specific range and the nearest valid range will be automatically selected or you may select a range using the up and down arrows This resource is assigned to the following child device s Value 338 0338 Conflict information The setting you have chosen does not conflict with any other devices No devices are conflicting conca Edit Input Output Range in Win 98 SE When changing the settings the operating system will inform the user of any resource conflicts If there are resource conflicts it is necessary
10. In order for the Windows software to communicate with a Galil controller the controller must be entered in the Windows Registry In Windows 98 SE ME 2000 and XP operating systems OS the DMC 1417 is plug and play This means that on power up the computer will automatically detect the card and install the appropriate device driver A Found New Hardware dialog box may appear during installation of the device driver The controller will be identified by model name and entered into the Galil Registry Now the user can communicate to the controller using DMCTERM DMCWIN32 or WSDK32 Note In order for the PC to recognize the plug and play controller as a Galil device the Galil software must be loaded prior to installing the card Select Motion Controller E x Controller DMC 14x7 PCI Address 57332 Interrupt Level 18 Serial 0 Controller DMC 1800 PCI Address 57248 Interrupt Level 18 Serial 1234 DMC 1800 and DMC 1417 in the Galil Registry Using either an DMC 1410 or DMC 1411 card in a plug and play OS Win 98 SE 2000 ME XP will require adding the controller to the system in the Windows Device Manager In Win 98 SE and ME this feature is accessed through the Start Settings Control Panel Add New Hardware shortcut In Win 2000 and XP it can be accessed through My Computer Properties Hardware Hardware Wizard The procedures on the two operating systems are nearly identical but the dialog boxes look a little different The foll
11. USER MANUAL DMC 1410 1411 1417 Manual Rev 2 6 By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet Address support galilme com URL www galilmc com Rev Date 03 06 Using This Manual Your DMC 1400 SERIES motion controller has been designed to work with both servo and stepper type motors Installation and system setup will vary depending upon whether the controller will be used with stepper motors or servomotors To make finding the appropriate instructions faster and easier icons will be next to any information that applies exclusively to one type of system Otherwise assume that the instructions apply to all types of systems The icon legend is shown below Attention Pertains to servo motor use Attention Pertains to stepper motor use THIS PAGE LEFT BLANK INTENTIONALLY Contents Contents 1 Chapter 1 Overview 1 Intiod ctioh t e Re ien er ete RERO it ac US 1 Overview of Motor Types isso sla AGLA LI Asa terit a ii 2 Standard Servo Motors with 10 Volt Command Signal ii 2 Stepper Motor with Step and Direction Signals iii 2 DMC 1400 Functional Elements i 2 Microcomputer Section iis oust stick esse nA rete deste pue e ater ies 3 MotorInterface aa e no pucr na rt RR IA Lie 3 Comunication cia ete cute AIA tui ad tete i es 3 General O x oce oe d
12. NOTE The POSERR routine will continue to be executed until the position error is cleared is less than the ER limit Example Input Interrupt Instruction A 30000 BG LOOP JP LOOP EN ININT ST AM TEST JP TEST IN 1 0 JG 30000 BG RI EN Interpretation Label Input Interrupt on 1 Jog Begin Motion Loop Input Interrupt Stop Motion Test for Input 1 still low Restore Velocities Begin motion and Return to Main Program When Input changes in state from high to low the ININT subroutine will be executed NOTE Use the RI command to return from ININT subroutine Example Motion Complete Timeout Instruction BEGIN TW 1000 PA 10000 BG MC DMC 1410 1411 1417 Series Interpretation Begin main program Set the time out to 1000 ms Position Absolute command Begin motion Motion Complete trip point Chapter 7 Application Programming e 95 EN MCTIME MG X Fell Short EN End main program Motion Complete Subroutine Send out a message End subroutine This simple program will issue the message X Fell Short if the axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error Instruction BEGIN IN ENTER SPEED SPEED JG SPEED BG JP BEGIN EN CMDERR JP DONE _ED lt gt 2 JP DONE _TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN 751 JP BEGIN DONE ZSO EN The above program prompts In
13. Tell Position Returned Position data Request Position Command Returned data Enter invalid command Controller response Request error code Controller response Chapter 5 Programming Basics e 57 THIS PAGE LEFT BLANK INTENTIONALLY 58 e Chapter 5 Programming Basics DMC 1410 1411 1417 Series Chapter 6 Programming Motion Overview The DMC 141X provides several modes of motion including independent positioning and Jogging electronic cam electronic gearing and contouring Each one of these modes is discussed in the following sections The example applications described below will help guide you to the appropriate mode of motion Example Application Application Mode of Motion Mode of Motion Motion Commands Absolute or relative positioning where axis Point to Point Positioning PA PR follows prescribed velocity profile SP AC DC IT Velocity control where no final endpoint is Independent Jogging prescribed Motion stops on Stop command Motion Path described as incremental Contour Mode position points versus time Electronic gearing where axis is scaled to Electronic Gearing auxiliary encoder that can move in both directions Master slave where slave axis must follow a Electronic Gearing GR master such as conveyer speed Moving along arbitrary profiles or Contour Mode mathematically prescribed profiles such as sine or cosine trajectories Teaching or Record and Play Back Contour Mode with Automatic Array C
14. The filter parameters are represented by the three constants KP KI and KD which correspond to the proportional integral and derivative term respectively The damping element of the filter acts as a predictor thereby reducing the delay associated with the motor response The integrator function represented by the parameter KI improves the system accuracy With the KI parameter the motor does not stop until it reaches the desired position exactly regardless of the level of friction or opposing torque The integrator also reduces the system stability Therefore it can be used only when the loop is stable and has a high gain The output of the filter is applied to a digital to analog converter DAC The resulting output signal in the range between 10 and 10 Volts is then applied to the amplifier and the motor The motor position whether rotary or linear is measured by a sensor The resulting signal called position feedback is returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Fig 10 4 The mathematical model of the various components is given below CONTROLLER R X DIGITAL Y V E FILTER 1 ZOH DAC
15. at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship at our expense only to destinations in the United States Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer alteration modification negligence or misuse is not covered by this warranty EXCEPT AS SET FORTH ABOVE GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES COPYRIGHT 10 94 The software code contained in this Galil product is protected by copyright and must not be reproduced or disassembled in any form without prior written consent of Galil Motion Control Inc 154 e Appendices DMC 1410 1411 1417 Series Index Abort 41 Off On Error 27 43 Abort Motion 55 Absolute Position 62 95 Absolute Value 65 95 Address 122 Jumpers 143 Almost Full Flags 48 Amplifier AMP 1460 8 143 Amplifier Enable 44 Amplifier Gain 6 Amplifiers 9 44 142 Connections 41 148 Analysis SDK 35 Arithmetic Functions 94 99 Array 5 88 94 99 102 Arrays 57 72 83 103 140 Automatic Subroutine LIMSWI 42 A
16. resulting in decreasing error 38 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Chapter 3 Hardware Interface Overview The DMC 141X provides TTL digital inputs for forward limit reverse limit home and abort signals The controller also has 7 uncommitted inputs for general use as well as 3 TTL outputs This chapter describes the inputs and outputs and their proper connection All of the controller signal lines are accessible through the main 37 pin connector J3 for the DMC 1410 and 1417 or the main 40 pin connector for the DMC 1411 The ICM 1460 provides easy access to these signals through screw terminals Encoder Interface The DMC 141X accepts inputs from incremental encoders with two channels in quadrature or 90 electrical degrees out of phase The DMC 141X performs quadrature decoding of the two signals resulting in bi directional position information with a resolution of four times the number of full encoder cycles For example a 500 line encoder is decoded into 2000 quadrature counts per revolution An optional third channel or index pulse may be used for homing or synchronization Several types of incremental encoders may be used linear or rotary analog or digital single ended or differential Any line resolution may be used the only limitation being that the encoder input frequency must not exceed 2 000 000 full cycles sec or 8 000 000 quadrature counts sec The DMC 141X also accepts inputs from an additional
17. 40 msec from reference and reset reference SB1 Set Output 1 JP LOOP Loop EN Conditional Jumps The DMC 141X provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition The conditional jump determines if a condition is satisfied and then branches to a new location or subroutine Unlike event triggers the conditional jump instruction does not halt the program sequence Conditional jumps are useful for testing events in real time They allow the DMC 141X to make decisions without a host computer For example the DMC 141X can decide between two motion profiles based on the sate of an input line Command Format JP and JS Format Description _ JS destination logical condition Jump to subroutine if logical condition is satisfied DMC 1410 1411 1417 Series Chapter 7 Application Programming e 91 JP destination logical condition Jump to location if logical condition is satisfied The destination is a program line number or label where the program sequencer will jump if the specified condition is satisfied Not that the line number of the first line of program memory is 0 The comma designates IF The logical condition tests two operands with logical operators Logical operators less than or equal to greater than or equal to Conditional Statements The conditional statement is satisfied if it evaluates to any value
18. 6 The DMC 141X can be programmed with the instruction KP 20 6 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters Equivalent Filter Form Digital Digital KP KD KI Digital GN ZR KI Continuous PID T DMC 1410 1411 1417 Series DMC 1410 D z K z A z Cz z 1 D z 4 KP 4 KD 1 271 KI2 1 z l 4 KD KP KD KI 2 D z 4 GN z ZR z KI z 2 z 1 K 4GN A ZR C KI 2 G s P Ds I s P 4KP D 4T KD I KI2T Chapter 10 Theory of Operation e 135 THIS PAGE LEFT BLANK INTENTIONALLY 136 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series Appendices Electrical Specifications Servo Control ACMD Amplifier Command A A B B IDX IDX Main Encoder Input A A B B Aux Encoder input Stepper Control Pulse Direction Input Output Limits Home Abort Inputs thru OUT 3 Outputs IN 1 through IN 7 Inputs Power Requirements 45V 12V 12V DMC 1410 1411 1417 Series 10 Volts analog signal Resolution 16 bit 0003 Volts 3 mA maximum TTL compatible but can accept up to 12 Volts Quadrature phase on CHA CHB Can accept single ended A B only or differential A A B B Maximum A B edge rate 8 MHz Minimum IDX pulse width 120 nsec TTL 0 5 Volts level at 50 duty cycle 2 000
19. AT 10 Wait 10 msec from reference time SB1 Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference Clear Output 1 JP LOOP1 Repeat Loopl TASK2 Task2 label XQ TASK1 1 Execute Task1 LOOP2 Loop2 label PR 1000 Define relative distance BGX Begin motion AMX After motion done WT 10 Wait 10 msec JP LOOP2 IN 2 1 Repeat motion unless Input 2 is low DMC 1410 1411 1417 Series Chapter 7 Application Programming e 85 HX Halt all tasks The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread TASK1 is executed within TASK2 Debugging Programs The DMC 141X provides commands and operands that are useful in debugging application programs These commands include interrogation commands to monitor program execution determine the state of the controller and the contents of the controllers program array and variable space Operands also contain important status information that can help to debug a program Trace Commands The trace command causes the controller to send each line in a program to the host computer immediately prior to execution Tracing is enabled with the command TRO turns the trace function off Note When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed Data that is output from the controller is stored in an output FIFO buffer The output FIFO buffer can store u
20. Application Programming Interface software is available from Galil The API software is written in C and is included in DMCWIN download They can be used for development under DOS and Windows environments 16 and 32 bit Windows With the API s the user can incorporate already existing library functions directly into a C program Galil has also developed an ActiveX Toolkit This provides VBXs 16 bit and 32 bit OCXs for handling all of the DMC 141X communications including support of interrupts These objects install directly into Visual Basic Labview Visual C and Delphi and are part of the run time environment For more information contact Galil DMC 1410 1411 1417 Series Chapter 4 Communication e 49 THIS PAGE LEFT BLANK INTENTIONALLY 50 e Chapter 4 Communication DMC 1410 1411 1417 Series Chapter 5 Programming Basics Introduction The DMC 141X provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter The DMC 141X instruction set is BASIC like and easy to use Instructions consist of two uppercase letters that correspond phonetically with the appropriate function For example the instruction BG begins motion and ST stops the motion Commands can be sent live over the bus for immediate execution by the DMC 141X or an entire group of commands can be downloaded into the DMC 141X memory for execution at a later ti
21. ICM 1460 rev F and above only 148 AMP 1460 Mating Power Amplifiers i 149 AMP 1460 20 Watt Linear Amplifier Option i 150 ICM AMP 1460 Dra WNS soreness perie tert fe tee dart ipt erede pne da Degas da yes 151 List of Other Publications enne nennen nennen nre 152 Traming Seminars tpi tate e ete rd o pete tdt 152 DMC 1410 1411 1417 Series Contacting Us WARRANTY Index DMC 1410 1411 1417 Series Contents e v Chapter 1 Overview Introduction The DMC 1400 series of motion controllers was developed specifically for one axis applications allowing it to be smaller in size 1 2 size card and lower in cost than multi axis controllers This manual covers the three bus based controllers in the DMC 1400 Econo series lineup The DMC 1410 is a state of the art motion controller that plugs into the ISA bus The DMC 1411 is the equivalent in the PC 104 bus format whereas the DMC 1417 is a PCI controller Performance capability of these controllers includes 8 MHz encoder input frequency 16 bit motor command output DAC 2 billion counts total travel per move up to 250 usec sample rate bus interrupts and non volatile memory for parameter storage Designed for maximum system flexibility the DMC 141X can be interfaced to a variety of motors and drives including step motors servomotors and hydraulics The contr
22. Introduction a ete db di e ef dote 45 Communication with Controller ener 45 Communi cation Reglsters reed rt etd e d e deemed et 45 Simplified Communication Procedure for DMC 1410 1411 sess 45 Simplified Communication Procedure for DMC 1417 see 46 Iss t 47 Controller Response to DATA risi i nde e ete esr 49 Galil Software Tools Libraries ii 49 Chapter 5 Programming Basics 51 Introduction nc eo Reli np EDI eS 51 Command Syntax nean ete een e hee t eU 51 Controller Response to Commands sess nennen een rennen 52 Interrogating the Controller 2 oce t ere ie e eoe e sare lae sete 52 Interrogation Commands essere ener nennen rennes 32 Operands i ese hae n E aea e heat es 53 Command Summary 53 Instruction Set Examples isisisi e ia aaa 57 Chapter 6 Programming Motion 59 Overview sarai di en aaa 59 Point to Point Positioning 4 eee ASL UU petes de te ce reti iut 60 Independent Joz ering oet eere mtcr i lager 61 Electronic Gearlng cete rete E m tco besote ve eset toi ene 62 Electronic Catia riore den eR a cette tempe ui 62 HR eh ERU RA e tet rte Eie aii 66 Specifying Contour Segments
23. Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are specified by the instruction EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0 Step 3 Specify the slave positions Next we specify the slave positions with the instruction ET n x DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 63 where n indicates the order of the point The value n starts at zero and may go up to 256 The parameter x indicate the corresponding slave position For this example the table may be specified by This specifies the ECAM table Step 4 Enable the ECAM To enable the ECAM mode use the command EBn where n 1 enables ECAM mode and n 0 disables ECAM mode Step 5 Engage the slave motion To engage the slave motion use the instruction EGn where n is the master position at which the slave must be engaged If the value of any parameter is outside the range of one cycle the cam engages immediately When the cam is engaged the slave position is redefined modulo one cycle Step 6 Disengage the slave motion To disengage the cam use the command EQn where n is the master position at which the slave axis
24. SE NT 4 ME 2000 or XP The Galil Software CD ROM will open an HTML page automatically as soon a Instead Explore the CD and go to the July2000 CD folder To install the basic communications software click on DMCTERM and then run the application DMCTERM The other basic terminal software is called DMCWIN32 and is located under July2000 CD DMCWIN The Windows Servo Design Kit WSDK32 which is useful for tuning servos and viewing useful controller information can be downloaded off the CD as well However WSDK32 is a purchase only software package and is password protected on the CD Contact Galil for purchase information Step 2 Determine Overall Motor Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 141X can control standard servomotors brush or brushless or stepper motors For control of other types of actuators such as hydraulics please contact Galil The following configuration information is necessary to determine the proper motor configuration Standard Servo Motor Operation The DMC 141X has been setup by the factory for standard servo motor operation providing an analog command signal of 10 volt No hardware or software configuration is required for standard servo motor operation Stepper Motor Operation To configure the DMC 141X for stepper motor operation the controller requires that the command MT be given and a jumper placed to designat
25. SP 10000 REM SPEED IS 10000 AC 100000 REM ACCELERATION IS 100000 DC 100000 REM DECELERATION IS 100000 BG 84 e Chapter 7 Application Programming DMC 1410 1411 1417 Series REM BEGIN MOTION AM REM WAIT FOR AFTER MOTION EN REM END OF PROGRAM These REM statements will be removed when this program is downloaded to the controller Executing Programs Multitasking The DMC 141X can run up to two programs simultaneously The programs called threads are numbered 0 and 1 where 0 is the main thread The main thread differs from the others in the following points 1 Only the main thread may use the input command IN Note This is NOT the IN used to check general input status 2 Inacase of interrupts due to inputs limit switches position errors or command errors it is the program in thread 0 which jumps to those subroutines The execution of the various programs is done with the instruction XQ A n Where n indicates the thread number To halt the execution of any thread use the instruction HX n where n is the thread number Note that both the XQ and HX functions can be performed by an executing program Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The example below produces a waveform on Output 1 independent of a move Instruction Interpretation TASKI Taskl label ATO Initialize reference time Clear Output 1 LOOP1 Loop label
26. String variables with up to six characters may be input using the identifier Sn where n represents the number of string characters to be input If n is not specified six characters will be accepted For example IN Enter X Y or Z V S specifies a string variable to be input Output of Data Numeric and String Numerical and string data can be output from the controller using several methods The message command MG can output string and numerical data Also the controller can be commanded to return the values of variables and arrays as well as other information using the interrogation commands the interrogation commands are described in Chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is RESULT In addition to variables functions and commands responses can be used in the message command For example MG Input 1 is IN 1 MG The Proportional Gain of X is _KP Formatting Messages String variables can be formatted using the identifier Sn where n is the number of characters 1 through 6 For example MG STR S3 This statement returns 3 characters of the string variable named STR DMC 1410 1411 1417 Series Chapt
27. any associated commands All keywords are listed in the Command Summary Chapter 11 Examples of Keywords V1 LF Assign V1 the logical state of the Forward Limit Switch V3 TIME Assign V3 the current value of the time clock V4 _HM Assign V4 the logical state of the Home input Example Program Instruction Interpretation TIMER Timer INITIME TIME Initialize time variable PR50000 BG Begin move AM After move ELAPSED TIME Compute elapsed time INTIME 100 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Arrays EN End program LIMSWI Limit Switch Routine JP FORWARD _LF 0 Jump if Forward Limit AM Wait for Motion Done PR 1000 BG AM Move Away from Reverse Limit JP END Exit FORWARD Forward Label PR 1000 BG AM Move Away from Forward Limit END Exit RE Return to Main Program For storing and collecting numerical data the DMC 141X provides array space for 1000 elements The arrays are one dimensional and up to 6 different arrays may be defined Each array element has a numeric range of 4 bytes of integer 2 followed by two bytes of fraction 2 147 483 647 9999 Arrays can be used to capture real time data such as position torque and error values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Defining Arrays An array is defined with the command DM The user must specify a name and the number of entries to be held in
28. are shown in Fig 7 1 The program starts at a state that we define as A Here the controller waits for the input pulse on Il As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle Instruction Function A Label All Wait for input 1 PR 6370 Distance SP 3185 Speed BG Start Motion AM After motion is complete Set output bit 1 WT 20 Wait 20 ms Clear output bit 1 112 e Chapter 7 Application Programming DMC 1410 1411 1417 Series WT 80 Wait 80 ms JP HA Repeat the process alt Www START PULSE 11 MOTOR VELOCITY OUTPUT PULSE output TIME INTERVALS move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals Backlash Compensation by Dual Loop This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The slide is to be controlled by a rotary motor which is coupled to the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy is for 0 5 micron The basic dilemma is where to mount the sensor If you use a rotary sensor you get a 4 micron backlash error On the other hand if you use a linear encoder the backlash in the feedback loop will cause oscillations
29. consider this same example with an additional condition JP TEST V1 lt V2 amp V3 lt V4 V5 lt V6 92 e Chapter 7 Application Programming DMC 1410 1411 1417 Series This statement will cause the program to jump to the label TEST under two conditions 1 If V1 is less than V2 and V3 is less than V4 OR 2 If V5 is less than V6 Using the JP Command If the condition for the JP command is satisfied the controller branches to the specified label or line number and continues executing commands from this point If the condition is not satisfied the controller continues to execute the next commands in sequence Conditional Meaning JP Loop COUNT lt 10 Jump to Loop if the variable COUNT is less than 10 JS MOVE2 IN 1 1 Jump to subroutine MOVE if input 1 is logic level high After the subroutine MOVE is executed the program sequencer returns to the main program location where the subroutine was called JP BLUE ABS V2 gt 2 Jump to BLUE if the absolute value of variable V2 is greater than 2 JP C V1 V7 lt V8 V2 Jump to C if the value of V1 times V7 is less than or equal to the value of V8 V2 Jump to A Example Using JP command Move the X motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves Instruction Interpretation BEGIN Begin Program COUNT 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion com
30. due to instability An alternative approach is the dual loop where we use two sensors rotary and linear The rotary sensor assures stability because the position loop is closed before the backlash whereas the linear sensor provides accurate load position information The operation principle is to drive the motor to a given rotary position near the final point Once there the load position is read to find the position error and the controller commands the motor to move to a new rotary position which eliminates the position error Since the required accuracy is 0 5 micron the resolution of the linear sensor should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000 count per revolution results in a rotary resolution of 0 25 micron This results in equal resolution on both linear and rotary sensors To illustrate the control method assume that the rotary encoder is used as a feedback for the X axis and that the linear sensor is read and stored in the variable LINPOS Further assume that at the start both the position of X and the value of LINPOS are equal to zero Now assume that the objective is to move the linear load to the p
31. en 88 Command Summary Program Flow essen 88 Event Triggers amp Trippoints i 88 Bvent Trigger Examples avai necne epu ee A bm 89 Conditional JUMPS 2n tp ete eA PRO 91 Subro tibes 5 subire e As Ee E e eg i e ei ates 93 Stack Manipulation 2 2 bete e ege A e ea d ep ee EA do Ro 94 Automatic Subroutines for Monitoring Conditions eee 94 Mathematical and Functional Expressions enne eene 96 Mathematical Operators tee aa 96 Bit Wise Operatols o eiecti eerte e tetro Men ABO 97 FUDCtons ico casa ERRR 98 4 4 aco Mr etie p eei e Ri cia le La 98 Programmable Variables 2 iiim te ete RTL m debet eth 98 Scu M gado 99 ATA VS i RR D ORUM HER CREE i A 101 Defimmg AITys our etenim DR aaa 101 Assignment of Array Entries oe e Doer Cp b pri pee o Red 101 Automatic Data Capture into Arrays i 102 Input of Data Numeric and String iii 104 inanem memet eoo eant iced 104 Inputung String Vanables store e ea reete 105 Output of Data Numeric and String i 105 Sending Messages aiias epa aiat br ap serpit 105 Displaying Variables and ArrayS iii 106 Interrogation Commands pane ana lena adio eoi 107 Formatting Variables and Array Elements eene 108 Converting to User Units tenia eee ORE b
32. external supply of 10V to 35V Care should be taken to ensure the average power dissipation across the amplifier is less than 20watts 150 e Appendices DMC 1410 1411 1417 Series ICM AMP 1460 Drawing 37 PIN FEMALE D TYPE CONNECTOR O 1 500 4 PLACES E 4 1 1 I 1 1 4 945 3 265 i 00 200 4 PLACES 1 D0 360 4 PLACES O 0 825 0 175 x DMC 1410 1411 1417 Series Appendices e 151 List of Other Publications Step by Step Design of Motion Control Systems by Dr Jacob Tal Motion Control Applications by Dr Jacob Tal Motion Control by Microprocessors by Dr Jacob Tal Training Seminars Galil a leader in motion control with over 250 000 controllers working worldwide has a proud reputation for anticipating and setting the trends in motion control Galil understands your need to keep abreast with these trends in order to remain resourceful and competitive Through a series of seminars and workshops held over the past 15 years Galil has actively shared their market insights in a no nonsense way for a world of engineers on the move In fact over 10 000 engineers have attended Galil seminars The tradition continues with three different seminars each designed for your particular skill set from beginner to the most advanced MOTION CONTROL MADE EASY WHO SHOULD ATTEND Those who need a basic intro
33. for error conditions and to inhibit the motor on error These features help protect the various system components from damage WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machine Since the DMC 141X is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 141X Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 141X includes hardware input and output protection lines for various error and mechanical limit conditions These include Output Protection Lines Amp Enable This signal goes low when the motor off command is given when the position error exceeds the value specified by the Error Limit ER command or when off on error condition is enabled OE1 and the abort command is given This signal also goes low when the watch dog timer is activated or upon reset Note The standard configuration of the AEN signal is TTL active low Both the polarity and the amplitude can be changed if you are using the ICM 1460 interface board To make these changes see section entitled Amplifier Interface pg 3 42 Error Output The error output is a TTL signal which indicates an error condition in the controller This signal is available on the interconnect module as ERROR When the error si
34. is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no longer under servo control If the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running are terminated when a transition in the Abort input is detected For information on setting the Off On Error function see the Command Reference OE Uncommitted Digital Inputs The general use inputs are TTL and are accessible through the ICM 1460 as INI IN7 These inputs can be interrogated with the use of the command TI Tell Inputs the operand _TI and the function IN n see Chapter 7 Mathematical Functions and Expressions NOTE For systems using the ICM 1460 interconnect module there is an option to provide opto isolation on the inputs In this case the user provides an isolated power supply 5V to 24V and ground For more information consult Galil The inputs can be accessed directly from the 37 pin or 40 pin connector on the controller also For a description of the pinouts consult the appendix DMC 1410 1411 1417 Series Chapter 3 Hardware Interface e 41 Outputs The DMC 141X provides three general use outputs and an error signal output The general use outputs are TTL and are accessible through the ICM 1460 as OUTO O
35. must be executing an applications program from memory This can be a very simple program that does nothing but loop on a statement such as LOOP JP LOOP EN Motion commands such as JG5000 can still be sent from the PC even while the dummy applications program is being executed Instruction Interpretation TEST Test program JG1000 Set jog speed on X axis BG Begin motion on the X axis LOOP Dummy Program for endless loop JP HLOOP EN Jump to LOOP label LIMSWI Limit Switch Label MG LIMIT OCCURRED Print Message RE Return to main program Now when a forward limit switch occurs the LIMSWI subroutine will be executed NOTE The RE command is used to return from the LIMSWI subroutine 94 e Chapter 7 Application Programming DMC 1410 1411 1417 Series NOTE The LIMSWI will continue to be executed until the limit switch is cleared NOTE The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error Instruction MAIN JG10000 BG LOOP JP LOOP EN POSERR 1 MG EXCESS POSITION ERROR MG ERROR V1 RE Interpretation Main program Set jog speed Begin jog Dummy Program Loop Position Error Routine Read Position Error Print Message Print Error Return from Error Now if the position error on the X axis exceeds that specified by the ER command the POSERR routine will execute NOTE The RE command is used to return from the POSERR subroutine
36. of as a simple Resistor Capacitor single pole filter The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor Use of KS is most applicable when operating in full step or half step operation KS will cause the step pulses to be delayed in accordance with the time constant specified When operating with stepper motors you will always have some amount of stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving back and forth For example when operating with servo motors the trippoint AM After Motion is used to determine when the motion profiler is complete and
37. of the brushless motor In this case the controller could become unstable until the commutation phase has been set using the BZ command see next step It is highly recommended that the motor off command be given before executing the BN command In this case the motor will be disabled upon power up or reset and the commutation phase can be set before enabling the motor Step F Set Zero Commutation Phase DMC 1410 1411 1417 Series Chapter 2 Getting Started e 31 When an axis has been defined as sinusoidally commutated the controller must have an estimate for commutation phase When hall sensors are used the controller automatically estimates this value upon reset of the controller If no hall sensors are used the controller will not be able to make this estimate and the commutation phase must be set before enabling the motor If Hall Sensors are Not Available To initialize the commutation without Hall effect sensor use the command BZ This function drives the motor to a position where the commutation phase is zero and sets the phase to zero The BZ command argument is a real number which represents the voltage to be applied to the amplifier during the initialization When the voltage is specified by a positive number the initialization process will end up in the motor off MO state A negative number causes the process to end in the Servo Here SH state Warning This command must move the motor to find the zero commutation phase T
38. or 12V made through jumper location JP4 Removing the jumper allows the user to connect their own supply to the desired voltage level Up t024V 12V SERVO SM cone MOTOR AMPLIFIER 37 40 Pin Cable 7407 Open Collector Buffer The Enable signal can be inverted by using a 7406 Analog Switch Figure 3 1 Connecting AEN to an amplifier Other Inputs The reset input is a TTL level non isolated signal The reset is used to locally reset the DMC 141X without resetting the PC DMC 1410 1411 1417 Series Chapter 3 Hardware Interface e 43 THIS PAGE LEFT BLANK INTENTIONALLY 44 e Chapter 3 Hardware Interface DMC 1410 1411 1417 Series Chapter 4 Communication Introduction The DMC 1410 DMC 1411 DMC 1417 receive commands from a PC The controllers are configured as standard ISA PC 104 or PCI cards respectively that are mapped into the I O space Communication between the controller and the computer is in the form of ASCII characters where data is sent and received via READ and WRITE registers on the controller A handshake is required for sending and receiving data The DMC 141X contain a 256 character write FIFO buffer which permits sending commands at high speeds ahead of their actual processing by the controller It also contains a 256 character read buffer This chapter on communication discusses Communication Register Description A Simplified Method of Communicati
39. other than zero The conditional statement can be any valid DMC 141X numeric operand including variables array elements numeric values functions keywords and arithmetic expressions If no conditional statement is given the jump will always occur Examples Number V1 6 Numeric Expression V1 V7 6 ABS V1 gt 10 Array Element V1 lt Count 2 Variable 1 lt 2 Internal Variable _TPX 0 _TVX gt 500 VO V1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 141X will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and representing the logical AND and logical OR The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The operand between any two conditions requires that only one statement be true for the combined statement to be true Note Each condition must be placed in parentheses for proper evaluation by the controller In addition the DMC 141X executes operations from left to right For further information on Mathematical Expressions and the bit wise operators amp and see pg 7 96 For example using variables named V1 V2 V3 and V4 JP TEST V1 lt V2 amp V3 lt V4 In this example this statement will cause the program to jump to the label TEST if V1 is less than V2 and V3 is less than V4 To illustrate this further
40. properly entered into the Windows registry it should also be present in the Galil Registry The address and IRQ jumpers on the controller may need to be changed depending on the resources available in Windows see Step 3 for setting address and IRQ jumpers Connect to the controller through the Terminal utility in DMCWIN32 WSDK32 or DMCTERM Using Galil Software for Windows NT 4 In Windows NT 4 the DMC 1417 is also plug and play This means that on power up the computer will automatically detect the card and install the appropriate device driver A Found New Hardware dialog box may appear during installation of the device driver The controller will be identified by model name and entered into the Galil Registry Now the user can communicate to the controller using DMCTERM DMCWIN32 or WSDK32 To use a DMC 1410 or DMC 1411 in Win NT4 add the controller using the Galil Registry dialog To access the registry in DMCTERM and WSDK click on the File menu and Register Controller In DMCWIN32 select the Registry menu 22 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Edit Registry Once in the Galil Registry click New Controller under Non PnP Tools Select the appropriate controller from the pull down menu and adjust the timeout as seen fit Click Next to continue Select Model and General Parameters The registry information for the DMC 1410 and 1411 cards will show a default address of 1000 This
41. that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called overdamped response The results may be worse if we turn the faucet too fast The overreaction results in temperature oscillations When the response of the system oscillates we say that the system is unstable Clearly unstable responses are bad when we want a constant level What causes the oscillations The basic cause for the instability is a combination of delayed reaction and high gain In the case of the temperature control the delay is due to the water flowing in the pipes When the human reaction is too strong the response becomes unstable Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be DMC 1410 1411 1417 Series Chapter 10 Theory of Operation e 125 applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which is designed to help the stability and accuracy Typically such a filter produces in addition to the proportional gain damping and integrator The combination of the three functions is referred to as a PID filter
42. the TE command Programmable Position Limits The DMC 141X provides programmable forward and reverse position limits These are set by the BL and FL software commands Once a position limit is specified the DMC 141X will not accept position commands beyond the limit Motion beyond the limit is also prevented Example Instruction Interpretation DPO Define Position BL 2000 Set Reverse position limit FL 2000 Set Forward position limit 116 e Chapter 8 Error Handling DMC 1410 1411 1417 Series JG 2000 Jog BG Begin In this example the motor will jog forward at a speed of 2000 cts sec until it is stopped by the forward software limit at position 2000 Off On Error The DMC 141X controller has a built in function which can turn off the motors under certain error conditions This function is known as Off On Error To activate the OE function specify a 1 To disable this function specify a0 When this function is enabled the motor will be disabled under the following 3 conditions 1 The position error for the specified axis exceeds the limit set with the command ER 2 The abort command is given 3 The abort input is activated with a low signal Note If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Examples OE 1 Enable off on error 0 Disable off on error Autom
43. the address If the address jumpers are changed the Galil registry must be modified to reflect these changes Once communication is established click on the menu for terminal and you will receive a colon prompt Communicating with the controller is described in later sections Sending Test Commands to the Terminal After you connect your terminal press lt carriage return gt or the lt enter gt key on your keyboard In 66 97 response to carriage return CR the controller responds with a colon Now type TPX CR This command directs the controller to return the current position of the X axis The controller should respond with a number such as 0000000 24 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Step 6 Make connections to amplifier and encoder Once you have established communications between the software and the DMC 141X you are ready to connect the rest of the motion control system The motion control system generally consists of an ICM 1460 Interface Module a servo amplifier and a motor to transform the current from the servo amplifier into torque for motion Galil also offers the AMP 1460 Interface Module which is an ICM 1460 equipped with a servo amplifier for a DC brush motor A signal breakout board of some type is strongly recommended If you are using a breakout board from a third party consult the documentation for that board to insure proper system connection If you are using the ICM 1460 or AM
44. the array An array name can contain up to eight characters starting with an uppercase alphabetic character The number of entries in the defined array is enclosed in Example DM 7 Defines an array names POSX with seven entries DM SPEED 100 Defines an array named speed with 100 entries DM 0 Frees array space Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the POSX array defined with the DM command DM POSX 7 would be specified as POSX 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples DM SPEED 10 Dimension Speed Array SPEED 1 7650 2 Assigns the first element of the array SPEED the value 7650 2 SPEED 1 Report array element value POSX 10 _TP Assigns the 10th element of the array POS the returned value from the tell position command DMC 1410 1411 1417 Series Chapter 7 Application Programming e 101 CON 2 COS POS 2 Assigns the second element of the array CON the cosine of the variable POS multiplied by 2 TIMER 1 TIME Assigns the first element of the array timer the returned
45. the motor at the maximum speed nn For stepper motors the amplifier converts step and direction signals into current Encoder An encoder translates motion into electrical pulses that are fed back into the controller The DMC 141X accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as CHA and CHB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended CHA and CHB or differential CHA CHA CHB CHB The DMC 141X decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization The DMC 141X can also interface to encoders with pulse and direction signals There is no limit on encoder line density however the input frequency to the controller must not exceed 2 000 000 full encoder cycles second or 8 000 000 quadrature counts sec For example if the encoder line density is 10 000 cycles per inch the maximum speed is 200 inches second The standard voltage level is TTL zero to five volts however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 141X Single ended 12 Volt signals require a 6 volt bias voltage input to the complementary inputs Watch Dog Timer The DMC 141X provides an internal watchdog timer which checks for proper microprocessor operation The timer toggl
46. the next window will display a list of devices Select Add a new device from the top of the list Add Remove Hardware Wizard Choose a Hardware Device DMC 1410 1411 1417 Series Which hardware device do you want to troubleshoot The following hardware is already installed on your computer If pou are having problems with one of these devices select the device and then click Next If you are attempting to add a device and it is not shown below select Add a new device and then click Next Devices Add a new device PCI Device m ACPI Fixed Feature Button m Intel r 82802 Firmware Hub Device m System timer m Direct memory access controller Chapter 2 Getting Started e 15 4 The Hardware Wizard prompts for Windows to search for the new device This feature is for devices such as modems that can be found by random queries of all available communication ports Select No and proceed to the next dialog Add Remove Hardware Wizard Find New Hardware Windows can also detect hardware that is not Plug and Play compatible 16 e Chapter 2 Getting Started DMC 1410 1411 1417 Series 5 With DMCWIN32 or DMCTERM already installed the following window will say Select the type of hardware you want to install Click on the Diamond with either Galil or Galil Motion Control written to the side of it and the list of Galil controllers will be displayed Select the D
47. to compare the available resources to those on the jumpers and select a configuration that is compatible If all configurations have a resource conflict then the user will have to reconfigure or remove another card to free up some resources This is most likely to happen with IRQs as they can be scarce Note The Input Output Range is used to assign a communication address to the controller This address is given in hexadecimal which means the user should use the scientific calculator in Start Programs Accessories to convert the decimal address desired into its hexadecimal equivalent The user can just enter a single hexadecimal number into the Value box and the OS will assign an I O range to it In Win 2000 the procedure is the same except the user has the opportunity to set resources examine conflicts without rebooting first Highlight the Interrupt Request and Input Output Range individually and select Change Setting to make the appropriate adjustments Similar to Windows 98 the Input Output Range must be assigned as a hexadecimal number Chapter 2 Getting Started e 21 Add New Hardware Wizard Properties 7 2 xl Resources S Unknown Device Resource settings Resource type Setting Interrupt Request Input Output Range Setting based on Basic configuration 0000 F Use automatic settings Change Setting Conflicting device list 7 Once the controller is
48. used as a trippoint When Complete This allows the DMC 141X to use the next increment only when it is finished with the previous one Zero parameters for DT or CD exit the contour mode If no new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 67 Command Summary Contour Mode Specifies contouring mode Specifies position increment over time interval Range is 32 000 Zero ends contour mode Specifies time interval 2 msec for position increment where n is an integer between 1 and 8 Zero ends contour mode If n does not change it does not need to be specified with each CD Waits for previous time interval to be complete before next data record is processed General Velocity Profiles The Contour Mode is ideal for generating any arbitrary velocity profiles The velocity profile can be specified as a mathematical function or as a collection of points The design includes two parts Generating an array with data points and running the program Generating an Array An Example Consider the velocity and position profiles shown in Fig 6 3 The objective is to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe th
49. value of the TIME keyword Using a Variable to Address Array Elements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter For example Instruction Interpretation A Begin Program COUNT 0 DM POS 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec POS COUNT _TP Record position into array element POS COUNT Report position COUNT COUNT 1 Increment counter JP LOOP COUNT lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named POS The variable COUNT is used to increment the array element counter The above example can also be executed with the automatic data capture feature described below Uploading and Downloading Arrays to On Board Memory Arrays may be uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A Start is the first element of array default 0 End is the last element of array default last element Delim specifies whether the array data is separated by a comma delim 1 or carriage return delim 0 The file is terminated using lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 141X provides a special feature for automatic capture of data such as position
50. 000 pulses sec maximum frequency TTL 0 5 Volts Line receiver inputs biased for 0 5v operation Can accept up to a 12 V signal TTL buffer output 0 5V Line receiver inputs biased for 0 5V operation Can accept up to a 12 V signal 400 mA 20 mA 20mA Appendices e 137 Performance Specifications Minimum Servo Loop Update Time Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Array Size Program Size 250 usec 1 quadrature count Phase locked better than 005 System dependent 2147483647 counts per move Up to 8 000 000 counts sec 2 counts sec 16 bit DAC over 10V range 0003V 2 billion 4 bytes integer 32 bits 2 bytes fraction 16 bits 1 104 4 bytes integer 32 bits 2 bytes fraction 16 bits 1000 elements 6 arrays 250 lines x 40 characters Connectors DMC 1410 1417 J3 General I O 37 PIN D type 1 Reset 2 Amp Enable 3 Output 3 4 Output 1 5 PWM or Step Out 6 Input 7 7 Input 5 8 Input 3 9 Input 1 and latch 10 5V 11 Ground 12 12V 13 Ground 14A 15 16I 17 Auxiliary A 18 Auxiliary B 20 Error 21 Amp Command for Servo motors 22 Output 2 23 Reserved 24 Sign or Direction 25 Input 6 26 Input 4 27 Input 2 28 Forward Limit 29 Reverse Limit 30 Home 31 12v 32 A 33 B 34 I 3
51. 1 41 Index 41 56 142 Quadrature 41 142 Error Automatic Error Routine 119 Codes 58 Handling 1 85 117 Error Handling 42 Error Limit 27 29 Off On Error 27 43 Excessive Error 1 Execute Program 39 56 Feedforward 57 FIFO 5 49 Filter Parameter Damping 36 Integrator 36 PID 30 Proportional Gain 36 Find Edge 42 Flags Almost full 48 Formatting 55 109 11 Hexadecimal 108 12 Variable 40 83 140 Frequency 6 Function 43 94 Functions Arithmetic 94 99 Gain 9 44 57 102 127 151 Proportional 36 Gearing 1 61 Halt Off On Error 27 43 Hardware Address 122 Amplifier Enable 44 Jumper 122 123 4 e Index TTL 6 41 Home Input 42 Home Inputs 42 56 78 139 Homing 42 Find Edge 42 I O Amplifier Enable 44 Digital Input 41 Home Input 42 TTL 6 41 ICB 1460 8 143 ICM 1100 27 Index 41 56 142 Index Pulse 28 42 Inputs Digital Inputs 1 42 113 Index 41 56 142 Interconnect Module 148 Limit Switch 120 Installation 9 121 Integrator 36 57 128 Interconnect Board 8 143 Interconnect Module 148 ICM 1100 27 Internal Variable 94 Interrogation 36 54 55 109 Interrupt 49 56 85 143 Jog 55 63 Jumper 122 123 Jumpers 143 Keyword 94 99 TIME 102 Label 67 68 72 Latch 54 Record 72 Teach 72 Limit Torque Limit 29 Limit Switch 42 43 102 120 Limit Switch Routine 103 119 LIMSWI 42 Masking Bit Wise 94 Master Reset 143 Math Function Absolu
52. 2 e Chapter 5 Programming Basics DMC 1410 1411 1417 Series For example the following example illustrates how to display the current position of the X axis TP lt enter gt Tell position 0000000000 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark Type the command followed by a PR Request X axis value The controller can also be interrogated with operands Operands Most DMC 141X commands have corresponding operands that can be used for interrogation Operands must be used inside of valid DMC expressions For example to display the value of an operand the user could use the command MG operand where operand is a valid DMC operand All of the command operands begin with the underscore character _ For example the value of the current position on the X axis can be assigned to the variable V with the command V _TP The Command Reference denotes all commands which have an equivalent operand as Used as an Operand Also see description of operands in Chapter 7 Command Summary Each DMC 141X command is described fully in the DMC 1400 Series Command Reference A summary of the commands follows The commands are grouped in this summary by the following functional categories Motion Program Flow General Configuration Control Settings Status and Error Limits Motion commands are those to specify modes of motion such as Jog Mode o
53. 45 250 s ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 sT 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis 130 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 141X controller and the following parameters 0 1 Torque constant J 2 1074 kg m System moment of inertia R 2 Q Motor resistance K 4 Amp Volt Current amplifier gain KP 12 5 Digital filter gain KD 245 Digital filter zero KI 0 No integrator N 500 Counts rev Encoder line density ms Sample period The transfer functions of the system elements are Motor M s P I Kt Js2 500 52 rad A Amp K4 4 Amp V DAC Kg 0 0003 V count Encoder Kg 4N 2n 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 T 0 001 Therefore D z 12 5 245 1 z 1 Accordingly the coefficients of the continuous filter are P 50 D 0 98 The filter eq
54. 5 Auxiliary A 36 Auxiliary B 37 Abort 138 e Appendices DMC 1410 1411 1417 Series 19 Reserved DMC 1411 J3 General I O 40 PIN IDC 1 Reset 3 Amp Enable 5 Output 3 7 Output 1 9 PWM or Step Out 11 Input 7 13 Input 5 15 Input 3 17 Input 1 and latch 19 5V 21 Ground 23 12V 25 Ground 27 A 29 311 33 Auxiliary A 35 Auxiliary B 37 Reserved 39 NC P1 64 PIN PC 104 BUS P2 40 PIN PC 104 BUS Active low 2 Error 4 Amp Command for Servo motors 6 Output 2 8 Reserved 10 Sign or Direction 12 Input 6 14 Input 4 16 Input 2 18 Forward Limit 20 Reverse Limit 22 Home 24 12v 26 A 28 B 30 I 32 Auxiliary A 34 Auxiliary B 36 Abort 38 NC 40 NC Pin Out Description OUTPUTS Analog Motor Command Amp Enable OE1 10 Volt range signal for driving amplifier In servo mode motor command output is updated at the controller sample rate In the motor off mode this output is held at the OF command level Signal to disable and enable an amplifier Amp Enable goes low on Abort and DMC 1410 1411 1417 Series Appendices e 139 PWM STEP OUT PWM STEP OUT Sign Direction Error Output 1 Output 3 IPWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a co
55. 7 Response from Interrogation Command With Leading Zeros LZI Enables the LZ function TP Tell Position Interrogation Command 9 5 0 7 Response from Interrogation Command Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrogation commands may be formatted locally To format locally use the command Fn m or n m on the same line as the interrogation command The symbol F specifies that the response should be returned in decimal format and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal For example Examples TP F2 2 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 00 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format The default format for VF is VF 10 4 Hex values are returned preceded by a and in 2 s complement V1 10 Assign VI Vl Return V1 0000000010 0000 Default format 108 e Chapter 7 Applicati
56. 951 GL 1800 Microcomputer O 7 In Interface ERRON 9 0 Motor Encoder e Limits 256 EEPROM Interface wi Encoders Watch Dog Timer Figure 1 1 DMC 141X Functional Elements 2 e Chapter 1 Overview DMC 1410 1411 1417 Series Microcomputer Section The main processing unit of the DMC 141X is a specialized 32 bit Motorola 68331 Series Microcomputer with 32K RAM 256K available as an option 64K EPROM and 256 bytes EEPROM The RAM provides memory for variables array elements and application programs The EPROM stores the firmware of the DMC 141X The EEPROM allows certain parameters to be saved in non volatile memory upon power down Motor Interface For each axis a GL 1800 custom sub micron gate array performs quadrature decoding of the encoders at up to 8 MHz generates a 10 Volt analog signal 16 Bit D to A for input to a servo amplifier and generates step and direction signal for step motor drivers Communication The communication interface with the host PC occurs over the ISA PC 104 or PCI bus uses a bi directional FIFO 7201 and includes PC interrupt handling circuitry General I O The DMC 141X provides interface circuitry for seven TTL inputs and three TTL outputs System Elements As shown in Fig 1 2 the DMC 141X is part of a motion control system that includes amplifiers motors and encoders These elements are described below Power Supply
57. FO is full Write Procedure To send data to the DMC 141X read the status register at address N 1 and check bit 1 If bit 1 is one the DMC 141X FIFO buffer is not full and up to 256 characters may be written to the WRITE register at address N If bit 1 is zero the buffer is full and no additional data should be sent Clear FIFO Procedure The FIFO buffer may be cleared by writing a zero to CLEAR BUFFER register at N 1 This however will erase all previous data sent to the controller Interrupts The DMC 141X provides a hardware interrupt line that will when enabled interrupt the PC Interrupts free the host from having to poll for the occurrence of certain events such as motion complete or excess position error The DMC 141X uses only one of the PC s interrupts however it is possible to interrupt on multiple conditions The controller provides a register that contains a byte designating each condition The user can select the interrupt request level in addition to the interrupt conditions The user can also send an interrupt with the UI command Configuring Interrupts To use the DMC 141X interrupt you must complete the following steps 1 The DMC 1410 and 1411 board must contain one jumper to designate the interrupt line for the PC bus The available lines are IRQ5 IRQ9 IRQ10 IRQ11 IRQ12 and IRQ15 Place a jumper on the desired line Only one line may be jumped Note that for the ISA or PC 104 bus only one I O card can
58. MC 1410 or 1411 card from the list Note If there is no Galil diamond on the Hardware Type window click on Other Devices instead At that point the list of Galil ISA and PC 104 cards will appear Add Remove Hardware Wizard Select a Device Driver a Which driver do you want to install for this device CY Select the manufacturer and model of your hardware device and then click Next If you have a disk that contains the driver you want to install click Have Disk Models Galil DMC 10x0 Motion Controller Galil DMC 14x0 Motion Controller Galil DMC 14x1 Motion Controller Galil DMC 1 4x7 Motion Controller Galil DM C 16x0 Motion Controller Galil DMC 17x0 Motion Controller Galil 1 8 0 Motinn Controller z Have Disk lt Back Cancel DMC 1410 1411 1417 Series Chapter 2 Getting Started e 17 6 With the device selected the OS then needs to allocate any required resources i In Win98 SE and ME the OS automatically assigns resources that are most likely incompatible Add New Hardware Wizard QN Input Output Range 0214 0217 Interrupt Request 05 Automatically Assigned resources in Win 98 SE 18 e Chapter 2 Getting Started DMC 1410 1411 1417 Series At this point the user must reboot and go to the Device Manager under My Computer Properties System Properties E Display adapters H 6 Floppy disk controllers EX Gail Galil DMC 14x0 Motion Controller RE Galil DMC 14x1 Motion Controller
59. P 1460 with the DMC 1410 or DMC 1417 connect the 37 pin cable between the controller and interconnect module If you are using the DMC 1411 connect the 40 pin cable between the controller and interconnect module System connection procedures will depend on which components are included in your system Here are the first steps for connecting a motion control system Step A Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are operating properly the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller you need to verify that the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 kQ resistor and measure the voltage across the resistor Only if the voltage is zero proceed to connect the two ground signals directly The amplifier enable signal is used by the controller to disable t
60. UTI and OUT2 These outputs can be turned On and Off with the commands SB Set Bit CB Clear Bit OB Output Bit and OP Output Port For more information about these commands see the Command Summary The value of the outputs can be checked with the operand _OP and the function OUT n see Chapter 7 Mathematical Functions and Expressions The error signal output is available on the interconnect module as ERROR This is a TTL signal which is low when the controller has an error Note When the error signal is active the LED on the controller will be on An error condition indicates one of the following conditions 1 Atleast one axis has a position error greater than the error limit The error limit is set by the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal The outputs can be accessed directly from the 37 pin or 40 pin connector on the controller For a description of the pinouts consult the appendix Amplifier Interface The DMC 141X generates a 10 Volt range analog signal ACMD pin 21 and ground for input to power amplifiers which have been sized to drive the motor and load For best performance the amplifier should be configured for a current mode of operation with no additional compensation The gain should be set such that
61. VE IP TE TP The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the decimal point using the PF command Position Format is specified by m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format Hex values are returned preceded by a and in 2 s complement Hex values should be input as signed 2 s complement where negative numbers have a negative sign The default format is PF 10 0 If the number of decimal places specified by PF is less than the actual value a nine appears in all the decimal places Examples DP21 Define position TPX Tell position 0000000021 Default format PF4 Change format to 4 places TPX Tell position DMC 1410 1411 1417 Series Chapter 7 Application Programming e 107 0021 New format PF 4 Change to hexadecimal format TPX Tell Position 0015 Hexadecimal value PF2 Format 2 places TPX Tell Position 99 Returns 99 if position greater than 99 Removing Leading Zeros from Response to Interrogation Response The leading zeros on data returned as a response to interrogation commands can be removed by the use of the command LZ Example Using the LZ command LZO Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 0000000000 000000000
62. a 10 Volt input results in the maximum required current The DMC 141X also provides an AEN amplifier enable signal to control the status of the amplifier This signal toggles when the watchdog timer activates when a motor off command is given or when 1 Off on error is enabled command is given and the position error exceeds the error limit As shown in Figure 3 1 AEN can be used to disable the amplifier for these conditions The standard configuration of the AEN signal is TTL active high In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed if you are using the ICM 1460 interface board To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level note the state of the jumper on the ICM 1460 When JP4 has a jumper from AEN to 5V default setting the output voltage is 0 5V To change to 12 volts pull the jumper and rotate it so that it connects the pins marked AEN and 12V If the jumper is removed entirely the output is an open collector signal allowing the user to connect to external supplies with voltages up to 24V 42 e Chapter 3 Hardware Interface DMC 1410 1411 1417 Series DMC 141X ICM 1460 Connection to 5V
63. ables the periodic synchronization of the motor with the auxiliary encoder that is the master The electronic cam is a more general type of electronic gearing that allows a table based relationship between the motor and master 62 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series To illustrate the procedure of setting the cam mode consider the cam relationship shown in Figure 6 1 Step 1 Specify the master cycle and the change in the slave axis In the electronic cam mode the position of the master is always expressed within one cycle In this example the position of the master is always expressed in the range between 0 and 6000 Similarly the slave position is also redefined such that it starts at zero and ends at 1500 At the end of a cycle when the master is 6000 and the slave is 1500 the positions of both the aux encoder and the x axis are defined to zero To specify the master cycle and the slave cycle change we use the instruction EM EM n m where n specifies the cycle of the slave axis and m specifies the cycle of the master aux encoder The cycle of the master is limited to 8 388 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 1500 6000 Step 2 Specify the master interval and starting point
64. ally open switch will make _HMX read 1 initially and a normally closed switch will make _HMX read zero Furthermore with CN 1 a normally open switch will make HMX read O initially and a normally closed switch will make _HMX read 1 Therefore the CN command will need to be configured properly to ensure the correct direction of motion in the home sequence Upon detecting the home switch changing state the motor begins decelerating to a stop Note The direction of motion for the FE command also follows these rules for the state of the home input Stage 2 The motor then traverses at 256 counts sec in the opposite direction of Stage 1 until the home switch toggles again If Stage 3 is in the opposite direction of Stage 2 the motor will stop immediately at this point and change direction If Stage 2 is in the same direction as Stage 3 the motor will never stop but will smoothly continue into Stage 3 Stage 3 The motor traverses forward at 256 counts sec until the encoder index pulse is detected The motor then stops immediately The DMC 141X defines the home position as the position at which the index was detected and sets the encoder reading at this point to zero The 4 different motion possibilities for the home sequence are shown in the following table Direction of Motion Switch Type CN Setting Initial HMX state Stage 3 Normally Open Reverse Forward Forward ne ow e Normally Closed from free Forwar
65. ample V1 returns the value of the variable V1 Operands Operands allow motion or status parameters of the DMC 141X to be incorporated into programmable variables and expressions Most DMC 141X commands have an equivalent DMC 1410 1411 1417 Series Chapter 7 Application Programming e 99 operand which are designated by adding an underscore _ prior to the DMC 141X command The command reference indicates which commands have an associated operand Status commands such as Tell Position return actual values whereas action commands such as KP or SP return the values in the DMC 141X registers Examples of Operands POSX _TP Assigns value from Tell Position to the variable POSX GAIN _KP 2 Assigns value from KP multiplied by two to variable GAIN JP LOOP _TE gt 5 Jump to LOOP if the position error is greater than 5 ERROR _TC 1 Jump to ERROR if the error code equals 1 Operands can be used in an expression and assigned to a programmable variable but they cannot be assigned a value For example _KP 2 is invalid Special Operands Keywords The DMC 141X also provides a few additional operands that give access to internal variables that are not accessible by standard DMC 141X commands Dmm Free Running Real Time Clock off by 2 4 Resets with power on Note TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords _LF LR and TIME do not have
66. ample an operator can be prompted to input a number in revolutions A program could be used such that the input number is converted into counts by multiplying it by the number of counts revolution Example Instruction Interpretation RUN Label IN ENTER OF REVOLUTIONS N1 Prompt for revs PR N1 2000 Convert to counts IN ENTER SPEED IN RPM S1 Prompt for RPMs SP S1 2000 60 Convert to counts sec DMC 1410 1411 1417 Series Chapter 7 Application Programming e 109 IN ENTER ACCEL IN RAD SEC2 A1 Prompt for ACCEL AC A1 2000 2 3 14 Convert to counts sec 2 BG Begin motion EN End program Programmable Hardware I O Digital Outputs The DMC 141X has a 3 bit uncommitted output port for controlling external events Each bit on the output port may be set and cleared with the software instructions SB Set Bit and CB Clear Bit OB define output bit and OP Output port For example Instruction Function SB2 Set bit 2 of output port Clears bit 1 of output port CB3 Clear bit 3 of output port The Output Bit OB instruction is useful for setting or clearing outputs depending on the value of a variable array input or expression Any non zero value results in a set bit Instruction Function OB1 POS Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 OB 2 IN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 3 IN 1 amp IN Output 3 only if Input 1 and Input 2
67. ample Time ZR Zero STATUS RP Report Command Position RL Report Latch SC Stop Code TB Tell Status TC Tell Error Code TD Tell Dual Encoder TE Tell Error TI Tell Input TP Tell Position TR Trace TS Tell Switches TT Tell Torque TV Tell Velocity ERROR AND LIMITS BL Reverse Software Limit ER Error Limit FL Forward Software Limit OE Off on Error EDITOR ED Edit mode return Save line lt cntrl gt P Previous line lt cntrl gt I Insert line cntrl D Delete line cntrl Q Quit Editor ARITHMETIC FUNCTIONS SIN Sine COS Cosine ABS Absolute value FRAC Fraction portion INT Integer portion RND Round SQR Square root DMC 1410 1411 1417 Series 56 e Chapter 5 Programming Basics IN Return digital input AN Return analog input Add Subtract Multiply Divide amp And Or Parentheses Instruction Set Examples Below are some examples of simple instructions It is assumed your system is hooked up and the motors are under stable servo control Note the colon is returned by the controller and appears on the screen You do not need to type the DP 0 lt enter gt PF 6 lt enter gt PR 100 lt enter gt BG lt enter gt TP lt enter gt 00100 PR lt enter gt 00100 TC1 lt enter gt 1 Unrecognized command DMC 1410 1411 1417 Series Define axis position as 0 Define position format as 6 digits Specify position command Begin Motion
68. amplifier with K 2 A V with the motor described by the previous example will have the transfer function P V 1000 s2 rad V DMC 1410 1411 1417 Series Chapter 10 Theory of Operation e 127 If the motor is a DC brushless motor it is driven by an amplifier that performs the commutation The combined transfer function of motor amplifier combination is the same as that of a similar brush motor as described by the previous equations Velocity Loop The motor driver system may include a velocity loop where the motor velocity is sensed by a tachometer and is fed back to the amplifier Such a system is illustrated in Fig 10 5 Note that the transfer function between the input voltage V and the velocity is 0 V Ka KyJs 1 Ka Kg Js 1 Kg sT 1 where the velocity time constant T1 equals TI VKa Kc Kg This leads to the transfer function P V VIK s sT1 1 K e Figure 10 5 Elements of velocity loops The functions derived above are illustrated by the block diagram of Fig 10 6 128 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series VOLTAGE SOURCE V E W P ei co ii LIL ST_ 1 ST 1 S CURRENT SOURCE V W VELOCITY LOOP V W P K ST 1 S Figure 10 6 Mathematical model of the motor and amplifier in three operational modes En
69. an be monitored by the command TD Tell Dual TD gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Stepper Smoothing Filter Output Buffer Output Motion Profiler Adds a Delay 3 To Stepper Driver Reference Position RP Step Count Register TD Motion Complete Trippoint When used in stepper mode the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position The MC trippoint Motion Complete is generally more useful than AM trippoint After Motion since the step pulses can be delayed from the commanded position due to stepper motor smoothing Using an Encoder with Stepper Motors An encoder may be used on a stepper motor to check the actual motor position with the commanded position If an encoder is used it must be connected to the main encoder input Note The auxiliary encoder is not available while operating with stepper motors The position of the encoder can be interrogated by using the command TP The position value can be defined by using the command DE Note Closed loop operation with a stepp
70. ands from TCI diagnoses error Motor Doesn t Move Response of controller 2 Anything Correct problem reported by SC from TCI diagnoses error DMC 1410 1411 1417 Series Chapter 9 Troubleshooting e 121 THIS PAGE LEFT BLANK INTENTIONALLY 122 e Chapter 9 Troubleshooting DMC 1410 1411 1417 Series Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Fig 10 1 COMPUTER CONTROLLER gt DRIVER ah Figure 10 1 Elements of Servo Systems The operation of such a system can be divided into three levels as illustrated in Fig 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming The first level the closing of the loop assures that the motor follows the commanded position This is done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling is the generation of the desired position function this function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the l
71. apter 2 Getting Started DMC 1410 1411 1417 Series Example 2 Profiled Move Objective Rotate a distance of 10 000 counts at a slew speed of 20 000 counts sec and an acceleration and deceleration rates of 100 000 counts s Instruction Interpretation PR 10000 Distance SP 20000 Speed DC 100000 Deceleration AC 100000 Acceleration BG Start Motion In response the motor turns and stops Example 3 Position Interrogation The position of the axis may be interrogated with the instruction TP Tell position which returns the position of the main encoder The position error which is the difference between the commanded position and the actual position can be interrogated by the instructions TE Tell error Example 4 Absolute Position Objective Command motion by specifying the absolute position Instruction Interpretation DP 0 Define the current position as 0 PA 7000 Sets the desired absolute position BG Start motion Example 5 Velocity Control Jogging Objective Drive the motor at specified speeds Instruction Interpretation JG 10000 Set Jog Speed AC 100000 Set acceleration DC 50000 Set deceleration BG Start motion after a few seconds command JG 40000 New speed and Direction TV Returns speed This causes velocity changes including direction reversal The motion can be stopped with the instruction ST Stop DMC 1410 1411 1417 Series Chapter 2 Getting Started e 35 Example 6 Operation Under Torque Li
72. apture Backlash Correction Dual Loop DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 59 Following a trajectory based on a master Electronic Cam encoder position Motion Smoothing Applies to all of the above motion Smoothes motion to eliminate vibrations due to jerk discontinuities in acceleration Point to Point Positioning In this mode motion between the specified axes is independent and each axis follows its own profile The user specifies the desired absolute position PA or relative position PR slew speed SP acceleration ramp AC and deceleration ramp DC for each axis On begin BG the DMC 141X profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory The controller determines a new command position along the trajectory every sample period until the specified profile is complete Motion is complete when the last position command is sent by the DMC 141X profiler Note The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified The speed SP and the acceleration AC can be changed at any time during motion however the deceleration DC and position PR or PA cannot be changed until motion is complete Remember motion is complete when the profiler is finished not when the actual motor is in position The Stop command ST can be issued at any time to decelerate the motor to a sto
73. are high 2 The output port may also be written to as an 3 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 3 bit output port where 20 is output 1 2 is output 2 and 2 is output 3 A 1 designates that bit is on The value in the output port is the sum of bits 0 1 and 2 For example Instruction Function OP6 Sets outputs 2 and 3 of output port to high All other bits are 0 21 22 6 OPO Clears all bits of output port to zero The output port is useful for firing relays or controlling external switches and events during a motion sequence Example Turn on Output After Move Instruction Interpretation OUTPUT Label PR 2000 Position Command BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec 110 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Clear Output 1 EN End Digital Inputs The DMC 141X has seven digital inputs for controlling motion by local switches The IN n function returns the logic level of the specified input 1 through 7 For example a Jump on Condition instruction can be used to execute a sequence if a high condition is noted on an input 3 To halt program execution the After Input AI instruction waits until the specified input has occurred Example JP HA OIN 1 0 Jump to A if input 1 is low JP EB IN 2 1 Jump to B if input 2 is high AI7 Wait until input 7 is high AI 6 Wait until
74. are labeled PWM and SIGN on the ICM 1460 Consult the documentation for your step motor amplifier Step C Configure DMC 141X for motor type using MT command You can configure the DMC 141X for active high or active low pulses Use the command MT 2 for active high step motor pulses and MT 2 for active low step motor pulses See description of the MT command in the Command Reference Step 8 Tune the Servo System The system compensation provides fast and accurate response by adjusting the filter parameters The following presentation suggests a simple and easy way for compensation More advanced design methods are available with software design tools from Galil such as the Windows Servo Design Kit WSDK software DMC 1410 1411 1417 Series Chapter 2 Getting Started e 33 If the torque limit was set as a safety precaution in the previous step you may want to increase this value See Step B of the section Setting Torque Limit as a Safety Precaution The filter has three parameters the damping KD the proportional gain KP and the integrator KI The parameters should be selected in this order To start set the integrator to zero with the instruction KIO CR Integrator gain and set the proportional gain to a low value such as KP 1 CR Proportional gain KD 100 lt CR gt Derivative gain For more damping you can increase KD maximum is 4095 Increase gradually and stop after the motor vibrates A vibration is noticed by a
75. ata Capture Returns a 0 or 1 where 0 denotes not recording 1 denotes recording in progress RD Returns address of next array element Example Recording into An Array During a position move store the position and position error every 2 msec Instruction Interpretation RECORD Begin program DM XPOS 300 Define position array DM XERR 300 Define error array RA XPOS XERR Select arrays for capture RD_TP _TE Select data types PR 10000 Specify move distance RCI Start recording now at rate of 2 msec DMC 1410 1411 1417 Series Chapter 7 Application Programming e 103 BG A JP A RC 1 Begin motion Loop until done MG DONE Print message EN End program PLAY Play back N 0 Initial Counter DONE label N Print Counter XPOSI N Print position XERR N Print error N N 1 Increment Counter JP DONE N lt 300 Jump to DONE as long as there are positions left EN End Program Deallocating Array Space Array space may be deallocated using the DA command followed by the name DA 0 deallocates all the arrays Input of Data Numeric and String Input of Data The command IN is used to prompt the user to input numeric or string data Using the IN command the user may specify a message prompt by placing a message in quotations When the controller executes an IN command the controller will wait for the input of data The input data is assigned to the specified variable or array element An Example
76. atic Error Routine The POSERR label causes the statements following to be automatically executed if error on any axis exceeds the error limit specified by ER The error routine must be closed with the RE command The RE command returns from the error subroutine to the main program NOTE The Error Subroutine will be entered again unless the error condition is gone Example Instruction Interpretation A JP Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay ST Stop motor AM After motor stops SH Servo motor here to clear error RE Return to main program NOTE An applications program must be executing for the POSERR routine to function Limit Switch Routine The DMC 141X provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automatic execution of a limit switch subroutine The LIMSWI label specifies the start of the limit switch subroutine This label causes the statements following to be automatically executed if any limit switch is activated and that axis motor is moving in that direction The RE command ends the subroutine DMC 1410 1411 1417 Series Chapter 8 Error Handling e 117 The state of the forward and reverse limit switches may also be tested during the jump on condition statement The _LR condition specifies the reverse limit and _LF specifies the forward limit The CN command can be used to configure t
77. be attached to each interrupt request line The DMC 1417 does not require IRQ jumpers to be set the interrupt line is set automatically by the computer s BIOS or operating system DMC 1410 1411 1417 Series Chapter 4 Communication e 47 2 Your host software code must contain an interrupt service routine and must initialize the interrupt vector table in the PC The interrupt vector table and an example interrupt service routine DMCINTRP C are included in the DMCWIN software Failure to have proper interrupt servicing in your host program could cause disastrous results including resetting or hanging your computer 3 The Interrupt conditions must be enabled with the EI instruction The UI instruction does not require EN The EI instruction has the following format where n 2 DO mee DOS ecs s mer mee These conditions must be re enabled after each occurrence If you want an interrupt for Input 2 and motion complete you would enable bit 1 and bit 8 N 2 2 258 EI 258 The DMC 141X also provides a User Interrupt that can be sent by sending the command UI to the DMC 141X The UI command does not require the EI command Servicing Interrupts Once an interrupt occurs the host computer can read information about the interrupt by using the command IV Returned data has the following meaning The bit information shown in the table below is sent to screen automatically The IV command do
78. bel for timeout on Motion Complete trip point POSERR Label for excess Position Error subroutine CMDERR Label for incorrect command subroutine DMC 1410 1411 1417 Series Chapter 7 Application Programming e 83 Commenting Programs Using the Command NO The DMC 141X provides a command NO for commenting programs This command allows the user to include up to 38 characters on a single line after the NO command and can be used to include comments from the programmer as in the following example MOVE NO ABSOLUTE POINT TO POINT MOVE NO SPEED 10000 COUNTS SECOND SP 10000 NO ACCELERATION 100000 COUNTS SEC 2 AC 100000 NO DECELERATION 100000 COUNTS SEC 2 DC 100000 NO MOVE TO ABSOLUTE POSITION 150000 PA 150000 NO BEGIN MOVE BG NO AFTER MOVE COMPLETES AM NO MOVE TO ABSOLUTE POSITION 0 PAO NO BEGIN MOVE BG NO AFTER MOVE AM NO END PROGRAM EN Note The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Using REM Statements with the Galil Terminal Software If you are using Galil software to communicate with the DMC 141X controller you may also include REM statements REM statements begin with the word REM and may be followed by any comments that are on the same line The Galil terminal software will remove these statements when the program is downloaded to the controller For example PATH PA 10000 REM SIMPLE MOVE
79. coder The encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the position resolution is increased to 4N quadrature counts rev The model of the encoder can be represented by a gain of Kg 4N 20 count rad For example a 1000 lines rev encoder is modeled as 638 DMC 1410 1411 1417 Series Chapter 10 Theory of Operation e 129 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65 536 and the output voltage range is 10V or 20V Therefore the effective gain of the DAC is K 20 65 536 0 0003 V count Digital Filter The digital filter has a transfer function of D z K z A z Cz z 1 and a sampling time of T The filter parameters K A and C are selected by the instructions KP KD KI or by GN ZR and KI respectively The relationship between the filter coefficients and the instructions are K KP KD 4 orK GN 4 A KD KP KD orA ZR C KI2 This filter includes a lead compensation and an integrator It is equivalent to a continuous PID filter with a transfer function G s G s P sD I s P 4KP D 4T KD I KINT For example if the filter parameters of the DMC 141X are KP 4 KD 36 KI 0 5 T 20 001 s the digital filter coefficients are K 40 A 0 9 C 0 25 and the equivalent continuous filter G s is G s 4 0 14
80. compare it to a familiar closed loop operation adjusting the water temperature in the shower One control objective is to keep the temperature at a comfortable level say 90 degrees F To achieve that our skin serves as a temperature sensor and reports to the brain controller The brain compares the actual temperature which is called the feedback signal with the desired level of 90 degrees F The difference between the two levels is called the error signal If the feedback temperature is too low the error is positive and it triggers an action which raises the water temperature until the temperature error is reduced sufficiently The closing of the servo loop is very similar Suppose that we want the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way
81. d Normally Closed CN 1 Reverse Forward Forward Example Homing Instruction Interpretation HOME Label CN 1 Configure the polarity of the home input AC 1000000 Acceleration Rate DC 1000000 Deceleration Rate SP 5000 Speed for Home Search HM Home BG Begin Motion AM After Complete MG AT HOME Send Message DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 77 EN End Figure 6 6 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 HOME SWITCH HMX 0 VELOCITY MOTION BEGINS IN FORWARD DIRECTION gt VELOCITY MOTION CHANGES DIRECTION lt POSITION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD INDEX INDEX PULSES POSITION POSITION Figure 6 6 Homing Sequence for Normally Closed Switch and CN 1 78 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series Example Find Edge EDGE AC 2000000 DC 2000000 SP 8000 FE BG AM MG FOUND HOME DP 0 EN High Speed Position Label Acceleration rate Deceleration rate Speed Find edge command Begin motion After complete Send message Define position as 0 End Capture Often it is desirable to capture the position precisely for registration applications The DMC 141X provides a position latch feature This feature allows the position to be captured in les
82. d as opto input output common See next section for detail The screw terminal for amplifier enable output can be configured as the stepper motor direction output for Y axis for DMC1425 controller This needs to be specified when ordering the controller Please contact Galil for detailed info The screw terminal for ERROR Output can be configured as the stepper motor pulse output for Y axis for DMC 1425 controller This needs to be specified when ordering the controller Please contact Galil for detailed info Appendices e 147 4 The screw terminal for CMP can be configured as input output common for opto isolated I O Please see next section for detail J8 9 Encoder 10pin header 1 Main Encoder A 2 5 VDC NC NC Main encoder B Main encoder I Opto Isolation Option for ICM 1460 rev F and above only The ICM 1460 module from Galil has an option for opto isolated inputs and outputs Any of the following pins can be chosen to be the input output common pin labeled as 12V pin 2 labeled as 12V and pin 13 labeled as CMP ICOM When pin 1 is used as input output common the 12V output be comes inaccessible when pin 2 is used the 12V becomes inaccessible and when pin13 is used the output compare function is not available The common point needs to be specified at the time of ordering The ICM 1460 can also be configured so that the opto common is jumped with Vcc 5V In this case no screw c
83. d depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies the KP proportional and KI integral terms to the position error based on the load encoder and applies the KD derivative term to the motor encoder This method results in a stable system Note It is recommended that the resolution of the rotary encoder be greater than the effective resolution of the load encoder for stability The dual loop method is activated with the instruction DV Dual Velocity where DV 1 activates the dual loop for the four axes and DV O disables the dual loop Note that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if
84. disengaged This disengages the slave axis at a specified master position If the parameter is outside the master cycle the stopping is instantaneous Programmed start and stop can only be used when the master moves forward 64 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series SOOO PR Mn m 1500 eis ots t ea 0 2000 4000 6000 Master X Figure 6 1 Electronic Cam Example To illustrate the complete process consider the cam relationship described by the equation Y 2 0 5 X 100 sin 0 18 X where X is the master with a cycle of 2000 counts The cam table can be constructed manually point by point or automatically by a program The following program includes the set up The cycle of the master is 2000 Over that cycle X varies by 1000 This leads to the instruction EM 1000 2000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18X and X varies in increments of 20 the phase varies by increments of 3 6 The program then computes the values of X according to the equation and assigns the values to the table with the instruction ET N X Instruction Interpretation SETUP Label EM 1000 2000 Cam cycles EP 20 0 Master position increments N 0 Index LOOP Loop to construct table fr
85. duction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30pm ADVANCED MOTION CONTROL WHO SHOULD ATTEND Those who consider themselves a servo specialist and require an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of Motion Control Made Easy or equivalent is required Analysis and design tools as well as several design examples will be provided TIME 8 hours 8 5pm PRODUCT WORKSHOP WHO SHOULD ATTEND Current users of Galil motion controllers Conducted at Galil s headquarters in Rocklin CA students will gain detailed understanding about connecting systems elements system tuning and motion programming This is a hands on seminar and students can test their application on actual hardware and review it with Galil specialists TIME Two days 8 30 5pm 152 e Appendices DMC 1410 1411 1417 Series Contacting Us Galil Motion Control 3750 Atherton Road Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet address www galilmc com DMC 1410 1411 1417 Series Appendices e 153 WARRANTY All products manufactured by Galil Motion Control are warranted against defects in materials and workmanship The warranty period for controller boards is 1 year The warranty period for all other products is 180 days In the event of any defects in materials or workmanship Galil Motion Control will
86. e Examples Input Interrupt Instruction Interpretation A Label A Il Enable input 1 for interrupt function JG 30000 Set speed DMC 1410 1411 1417 Series Chapter 7 Application Programming e 111 BG Begin motion B Label B TP Report position WT 1000 Wait 1000 milliseconds JP EB Jump to EB EN End of program ININT Interrupt subroutine MG Interrupt has occurred Displays the message ST Stops motion LOOP JP LOOP IN 1 0 Loop until Interrupt cleared JG 15000 Specify new speeds WT 300 Wait 300 milliseconds BG Begin motion RI Return from Interrupt subroutine Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal that activates the cutter Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 27 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals
87. e also supported in QNX and LINUX If compatibility with another operating system is desired contact Galil Simplified Communication Procedure for DMC 1417 The following diagram shows the PCI configuration space The I O base address N mentioned in the Communication Registers section is reference in the PCI configuration space at offset 18H IPCI CFG To ensure software compatibility with other versions of PCI 9050 family and to PCI ensure compatibility with future enhancements write 0 to all unused bits Writable Oh DeicD Vendor DN Don status Command Y Y 7 0 lt Z a N Y 46 e Chapter 4 Communication DMC 1410 1411 1417 Series The following information can be used to identify the DMC 1417 controller DEVICE ID VENDOR ID SUBSYSTEM ID SUBSYSTEM VENDOR ID The DMC 1417 is only supported Windows 98 SE ME NT 4 and XP If compatibility with another operating system is desired contact Galil Read Procedure To receive data from the DMC 141X read the status register at address N 1 and check bit 0 If bit 0 is zero the DMC 141X has data to be read in the READ register at address N Bit 0 must be checked for every character read and should be read until it signifies empty Reading data from the READ register when the register is empty will result in reading an FF hex NOTE Failure to ever read the data in the read register will ultimately cause the DMC 141X to hang up once the Read FI
88. e currently being edited For example if the editor is at line number 2 and lt ctrl gt D is applied line 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt ctrl gt Q The lt ctrl gt Q quits the editor mode In response the DMC 141X will return a colon After the Edit session is over the user may list the entered program using the LS command If no operand follows the LS command the entire program will be listed The user can start listing at a specific line or label using the operand n A command and new line number or label following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation LS List entire program LS 5 Begin listing at line 5 LS 5 9 List lines 5 through 9 LS A 9 List line label A through line 9 Program Format A DMC 141X program consists of several DMC 141X instructions combined to solve a machine control application Action instructions such as starting and stopping motion are combined with Program Flow instructions to form the complete program Program Flow instructions evaluate real time conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 141X program instruction must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a 82 e Chapter 7 Application Programming DMC 1410 1411 1417 S
89. e home switch High level causes forward motion The motor will then decelerate to stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP It is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch 40 e Chapter 3 Hardware Interface DMC 1410 1411 1417 Series The Find Index routine is initiated by the command sequence FI lt return gt BG lt return gt Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HM lt return gt BG lt return gt Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detecting the transit
90. e position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner o 1 cos 2xT B X AT B 2 2xT B Note is the angular velocity X is the position and T is the variable time in milliseconds In the given example A 6000 and B 120 the position and velocity profiles are X SOT 6000 27 sin 2x T 120 Note that the velocity in count ms is 50 1 cos 2x T 120 ACCELERATION VELOCITY POSITION Figure 6 3 Velocity Profile with Sinusoidal Acceleration 68 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series The DMC 141X can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X SOT 955 sin 3T A complete program to generate the contour movement in this example is given below To generate an array we compute the position value at intervals of 8 ms This is stored at the array POS Then the difference between the positions is computed and is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example Instruction POINTS DM POS 16 DM DIF 15 C 0 T 0 A V1 50 T V2 3 T V3 955 SIN V2 V1 V4 INT V3 POS C V4 T T 8 C C 1 JP A C lt 16 B C 0 C D C 1 DIF C POS D POS C C C 1 JP C C lt 15 EN RUN CM DT3 C 0 E CD DIF C WC C C 1 JP E C l
91. e stepper motor The installation of the stepper motor jumper is discussed in the following section entitled Installing Jumpers on the DMC 141X Further instructions for stepper motor connections are discussed in Step 7b Step 3 Configuring Jumpers on the DMC 141X Address Jumpers on the DMC 1410 and DMC 1411 The default address of the DMC 1410 and DMC 1411 is 1000 no jumpers installed If the address 1000 is not available i e the operating system has already allocated it to another device Galil recommends using the address 816 or 824 as they is likely to be available Changing the I O address at which the controller resides is a two step process First you must configure the address of the controller card physically using the Address DIP Switches or jumpers located on the card Then you must configure your communications software to use the address that you have selected Configuring the software for a particular address is discussed in Step 5 of this chapter 8 e Chapter 2 Getting Started DMC 1410 1411 1417 Series The DMC 1410 address N is selectable by setting the Address DIP Switches A2 A3 A4 A5 A6 A7 and A8 where each switch represents a digit of the binary number that is equivalent to N minus 512 Switch A2 represents the 2 digit the 3rd binary digit from the right switch A3 represents the 2 digit the 4th binary digit from the right and so on up to the most significant digit which is represented by switch A8 The 2
92. ebile asia ica R 3 System El ments teer p PD ee brain 3 MOO ili ia dei alari diario pev E 3 Amplifier Driver ii eee rie RT ott 4 Encoder ise pen ueteri E e ira to 4 Watch Dose Tamer ei eere He RE ere t ete ri tede ix 4 Chapter 2 Getting Started 5 The DMC 141X Motion Controller eene enne enne en enne nennen nnne 5 Elements Y ou Need teer mee a e ep asia 6 Installing the DMC 1400 Controller i 7 Step 1 Installing the Communications Software eee 7 Step 2 Determine Overall Motor Configuration eee 8 Step 3 Configuring Jumpers on the DMC 141X essen 8 Step 4a Plugging the DMC 1410 or DMC 1417 into the PC esses 10 Step 4b Installing the DMC 1411 on the PC 104 stack eee 10 Step 5 Establishing Communication between the DMC 141X and the host PC 11 Step 6 Make connections to amplifier and encoder sees 25 Step 7a Connect Standard Servo Motor eee 26 Step 7b Connect brushless motors for sinusoidal commutation DMC 1410 1417 only sona 1 ntm eben Pe tede e tee Eee ee 30 Step 7c Connect Step Motors sess nennen nennen rennes 33 Step 8 Tune the Servo System esses nennen nennen nennen rennes 33 Design Examples dte eot ele PE ei ce ee tati ie 34 Example 1 Sy
93. ectronic Gearing This mode allows the main encoder axis to be electronically geared to the auxiliary encoder The master may rotate in both directions and the geared axis will follow at the specified gear ratio The gear ratio may be changed during motion GR specifies the gear ratio for the slave where the ratio may be a number between 127 9999 with a fractional resolution of 0001 GR 0 turns off electronic gearing A limit switch will also disable electronic gearing Electronic gearing allows the geared motor to perform a second independent move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced an additional distance with PR JG or IP commands Command Summary Electronic Gearing Sets gearing mode and gear ratio 0 disables electronic gearing Trippoint for motion past assigned point in reverse direction Trippoint for motion past assigned point in forward direction Example Electronic Gearing Run geared motor at speeds of 1 132 times the speed of an external master hooked to the auxiliary encoder The master motor is driven externally at speeds between 0 and 1800 RPM 2000 counts rev encoder GR 1 132 Specify gear ratio and enable gear mode Now suppose the gear ratio of the slave is to change on the fly to 2 This can be achieved by commanding GR 2 Specify gear ratio for X axis to be 2 Electronic Cam The electronic cam is a motion control mode that en
94. ecution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command hen active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Uncommitted inputs May be defined by the user to trigger events Inputs checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input lis used for the high speed latch High speed position latch to capture axis position in less than 1 usec on occurrence of latch signal AL command arms latch Input 1 is latch Jumpers Label SM A2 A8 MRST OPT IRQS IRQ 9 IRQ 10 IRQ 11 IRQ 12 IRQ 15 Function If jumpered The SM jumper selects the sign magnitude mode for servo motors or selects stepper motors If you are using stepper motors SM must always be jumpered The Analog command is not valid with SM jumpered Seven Dip Switches for Address Selection Please follow silkscreen not switch labels DMC 1410 and 1411 only Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET
95. eedback command a move with the instruction SH lt CR gt Servo Here to turn motors on Chapter 2 Getting Started e 27 PR 1000 lt CR gt Position relative 1000 counts BG lt CR gt Begin motion When the polarity of the feedback is wrong the motor will attempt to run away The controller should disable the motor when the position error exceeds 2000 counts In this case the polarity of the loop must be inverted Inverting the Loop Polarity When the polarity of the feedback is incorrect the user must invert the loop polarity and this may be accomplished by several methods If you are driving a brush type DC motor the simplest way is to invert the two motor wires typically red and black For example switch the M1 and M2 connections going from your amplifier to the motor When driving a brushless motor the polarity reversal may be done with the encoder If you are using a single ended encoder interchange the CHA and CHB signals If on the other hand you are using a differential encoder interchange only CHA and CHA The loop polarity and encoder polarity can also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section NOTE To avoid a run away condition after a master reset it is recommended that the motor wires be physically inverted rather than using the software commands Sometimes the feedback polarity is correct the motor does not at
96. encoder This is called the auxiliary encoder and can be used for dual loop applications The encoder inputs are not isolated All of the encoder signals for the DMC 1410 DMC 1417 and DMC 1411 are accessible through the ICM 1460 or directly from the interface connector on the controller The pin outs of the ICM 1460 and the connectors are explained in the appendix The DMC 141X can interface to incremental encoders of the pulse and direction type instead of two channels in quadrature In that case replace Channel A by the pulse signal and Channel B by the direction and use the CE command to configure the DMC 141X for pulse and direction encoder format For pulse and direction format the DMC 141X provides a resolution of 1X counts per pulse Note that while TTL level signals are common the DMC 141X encoder inputs accept signals in the range of 12V If you are using a non TTL single ended encoder signal no complement to assure proper bias connect a voltage equal to the average signal to the complementary input For example if Channel A varies between 2 and 12V connect 7 volts to Channel A complement input DMC 1410 1411 1417 Series Chapter 3 Hardware Interface e 39 Inputs The DMC 141X provides buffered digital inputs for limit switches homing abort as well as 7 uncommitted inputs The Limit switches Home switch Abort switch and general purpose inputs are all TTL and accessible through the ICM 1460 screw terminals A descrip
97. ent is 10A the amplifier gain should be 1 A V For velocity mode amplifiers a command signal of 10 Volts should run the motor at the maximum required speed For step motors the driver should accept step and direction signals For start up of a step motor system refer to Connecting Step Motors in Step 7c of Installing the DMC 1400 Controller The WSDK software is highly recommended for first time users of the DMC 141X It provides step by step instructions for system connection tuning and analysis Installing the DMC 1400 Controller Installation of a complete operational DMC 141X system consists of 8 steps These steps will be slightly different depending on the exact model of your controller DMC 1410 DMC 1411 or DMC 1417 Step 1 Install the communications software Step 2 Determine overall motor configuration Step 3 Install jumpers on the DMC 141X Step 4a Plug the DMC 1410 or DMC 1417 into the PC OR Step 4b Insert the DMC 1411 into the PC 104 Stack Step 5 Establish communications between the DMC 141X and the host PC Step 6 Make connections to amplifier and encoder Step 7a Connect standard servo motor OR Step 7b Connect step motor Step 8 Tune servo system Step 1 Installing the Communications Software After applying power to the computer you should install the Galil software that enables communication between the controller and PC The CD ROM used for the following installations is Version 11 01
98. eory of Operation e 133 L s M s Kg Kg H s 3 175 106 s2 s 2000 Then the open loop transfer function A s is A s L s G s Now determine the magnitude and phase of L s at the frequency c 500 L j500 3 175 106 500 2 3500 2000 This function has a magnitude of ILG500 1 0 00625 and a phase Arg L j500 180 tan 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that A j500 1 Arg A j500 135 However since A s L s G s then it follows that G s must have magnitude of IGG500 I IA j500 L 500 160 and a phase arg G j500 arg AG500 arg LG500 135 194 59 In other words we need to select a filter function G s of the form G s x P sD so that at the frequency c 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as 16 j500 I IP 05000 160 and arg G j500 tan1 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 2 Therefore D 0 274 and G 82 4 0 2745 The function G is equivalent to a digital filter of the form D z 4 KP 4 KD 1 z l 134 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series where KP P 4 and KD D 4T Assuming a sampling period of T 1ms the parameters of the digital filter are KP 20 6 KD 68
99. ep directions on servo system setup are also included on the WSDK Windows Servo Design Kit software offered by Galil See section on WSDK for more details 26 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Check the Polarity of the Feedback Loop It is assumed that the motor and amplifier are connected together and that the encoder is operating correctly Step D Before connecting the motor amplifiers to the controller read the following discussion on setting Error Limits and Torque Limits Step A Step B Step C Step D DMC 1410 1411 1417 Series Set the Error Limit as a Safety Precaution Usually there is uncertainty about the correct polarity of the feedback The wrong polarity causes the motor to run away from the starting position Using a terminal program such as DMCTERM the following parameters can be given to avoid system damage Input the commands ER 2000 lt CR gt Sets error limit to be 2000 counts OE 1 CR Disables amplifier when excess error exists If the motor runs away and creates a position error of 2000 counts the motor amplifier will be disabled Note This function requires the AEN signal to be connected from the controller to the amplifier Setting Torque Limit as a Safety Precaution To limit the maximum voltage signal to your amplifier the DMC 141X controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid exce
100. er 7 Application Programming e 105 Numeric data may be formatted using the Fn m expression following the completed MG statement n m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is RESULT F5 2 If the value of the variable RESULT is equal to 4 1 this statement returns the following The Final Value is 00004 10 If the value of the variable RESULT is equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppressed by sending N at the end of the statement This is useful when a text string needs to surround a numeric value Example A JG 50000 BG AS MG The Speed is TV F5 1 N MG counts sec EN When A is executed the above example will appear on the screen as The speed is 50000 counts sec Using the MG Command to Configure Terminals The MG command can also be used to configure a terminal Any ASCII character can be sent by using the format n where n is any integer between 1 255 Example MG 407 4255 sends the ASCII characters represented by 7 and 255 to the bus Summary of Message Functions Funct
101. er motor is not possible Command Summary Stepper Motor Operation be Derine Encoder Reson When ing mene DP pete Reference Poston and Step Conn Reiter fir Moon Snooting Idependent Time Conn Ss eed DE IT i KS Operand Summary Stepper Motor Operation OPERAND DESCRIPTION Contains the value of the step count register 72 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series pps Contains the value of the main encoder Contains the value of the Independent Time constant for the x axis Contains the value of the Stepper Motor Smoothing Constant for the x axis Contains the motor type value for the x axis Contains the commanded position generated by the profiler Contains the value of the step count register Contains the value of the main encoder Dual Loop Auxiliary Encoder The DMC 141X provides an interface for a second encoder except when the controller is configured for stepper motor operation When used the second encoder is typically mounted on the motor or the load but may be mounted in any position The most common use for the second encoder is backlash compensation described below The second encoder may be of the standard quadrature type or it may be of the pulse and direction type The controller also offers the provision for inverting the direction of the encoder rotation The main and auxiliary encoders are configured with the CE command The com
102. er normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements Command Summary Program Flow MC Trigger In position trigger TW sets timeout for in position Event Triggers amp Trippoints To function independently from the host computer the DMC 141X can be programmed to make decisions based on the occurrence of an event Such events include waiting for motion to be complete waiting for a specified amount of time to elapse or waiting for an input to change logic levels The DMC 141X provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the DMC 141X can make decisions based on its own status or external events without intervention from a host computer DMC 141X Event Triggers Command mman Command sid Halts program execution until the LC motion is complete Halts program execution until position c
103. erator is a Logical Or These operators allow for bit wise operations on any valid DMC 141X numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value that is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The characters can be individually separated by using bit wise operations as illustrated in the following example Instruction Interpretation TEST Begin main program IN ENTER LEN S6 Input character string of up to 6 characters into variable LEN FLEN FRAC LEN Define variable FLEN as fractional part of variable LEN FLEN 10000 FLEN Shift FLEN by 32 bits IE convert fraction FLEN to integer LEN1 FLEN amp 00FF Mask top byte of FLEN and set this value to variable LEN2 FLEN amp FF00 100 Let variable LEN2 top byte of FLEN LEN3 LEN amp 000000FF Let variable LEN3 bo
104. eries single program line where the maximum number of instructions on a line is limited by 40 characters A carriage return enters the final command on a program line Using Labels in Programs All DMC 141X programs must begin with a label and end with an End EN statement Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted The maximum number of defined labels is 126 Valid labels BEGIN SQUARE X1 BEGINI Invalid labels 1Square 123 Example Program Instruction Interpretation START Beginning of the Program PR 10000 Specify relative distances BG Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves the motor 10000 After the motion is complete the motor rests for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 141X also has some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines The following table lists the automatic subroutines supported by the controller Sample programs for these subroutines can be found in the section Automatic Subroutines for Monitoring Conditions ININT Label for Input Interrupt subroutine LIMSWI Label for Limit Switch subroutine MCTIME La
105. es the Amplifier Enable Output AEN that can be used to switch the amplifiers off in the event of a serious DMC 141X failure The AEN output is normally high During power up and if the microprocessor ceases to function properly the AEN output will go low The error light for each axis will also turn on at this stage A reset is required to restore the DMC 141X to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 141X is damaged 4 e Chapter 1 Overview DMC 1410 1411 1417 Series Chapter 2 Getting Started The DMC 141X Motion Controller c3 JP1 Ei i 3 JP4 La Do JP3 Figure 2 1 Outline of the DMC 1410 J3 J3 JP4 JP1 3 2 5 6 1 JP3 JP5 Figure 2 2 Outline of the 1411 DMC 1410 1411 1417 Series Chapter 2 Getting Started e 5 B tpe Figure 2 3 Outline of the DMC 1417 DMC 141X Firmware ROM Labeled with EEPROM for program parameter storage firmware revision number i e DMC 141X Rev 2 0a 2 Motorola 68331 microprocessor 40 Pin Ribbon connection for controller signal break out DMC 1411 37 Pin D connection for controller signal break out DMC 1410 1417 GL 1800 custom gate array JP1 Master Reset la Address Dip Switches DMC 1410 Jumpers for setting interrupt IRQ line Error LED JP4 J
106. esn t apply to the DMC 1417 Application program stopped 48 e Chapter 4 Communication DMC 1410 1411 1417 Series User interrupt Watchdog Limit switch Motion complete Example Interrupts Send User Interrupt when at speed Instruction Interpretation 1 Label PR 1000 Position SP 5000 Speed BG Begin AS At speed UI Send interrupt EN End This program sends an interrupt when the axis has reached its slew speed IV clears the interrupt and re enables Controller Response to DATA Most DMC 141X instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon Instructions are sent in ASCII and the DMC 141X decodes each ASCII character one byte one at a time It takes approximately 5 msec for the controller to decode each command After the instruction is decoded the DMC 141X returns a colon if the instruction was valid or a question mark if the instruction was not valid or was not recognized For instructions requiring data such at Tell Position TP the DMC 141X will return the data followed by a carriage return line feed and It is good practice to check for after each command is sent to prevent errors An echo function is provided to enable associating the DMC 141X response with the data sent The echo is enabled by sending the command EO to the controller Galil Software Tools and Libraries API
107. ess into place Secure board to stand offs with screws Qu X di Insert 40 pin ribbon to J3 Make sure pin 1 is oriented properly 10 e Chapter 2 Getting Started DMC 1410 1411 1417 Series 7 Power up PC Step 5 Establishing Communication between the DMC 141X and the host PC Using Galil Software for DOS DMC 1410 and DMC 1411 only To communicate with the DMC 141X type DMCTERM at the prompt You will need to provide information about your controller such as controller type DMC 1410 DMC 1411 address and IRQ Once you have established communication the terminal display should show colon If you do not receive a colon press the carriage return If you still do not received a colon and are using the DMC 1410 or DMC 1411 the most likely cause is an address conflict in your computer If the default of address 1000 causes a conflict Galil recommends the addresses of 816 and 824 since they are likely to avoid conflict Please refer to the section Changing the I O Address of the DMC 1410 and DMC 1411 to change the address Using Galil Software for Windows 3 x 95 and 98 First Edition DMC 1410 and DMC 1411 only In order for the Windows software to communicate with a Galil controller the controller must be registered in the Windows Registry To register a controller you must specify the model of the controller the communication parameters and other information The registry is accessed through the Galil s
108. everal commands that allow the DMC 141X to make its own decisions These commands include conditional jumps event triggers and subroutines For example the command JP LOOP n lt 10 causes a jump to the label LOOP if the variable n is less than 10 For greater programming flexibility the DMC 141X provides 126 user defined variables arrays and arithmetic functions For example the length in a cut to length operation can be specified as a variable in a program and then be assigned by an operator The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 250 lines X 40 characters Using the DMC 141X Editor to Enter Programs The DMC 141X has an internal editor which may be used to create and edit programs in the controller s memory The internal editor is opened by the command ED Note that the command ED will not open the internal editor if issued from Galil s Window based software in this case a Windows based editor will be automatically opened The Windows based editor provides much more functionality and ease of use therefore the internal editor is most useful when using a simple terminal with the controller and a Windows based editor is not available In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If des
109. for Inputting Numeric Data A IN Enter Length LENX EN In this example the message Enter Length is displayed on the computer screen The controller waits for the operator to enter a value The operator enters the numeric value that is assigned to the variable LENX Cut to Length Example In this example a length of material is to be advanced a specified distance When the motion is complete a cutting head is activated to cut the material The length is variable and the operator is prompted to input it in inches Motion starts with a start button that is connected to input 1 The load is coupled with a 2 pitch lead screw A 2000 count rev encoder is on the motor resulting in a resolution of 4000 counts inch The program below uses the variable LEN to length The IN command is used to prompt the operator to enter the length and the entered value is assigned to the variable LEN Instruction Interpretation BEGIN LABEL AC 800000 Acceleration 104 e Chapter 7 Application Programming DMC 1410 1411 1417 Series DC 800000 Deceleration SP 5000 Speed LEN 3 4 Initial length in inches CUT Cut routine All Wait for start signal IN Enter Length IN LEN Prompt operator for length in inches PR LEN 4000 Specify position in counts BG Begin motion to move material AM Wait for motion done SB1 Set output to cut WT100 CB1 Wait 100 msec then turn off cutter JP CUT Repeat process EN End program Inputting String Variables
110. gnal is low this indicates one of the following error conditions 1 Atleastone axis has a position error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal DMC 1410 1411 1417 Series Chapter 8 Error Handling e 115 Input Protection Lines Abort A low input stops commanded motion instantly without a controller deceleration Any motion program currently running will also be stopped When the Off On Error function is enabled the amplifiers will be disabled This could cause the motor to coast to a stop If the Off On Error function is not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in this chapter Forward Limit Switch Low input inhibits motion in forward direction If the motor is moving in the forward direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches To query the state of a Forward Limit Switch type MG_LFx w
111. he motor This signal is labeled AMPEN on the ICM 1460 and should be connected to the enable signal on the amplifier Note that many amplifiers designate this signal as the INHIBIT signal Use the command MO to disable the motor amplifiers check to insure that the motor amplifiers have been disabled often this is indicated by an LED on the amplifier This signal changes under the following conditions the watchdog timer activates the motor off command MO is given or the OE1 command Enable Off On Error is given and the position error exceeds the error limit or an abort is issued As shown in Figure 3 1 AEN can be used to disable the amplifier for these conditions The standard configuration of the AEN signal is TTL active high In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed if you are using the ICM 1460 interface board To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AEN signal note the state of jumper at location JP1 on the ICM 1460 When a jumper is placed across AEN and SV the output voltage is 0 5V To change to 12 volts pull the jumper and rotate it so that AEN is connected to 12V If you remove the jumper t
112. he output signal is an open collector allowing the user to connect an external supply with voltages up to 24V DMC 1410 1411 1417 Series Chapter 2 Getting Started e 25 Step C Connect the encoders For stepper motor operation an encoder is optional For servo motor operation if you have a preferred definition of the forward and reverse directions make sure that the encoder wiring is consistent with that definition The DMC 141X accepts single ended or differential encoder feedback with or without an index pulse If you are not using the AMP 1460 or the ICM 1460 you will need to consult the appendix for the encoder pinouts for connection to the motion controller The AMP 1460 and the ICM 1460 can accept encoder feedback from a 10 pin ribbon cable or individual signal leads For a 10 pin ribbon cable encoder connect the cable to the protected header connector labeled JP2 For individual wires simply match the leads from the encoder you are using to the encoder feedback inputs on the interconnect board The signal leads are labeled CHA CHB and INDEX These labels represent channel A channel B and the INDEX pulse respectively For differential encoders the complement signals are labeled CHA CHB and INDEX Note When using pulse and direction encoders the pulse signal is connected to CHA and the direction signal is connected to CHB The controller must be configured for pulse and direction with the command CE See the command summa
113. he polarity of the limit switches Limit Switch Example Instruction A JP A EN LIMSWI 1 V2 LR JP LF V1 0 JP LR V2 0 JP END ALF MG FORWARD LIMIT ST AM PR 1000 BG AM JP END LR MG REVERSE LIMIT ST AM PR1000 BG AM END RE Interpretation Dummy Program Limit Switch Utility Check if forward limit Check if reverse limit Jump to LF if forward Jump to RF if reverse Jump to end LF Send message Stop motion Move in reverse End LR Send message Stop motion Move forward End Return to main program NOTE An applications program must be executing for LIMSWI to function 118 e Chapter 8 Error Handling DMC 1410 1411 1417 Series Chapter 9 Troubleshooting Overview The following discussion helps with getting the system to work For your convenience the potential problems have been divided into groups as follows 1 Installation 2 Communication 3 Stability and Compensation 4 Operation The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM DIAGNOSIS CAUSE REMEDY Motor runs away with no connections from controller to amplifier input Motor is enabled even when MO command is given Unable to read the auxiliary encoders Unable to read main or auxiliary encoder input DMC 1410 1411 1417 Series Adjusting offset causes the motor to change speed The SH command disables the motor No auxiliary e
114. here x is the specified axis Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches To query the state of a Reverse Limit Switch type MG_LRx where x is the specified axis Software Protection The DMC 141X provides a programmable error limit The error limit can be set for any number between 1 and 32767 using the ER n command The default value for ER is 16384 Example ER 200 Set error limit for 200 The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position If the absolute value of the error exceeds the value specified by ER the DMC 141X will generate several signals to warn the host system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 AEN Output Line Goes low The Jump on Condition statement is useful for branching on a given error within a program The position error can be monitored during execution using
115. his movement is instantaneous and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The applied voltage will typically be sufficient for proper operation of the BZ command For systems with significant friction this voltage may need to be increased and for systems with very small motors this value should be decreased For example BZ 2 CR will drive the axis to zero using a 2V signal The controller will then leave the motor enabled For systems that have external forces working against the motor such as gravity the BZ argument must provide a torque 10x the external force If the torque is not sufficient the commutation zero may not be accurate If Hall Sensors are Available The estimated value of the commutation phase is good to within 30 This estimate can be used to drive the motor but a more accurate estimate is needed for efficient motor operation There are 3 possible methods for commutation phase initialization Method 1 Use the BZ command as described above Method 2 Drive the motor close to commutation phase of zero and then use BZ command This method decreases the amount of system jerk by moving the motor close to zero commutation phase before executing the BZ command The controller makes an estimate for the number of encoder counts between the current position and the position of zero commutation phase This value is stored in the operand _BZx Using this operand the controlle
116. his reference is connected to the Home input line The HM command initializes the motor to the encoder index pulse in addition to the Home input The configure command CN is used to define the polarity of the home input The Find Edge FE instruction is useful for initializing the motor to a home switch The home switch is connected to the Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew speed and slew until a transition is detected on the Homing line The motor will then decelerate to a stop A high deceleration value must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch The Home HM command can be used to position the motor on the index pulse after the home switch is detected This allows for finer positioning on initialization The HM command and BG command causes the following sequence of events to occur Stage 1 Upon begin the motor accelerates to the slew speed specified by the JG or SP commands The direction of its motion is determined by the state of the homing input If _HMX reads 1 76 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series initially the motor will go in the reverse direction first direction of decreasing encoder counts If HMX reads 0 initially the motor will go in the forward direction first CN is the command used to define the polarity of the home input With CN 1 the default value a norm
117. his window the user can type in the following program Instruction Interpretation A Define label PR 700 Distance SP 2000 Speed BG Start motion EN End program This program can be downloaded to the controller by selecting the File menu option download Once this is done close the editor 36 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Now the program may be executed with the command XQ Start the program running Example 10 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction FA V1 1000 Loop PA VI BG AM WT 500 TP VI V1 1000 JP Loop V1 lt 10001 EN Interpretation Label Define current position as zero Set initial value of V1 Label for loop Move motor V1 counts Start motion After motion is complete Wait 500 ms Tell position Increase the value of V1 Repeat if V1 lt 10001 End After the above program is entered quit the Editor Mode lt ctrl gt Q To start the motion command XQ A Execute Program A Example 11 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction B DP PR 30000 SP 5000 BG AD 4000 TP EN Interpretation Label Define initial position Set target Set speed Start motion Wait until X moved 4000 Tell position End program To start the program command XQ B Execute Program B Example 12 Control Variables Objecti
118. id Variable Names POSX POSI SPEEDZ Invalid Variable Names REALLONGNAME Cannot have more than 8 characters 123 Cannot begin variable name with number SPEED 7 Cannot have spaces in the name Assigning Values to Variables Assigned values can be numbers internal variables and keywords functions controller parameters and strings The range for numeric variable values is 4 bytes of integer l followed by two bytes of fraction 2 147 483 647 9999 Numeric values can be assigned to programmable variables using the equal sign Any valid DMC 141X function can be used to assign a value to a variable For example V1 ABS V2 or V2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters that must be in quotation Example POSX TP Assigns returned value from TP command to variable POSX SPEED 5 75 Assigns value 5 75 to variable SPEED INPUT IN 2 Assigns logical value of input 2 to variable INPUT V2 V1 V3 V4 Assigns the value of V1 plus V3 times V4 to the variable V2 VAR CAT Assign the string CAT to VAR Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as PR or SP PR V1 Assign V1 to PR command SP VS 2000 Assign VS 2000 to SP command Displaying the Value of Variables at the Terminal Variables may be sent to the screen using the format variable For ex
119. ide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Step motors with step and direction signals 3 Other actuators such as hydraulics For more information contact Galil The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motors with 10 Volt Command Signal The DMC 141X achieves superior precision through the use of a 16 bit motor command output DAC anda sophisticated PID filter that features velocity and acceleration feedforward and integration and torque limits The controller is configured at the factory for standard servo motor operation In this configuration the controller provides an analog signal 10 volt to connect to a servo amplifier This connection is described in Chapter 2 Stepper Motor with Step and Direction Signals The DMC 141X can control stepper motors In this mode the controller provides two signals to connect to the stepper motor Step and Direction For stepper motor operation the controller does not require an encoder and operates the stepper motor in an open loop fashion Chapter 2 describes the proper connection and procedure for using stepper motors DMC 1400 Functional Elements The DMC 141X circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed below To Host 256 Byte Communication FIFO ELLE QN Amplifier 68
120. in recording 4 msec interval Continue until done recording Compute DX Dimension Array for DX Initialize counter Label Compute the difference Store difference in array Increment index Repeat until done Begin Playback Specify contour mode Specify time increment Initialize array counter Loop counter Specify contour data I I 1 Increment array counter JP B I lt 500 Loop until done End contour mode End program For additional information about automatic array capture see Chapter 7 Arrays 70 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation In order to command stepper motor operation the appropriate stepper mode jumpers must be installed See chapter 2 for this installation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step output pulses 2 5 specifies a stepper motor with active low step output pulses and reversed direction 2 5 specifies a stepper motor with active high step output pulse and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought
121. information for your controller Select OK and close the registry window You will now be able to communicate with the DMC 141X Once the entry has been selected click on the OK button If the software has successfully established communications with the controller the registry entry will be displayed at the top of the screen If you are not properly communicating with the controller the program will pause for 3 15 seconds The top of the screen will display the message Status not connected with Galil motion controller and the following error will appear STOP Unable to establish communication with the Galil controller A time out occurred while waiting for a response from the Galil controller If this message appears you must click OK In this case there is most likely an address conflict DMC 1410 1411 1417 Series Chapter 2 Getting Started e 11 If you receive this error and are using the DMC 1410 or DMC 1411 the most likely cause is an address conflict in your computer If the default of address 1000 causes a conflict Galil recommends the addresses of 816 and 824 since they are likely to avoid conflict Please refer to the section Changing the I O Address of the DMC 1410 and DMC 1411 to change the address Once you establish communications click on the menu for terminal and you will receive a colon prompt Communicating with the controller is described in later sections Using Galil Software for Windows 98 SE ME XP and 2000
122. information should be changed as necessary to reflect any changes to the controller s address jumpers Hardware interrupts may also be set in the registry although for initial communication these are not necessary The default interrupt selection is None DMC 1410 1411 1417 Series Chapter 2 Getting Started e 23 ISA Bus Parameters 10 Port Address Interrupt Line None Data Record Access e x DME Game M Data Record Keresh Hate dg lt Back Cancel Once the appropriate Registry information has been entered Select and close the registry window After rebooting the computer communication to the DMC 1410 or 1411 card can be established Reopen one of the communication programs and select the controller from the registry list If there are communication problems the program will pause for 3 15 seconds The top of the dialog box will display the message Status not connected with Galil motion controller and the following error will appear STOP Unable to establish communication with the Galil controller A time out occurred while waiting for a response from the Galil controller If this error occurs in Windows NT 4 the most likely cause is an address conflict in the computer If the default of address 1000 causes a conflict Galil recommends the addresses of 816 and 824 since they are likely to avoid conflict Please refer to Step 3 Configuring Jumpers on the DMC 141x to change
123. input 6 is low Example Start Motion on Switch Motor X must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor X must stop turning Solution Connect panel switch to input 1 of DMC 141X High on input 1 means switch is in on position Instruction Function S JG 4000 Set speed AI 1 BG Begin after input 1 goes high AI 1 ST Stop after input 1 goes low AM JP 5 After motion repeat EN Input Interrupt Function The DMC 141X provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the II m n o command The m specifies the beginning input and n specifies the final input in the range The parameter o is an integer that represents a binary range of inputs For example if inputs 1 and 3 want to be used for the input interrupt function then the corresponding value of o is 2242 or 5 A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RI command is used to return from this subroutine to the place in the program where the interrupt had occurred If it is desired to return to somewhere else in the program after the execution of the ININT subroutine the Zero Stack ZS command is used followed by unconditional jump statements IMPORTANT Use the RI instruction not EN to return from the ININT subroutin
124. ion Description MG Message command un Surrounds text string Fn m Formats numeric values in decimal n digits to the right of the decimal point and m digits to the left n m Formats numeric values in hexadecimal An Sends ASCII character specified by integer n N Suppresses carriage return line feed Sn Sends the first n characters of a string variable where n is 1 through 6 Displaying Variables and Arrays Variables may also be sent to the screen using the format variable or array x For example V returns the value of the variable V1 106 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Example Printing a Variable and an array element Instruction Interpretation DISPLAY Label PR 1000 Position Command BG Begin AM After Motion V1 _TP Assign Variable V1 Vl Print V1 EN End Interrogation Commands The DMC 141x has a set of commands that directly interrogate the controller When these commands are entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF and Leading Zeros LZ command For a complete description of interrogation commands see Chapter 5 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by theses interrogation commands BL LE DE PA DP PR EM TN FL
125. ion in the logic state on the Home Input the motor will decelerate to a stop at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of 256 counts sec When the logic state changes again the motor moves forward in the direction of increasing encoder count at the same speed until the controller senses the index pulse After detection it decelerates to a stop and defines this position as 0 The logic state of the Home input can be interrogated with the command MG HM This command returns a O or 1 if the logic state is low or high respectively The state of the Home input can also be interrogated indirectly with the TS command For examples and further information about Homing see command HM FI FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state NOTE The response of the abort input is significantly different from the response of an activated limit switch When the abort input is activated the controller stops generating motion commands immediately whereas the limit switch response causes the controller to make a decelerated stop NOTE The effect of an Abort input is dependent on the state of the off on error function for each axis If the Off On Error function
126. ired the user can edit a specific line number or label by specifying a line number or label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN DMC 1410 1411 1417 Series Chapter 7 Application Programming e 81 Line numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 40 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below Edit Mode Commands lt RETURN gt Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of lt RETURN gt will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a lt return gt is given lt ctrl gt P The lt ctrl gt P command moves the editor to the previous line lt ctrl gt I The lt ctrl gt I command inserts a line above the current line For example if the editor is at line number 2 and lt ctrl gt I is applied a new line will be inserted between lines 1 and 2 This new line will be labeled line 2 The old line number 2 is renumbered as line 3 lt ctrl gt D The lt ctrl gt D command deletes the lin
127. is prepared to execute a new motion command However when operating in stepper mode the controller may still be generating step pulses when the motion profiler is complete This is caused by the stepper motor smoothing filter KS To understand this consider the steps the controller executes to generate step pulses First the controller generates a motion profile in accordance with the motion commands Second the profiler generates pulses as prescribed by the motion profile The pulses that are generated by the motion profiler can be monitored by the command RP Reference Position RP gives the absolute value of the position as determined by the motion profiler The command DP can be used to set the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Third the output of the motion profiler is filtered by the stepper smoothing filter This filter adds a delay in the output of the stepper motor pulses The amount of delay depends on the parameter which is specified by the command KS As mentioned earlier there will always be some amount DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 71 of stepper motor smoothing The default value for KS is 2 which corresponds to a time constant of 6 sample periods Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver The pulses which are generated by the smoothing filter c
128. least significant rightmost digits are not represented A switch in the ON position means the value of the digit represented by that switch is 0 if the switch is in the OFF position the digit is 1 The same process is used for the DMC 1411 except this card uses jumpers for setting the address These jumpers located at JP5 are represented by a 1 with a jumper on and a 0 with the jumper removed Because the least significant digit represented by the Address DIP Switches or jumpers is the 2 digit A2 only addresses divisible by 4 are configurable on the controller The controller can be configured for any 4th address between 512 and 1024 See Appendix A for a complete list of DIP switch or jumper settings corresponding to all configurable addresses between 512 and 1024 This is in the table entitled Dip Switch and Jumper Address Settings To configure an address you must do the following Step 1 Select an address N between 512 and 1024 divisible by 4 Example 516 Step 2 Subtract 512 from N Example 516 512 4 Step 3 Convert the resultant number into a 9 digit binary number being sure to represent all leading zeros Using our example Converting 4 to binary results in 100 As a 9 digit binary number this is represented by 000000100 Step 4 Truncate the 2 least significant rightmost digits Example 0000001 Step 5 Set the Address DIP Switches as described above Note that the dip switch is marked with an On
129. m sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of the LIMSWI routine Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 141X program sequences The DMC 141X can monitor several important conditions in the background These conditions include checking for the occurrence of a limit switch a defined input position error or a command error Automatic monitoring is enabled by inserting a special predefined label in the application program The pre defined labels are LIMSWI Limit switch on any axis goes low ININT Input specified by II goes low POSERR Position error exceeds limit specified by ER MCTIME Motion Complete timeout occurred CMDERR Bad command given For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the POSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt subroutine When the specified input occurs the program will be executed automatically NOTE An application program must be running for automatic monitoring to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the HLIMSWI routine to function the DMC 141X
130. mand form is CE x where x equals the sum of n and m below Normal quadrature Normal quadrature Pulse amp direction Pulse amp direction Reverse quadrature Reversed quadrature Reverse pulse amp direction Reversed pulse amp direction For example to configure the main encoder for reversed quadrature m 2 and a second encoder of pulse and direction n 4 the total is 6 and the command is CE 6 Additional Commands for the Auxiliary Encoder The DE command can be used to define the position of the auxiliary encoders For example DEO sets the initial value The positions of the auxiliary encoders may be interrogated with DE For example DE returns the value of the auxiliary encoder The auxiliary encoder position may be assigned to variables with the instructions V1 DE The current position of the auxiliary encoder may also be interrogated with the TD command Backlash Compensation The dual loop methods can be used for backlash compensation This can be done by two approaches DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 73 1 Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning an
131. marking In this case ON 0 and OFF 1 The same process can be used for the DMC 1411 address jumpers with a jumper on equal to 1 and jumper off equal to a 0 Example See following illustration Master Reset Jumpers The jumper JP1 is the Master Reset jumper When the MRST jumper is connected the controller will perform a master reset upon PC power up This jumper is located at JP1 for the DMC 1410 1411 and 1417 Whenever the controller has a master reset all motion control parameters stored in EEPROM will be ERASED DMC 1410 1411 1417 Series Chapter 2 Getting Started e 9 Stepper Motor Jumpers If the DMC 1410 1417 will be driving a stepper motor the stepper mode SM jumper must be connected This jumper is labeled JP4 Do not jumper off OPT for the DMC 1410 1417 The jumper location marked OPT or MO is for use by Galil technicians only If you are using a DMC 1411 for a stepper motor install jumper on OPT only and leave SMX open Note On hardware Rev C and earlier of the DMC 1411 the silkscreen for JP4 is labeled incorrectly The jumper that is labeled OPT is actually the stepper mode jumper and the jumper labeled SM is for use by Galil technicians only Setting the Optional Interrupt Line on the DMC 1410 and DMC 1411 IRQ jumpers are not necessary for communication with the Galil controllers Rather they are an option that may be used for notifying the PC of events that occur on the motion controller The selectable IRQ jumpe
132. me Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter This section describes the DMC 141X instruction set and syntax A complete listing of all DMC 141X instructions is included in the command reference section Command Syntax DMC 141X instructions are represented by two ASCII upper case characters followed by applicable arguments A space may be inserted between the instruction and arguments A semicolon or lt enter gt is used to terminate the instruction for processing by the DMC 141X command interpreter Note If you are using a Galil terminal program commands will not be processed until an lt enter gt command is given This allows the user to separate many commands on a single line and not begin execution until the user gives the lt enter gt command IMPORTANT All DMC 141X commands are sent in upper case For example the command PR 4000 lt enter gt Position relative PR is the two character instruction for position relative 4000 is the argument that represents the required position value in counts The lt enter gt terminates the instruction The space between PR and 4000 is optional To view the current values for each command specify the command followed by a Example Syntax for Specifying Data PR 1000 Specify as 1000 PR Interrogate value in PR register DMC 1410 1411 1417 Series Chapter 5 Programming Basics e 51 Controller Re
133. mit The magnitude of the motor command may be limited independently by the instruction TL The following program illustrates that effect Instruction Interpretation TL 0 2 Set output limit to 0 2 volts JG 10000 Set speed BG Start motion The motor will probably not move as the output signal is not sufficient to overcome the friction If the motion starts it can be stopped easily by a touch of a finger Increase the torque level gradually by instructions such as TL 1 0 Increase torque limit to 1 volt TL 9 98 Increase torque limit to maximum 9 98 Volts The maximum level of 10 volts provides the full output torque Example 7 Interrogation The values of the parameters may be interrogated using a For example the instruction KP Return gain The same procedure applies to other parameters such as KI KD FA etc Example 8 Operation in the Buffer Mode The instructions may be buffered before execution as shown below Instruction Interpretation PR 600000 Distance SP 10000 Speed WT 10000 Wait 10000 milliseconds before reading the next instruction BG Start the motion Example 9 Motion Programs Motion programs may be edited and stored in the memory They may be executed at a later time The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited For example in response to the first ED command the Galil Windows software will open a simple editor window From t
134. mmand is given BG the motor accelerates up to speed and continues to jog at that speed until a new speed or stop ST command is issued If the jog speed is changed during motion the controller will make an accelerated or decelerated change to the new speed An instant change to the motor position can be made with the use of the IP command Upon receiving this command the controller commands the motor to a position which is equal to the specified increment plus the current position This command is useful when trying to synchronize the position of two motors while they are moving Note that the controller operates as a closed loop position controller while in the jog mode The DMC 141X converts the velocity profile into a position trajectory where a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging Time constant for independent motion smoothing Increments position instantly Operand Summary Jogging Return acceleration rate Return deceleration rate DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 61 returns the actual velocity of the axis averaged over 25 sec Example Jog in X only Jog motor at 50000 count s A AC 20000 Specify acceleration as 20000 counts sec DC 20000 Specify deceleration as 20000 counts sec JG 50000 Specify speed and direction as 50000 counts sec BG Begin motion EN El
135. ncoder inputs are working The encoder does not work when swapped with another encoder input 1 Amplifier has an internal offset 2 Damaged amplifier 1 The amplifier requires the LAEN option on the Interconnect Module 1 Auxiliary Encoder Cable is not connected 1 Wrong encoder connections 2 Encoder is damaged 3 Encoder configuration incorrect Adjust amplifier offset Amplifier offset may also be compensated by use of the offset configuration on the controller see the OF command Replace amplifier Contact Galil Connect Auxiliary Encoder cable Check encoder wiring For single ended encoders CHA and CHB only do not make any connections to the CHA and CHB inputs Replace encoder Check CE command Chapter 9 Troubleshooting e 119 Unable to read main or The encoder works 1 Wrong encoder Check encoder wiring For single auxiliary encoder input correctly when swapped connections ended encoders CHA and CHB with another encoder input only do not make any connections 2 Encoder to the CHA and CHB inputs configuration incorrect Check CE command 3 Encoder input or Contact Galil controller is damaged Encoder Position Drifts Swapping cables fixes the 1 Poor Connections Review all terminal connections problem intermittent cable and connector contacts Encoder Position Drifts Significant noise can be 1 Noise Shield encoder cables seen on CHA and or CHB Avoid placing po
136. nd DAC on the controller and is brought out on the ICM 1460 at pin 38 ACMD2 It is not necessary to be concerned with cross wiring the 1 and 2 signals If this wiring is incorrect the setup procedure will alert the user Step D 30 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Step C Specify the Size of the Magnetic Cycle Use the command BM to specify the size of the brushless motors magnetic cycle in encoder counts For example if you are using a linear motor where the magnetic cycle length is 62 mm and the encoder resolution is 1 micron the cycle equals 62 000 counts This can be commanded with the command BM 62000 lt CR gt On the other hand if you are using a rotary motor with 4000 counts per revolution and 3 magnetic cycles per revolution three pole pairs the command is BM 1333 333 lt CR gt Step D Test the Polarity of the DACs and Hall Sensor Configuration Use the brushless motor setup command BS to test the polarity of the output DACs This command applies a certain voltage V to each phase for some time T and checks to see if the motion is in the correct direction The user must specify the value for V and T For example the command BS 2 700 lt CR gt will test the brushless axis with a voltage of 2 volts applying it for 700 millisecond for each phase In response this test indicates whether the DAC wiring is correct and will indicate an approximate value of BM If the wiring is correct
137. necessary Sampled Dual Loop Example In this example we consider a linear slide that is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it is best to use a rotary encoder on the motor Connect the rotary encoder to the main encoders input and connect the linear encoder to the auxiliary encoder input Let the required motion distance be one inch and assume that this corresponds to 40 000 counts of the rotary encoder and 10 000 counts of the linear encoder The design approach is to drive the motor a distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program Instruction Interpretation DUALOOP Label CE0 Configure encoder DEO Set initial value PR 40000 Main move 74 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series BG Start motion Correct Correction loop AM Wait for motion completion V1 10000 _DE Find linear encoder error V2 _TE 4 V1 Compensate for motor error JP END ABS V2 lt 2 Exit if error is small PR V2 4 Correction move BG Start correction JP Correct Repeat END EN Motion Smoothing The DMC 141X controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system Trapezoidal velocit
138. nventional amplifier that accepts a 10 Volt analog signal this pin is not used and should be left open The switching frequency is 16 7 kHz The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM signal is 2 duty cycle for full negative voltage 50 for 0 Voltage and 99 8 for full positive voltage In the Sign Magnitude Mode Jumper SM the PWM signal is 0 for O Voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output For step motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Upon Reset the output will be low if the SM jumper is on If the SM jumper is not on the output will be Tri state Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER These 3 TTL outputs are uncommitted and may be designated by the user to toggle relays and trigger external events The output lines are toggled by Set Bit SB and Clear Bit CB instructions The OP instruction is used to define the state of all the bits of the Output port INPUTS Main Encoder Index Main Encoder A B Aux Encoder A B A B Abort input Reset input Main Encoder A B Po
139. oftware such as WSDK and DTERM DTERM is installed with DMCWIN and installed as the icon Galil Terminal From WSDK the registry is accessed under the FILE menu From the DTERM program the registry is accessed from the REGISTRY menu The registry window is equipped with buttons to Add Change or Delete a controller Pressing any of these buttons will bring up the Set Registry Information window Use the Add button to add a new entry to the Registry You will need to supply the Galil Controller type The controller model number must be entered and if you are changing an existing controller this field will already have an entry Pressing the down arrow to the right of this field will reveal a menu of valid controller types Choose the corresponding controller DMC 1410 or DMC 1411 The registry information for the DMC 1410 and DMC 1411 will show a default address of 1000 This information should be changed as necessary to reflect any changes to the controllers address jumpers Hardware interrupts may also be set in the registry although for initial communication these are not necessary The default is no interrupt Driver information is also listed in which Galil recommends using the standard Galil Drivers The registry entry also displays timeout and delay information These are advanced parameters that should only be modified by advanced users see software documentation for more information Once you have set the appropriate Registry
140. oller accepts feedback from a quadrature linear or rotary encoder with input frequencies up to 8 million quadrature counts per second An additional encoder input is available for gearing or cam applications hand wheel inputs or dual loop Modes of motion include jogging point to point positioning electronic cam electronic gearing and contouring Several motion parameters can be specified including acceleration and deceleration rates and slew speed The DMC 141X also provides motion smoothing to eliminate jerk For synchronizing motion with external events the DMC 141X includes seven digital inputs and three programmable outputs Event triggers can automatically check for elapsed time distance and motion complete The DMC 141X is easy to program Instructions are represented by two letter commands such as BG for Begin and SP for Speed Conditional Instructions Jump Statements and arithmetic functions are included for writing self contained applications programs An internal editor allows programs to be quickly entered and edited and support software such as the WSDK allows quick system set up and tuning To prevent system damage during machine operation the DMC 141X provides many error handling features These include software and hardware limits automatic shut off on excessive error abort input and user definable error and limit routines DMC 1410 1411 1417 Series Chapter 1 Overview e 1 Overview of Motor Types The DMC 141X can prov
141. om equation P N 3 6 Note 3 6 0 18 20 DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 65 S SIN P 100 Define sine position X N x10 S Define slave position ET N X Define table N N 1 JP LOOP N lt 100 Repeat the process EN Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center of the cycle Master Aux Encoder 1000 and X 500 This implies that X must be driven to that point to avoid a jump This is done with the program Instruction Interpretation RUN Label EB1 Enable cam PA500 starting position SP5000 speed BGX Move motor AMX After moved AII Wait for start signal EG 1000 Engage slave AI 1 Wait for stop signal EQ 1000 Disengage slave EN End Contour Mode The DMC 141X also provides a contouring mode This mode allows any arbitrary position curve for the axis to be prescribed which is ideal for following computer generated paths or user defined profiles Specifying Contour Segments The Contour Mode CM command specifies the contour mode The contour is described by position increments CD n over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2 samples where n is a number between 1 and 8 the default sample period is 1 ms but this can be adjusted with the TM command The controller performs linear interpolation between the specified inc
142. ommand has reached the specified relative distance from the start of the move ARn Halts program execution until after specified distance from the last AR or AD command has elapsed APn Halts program execution until after absolute position occurs 88 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Halt program execution until after forward motion reached absolute position If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs ene MC n n Sn reached absolute position If position is already past the point then MR will trip immediately Will function on geared axis or aux inputs Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stop code will be set to 99 An application program will jump to label MCTIME AI Halts program execution until after specified input is at specified logic level n specifies input line Positive is high logic level negative is low level n 1 through 7 A Halts program execution until specified axis has reached its slew speed AT Halts program execution until n msec from reference time AT 0 sets reference AT n waits n msec from reference AT n waits n msec from reference and sets new reference after elapsed time
143. on Advanced Communication Techniques Controller Response to Data and Bus Interrupts Communication with Controller Communication Registers CLEAR BUFFER for clearing write FIFO N 1 Write only buffer The DMC 141X provides four registers for communication The READ register and WRITE register occupy address N in the controller I O space The CONTROL register and the CLEAR BUFFER register occupy address N 1 in the I O space The READ register is used for receiving data from the DMC 141X The WRITE register is used to send data to the DMC 141X The STATUS and CLEAR BUFFER registers are used for controlling communication interrupts and clearing the FIFO buffers Simplified Communication Procedure for DMC 1410 1411 The simplest approach for communicating with the DMC 141X is to check bits O and 1 of the STATUS register at address N 1 Bit 1 is for WRITE STATUS and bit 0 is for READ STATUS DMC 1410 1411 1417 Series Chapter 4 Communication e 45 Any high level computer language such as C Basic Pascal or Assembly may be used to communicate with the DMC 141X as long as the READ WRITE procedure is followed as described below 0 READ No data to be read Must not read BUFFER STATUS BUFFER STATUS Excessive position error No error e If read buffer gets full controller holds execution of communication The DMC 1410 and DMC 1411 controllers are compatible in all the Microsoft operating systems except Windows CE They ar
144. on Programming DMC 1410 1411 1417 Series VF2 2 Change format Vl Return V1 10 00 New format VF 2 2 Specify hex format Vl Return V1 0A 00 Hex value VFI Change format VI Return V1 9 Overflow Local Formatting of Variables PF and VF commands are global format commands that affect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m or n m following the variable name and the symbol F specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal For example Examples V1 10 Assign VI Vl Return V1 0000000010 0000 Default Format V1 F4 2 Specify local format 0010 00 New format VI 4 2 Specify hex format 000A 00 Hex value VI ALPHA Assign string ALPHA to V1 V1 S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 141X position parameters such as PR and PA have units of quadrature counts Speed parameters such as SP and JG have units of counts sec Acceleration parameters such as AC and DC have units of counts sec The controller interprets time in milliseconds All input parameters must be converted into these units For ex
145. onnections is needed and the internal 5V will be used for powering the input output Option for separate input output commons is also available This will require the use of both pin 1 and pin 2 When selecting this option both 12V and 12V become inaccessible Opto isolated Inputs ICM 1460 TO CONTROLLER CONNECTIONS vec OPTO COMMON RP2 RP4 2 2 RP3 RP1 4 7K OHMS IN x To controller IN x The signal IN x is one of the isolated digital inputs where x stands for the digital input terminal The OPTO COMMON signal is available on TERMINAL 13 labeled CMP ICOM The OPTO COMMON point should be connected to an isolated power supply in order to obtain isolation from the controller By connecting the OPTO COMMON to the side of the power supply the inputs will be activated by sinking current By connecting the OPTO COMMON to the GND side of the power supply the inputs will be activated by sourcing current 148 e Appendices DMC 1410 1411 1417 Series The opto isolation circuit requires Ima drive current with approximately 400 usec response time The voltage should not exceed 24V without placing additional resistance to limit the current to 11 ma Opto isolated Outputs CONTROLLER ICM 1460 CONNECTIONS VCC RPS 2 2K OPTO COMMON wane OUTPUT our x The signal OUT x is one of the isolated digital outputs where x stands for the digital output terminal The OPTO COMMON needs to be connected to an isolated
146. ons The order of execution is from left to right Examples VI ABS V7 The variable V1 is equal to the absolute value of variable V7 V2 5 SIN POS The variable V2 is equal to five times the sine of the variable POS V3 IN 1 The variable V3 is equal to the digital value of input 1 V4 ANJ 5 The variable V4 is equal to the digital value of analog input 5 e Variables For applications that require a parameter that is a variable the DMC 141X provides 126 variables These variables can be numbers or strings A program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by the program calculations For example a cut to length application may require that a cut length be variable Example PR POSX Assigns variable POSX to PR command JG RPMY 70 Assigns variable RPMY multiplied by 70 to JG command Programmable Variables The DMC 141X allows the user to create up to 126 variables Each variable is defined by a name that can be up to eight characters The name must start with an alphabetic character however numbers are permitted in the rest of the name Spaces are not permitted Variable names should 98 e Chapter 7 Application Programming DMC 1410 1411 1417 Series not be the same as DMC 141X instructions For example PR is not a good choice for a variable name Examples of valid and invalid variable names are Val
147. ontains the last line of program execution Useful to determine where program stopped _DL contains the number of available labels 126 max UL contains the number of available variables 126 max _DA contains the number of available arrays 6 max _DM contains the number of available array elements 1000 max _AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to specify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation Instruction Interpretation ED Edit Mode 000 A Program Label 001 PR1000 Position Relative 1000 002 BGX Begin 003 PR5000 Position Relative 5000 004 EN End lt cntrl gt Q Quit Edit Mode XQ HA Execute A 2003 PR5000 Error on Line 3 TCI Tell Error Code 77 Command not valid while running Command not valid while running ED 3 Edit Line 3 003 AMX PR5000 BGX Add After Motion Done lt cntrl gt Q Quit Edit Mode XQ HA Execute A DMC 1410 1411 1417 Series Chapter 7 Application Programming e 87 Program Flow Commands The DMC 141X provides several instructions that control program flow The DMC 141X sequenc
148. oop forces the motor to follow the commanded position DMC 1410 1411 1417 Series Chapter 10 Theory of Operation e 123 The highest level of control is the motion program This can be stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 SP 20000 AC 200000 BG EN This program corresponds to the velocity profiles shown in Fig 10 3 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The operation of the servo system is done in two manners First it is explained qualitatively in the following section Later the explanation is repeated using analytical tools for those who are more theoretically inclined 124 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series X VELOCITY X POSITION TIME Figure 10 3 Velocity and Position Profiles Operation of Closed Loop Systems To understand the operation of a servo system we may
149. op and do not require encoder feedback When a stepper is used the auxiliary encoder for the corresponding axis is unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input corresponding to that axis The commanded position of the stepper can be interrogated with RP or DE while the TD command will give the actual step position The encoder position can be interrogated with TP The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a range between 0 5 and 8 where 8 implies the largest amount of smoothing See Command Reference regarding KS The DMC 141X profiler commands the step motor amplifier All DMC 141X motion commands apply such as PR PA VP CR and JG The acceleration deceleration slew speed and smoothing are also used Since step motors run open loop the PID filter does not function and the position error is not generated To connect step motors with the DMC 141X you must follow this procedure Step A Install SM jumpers In order for the DMC 141X to operate in stepper mode the corresponding stepper motor jumper installed For a discussion of SM jumpers see section Step 2 Install jumpers on the DMC 141X Step B Connect step and direction signals from controller to motor amplifier Connect the step and direction signals from the controller to respective signals on your step motor amplifier These signals
150. or best performance the amplifier should be configured for a current mode of operation with no additional compensation The gain should be set such that a 10 Volt input results in the maximum required current The DMC 1460 also provides an AEN amplifier enable signal to control the status of the amplifier This signal toggles when the watchdog timer activates when a motor off command is given or when OE1 Off on error is enabled command is given and the position error exceeds the error limit As shown in Figure 3 5 AEN can be used to disable the amplifier for these conditions The standard configuration of the AEN signal is TTL active low Both the polarity and the amplitude can be changed if you are using the ICM 1460 interface board To change the polarity from active low zero volts disable to active high replace the 7407 IC with a 7406 To change the voltage level note the state of the jumper on the ICM 1460 When JP4 has a jumper from AEN to 5V default setting the output voltage is 0 5V To change to 12 volts pull the jumper and rotate it so that it connects the pins marked AEN and 12V If the jumper is removed entirely the output is an open collector signal allowing the user to connect to external supplies with voltages up to 24V AMP 1460 20 Watt Linear Amplifier Option The ICM 1460 Interconnect Module can be purchased with a 20 watt linear amplifier suitable for driving small motors This amplifier requires an
151. osition of 1000 DMC 1410 1411 1417 Series Chapter 7 Application Programming e 113 The first step is to command the X motor to move to the rotary position of 1000 Once it arrives we check the position of the load If for example the load position is 980 counts it implies that a correction of 20 counts must be made However when the X axis is commanded to be at the position of 1000 suppose that the actual position is only 995 implying that X has a position error of 5 counts which will be eliminated once the motor settles This implies that the correction needs to be only 15 counts since 5 counts out of the 20 would be corrected by the X axis Accordingly the motion correction should be Correction Load Position Error Rotary Position Error The correction can be performed a few times until the error drops below 2 counts Often this is performed in one correction cycle Example motion program Instruction Function A Label DPO Define starting positions as zero LINPOS 0 PR 1000 Required distance BG Start motion B AM Wait for completion WT 50 Wait 50 msec LIN POS DE Read linear position ER 1000 LINPOS _TE Find the correction JP 4C ABS ER lt 2 Exit if error is small PR ER Command correction BG JP B Repeat the process C EN 114 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Chapter 8 Error Handling Introduction The DMC 141X provides several hardware and software features to check
152. owing procedure depicts the DMC 1410 1411 installation process 12 e Chapter 2 Getting Started DMC 1410 1411 1417 Series Add Remove Hardware Wizard Welcome to the Add Remove Hardware Wizard This wizard helps you add remove unplug and troubleshoot your hardware To continue click Next lt Back Cancel Windows 2000 Hardware Wizard Note All the pictures in this Hardware Wizard section are from Windows 2000 unless specified otherwise 1 On the first dialog select Add Troubleshoot Add Remove Hardware Wizard Choose a Hardware Task Fates Which hardware task do you want to perform ey Select the hardware task you want to perform and then click Next Add Troubleshoot a device Choose this option if you are adding a new device to your computer or are having problems getting a device working Uninstall Unplug a device Choose this option to uninstall a device or to prepare the computer to unplug a device Back Cancel DMC 1410 1411 1417 Series Chapter 2 Getting Started e 13 2 Let the Hardware Wizard try to detect a new Plug and Play device Add Remove Hardware Wizard New Hardware Detection The wizard automatically locates new Plug and Play hardware 14 e Chapter 2 Getting Started DMC 1410 1411 1417 Series 3 Ifa device is found the Hardware Wizard will then ask if the device is on a list of found devices Say no and proceed to the next dialog box In Win 2000
153. p before it reaches its final position An incremental position movement IP may be specified during motion as long as the additional move is in the same direction Here the user specifies the desired position increment n The new target is equal to the old target plus the increment n Upon receiving the IP command a revised profile will be generated for motion towards the new end position The IP command does not require a begin Note If the motor is not moving the IP command is equivalent to the PR and BG command combination Command Summary Point to Point Positioning 60 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series Operand Summary Point to Point Positioning Return acceleration rate Return deceleration rate _PA Returns current destination if axis is moving otherwise returns current commanded position Returns current incremental distance Example Absolute Position PA 10000 Specify absolute position of 10 000 counts AC 1000000 Acceleration of 1 000 000 counts sec DC 1000000 Deceleration of 1 000 000 counts sec SP 50000 Speeds of 50 000 counts sec BG Begin motion Independent Jogging The jog mode of motion is very flexible because the speed direction and acceleration can be changed during motion In this mode the user specifies the jog speed JG acceleration AC and the deceleration DC rate The direction of motion is specified by the sign of the JG parameters When the begin co
154. p to 512 characters of information In normal operation the controller places output into the FIFO buffer The software on the host computer monitors this buffer and reads information as needed When the trace mode is enabled the controller will send information to the FIFO buffer at a very high rate In general the FIFO will become full since the software is unable to read the information fast enough When the FIFO becomes full program execution will be delayed until it is cleared If the user wants to avoid this delay the command CW 1 can be given This command causes the controller to throw away the data that cannot be placed into the FIFO In this case the controller does not delay program execution Error Code Command When there is a program error the DMC 141X halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG _ED The user can obtain information about the type of error condition that occurred by using the command TC1 This command reports back a number and a text message that describes the error condition The command TCO or TC will return the error code without the text message For more information about the command TC see the Command Reference Stop Code Command The status of motion for each axis can be determined by using the stop code command SC This can be useful when motion on an axis has stopped unexpectedly The command SC will retu
155. plete WT 100 Wait 100 msec PAO Position absolute 0 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec COUNT COUNT 1 Decrement loop counter JP LOOP COUNT gt 0 Test for 10 times thru loop EN End Program Subroutines A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program location where the subroutine was called unless the subroutine stack is manipulated as described in the following section DMC 1410 1411 1417 Series Chapter 7 Application Programming e 93 Stack Manipulation It is possible to manipulate the subroutine stack by using the ZS command Every time a JS instruction interrupt or automatic routine such as POSERR or LIMSWI is executed the subroutine stack is incremented by 1 Normally the stack is restored with an EN instruction Occasionally it is desirable not to return back to the program line where the subroutine or interrupt was called The ZS1 command clears 1 level of the stack This allows the program sequencer to continue to the next line The ZSO command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is often desirable to restart the progra
156. position error inputs or torque This is useful for teaching motion trajectories or observing system performance Two types of data can be captured and stored in two arrays The capture rate or time interval may be specified Recording can be done as a one time event or as a circular continuous recording 102 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Commands I Automatic Data Capture Command Command Description sss RA n m Selects up to two arrays for data capture The arrays must have been defined with the DM command RD typel type2 Selects the type of data to be recorded where typel and type2 represent the various types of data see table below The order of data type is important and corresponds with the order of n m arrays in the RA command The RC command begins data collection Sets data capture time interval where n is an integer between 1 and 8 and designates 2 msec between data m is optional and specifies the number of elements to be captured If m is not defined the number of elements defaults to the smallest array defined by DM When m is a negative number the recording is done continuously in a circular manner _RD is the recording pointer and indicates the address of the next array element n 0 stops recording Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Summary Automatic D
157. power supply The OUT x can be used to source current from the power supply The maximum sourcing current for the OUT x is 25 ma Sinking configuration can also be specified Please contact Galil for details When opto isolated outputs are used either a pull up or pull down resistor needs to be provided by the user depending upon whether the signal is sinking or sourcing AMP 1460 Mating Power Amplifiers The AMP 1460 provides the features of the ICM 1460 with the addition of a brush type servo amplifier The amplifier is rated for 7 amps continuous 10 amps peak at up to 80 volts The gain of the AMP 1460 is amp per volt The AMP 1460 requires an external DC supply The AMP 1460 connects to the controller with a cable 37 pin cable and screw type terminals are provided for connecting to motors encoders and external switches e 7 amps continuous 10 amps peak 20 to 80 volts DC supply e Connects directly to DMC 141X series controllers via 37 pin cable e Screw type terminals for easy connection to motors encoders and switches Specifications Minimum motor inductance 1 mH PWM frequency 30 KHz Ambient operating temperature 0 70 Dimensions 6 9 x 4 9 x 2 6 DMC 1410 1411 1417 Series Appendices e 149 Weight 1 pound Mounting Keyholes 2 Gain 1 amp volt The DMC 141X generates a 10 Volt range analog signal ACMD and ground pin 21 for input to power amplifiers that have been sized to drive the motor and load F
158. r Position Relative and to specify motion parameters such as speed acceleration and deceleration and distance Program flow commands are used in Application Programming to control the program sequencer They include the jump on condition command and event triggers such as after position and after elapsed time General configuration commands are used to set controller configurations such as setting and clearing outputs formatting variables and motor encoder type The control setting commands include filter settings such as KP KD and KI and sample time Error Limit commands are used to configure software limits and position error limits MOTION AB Abort Motion AC Acceleration BG Begin Motion CD Contour Data CM Contour Mode DMC 1410 1411 1417 Series Chapter 5 Programming Basics e 53 DC Deceleration DT Contour Time Interval FE Find Edge FI Index GR Gear Ratio HM Home IP Increment Position JG Jog Mode PA Position Absolute PR Position Relative SP Speed ST Stop PROGRAM FLOW AD After Distance AI After Input AM After Motion Complete AP After Absolute Position AR After Relative Distance AS AtSpeed AT After Time EB Enable CAM EG Engage ECAM EM CAM cycle command EN End Program EP CAM interval and starting point EQ Disengage ECAM ET ECAM table entry HX Halt Task IN Input Variable II Input Interrupt JP Jump To Program Location JS Jump To Subroutine MC After motor is in position MF Af
159. r can be commanded to move the motor The BZ command is then issued as described above For example to initialize the X axis motor upon power or reset the following commands may be given SH CR Enable X axis motor PRX 1 BZX CR Move X motor close to zero commutation phase BG CR Begin motion on X axis AM CR Wait for motion to complete on X axis BZX 1 CR Drive motor to commutation phase zero and leave motor on Method 3 Use the command BC This command uses the hall transitions to determine the commutation phase Ideally the hall sensor transitions will be separated by exactly 60 and any deviation from 60 will affect the accuracy of this method If the hall sensors are accurate this method is recommended The BC command 32 e Chapter 2 Getting Started DMC 1410 1411 1417 Series monitors the hall sensors during a move and monitors the Hall sensors for a transition point When that occurs the controller computes the commutation phase and sets it For example to initialize the motor upon power or reset the following commands may be given SH lt CR gt Enable motor BC lt CR gt Enable the brushless calibration command PR 50000 lt CR gt Command a relative position movement BG lt CR gt Begin motion When the hall sensors detect transition the commutation phase is reset Step 7c Connect Step Motors In Stepper Motor operation the pulse output signal has a 50 duty cycle Step motors operate open lo
160. rements where one point is generated for each sample Consider for example the trajectory shown in Fig 6 2 The position X may be described by the points The sample time is 1 ms Point 1 X 0 at T 0ms Point 2 X 48 at T 4ms Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments 66 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series Increment 1 CD 48 Time change 4 ms DT2 Increment 2 CD 240 Time change 8 ms DT 3 Increment 3 CD 48 Time change 16 ms DT 4 When the controller receives the command to generate a trajectory along these points it interpolates linearly between the points The resulting interpolated points include the position 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are Instruction Interpretation HA CM Specifies contour mode DT 2 Specifies first time interval 2 CD 48 WC Specifies first position increment DT 3 Specifies second time interval 2 CD 240 WC Specifies second position increment DT 4 Specifies the third time interval 2 CD 48 WC Specifies the third position increment DTO CDO Exits contour mode EN POSITION COUNTS peice don ton tuin te Ln eee age 240 192 96 ig esr s TIME ms 0 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 2 The Required Trajectory Additional Commands The command WC is
161. rn a number representing the motion status See the command reference for further information RAM Memory Interrogation Commands For debugging the status of the program memory array memory or variable memory the DMC 141X has several useful commands The command DM will return the number of array elements currently available The command DA will return the number of arrays that can be currently defined For example a standard DMC 141X controller will have a maximum of 1000 array elements in up to 6 arrays If an array of 100 elements is defined the command DM will return the value 900 and the command DA will return 5 To list the contents of the variable space use the interrogation command LV List Variables To list the contents of array space use the interrogation command LA List Arrays To list the 86 e Chapter 7 Application Programming DMC 1410 1411 1417 Series contents of the Program space use the interrogation command LS List To list the application program labels only use the interrogation command LL List Labels Operands In general all operands provide information that may be useful in debugging an application program Below is list of operands that are particularly valuable for program debugging To display the value of an operand the message command may be used For example since the operand ED contains the last line of program execution the command MG ED will display this line number _ED c
162. rs are only available on the DMC 1410 and the DMC 1411 The PCI drivers for the DMC 1417 will automatically assign it an IRQ based on system availability On the DMC 1410 and DMC 1411 select which IRQ line will be used when the controller needs to notify the PC of an interrupt Step 5 in this chapter tells how to select an IRQ line that is open on your PC meaning not shared with any other device Step 4a Plugging the DMC 1410 or DMC 1417 into the PC The DMC 1410 and 1417 are installed directly into the ISA and PCI expansion buses respectively Here s a description of how it s done 1 Make sure the PC is in the power off condition Unplug the power cord from PC 2 Remove the screws that hold the PC System Unit cover in place These screws are usually located in the back of the system unit Remove unit cover 4 Remove the metal plate covering the expansion bus slot where the controller is to be inserted 5 Insert the DMC 1410 or 1417 card into the expansion bus and secure with screw 6 Re secure system unit cover and tighten screws Insert the 37 pin ribbon cable to J3 connector Ends of cable should be terminated appropriately to system components 8 Power up PC Step 4b Installing the DMC 1411 on the PC 104 stack 1 Make sure power is off Check pins on P1 and P2 connectors to make sure they are straight Screw in stand offs to holes opposite P1 P2 connectors Carefully align DMC 1411 over P1 P2 connectors and pr
163. ry for further information on the command CE Step D Verify proper encoder operation Once the encoder is connected as described above turn the motor shaft and interrogate the position with the instruction TP lt return gt The controller response will vary as the motor is turned At this point if TP does not vary with encoder rotation there are three possibilities 1 The encoder connections are incorrect check the wiring as necessary 2 The encoder has failed using an oscilloscope observe the encoder signals Verify that both channels A and B have a peak magnitude between 5 and 12 volts Note that if only one encoder channel fails the position reporting varies by one count only If the encoder failed replace the encoder If you cannot observe the encoder signals try a different encoder 3 There is a hardware failure in the controller connect the same encoder to a different axis If the problem disappears you probably have a hardware failure Consult the factory for help Step 7a Connect Standard Servo Motor The following discussion applies to connecting the DMC 141X controller to standard servo motor amplifiers The motor and the amplifier may be configured in the torque or the velocity mode In the torque mode the amplifier gain should be such that a 10 Volt signal generates the maximum required current In the velocity mode a command signal of 10 Volts should run the motor at the maximum required speed Step by st
164. s 1 9 12 142 PWM 140 42 140 42 151 Stop Code 54 Stop Motion or Program 56 61 84 119 127 143 Subroutine 42 56 85 118 143 Subroutine Stack 56 95 Synchronization 6 41 64 Teach 72 Latch 54 Record 72 Tell Error 54 Tell Position 54 Tell Torque 54 Terminal 42 Theory 36 Damping 36 PID 30 Time Clock 102 Sample Time 55 58 TIME 102 Time Interval 72 Timeout 13 Torque Limit 29 58 Trippoints 39 90 TTL 6 41 Tuning SDK 35 Upload 57 Variable 40 83 140 Internal 94 Index e 5
165. s example waits for input 1 to go low and then starts motion Note The AI command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Input Interrupt function II or use a conditional jump on an input such as JP GO IN 1 1 Instruction Interpretation INPUT Program Label ALI Wait for input 1 low PR 10000 Position command BG Begin motion EN End program Event Trigger Set output when At speed Instruction Interpretation ATSPEED Program Label JG 50000 Specify jog speed AC 10000 Acceleration rate BG Begin motion AS Wait for at slew speed 50000 Set output 1 EN End program 90 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Event Trigger Multiple move with wait Instruction Interpretation MOVES Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration BG Start Motion AD 10000 Wait a distance of 10 000 counts SP 5000 New Speed AM Wait until motion is completed WT 200 Wait 200 ms PR 10000 New Position SP 30000 New Speed AC 150000 New Acceleration BG Start Motion EN End Define Output Waveform Using AT The following program causes Output 1 to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec Instruction Interpretation OUTPUT Program label ATO Initialize time reference SB1 Set Output 1 LOOP Loop AT 10 After 10 msec from reference Clear Output 1 AT 40 Wait
166. s than 1 usec of the external low or high input signal The DMC 141X software commands AL and RL are used to arm the latch and report the latched position The steps to use the latch are as follows 1 Give the AL command to arm the latch 2 Test to see if the latch has occurred Input 1 goes low by using the _AL command Example V1 AL returns the state of the latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the report latch RL command or _RL Note The latch must Example High Instruction Latch JG 5000 BG AL Wait JP Wait AL 1 Result _RL Result EN DMC 1410 1411 1417 Series be re armed after each latching event Speed Latch Interpretation Latch program Jog Begin Arm Latch Loop for Latch 1 Wait for latch Report position Print result End Chapter 6 Programming Motion e 79 THIS PAGE LEFT BLANK INTENTIONALLY 80 e Chapter 6 Programming Motion DMC 1410 1411 1417 Series Chapter 7 Application Programming Introduction The DMC 141X provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 141X memory freeing the host computer for other tasks However the host computer can still send commands to the controller at any time even while a program is being executed In addition to standard motion commands the DMC 141X provides s
167. sition feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximum frequency does not exceed 8 000 000 quadrature states sec The controller performs quadrature decoding of the encoder signals resulting in a resolution of quadrature counts 4 x encoder cycles Note Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses into CHA and direction into Channel B and using the CE command to configure this mode Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Inputs for additional encoder Used when an encoder on both the motor and the load is required A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored 140 e Appendices DMC 1410 1411 1417 Series Forward Limit Switch Reverse Limit Switch Home Switch Input Input 7 Latch input hen active inhibits motion in forward direction Also causes ex
168. spectively The value of the operand is either a 0 or 1 corresponding to the logic state of the limit switch Using a terminal program the state of a limit switch can be printed to the screen with the command MG _LF or MG_LR This prints the value of the limit switch operands for the axis The logic state of the limit switches can also be interrogated with the TS command For more details on TS see the Command Reference Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user There are three homing routines supported by the DMC 141X Find Edge FE Find Index FD and Standard Home HM The Find Edge routine is initiated by the command sequence FE lt return gt BG lt return gt The Find Edge routine will cause the motor to accelerate then slew at constant speed until a transition is detected in the logic state of the Home input The direction of the FE motion is dependent on the state of th
169. sponse to Commands The DMC 141X returns a for valid commands The DMC 141X returns a for invalid commands For example if the command BG is sent in lower case the DMC 141X will return a bg lt enter gt invalid command lower case DMC 141X returns When the controller receives an invalid command the user can request the error code The code will specify the reason for the invalid command response To request the error code type the command TC1 For example TC1 lt enter gt Tell Code command 1 Unrecognized command Returned response There are several coded reasons for receiving an invalid command response The most common reasons are and unrecognized command such as typographical entry or lower case a command given at improper time or a command out of range such as exceeding maximum speed A complete listing of all codes is listed in the TC command in the Command Reference section Interrogating the Controller Interrogation Commands The DMC 141X has a set of commands that directly interrogate the controller When the command is entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and Leading Zeros LZ command See Chapter 7 and the Command Reference Summary of Interrogation Commands Pee sc E rc n Te TR E E 5
170. ssive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to the velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt TL 1 lt CR gt Sets torque limit to 1 Volt Note Once the correct polarity of the feedback loop has been determined the torque limit should in general be increased to the default value of 9 99 The servo will not operate properly if the torque limit is below the normal operating range See description of TL in the command reference Disable motor Issue the motor off command to disable the motor MO lt CR gt Turns motor off Connecting the Motor Once the parameters have been set connect the analog motor command signal ACMD to the amplifier input Issue the servo here command to turn the motors on To test the polarity of the f
171. stem Set up enne nre trennen 34 Example 2 Profiled Move enne nennen a nennen nnne 35 Example 3 Position Interrogation i 35 Example 4 Absolute Position ii 35 DMC 1410 1411 1417 Series Contents e i ii e Contents Example 5 Velocity Control Jogging ii 35 Example 6 Operation Under Torque Limit i 36 Example Interrogation eee EHE dial aa 36 Example 8 Operation in the Buffer Mode sese 36 Example 9 Motion Programs i 36 Example 10 Motion Programs with LOOpS nennen 37 Example 11 Motion Programs with Trippoints i 37 Example 12 Control Variables iii 37 Example 13 Control Variables and Offset ii 38 Chapter 3 Hardware Interface 39 OVEIVIEW La 1o e tec E alia bete av Se e Eee 39 Encoder Interface nut lie head Was asia aio et e ais 39 RA Sed Bed iva 40 LinntS witch 40 Home Switch al eee eal orco tese rtr IR be 40 Abort Input eet er ete IR doa cues D Y e Eres Qe RE ae Une Ge eee S 41 Uncommitted Digital Inputs i 41 nn ce 42 Amplifiers ia eit o AMORI a rate raa e ii 42 Other i e ee t et ve ege et te A ER pe pedet rl e C 43 Chapter 4 Communication 45
172. t 15 DTO CDO DMC 1410 1411 1417 Series Interpretation Program defines X points Allocate memory Set initial conditions C is index T is time in ms Argument in degrees Compute position Integer value of V3 Store in array POS Program to find position differences Compute the difference and store End first program Program to run motor Contour Mode 4 millisecond intervals Contour Distance is in DIF Wait for completion Stop Contour Chapter 6 Programming Motion e 69 EN End the program Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 141X automatic array capture feature to capture position data The captured data may then be played back in the contour mode The following array commands are used DM C n RA CI RD_TP RC n m RC or _RC Dimension array Specify array for automatic record Specify data for capturing Specify capture time interval where n is 2n msec m is number of records to be captured Returns a 1 if recording Record and Playback Example RECORD DM POS 501 RA POSI RD_TP MO RC2 A JPHA RC 1 COMPUTE DM DX 500 C 0 L D C 1 DELTA POS D POS C DX C DELTA C C 1 JP L C lt 500 PLAYBCK CM DT2 I 0 8B CD POS IJ WC DT 0 CDO EN Begin Program Dimension array with 501 elements Specify automatic record Specify position to be captured Turn motor off Beg
173. te Value 65 95 Bit Wise 94 Sine 68 Math Functions 98 Absolute Value 58 100 118 Cosine 58 61 99 100 104 Sin 58 100 Mathematical Expression 94 Memory 1 38 53 71 83 88 102 DMC 1410 1411 1417 Series Array 5 88 94 99 102 Message 88 96 99 Messages 107 Modelling 125 Motor Command 1 30 132 140 Moving Contour Mode 55 61 Home Inputs 42 56 78 139 Jog 55 63 S Curve 77 Slew Speed 1 51 91 143 Multitasking 87 No Operation 56 Non volatile Memory 1 Off On Error 27 43 Operand Internal Variable 94 Operators Bit Wise 94 Optoisolation Home Input 42 Output ICM 1100 27 Motor Command 30 Outputs 1 44 55 112 127 139 Digital Outputs 112 Interconnect Module 148 Motor Command 1 132 140 PID 30 128 Play Back 61 106 Position Capture 81 Latch 54 Teach 72 Position Error 27 Position Latch 81 143 Programmable EEPROM 5 Proportional Gain 36 Protection Error Limit 27 29 Torque Limit 29 PWM 6 140 42 140 42 151 Quadrature 6 41 142 Quit Abort 41 Record 57 61 72 Latch 54 Teach 72 Reset 42 45 57 93 117 140 141 DMC 1410 1411 1417 Series S Curve 77 Sample Time 55 58 SDK 35 Selecting Address 122 Servo Design Kit 8 SDK 35 Sin 58 100 Sine 68 Single Ended 6 28 30 Slew 62 Slew Speed 1 51 91 143 Smoothing 77 Software SDK 35 Stability 76 115 121 128 Status 54 88 Interrogation 36 54 55 109 Stop Code 54 Step Motor
174. tempt to run away but the direction of motion is reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals If the motor moves in the required direction but stops short of the target it is most likely due to insufficient torque output from the motor command signal ACMD Reducing system friction on the motors can alleviate this The instruction TT lt CR gt Tell torque reports the level of the output signal It will show a non zero value that is below the friction level Once you have established that you have closed the loop with the correct polarity you can move on to the compensation phase servo system tuning to adjust the PID filter parameters KP KD and KI It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section 28 e Chapter 2 Getting Started DMC 1410 1411 1417 Series AMP 1460 Power Supply VAMP AMPGND DMC 1410 1411 1417 Series Description Connection Channel A MA Channel B MB Channel A MA Channel B MB Index I Index 1 Gnd GND 5V 5V Motor 1 da Motor i Motor 2 Figure 2 3 System Connections with the AMP 1460 Amplifier Chapter 2 Getting Started e 29
175. ter motion forward direction MG Message MR After motion reverse direction NO No operation RE Return from Error Subroutine RI Return from Interrupt TW Timeout for in position WC Wait for Contour Data WT Wait XQ Execute Program ZS Zero Subroutine Stack 54 e Chapter 5 Programming Basics DMC 1410 1411 1417 Series GENERAL CONFIGURATION AL BN CB CE CN DA DE DL DM DP EB ED EI EG EM EO EP EQ ET LS MO MT OB OP PF QU QD RA RC RD RS SB UI UL VE Arm Latch Burn Clear Bit Configure Encoder Type Configure Switches and Stepper Deallocate Arrays Define Dual Encoder Position Download Dimension Arrays Define Position Enable ECAM Edit Mode Enable Interrupts Engage ECAM Cam cycle command Echo Off Cam table interval and starting point Disengage ECAM ECAM table entry List Motor Off Motor Type Define Output Bit Output Port Position Format Upload array Download array Record Array Record Record Data Reset Set Bit User Interrupt Upload Variable Format CONTROL FILTER SETTINGS DV FA FV GN IL IT KD Damping for dual loop Acceleration Feedforward Velocity Feedforward Gain Integrator Limit Smoothing Time Constant Independent Derivative Constant DMC 1410 1411 1417 Series Chapter 5 Programming Basics e 55 KI Integrator Constant KP Proportional Constant KS Stepper Smoothing Constant OF Offset SH Servo Here TL Torque Limit TM S
176. terpretation Begin main program Prompt for speed Begin motion Repeat End main program Command error utility Check if error on line 2 Check if out of range Send message Send message Adjust stack Return to main program End program if other error Zero stack End program the operator to enter a jog speed If the operator enters a number out of range greater than 8 million the CMDERR routine will be executed prompting the operator to enter a new number Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 141X provides the use of the following mathematical operators Operator Multiplication The numeric range for addition subtraction and multiplication operations is 2 147 483 647 9999 The precision for division is 1 65 000 96 e Chapter 7 Application Programming DMC 1410 1411 1417 Series Mathematical operations are executed from left to right Calculations within parentheses have precedence Examples SPEED 7 5 V1 2 The variable SPEED is equal to 7 5 multiplied by V1 and divided by 2 COUNT COUNT 2 The variable COUNT is equal to the current value plus 2 RESULT _TP COS 45 40 Puts the position 28 28 in RESULT 40 cosine of 45 is 28 28 TEMP IN 1 amp IN 2 TEMP is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The op
177. the approximate value for BM will agree with the value used in the previous step Note In order to properly conduct the brushless setup the motor must be allowed to move a minimum of one magnetic cycle in both directions Note When using Galil Windows software the timeout must be set to a minimum of 10 seconds time out 10000 when executing the BS command This allows the software to retrieve all messages returned from the controller If Hall Sensors are Available Since the Hall sensors are connected randomly it is very likely that they are wired in the incorrect order The brushless setup command indicates the correct wiring of the Hall sensors The hall sensor wires should be re configured to reflect the results of this test The setup command also reports the position offset of the hall transition point and the zero phase of the motor commutation The zero transition of the Hall sensors typically occurs at 0 30 or 90 of the phase commutation It is necessary to inform the controller about the offset of the Hall sensor and this is done with the instruction BB Step E Save Brushless Motor Configuration It is very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configured the burn command BN should be given If Hall Sensors are Not Available Without hall sensors the controller will not be able to estimate the commutation phase
178. tion of their usage is found below Limit Switch Input The forward limit switch FLS inhibits motion in the forward direction immediately upon activation of the switch The reverse limit switch RLS inhibits motion in the reverse direction immediately upon activation of the switch If a limit switch is activated during motion the controller will make a decelerated stop using the deceleration rate previously set with the DC command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position When a forward or reverse limit switch is activated the current application program that is running will be interrupted and the controller will automatically jump to the LIMSWI subroutine if one exists This is a subroutine that the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch Automatic Subroutines are discussed in Chapter 6 After a limit switch has been activated further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to an inactive state This usually involves physically opening the tripped switch Any attempt at further motion before the logic state has been reset will result in the following error 022 Begin not possible due to limit switch error The operands _LF and _LR contain the state of the forward and reverse limit switches re
179. to be activated Reserved Interrupt Request Line Jumper one only DMC 1410 and 1411 only Accessories and Options Part DMC 1410 DMC 1411 DMC 1417 ICM 1460 AMP 1460 Cable 37 pin D Cable 40 pin Ribbon Description 1 axis Controller for ISA bus 1 axis motion controller for PC 104 bus 1 axis motion controller for PCI Interconnect module Interconnect module with 1 axis power amplifier 37 pin cable for DMC 1410 amp DMC 1417 40 pin to 37 pin cable for DMC 1411 DMC 1410 1411 1417 Series Appendices e 141 Galil Software CD Terminal emulation and communication drivers and DLL for Windows TM WSDK 16 bit Servo Design Kit for Windows 3 X WSDK 32 bit Servo Design Kit for Windows 95 98 NT 4 ME 2000 and XP VB Toolkit Visual Basic Tool Kit TM Windows MS DOS and Visual Basic are trademarks of Microsoft Corporation 142 e Appendices DMC 1410 1411 1417 Series Address Settings of the DMC 1410 1411 Use this table to find the dip switch or jumper settings for any of the available addresses of the DMC 1410 or 1411 Address Dip A8 Dip A7 Dip A6 Dip A5 Dip A4 Dip A3 Dip A2 648 x x x x DMC 1410 1411 1417 Series Appendices e 143 d e f k e T_T R f e p T_T h i f k e C o Rh 1 k T k k E T TR ES TG CS E TR T_T T_T E T_T Dl pol E o CS bb Dl pol TR
180. tor Amphfier xs er ete tede tti eii e He at it dtes 126 RA RR RR RI 129 tais a A ani rana dp da pad SE dd pt 130 K 20 65 536 0 0003 V count er tp ep ets 130 Digital Filter et re ect pr et eec e rat etit 130 p 130 System Analysis eet er pci re Tet gc e E ledit trees 131 System Design and Compensation ie 133 The Analytical Method etu mette ene ra eoe 133 Appendices 137 Electrical Specifications eae e e oa 137 Servo Control iier pete ie teres ede aei aeterne op EAN 137 Stepper Control 3 tnr D Rer yr a hai pe ea 137 Input Output RUE ea RESET 137 Power Requirements dpi tenete tede tee Do oreet deer ian 137 Performance Specifications tenete rieira eia iae ee ede neon ENR ee 138 GIOIELLI IL LIU 138 DMC 1410 1417 J3 General I O 37 PIN D type eee 138 DMC 1411 J3 General I O 40 PIN IDC esee 139 Pin Out Description pani bats ile bees De RETE Rota 139 lunc ds 141 Accessories and Options is ie AUR e ET Pee gi a ete eb ALII Lia 141 Address Settings of the DMC 1410 1411 ii 143 ICM 1460 Interconnect Module Rev F enne enne enne 146 J8 9 Encoder 10pin header eene 148 Opto Isolation Option for
181. ttom byte of LEN LEN4 LEN amp 0000FF00 100 Let variable LEN4 second byte of LEN LENS LEN amp 00FF0000 10000 Let variable LENS third byte of LEN LEN6 LEN amp FF000000 1000000 Let variable LEN6 fourth byte of LEN MG LEN6 54 Display LENG as string message of up to 4 chars MG LENS S4 Display LENS as string message of up to 4 chars MG LENA 54 Display LEN4 as string message of up to 4 chars MG LEN3 S4 Display LEN3 as string message of up to 4 chars MG S4 Display LEN2 as string message of up to 4 chars MG LEN S4 Display LEN as string message of up to 4 chars EN This program will accept a string input of up to 6 characters parse each character and then display each character Notice also that the values used for masking are represented in hexadecimal as denoted by the preceding For more information see section Sending Messages To illustrate further if the user types in the string TESTME at the input prompt the controller will respond with the following DMC 1410 1411 1417 Series Chapter 7 Application Programming e 97 T Response from command MG LEN6 S4 E Response from command MG LENS S4 S Response from command MG LEN4 S4 T Response from command MG LEN3 S4 M Response from command MG LEN2 S4 E Response from command MG LENI S4 Functions Function mun TT Functions may be combined with mathematical expressi
182. uation may be written in the continuous equivalent form G s 50 0 98s 0 98 s 51 The system elements are shown in Fig 10 7 DMC 1410 1411 1417 Series Chapter 10 Theory of Operation e 131 FILTER ZOH DAC AMP MOTOR V 2000 500 0 98 S 51 e 0 0003 4 eset 512000 S ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s is the product of all the elements in the loop A 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency o at which A j v equals one This can be done by the Bode plot of AG c as shown in Fig 10 8 Magnitude 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 j200 2 0200 2000 a Arg A j200 tan 1 200 51 180 tan 200 2000 a 76 180 6 110 Finally the phase margin PM equals PM 180 a 70 132 e Chapter 10 Theory of Operation DMC 1410 1411 1417 Series As long as PM is positive the system is stable However for a well damped system PM should be between 30 degrees and 45 degrees The phase margin of 70 degrees given above indicated overdamped response Next we disc
183. udible sound or by interrogation If you send the command TE lt CR gt Tell error a few times and get varying responses especially with reversing polarity it indicates system vibration When this happens simply reduce KD Next you need to increase the value of KP gradually maximum allowed is 1023 You can monitor the improvement in the response with the Tell Error instruction KP 10 lt CR gt Proportion gain TE lt CR gt Tell error As the proportional gain is increased the error decreases Again the system may vibrate if the gain is too high In this case reduce KP Typically KP should not be greater than KD 4 Finally to select KI start with zero value and increase it gradually The integrator eliminates the position error resulting in improved accuracy Therefore the response to the instruction lt CR gt becomes zero As KI is increased its effect is amplified and it may lead to vibrations If this occurs simply reduce KI For a more detailed description of the operation of the PID filter and or servo system theory see Chapter 10 Theory of Operation Design Examples Here are a few examples for tuning and using your controller Example 1 System Set up This example assigns the system filter parameters error limits and enables the automatic error shut off Instruction Interpretation KP 10 Set proportional gain KD 100 Set damping KI 1 Set integral OE1 Set error off ER 1000 Set error limit 34 e Ch
184. umper used for configuring stepper motor operation labeled as SMX Controller RAM JPS Jumpers used for setting controller address DMC 1411 Elements You Need Before you start you must get all the necessary system elements These include 1l DMC 1410 Controller and 37 pin cable Galil part number Cable 37 pin D DMC 1417 and 37 pin cable or DMC 1411 controller and 40 pin to 37 pin cable Galil part number Cable 40 pin ribbon Servo motor with Encoder or stepper motor Appropriate motor drive Servo amp Power Amplifier or AMP 1460 or stepper drive Power Supply for Amplifier PC for communication ISA PC 104 or PCI back plane Communication CD from Galil WSDK Servo Design Software not necessary but strongly recommended SX XO Cen Zr LEX O Interface Module ICM 1460 with screw type terminals or integrated Interface Module Amplifier AMP 1460 Note An interconnect module is not necessary but strongly recommended 6 e Chapter 2 Getting Started DMC 1410 1411 1417 Series The motors may be servo brush or brushless type or steppers The driver amplifier should be suitable for the motor and may be linear or pulse width modulated and it may have current feedback or voltage feedback For servomotors the drivers should accept an analog signal in the 10 Volt range as a command The amplifier gain should be set so that a 10V command will generate the maximum required current For example if the motor peak curr
185. us amp enable voltages e Analog switching chip for enabling and disabling analog command voltage Specifications Dimensions 6 9 x 4 9 x 2 6 Weight 1 pound 12 Volts Rev A F Rev G Termina Terminal AMPEN SIGNY ACMDX PULSE X Amplifier enable X axis or Y Axis Sign Output for Stepper X Axis Motor command or Pulse Output for Stepper o av CI E RE 30 ey Analog Input 1 146 e Appendices DMC 1410 1411 1417 Series DIV O N o o o u lt a Uu ies Bl wl ry Olopyjoyly nrnrypasyuyst Go O oo Ne DMC 1410 1411 1417 Series so o o 2 B 5 E 2 a 5 E 27 EM 2 30 EN EM IE EM 36 EM EM Ea Lo Analog Input 2 Signal Ground Error signal or Y Axis Pulse Output for Stepper Output 3 Ew 1 wooo 5 s EM fo io Ho Output 2 2 E Output 1 3 Circular Compare Input common for Opto option 4 pis Signal Ground 16 m 8 2 a 22 nrc 1 toputt tnputforLatchFuntioo o 23 esx t Forward timitswitehimput a RSX t Reverse timit switch input __ _ 1 Homeinpu e ae 27 la 5 9 Im o m 3a M 9 59 M A 5 A 39 LA Mola ES o 3 sv EM Jo 5 3 Abort Input Signal Ground Signal Ground ACMD2 SIGNX The screw terminals for 12V can be configure
186. uss the design of control systems System Design and Compensation The closed loop control system can be stabilized by a digital filter which is preprogrammed in the DMC 141X controller The filter parameters can be selected by the user for the best compensation The following discussion presents an analytical design method The Analytical Method The analytical design method is aimed at closing the loop at a crossover frequency with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Consider a system with the following parameters Kt Nm A Torque constant J 2 1074 kg m System moment of inertia R 2 Q Motor resistance K 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of the DMC 141X outputs 10V for a 16 bit command of 32 768 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of 500 rad s and a phase margin of 45 degrees The first step is to develop a mathematical model of the system as discussed in the previous system Motor M s P I Kj Js2 1000 s2 Amp K 2 Amp V DAC Kg 10 32 768 Encoder Kg 4N 2x 636 ZOH H s 2000 s 2000 Compensation Filter G s P sD The next step is to combine all the system elements with the exception of G s into one function L s DMC 1410 1411 1417 Series Chapter 10 Th
187. uxiliary Encoder 73 149 150 Dual Encoder 54 Backlash Compensation 75 115 Dual Loop 73 BASIC 53 115 125 127 144 Bit Wise 94 Burn 57 EEPROM 5 Capture Data Record 72 Clock 102 Comments 56 Communication 5 8 47 121 Almost Full Flag 48 FIFO 5 47 49 Master Reset 143 Configuration Jumper 122 123 Configuring DMC 1410 1411 1417 Series Encoders 57 76 Contour Mode 55 61 Control Filter Damping 36 Integrator 36 Proportional Gain 36 Coordinated Motion Ecam 65 66 Electronic Cam 64 67 Cycle Time Clock 102 Damping 36 57 128 Data Capture 104 Arrays 103 Debugging 88 Differential Encoder 28 30 Digial Filter PID 128 Digital Filter 53 132 Damping 57 128 Feedforward 57 Gain 9 41 44 57 102 127 151 Integrator 57 128 Modelling 125 Stability 76 115 121 128 Digital Input 41 Digital Inputs 1 42 113 Digital Outputs 112 Dip Switch 11 Download 57 Dual Encoder 54 57 75 76 105 115 Dual Loop 73 Dual Loop 57 61 73 76 Ecam 65 66 Electronic Cam 64 67 ECAM 1 61 Echo 57 Edit Mode 89 Editor 38 57 EEPROM 5 11 Index e 155 Electronic Cam 56 64 67 Electronic CAM 1 61 Electronic Gearing 1 61 Gearing 1 61 Enable Amplifer Enable 44 Encoder Auxiliary Encoder 73 149 150 Differential 28 30 Dual Encoder 54 Index Pulse 28 42 Quadrature 6 Encoders 57 62 76 105 118 Auxiliary Encoders 41 61 142 Dual Loop 57 61 76 Frequency
188. ve To show how control variables may be utilized Instruction A DPO PR 4000 SP 2000 DMC 1410 1411 1417 Series Interpretation Label Define current position as zero Initial position Set speed Chapter 2 Getting Started e 37 BG Move AM Wait until move is complete WT 500 Wait 500 ms B Vi TP Determine distance to zero PR 1 2 Command move 1 2 the distance BG Start motion AM After motion WT 500 Wait 500 ms Vl Report the value of V1 JP HC V1 0 Exit if position 0 JP EB Repeat otherwise C EN End To start the program command XQ A Execute Program A This program moves the motor to an initial position of 1000 and returns it to zero on increments of half the distance Note _TP is an internal variable that returns the value of the position Internal variables may be created by preceding a DMC 141X instruction with an underscore _ Example 13 Control Variables and Offset Objective Illustrate the use of variables in iterative loops and use of multiple instructions on one line Instruction Interpretation A Set initial values KIO DPO V1 8 V2 0 Initializing variables to be used by program B Program label B OF V1 Set offset value WT 200 Wait 200 msec V2 _TP Set variable V2 to the current position JP C ABS V2 lt 2 Exit if error small MG V2 Report value of V2 1 1 1 Decrease Offset JP EB Return to top of program HC EN End This program starts with a large offset and gradually decreases its value
189. wer cables near encoder signals encoder cables Avoid Ground Loops Use differential encoders Use 12V encoders Communication SYMPTOM DIAGNOSIS CAUSE REMEDY Cannot communicate with Galil software returns error 1 Address conflict Change address jumper positions the DMC 1410 or DMC message when and change if necessary Chap 4 1411 communication is IRQ address attempted Select different IRQ Address selection does not agree with From Galil software edit Galil registry Registry information Cannot communicate with Galil software returns error l Wrong Operating The DMC 1417 is only recognized the DMC 1417 message when System in Win 98 SE NT 4 ME communication is 2000 XP Win 95 98 FE and DOS attempted are not supported Search for Galilpci sys If it s on the PC delete it restart and try communication again If problems persist contact Galil Driver incompatibility 120 e Chapter 9 Troubleshooting DMC 1410 1411 1417 Series Stability Servo motor runs away Reversed Motor Type 1 Wrong feedback Reverse Motor or Encoder Wiring when the loop is closed corrects situation MT 1 polarity remember to set Motor Type back to default value MT 1 Motor oscillates 2 Too high gain or Decrease KI and KP Increase KD too little damping Operation SYMPTOM DIAGNOSIS CAUSE REMEDY Controller rejects Response of controller Anything E 2088 problem reported by TC1 comm
190. y profiles have acceleration rates that change abruptly from zero to maximum value The discontinuous acceleration results in infinite jerk that causes vibration The smoothing of the acceleration profile makes for less vibration in the system Using the IT Command The smoothing is accomplished by filtering the acceleration profile The degree of the smoothing is specified by the command ITn Independent time constant It is used for smoothing profiled moves of the type JG PR and PA The smoothing parameter n is a number between 0 and 1 and determines the degree of filtering where the maximum value of 1 implies no filtering resulting in trapezoidal velocity profiles Smaller values of the smoothing parameters imply heavier filtering and smoother moves The following example illustrates the effect of the smoothing Fig 6 5 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing Instruction Interpretation PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT 5 Filter for Smoothing BG Begin DMC 1410 1411 1417 Series Chapter 6 Programming Motion e 75 Homing ACCELERATION VELOCITY ACCELERATION VELOCITY Figure 6 5 Trapezoidal velocity and smooth velocity profiles The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference T

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