Galil PlugIn for Mach3
Contents
1. X t tlimit pin 1 A limit pin 4 X limit pin 9 A limit pin 12 X home pin 17 A home pin 20 YO pM Sa pin 2 B limit pin 5 Y limit pin 10 B limit pin 3 Y home pin 18 B home pin 21 Z limit pin 3 C limit pin 6 Z limit pin 11 C limit pin 14 Z home pin 19 C home pin 22 Galil Plugin for Mach3 General I O Galil controllers of 1 4 axes usually have 8 inputs and 8 outputs available 5 8 axis controllers have a total of 16 inputs and 16 outputs available It is now necessary to configure the I O in ports amp pins to enable Mach to access and control the Galil I O Prior to this release the Galil inputs were mapped to porti and the pin number was the Galil input number The same was true of the outputs While this was simple problems were found in the implementation that necessitated change With this release the I O must be configured in Mach using the pin numbers from the table below The I O must also be identified as active low or high Inputs 1 4 axis control 5 8 axis control only All use port 1 Input 1 pin 25 Input 9 pin 33 Input 2 pin 26 Input 10 pin 34 Input 3 pin 27 Input 11 pin 32. E F Axis MPG Control The Galil Plugin provides a way to drive the axes directly with MPGs via Galil axis gearing This dramatically smoothes the MPG response since it is not pulsed from Mach s 100ms update loop There are several possible MPG configurations You can use an MPG pendant with a pulse generator wheel and selector switches to choose controlled axis and increment per pulse With this setup the inputs from the pendant need to be wired into the Galil inputs and a brain file used in Mach to map inputs to the MPG Alternatively An MPG pulse generator wheel can be connected to an unused Galil encoder input and the tab out MPG screen can direct output and amount to the proper axis A third method uses 1 to 3 MPG encoders wired to unused Galil encoder inputs The first MPG can control Mach s X axis the second can control Mach s Y axis and the third can control Mach s Z axis Axis selection is controlled with the tab out MPG screen menu In any case Galil Plugin for Mach3 to use an MPG requires that the MPG is enabled through the Ports and Pins screen and the MPG page by checking the enable box The MPGs use either an un configured Galil axis meaning Mach is not using it and it is not mapped in the axis mapping or one of the Galil axes secondary encoders For example if Mach is configured to use X Y and Z axes and they are mapped to the Galil A B and C axes respectively you could ch
3. The Mach Spindle can be mapped to any unused Galil axis It is important not to map more axes than you have configured in Mach This is to allow unused Galil axes to remain independent and is handy if you are using the Galil to drive brushless motors that require an extra axis to perform the sinusoidal commutation Since the Galil controller will automatically map these sinusoidal axes to the last unused axes on the Galil controller we don t want Mach trying to send movement information to these axes For example if the X A Y B and Z C Galil Plugin for Mach3 Galil axes are driving brushless motors the Galil maps the commutation axes to F G and H on an 8 axis controller In this case it is very important not to map the F G and H axes to any Mach axes If any Mach axis is unused just leave it blank as in the example above and don t try to map it to a Galil axis It is also useful to hide Galil axes from Mach so that the axis can be controlled from a thread running on the Galil controller This is useful in cases where the hidden axis is used as a drive for semi continuously running devices such as a sewing machine motor which are controlled through the Galil thread and not Mach If you wish to have the Galil home and then look for an index pulse check the appropriate Use Index Pulse checkbox Using index pulses requires use of encoders that are capable of providing an index pulse Motor Type The Motor Type
4. K Open Multicast Handle V Event driven DMCCommand ox eee Galil Plugin for Mach3 Installing the Plugin The Plugin comes as an m3p file Double clicking the m3p file should install the plug In in the correct Mach location The file is installed in the Mach3 PlugIns directory If the plug in doesn t appear in the controller configuration menu at startup check for the existence of Galil dll in this directory If it is not found here then do a search for this file and copy and paste it manually into this directory Prerequisites While the setup and configuration of the Galil controller is beyond the scope of this manual a few things are worth mentioning The Galil controller needs to be registered in the Galil SmartTerm software Follow the instructions in Chapter 4 Communications settings in the Galil User s Manual for your particular controller Proper controller registration is required for the Mach3 Galil Plugin to communicate with the controller If you are running servos the PID filter values should be set in the controller prior to running the Galil Plugin This is known as tuning the servos Also in Chapter 4 of the Galil User s Manual is a description of the Windows Servo Design Kit WSDK which is Galil s software that is capable of automatically tuning the servos The full version of GalilTools can also be used as well Manually tuning the servos is also possible via the KP KI and KD commands throug
5. Linear Interpolation The Plugin is capable of using two modes of motion linear interpolation and contour mode Linear Interpolation works with all Galil controllers and thus is the default However if have an Accelera controller you may wish to uncheck this checkbox to enable Contour mode The Vector Time Constant and Vector Deceleration are effective in the liner interpolation mode only For most situations set the Vector Time Constant to 1 Setting this to a lower value will have the effect of smoothing the moves The Vector Time Constant is a velocity filter Setting the value progressively lower increases the filtering to attempt to maintain a more constant velocity over the move sequences The Galil is a very powerful motion controller in its own right and it is capable or performing its own trajectory planning But Mach is doing the same thing So the Vector Deceleration should be set to a range that allows Mach to take the lead in this department Start with 30 000 000 That s thirty million Queue Buffer Level The Plugin uses an internal buffer to stream the commands to the Galil controller This is the Queue Buffer Level and it can be tweaked to suit the speed of the Mach PC If you are experiencing motor stutters in mid moves then start incrementing this value by one until the stutter is gone The default value is 10 and it will go as high as 100 A side effect of increasing this number is that feed rate overrides and feed hol
6. drop down boxes allows setup of the Galil MT and CE values from within Mach The options include MT 2 5 CE12 MT2 5 CE12 Step Motor Reverse Hi active Step Motor Reverse Lo active Servo Motor ed CEQ Servo Reverse MT 1 CEQ Step Motor Hi active MT 2 CE4 Step Motor Lo active MT2 CE4 The step motor options require that the SM jumper is placed on the appropriate Galil axis jumpers for non Accelera models Spindle Spindle has Encoder If your spindle has an encoder and you wish to use it to allow the Galil controller to keep the spindle speed constant then enable this checkbox Counts Rev This value is the number of counts per revolution for the spindle encoder The value should be in quadrature counts e g If your encoder has 512 counts per revolution the Galil will see it as 2048 counts per revolution In this example 2048 is what you should enter in this field Accel Revs Second This is the acceleration and deceleration value for the encoder based spindle in revolutions per second Galil Plugin for Mach3 Galil Configuration General Axis Setup MPG Extended 10 Custom Notify MPG Control MPG 1 Axis MPG 2 Axis MPG 3 Axis G v z v Ef w XYZ D H Axis Encoder 1 Disables MPG input V Use Aux Encdr Use Aux Encdr Use Aux Encdr MPG s must be enabled in the Config Ports and Pins MPG screen Invert MPG Axis Direction When Checked iis iy Be ip
7. homes switches either You must choose one switch type for the limits and one switch type for the home switches However you could mix switch types if you wire them with relays that do the right thing on the machine The important thing is that the switch state that the Galil sees must be consistent Use Limits for Homes For machines where no separate home switches are available you will need to enable this checkbox It is preferable to install home switches since there is a dedicated home switch input per axis on the Galil ICM Perform Axis Squaring for Slaves Gantry style machines that have a slaved axis require special homing routines The default way the plugin homes a gantry axis is that it first homes the master and slave axes together It will then disconnect the slave and home it to square the gantry If you do not wish to square the gantry then uncheck this checkbox Motor Options These check boxes determine how Mach gets the position feedback and speed Most of the time these should remain unchecked If stepper motors are configured using the SM jumpers checking the boxes may be necessary to display position in the DRO displays Galil Plugin for Mach3 Diagnostics Enable Debug File Output Enabling this checkbox creates a GalilDebug txt file in the Plugin s directory This output may be useful for the developers if you are running into problems Leave it unchecked for normal operation Move Settings Use
8. the Mach axes or mixed in any manner desired Limit switches home switches general inputs and general outputs are supported through the Mach Ports and Pins settings And support for extended I O is also provided Galil Plugin for Mach3 Controller Compatibility Accelera Series DMC 40x0 Ethernet DMC 18x6 PCI BUS Optima Series DMC 17x0 ISA BUS DMC 18x0 PCI BUS DMC 21x0 Ethernet DMC 22x0 Ethernet Econo Series DMC 21x2 3 Ethernet DMC 18x2 PCI Single and Dual Axis DMC 14x5 The Optima DMC 20x0 USB controllers may work but none have been tested Galil has versions of the above controllers that operate in distributed mode via Ethernet They are the DMC 31x2 3 and the DMC 34x5 These controllers are not supported in their distributed form but can be loaded with the non distributed mode firmware to effectively turn them into a DMC 21x2 3 or DMC 14x5 Ethernet Controllers Galil Ethernet controllers have a few special items that need some consideration A good quality network is required The Galil Controllers will answer just about any TCP IP port and will open a handle when contacted by any remote machine There is a limit of 8 handles which can be used up rather quickly making your Galil controller unusable until it is reset Obviously a port sniffer running on the network will pretty much make a Galil Ethernet controller hose up pretty fast So it is best to have the Galil controller on an isolated net
9. 3 Automatic mode Automatic mode is where the controller will send a data record to the host PC at a predetermined interval The automatic mode produces a smoother Mach interface because the Plugin doesn t have the overhead of requesting a data record and waiting for it Automatic mode will feel more like a bus based controller However the automatic data record mode uses UDP to transmit the stream of data records to the host UDP is a connectionless protocol and there is no way of determining if there is a dropped packet So if automatic mode is chosen you must ensure that the network is in good shape Or preferably use a crossover cable between the controller and the Mach PC If automatic mode is chosen and the data stream to the host PC is unreliable Mach will crash from a lack of information from the Galil controller In this case simply choose the Manual data record refresh mode Below is an example of how the controller s Communication Parameters should be set for automatic data records Set the Refresh Rate to 25 milliseconds and the Cache Depth to 2 Controller Communications Parameters General Parameters Ethernet Parameters IP Address 192 168 1 72 Set IP Address Cable Info Time interval at which data records are sent Primary Handle from the controller to the PC TCP v Unsolicited Messages Data Records Take no action v Auto data record refresh v Refresh Rate msec 25 lt z Cache Depth 2
10. 5 Input 4 pin 28 Input 12 pin 36 Input 5 pin 29 Input 13 gt gt pin 37 Input 6 pin 30 Input 14 pin 38 Input 7 pin 31 Input 15 pin 39 Input 8 pin 32 Input 16 pin 40 Outputs 1 4 axis control 5 8 axis control only All use port 1 Output 1 pin 41 Output 9 pin 49 Output 2 pin 42 Output 10 pin 50 Output 3 pin 43 Output 11 pin 51 Output 4 pin 44 Output 12 pin 52 Output 5 5 pin 45 Output 13 pin 53 Output 6 pin 46 Output 14 pin 54 Output 7 pin 7 Output 15 pin 55 Output 8 pin 48 Output 16 pin 56 Galil Plugin for Mach3 Probing The Galil Plugin is capable of using a probe for various probing functions This is accomplished using the Galil high speed position latch functions Unfortunately the latch inputs share general purpose inputs on the Galil ICM Galil axes A B C and D use inputs 1 2 3 and 4 and Galil axes E F G and H use inputs 9 10 11 and 12 for the latch inputs IMPORTANT A probe should be wired to ALL latch inputs for any moving axis on your machine For example if you have a 3 axis mill and you are using Galil axes A B and C to drive them then the probe s output should be wired to inputs 1 2 and 3 This is because the G31 probe command will move in all 3 dimensions If you have 3 axis mill with a 4 axis rotary
11. Galil Plugin for Mach3 Table of Contents Overview 2 Controller Compatibility e Ethernet Controllers Prerequisites Installing the Plugin Configuring the Plugin e General Motor Options Diagnostics Move Settings Analog Inputs Axis Mapping Motor Type Spindle MPG Control Extended I O Custom Notify Messages 6 Configuring Mach e Limit Home Switch Connections e General I O e Probing 7 Credits oeo Galil Plugin for Mach3 Overview The Galil Plugin controls the popular Galil Motion Controllers The Galil is a very powerful motion controller that will control up to 8 axes and provides I O capabilities as well When used with Mach it provides a means of controlling a closed loop servo system as well as a stepper system Stepper motor and servos can even be mixed For servos the Galil controllers provide an industry standard 10V motor command that works with most analogue servo amps It is one of the few ways to run analogue amps with Mach For stepper motors the Galil Controllers provide the standard pulse and direction interface Unlike the parallel port stepper driver the Galil controller can provide step pulse rates at up to 3 MHz The Plugin works by taking the Mach step and direction signals that would normally go to the parallel ports and converting them into linear interpolated moves in the Galil command language A spindle is also supported Galil axes can be mapped 1 to 1 with
12. I DROSS MG_BY O O O O O O O O O O O O O O O O O O O O O O 0 0 0 0 0 0 0 0 0 0 0 0 C 0 0 0 0 0 0 0 0 0 Custom Notify Messages The Galil Plugin allows the user to make use of the powerful Galil command set via custom notify messages There are 24 possible messages that can be configured Enable Enable this message Message ID The Mach message ID This is the ID that Mach sends the Plugin Commands The Galil commands to send to the controller when the Plugin receives its corresponding message ID More than one command can be sent provided that they are separated by semicolons The entire command string can be no longer than 80 characters the Galil command line length There is support for limited substitutions in the command string DROxxxx will substitute the value of the Mach DRO with OEM code xxxx LEDxxxx will substitute the values of the Mach LED with OEM code xxxx For instance if you wanted to set a Galil variable to the value of a Mach DRO then the cammand string would look like this SPI DRO55 This will set the Galil variable SPI equal to the value in the Mach DRO 55 Galil Plugin for Mach3 Configuring Mach Limit Home connections Limit and home switches are configured on the ports amp pins inputs screen They are wired to the Galil inputs and configured as in the table below All use port 1
13. allows different Mach profiles on the same machine to control different Galil controllers This may be useful for people who wish to drive both a mill and a lathe from the same PC Not at the same time though Simply choose which controller you wish to use in this Mach profile from the dropdown list WARNING You must have previously registered a Galil controller in the SmartTerm software before any controllers will show up in the drop down list Galil Plugin for Mach3 Bus based controllers may require you to reboot the PC before a newly registered bus based controller will be visible Disable Amplifiers When in E Stop Disables the amplifiers when Mach is in an e stop condition The Galil lets you control the active state of the limit switches This allows for both normally open and normally closed switches to be used It is popular to wire the limit switches with normally closed switches for safety reasons In the event of a cable cut the machine will stop A normally closed switched system will be active low A normally open switched system will be active high Config Galil Limits Active Low If you have normally closed switches on your limits then this checkbox should be enabled Config Galil Homes Active Low Similarly if your home switches are active low enable this checkbox Unfortunately you cannot have a mixture of normally closed and normally open limit switches And you cannot have a mixture of switch types for the
14. driven from Galil axes A B C and D then the probe s output should be wired to inputs 1 2 3 and 4 When setting up Mach for probing it is imperative that the Probe signal is enabled in Ports and Pin on the Input Signals tab and the port and pin should be mapped to one of the Galil latch input pins For example if your 3 axis mill uses Galil axes A B and C to drive Mach axes X Y and Z then the probe s output signal should be wired to Galil inputs 1 2 and 3 and the Mach Probe signal should be enabled and mapped to port 1 and one of pins 25 26 or 27 Which pin is mapped really does not matter since all of the inputs will be active upon a probe hit Credits Galil Plugin for Mach3 Brian Barker briano machsupport com Thanks go to Brian for feeling adventurous and writing the Galil Plugin Without Brian the Galil PlugIn would not have materialized at all Jeff Birt Jeff added the Extended I O support Kenny Crouch kcrouch cruises4fun com Kenny added the MPG support and improved the flow of the Galil command to the controller He also made it possible to run Galil threads while under Mach control He was able to smooth things out tremendously Steve Murphree smurph smcomp com Steve added the following The ability to control registered Galil controllers other than the first registered controller Axis mapping Contour Mode movement control He originated this manual and continues to mainta
15. ds will be slower so start low and increase it only to the point where your problem disappears Mach ExBuffer For external motion Plugins Mach maintains a buffer for the move sequences This value impacts the response time of the feed rate override and the feed hold Lower the value yield the better the responses However setting the value too low will cause the plugin to cease producing moves 15 the default value is safe Faster Mach machines may be able to use a value of 11 or 12 Analog Inputs User DRO Start This is the starting User DRO OEM code for the range of 8 analog inputs that are available on some Galil controllers Galil Plugin for Mach3 Galil Configuration General Axis Setup MPG Extended 10 Custom Notify Axis Mapping Motor Types Mach Galil Use Index Galil Motor Type Axis Axis Pulse Axis r Benom Yi Stepper Lo active Stepper Lo Active bed Stepper Lo Active v Servo Motor z Spindle Spindle Has Encoder Counts Rey quadrature 8192 Accel Revs Sec 1500 Axis Mapping You can map axes in a different order than the standard XYZABC order that Mach provides For instance you may wish to drive your Mach X axis with the Galil G axis Simply choose the Galil G axis in the dropdown list for the Mach X axis The limit switches travel with the Galil axis so in the example above you would wire your limits to the Galil G axis but they would appear as Mach X axis signals
16. h SmartTerm After tuning the servos with whatever method you choose the KP KI and KD values should be saved to the controller with the BN command All home and limit switches should be connected and verified You can use the Display Data Record menu option in the Tools menu of SmartTerm to verify these switches Galil Plugin for Mach3 Configuring the Plugin Galil Configuration General Axis Setup MPG Extended 10 Custom Notify General Galil Controller Controller3 ETH DMC 21x3 2 SN 10161 bd Disable Amplifiers When In E Stop Config Galil Limits Active Low F Use Limits for Homes Config Galil Homes Active Low V Perform Axis Squaring for Slaves Motor Options Use Ref Position Not Encoder For Position Feedback Use Calculated Actual Speed Instead of Encoder Diagnostics V Enable Debug File Output Move Settings M Use Linear Interpolation vetor Time Const 1 004 1 0 Mach ExBuffer 15 Vector Deceleration 30000000 1024 67107640 Queue Buffer Level 10 10 100 Analog Inputs User DRO Start 1100 1000 1247 Cancel General Galil Controller When setting up communications with the Galil controller in the Galil SmartTerm software you register the controller and provide information about it This registration puts the controller into the Galil registry This version of the Plugin allows you to choose which registered controller to use for Mach This
17. in version control of the plug in software Encoder controlled Spindle Analog Input support Custom Notify Messages Use Limits for Homes
18. oose the Galil D axis to drive your first MPG You would then hook the MPG encoder to the Galil D main encoder terminals on the ICM If you have used all of your Galil axes for Mach you can then choose the Galil axis A and check the Use Aux Encdr check box to drive your first MPG You would then hook the MPG encoder to the Galil A secondary encoder terminals on the ICM Follow this method for each MPG you wish to connect WARNING It is very important that if you don t have an MPG configured in Mach then you must not configure the MPG setting in the Galil Plugin configuration Otherwise you may get weird axis movements X tied to Y etc Galil Plugin for Mach3 Galil Configuration General Axis Setup MPG Extended 10 Custom Notify Extended I O Extened I O Enabled 10 LED Start Configuration Block2 yc 123 Enabled fey FI is 5 4 ay el a Inverted sl 77 6F SJ 47 37 27 1 Block3 input 456 Hel MOM BMS Bom wee mci MR BS mls me o Block4 Output 789 aes BGM MGS Mm ml mf Inverted sf 77 6f sv 47 37 27 1 Block5 yc F 12 Srl MC BS o mS mle a Inverted sf 7 7 67 SJ 47 37 27 1 Block6 input 345 Enabled af 7f 6 sft 4f af 2 1 Inverted al ZI 6 5 4 37 2f 7 Block output 678 Heel BOE MEMS Mom mom Inverted sl 77 6f SJ 47 37 27 1 Blocks yc 901 Enabled ef Zr 6 sf 4f af 2f 1 Inverted sf 7 7 6f SJ 4f 37 2f 1 Block input 234 gee BOR BERS wom mem Inverted
19. sf 77 6f sy 4f 3f 2 Extended I O Extended I O is not available on the Econo Series PCI controllers It is an option on the Optima Series bus controllers and the Econo Ethernet controllers It is standard on the Optima Ethernet and USB controllers For the Optima controllers there are 64 bits of configurable extended I O However the Econo Ethernet controllers only provide 40 bits of configurable extended I O The extended I O is configurable in blocks of eight as either inputs or outputs Extended I O Enabled To enable extended I O this checkbox must be enabled 1 O You must explicitly enable each block as either and Input or Output blocks or leave it in the not configured state NC LED Start Each block must be configured with a range of Mach user LEDs Since each block consists of 8 I O points each block will use 8 Mach user LEDs This filed is the number of the first Mach user LED in the block Galil Plugin for Mach3 Enabled Each I O bit can be enabled or disabled depending on the state of its associated Enabled checkbox Inverted The state of the I O point active high or active low can be configured with its associated Inverted checkbox Leave extended I O disabled if you do not have extended I O or do not wish to use it Galil Plugin for Mach3 Galil Configuration General Axis Setup MPG Extended IO Custom Notify Custom Notify Messages Enable Message ID Commands 0 O SP
20. work along with your Mach machine In the Galil Controller Communication Parameters dialog set the following items as described below The Primary Handle drop down list should be set to TCP The Unsolicited Messages drop down list should be set to Take no action The Ethernet controllers also have a feature that allows them to listen to a Multicast address This allows for one message to Galil Plugin for Mach3 reach all controllers on a network This is undesirable for the Mach Galil combination Uncheck the Open Multi cast Handle check box Data records for Ethernet controllers are handled differently than the bus based controllers There are two modes for data records on Ethernet controllers Either mode works with the Galil Plugin Manual mode Manual mode is where a command has to be sent to the controller to request a data record and then the controller will send one back Below is an example of how the controller s Communication Parameters should be set for manual data records Controller Communications Parameters General Parameters Ethernet Parameters IP Address 192 168 1 72 Set IP Address Cable Info Use event driven communications for the Primary Handle DMCCommand function TCP hd Unsolicited Messages Data Records Take no action v Manual data record refresh fig ZE 7 M Open Multicast Handle V Event driven DMCCommand oc ewer Galil Plugin for Mach
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