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DMC-30000 User Manual - Galil Motion Control

1. 3 88 19 3 500 i r DMG 30010 TF 3 3 250 4 20 2 463 1 589 O 4 TON DUTT O e JET Er 48 i L 125 PLCS Chapter 2 Getting Started gt 17 DMC 30000 User Manual DMC 30012 BOX DMC 30016 BOX and DMC 30017 BOX 6 32 EARTH NUT 25 1 4 MAX INSERTION DEPTH O60000n ooo ole 101000 Ow gt U 2 688 1 26 156 M 1 45 g 4 PLCS 2 953 Chapter 2 Getting Started gt 18 DMC 30000 User Manual Mounting Instructions CARD All 4 standoff locations must be used when mounting the CARD version of the DMC 30000 controllers See Figure 2 1 and Figure 2 2 for mounting screw sizing and locations BOX All 4 mounting holes should be used to mount the controller to a secure base See Figure 2 3 and Figure 2 4 for mounting hole locations and sizes DMC 30012 DMC 30016 and DMC 30017 The bases for the DMC 30012 DMC 30016 and DMC 30017 are used as the heat sync for the internal amplifier The DMC 30012 and DMC 30017 must be mounted to an external heat sync for high duty cycle applications Elements Needed For a complete system Galil recommends the following elements 1 DMC 30000 motion controller 2 Motor Amplifier In
2. LOOP Dummy Program JP LOOP EN Loop POSERR Position Error Routine V1i _TEX Read Position Error MG EXCESS POSITION ERROR Print Message MG ERROR V1 Print Error RE Return from Error Download program XQ LOOP Execute Dummy Program JG 100000 Jog at High Speed BGX Begin Motion Example Input Interrupt A Label TIL Input Interrupt on 1 JG 30000 Jog BGX Begin Motion LOOP JP LOOP EN Loop ININT Input Interrupt STX AM Stop Motion TEST JP TEST IN 1 0 Test for Input 1 still low JG 30000 Restore Jog BGX Begin motion RIO Return from interrupt routine to Main Program and do not re enable trippoints Chapter 7 Application Programming 115 DMC 30000 User Manual Example Motion Complete Timeout BEGIN Begin main program TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command BGX Begin motion CX Motion Complete trippoint EN End main program CTIME Motion Complete Subroutine G xX fell short Send out a message E End subroutine This simple program will issue the message X fell short if the X axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error BEGIN Begin main program speed 2000 Set variable for speed JG speed BGX Begin motion LOOP JG speed WT100 Update Jog speed based upon speed variable JP LOOP EN End main prog
3. Feedback Type Directions Standard Differential Swap channels A and A Quadrature Single ended Swap channels A and B Sin Cos 1 Vox pk Swap signals Vot and Vo SSI or BiSS Follow encoder manufacturers instructions Cannot change the direction of feedback without external Analog feedback i hardware to invert analog signal Table 2 3 Directions for reversing feedback direction based upon feedback type The polarity of the control loop may still be inverted by either re wiring the motor or using the MT command see Step 7 Setting Safety Features before Wiring Motors pg 19 regarding positive feedback loops Step 7 Setting Safety Features before Wiring Motors This section applies to servo motors only Step A Set Torque Limit TL will limit the output voltage of the 10V motor command line This output voltage is either translated into torque or velocity by the amplifier Galil s internal amplifiers are in torque mode This command should be used to avoid excessive torque or speed when initially setting up a servo system The user is responsible for determining the relationship between the motor command line and the amplifier torque velocity using the documentation of the motor and or amplifier See the TL setting in the Command Reference for more details See the AG command in the command reference for current gains of Galil s internal amplifiers The amplifier gain can also be used to cha
4. Power Connector Locations Options Ordered Controller Power Controller Power AMP SDM Power Controller Power 2 pin Molex on bottom side 4 pin Molex on bottom side 2 pin Molex 2 pin molex near AMP power DMC 30010 X DMC 30011 X DMC 30012 X DMC 30012 BOX ISCNTL X X DMC 30016 X DMC 30016 BOX ISCNTL X X DMC 30017 X DMC 30017 BOX ISCNTL X X Table 2 1 Available power connectors based upon option ordered The DMC 30000 power should never be plugged in HOT Always power down the power supply before installing or removing the power connector to the controller NOTE Any emergency stop or disconnect switches should be installed on the AC input to the DC power supply Relays and or other switches should not be installed on the DC line between the Galil and the Power supply An example system is shown in Figure 2 5 with a DMC 30012 POWER SUPPLY rit A NZ on GALIL MOTION maoemusa The green power light indicator should go on when power is applied Step 5 Establish Communications with Galil Software See Ethernet Configuration pg 47 for details on using Ethernet with the DMC 30000 To configure a NIC card using Windows to connect to a DMC controller see this two minute video http www galil com learn online videos connecting galil ethernet motion controller For connecting using serial see RS 232 Port pg 46 for proper configuration of the Main DMC serial port See the G
5. Data Record Map Key Acronym Meaning UB Unsigned byte UW Unsigned word SW Signed word SL Single long record UL Unsigned long ADDR TYPE ITEM 00 UB 1 Byte of Header 01 UB 2 Byte of Header 02 UB 3 Byte of Header 03 UB 4 Byte of Header 04 05 UW sample number 06 07 UW general input block 0 inputs 1 16 08 09 UW general output block O outputs 1 16 10 UB error code 11 UB thread status see bit field map below 12 13 UW analog input 2 14 15 UW analog output 1 16 17 UW analog output 2 18 21 UL amplifier status 22 25 UL Segment Count for Contour Mode 26 27 UW Buffer space remaining Contour Mode 28 29 UW segment count of coordinated move for S plane 30 31 UW coordinated move status for S plane see bit field map below 32 35 SL distance traveled in coordinated move for S plane 36 37 UW Buffer space remaining S Plane 38 39 UW A axis status see bit field map below 40 UB A axis switches see bit field map below 41 UB A axis stop code 42 45 SL A axis reference position 46 49 SL A axis motor position 50 53 SL A axis position error 54 57 SL A axis auxiliary position 58 61 SL A axis velocity 62 65 SL A axis torque 66 67 UW analog input 1 68 UB A Hall Input Status 69 UB Reserved 70 73 SL A User defined variable ZA Not all I O shown in the data record are available on the standard DMC 30000 controller Chapter 4 Software Tools and Communication 58 DMC 30000 User Manual Explanation Data Record Bi
6. The following example illustrates the effect of smoothing Figure 6 13 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed ET 5 Filter for smoothing BG X Begin ACCELERATION D 25 zZ O VELOCITY no ACCELERATION 2D se G OR 2 We 2o oO Q VELOCITY E E Lo es Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command smoothes the frequency of step motor pulses Similar to the command IT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS x where x is an integer from 0 5 to 128 and represents the amount of smoothing Chapter 6 Programming 98 DMC 30000 User Manual The smoothing parameters x y z w and n are numbers between 0 5 and 128 and determine the degree of filtering The minimum value of 0 5 implies the least filtering resulting in trapezoidal velocity profiles Larger values of the smoothing parameters imply heavier filtering and smoother moves Note that KS is valid only for step motors Homing The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference This reference is connected to
7. p ctsis TM Xn Where m isthe number of counts per magnetic cycle cts magnetic cycle n isthe desired number of TM samples per magnetic cycle 8 or more recommended samples magnetic cycle Example Assume that an encoder provides 4000 cts rev and that a motor has 2 pole pairs Each pole pair represents a single magnetic cycle m can be calculated as follows m 4000 is rev 2000 7 a magnetic cycles cts magnetic cycle If TM 250 is set and 8 servo samples per magnetic cycle is desired the maximum speed in counts per second would be 6 ZOO cei piscnaunnegite xI Of us s 1 000 000 2 1 rs St samptesi magnetic ccycle Finding Proper Commutation Using the DMC 30014 requires version 1 1d revision firmware or higher be sure this is installed on your controller http www galilmc com support firmware downloads ph The 6 commands used for set up are the BA BM BX BZ BC and BI commands Please see the command reference for details For detailed information on setting up commutation on the DMC 30014 can be found here 1 Issue the BA command to specify which axis you want to use the sinusoidal amplifier on 2 Calculate the number of encoder counts per magnetic cycle For example in a rotary motor that has 2 pole pairs and 10 000 counts per revolution the number of encoder counts per magnetic cycle would be 10 000 2 5000 Assign this value to BM A2 DMC 30014 194 DMC 30
8. 800 600 400 200 o Desired Velocity Profile s Velocity Time Seconds To accomplish this we need to calculate the desired velocities and change in positions In this example we will assume a delta time of of a second which is 256 samples 1024 samples 1 second with the default TM of 1000 Velocity counts second Position counts v t 1000 t 1 1000 p t 1000 1 1000 at v 25 3375 p 0 to 25 57 v 5 an p 25 to 5 151 v 75 eae p 5 to 75 214 v 1 iodo p 75 to 1 245 v 1 25 p 1 to 1 25 245 VU 5 s0 p 1 25 to 1 5 214 v 1 75 ie p 1 5 to 1 75 151 v 2 p 1 75 to 2 57 Chapter 6 Programming 84 DMC 30000 User Manual The DMC program is shown below and the results can be seen in Figure 6 10 INSTRUCTION INTERPRETATION PVT Label PVX 57 437 256 Incremental move of 57 counts in 256 samples with a final velocity of 437 counts sec PVX 151 750 256 Incremental move of 151 counts in 256 samples with a final velocity of 750 counts sec PVX 214 937 256 Incremental move of 214 counts in 256 samples with a final velocity of 937 counts sec PVX 245 1000 256 Incremental move of 245 counts in 256 samples with a final velocity of 1000 counts sec PVX 245 937 256 Incremental move of 245 counts in 256 samples with a final velocity of 937 counts sec PVX
9. A s 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency w at which A j w equals one This can be done by the Bode plot of A j w as shown in Figure 10 8 Magnitude 50 200 2000 W rad s 0 1 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 j200 2000 a Arg A j200 tan7 200 51 180 tan 4 200 2000 a 76 180 6 110 Finally the phase margin PM equals PM 180 a 70 As long as PM is positive the system is stable However for a well damped system PM should be between 30 and 45 The phase margin of 70 given above indicated over damped response Next we discuss 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 30000 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 w c with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Chapter 10 Theory of Operation 158 DMC 30000 User Ma
10. Chapter 7 Application Programming Overview The DMC 30000 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 30000 memory freeing the host computer for other tasks However the host computer can send commands to the controller at any time even while a program is being executed Only ASCII commands can be used for application programming In addition to standard motion commands the DMC 30000 provides commands that allow the DMC 30000 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 30000 provides user defined variables arrays and arithmetic functions For example with a cut to length operation the length can be specified as a variable in a program which the operator can change as necessary The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 80 characters x 1000 lines Program Format A DMC 30000 program consists of DMC 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
11. Event Trigger Change Speed along Vector Path The following program changes the feed rate or vector speed at the specified distance along the vector The vector distance is measured from the start of the move or from the last AV command VECTOR VM XN VS 5000 VP 10000 20000 VP 20000 30000 VE BGS AV 5000 VS 1000 EN Label Coordinated path Vector position Vector position End vector Begin sequence After vector distance Reduce speed End Event Trigger Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves Chapter 7 Application Programming 109 DMC 30000 User Manual OVES R 12000 P 20000 C 100000 D 10000 00 T 200 0000 P 30000 C 150000 zo m AWPrPn SP HNP Ww Pn UM a Oo Label Distance Speed Acceleration Start Motion Wait a distance of 10 000 counts New Speed Wait until motion is completed Wait 200 ms New Position New Speed New Acceleration Start Motion 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 OUTPUT ATO OBLE LOOP AT 10 Cells AT 40 SB JP LOOP 1 r Program label Initialize time reference Set Output 1 Loop After 10 msec from reference Clear O
12. RXD RS 422 Option Only Connects a 1200hm Termination resistor between the differential Receive inputs on the Aux Serial port Pins 2 and 7 on RS 422 Auxiliary Port CTS RS 422 Option Only Connects a 1200hm Termination resistor between the differential Clear To Send inputs on the Aux Serial port Pins 1 and 6 on RS 422 Auxiliary Port Part number ordering example DMC 30010 CARD 422 Mounting Options DIN DIN Rail Mounting The DIN option on the DMC 30000 motion controller provides DIN rail mounts on the base of the controller This will allow the controller to be mounted to any standard DIN rail Requires BOX option Part number ordering example DMC 30010 BOX DIN Internal Amplifier Options ISCNTL Isolate Controller Power The ISCNTL option isolates the power input for the controller from the power input of the amplifiers With this option the power is brought in through the 2 pin Molex connector on the side of the controller as shown in the Power Wiring Diagrams section of the Appendix This option is not valid when Galil amplifies are not ordered with the DMC 30000 Part number ordering example DMC 30012 BOX ISCNTL Appendices 167 DMC 30000 User Manual SR90 SR 49000 Shunt Regulator Option The SR 49000 is a shunt regulator for the DMC 30000 controller and internal amplifiers This option is highly recommended for any application where there is a large inertial load or a gravitational load
13. USER MANUAL DMC 30000 Manual Rev 1 0g By Galil Motion Control Inc 270 Technology Way Rocklin California 95765 916 626 0101 support galilmc com galil com 08 2015 Using This Manual This user manual provides information for proper operation of the DMC 30000 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller It is recommended that the user download the latest version of the Command Reference and User Manual from the Galil Website http www galil com downloads manuals and data sheets The DMC 30000 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 servo motors 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 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 machinery Galil shall not be liable or responsible for any incidental or consequential damages WARNING DMC 30000 C
14. gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point As an example consider the following program Chapter 6 Programming 74 DMC 30000 User Manual ALT DP 0 LM XY LI 4000 lt 4000 gt 1000 LI 1000 lt 4000 gt 1000 LI 5000 lt 4000 gt 1000 BG S EN Changing Feed Rate Label for alternative program Define Position of 0 Enable LM mode Specify first linear segment with a vector speed of 4000 and end speed 1000 Specify second linear segment with a vector speed of 4000 and end speed 1000 Specify third linear segment with a vector speed of 4000 and end speed 1000 End linear segments Begin motion sequence Program end The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS to be scaled VR also applies when the vector speed is s
15. 07 Read Exception Status Read Error Code 15 Force Multiple Coils Write Multiple Bits 16 Preset Multiple Registers Write Words 17 Report Slave ID The DMC 30000 provides three levels of Modbus communication The first level allows the user to create a raw packet and receive raw data It uses the MBh command with a function code of 1 The format of the command is MBh 1 len array where len is the number of bytes array is the array with the data The second level incorporates the Modbus structure This is necessary for sending configuration and special commands to an I O device The formats vary depending on the function code that is called For more information refer to the Command Reference The third level of Modbus communication uses standard Galil commands Once the slave has been configured the commands that may be used are IN AN SB CB OB and AO For example AO 2020 8 2 would tell I O number 2020 to output 8 2 volts If a specific slave address is not necessary the I O number to be used can be calculated with the following 1 O Number HandleNum 1000 Module 1 4 BitNum 1 Where HandleNum is the handle number from 1 A to 8 8 Module is the position of the module in the rack from 1 to 16 BitNum is the I O point in the module from 1 to 4 Modbus Examples Example 1 DMC 30000 connected as a Modbus master to a RIO 47120 via Modbus The DMC 30000 will set or clear all 16 of the RIO s digi
16. 10 volts should run the motor at the maximum required speed The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed Stepper Motor Amplifiers For step motors the amplifiers should accept step and direction signals Overview of the Galil Amplifiers With the DMC 30000 Galil offers amplifiers that are integrated into the same enclosure as the controller Using the Galil Amplifier provides a simple straightforward motion control solution in one box DMC 30012 DMC 30000 with 800W Sinusoidal Amplifier The DMC 30012 A1 DMC 30012 provides an amplifier that drives motors operating at 20 80 VDC up to 10 Amps continuous 15 Amps peak The gain settings of the amplifier are user programmable at 0 4 Amp Volt 0 8 Amp Volt and 1 6 Amp Volt The switching frequency is 33 kHz The amplifier offers protection for over voltage under voltage over current and short circuit The SR90 SR 49000 Shunt Regulator Option is also available for the DMC 30012 DMC 30016 DMC 30000 with 1 4 Amp stepper driver The DMC 30016 A3 DMC 30016 includes a microstepping drive for operating two phase bipolar stepper motors Chapter 1 Overview 10 DMC 30000 User Manual The DMC 30016 drive operates a two phase bipolar stepper motor in full step half step 1 4 step or 1 16 step It is user configurable from 0 5A to 1 4A per phase in 7 mA increments at 12 30VDC The dimensions of the DMC 3001
17. 214 750 256 Incremental move of 214 counts in 256 samples with a final velocity of 750 counts sec PVX 151 437 256 Incremental move of 151 counts in 256 samples with a final velocity of 437 counts sec PVX 57 0 256 Incremental move of 57 counts in 256 samples with a final velocity of 0 counts sec PVX 0 0 0 Termination of PVT buffer BTX Begin PVT EN Actual Velocity and Position vs Time 1200 1400 1200 1000 3 e So y 8 Velocity Position 600 Position counts D a S 400 Velocity counts second Q Q O N S te 200 Time Samples Contour Mode The DMC 30000 also provides a contouring mode This mode allows any arbitrary position curve to be prescribed This is ideal for following computer generated paths such as parabolic spherical or user defined profiles The path is not limited to straight line and arc segments and the path length may be infinite Specifying Contour Segments The Contour Mode is specified with the command CM A contour is described by position increments which are described with the command CD x over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2 sample period 1 ms for TM1000 where n is a number between 1 and 8 The controller performs linear interpolation between the specified increments where one point is generated for each
18. 4 20mA analog inputs The 4 20mA option converts the analog inputs into 4 20mA analog inputs This is accomplished by installing 237W precision resistors between the analog inputs and ground The equation for calculating the current is Ima 2 11 V Where Ima current in mA V Voltage reading from DMC 30000 Part number ordering example DMC 30010 CARD 4 20mA LSNK 25mA Sinking Outputs The LSNK option modifies the digital outputs on the DMC 30000 to be capable of sinking up to 25mA per output For detailed information see the 25mA Sinking Optoisolated Outputs LSNK section in Chapter 3 Connecting Hardware Part number ordering example DMC 30010 CARD LSNK LSRC 25mA Sourcing Outputs The LSRC option modifies the digital outputs on the DMC 30000 to be capable of sourcing up to 25mA per output For detailed information see the 25mA Sourcing Optoisolated Outputs LSRC section in Chapter 3 Connecting Hardware Part number ordering example DMC 30010 CARD LSRC HSRC 500mA Sourcing Outputs The HSRC option modifies the digital outputs on the DMC 30000 to be capable of sourcing up to 500mA per output For detailed information see the 500mA Sourcing Optoisolated Outputs HSRC section in Chapter 3 Connecting Hardware Part number ordering example DMC 30010 CARD HSRC HSNK 500mA Sinking Outputs The HSNK option modifies the digital outputs on the DMC 30000 to be capable of sinking up to 500mA per output For detailed
19. CB1 Clear Output Bit 1 pick up pen VP 1000 1000 LE BGS Define vector position move pen AMS Wait for after motion trippoint SB1 Set Output Bit 1 put down pen JS Square CB1l Jump to square subroutine EN End Main Program Square Square subroutine vl 500 JS L Define length of side vl v1 JS L Switch direction EN End subroutine L PR vl v1 BGX Define X Y Begin X AMX BGY AMY After motion on X Begin Y EN End subroutine 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 program 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 Auto Start Routine The DMC 30000 has a special label for automatic program execution A program which has been saved into the controller s non volatile memory can be automatically executed upon power up or reset
20. Command Error w Multitasking A Begin thread 0 continuous loop JP A EN End of thread 0 B Begin thread 1 1 Create new variable KP N Set KP to value of N an invalid value TX Issue invalid command EN End of thread 1 CMDERR Begin command error subroutine IF TC 6 If error is out of range KP 1 1 Set N to a valid number XQ _ED2 ED1 1 Retry KP N command ENDIF LE Tesh If error is invalid command TY XQ _ED3 ED1 1 Skip invalid command ENDIF EN End of command error routine Example Communication Interrupt A DMC 30000 is used to move the axis back and forth from 0 to 10000 This motion can be paused resumed and stopped via input from an RS 232 device BEGIN Label for beginning of program Cah 2 Setup communication interrupt for auxiliary serial port MG P2 Type 0 to stop motion Message out of auxiliary port MG P2 Type 1 to pause motion Message out of auxiliary port MG P2 Type 2 to resume motion Message out of auxiliary port rate 2000 Variable to remember speed SPA rate Set speed of A axis motion LOOP Label for Loop PAA 10000 Move to absolute position 10000 BGA Begin Motion on A axis AMA Wait for motion to be complete PAA 0 Move to absolute position 0 BGA Begin Motion on A axis AMA Wait for motion to be complete JP LOOP Continually loop to make back and forth motion EN End main program COMINT Interrupt Routine JP STOP PI1CH 0 Check
21. 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 Chapter 7 Application Programming 133 DMC 30000 User Manual If the number of decimal places specified by PF is less than the actual value a nine appears in all the decimal places Example Instruction Interpretation DP21 Define position TPA Tell position 0000000021 Default format PF4 Change format to 4 places TPA Tell position 0021 New format PF 4 Change to hexadecimal format TPA Tell Position 0015 Hexadecimal value gt PF2 Format 2 places TPA Tell Position 99 Returns 99 if position greater than 99 Adding Leading Zeros from Response to Interrogation Commands The leading zeros on data returned as a response to interrogation commands can be added by the use of the command LZ The LZ command is set to a default of 1 LZ0 Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 Response With Leading Zeros LZ1 Enables the LZ function TP Tell Position Interrogation Command 95 Response 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 Sn m on the same line as the interrogation command The symbol F specifies that the response should be retu
22. Pie Grant Format scciidari iaia 98 Executing Programs Multitasking coissiccscesssssisesssariserseteisetiaeioadens Debugaing Programi 5 fas sa asses sands bas toute esses Oi lunes Spsaiseiet sod delat 100 Program Flow Commands iscissi 102 Mathematical and Functional Expressions csscsssesseecteeretees 117 Or AO NO ie 5 as Uinta tesa E E uaa E A E E A A E EAT 119 Output of Data Numeric and String Hardware I O EA EN HES Col bee far 1 Ca eee ae nf OY OREO eT PER EE eee E DSP ome pT 135 Chapter 8 Hardware amp Software Protection 138 PRES UO s i ssacnkcsdi ces akorn shin cheenidatasce natal ca laneabaanuameanncenmecomnctaas Hardware Protection Pi NE SU NNN ss i cr Nel la a a fa Chapter 9 Troubleshooting 142 sts as es cies ead nota ves asda E NE E A E A 142 Chapter 10 Theory of Operation 145 BN cies ext cuit A 145 Operation of Closed Loop Systems 147 Beets GGT Gs aidera ET 148 BUTT ANDES onn 152 DMC 30000 Contents iii 15 Performance Specifications Ordering Options Power Conncotor Pari NOmDErS uirursiuisincuiininaisisaiariaiiaa 164 Power Wa Dintram eaa aA Input Current Limitations CULO CT ae SLT CAL OLE Sr Oe ere eer eer rte Rene er arent eee ee re eer eee WARRANT Yc aE EE Al DMC 30012 180 A2 DMC 30014 186 PEETA T EE AEETI A AA ein eae 186 Electrica Sper CAOS aaa 187 ODE esan 189 Error Monitoring and Protectii ccccisisscarsleiaestsmiviasuear
23. The pulses which are generated by the smoothing filter can 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 p Output Motion Profiler Adds a Delay 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 N
24. This will exit the mode once the segment is reached in the buffer To avoid an abrupt stop the user should slow the motion to a zero velocity prior to executing this command The controller will instantly command a zero velocity once a PVA 0 0 0 is executed In addition a ST command will also exit PVT mode Motion will come to a controlled stop using the DC value for deceleration The same controlled stop will occur if a limit switch is activated in the direction of motion As a result the controller will be switched to a jog mode of motion Error Conditions and Stop Codes If the buffer is allowed to empty while in PVT mode then the profiling will be aborted and the motor will come to a controlled stop on that axis with a deceleration specified by the DC command Also PVT mode will be exited and the stop code will be set to 32 During normal operation of PVT mode the stop code will be 30 If PVT mode is exited normally PVA 0 0 0 then the stop code will be set to 31 Additional PVT Information It is the users responsibility to enter PVT data that the system s mechanics and power system can respond to ina reasonable manner Because this mode of motion is not constrained by the AC DC or SP values if a large velocity or position is entered with a short period to achieve it the acceleration can be very high beyond the capabilities of the system resulting in excessive position error The position and velocity at the end of the segment are g
25. a screen capture from the GalilTools scope w H 8 3 R xi ee Vertical Horizontal didt Source Scale fdv Offset div mo _RPAAxis Aref SODcount S 5 ao m sooo sO 2 S ao R ao x 2 a eb RP 0 221383 0 4 42765 1 R RF 0 442765 COTS f sO sO Tian 0 221383 S 3 0 221383 4 soms 0 Trigger Channel W _RP Edge Level 2500 count Mode Repeat m READY Example Motion 2 The previous step showed the plot if the motion continued all the way to 5000 however partway through the motion the object that was being tracked changed direction so the host program determined that the actual target position should be 2000 counts at that time Figure 6 1 shows what the position profile would look like if the move was allowed to complete to 5000 counts The position was modified when the robot was at a position of 4200 counts Figure 6 2 Note that the robot actually travels to a distance of almost 5000 counts before it turns around This is a function of the deceleration rate set by the DC command When a direction change is commanded the controller decelerates at the rate specified by the DC command The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position In Figure 6 2 the velocity profile is triangular because the controller doesn t have sufficient time to re
26. asi m Peene TM X n Where m is the number of counts per magnetic cycle cts magnetic cycle n is the desired number of TM samples per magnetic cycle 8 or more recommended samples magnetic cycle Example Assume that an encoder provides 4000 cts rev and that a motor has 2 pole pairs Each pole pair represents a single magnetic cycle m canbe calculated as follows 4000 m cts rev 2000 magnetic cycles cts Imagnetic cycle If TM 250 is set and 8 servo samples per magnetic cycle is desired the maximum speed in counts per second would be 6 2000 cts magnetic cycle x1 Ors Is 25 Ois sample x 8 Speed 1 000 000 cts s samples magnetic ccycle Sinusoidal Commutation See Step 8a Commutation of 3 phased Brushless Motors pg 23 for the steps on commutating the sinusoidal amplifier Setting Amplifier and Current Loop Gains The AG command will set the amplifier gain Amps Volt and the AU command will set the current loop gain for the DMC 30012 The current loop gain will need to be set based upon the bus voltage and inductance of the motor and is critical in providing the best possible performance of the system The DMC 30012 has 3 amplifier gain settings as shown in Table A1 1 See the AG command in the Command Reference for more details A1 DMC 30012 187 DMC 30000 User Manual AG setting Gain Value 0 0 4 A V 1 0 8 A V 2 1 6 A V Table
27. default last element delim specifies whether the array data is separated by a comma delim 1 or a 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 30000 provides a special feature for automatic capture of data such as position position error inputs or torque This is useful for teaching motion trajectories or observing system performance Up to six types of data can be captured and stored in six arrays The capture rate or time interval may be specified Recording can done as a one time event or as a circular continuous recording Command Summary Automatic Data Capture Command Description RA n m J ol pl Selects up to eight arrays for data capture The arrays must be defined with the DM command RD typel type2 type3 type4 Selects the type of data to be recorded where type type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command RC n m 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
28. if this is the case Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller 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 kOMresistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal is defaulted to 5V high amp enable the amplifier enable signal will be high when the controller expects the amplifier to be enabled Pin outs for the amplifier enable signal is found on the 44 pin I O connector J5 I O 44 pin HD D Sub Connector Female pg 173 For re configuring the DMC for a different amplifier enable voltage use output 4 as an alternative amplifier enable signal see Amplifier Enable pg 43 for full details and specifications on the amplifier enable signal Once the amplifier enable signal is correctly wired issuing a MO will disable the amplifier and an SH will enable it Step C Connect the Encoders optional for stepper systems See Step 6 Connecting Encoder
29. or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application A4 DMC 30017 205 DMC 30000 User Manual A5 DMC 31000 Description The DMC 31000 is an option that allows for the controller to accept sinusoidal encoder signals in addition to standard differential quadrature encoder signals The DMC 31000 option can provide interpolation for a single 1 Wiis differential sinusoidal encoder resulting in a higher position resolution The AF command is used to select the degree of interpolation see AF in the command reference for more details The DMC 31000 options requires differential signals if using a quadrature encoder See the ID command in the Command Reference for board identification NOTE When wiring either Sin Cos or standard differential encoders on an axis will use the same pins see DMC 31000 Encoder 15 pin HD D Sub Connector Female pg 202 for pin outs The DMC 31000 requires specific firmware for the implementation of Sin Cos encoders Any unit ordered with this option will automatically be loaded with this firmware at the factory With this firmware the maximum speed settings will be increased from 22 000 000 cts s to 50 000 000 cts s See Theory of Operation pg 202 and Calculating Equivalent Counts pg 203 for learning how the DMC 31000 interpolates Sin Cos signals Analog Inputs With the DMC 31000 the analog inputs a
30. pg 37 HSNK 500mA sinking outputs 500mA Sinking Optoisolated Outputs HSNK pg 37 4 20mA 4 20mA analog inputs TRES Termination Resistors SR90 Shunt regulator SER SSI and BiSS Feedback HALLF Filtered Hall Sensor inputs Ordering Options starting on 160 ISCNTL Isolate controller and AMP power 422 RS 422 on Serial Port DIN DIN Rail Mounting Clips box required MO Motor off jumper installed 2PB 2 phase brushless servo 2 phased Brushless Servo Mode 2PB Electrical Valid with the DMC 30017 Specifications pg 198 Table 1 4 Form Factor Options WARNING If no option is specified the default optoisolated outputs for the DMC 30000 are 4mA sinking see Standard 4mA Sinking Optoisolated Outputs pg 35 for further details Overview of Motor Types The DMC 30000 can provide 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 and ceramic motors For more information contact Galil The user can configure the axis for any combination of motor types providing maximum flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 30000 achieves superior precision through the use of a 16 bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feed forward an extra pole filter and integration limits The controller is configured by the factory for standard servo
31. the amplifier gain of the DMC 30012 is 0 8A V TL setting 2 0A 0 8A V 2 5 V TK setting 5 0A 0 8A V 7 5 V Brushed Motor Operation The AMP 43540 can be setup to run brushed motors by setting the BR command to 1 for a particular axis Wire the motor power leads to phases A and C on the motor power connector A1 DMC 30012 188 DMC 30000 User Manual Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 2 or 3 The command will return an eight bit number representing specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label HAMPERR in their program to handle amplifier errors As long as a program is executing in thread zero and the AMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition See the TA command f
32. 10000 PA 20000 Specify Absolute position BGX Begin motion AD 1000 Wait until 1000 counts SB1 Set output bit 1 EN End program Chapter 7 Application Programming 108 DMC 30000 User Manual 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 TRIP JG 50000 BGX n 0 REPEAT R 10000 PX Bl T50 Bl n 1 P REPEAT n lt 5 isa ie QpaQB nH Pp x lt e Label Specify Jog Speed Begin Motion Repeat Loop Wait 10000 counts Tell Position Set output 1 Wait 50 msec Clear output 1 Increment counter Repeat 5 times Stop End Event Trigger Start Motion on Input This example waits for input 1 to go low and then starts motion Note The Al 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 INPUT AI 1 PR 10000 BGX EN Program Label Wait for input 1 low Position command Begin motion End program Event Trigger Set output when At speed ATSPEED JG 50000 AC 10000 BGX ASX SB1 EN Program Label Specify jog speed Acceleration rate Begin motion Wait for at slew speed 50000 Set output 1 End program
33. 39 31 0020 2 Position DMC 30017 Motor Molex 39 31 0040 4 Position Power Controller TE Connectivity 5 104362 1 2 Position DMC 30012 ISCNTL Power Amplifier Molex 39 31 0020 2 Position Motor Molex 39 31 0040 4 Position Power Controller TE Connectivity 5 104362 1 2 Position DMC 30016 ISCNTL Power Amplifier Molex 39 31 0020 2 Position Motor Molex 39 31 0040 4 Position Power Controller TE Connectivity 5 104362 1 2 Position DMC 30017 ISCNTL Power Amplifier Molex 39 31 0020 2 Position Motor Molex 39 31 0040 4 Position Table A 2 Connectors listed by DMC 30000 part number Appendices 169 DMC 30000 User Manual Power Wiring Diagrams The following diagrams shows how to power the different models of the DMC 30000 family The connectors are keyed and indicate the correct orientation and pin numbers for the power input See Input Power Requirements for detailed Electrical Specifications DMC 30010 CARD Requires a 5VDC and 12VDC triple power supply OLOOS OQWNG f w00000000000000 pO0000000000000 oooooo0o00000000 0s U O NO Oo NO lt lt IF Z m Ow VD EE a gt A gt M l ZD H Z re Appendices 170 DMC 30000 User Manual DMC 30010 BOX Requires a 5VDC and 12VDC triple power supply 4 O VSNNI JAVW TOULNOD NOILOW TITVO eggeaggessasat ana
34. A4 2 For example if the encoder cycle is 40 microns AF10 results in 2 1024 counts per cycle or a resolution of 39 nanometers per count Calculating Equivalent Counts The units of distance is counts in DMC code and all feedback types including sin cos feedback is translated into equivalent counts Below is a brief example of how a user would calculate sin cos periods into counts which is helpful in determining the resolution of the system Example Assume that a motor has 1000 sin cos periods per revolution With no interpolation the controller will interpret a single sin cos period as 4 equivalent counts Thus the total counts per revolution would be as follows sin cos period counts counts rev rev al x 4 E 4000 sin cos period A5 DMC 31000 208 DMC 30000 User Manual Using AF 5 the user has selected to interpolate the the sin cos signal to 2 counts per sin cos period The following counts rev would calculated as follows 1000 counts sin cos period sin cos period rev i 7 32 000 counts rev A5 DMC 31000 209 DMC 30000 User Manual
35. AMPERR routine NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short from a motor lead to ground Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the HAMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle A1 DMC 30012 189 DMC 30000 User Manual ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application A1 DMC 30012 190 DMC 30000 User Manual A2 DMC 30014 Introduction The DMC 30014 contains a linear drive for sinusoidally commutating brushless motors The DMC 30014 requires a single 15 30 VDC input and outputs a typical power of 20 W The gain of the transconductance
36. AO 2 1 AO1 can act as motor command line or as a general use analog output AO 2 1 have the same specifications as the motor command line Opto isolated Digital Outputs DO 4 1 4mA sinking Options 500mA sinking sourcing 25 mA sinking sourcing Auxiliary Inputs as Uncommitted Inputs DI 82 81 The axillary pins can be used as uncommitted inputs and are assigned to the following bits DI81 DI82 These inputs have the same specifications as listed above for encoder inputs Input Power Requirements Controller Model Input Voltage Requirement Current Power Requirement 5 VDC 5 0 5 Amps DMC 30010 12VDC 10 0 05 Amps 12VDC 410 0 05 Amps DMC 30011 9 48 VDC 3 Watts DMC 30011 P80V 20 80 VDC DMC 30012 20 80 VDC 5 Watts 1 Power Requirements the required power with no external I O connections 2 Does not include power for the motor The power supply should be sized based upon load and motor specifications 5 12V Power Output Specifications Output Voltage Tolerance Max Current Output 5V 5 0 5A 12V 10 10mA 12V 10 10mA Appendices 163 DMC 30000 User Manual Performance Specifications Minimum servo loop update rate Position Accuracy Velocity Accuracy Long Term Short Term Position Range Maximum Velocity Servo motor Stepper Velocity Resolution Motor Command Resolution Variable Range Variable Resolution
37. BG command can be issued for all axes either simultaneously or independently XYZ or W axis specifiers are required to select the axes for motion When no axes are specified this causes motion to begin on all axes 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 stop 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 Independent Axis COMMAND DESCRIPTION PR x Specifies relative distance PA x Specifies absolute position SP X Specifies slew speed AC x Specifies acceleration rate DC x Specifies deceleration rate BG A Starts motion ST X Stops motion before end of move IP x Changes position targe
38. Change the speed JP B Repeat the process EN End Backlash Compensation by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective way to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method described below 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 Chapter 7 Application Programming 141 DMC 30000 User Manual 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 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
39. Each one of these modes is discussed in the following sections EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each Independent Axis Positioning PA PR SP AC DC axis is independent and follows prescribed velocity profile Velocity control where no final endpoint is Independent Jogging JG AC DC ST prescribed Motion stops on Stop command Absolute positioning mode where absolute Position Tracking PA AC DC SP PT position targets may be sent to the controller while the axis is in motion Motion Path described as incremental Contour Mode CM CD DT position points versus time Motion Path described as incremental PVT Mode PV BT position velocity and delta time 2 to 8 axis coordinated motion where path is Linear Interpolation Mode LM LI LE VS VR described by linear segments VA VD 2 D motion path consisting of arc segments Vector Mode Linear and Circular Interpolation VM VP CR VS VR and linear segments such as engraving or Motion VA VD VE quilting Electronic gearing where slave axes are scaled Electronic Gearing GA GD _GP GR GM to master axis which can move in both if gantry directions Master slave where slave axes must followa Electronic Gearing and Ramped Gearing GA GD _GP GR master such as conveyer speed Moving along arbitrary profiles or Contour Mode CM CD DT mathema
40. Feedback pg 17 Step D Connect the Command Signals The DMC has two ways of controlling amplifiers 1 Using a motor command line 10V analog output The motor and the amplifier may be configured in torque or velocity mode In the torque mode the amplifier gain should be such that a 10V signal generates the maximum required current In the velocity mode a command signal of 10V should run the motor at the maximum required speed 2 Using step 0 5V PWM and direction 0 5V toggling line this is referred to as step dir for short Pin outs for the command signals are found under the 44 pin I O connector Chapter 2 Getting Started gt 32 DMC 30000 User Manual J5 I O 44 pin HD D Sub Connector Female pg 173 For full electrical specifications refer to Step Direction Lines pg 43 for Step Dir Motor Command Line pg 43 for 10V motor command line To configure the command signal type and other configuration commands see Table 2 9 below for a brief synopsis For a full list of configuration commands see the Command Reference Step E Issue the appropriate configuration Commands Command Description MT The motor type command configures what type of control method to use switches axis between motor command or step dir options TL Servo only Limits the motor command line s continuous output in Volts TK Servo only Limits the motor command line s peak output in Volts Table 2 9 Brief listing
41. Figure 10 4 The mathematical model of the various components is given below CONTROLLER POSS SS SoS Se Se ee eS SS eee x DIGITAL Y l gt 2 ZOH DAC i AMP MOTOR FILTER ENCODER Motor Amplifier The motor amplifier may be configured in three modes 1 Voltage Drive 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Drive The amplifier is a voltage source with a gain of K V V The transfer function relating the input voltage V to the motor position P is P V K K S ST 1ST 1 where 2 T RJ K is and T L R i and the motor parameters and units are Ki Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m7 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 Chapter 10 Theory of Operation 153 DMC 30000 User Manual R 2Q0 J 0 0283 oz in s 2 104 kg m2 L 0 004H Then the corresponding time constants are Tm 0 04 sec and T 0 002 sec Assuming that the amplifier gain is K 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current
42. I which is proportional to the input voltage V with a gain of K The resulting transfer function in this case is P V K K Js where Kt and J are as defined previously For example a current amplifier with K 2 A V with the motor described by the previous example will have the transfer function P V 1000 s rad V 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 Figure 10 5 Note that the transfer function between the input voltage V and the velocity w is w V K K Js 1 K K K Js 1 K sT 1 where the velocity time constant T4 equals T4 J K K Kg This leads to the transfer function P V 1 K s sT 1 E K Kt Js Chapter 10 Theory of Operation 154 DMC 30000 User Manual The resulting functions derived above are illustrated by the block diagram of Figure 10 6 VOLTAGE SOURCE V E WwW P K 11K 1 ST 1 ST 1 S CURRENT SOURCE V l WwW P K K 1 g JS s VELOCITY LOOP V i W A P
43. Manual Conditional Jumps The DMC 30000 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 controller to make decisions without a host computer For example the DMC 30000 can decide between two motion profiles based on the state of an input line Command Format JP and JS FORMAT DESCRIPTION JS destination logical condition Jump to subroutine if logical condition is satisfied 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 Note 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 OPERATOR DESCRIPTION lt less than gt greater than equal to lt less than or equal to gt greater than or equal to lt gt not equal Conditional Statements The conditional statement is satisfied if it evaluates to any
44. Move Mode of Motion Contour Motion is slewing Motion is stopping Motion is due to ST making final of Limit decel Switch Latch is armed 3rd Phase of HM in Progress Motor Off Chapter 4 Software Tools and Communication 59 DMC 30000 User Manual Axis Switches 1 Byte BIT 7 BIT 6 BIT5 BIT 4 BIT 3 BIT 2 BIT 1 BITO Latch ed N A N A State of State of State of Stepper Mode Occurred Input Forward Limit Reverse Limit Home Input Amplifier Status 4 Bytes BIT 31 BIT 30 BIT 29 BIT 28 BIT 27 BIT 26 BIT 25 BIT 24 N A N A N A N A N A N A N A ELO Active BIT 23 BIT 22 BIT 21 BIT 20 BIT 19 BIT 18 BIT 17 BIT 16 N A N A N A N A N A N A N A Peak current BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 N A N A N A N A N A N A N A Hall Error BIT 7 BIT 6 BIT5 BIT 4 BIT 3 BIT 2 BIT 1 BIT O N A N A N A N A Under Voltage Over Temp Over Voltage Over Current Notes Regarding Velocity and Torque Information The velocity information that is returned in the data record is 64 times larger than the value returned when using the command TV Tell Velocity See command reference for more information about TV The Torque information is represented as a number in the range of 32767 Maximum negative torque is 32767 Maximum positive torque is 32767 Zero torque is 0 QZ Command The QZ command can be very useful when using the QR command sin
45. Stop or Abort situation Figure A2 1 DMC 30016 A3 DMC 30016 197 DMC 30000 User Manual Electrical Specifications DC Supply Voltage Max Current per axis Maximum Step Frequency Motor Type Mating Connectors 12 30 VDC In order to run the DMC 30016 in the range of 12 20 VDC the ISCNTL Isolate Controller Power option must be ordered 1 4 Amps Phase Amps Selectable with AG command 3 MHz Bipolar 2 Phase On Board Connector Terminal Pins POWER 2 pin Molex Mini Fit Jr MOLEX 39 31 0020 MOLEX 44476 3112 A B C D 4 pin Motor Power Connectors 4 pin Molex Mini Fit Jr MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Motor Connector Power Connector Power Connector Pin Number Connection 1 DC Power Supply Ground 2 VS DC Power Motor Connector 1 B 2 B 3 A 4 A Note The stepper motor wiring on the DMC 30016 is not compatible with other Galil stepper drivers such as the SDM 44140 and SDM 44040 A3 DMC 30016 198 DMC 30000 User Manual Operation The AG command sets the current on each axis the LC command configures each axis s behavior when holding position and the YA command sets the step driver resolution These commands are detailed below see also the command reference for more information Stepper Mode With the DMC 30016 the con
46. T x E VaN port LOAD CPU IRF7342 101 vozLagw ore 4 Output GND 500mA Sinking Optoisolated Outputs HSNK Description The 500mA sinking option refereed to as high power sinking HSNK is capable of sinking up to 500mA per output and up to 1 5 A per bank The voltage range for the outputs is 12 24 VDC These outputs are capable of driving inductive loads such as solenoids or relays The outputs are configured for low side sinking Electrical Specifications Output PWR Max Voltage 24 VDC Output PWR Min Voltage 12 VDC Max Sink Current per Output 0 5 A not to exceed 1 5 A for all 4 outputs Wiring the 500mA Sinking Optoisolated Outputs With this configuration the output power supply will be connected to Output PWR labeled OPB and the power supply return will be connected to Output GND labeled OPA Note that the load is wired between Output PWR and DO The wiring diagram for Bank 0 is shown in Figure 3 8 Refer to Pin outs in the Appendix for pin out information Chapter 3 Connecting Hardware 42 DMC 30000 User Manual Output PWR 3 3V Ez Output GND Feedback Inputs and Multi Function MF Pins Feedback Options There are many different options for feedback with the DMC 30000 series controllers The indicates which feedback options are available with each co
47. The SR 49000 is installed inside the box of the DMC 30000 controller The Shunt Regulator activates when the voltage supplied to the amplifier rises above 90V When activated the power from the power supply is dissipated through a 5W 20W power resistor The SR 49000 can be ordered to activate at different voltages 33V 66V and 9OV are all standard ordering options and can be ordered as SR33 SR66 and SR90 respectively Part number ordering example DMC 30012 BOX SR90 Miscellaneous Options RTC Real Time Clock The DMC 30000 provides a real time clock feature The RTC option provides an extended feature set For details see the Real Time Clock section in Chapter 6 Real time clock DMC 30000 DMC 30000 RTC RT providing Hours Minutes Seconds Yes Yes RY providing Year Month of year Day of month Day of week No Yes Settable via TIME protocol server IH and RO commands Yes Yes Clock persists through DMC power loss No Yes C No power clock battery life N A 1 week Part number ordering example DMC 30010 BOX RTC MO Motor Off Jumpers Installed When a jumper is installed on the MO pins the controller will be powered up in the motor off state This option will cause jumper to be installed at the factory Part number ordering example DMC 30012 BOX MO Appendices 168 DMC 30000 User Manual Power Connector Part Numbers Overview The DMC 30000 uses different connectors
48. The encoder inputs can be ordered with 120 Q termination resistors installed See TRES Encoder Termination Resistors in the Appendix for more information Chapter 3 Connecting Hardware 43 DMC 30000 User Manual Electrical Specifications Maximum Voltage 12 VDC Minimum Voltage 12 VDC Maximum Frequency Quadrature 15 MHz inputs are internally pulled up to 5V through a 4 7 kQ resistor inputs are internally biased to 1 3V pulled up to 5V through a 7 1 kQ resistor pulled down to GND through a 2 5 KQ resistor The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use The controller has one auxiliary encoder which consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 and 82 The Aux encoder inputs are not available when the controller is configured for step and direction outputs stepper Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is of the full voltage range for example connect the input to the 5 volts on the Galil if the signal is O 12V logic Electrical Specifications Maximum Voltage 12 VDC Minimum Voltage 12 VDC
49. To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application See the ELO Electronic Lock Out Input section in Chapter 3 Connecting Hardware for information on connecting the ELO input Using External Amplifiers Use the connectors on top of the controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Error Reference source not found in Chapter 2 Protection Circuitry The DMC 30016 has short circuit protection The short circuit protection will protect against phase to phase shorts a shorted load and a short to ground or chassis In the event of any of a fault bit O of TAO will be set DMC 30016 will be disabled In the event that power is removed to the DMC 30016 but not to the controller an amplifier error will occur To recover from an error state the controller must be set into MO state LC must set to 0 and then the SH command must be issued A3 DMC 30016 200 DMC 30000 User Manual A4 DMC 30017 Description The DMC 30017 includes a microstepping drive for operating two phase bipolar stepper motors the drive can also be configured for a sinusoidally commutated PWM amplifier for driving 3 phase brushless servo motors or a brushed motor If the 2PB option is ordered it can be capable of driving 2 phased brushless motors Micro
50. by beginning the program with the label HAUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 30000 program sequences The controller 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 applications program The pre defined labels are SUBROUTINE DESCRIPTION LIMSWI Limit switch on any axis goes low ININT Input specified by Il goes low POSERR Position error exceeds limit specified by ER MCTIME Motion Complete timeout occurred Timeout period set by TW command CMDERR Bad command given AUTO Automatically executes on power up Automatically executes when a checksum is encountered during AUTO start up Check error condition with _RS bit O for variable checksum error ee bit 1 for parameter checksum error bit 2 for program checksum error bit 3 for master reset error there should be no program AMPERR Error from internal Galil amplifier Chapter 7 Application Programming 114 DMC 30000 User Manual For example the POSERR subroutine will automatically be executed when any axis exceeds its position e
51. conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 30000 instruction in a program must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 80 characters A carriage return enters the final command on a program line Using Labels in Programs All DMC 30000 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 in a label The maximum number of labels which may be defined is 126 Valid labels BEGIN SQUARE Chapter 7 Application Programming 103 DMC 30000 User Manual X1 BEGIN1 Invalid labels 1Square 123 A Simple Example Program START Beginning of the Program PR 10000 Specify relative distance BG A Begin Motion AM A Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves 10000 counts After the motion is complete the motors rest for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 30000 have some special labels which are used to define input interrupt subroutines limit switch subrou
52. 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 position of 1000 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
53. example a particular motor has a continuous current rating of 0 5A and peak current rating of 1 5A The gain of the DMC 30014 is 0 2A V TL setting 0 5A 0 2A V 2 5V TL n 2 5 TK setting 1 5A 0 2A V 7 5V TK n 7 5 Scope j Yertical Horizontal didt Source Scale div Offset div TTA Axis Atorow 2V 3 OV amp NH 2 IRIRI EIEEE gt AN B e RP IP a RP lt SH GR IE Ie Trigger Channel Ill TTA y Edge j m Level 0 1 v Mode Repeat v READY dmAa 9 0V TTA dt Brushed Motor Operation The controller must be configured for brushed motor operation at the factory Contact Galil prior to placing the order Once the amplifier is configured for a brushed motor the controller needs to be set for brushed mode by setting the BR command to a value of 1 The A and C motor phases are used for connecting to the brushed motor B phase is a no connect A2 DMC 30014 195 DMC 30000 User Manual Error Monitoring and Protection ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will change state and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and an SH must be issued or the controller must be reset It is r
54. firmware is corrupt MR Master Reset enable Returns controller to factory default settings and erases FLASH Requires power on or RESET to be activated Appendices 179 DMC 30000 User Manual Baud Rate Jumper Settings 19 2 BAUD RATE ON 19200 OFF 115200 Recommended Appendices 180 DMC 30000 User Manual Signal Descriptions Outputs Inputs Analog Outputs 1 2 Motor Command 10 Volt range signal for driving amplifier or for a general purpose analog output 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 Amplifier Enable Signal to disable and enable an amplifier Amp Enable goes low on Abort and OE1 MF2 Step Output For stepper motors When MT is set to 2 2 2 5 or 2 5 the MF2 pins 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 With an internal amplifier BR 1 must be set as well as MT MF4 Direction For stepper motors When MT is set to 2 2 2 5 or 2 5 the MF2 pins produces the direction output for stepper motors With an internal amplifier BR 1 must be set as well as MT Error The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER Output 1 Output 4 The optically isolated outputs are u
55. function code 16 Start at address 30000 and write to 2 registers using the data in the array pump MBB 16 30000 2 pump Results Analog output will be set to 0x40933333 which is 4 6V To view an example procedure for communicating with an OPTO 22 rack refer to List of Other Publications in the Appendices As a Modbus Slave Function Code DMC 30000 Slave Description 3 Read Arrays 16 Write Arrays A Modbus master has the ability to read and write array data on the DMC 3x0xx acting as a slave Up to 1000 elements are available Each element is accessible as a 16 bit unsigned integer Modbus register 1xxx or as a 32 bit floating point number Modbus registers 2xxx This capability is enabled by setting the ME command see the RIO Command Reference for further details 5 Only DMC 3x0xx firmware revisions Rev 1 2a and later support Modbus slave capability via the ME command Chapter 4 Software Tools and Communication 57 DMC 30000 User Manual Data Record The DMC 30000 can provide a binary block of status information with the use of the QR and DR commands These commands along with the QZ command can be very useful for accessing complete controller status The following is the byte map for the binary data See the QR QZ and DR command for specific command usage information
56. have a deterministic loop operating on the controller These instances range from writing PLC type scan threads to writing custom control algorithms The key to having a deterministic loop time is to have a trippoint that will wait a specified time independent of the time it took to execute the loop code In this definition the AT command is a perfect fit The below code is an example of a PLC type scan thread that runs at a 500ms loop rate A typical implementation would be to run this code in a separate thread ex XQ plcscan 2 REM this code will set output 3 high if REM inputs 1 and 2 are high and input 3 is low REM else output 3 will be low REM if input 4 is low output 1 will be high REM and ouput 3 will be low regardless of the REM states of inputs 1 2 or 3 plicscan ATO set initial time reference scan REM mask inputs 1 4 ti TIO amp F REM variables for bit 1 and bit 3 b1 0 b3 0 REM if input 4 is high set bit 1 and clear bit 3 REM ti amp 8 gets 4th bit if 4th bit is high result 8 IF ti amp 8 8 b1 1 ELSE REM ti amp 7 get lower 3 bits if 011 then result 3 IF ti amp 7 3 b3 1 ENDIF ENDIF REM set output bits 1 and 3 accordingly REM set outputs at the end for a PLC scan OB1 b1 0B3 b3 REM wait 500ms for 500 samples use AT 500 1 REM the will reset the time referenc Chapter 7 Application Programming 121 DMC 30000 User Manual AT 500 JP scan Mathematical and Functional
57. information see the 500mA Sinking Optoisolated Outputs HSNK section in Chapter 3 Connecting Hardware Appendices 165 DMC 30000 User Manual Part number ordering example DMC 30010 CARD HSNK DMC 31000 Sin Cos and 16 bit Analog Inputs The DMC 31000 provides 16 bit configurable 10V analog inputs in place of the standard 12 bit 0 5V analog inputs See the Analog Inputs section in Chapter 3 Connecting Hardware for more information Part number ordering example DMC 31012 BOX Feedback Options TRES Encoder Termination Resistors The TRES option provides termination resistors on all of the main and auxiliary encoder inputs on the DMC 30000 motion controller The termination resistors are 120 Q and are placed between the positive and negative differential inputs on the Main A B Index channels as well as the Auxiliary A and B channels as in Figure A 1 MAMB MAA ABE MAMB MAA ABP Installed whenTRES option is ordered Single Ended Encoders Single ended encoders will not operate correctly with the termination resistors installed If a combination of differential encoder inputs with termination resistors and single ended encoders is required on the same controller contact Galil directly DMC 31xxx When ordered with the DMC 31xxx Sin Cos Encoder option termination resistors will be placed on the Aux Encoder inputs By default the DMC 31xxx already has termination resistors on the Main Encoder Inputs Part number orderi
58. 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 RC Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Recording Data type Description TIME Controller time as reported by the TIME command _AFA Analog input _DEA 2 encoder position dual encoder _NO Status bits _OP Output _RLA Latched position _RPA Commanded position _SCA Stop code _TEA Position error TI Inputs _TPA Encoder position _TSA Switches only bit 0 4 valid TTA Torque reports digital value 32544 NOTE X may be replaced by Y Z or W for capturing data on other axes Chapter 7 Application Programming 128 DMC 30000 User Manual Operand Summary Automatic Data Capture _RC Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress RD Returns address of next array element Example Recording into An Array During a position move store the X and Y positions and position error every 2 msec RECORD Begin program DM XPOS 300 YPOS 300 Define X Y position arrays DM XERR 300 YERR 300 Define X Y error arrays RA XPOS XERR YPOS YERR Select arrays for capture RD TPX TEX TPY TRY Select data types PR 10000 20000 Specify move distance REI Start recording
59. may be sent to the screen using the format variable or array x For example v1 returns the value of v1 Example Printing a Variable and an Array element Instruction Interpretation DISPLAY Label DM posA 7 Define Array posA with 7 entries PR 1000 Position Command BGX Begin AMX After Motion vl TPA Assign Variable v1 posA 1 _TPA Assign the first entry vl Print v1 Interrogation Commands The DMC 30000 has a set of commands that directly interrogate the controller When these command 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 DE PR EM TN Eh VE LP se 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 PF 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
60. motor error JP END ABS V2 lt 2 Exit if error is small PR V2 4 Correction move BGX Start correction JP CORRECT Repeat END Motion Smoothing The DMC 30000 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value The discontinuous acceleration results in jerk which causes vibration The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration Chapter 6 Programming 97 DMC 30000 User Manual Using the IT Command When operating with servo motors motion smoothing can be accomplished with the IT command S This command filters the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following command IT X Independent time constant The command IT is used for smoothing independent moves of the type JG PR PA and to smooth vector moves of the type VM and LM The smoothing parameter x is a number between 0 and 1 and determine the degree of filtering 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
61. motor operation In this configuration the controller provides an analog signal 10 volts to connect to a servo amplifier This connection is described in Chapter 2 Chapter 1 Overview 9 DMC 30000 User Manual Stepper Motor with Step and Direction Signals The DMC 30000 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 If encoders are available on the stepper motor Galil s Stepper Position Maintenance Mode may be used for automatic monitoring and correction of the stepper position See Stepper Position Maintenance Mode SPM in Chapter 6 for more information Overview of External Amplifiers The amplifiers should be suitable for the motor and may be linear or pulse width modulated An amplifier may have current feedback voltage feedback or velocity feedback Amplifiers in Current Mode Amplifiers in current mode should accept an analog command signal in the 10 volt range The amplifier gain should be set such that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V Amplifiers in Velocity Mode For velocity mode amplifiers a command signal of
62. 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 Instruction v1 10 vl 0000000010 0000 vl F4 2 0010 00 v1l 4 2 000A 00 v1 ALPHA vl S4 ALPH The local format is also used with the MG command Converting to User Units Interpretation Assign v1 Return v1 Default Format Specify local format New format Specify hex format Hex value Assign string ALPHA to v1 Specify string format first 4 characters Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 30000 position parameters such as PR PA and VP have units of quadrature counts Speed parameters such as SP JG and VS have units of counts sec Acceleration parameters such as AC DC VA and VD have units of counts sec2 The controller interprets time in milliseconds All input parameters must be converted into these units For example 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 Chapter 7 Application Programming 135 DMC 30000 User Manual Instruction Interpretation RUN Label MG ENTER OF REVOLUTIONS n1 1 Prompt for revs rev JP rev nl 1 Wait
63. of 3 phased Brushless Motors If a motor is not correctly commutated it will not function as expected Commutation is the act of properly getting each of the 3 internal phases of a servo motor to switch at the correct time to allow smooth 360 degree rotation in both directions The following sections provide a brief description and guide on how to perform sinusoidal commutation with the DMC 30012 Sinusoidal Commutation Galil provides several sinusoidal commutation methods The following list provides a brief description of how each method works and Table 2 7 discusses the pros and cons of each Detailed instructions for each method follow on pg 23 BZ Method The BZ method forces the motor into a zero degree magnetic phase by exciting only two of the three phases The location on the motor within it s magnetic phases is known and sinusoidal commutation is initialized Commands required BA BM BZ BX Method The BX method uses a limited motion algorithm to determine the proper location of the motor within the magnetic cycle It is expected to move no greater than 10 degrees of the magnetic cycle The last stage of the BX command will lock the motor into the nearest 15 degree increment Commands required BA BM BX BI BC Method The motor initially boots up in a pseudo trapezoidal mode The BC function monitors the status of the hall sensors and replaces the estimated commutation phase value with a more preci
64. of most commonly used configuration commands for the motor command and step dir lines Step F If using a servo motor continue to Step 10 Tune the Servo System pg 28 If using a stepper motor skip to Step G Step G Enable and use your motor A SH will enable the external amplifier once enabled you can send DMC motion commands to move the motor see Chapter 6 Programming pg 62 for details Step 10 Tune the Servo System Adjusting the tuning parameters is required when using servo motors A given set of default PID s is provided but are not optimized and should not be used in practice For the theory of operation and a full explanation of all the PID and other filter parameters see Chapter 10 Theory of Operation pg 145 For additional tuning resources and step by step tuning guides see the following Application Notes Manual Tuning Methods http www galil com download application note note3413 pdf Manual Tuning using the Velocity Zone method http www galil com download application note note549 1 pdf Autotuning Tools GalilSuite http Awww galil com download manual galilsuite tuner html Chapter 2 Getting Started gt 33 DMC 30000 User Manual Chapter 3 Connecting Hardware Overview The DMC 30000 provides optoisolated digital inputs for forward limit reverse limit home and abort signals The controller also has 8 optoisolated uncommitted inputs 4 optoisolated outputs 2 analog inputs 0 5V 12 bit ADC an
65. 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 INSTRUCTION FUNCTION A Label DPO Define starting positions as zero LINPOS 0 PR 1000 Required distance BGX Start motion B AMX Wait for completion WT 50 Wait 50 msec LINPOS _DEX Read linear position ERR 1000 LINPOS _ TEX Find the correction JP C ABS ERR lt 2 Exit if error is small PR ERR Command correction BGX JP B Repeat the process C EN Chapter 7 Application Programming 142 DMC 30000 User Manual Chapter 8 Hardware amp Software Protection Introduction The DMC 30000 provides several hardware and software features to check 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 30000 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 30000 Galil shall not be liable
66. or responsible for any incidental or consequential damages Hardware Protection The DMC 30000 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 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 ERR When the error signal is low this indicates an error condition and the Error Light on the controller will be illuminated For details on the reasons why the error output would be active see Error Light Red LED in Chapter 9 Input Protection Lines General Abort A low input stops commanded motion instantly without a controlled deceleration For any axis in which 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 Chapter 8 Hardware amp Software Protection 143 DMC 30000 User Manua
67. sample If the time interval changes for each segment use CD x n where n is the new DT value Consider for example the trajectory shown in Figure 6 11 The position X may be described by the points Point 1 X 0 at T Oms Point 2 X 48 at T 4ms Chapter 6 Programming 85 DMC 30000 User Manual Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 DX 48 Time 4 DT 2 Increment 2 DX 240 Time 8 DT 3 Increment 3 DX 48 Time 16 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 A CMX Specifies X axis for contour mode CD 48 2 Specifies first position increment and time interval 2 ms CD 240 3 Specifies second position increment and time interval 2 ms CD 48 4 Specifies the third position increment and time interval 2 ms CD 0 0 End Contour buffer Wait JP Wait CM lt gt 511 Wait until path is done EN POSITION COUNTS age ase e dl eclenl owe earas EEEE A Maes eal 288 peteetteesrertttrrrentrt tte 240 L 192 H 96 l ABO Hoo TIME ms fi 1 fi 1 fi J 0 4 8 12 16 20 24 28 SEGMENT 1 i SEGMENT 2 SEGMENT 3 Additional Commands _CM gives the amount of space available in the contour buffer 511 max
68. specifies the coordinates of the end points of the vector movement with respect to the starting point The command CR r q d define a circular arc with a radius r starting angle of q and a traversed angle d The notation for q is that zero corresponds to the positive horizontal direction and for both q and d the counter clockwise CCW rotation is positive The CR command is useful for producing a sine wave as the move output as a single axis of a circle is a sinusoidal profile Up to 31 segments of CR or VP may be specified in a single sequence and must be ended with the command VE The motion can be initiated with a Begin Sequence BGS command Once motion starts additional segments may be added The Clear Sequence CS command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or AB1 ST stops motion at the specified deceleration AB1 aborts the motion instantaneously The Vector End VE command must be used to specify the end of the coordinated motion This command requires the controller to decelerate to a stop following the last motion requirement If a VE command is not given an Abort AB1 must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 30000 sequence buffer to ensure continuous motion If the controller receives no additional motion segments a
69. stepping Drive The micro stepping drive produces 256 microsteps per full step or 1024 steps per full cycle which results in 51 200 steps rev for a standard 200 step motor The maximum step rate generated by the controller is 3 000 000 microsteps second The DMC 30017 can drive stepper motors at up to 6 Amps at 20 80VDC There are four selectable current gains 0 75 A 1 5 A 3 A and 6A A selectable low current mode reduces the current by 75 when the motor is not in motion 3 phased Brushless Sinusoidal Amplifier The DMC 30017 can also be used as a sinusoidally commutated amplifier See A1 DMC 30012 for specifications To get the DMC 30017 into this mode issue MT 1 2 phased Brushless Sinusoidal Amplifier The DMC 30017 2BP can drive a sinusoidally commutated two phase brushless servo motor also known as a closed loop stepper See 2 phased Brushless Servo Mode 2PB Electrical Specifications pg 198 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation A4 DMC 30017 201 DMC 30000 User Manual Stepper Mode Elect
70. 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 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 normally open switch will make _HMX read 1 initially and a normally closed switch will make _HMX re
71. 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 OE Command If the Off On Error function is enabled the motor 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 This can be configured with the CN command For information see the Command Reference OE and CN Chapter 3 Connecting Hardware 35 DMC 30000 User Manual ELO Electronic Lock Out Input Used in conjunction with Galil amplifiers this input allows the user the shutdown the amplifier at a hardware level For more detailed information on how specific Galil amplifiers behave when the ELO is triggered see individual sections in the Appendices Reset Input Reset Button When the Reset line is triggered the controller will be reset The reset line and reset button will not master reset the controller unless the MRST jumper is installed during a controller reset Uncommitted Digital Inputs The DMC 30000 has 8 op
72. 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 loop forces the motor to follow the commanded position 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 Chapter 10 Theory of Operation 150 DMC 30000 User Manual LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL 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 X EN This program corresponds to the velocity profiles shown in Figure 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 following section explains the operation of the servo system First it is explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined X VEL ITY Y V
73. the polarity of the limit switches The OE command can also be configured so that the axis will be disabled upon the activation of a limit switch Software Protection The DMC 30000 provides a programmable error limit as well as encoder failure detection It is recommended that both the position error and encoder failure detection be used when running servo motors with the DMC 30000 Along with position error and encoder failure detection then DMC 30000 has the ability to have programmable software limit Position Error The error limit can be set for any number between 0 and 2147483647 using the ER n command The default value for ER is 16384 Example ER 200 Set X axis 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 controller 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 or OE3 AEN Output Line Switches to Motor Off state The Jump on Condition statement is useful for branching on a given error within a program The position error of X Y Z and W can be monitored during execution using the TE command Encoder Failure detection The en
74. 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 30000 converts the velocity profile into a position trajectory and 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 COMMAND DESCRIPTION AC x Specifies acceleration rate BG X Begins motion DC x Specifies deceleration rate IP x Increments position instantly IT Time constant for independent motion smoothing JG x Specifies jog speed and direction STA Stops motion Parameters can be set with explicit notation such as JGA 2000 Operand Summary Independent Axis OPERAND DESCRIPTION _ACA Return acceleration rate _DCA Return deceleration rate _SPA Returns the jog speed _TVA Returns the actual velocity averaged over 256 samples Chapter 6 Programming 69 DMC 30000 User Manual Example Jog in X only Jog motor at 50000 count s A AC 20000 Specify acceleration of 20000 counts sec DC 20000 Specify deceleration of 20000 counts sec JG 50000 Specify jog speed BG X Begin m
75. using REM statements instead of NO or is to save program memory The other benefit to using REM commands comes when command execution of a loop thread or any section of code is critical Although they do not take much time NO and comments still take time to process So when command execution time is critical REM statements should be used The 2 examples below demonstrate the difference in command execution of a loop containing comments Note Actual processing time will vary depending upon number of axes communication activity number of threads currently executing etc a i 0 initialize a counter t TIME set an initial time reference loop NO this comment takes time to process this comment takes time to process i it l this comment takes tim to process JP loop i lt 1000 G TIME t display number of samples from initial time reference EN When executed on a DMC 30012 the output from the above program returned a 158 which indicates that it took 158 samples TM 1000 to process the commands from t TIME to MG TIME t This is about 154ms 2ms Now when the comments inside of the loop routine are changed into REM statements a REM statement must always start on a new line the processing is greatly reduced When executed on the same DMC 30012 the output from the program shown below returned a 84 which indicates that it took 84 samples to process the commands from t TIME to MG TIME t This is
76. value of V3 POS C V4 Store in array POS T T 8 C C 1 JP A C lt 16 B Program to find position differences c 0 C D C 1 DIF C POS D POS C Compute the difference and store C C 1 JP C C lt 15 RUN Program to run motor CMX Contour Mode DTS 8 millisecond intervals Cc 0 E CD DIF C Contour Distance is in DIF C C 1 JP E C lt 15 CD 0 0 End contour buffer Wait IP Wait CM lt gt 511 Wait until path is done 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 30000 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 Dimension array RA C Specify array for automatic record up to 4 for DMC 30000 RD _TPX Specify data for capturing such as _TPX or _TPZ RC n m Specify capture time interval where n is 2 sample periods 1 ms for TM1000 m is number of records to be captured RC or _RC Returns a 1 if recording Chapter 6 Programming 88 DMC 30000 User Manual Record and Playback Example RECORD Begin Program DM XPOS 501 Dimension array with 501 elements RA XPOS Specify automatic record RD _TPX Specify X position to be captured OX Turn X motor off RC2 Begin recording 4 msec interval at TM1000 A JP A RC 1 Continue until done recording COMPUTE Compute DX DM DX 500
77. wiring and settings and retest starting at Step 1 4 Using the encoder specification sheet translate a physical distance of the motor into counts read by the controller For example a 2000 line encoder means that the controller reads 2000 4 8000 counts revolution and a half turn of the motor would be 4000 counts 5 Issue TP to determine the current motor position record this value Move the motor by hand some measured physical distance 7 Query TP again Take the absolute difference from the current TP and the TP recorded from Step 5 o Chapter 2 Getting Started 23 DMC 30000 User Manual 8 Determine if the physical distance moved is equal to the expected amount of counts calculated in Step 4 move on to Step 9 Otherwise check the encoder wiring and settings and retest starting at Step 1 9 Perform Step 5 8 again instead moving a physical distance in the opposite direction If the physical distance correctly translates to the expected amount of counts the encoder is wired correctly Step D Reverse encoder direction if necessary Table 2 3 below provides instructions for how to reverse the direction of feedback by rewiring the encoder to the DMC controller The direction of standard quadrature encoders can be be reversed using the CE command Reversing the direction of the feedback may cause a servo motor to runaway see Step 7 NOTE Setting Safety Features before Wiring Motors pg 19 regarding Runaway Motors
78. 0 from sending additional characters Note the RTS line goes high for inhibit RS 422 Configuration The DMC 30000 can be ordered with the auxiliary port configured for RS 422 communication RS 422 communication is a differentially driven serial communication protocol that should be used when long distance serial communication is required in an application For more information see RS 422 Serial Port Serial Communication in the in Appendix Ethernet Configuration Communication Protocols The Ethernet is a local area network through which information is transferred in units known as packets Communication protocols are necessary to dictate how these packets are sent and received The DMC 30000 supports two industry standard protocols TCP IP and UDP IP The controller will automatically respond in the format in which it is contacted TCP IP is a connection protocol The master or client connects to the slave or server through a series of packet handshakes in order to begin communicating Each packet sent is acknowledged when received If no acknowledgment is received the information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connection If information is lost the controller does not return a colon or question mark Because UDP does not provide for lost information the sender must re send the packet It is recommended that the motion control network containing the controller and any other related d
79. 0 full step per revolution motor this requires an encoder with at least 4000 counts per revolution A4 DMC 30017 203 DMC 30000 User Manual Electri cal Specifications The 2PB option must be ordered for the DMC 30017 to be capable of driving 2 phased brushless motors The amplifier is a 2 phased brushless transconductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage Continuous Current Peak Current Nominal Amplifier Gain Switching Frequency Minimum Inductance 20 80 VDC 10 Amps 15 Amps 0 8 Amps Volt 33 kHz Vsupply 24VDC 0 75 mH Vsupply 48VDC 1 2 mH Brushless Motor Commutation angle 90 Mating Connectors On Board Connector Terminal Pins 2 pin Molex Mini Fit Jr POWER MOLEX 39 31 0020 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr Power Connectors MOLEX 39 31 0040 hr ee te For mating connectors see http www molex com Motor Connector Power Connector Power Connector Pin Number Connection 1 DC Power Supply Ground 2 VS DC Power Motor Connector 1 B 2 B 3 A 4 A A4 DMC 30017 204 DMC 30000 User Manual Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless opera
80. 00 will return a bg invalid command lower case 2 DMC 30000 returns a When the controller receives an invalid command the user can request the error code The error code will specify the reason for the invalid command response To request the error code type the command TC1 For example 22nC1 Tell Code command 1 Unrecognized command Returned response There are many reasons for receiving an invalid command response The most common reasons are unrecognized command such as typographical entry or lower case command given at improper time such as during motion 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 30000 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 Application Programming and the Command Reference Chapter 5 Command Basics 65 DMC 30000 User Manual Summary of Interrogation Commands RP Report Command Position RL Report Latch R V Firmware Revision Information SC Stop Code TA Tell Amplifier Erro
81. 000 User Manual 3 Issue either the BZ or BX command Either the BX or BZ command must be executed on every reset or power up of the controller BZ Command Issue the BZ command to lock the motor into a phase Note that this will cause up to a magnetic cycle of motion Be sure to use a high enough value with BZ to ensure the motor is locked into phase properly BX Command Issue the BX command The BX command utilizes a minimal movement algorithm in order to determine the correct commutation of the motor Setting Peak and Continuous Current TL and TK The peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A5 2 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts The TL command is limited to 5V for the DMC 30014 This limits to continuous current output of the amplifier to 1A The TK command can be set to 9 998V which provides a peak current output of 2A To set TL and TK for a particular motor find the continuous current and peak current ratings for that motor and divide that number by the amplifier gain For
82. 000 lines In this case the software will remove all comments as part of the compression and it will download all NO comments to the controller Chapter 7 Application Programming 104 DMC 30000 User Manual Executing Programs Multitasking The DMC 30000 can run up to 6 independent programs simultaneously These programs are called threads and are numbered 0 through 5 where 0 is the main thread Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The main thread differs from the others in the following ways 1 When input interrupts are implemented for limit switches position errors or command errors the subroutines are executed as thread 0 To begin execution of the various programs use the following 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 commands can be performed by an executing program The example below produces a waveform on Output 1 independent of a move TASK1 Task1 label ATO Initialize reference time CB1 Clear Output 1 LOOP1 Loop1 label AT 10 Wait 10 msec from reference time SB1 Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference CB1 Clear Output 1 JP LOOP1 Repeat Loop1 TASK2 Task2 label XQ TASK1 1 Execute Task1 LOOP2 Loop2 label PR 1000 Define
83. 20 Digital Ground Electrical Specifications MF2 MF4 Output Voltage o 5VvbDc Current Output 20 mA_ Sink Source t DMC 31000 units shipped before February 2013 and DMC 30000 units shipped before April 2013 have a different specification as shown below Output Voltage 0 3 3 VDC Current Output 4mA Sink Source Electrical Specifications MF1 MF3 Maximum Input Voltage 5 VDC Minimum Input Voltage 0 VDC TTL Outputs Output Compare The output compare signal is a TTL output signal and is available on the I O D Sub connector labeled as CMP Output compare is controlled by the position of the main encoder input on the controller Output compare is controlled by the position of any of the main encoder inputs on the controller The output can be programmed to produce either a brief active low pulse 510 nsec based on an incremental encoder value or to activate once one shot when an axis position has been passed When setup for a one shot the output will stay low until the OC command is called again For further information see the command OC in the Command Reference NOTE Output compare is not valid with sampled feedback types such as SSI BiSS Sin Cos and Analog Electrical Specifications Output Voltage 0 5 VDC Current Output 20mA Sink Source Chapter 3 Connecting Hardware 45 DMC 30000 User Manual Error Output The controller provides a TTL signal ERR to indicate a controller error
84. 3520 is Inverter Mode The minimum inductance calculations above are based on Inverter mode If you have a motor with lower inductance Chopper mode can be applied for the PWM output Contact a Galil Applications Engineer to review minimum inductance requirements if Chopper mode operation is required Mating Connectors On Board Connector Terminal Pins 2 pin Molex Mini Fit Jr POWER MOLEX 39 31 0020 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr Phase Connectors MOLEX 39 31 0040 MOLE ANAL O 3 2 Motor Connector Power Connector Power Connector Pin Number Connection 1 DC Power Supply Ground 2 VS DC Power Motor Connector 1 Phase C 2 Phase B N C for Bushed Motors 3 No Connect 4 Phase A A1 DMC 30012 186 DMC 30000 User Manual Operation Commutation Related Velocity When using sinusoidal commutation and higher speed applications it is a good idea to calculate the speed at which commutation can start to affect performance of the motor In general it is recommended that there be at least 8 servo samples for each magnetic cycle The time for each sample is defined by TM TM 1000 is default and is in units of us per sample or us sample TM can be lowered to achieve higher speeds Below is the equation that can be used to calculate the desired maximum commutation speed in counts per second cts s 6 mxX10 Speed
85. 6 controller and drive package are 3 9 x 5 0 x 1 5 and no external heatsink is required DMC 30017 DMC 30000 with 6Amp stepper driver or 800W Sinusoidal Amplifier The DMC 30017 A4 DMC 30017 includes a microstepping drive for operating two phase bipolar stepper motors the drive can also be configured for a sinusoidally commutated PWM amplifier for driving brushed or brushless servo motors Micro stepping Drive The micro stepping drive produces 256 microsteps per full step or 1024 steps per full cycle which results in 51 200 steps rev for a standard 200 step motor The maximum step rate generated by the controller is 3 000 000 microsteps second The DMC 30017 can drive stepper motors at up to 6 Amps at 20 80VDC There are four selectable current gains 0 75 A 1 5 A 3 A and 6A A selectable low current mode reduces the current by 75 when the motor is not in motion Sinusoidally Commutated Amplifier When set to servo mode the DMC 30017 has the same specs as the DMC 30012 The 2PB option will configure the DMC 30017 to drive 2 phased brushless servo motors see 2 phased Brushless Servo Mode 2PB Electrical Specifications pg 198 for details Chapter 1 Overview 11 DMC 30000 User Manual Functional Elements The DMC 30000 circuitry can be divided into the following functional groups as shown in Figure 1 3 and discussed belo
86. 999 5117 The reason for this error relies in the precision of the controller 1 4 must be stored to the nearest multiple of 1 65536 which is 91750 65536 1 3999 Thus 91750 65536 80000 111999 5117 and reveals the source of the error By ignoring decimals and multiplying by integers first since they carry no error and then adding the decimal back in by dividing by a factor of 10 will allow the user to avoid any errors caused by the limitations of precision of the controller Continuing from the example above var 14 80000 Ignore decimals MG var Print result 1120000 0000 var var 10 Divide by 10 to add in decimal MG var Print correct result 112000 0000 Chapter 7 Application Programming 122 DMC 30000 User Manual Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The operator is a Logical Or These operators allow for bit wise operations on any valid DMC 30000 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 which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as o
87. A1 1 Amplifier Gain Settings for DMC 30012 With an amplifier gain of 2 1 6 A V the maximum motor command output is limited to 6 25 V TL of 6 25 AU sets the gain for the current loop on the amplifier The goal is to set the gain as high as possible without causing the current loop to go unstable In most cases AU 0 should not be used Table A1 2 indicates the recommended AU settings for 24 and 48 VDC power supplies Vsupply VDC Inductance L mH AU 0 L lt 1 1 24 1 lt L lt 2 3 2 2 3 lt L lt 4 2 3 4 2 lt L 4 0 L lt 2 4 1 48 2 4 lt L lt 4 2 2 4 2 lt L lt 7 3 7 lt L 4 Table A1 2 Amplifier Current Loop Gain Settings To set the AU command put the axis in a motor off MO state and set the preferred AG setting Issue the proper AU setting as indicated in Table A1 2 To verify that the current loop is stable set the PID s KP KD and KI to 0 and then enable the axis SH An unstable current loop will result in oscillations of the motor or a high frequency buzz from the motor See the AU command in the Command Reference for more details Setting Peak and Continuous Current TL and TK To set TL and TK for a particular motor find the continuous current and peak current ratings for that motor and divide that number by the amplifier gain For example a particular motor has a continuous current rating of 2 0 A and peak current rating of 5 0 A With an AG setting of 1
88. Application Programming 125 DMC 30000 User Manual Operands Operands allow motion or status parameters of the DMC 30000 to be incorporated into programmable variables and expressions Most DMC commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 30000 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 30000 registers The axis designation is required following the command Examples of Internal Variables posx _TPX Assigns value from Tell Position X to the variable posx deriv _KDX 2 Assigns value from KDX multiplied by two to variable deriv JP LOOP TEX gt 5 Jump to LOOP if the position error of X is greater than 5 JP 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 _KDX 2 is invalid Special Operands Keywords The DMC 30000 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 30000 commands Keyword Function _BGA Returns a 1 if motion on the axis otherwise returns 0 JB Returns serial of the board _DA Returns the number of arrays available _DL Returns the num
89. BS 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 which must be in quotation Examples posx _TPX Assigns returned value from TPX 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 vltv3 v4 Assigns the value of v1 plus v3 times v4 to the variable v2 var CAT Assign the string CAT to var MG var S3 Displays the variable var CAT Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as SP or PR 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 example v1 returns the value of the variable v1 Example Using Variables for Joystick The example below reads the voltage of an X Y joystick and assigns it to variables vX and vY to drive the motors at proportional velocities where 10 Volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 JOYSTIK Label JG 0 Set in Jog mode BGX Begin Motion ATO Set AT time reference LOOP Loop vX AN 1 20000 Read joystick X JG vX Jog at variable vX AT 4 Wait 4ms from last time reference creates a deterministic loop time JP LOOP Repeat EN End Chapter 7
90. COMMAND DESCRIPTION GA n Specifies master axes for gearing where n DA Sor N GD a Sets the distance the master will travel for the gearing change to take full effect _GPA This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately and the distance traveled since gearing changes take effect over a specified interval GR a Sets gear ratio 0 disables electronic gearing for specified axis GM a a 1 sets gantry mode 0 disables gantry mode MR x Trippoint for reverse motion past specified value MF x Trippoint for forward motion past specified value Example Simple Master Slave Master axis is the virtual axis and moves 10000 counts A axis will move 50000 counts GA N Specify master axes as the N axis GR 5 Set gear ratio of 5x PRN 10000 Specify N position BGN Begin motion Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization the motor The master axis encoder can be the auxiliary encoder input or the virtual axis The electronic cam is a more general type of electronic gearing which allows a table based relationship between the axes It allows synchronizing all the controller axes To illustrate the procedure of setting the cam mode consider the cam relationship shown in Figure 6 8 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master a
91. Dimension Array for DX Cc 0 Initialize counter L Label D C 1 DELTA XPOS D XPOS C Compute the difference DX C DELTA Store difference in array C C 1 Increment index JP L C lt 500 Repeat until done PLAYBCK Begin Playback CMX Specify contour mode DT2 Specify time increment T 0 Initialize array counter B Loop counter CD DX I I I 1 Specify contour data I I 1 Increment array counter JP B 1 lt 500 Loop until done CD 0 0 End contour buffer Wait JP Wait CM lt gt 511 Wait until path is done EN End program For additional information about automatic array capture see Chapter 7 Application Programming Virtual Axis The DMC 30000 controller has an additional virtual axis designated as the N axis This axis has no encoder and no DAC However it can be commanded by the commands AC DC JG SP PR PA BG IT GA VM VP CR ST DP RP The main use of the virtual axis is to serve as a virtual master in ECAM mode and to perform an unnecessary part of a vector mode These applications are illustrated by the following examples ECAM Master Example Suppose that the motion of the XY axes is constrained along a path that can be described by an electronic cam table Further assume that the ecam master is not an external encoder but has to be a controlled variable This can be achieved by defining the N axis as the master with the command EAN and setting the modulo of the master with a command such as EMN 4000 Next the table is constr
92. ELOCITY X POSITION Y POSITION TIME Chapter 10 Theory of Operation 151 DMC 30000 User Manual Operation of Closed Loop Systems To understand the operation of a servo system we may 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 cur
93. ERR EM mask out if in brushed mode for _TA1 ask COM _BRA ask _TAl mask amp SOQ000FFFF EM amplifier error status G A ER TAO TAO G A ER TA1 mask G A ER TA2 TA2 G A ER TA3 TA3 WT5000 REM the sum of the amperr bits should be 0 with no amplifier error er TAOt tmask TA2 TA3 JP AMPERR er0 REM Notify user amperr has cleared G AMPERR RESOLVED WT3000 RE JS Subroutine Stack Variables a b c d e f g h There are 8 variables that may be passed on the subroutine stack when using the JS command Passing values on the stack is advanced DMC programming and is recommended for experienced DMC programmers familiar with the concept of passing arguments by value and by reference 1 Passing parameters has no type checking so it is important to exercise good programming style when passing parameters See examples below for recommended syntax 2 Do not use spaces in expressions containing 3 Global variables MUST be assigned prior to any use in subroutines where variables are passed by reference 4 Please refer to the JS command in the controller s command reference for further important information Example A Simple Adding Function Add JS SUM 1 2 3 4 5 6 7 8 MG JS EN SUM EN at b c d e f g h Chapter 7 Application Programming 118 DMC 30000 User Manual Executed program from programl dmc 36 0000 Example Variable and an Important Note a
94. Expressions Mathematical Operators For manipulation of data the DMC 30000 provides the use of the following mathematical operators Operator Function Addition Subtraction Multiplication Division Modulus Logical And Bit wise Logical Or On some computers a solid vertical line appears as a broken line Q Parenthesis SY I oe Q 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 countt 2 The variable count is equal to the current value plus 2 result _TPX COS 45 40 Puts the position of X 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 Mathematical Operation Precision and Range The controller stores non integers in a fixed point representation not floating point Numbers are stored as 4 bytes of integer and 2 bytes of fraction within the range of 2 147 483 647 9999 The smallest number representable and thus the precision is 1 65536 or approximately 0 000015 Example Using basic mathematics it is known that 1 4 80 000 112 000 However using a basic terminal a DMC controller would calculate the following var 1 4 80000 Storing the result of 1 4 80000 in var MG var Prints variable var to screen 111
95. F command evaluates false the controller will skip commands until the ELSE command If the argument for the IF command evaluates true the controller will execute the commands between the IF and ELSE command Nesting IF Conditional Statements The DMC 30000 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 30000 allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to specify a variety of different cases for branching Command Format IF ELSE and ENDIF Format Description IF conditional statement s Execute commands proceeding IF command up to ELSE command if conditional statement s is true otherwise continue executing at ENDIF command or optional ELSE command ELSE Optional command Allows for commands to be executed when argument of IF command evaluates not true Can only be used with IF command ENDIF Command to end IF conditional statement Program must have an ENDIF command for every IF command Example using IF ELSE and ENDIF TEST Begin Main Program TEST II 3 Enable input interrupts on input 1 and input 2 G WAITING FOR INPUT 1 INPUT 2 Output message LOOP Label to be used for endless loop JP LOOP Endless loop EN End of main program ININT Input Interrupt Subroutine IF IN 1 0 IF co
96. Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX BGX The Find Edge routine will cause the motor to accelerate and 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 the home switch High level causes forward motion The motor will then decelerate to a 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 When using the FE command it is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine is initiated by the command sequence FIX BGX 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 and then moves back to the index pulse and speed HV 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 HMX BGX Standard Homing is a combinat
97. For some applications such as tracking an object the controller must proceed towards a target and have the ability to change the target during the move In a tracking application this could occur at any time during the move or at regularly scheduled intervals For example if a robot was designed to follow a moving object at a specified distance and the path of the object wasn t known the robot would be required to constantly monitor the motion of the object that it was following To remain within a specified distance it would also need to constantly update the position target it is moving towards Galil motion controllers support this type of motion with the position tracking mode This mode will allow scheduled or random updates to the current position target on the fly Based on the new target the controller will either continue in the direction it is heading change the direction it is moving or decelerate to a stop The position tracking mode shouldn t be confused with the contour mode The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate In this mode the position can be updated randomly or at a fixed time rate but the velocity profile will always be trapezoidal with the parameters specified by AC DC and SP Updating the position target at a specific rate will not allow the user to create a custom profile The following example will demonstrate the possible different motions
98. Forward Reverse Forward Normally Closed CN 1 0 Forward Reverse Forward Normally Closed CN 1 1 Reverse Forward Forward Example Homing Instruction HOME CN 1 AC 1000000 DC 1000000 SP 5000 HM BG AM G AT HOME EN Figure 6 14 shows the velocity profile from the homing sequence of the example program above For this profile Interpretation Label Configure the polarity of the home input Acceleration Rate Deceleration Rate Speed for Home Search Home Begin Motion After Complete Send Message End the switch is normally closed and CN 1 HOME SWITCH MOTION BEGINS IN FORWARD DIRECTION MOTION CHANGES DIRECTION a MOTION IN FORWARD DIRECTION TOWARD INDEX INDEX PULSES _HMX 0 _HMX 1 POSITION VELOCITY POSITION VELOCITY POSITION VELOCITY POSITION POSITION Chapter 6 Programming 100 DMC 30000 User Manual Example Find Edge EDGE A D SP 8000 FE B A GI Q DP 0 E C 2000000 C 2000000 G FOUND HOME Label Acceleration rate Deceleration rate Speed Find edge command Begin motion After complete Send message Define position as 0 End Command Summary Homing Operation Command Description FE A Find Edge Routine This routine monitors the Home Input FI Find Index Routine This routine monitors the Index Input H Home Routine This rout
99. IP address to the DMC controller upon linking it to the network In order to ensure that the IP address is correct please contact your system administrator before connecting the I O board to the Ethernet network CAUTION The third method for setting an IP address is to send the IA command through the RS 232 port Note The IA command is only valid if DHO is set The IP address may be entered as a 4 byte number delimited by commas industry standard uses periods or a signed 32 bit number e g IA 124 51 29 31 or IA 2083724575 Type in BN to save the IP address to the DMC 30000 non volatile memory NOTE Galil strongly recommends that the IP address selected is not one that can be accessed across the Gateway The Gateway is an application that controls communication between an internal network and the outside world The third level of Ethernet addressing is the UDP or TCP port number The Galil board does not require a specific port number The port number is established by the client or master each time it connects to the DMC 30000 board Typical port numbers for applications are Port 23 Telnet Port 502 Modbus Communicating with Multiple Devices The DMC 30000 is capable of supporting multiple masters and slaves The masters may be multiple PC s that send commands to the controller The slaves are typically peripheral I O devices that receive commands from the controller NOTE The term Master is equivalent to the internet
100. K ST 1 S Encoder 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 K 4N 2n count rad For example a 1000 lines rev encoder is modeled as K 638 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65536 and the output voltage range is 10V or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count Digital Filter The digital filter has three element in series PID low pass and a notch filter The transfer function of the filter The transfer function of the filter elements are K Z A CZ PID Diz Z sZ l 8 Low pass Iz 2 8 Chapter 10 Theory of Operation 155 DMC 30000 User Manual Z z Z z Notch N z 4 PZ P The filter parameters K A C and B are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are K KP KD A KD KP KD C Kl B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD 1 s a s a where P KP D T KD l KI T i 2 ey B where T is the sampling period and B is the pole
101. Number of Variables Array Size Program Size 4 Number of threads Maximum Burn Cycles Rev A amp B Rev c 125 usec 1 quadrature count Phase locked better than 0 005 System dependent 2147483647 counts per move 15 000 000 counts sec 3 000 000 pulses sec 2 counts sec 16 bit or 0 0003 V 2 billion 1x104 254 3000 elements 6 arrays 1000 lines x 80 characters 6 10 000 100 000 1 Rev C boards are those with serial numbers BZ 579 and greater In addition Rev C boards are required to have firmware revision 1 1b or greater in order to have this extended burn cycle capability 2 DMC 30000 models with firmware revisions 1 1c and earlier have a greater limitation on programming memory and multi threading Please refer to the DMC 30000 firmware release notes for details http www galilmc com support downloads firmware_rev firm30000 html Appendices 164 DMC 30000 User Manual Ordering Options Overview The DMC 30000 can be ordered in many different configurations and with different options This section provides information regarding the different Y options See Chapter 1 Overview Part Numbers pg 2 available on the DMC 30000 motion controller interconnect modules and internal amplifiers For information on pricing and how to order your controller with these options see our DMC 30000 part number generator on our website http www galilmc com products dmc 300xx part number ph 1 O Options 4 20mA
102. The speed of a motor is controlled by a joystick The joystick produces a signal in the range between 10V and 10V The objective is to drive the motor at a speed proportional to the input voltage Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec The program reads the input voltage periodically and assigns its value to the variable VIN To get a speed of 200 000 ct sec for 10 volts we select the speed as Speed 20000 x VIN The corresponding velocity for the motor is assigned to the VEL variable Instruction A JGO BGX B IN AN 1 EL VIN 20000 G VEL P B V V El Grt Position Control by Joystick This system requires the position of the motor to be proportional to the joystick angle Furthermore the ratio between the two positions must be programmable For example if the control ratio is 5 1 it implies that when the joystick voltage is 5 Volts corresponding to 1028 counts the required motor position must be 5120 counts The variable V3 changes the position ratio INSTRUCTION FUNCTION A Label V3 5 Initial position ratio DPO Define the starting position JGO Set motor in jog mode as zero BGX Start B VIN AN 1 Read analog input V2 V1 V3 Compute the desired position V4 V2 _TPX _TEX Find the following error V5 V4 20 Compute a proportional speed JG V5
103. 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 S 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 Response from command MG len6 S4 Response from command MG len5 S4 Response from command MG len4 S4 Response from command MG len3 S4 Response from command MG len2 S4 Response from command MG len1 S4 mz2zai wmo Chapter 7 Application Programming 123 DMC 30000 User Manual Functions FUNCTION DESCRIPTION SIN n Sine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution COS n Cosine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution TAN n Tangent of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution ASIN n Arc Sine of n between 90 and 90 Angle resolution in 1 64000 degrees ACOS n Arc Cosine of n between 0 and 180 Angle resolution in 1 64000 degrees ATAN n Arc Tangent of n between 90 and 90 Angle resolution in 1 64000 degrees COM n 1 s Complement of n ABS n Absolute value of n FRAC n Fraction portion of n INT
104. User Manual Motor Off Jumper It is recommended to use the MO jumper when connecting motors for the first time With a jumper installed at the MO location the controller will boot up in the motor off state where the amplifier enable signals are toggled to inhibit disable RS232 Baud Rate Jumpers If using the RS232 port for communication the baud rate is set via jumpers To set the baud rate use the jumper settings as found in Baud Rate Selection pg 46 Master Reset and Upgrade Jumpers Jumpers labeled MRST and UPGD are the Master Reset and Upgrade jumpers respectively When the MRST pins are shorted via a jumper the controller will perform a master reset upon a power cycle the reset input pulled down or a push button reset Whenever the controller has a master reset all programs arrays variables and motion control parameters stored in EEPROM will be erased and restored back to factory default settings The UPGD jumper enables the user to unconditionally update the controller s firmware This jumper should not be used without first consulting Galil Step 3 Install the Communications Software After applying power to the controller a PC is used for programming Galil s development software enables communication between the controller and the host device The most recent copy of Galil s development software can be found here http www galil com downloads software Step 4 Connect Power to the Controller Da
105. a 1 T In 1 PL Chapter 10 Theory of Operation 161 DMC 30000 User Manual Appendices Electrical Specifications NOTE Electrical specifications are only valid once controller is out of reset Servo Control Motor command line 10 V analog signal Resolution 16 bit DAC or 0 0003 volts 3 mA maximum Output impedance 500 Q Main and auxiliary encoder inputs TTL compatible but can accept up to 12 volts Quadrature phase on CHA CHB Single ended or differential Maximum A B edge rate 15 MHz Minimum IDX pulse width 30 nsec Stepper Control Step MF2 MF2 Differential 0 5 V level at 50 duty cycle 3 000 000 pulses sec maximum frequency Direction MF4 MF4 Differential 0 5 V 1 DMC 31000 units shipped before February 2013 and DMC 30000 units shipped before April 2013 have a different specification see Multi Function Pins MF pg 39 Appendices 162 DMC 30000 User Manual Input Output Opto isolated Inputs DI 8 1 Limit switches home abort reset 2 2 kQ in series with opto isolator Active high or low requires at least 1mA to activate Once activated the input requires the current to go below 0 5mA All Limit Switch and Home inputs use one common voltage LSCOM which can accept up to 24 volts Analog Inputs Al 2 1 0 5V Standard 12 Bit Analog to Digital converter 10 volts and 16 bit with DMC 31xxx option Analog outputs
106. a and 7 32 amp 64 bit as well as Linux are available Chapter 1 Overview 6 DMC 30000 User Manual Part Numbers The DMC 30000 is internally made of up three different boards the I O board which also acts as a break out board the DMC controller board and the optional internal amplifier AMP SDM Figure 1 1 below shows how the internal DMC 30000 is laid out DMC The DMC 30000 part numbers modifies each of these boards As shown in Figure 1 2 the first X DMC 3X000 modifies which I O board is used while the last X DMC 3000X modifies either the optional amplifier board and or how the unit is powered In addition the user also can specify whether the DMC 30000 comes in a card or box form factor by specifying either CARD or BOX in the XXXX place holder Lastly the DMC 30000 has several additional configuration options that can be added to the Y place holder Note several Y options can be added by placing a comma between options DMC 3XXXX XXXX Y AXAK Y Form Factor Amplifier Board Power Type Axis Count 1 Single Axis Controller Reserved 0 For all standard products I O Board Type Chapter 1 Overview 7 DMC 30000 User Manual The following tables provide a summary of the DMC 30000 options and where find the appropriate documentation for each I O Board Options DMC 3X000 where X is Description Documentation 0 Default Option i F i Adds 10V
107. about 82ms 2ms and about 50 faster than when the comments where downloaded to the controller Chapter 7 Application Programming 120 DMC 30000 User Manual a i 0 initialize a counter t TIME set an initial time reference loop REM this comment is removed upon download and takes no time to process REM this comment is removed upon download and takes no time to process i i 1 REM this comment is removed upon download and takes no time to process JP loop i lt 1000 G TIME t display number of samples from initial time reference EN WT vs AT and coding deterministic loops The main difference between WT and AT is that WT will hold up execution of the next command for the specified time from the execution of the WT command AT will hold up execution of the next command for the specified time from the last time reference set with the AT command A ATO set initial AT time reference WT 1000 1 wait 1000 samples tl TIME AT 4000 1 wait 4000 samples from last time reference t2 TIME t1 REM in the above scenario t2 will be 3000 because AT 4000 1 will have REM paused program execution from the time reference of ATO REM since the WT 1000 1 took 1000 samples there was only 3000 samples left REM of the 4000 samples for AT 4000 1 MG t t2 this should output 1000 3000 EN End program Where the functionality of the operation of the AT command is very useful is when it is required to
108. ach the set speed of 50000 counts sec before it is commanded to change direction The below code is used to simulate this scenario Chapter 6 Programming 71 DMC 30000 User Manual PT AC DC EX2 Let 150000 150000 50000 50007 4200 2000 H 3 3 Place the X axis in Position tracking mode Set the X axis acceleration to 150000 counts sec2 Set the X axis deceleration to 150000 counts sec2 Set the X axis speed to 50000 counts sec Command the X axis to abs position 5000 encoder counts Change end point position to pos ition 2000 CUTS didt ao ao S so ao ao anes ao a eo ao Tigger Vertical Horizontal Source RPA Axis A refi _RPA Axis A refl x x x x Scale div 1000 cour 10000 co j 2 lt Offset div 0 221383 0 4 42765 0 442765 0 221383 0 221383 101 562 ni 3 Channel Ml RPA Edge Level 0 counts Mode RPA dE RPA Repeat m READY Stop R oP P Be e e a eE ay Example Motion 3 In this motion the host program commands the controller to begin motion towards position 5000 changes the target to 2000 and then changes it again to 8000 Figure 6 3 shows the plot of position vs time and velocity vs time Below is the code that is used to simulate this scenario EX3 PT AC DC SP PA WT ha 15 L5 50 50 30 2 200 SOOO O S Place th
109. ad zero Furthermore with CN 1 a normally open switch will make _HMxX read 0 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 HV 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 HV counts sec until the encoder index pulse is detected The motor then decelerates to a stop and goes back to the index The DMC 30000 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 Chapter 6 Programming 99 DMC 30000 User Manual Direction of Motion Switch Type CN Setting Initial HMX state Stage 1 Stage 2 Stage 3 Normally Open CN 1 1 Reverse Forward Forward Normally Open CN 1 0
110. agnitude of Chapter 10 Theory of Operation 159 DMC 30000 User Manual G j500 A j500 L j500 160 and a phase arg G j500 arg A j500 arg L j500 135 194 59 In other words we need to select a filter function G s of the form G s P sD so that at the frequency w 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as G j500 P j500D 160 and arg G j500 tan 4 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 Therefore D 0 274 and G 82 4 0 274s The function G is equivalent to a digital filter of the form D z KP KD 1 z74 where P KP D KD T and KD D T Assuming a sampling period of T 1ms the parameters of the digital filter are KP 82 4 KD 274 The DMC 30000 can be programmed with the instruction KP 82 4 KD 274 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 DMC 30000 Digital D z K z A z Cz z 1 1 B Z B KP KD KI PLK KP KD A KD KP KD Chapter 10 Theory of Operation 160 DMC 30000 User Manual C KI B PL Digital D z KP KD 1 274 KI 2 1 z7 1 PL Z PL Continuous G s P Ds l s a s a PID T P KP D T KD 1 KI T
111. alilSuite manual for using the software to communicate http www galil com download manual galilsuite Step 6 Connecting Encoder Feedback The type of feedback the unit is capable of depends on the additional options ordered Table 2 2 shows the different Encoder feedback types available for the DMC 30000 including which part numbers are required Note that each feedback type has a different configuration command See the Command Reference for full details on how to properly configure each axis Chapter 2 Getting Started gt 22 DMC 30000 User Manual Different feedback types can be used on the same controller For instance the main encoder could be using SSI and the auxiliary encoder could be using Standard quadrature By default all encoder inputs are configured for Standard quadrature Feedback Type Configuration Command Part Number Required Connection Location Standard quadrature CE Standard on all units Encoder Step Dir CE Standard on all units Encoder Standard on all units Analog AF 12 bit Standard 16 bit Analog optional SSI SI SER option Encoder BISS SS SER option Encoder Sin Cos 1 Vpk pk AF DMC 310xx Encoder None2 Other Contact Galil at 1 800 377 6329 Table 2 2 Configuration commands ICM Part numbers required for a given feedback type 1 All wiring electrical information regarding using analog inputs can be found in the Analog Inputs pg 41 2 Although stepp
112. ally looks like this 192 168 15 1 The IP address is constrained by each local network and must be assigned locally Assigning an IP address to the DMC 30000 controller can be done in a number of ways The first method for setting the IP address is using a DHCP server The DH command controls whether the DMC 30000 controller will get an IP address from the DHCP server If the unit is set to DH1 default and there is a DHCP server on the network the controller will be dynamically assigned an IP address from the server Setting the board to DHO will prevent the controller from being assigned an IP address from the server The second method to assign an IP address is to use the BOOT P utility via the Ethernet connection The BOOT P functionality is only enabled when DH is set to 0 Either a BOOT P server on the internal network or the Galil software may be used When opening the Galil Software it will respond with a list of all DMC 30000 s and other controllers on the network that do not currently have IP addresses The user must select the board and the software will assign the specified IP address to it This address will be burned into the controller BN internally to save the IP address to the non volatile memory NOTE if multiple boards are on the network use the serial numbers to differentiate them Be sure that there is only one BOOT P or DHCP server running If your network has DHCP or BOOT P running it may automatically assign an
113. and line AO1 This signal along with GND provides the input to the motor amplifiers The amplifiers must be sized to drive the motors and load For best performance the amplifiers should be configured for a torque 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 Electrical Specifications See Analog Outputs Electrical Specifications pg 42 Step Direction Lines With the controller set to stepper mode MT 2 2 2 5 or 2 5 the step and direction outputs are found on the O connector list as MF2 and MF4 Electrical Specifications Details and pin out information can be found in the Multi Function Pins MF section of Chapter 3 Amplifier Enable The DMC 30000 provides an amplifier enable signal labeled AEN This signal toggles under the following conditions The MO motor off command is given the watchdog timer activates or a particular set of conditions controlled by the OE off on error command occurs The AEN enable signal is 5V active high amp enable HAEN In other words the AEN signal will be high when the controller expects the amplifier to be enabled Chapter 3 Connecting Hardware 48 DMC 30000 User Manual If higher voltages or optoisolation is required the sixth argument of the CN command will configure the unit to use output 4 as the amplifier enable signal in lieu of AEN The electrical specifica
114. anual BZ BX Method WARNING The BZ command must move the motor to find the zero commutation phase This movement is sudden and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The BZ and BX method are wired in the same way Both BZ and BX require encoder feedback to the controller and the motor phases to the drive 1 Check encoder position with the TP command Ensure the motor is in an MO state and move the motor manually in the desired positive direction while monitoring TP If TP reports a smaller or more negative number reverse encoder direction see Step 6 Connecting Encoder Feedback pg 17 2 Select which axis will be using sinusoidal commutation by issuing the BA command 3 Set brushless modulus using the BM configuration command BM is the distance in counts of a single magnetic cycle of the motor This can be calculated by dividing counts revolution of the encoder by the number of pole pairs of the motor For a linear motor the number of encoder counts per magnetic phase may need to be calculated from motor and encoder manufacturers information 4 Try commutating the motor using either BZ or BX command Note that the BZ and BX commands require a single argument which is the user allotted maximum voltage to be applied on the motor command line during the commutation routine Ensure that the command voltage for BZ or BX is sufficient to move the motor a If the
115. ber of available labels for programming _D Returns the available array memory _ HMA Returns status of Home Switch equals 0 or 1 _LFA Returns status of Forward Limit switch input equals O or 1 _LRA Returns status of Reverse Limit switch input equals 0 or 1 _UL Returns the number of available variables TIME 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 any associated commands All keywords are listed in the Command Reference Examples of Keywords v1l _LFA Assign V1 the logical state of the Forward Limit Switch v3 TIME Assign V3 the current value of the time clock v4 _HMA Assign V4 the logical state of the Home input Arrays For storing and collecting numerical data the DMC 30000 provides array space for 3000 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 analog input values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Chapter 7 Application Programming 126 DMC 30000 User Manual Defining Arrays A
116. bort Input 43 OPA Output GND PWR Bank 0 14 DO2 Digital Output 2 29 DO1 Digital Output 1 44 DO3 Digital Output 3 15 OPB Output PWR GND Bank 0 30 DO4 Digital Output 4 Multi Functional Pins MFn 01 Analog Output 1 is used as the motor command output for the DMC 3xx10 and DMC 3xx11 2 Can be used as an alternative amplifier enable line see Amplifier Enable pg 43 The Multi Functional Pins on the DMC 30000 have different functionality depending upon how the controller was ordered and how the controller is setup by the user If the controller is ordered with SER serial encoder interface then the MF pins can be used to interface to a serial encoder MF1 and MF2 are only used for the Main serial encoder input MF3 and MF4 are used for the Aux serial encoder input See the SI and SS commands in the command reference for more detail When the controller is setup for stepper motor operation the MF 2 and MF4 pins are used for step and direction respectively Single Description for Multi Functional Pins Label Pin MT 2 or 2 5 SER option with BiSS or SSI Enabled MF1 35 No Connect Main Axis Data D0O or SLO MF1 5 No Connect Main Axis Data DO or SLO MF2 6 STEP Main Axis Clock CO or MA MF2 21 STEP Main Axis Clock CO or MA MF3 22 No Connect Aux Axis Data D1 or SLO MF3 36 No Connect Aux Axis Data D1 or SLO MF4 37 DIR Aux Axis Cloc
117. bout Creating Global Variables Var value 5 global 8 JS SUM value 1 2 3 4 5 6 7 MG value MG _JS EN SUM a bt ct d et f g h global EN a Executed program from program2 dmc 36 0000 36 0000 Example Working with Arrays Array DM speeds 8 DM other 256 JS zeroAry speeds 0 JS zeroAry other 0 EN zeroAry a b 0 b b 1 JP zeroAry b lt a 1 EN Example Abstracting Axes Axes JS runMove 0 10000 1000 100000 100000 MG Position _ JS EN runMove a a PR a SP a c AC a d DC a e BG a MC a EN TP a Example Local Scope Local JS POWER 2 2 MG JS JS POWER 2 16 MG JS JS POWER 2 8 MG JS POWER c 1 F b 0 EN 1 ENDIF Chapter 7 Application Programming 119 DMC 30000 User Manual IF b lt 0 d 1 b ABS b ELSE d 0 ENDIF PWRHLPR c c a b b 1 JP PWRHLPR b gt 0 IF d 1 c 1 c ENDIF EN C Executed program from programl dmc 4 0000 65536 0000 0 0039 General Program Flow and Timing information This section will discuss general programming flow and timing information for Galil programming REM vs NO or comments There are 2 ways to add comments to a dmc program REM statements or NO comments The main difference between the 2 is that REM statements are stripped from the program upon download to the controller and NO or comments are left in the program In most instances the reason for
118. ce it provides information about the controller and the data record The QZ command returns the following 4 bytes of information BYTE INFORMATION 0 number of axes present 1 for the DMC 30000 1 number of bytes in general block of data record 18 for the DMC 30000 2 number of bytes in coordinate plane block of data record 16 for the DMC 30000 3 number of bytes the axis block of data record 36 for the DMC 30000 Chapter 4 Software Tools and Communication 60 DMC 30000 User Manual GalilTools Windows and Linux GalilSuite is Galil s latest set of development tools for the latest generation of Galil controllers It is highly recommended for all first time purchases of Galil controllers as it provides easy set up tuning and analysis GalilSuite replaces GalilTools with an improved user interface real time scopes advanced tuning methods and communications utilities Supported Controllers DMC40x0 DMC41x3 DMC30010 DMC21x3 2 RIO47xxx DMC18x6 PCI Driver required separate installer DMC18x0 PCI Driver required separate installer DMC18x2 PCI Driver required separate installer Contact Galil for other hardware products Supported Operating Systems Microsoft Windows 8 Microsoft Windows 7 Microsoft Windows XP SP3 Scope Watch and Viewer support require an Ethernet or PCI connection and controller firmware supporting the DR command No Scope Watch or Viewer support Contact Ga
119. ck and forth For example when operating with servo motors the trippoint AM After Motion is used to determine when the Chapter 6 Programming 90 DMC 30000 User Manual motion profiler is complete and 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 of stepper motor smoothing Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver
120. client The term Slave is equivalent to the internet server An Ethernet handle is a communication resource within a device The DMC 30000 can have a maximum of 6 Ethernet handles open at any time When using TCP IP each master or slave uses an individual Ethernet handle In UDP IP one handle may be used for all the masters but each slave uses one Pings and ARPs do not occupy handles If all 6 handles are in use and a 7 master tries to connect it will be sent a reset packet that generates the appropriate error in its windows application NOTE There are a number of ways to reset the controller Hardware reset push reset button or power down controller and software resets through Ethernet or RS 232 by entering RS Chapter 4 Software Tools and Communication 53 DMC 30000 User Manual When the Galil controller acts as the master the IH command is used to assign handles and connect to its slaves The IP address may be entered as a 4 byte number separated with commas industry standard uses periods or as a signed 32 bit number A port number may also be specified but if it is not it will default to 1000 The protocol TCP IP or UDP IP to use must also be designated at this time Otherwise the controller will not connect to the slave Ex IHB 151 25 255 9 lt 179 gt 2 This will open handle 2 and connect to the IP address 151 25 255 9 port 179 using TCP IP Which devices receive what information from the controller depends
121. coder failure detection on the controller operates based upon two factors that are user settable a threshold of motor command output OV a time above that threshold OT in which there is no more than 4 counts of Chapter 8 Hardware amp Software Protection 144 DMC 30000 User Manual change on the encoder input for that axis The encoder failure detection is activated with the OA command When an encoder failure is detected and OA is set to 1 for that axis the same conditions will occur as a position error Conditions for proper operation of Encoder Failure detection e The axis must have a non zero KI setting order to detect an encoder failure when the axis is not profiling e The IL command must be set to a value greater than the OV setting e The TL command must be set to a value greater than the OV setting Example The A axis is setup with the following settings for encoder failure detection OA 1 OT 500 OV 3 E 1 R 1000 FO The A axis is commanded to move 300 counts but the B channel on the encoder has failed and no longer operates Because the ER setting is greater than the commanded move the error will not be detected by using the OE and ER commands but this condition will be detected as a encoder failure When the axis is commanded to move a 300 counts the position error will cause the motor command voltage to be increased to a value that will be greater than the OV value 3 volts in this case Once the motor comma
122. coder inputs may also be used as additional Chapter 1 Overview 12 DMC 30000 User Manual inputs 2 inputs The general inputs as well as the index pulse can also be used as high speed latches for each axis A high speed encoder compare output is also provided System Elements As shown in Figure 1 4 the DMC 30000 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Power Supply Computer Motor DMC 30000 Controller 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 required speed and acceleration Galil s MotorSizer Web tool can help with motor sizing http www galil com learn motorsizer 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 be configured to control full step half step or microstep drives An encoder is not required when step motors are used Other motors and devices such as Ultrasonic Ceramic motors and voice coils can be controlled with the DMC 30000 Amplifier Driver The power amplifier converts a 10 volt signal from the controller into current to drive the motor For stepper motors the amplifier converts step and direction signals into current The amplifier should be sized properly to m
123. commutation fails and TC 1 returns error codes 114 BZ command runawayor160 BX failure turn off the controller and amplifier and swap motor leads A and B and re perform steps 1 4 b If the commutation fails and TC 1 returns error code 112 BZ timeout try increasing the timeout time with the BZ lt t command t defaults to 1000 msec 5 Once commutation succeeds servo the motor SH and test commutation by jogging the motor slowly JG 1000 BG A a If the motor stalls cogs or runs away turn off the controller and amplifier and swap motor leads A and B and re perform steps 1 4 b If the motor rotates smoothly 360 deg in both directions the motor is properly wired and commutated Note Commutation initialization is required each time the controller is booted up BI BC Method NOTE The motor must have hall sensors to work with BI BC BI BC method uses the motors hall sensors to initialize the brushless degrees of the motor The halls motor phases and encoder feedback must all be wired to the DMC The hall inputs must be aligned so that hall A aligns with the excitement of motor phase A and B hall B aligns with the excitement of motor phases B and C and hall C aligns with the excitement of motor phases C and A Setting up the motor for BI BC initialization may require wiring changes to both the motor leads and the hall inputs The following steps will ensure that the correct configuration is reached 1 Put
124. condition When an error condition occurs the ERR signal will go low and the controller LED will go on An error occurs because of one of the following conditions 1 Atleast one 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 The ERR signal is found on the I O A D D Sub connector For additional information see Error Light Red LED in Chapter 9 Troubleshooting Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA_ Sink Source Analog Inputs DMC 30000 The DMC 30000 has two 0 5V analog inputs The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 1 22mV The analog inputs are specified as AN x where x is a number 1 or 2 The analog inputs can be set to a differential mode where analog input 2 is the differential input to analog input 1 Electrical Specifications Maximum Voltage 5V Minimum Voltage OV Resolution 12 bit Input Impedance 100 kQ CPU All2 1 Chapter 3 Connecting Hardware 46 DMC 30000 User Manual DMC 31000 The DMC 31000 has two analog inputs configured for the range between 10V and 10V The inputs are decoded by a 16 bit A D decoder giving a voltage resolut
125. configurable analog inputs AS DMC 31000 pg 201 and Sin Cos feedback Table 1 1 I O Board Options Amplifier Board Power Type Options DMC 3000X where Xis Description Documentation Amplifier None Input Power Requirements pg 158 0 Power 5 12 VDC n Amplifier None Power Connector Part Numbers pg 164 Power steve Default Power Wiring Diagrams pg 165 Amplifier 800W sine drive 2 Power 20 80 VDC A1 DMC 30012 pg 180 Amplifier 1 A stepper drive 6 Power 12 30 VDC A3 DMC 30016 pg 192 7 Amplifier Servo and stepper drive 4 DMC 30017 pg 196 Power 20 80 VDC Table 1 2 Amplifier Board and Power Options Form Factor Options Where XXXX is Description Documentation CARD Dimensions pg 10 DMC 30011 CARD pg 11 BOX DMC 30010 BOX and DMC 30011 BOX pg 12 DMC 30012 BOX DMC 30016 BOX and DMC 30017 BOX pg 13 The box option is required for DMC 30000 models that use an internal amplifier Table 1 3 Form Factor Options Chapter 1 Overview 8 DMC 30000 User Manual Y Additional Options Where Y is Description Documentation LSNK 25mA Sinking outputs 25mA Sinking Optoisolated Outputs LSNK pg 35 LSRC 25mA sourcing outputs 25mA Sourcing Optoisolated Outputs LSRC pg 36 HSRC 500mA sourcing outputs 500mA Sourcing Optoisolated Outputs HSRC
126. ctive 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 the position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner 1 cos 27 B X 4 sin 27 B Note w 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 50T 6000 27 sin 2m T 120 Note that the velocity w in count ms is w 50 1 cos 2n T 120 The DMC 30000 can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X 50T 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 INTERPRETATION POINTS Program defines X points DM POS 16 Allocate memory DM DIF 15 c 0 Set initial conditions C is index T 0 Tis time in ms A V1 50 T V2 3 T Argument in degrees Chapter 6 Programming 87 DMC 30000 User Manual V3 955 SIN V2 V1 Compute position V4 INT V3 Integer
127. cy Hz 12000 1 57 1590 10 1 18Hz SinWv vector speed VS12000 1 2 amplitude of sine wave r 1590 AN r 90 90 r 0 720 r 0 720 r 0 720 lt aaaadc T N NNN BGS Continue to create sine wave LOOP CR r 0 720 CR r 0 720 wt JP wt LM lt 30 JP LOOP Scope a a Vertical Horizontal d dt Source Scale div Offset div Z Te so cant 0 ae ie 500 1 nO gs 00 A A a x 20000 o B ao 17998 1 l j ao x 2 2 ao x 2 3 a0 x 2 4 t 200 ms 4 Trigger Channel W LRP Edge w Level Ocounts sae maces Sea d_RPA 3188 counts RPA dt 832 ms ijdt Electronic Gearing This mode allows up the axis to be electronically geared to the Auxiliary encoder or the virtual axis The master may rotate in both directions and the axis will follow at the specified gear ratio The gear ratio may be changed during motion The GA command specifies the master axes and the GR command specifies the gear ratio for the slave where the ratio may be a number between 127 9999 with a fractional resolution of 0001 There are two modes standard gearing and gantry mode The gantry mode enabled with the command GM allows the gearing to stay enabled even if a limit is hit or an ST command is issued GR O turns off gearing in both modes Chapter 6 Programming 78 DMC 30000 User Manua Electronic gearing allows the geared motor to perform a second independen
128. cycle of the motor For a rotary motor this can be calculated by dividing counts revolution of the encoder by the number of electrical cycles per revolution For a typical 2 phase brushless motor a single electrical cycle takes 4 steps implying that 200 step revolution motor would have 50 electrical cycles per revolution 4 Try commutating the motor using BZ Note that BZ requires a single argument which is the user allotted maximum voltage to be applied on the motor command line during the commutation routine Ensure that the command voltage for BZ is sufficient to move the motor If BZ is not large enough it may not properly and lock into the zero point of the magnetic cycle a If the commutation fails and TC 1 returns error codes 114 BZ command runaway turn off the controller and amplifier and swap motor leads A and A with B and B respectively and re perform steps 1 4 b If the commutation fails and TC 1 returns error code 112 BZ timeout try increasing the timeout time with the BZ lt t command t defaults to 1000 msec 5 Once commutation succeeds servo SH to enable the motor Step 9 Connecting External Amplifiers and Motors System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC There can also be a combination of axes running from Galil integrated amplifiers and drivers and external amplifiers or drivers Table 2 8 below shows a brief synopsis o
129. d 1 uncommitted analog output 10V 16 bit DAC This chapter describes the inputs and outputs and their proper connection Pin out information can be found in the Pin outs section in the Appendices Overview of Optoisolated Inputs 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 SD command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position The controller can be configured to disable the axis upon the activation of a limit switch see the OE command in the command reference for further detail When a forward or reverse limit switch is activated the current application program that is running in thread zero will be interrupted and the controller will automatically jump to the LIMSWI subroutine if one exists This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch Automatic Subroutines for Monitoring Conditions are discussed in Chapter 7 Application Programming After a limit switch has been activated further motion in the direction of
130. d LED 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 Adjusting offset causes the motor to change speed 1 Amplifier has an internal offset 2 Damaged amplifier Adjust amplifier offset Amplifier offset may also be compensated by use of the offset configuration on the controller see the OF command Replace amplifier Motor is enabled even when MO command is given The SH command disables the motor 1 The amplifier requires the a different Amplifier Enable setting on the Interconnect Module Refer to Chapter 3 or contact Galil Unable to read main or auxiliary encoder input The encoder does not work when swapped with another encoder input 1 Wrong encoder connections 2 Encoder is damaged 3 Encoder configuration incorrect 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 Unable to read main or auxiliary encoder input The encoder works correctly when swapped with another encoder input 1 Wrong encoder connections 2 Encoder configuration incorrect 3 Encoder input or controller is damaged Check encoder wiring For single ended encoders MA and MB only do n
131. d must be set toa 1 This setting will disable the requirement to have the BA BM and BX or BZ commands executed prior to being able to issue the SH command for that axis Chapter 3 Connecting Hardware 47 DMC 30000 User Manual Using AO1 as a General Purpose Output With internal amplifiers AO1 can be used as a general purpose output when the controller is set to drive a brushless servo motor with the internal amplifier AO 1 n where n is a number from 10 to 10 will set analog output 1 The analog output can be set with the AO command once MT is set to 1 or 1 and the BA command is set for the A axis BA A External Amplifier Interface Overview The DMC 30000 provides both amplifier enable and control signals to external amplifiers For servo motors it provides a 10V analog output called the motor command line For stepper motors various pulse and direction signal types are provided depending on the MT setting these are called the Step Direction Lines The amplifier enable signal is a simple digital signal that toggles the amplifier on or off A summary of these features on the DMC 30000 is provided below Motor Command Line AO1 can either act as the motor command line or as a general output depending on the option ordered see Configuring AO1 with Internal Amplifiers under the Analog Outputs section pg 42 for more details The DMC 30000 motor command voltage ranges between 10V and is output on the motor comm
132. dX val ZS1 C1I2 IP PRINT C ST AMX CI 1 F E E E mag Lo J J U MG 8 THE END ZS EN 1 NU MG ENTER P1CH S AXIS SPEED N pP MLP P1CD lt 2 ERROR P1CD 2 P1NM G P NUMLOOP CI 1 N P P se ak ERROR CI 1 G INVALID TRY AGAIN P NMLP N AG Interpretation Label for Auto Execute Initial A speed Initial B speed Set Port 1 for Character Interrupt Specify jog mode speed Begin motion Routine to print message to terminal Print message Loop to change Jog speeds Set new jog speed End of main program Interrupt routine Check for A Check for S Jump if not X Y S New X speed Jump to Print Stop motion on S End Re enable interrupt Routine for entering new jog speed Prompt for value Check for enter Routine to check input from terminal Jump to error if string Read value End subroutine Error Routine Error message End 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 com
133. depending upon the type of controller used The following section details the part numbers used on the controller for the different ordering options Table A 1 Connector Part Numbers details the connector part numbers used on the DMC 30000 series controllers Table A 2 Connectors listed by DMC 30000 part number lists the on board connectors for the different DMC 30000 controller options On Board Connector Common Mating Connectors Crimp Part Number Type Molex 39 31 0040 Molex 39 01 2045 Molex 44476 3112 4 Position Molex 39 31 0020 Molex 39 01 2025 Molex 44476 3112 2 Position Molex 50 57 9402 Molex 16 02 0103 boy Adam Tech CDH 02 Adam Tech CDH C B Bulk er ae CONNECTIE 5 1043821 Oupiin 4077 02HB 1k Min Adam Tech CDH C R Reel 2 Position Oupiin 4077 PIN T T15K 15k Reel Molex 50 57 9404 Molex 16 02 0103 Xa Adam Tech CDH 04 Adam Tech CDH C B Bulk Ea TEConnectivityi 32104302 3 Oupiin 4077 04HB 1k Min Adam Tech CDH C R Reel tPosition Oupiin 4077 PIN T T15K 15k Reel Table A 1 Connector Part Numbers DMC 30000 Part Number On Board Connector Type DMC 30010 Power TE Connectivity 5 104362 3 4 Position DMC 30011 Power TE Connectivity 5 104362 1 2 Position Power Molex 39 31 0020 2 Position DMC 30912 Motor Molex 39 31 0040 4 Position Power Molex 39 31 0020 2 Position DMC 30916 Motor Molex 39 31 0040 4 Position Power Molex
134. djdt_RPA Note the controller treats the point where the velocity passes through zero as the end of one move and the beginning of another move IT is allowed however it will introduce some time delay Trippoints Most trippoints are valid for use while in the position tracking mode There are a few exceptions to this the AM and MC commands may not be used while in this mode It is recommended that AR MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position Command Summary Position Tracking Mode COMMAND DESCRIPTION AC n Acceleration settings AP n trippoint that holds up program execution until an absolute position has been reached DC n Deceleration settings MF n trippoint to hold up program execution until n number of counts have passed in the forward direction MR n trippoint to hold up program execution until n number of counts have passed in the reverse direction PT n Command used to enter and exit the Trajectory Modification Mode PA n Command Used to specify the absolute position target SP n Speed settings Linear Interpolation Mode The DMC 30000 provides a linear interpolation mode that allows the buffering of relative moves for a single axis In linear interpolation mode the motion path is described in terms of incremental distances for each axis An unlimited number of incremental segments may be given in a continuo
135. e 16 bit output port where bit O is output 1 bit1 is output2 and so on A 1 designates that the output is on Example Output Port Instruction Interpretation OP6 Sets outputs 2 and 3 of output port to high All other bits are 0 21 225 6 OPO Clears all bits of output port to zero Sets all bits of output port to one OP 15 0 1 2 3 2 2 2 2 gt The output port is useful for setting relays or controlling external switches and events during a motion sequence Chapter 7 Application Programming 136 DMC 30000 User Manual 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 CB1 Clear Output 1 EN End Digital Inputs The general digital inputs for are accessed by using the IN n function or the TI command The IN n function returns the logic level of the specified input n where n is a number 1 through 8 Example Using Inputs to control program flow Instruction Interpretation JP A IN 1 0 Jump to A if input 1 is low JP B IN 2 1 Jump to B if input 2 is high AI 7 Wait until input 7 is high AI 6 Wait until input 6 is low Example Start Motion on Switch Motor A must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor A must stop turning Solution Connect panel switch to input 1 of DMC 30000 High on input 1 means switch is
136. e Analog inputs Because the analog inputs on the Galil controller can be used to close a position loop they have a very high bandwidth and will therefor read noise that comes in on the analog input Often when an analog input is used in a motion control system but not for closed loop control the higher bandwidth is not required In this case a simple digital filter may be applied to the analog input and the output of the filter can be used for in the motion control application This example shows how to apply a simple single pole low pass digital filter to an analog input This code is commonly run in a separate thread XQ filt 1 example of executing in thread 1 Pat REM an1 filtered output Use this instead of AN 1 anl AN 1 set initial value REM k1 k2 1 this condition must be met REM use division of m 2 n for elimination of round off REM increase k1 less filtering REM increase k2 more filtering k1 32 64 k2 32 64 ATO set initial time reference loop REM calculate filtered output and then way 2 samples from last REM time reference last AT 2 1 or ATO a J nl k1 AN 1 k2 anl AT 2 1 P loop Chapter 7 Application Programming 139 DMC 30000 User Manual 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 which activates the cutter Allowin
137. e X axis in Position tracking mode 80 000 Set the X axis acceleration to 150000 counts sec2 000 Set the X axis deceleration to 150000 counts sec2 00 Set the X axis speed to 50000 counts sec Og Command the X axis to abs position 5000 encoder counts 00 Change end point position to 2000 On Change end point position to 8000 Figure 6 4 demonstrates the use of motion smoothing IT on the velocity profile in this mode The jerk in the system is also affected by the values set for AC and DC vertical didt Source a mO FraAs ye mE RPA Ais sg ao ao eo eo ao Tigger Horizontal Scale jav Aref 2000 courlt Aref 2 0 221383 o 4 42765 0 442765 0 221383 z E E E E E 0 221383 CACAO 150 ms 10000 cous 3 Offset div e AAAA 4 2 2 8 y Channel W _RP M Edge m Level Ocounts w Mode Repeat w RPA jdt FPA READY TT Chapter 6 Programming 72 DMC 30000 User Manual g cope Lax j A Vertical _ horizontal anc oo didt Source Scale div Offset dv a ia MO RPA Axis Aref v 2000 cour S 0 a a F m RPA Axs A refa 10000 cous 2 pm x ao al e a1 G A oe esa ces ao v o z2i363 i o e BD F ao w 4 42765 Bla G By a ao x asseresSl 2 E k a e S gt u0 y 0 221383 3 ao x 022133 6 4 a G 150m E i Wager Channel MI _RP w Edge m Level Ocounts Mode Repeat v READY Stop RPA
138. e a third channel or index for synchronization The DMC 30000 can be ordered with 120 Q termination resistors installed on the encoder inputs See the Ordering Options in the Appendix for more information The DMC 30000 can also interface to encoders with pulse and direction signals Refer to the CE command in the command reference for details There is no limit on encoder line density however the input frequency to the controller must not exceed 3 750 000 full encoder cycles second 15 000 000 quadrature counts sec For example if the encoder line density is 10 000 cycles per inch the maximum speed is 200 inches second If higher encoder frequency is required please consult the factory The standard encoder voltage level is TTL 0 5v however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 30000 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 30000 can accept analog feedback instead of an encoder For electrical specifications see Analog Inputs pg 41 and the AF in the command reference for configuration To interface with other types of position sensors such as absolute encoders Galil can customize the controller and command set Please contact Galil to discuss particular system and application requirements with an Applications Engineer Watch Dog Timer The DMC 30000 provides an internal watch dog timer
139. e application program labels only use the interrogation command LL List Labels Operands In general all operands provide information which may be useful in debugging an application program Below is a list of operands which 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 contains the last line of program execution Useful to determine where program stopped _DL contains the number of available labels _UL contains the number of available variables _DA contains the number of available arrays _DM contains the number of available array elements _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 Chapter 7 Application Programming 106 DMC 30000 User Manual Download code A Program Label PR1000 Position Relative 1000 BGX Begin PR5000 Position Relative 5000 EN End Fro
140. e real time clock provides true time in seconds minutes and hours The RT command provides a method to set the time and operands to return the current time The default real time clock does not persist through a power cycle and must be set whenever power is restored The DMC 30000 can be ordered with a clock upgrade RTC including a higher precision clock than the default and a battery backup for the time hardware All hardware is within the standard sheet metal footprint The RTC clock will continue to run when power is removed from the cotnroller The RTC option also provides a calendar function including year month of year day of month and day of week This feature can be set and queried through the RY command Both versions of the real time clock can be set to a TIME protocol RFC 868 server Using IH the DMC 30000 can connect to a TIME server over TCP on port 37 and receive the 32bit response The firmware will then set the time and calendar if applicable to the TIME server value The command RO is used to set the GMT time zone offset for localization of the current time The TIME protocol synchronization is designed to connect to a server on the local network Contact Galil if a local server is not available e g an Internet Gateway is required to contact NIST See the RTC Real Time Clock pg 163 section in the Appendix for further details and specifications for the RTC option Chapter 6 Programming 102 DMC 30000 User Manual
141. ecommended that OE1 be used for all axes when the ELO is used in an application See the ELO Electronic Lock Out Input section in Chapter 3 Connecting Hardware for information on connecting the ELO input Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the HAMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle A2 DMC 30014 196 DMC 30000 User Manual A3 DMC 30016 Description The DMC 30016 contains a drive for operating two phase bipolar step motors The DMC 30016 requires a single 12 30 VDC input The unit is user configurable for 0 5 to 1 4 Amps per phase and for full step half step 1 4 step or 1 16 step Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency
142. ect the error and return to the main code The drive is a full step drive with a 1 8 step motor and 4000 count rev encoder setup OE 1 Set the profiler to stop axis upon error KS 16 Set step smoothing MT 2 2 2 2 Motor type set to stepper YA 2 Step resolution of the drive YB 200 Motor resolution full steps per revolution yc 4000 Encoder resolution counts per revolution SH A Enable axis WT 100 Allow slight settle time motion Perform motion SP25125 Set the speed PR 1000 Prepare mode of motion BG A Begin motion EN End of program subroutine REM When error occurs the axis will stop due to OE1 In REM POSERR query the status YS and the error QS correct REM and return to the main code Chapter 6 Programming 94 DMC 30000 User Manual POSERR Automatic subroutine is called when _YS 2 WT 100 Wait helps user see the correction spsave _SPA Save current speed setting JP return YSA lt gt 2 Return to thread zero if invalid error SP64 Set slow speed setting for correction G ERROR QSA YRA _QSA Else error is valid use QS for correction C A Wait for motion to complete G CORRECTED ERROR NOW QSX WT 100 Wait helps user see the correction return SPA spsave Return the speed to previous setting RE 0 Return from POSERR Example Friction Correction The following example illustrates how the SPM mode can be usefu
143. ection of the motor leads by swapping phase A and phase B 2 Reverse the direction of the encoder see Step 6 Connecting Encoder Feedback pg 17 2 phased Brushless Motor Choose one of the following 1 Reverse direction of the encoder see Step 6 Connecting Encoder Feedback pg 17 2 Reverse direction of the motor by swapping the phases on A and A with the respective phase of B and B 3 phased Brushless Motor Choose one of the following 3 Reverse direction of the encoder see Step 6 Connecting Encoder Feedback pg 17 Chapter 2 Getting Started gt 25 DMC 30000 User Manual 4 Reverse direction of the motor by swapping any two motor phases or two hall sensors if using a trapezoidal amplifier The motor will now have to be re commutated by using either the Trapezoidal or Sinusoidal method see Step 8a Commutation of 3 phased Brushless Motors pg 23 Non wiring Options The direction of the motor command line can be reversed by using the MT command or reverse direction of the feedback by using the CE command standard quadrature and step direction feedback only It is not recommended to correct for reverse polarity using configuration commands as an unexpected condition may arise where these settings are accidentally over ridden causing a runaway See the Command Reference for more details Step D Other Safety Features This section only provides a brief list of safety features that the DMC can provide Other features inc
144. eet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation is required or the controller must be configured to provide sinusoidal commutation 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 the motor at the maximum speed Galil offers amplifiers that are integrated into the same enclosure as the DMC 30000 See the A1 DMC 30012 A3 DMC 30016 and the A4 DMC 30017 sections in the Appendices or http www galil com motion controllers single axis dmc 3x01x for more information Chapter 1 Overview 13 DMC 30000 User Manual Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 30000 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as MA and MB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended MA and MB or differential MA MA and MB MB The DMC 30000 decodes either type into quadrature states or four times the number of cycles Encoders may also hav
145. er current short circuit and over temperature A shunt regulator option is available If higher voltages are required please contact Galil If the application has a potential for regenerative energy it is recommended to order the controller with the ISCNTL Isolate Controller Power option and the SR90 SR 49000 Shunt Regulator Option Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation A1 DMC 30012 185 DMC 30000 User Manual Electrical Specifications The amplifier is a brush brushless transconductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage 20 80 VDC Continuous Current 10 Amps Peak Current 15 Amps Nominal Amplifier Gain 0 8 Amps Volt Switching Frequency 33 kHz Minimum Load Inductance Imie Ripple Where Vs Supply Voltage lippe 10 of the maximum current at chosen gain setting Brushless Motor Commutation angle 120 The default PWM output operation on the AMP 435x0 D3540 D
146. er produces in addition to the proportional gain damping and integrator The combination of the three functions is referred to as a PID filter 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 Chapter 10 Theory of Operation 152 DMC 30000 User Manual 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
147. er systems do not require feedback Galil supports a feedback sensor on each stepper axis Servo motors require a position sensor A note about using encoders and steppers When a stepper is used the auxiliary encoder is unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input The commanded position of the stepper can be interrogated with TD and the encoder position can be interrogated with TP The following steps provide a general guide for connecting encoders to the DMC unit Step A Wire the encoder The pin outs and electrical information for SSI and BiSS options can be found here SER Serial Encoder Interface pg 161 The pin outs and electrical information for the DMC 310xx Sin Cos option can be found here A5 DMC 31000 pg 201 The rest of the encoder pin outs is found under the the 15 pin encoder connector J4 Encoder 15 pin HD D Sub Connector Female pg 174 Step B Issue the appropriate configuration commands Find the appropriate configuration commands for the needed feedback type as shown in Table 2 2 pg 18 Step C Verify proper encoder operation 1 Ensure the motor is off my issuing an MO 2 Check the current position by issuing TP The value reported back is in the units of counts 3 Move the motor by hand and re issue TP The returned value should have been incremented or decremented from the first TP If there is no change check the encoder
148. evices be placed on a closed network If this recommendation is followed UDP IP communication to the controller may be utilized instead of a TCP connection With UDP there is less overhead resulting in higher throughput Also there is no need to reconnect to the controller with a UDP connection Because handshaking is built into the Galil communication protocol through the use of colon or question mark responses to commands sent to the controller the TCP handshaking is not required Packets must be limited to 512 data bytes including UDP TCP IP Header or less Larger packets could cause the controller to lose communication NOTE In order not to lose information in transit the user must wait for the controller s response before sending the next packet Addressing There are three levels of addresses that define Ethernet devices The first is the MAC or hardware address This is a unique and permanent 6 byte number No other device will have the same MAC address The DMC 30000 MAC address is set by the factory and the last two bytes of the address are the serial number of the board To find the Ethernet MAC address for a DMC 30000 unit use the TH command A sample is shown here with a unit that has a serial number of 11 Sample MAC Ethernet Address 00 50 4C 40 00 0B Chapter 4 Software Tools and Communication 52 DMC 30000 User Manual The second level of addressing is the IP address This is a 32 bit or 4 byte number that usu
149. f the connections required the full step by step guide is provided below Motor Type Connection Requirements Servo motors e Power to controller and amplifier Brushed and 3 phased brushless Amplifier enable e Encoder feedback e Motor command line e See amplifier documentation for motor connections Stepper motor e Power to controller and amplifier e Amplifier enable e PWM Step and direction line e Encoder feedback optional e See amplifier documentation for motor connections Table 2 8 Synopsis of connections required to connect an external amplifier Step A Connect the motor to the amplifier Chapter 2 Getting Started gt 31 DMC 30000 User Manual Initially do so 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 A Note Regarding Commutation This section applies to 3 phase external amplifiers only External amplifiers often will perform either trapezoidal or sinusoidal commutation without the need of a controller In this case be sure to use your amplifiers guide to achieve proper commutation Although very rare if an external amplifier requires the controller to perform sinusoidal commutation an additional 10 V motor command line may be required from the DMC Contact Galil
150. files to be defined by position velocity and time This motion is designed for systems where the load must traverse a series of coordinates with no discontinuities in velocity By specifying the target position velocity and time to achieve those parameters the user has control over the velocity profile Taking advantage of the built in buffering the user can create virtually any profile including those with infinite path lengths Specifying PVT Segments PVT segments are commanded using the PV command The PV command includes the target distance to be moved and target velocity to be obtained over the specified timeframe Positions are entered as relative moves similar to the standard PR command in units of encoder counts and velocity is entered in counts second The controller will interpolate the motion profile between subsequent PV commands using a 3rd order polynomial equation During a PV segment jerk is held constant and accelerations velocities and positions will be calculated every other sample Motion will not begin until a BT command is issued much like the standard BG command This means that the user can fill the PVT buffer prior to motion beginning PVT mode has a 127 segment buffer This buffer is a FIFO and the available space can be queried with the operand _PVA As the buffer empties the user can add more PVT segments by issuing new PV commands Exiting PVT Mode To exit PVT mode the user must send the segment command PVA 0 0 0
151. followed by a carriage return line feed and Chapter 4 Software Tools and Communication 50 DMC 30000 User Manual 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 30000 response with the data sent The echo is enabled by sending the command EO 1 to the controller Unsolicited Messages Generated by Controller When the controller is executing a program it may generate responses which will be sent via the RS 232 port or Ethernet handles This response could be generated as a result of messages using the MG command OR as a result of acommand error These responses are known as unsolicited messages since they are not generated as the direct response to a command Messages can be directed to a specific port using the specific Port arguments see the MG and CF commands in the Command Reference If the port is not explicitly given or the default is not changed with the CF command unsolicited messages will be sent to the default port The default port is the serial port When communicating via an Ethernet connection the unsolicited messages must be sent through a handle that is not the main communication handle from the host The GalilTools software automatically establishes this second communication handle The controller has a special command CW which can affect the format of unsolicited messages This command is used by Galil Software to differe
152. for S stop motion JP PAUSE P1CH 1 Check for P pause motion JP RESUME P1CH 2 Check for R resume motion EN1 1 Do nothing STOP Routine for stopping motion STA ZS EN Stop motion on A axis Zero program stack End Program PAUSE Routine for pausing motion rate _SPA Save current speed setting of A axis motion SPA 0 Set speed of A axis to zero allows for pause EN1 1 Re enable trippoint and communication interrupt RESUME Routine for resuming motion SPA rate Set speed on A axis to original speed EN1 1 Re enable trippoint and communication interrupt For additional information see section on Using Communication Interrupt Chapter 7 Application Programming 117 DMC 30000 User Manual Example Ethernet Communication Error This simple program executes in the DMC 30000 and indicates via the serial port when a communication handle fails By monitoring the serial port the user can re establish communication if needed LOOP Simple program loop JP LOOP EN TCPERR Ethernet communication error auto routine G Pl _TA4 Send message to serial port indicating which handle did not receive proper acknowledgment RE Example Amplifier Error The program below will execute upon the detection of an error from an internal Galil Amplifier The bits in TA1 will be set for all axes that have an invalid hall state even if BR1 is set for those axes this is handled with the mask variable shown in the code below AMP
153. function where n is the analog input 1 through 2 The resolution of the Analog to Digital conversion is 12 bits Analog inputs are useful for reading special sensors such as temperature tension or pressure The following examples show programs which cause the motor to follow an analog signal The first example is a point to point move The second example shows a continuous move Example Position Follower Point to Point Objective The motor must follow an analog signal When the analog signal varies by 5V motor must move 5000 counts Method Read the analog input and command A to move to that point Chapter 7 Application Programming 138 DMC 30000 User Manual Instruction Interpretation POINTS Label SP 7000 Speed AC 80000 DC 80000 Acceleration LOOP VP AN 1 1000 Read and analog input compute position PA VP Command position BGA Start motion AMA After completion JP LOOP Repeat EN End Example Position Follower Continuous Move Method Read the analog input compute the commanded position and the position error Command the motor to run at a speed in proportions to the position error Instruction Interpretation CONT Label AC 80000 DC 80000 Acceleration rate JG 0 Start job mode BGX Start motion LOOP vp AN 1 1000 Compute desired position ve vp _TPA Find position error vel ve 20 Compute velocity JG vel Change velocity JP LOOP Change velocity EN End Example Low Pass Digital Filter for th
154. g 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 2m inches and it corresponds to 4000 quadrature one inch of travel equals 4000 2n 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 11 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Figure 7 1 The program starts at a state that we define as A Here the controller waits for the input pulse on 11 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 AI1 Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AMX After motion is complete SB1 Set output bit 1 WT 20 Wait 20 ms CB1 Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process START PULSE 11 Eo F MOTOR VELOCITY OUTPUT PULSE output TIME INTERVALS move wait ready move Chapter 7 Application Programming 140 DMC 30000 User Manual Speed Control by Joystick
155. hase m 3 6 A Phase Table A3 1 Amplifier Gain Settings for DMC 30017 The axis must be in a motor off MO state prior to execution of the AG command The current ratings are peak current per phase Low Current Mode LC LC configures the behavior when holding position when RP is constant The settings are shown in Table A3 2 for LC m LC Setting Mode Description m 0 Full Current Motor uses 100 of current at all times when enabled m 1 Low Current Motor uses 25 of current while at resting state m 2 32767 Delayed Low Current m specifies the number of samples to wait between the end of the move and when the current is cut to 25 Table A3 2 LC settings for DMC 30017 3 phased Brushless Servo Mode Electrical Specifications If MT is set to 1 the DMC 30017 can drive a 3 phase DC brushless servo motor See A1 DMC 30012 pg 181 for wiring and operating the DMC 30017 as a 3 phased brushed servo drive 2 phased Brushless Servo Mode 2PB Electrical Specifications If the 2PB option is ordered and MT 1 is set the DMC 30017 can drive 2 phased brushless servo motors Due to the density of the magnetic cycle in 2 phased brushless motors usually 50 cycles per revolution for a 200 full step per revolution motor the 2PB option requires the use of an encoder directly on the back of the motor to close the loop in addition to a minimum BM value of 80 the length of electric cycle in counts For a 20
156. hat 1V is lost to the diode W 156 1X 24V 1V input DE RE 2692 input Using V JR and assuming that 1V is lost to the diode WV no 1V nc 6 3 74 u t tot R 3382Q Since the inputs already have 22000 current limiting resistor internally R 3382Q 2200Q 1182Q Which is most close to the standard resistor 1 2kQ Appendices 177 DMC 30000 User Manual Pin outs J5 1 0 44 pin HD D Sub Connector Female Pin Label Description Pin Label Description Pin Label Description 1 All Analog Input 1 16 AGND Analog Ground 31 Al2 Analog Input 2 2 AO2 Analog Output 2 17 AO1 MCMD Analog Output 1 32 12V 12V 3 N C No Connect 18 12V 12V 33 GND Ground 4 ERR Error Output 19 AEN Amplifier Enable 34 CMP Output Compare 5 MF1 Multi Function 1 20 GND Ground 35 MF1 Multi Function 1 6 MF2 Multi Function 2 21 MF2 Multi Function 2 36 MF3 Multi Function 3 7 MF4 Multi Function 4 22 MF3 Multi Function 3 37 MF4 Multi Function 4 8 LSC Limit Switch Common 23 5V 5V 38 FLS Forward Limit Switch 9 HOM Home Switch Input 24 RLS Reverse Limit 39 INC Input Common 10 DI2 Digital Input 2 25 DI1 Digital Input 1 40 DI3 Digital Input 3 11 DI5 Digital Input 5 26 DI4 Digital Input 4 41 DI6 Digital Input 6 12 DI8 Digital Input 8 27 DI7 Digital Input 7 42 ELO Electronic Lockout 13 RST Reset Input 28 ABRT A
157. he application level GalilTools is the basic programs that the majority of users will need to communicate with the controller to perform basic setup and to develop application code dmc programs that is downloaded to the controller At the Galil API level the GalilTools Communication Library is available for users who wish to develop their own custom application programs to communicate to the controller Custom application programs can utilize API function calls directly to our DLL s At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers Controller Response to Commands Most DMC 30000 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return Multiple commands may be concatenated by inserting a semicolon between each command After the instruction is decoded the DMC 30000 returns a response to the port from which the command was generated If the instruction was valid the controller returns a colon or the controller will respond with a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the RS 232 port back through the RS 232 port and to commands which are sent via the Ethernet port back through the Ethernet port For instructions that return data such as Tell Position TP the DMC 30000 will return the data
158. ic 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 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 X Y Z or W following LR or LF specifies the axis The CN command can be used to configure the polarity of the limit switches Limit Switch Example A JP A EN Dummy Program LIMSWI Limit Switch Utility V1 LFX Check if forward limit V2 LRX Check if reverse limit JP LF V1 0 Jump to LF if forward JP LR V2 0 Jump to LR if reverse JP END Jump to end LF LF G FORWARD LIMIT Send message STX AMX Stop motion PR 1000 BGX AMX Move in reverse JP END End LR LR G REVERSE LIMIT Send message STX AMX Stop motion PR1000 BGX AMX Move forward END End RE Return to main program Chapter 8 Hardware amp Software Protection 146 DMC 30000 User Manual Chapter 9 Troubleshooting Overview The following discussion may help you get your system to work Potential problems have been divided into groups as follows 1 Installation 2 Stability and Compensation 3 Operation 4 Error Light Re
159. iguration commands Table 2 6 provides a brief list of configuration commands that may need to be set depending on the motor type and motor specifications Command Description MT Configures an axis for use with either a stepper or servo motor AG Amplifier gain A V for servos or A Phase for steppers Configures an internal servo amplifier for brushed mode BR Also used to ignore halls when the use of an external amplifier is required in lieu of an internal Configures the current loop update rate AU Can also be used to switch capable amplifiers between chopper and inverter mode not valid with any 30xxx amplifier Continuous and peak limits for motor command output in volts Effectively TL TK Sask oe oe limits amplifier current according to Amplifier gain factor see AG YA Stepper drive resolution microstepping configuration LC Configures stepper motor current at holding or rest positions Table 2 6 Sample of motor and amplifier configuration commands Step D If using a servo motor continue to Step 10 Tune the Servo System pg 28 If using a stepper continue on to Step E Step E Enable and use the motor A SH will enable the internal amplifier and a MO will disable the internal amplifier Once enabled DMC motion commands can be sent to move the motor see Chapter 6 Programming pg 62 for details Chapter 2 Getting Started gt 27 DMC 30000 User Manual Step 8a Commutation
160. iicrsaerdntnienns 191 A3 DMC 30016 192 A4 DMC 30017 196 DCT I as cette eset este cars See ees 196 Stepper Mode Electrical Speci ficati ts c sccc asecscccacaasnenens vunenieans 197 PREY gc ak erg cee poe ae ee ede 198 A5 DMC 31000 201 Tecc p Bee Cee ere eee Ore Ere ee Cree rer ene eee ner eee rrr rt 201 Theor OP Maat VIGIS co cujciteseushiaiatecraes shin laais sel gar alone sales sete radu 202 DMC 30000 Contents iv Chapter 1 Overview Introduction The DMC 30000 Series is Galil s latest generation single axis motion controller It uses a 32 bit RISC processor to provide higher speed than older models The DMC 30000 is available as a compact card level or box level unit and connects to a stepper or servo motor amplifier of any power range The DMC 300xx can be purchased with internal drives which can minimize space cost and wiring The motion controller can operate stand alone or can be networked to a PC via Ethernet Features include PID compensation with both velocity and acceleration feed forward program memory with multitasking for concurrent execution of multiple programs and uncommitted optically isolated inputs and outputs for synchronizing motion with external events Modes of motion include point to point positioning jogging contouring PVT electronic gearing and electronic cam Like all Galil motion controllers these controllers use a simple English like command language
161. imum Zero parameters for DT followed by zero parameters for CD will 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 Specifying a 1 for the DT or as the time interval in the CD command will pause the contour buffer Issuing the CM command will clear the contour buffer Command Summary Contour Mode COMMAND DESCRIPTION CM A Specifies contour mode CD x Specifies position increment over time interval Range is 32 000 CD 0 0 ends the contour buffer This is much like the LE or VE commands DT n Specifies time interval 2 sample periods 1 ms for TM1000 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 CM Amount of space left in contour buffer 511 maximum Chapter 6 Programming 86 DMC 30000 User Manual 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 Figure 6 12 The obje
162. in on position Instruction Interpretation S JG 4000 Set speed AI 1 BGA Begin after input 1 goes high AI 1 STA Stop after input 1 goes low AMA JP S After motion repeat EN The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use The controller has one auxiliary encoder which consists of two inputs channel A and channel B The auxiliary encoder input is mapped to the inputs 81 and 82 Tthe auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is of the full voltage range for example connect the input to 5 volts if the signal is a O 12 volt logic NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Input Interrupt Function The DMC 30000 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 interrupt mask If m and n are unused o contains a number with the mask For example II 5 enables inputs 1 and 3 Chapter 7 Application Programmi
163. in outs in the Appendix for pin out information tay Output PWR aka Output GND 25mA Sinking Optoisolated Outputs LSNK Description The 25mA sinking option refereed to as lower power sinking LSNK are capable of sinking up to 25mA per output The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output PWR Max Voltage 24 VDC Output PWR Min Voltage 5 VDC ON Voltage No Load Output PWR 5 VDC 1 2 VDC Max Drive Current per Output 25mA Sinking Wiring the 25mA Sinking Outputs The 25mA sinking outputs the load is wired in the same fashion as the 4mA sinking outputs The output power supply will be connected to Output PWR labeled OPB and the power supply return will be connected to Output Chapter 3 Connecting Hardware 40 DMC 30000 User Manual GND labeled OPA Note that the load is wired between Output PWR and DO The wiring diagram for Bank 0 is shown in Figure 3 5 Refer to Pin outs in the Appendix for pin out information 33V Output PWR Output GND 25mA Sourcing Optoisolated Outputs LSRC Description The 25mA sourcing option refereed to as low power sourcing LSRC are capable of sourcing up to 25mA per output The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output PWR Max Voltage 24 VDC Output PWR Min Vol
164. ine combines FE and FI as Described Above SC Stop Code DP P S gt TS Tell Status of Switches and Inputs Operand Summary Homing Operation Operand Description _ HMA Contains the value of the state of the Home Input SCA Contains stop code _TSA Contains status of switches and inputs High Speed Position Capture The Latch Function Often it is desirable to capture the position precisely for registration applications Position capture can be programmed to latch on either a corresponding input see Table 6 1 or on the index pulse for that axis The position can be captured for either the main or auxiliary encoder within 25 microseconds of an high to low transition Input 1 A axis latch Table 6 1 Inputs and corresponding axis latch NOTE Latching is not valid with sampled feedback types such as SSI BiSS Sin Cos and Analog To insure a position capture within 25 microseconds the input signal must be a transition from high to low Low to high transitions may have greater delay The software commands AL and RL are used to arm the latch and report the latched position respectively The latch must be re armed after each latching event See the Command Reference for more details on these commands Chapter 6 Programming 101 DMC 30000 User Manual Real Time Clock The DMC 30000 is equipped with a real time clock feature Th
165. ing point numbers which is common 1 Begin by opening a connection to the PLC which has an IP address of 192 168 1 10 in our example IHB 192 168 1 10 lt 502 gt 2 2 Dimension an array to store the results DM myanalog 4 3 Send the appropriate MB command Use function code 4 as specified per the PLC Start at address 40006 Retrieve 4 modbus registers 2 modbus registers per 1 analog input as specified by the PLC MBB 4 40006 4 myanalog Results Array elements 0 and 1 will make up the 32 bit floating point value for analog input 3 on the PLC and array elements 2 and 3 will combine for the value of analog input 4 myanalog 0 16412 0x401C myanalog 1 52429 0xCCCD myanalog 2 49347 0xC0C3 myanalog 3 13107 0x3333 Chapter 4 Software Tools and Communication 56 DMC 30000 User Manual Analog input 3 0x401CCCCD 2 45V Analog input 4 0xC0C33333 6 1V Example 3 DMC 30000 connected as a Modbus master to a hydraulic pump The DMC 30000 will set the pump pressure by writing to an analog output on the pump located at Modbus address 30000 and consisting of 2 Modbus registers forming a 32 bit floating point value 1 Begin by opening a connection to the pump which has an IP address of 192 168 1 100 in our example IHB 192 168 1 100 lt 502 gt 2 2 Dimension and fill an array with values that will be written to the PLC DM pump 2 pump 0 16531 0x4093 pump 1 13107 0x3333 3 Send the appropriate MB command Use
166. inputs are internally pulled up to 5V through a 4 7kQ resistor inputs are internally biased to 1 3V pulled up to 5V through a 7 1kQ resistor pulled down to GND through a 2 5kQ resistor Multi Function Pins MF Multi Functional Pins MF n The Multi Functional Pins on the DMC 30000 have different functionalities dependent upon how the controller was ordered and how the controller is setup by the user If the controller is ordered with SER serial encoder interface then the MF pins can be used to interface to a serial encoder BiSS and SSI MF1 and MF2 are only used for the Main serial encoder input MF3 and MF4 are used for the Aux serial encoder input See the SI and SS commands in the command reference for more detail When the controller is setup for stepper motor operation the MF 2 and MF4 pins are used for step and direction respectively Chapter 3 Connecting Hardware 44 DMC 30000 User Manual Single Description for Multi Functional Pins Label Pin MT 2 or 2 5 SER option with BiSS or SSI Enabled MF1 35 No Connect Main Axis Data DO or SLO MF1 5 No Connect Main Axis Data DO or SLO MF2 6 STEP Main Axis Clock CO or MA MF2 21 STEP Main Axis Clock CO or MA MF3 22 No Connect Aux Axis Data D1 or SLO MF3 36 No Connect Aux Axis Data D1 or SLO MF4 37 DIR Aux Axis Clock C1 or MA MF4 7 DIR Aux Axis Clock C1 or MA GND
167. ion 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 transition 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 HV 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 moves back to the index and defines this position as 0 The logic state of the Home input can be interrogated with the command MG_HMxX This command returns a 0 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
168. ion of approximately 0003V The analog inputs are specified as AN x where x is anumber 1 thru 2 AQ settings With the DMC 31000 the analog inputs can be set to a range of 10V 5V 0 5V or 0 10V this allows for increased resolution when the full 10V is not required The inputs can also be set into a differential mode where analog input 2 can be set to the negative differential input for analog input 1 See the AQ command in the command reference for more information Electrical Specifications Resolution 16 bit Input Impedance Unipolar 0 5V 0 10V 42kO Bipolar 5V 10V 31kO Analog Outputs Analog output 1 AO1 has different functions depending on the option ordered AO1 functions as the motor command line for DMC 30010 and DMC 30011 models and cannot be used as a general analog output For DMC 30000 models ordered with internal amplifiers AO1 can be configured to work as either a motor command line for an external amplifier or as a general analog output see Configuring AO1 with Internal Amplifiers below for more details Analog output 2 AO2 is always available as a general use analog output Electrical Specifications Output Voltage Range 10V Resolution 16 bit optional Maximum Current Output 4mA sink source Output Impedance 500 W Configuring AO1 with Internal Amplifiers Using AO1 as A Motor Command Line With the controller set to servo mode MT 1 or 1 to drive an external servo amplifier the BR comman
169. ion 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 8 AS A Halts program execution until the axis has reached its slew speed AT tn m For m omitted or 0 halts program execution until n msec from reference time AT O sets reference AT n waits n msec from reference AT n waits n msec from reference and sets new reference after elapsed time For m 1 Same functionality except that n is number of samples rather than msec AV n Halts program execution until specified distance along a coordinated path has occurred WT n m For m omitted or 0 halts program execution until specified time in msec has elapsed For m 1 Same functionality except that n is number of samples rather than msec 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 TWOMOVE Label PR 2000 Position Command BGX Begin Motion AMX Wait for Motion Complete PR 4000 Next Position Move BGX Begin 2 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 SETBIT Label SP 10000 Speed is
170. k C1 or MA MF4 7 DIR Aux Axis Clock C1 or MA GND 20 Digital Ground Appendices 178 DMC 30000 User Manual J4 Encoder 15 pin HD D Sub Connector Female Pin Label Description 1 MI I Index Pulse Input 2 MB B Main Encoder Input 3 MA A Main Encoder Input 4 AB B Aux Encoder Input 5 GND Digital Ground 6 MI l Index Pulse Input 7 MB B Main Encoder Input 8 MA A Main Encoder Input 9 AA A Aux Encoder Input 10 HALA A Channel Hall Sensor 11 AA A Aux Encoder Input 12 AB B Aux Encoder Input 13 HALB B Channel Hall Sensor 14 HALC C Channel Hall Sensor 15 5V 5V J1 J2 Ethernet RJ45 The Ethernet connection is Auto MDIX 100bT 10bT Pin Signal TXP TXN RXP NC NC RXN NIOU BW NM NC 8 NC J3 RS 232 Main Port Male Standard connector and cable 9Pin 3 5 Signal NC TXD RXD NC GND NC CTS RTS WO SOIN I DWM BIW NY FR NC JP1 Jumper Description for DMC 30000 Label Function If jumpered OPT Reserved MO When controller is powered on or reset Amplifier Enable lines will be in a Motor Off state A SH will be required to re enable the motors 19 2 Baud Rate setting see table below UG Used to upgrade controller firmware when resident
171. l The Abort input by default will also halt program execution this can be changed by changing the 5 field of the CN command See the CN command in the command reference for more information ELO Electronic Lock Out Used in conjunction with Galil amplifiers this input allows the user the shutdown the amplifier at a hardware level For more detailed information on how specific Galil amplifiers behave when the ELO is triggered see Error Reference source not found in the Appendices 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 The OE command can also be configured so that the axis will be disabled upon the activation of a limit switch 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
172. l in correcting for X axis friction after each move when conducting a reciprocating motion The drive is a 1 256th microstepping drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to continue upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA256 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution Y C4000 Encoder resolution counts per revolution SHX Enable axis WT50 Allow slight settle time YS1 Enable SPM mode MOTION Perform motion SP16384 Set the speed PR10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction MOTION2 SP16384 Set the speed PR 10000 Prepare mode of motion BGX Begin motion CX JS CORRECT Move to correction JP MOTION CORRECT Correction code Spx _SPX LOOP Save speed value SP2048 Set a new slow correction speed WT100 Stabilize JP END ABS _QSX lt 10 End correction if error is within defined tolerance YRX _QSX Correction move CX WT100 Stabilize JP LOOP Keep correcting until error is within tolerance END End CORRECT subroutine returning to code SPX spx Chapter 6 Programming 95 DMC 30000 User Manual Dual Loop Auxiliary Encoder The DMC 30000 provides an interface for a second encoder except when the controller is configured for stepper motor operation or used in circular compare When used the second encoder is typically mounted on the m
173. l interrupt for communication allowing the application program to be interrupted by input from the user The interrupt is enabled using the Cl command The syntax for the command is Cl n n 0 Don t interrupt Port 1 n 1 Interrupt on lt enter gt Port 1 n 2 Interrupt on any character Port 1 n 1 Clear any characters in buffer The COMINT label is used for the communication interrupt For example the DMC 30000 can be configured to interrupt on any character received on Port 2 The COMINT subroutine is entered when a character is received and the subroutine can decode the characters At the end of the routine the EN command is used EN 1 will re enable the interrupt and return to the line of the program where the interrupt was called EN will just return to the line of the program where it was called without re enabling the interrupt As with any automatic subroutine a program must be running in thread 0 at all times for it to be enabled Example A DMC 30000 is used to jog the axis The speed of either axis may be changed during motion by specifying the axis letter followed by the new speed value An S stops motion on both axes Chapter 7 Application Programming 130 DMC 30000 User Manual Instruction AUTO speedA 10000 speedB 10000 CL 42 JG speedA BGX PRINT G P1 TO CHANGE SPEEDS G P1 TYPE A G P1l TYPE S TO STOP JOGLOOP G speedA P JOGLOO N COMINT P A P2CH A P C P2CH S ZS1 C1I2 JP JOGLOOP A JS NUM spee
174. l the temperature of the transistors falls below the threshold Mating Connectors On Board Connector Terminal Pins 2 pin Molex Mini Fit Jr POWER MOLEX 39 31 0020 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr Power Connectors MOLEX 39 31 0040 MOLE eet For mating connectors see http www molex com Motor Connector Power Connector Power Connector Pin Number Connection 1 DC Power Supply Ground 2 VS DC Power Motor Connector 1 Phase C 2 Phase B N C for Brushed Motors 3 No Connect 4 Phase A A2 DMC 30014 192 DMC 30000 User Manual Power Unlike a switching amplifier a linear amplifier does not have a straightforward relationship between the power delivered to the motor and the power lost in the amplifier Therefore determining the available power to the motor is dependent on the supply voltage the characteristics of the load motor and the required velocity and current All of the power delivered by the power supply is either used in the motor or lost in the amplifier Power of Power Supply Ps P P The power to the motor is both the power used to provide motion and the power lost to heat Power of the motor P Work Power Lostin Motor P K Velocity i iR Power of amplifier P V i R K Velocity i In addition there is a minimum power dissipated by the amplifier when powered regardless of load The minimu
175. l 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 BGA ASA MG The Speed is TVA F5 0 N MG counts sec EN When HA 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 be used to configure a terminal Any ASCII character can be sent by using the format n where n is any integer between 1 and 255 Example MG 407 4255 sends the ASCII characters represented by 7 and 255 to the bus Chapter 7 Application Programming 132 DMC 30000 User Manual Summary of Message Functions Function Description ee Surrounds text string Fn m Formats numeric values in decimal n digits to the left of the decimal point and m digits to the right Pl or En Send message to RS 232 Port or Ethernet Port Sn m Formats numeric values in hexadecimal n 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 thru 6 Displaying Variables and Arrays Variables and arrays
176. lectrical technician electrical engineer or electrical professional should wire the DMC product and related components Galil shall not be liable or responsible for any incidental or WARNING consequential damages All wiring procedures and suggestions mentioned in the following sections should be done with the controller in a powered off state Failing to do so can cause harm to the user or to the controller The following instructions are given for Galil products only If wiring an non Galil device follow the NOTE instructions provided with that product Galil shall not be liable or responsible for any incidental or consequential damages that occur to a 3 party device Step 1 Determine Overall Motor Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 30000 can control servo and stepper motors Galil has several internal amplifier options that can drive motors directly but can also control external amplifiers using either a 10V motor command line or PWM Step and direction lines There are also several feedback options that the DMC can accept See Part Numbers pg 2 for understanding the complete DMC unit and part number before continuing Step 2 Install Jumpers on the DMC 30000 The following jumpers are located in a rectangular cut out on the left side of the controller near the reset button Chapter 2 Getting Started gt 20 DMC 30000
177. lil for other OS options The GalilSuitecontains the following tools Tool Description Launcher Launcher Tool with the ability to create custom profiles to manage controller connections Terminal For sending and receiving Galil commands Editor To easily create and work on multiple Galil programs simultaneously Viewer To see a complete status of all controllers on a single screen Scope For viewing and manipulating data for multiple controllers real time Watch For simplified debugging of any controller on the system and a display of I O and motion status Tuner With up to four methods for automatic and manual PID tuning of servo systems Configuration For modifying controller settings backup restore and firmware download The latest version of GalilSuite can be downloaded here http www galil com downloads software For information on using GalilSuite see the user manual http www galil com download manual galilsuite Chapter 4 Software Tools and Communication 61 DMC 30000 User Manual Creating Custom Software Interfaces GalilTools provides a programming API so that users can develop their own custom software interfaces to a Galil controller Information on this GalilTools Communication Library can be found in the GalilTools manual http www galil com download manual galiltools library html HelloGalil Quick Start to PC programming For programmers developing Windows applicati
178. linear amplifier is 0 2 A V Typically a 24VDC supply will deliver 1A continuous and 2A peak The current loop bandwidth is approximately 4 kHz By default the amplifier will use 12 bit DAC s however there is an option for 16 bit DAC s to increase the current resolution for systems with high feedback gain Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation A2 DMC 30014 191 DMC 30000 User Manual Electrical Specifications The amplifier is a brushless type trans conductance linear amplifier for sinusoidal commutation The amplifier outputs a motor current proportional to the command signal input DC Supply Voltage 15 30 VDC In order to run the DMC 30014 in the range of 15 20 VDC the ISCNTL Isolate Controller Power option must be ordered Continuous Current 1 0 Amps Peak Current per axis 2 0 Amps Amplifier gain 0 2 A V Total max power output 20 W assuming proper thermal mounting and heat dissipation The amplifier has built in thermal protection which will cause the amplifier to be disabled unti
179. lude Encoder Failure Detection OA OT OV Automatic Subroutines to create an automated response to events such as limit switches toggling LIMSWI command errors POSERR and amplifier errors TA AMPERR and more For a full list of features and how to program each see Chapter 8 Hardware amp Software Protection pg 138 Step 8 Wiring Motors to Galil s Internal Amps Table 2 4 below provides a general overview of the connections required for most systems connecting to a DMC internal amplifier and controller system Following the table is a step by step guide on how to do so Motor Type Required Connections Brushed servo motor e Power to controller and internal amplifier e Motor power leads to internal amplifiers e Encoder feedback 2 phased brushless servo motor e Power to controller and internal amplifier e Motor power leads to internal amplifiers e Encoder feedback 3 phased Brushless servo motor e Power to controller and internal amplifier e Motor power leads to internal amplifiers e Encoder feedback e Hall sensors Optional Stepper motor e Power to controller and internal amplifier e Motor power leads to internal amplifier e Encoder feedback optional Table 2 4 Synopsis of connections required to connect a motor to Galil s internal amplifiers Step A Connect the encoder feedback optional for steppers See Step 6 Connecting Encoder Feedback pg 17 Step B Connect the m
180. lue of 5000 to the variable posx PR posx Assigns variable posx to PR command JG rpmY 70 Assigns variable rpmY multiplied by 70 to JG command Programmable Variables The DMC 30000 allows the user to create up to 254 variables Each variable is defined by a name which 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 not be the same as DMC 30000 instructions For example PR is not a good choice for a variable name NOTE It is generally a good idea to use lower case variable names so there is no confusion between Galil commands and variable names Examples of valid and invalid variable names are Valid Variable Names posx Chapter 7 Application Programming 124 DMC 30000 User Manual posi speedZ Invalid Variable Names RealLlongName Cannot have more than 8 characters 123 Cannot begin variable name with a number speed Z 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 231 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 30000 function can be used to assign a value to a variable For example v1 A
181. m Reset 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 Electronic Lock Out Controllers with Internal Amplifiers Only Input that when triggered will shut down the amplifiers at a hardware level Useful for safety applications where amplifiers must be shut down at a hardware level Forward Limit Switch When active inhibits motion in forward direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Reverse Limit Switch When 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 Home Switch 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 Input 1 Input 8 Uncommitted inputs May be defined by the user to trigger events Inputs are checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input 1 is latch A if the high speed position latch function is enabled Latch High speed position latch to capture axis position on occurrence of latch sig
182. m power that the amplifier will consume is roughly P min drop across op amp power stages drop across sense resistor op amp supply P x4 i i 54N A min Where N 1 5W for 24V and N 3W for 48V For example assume a 24VDC supply and a motor with R 4ohms and K 5V RPM and desired output currents of 1 and 5 amps First calculate the minimum power used in the amplifier P min lamp 4 i i 5 1 5 6W P min Samp 4 5 5 5 3 5 125W The power used by the motor will vary by its velocity even though the power lost in the motor is a constant for each value of current The more power sent to the motor the less power will be dissipated by the amplifier as heat Power Dissipated by the Amplifier for a Given Veloc 25 wees preus A2 DMC 30014 193 DMC 30000 User Manual Operation Commutation Related Velocity When using sinusoidal commutation and higher speed applications it is a good idea to calculate the speed at which commutation can start to affect performance of the motor In general it is recommended that there be at least 8 servo samples for each magnetic cycle The time for each sample is defined by TM TM 1000 is default and is in units of us per sample or us sample TM can be lowered to achieve higher speeds Below is the equation that can be used to calculate the desired maximum commutation speed in counts per second cts s 6 mX10 Speedi asi
183. m Terminal XQ A Execute A 2003 PR5000 Error on Line 3 TCL Tell Error Code 7 Command not valid while running Command not valid while running Change the BGX line to BGX AMX and re download the program XQ A Execute A Program Flow Commands The DMC 30000 provides instructions to control program flow The controller program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements Event Triggers amp Trippoints To function independently from the host computer the DMC 30000 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 30000 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 controller can make decision
184. mand 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 Chapter 7 Application Programming 131 DMC 30000 User Manual MG Analog input is AN 1 MG The Position of Ais TPA Specifying the Port for Messages The port can be specified with the specifier P1 for the RS 232 port or En for the Ethernet port MG P1 Hello World Sends message to RS 232 Port Formatting Messages String variables can be formatted using the specifier Sn where n is the number of characters 1 thru 6 For example MG STR S3 This statement returns 3 characters of the string variable named STR Numeric data may be formatted using the Fn m expression following the completed MG statement Sn 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 equa
185. n Integer portion of n RND n Round of n Rounds up if the fractional part of n is 5 or greater SQR n Square root of n Accuracy is 004 IN n Return digital input at general input n where n starts at 1 OUT n Return digital output at general output n where n starts at 1 AN n Return analog input at general analog in n where n starts at 1 Note that these functions are multi valued An application program may be used to find the correct band Functions may be combined with mathematical expressions The order of execution of mathematical expressions is from left to right and can be over ridden by using parentheses Examples v1l 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 2 5 AN 5 The variable v4 is equal to the value of analog input 5 plus 5 then multiplied by 2 Variables For applications that require a parameter that is variable the DMC 30000 provides 254 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 program calculations For example a cut to length application may require that a cut length be variable Example posx 5000 Assigns the va
186. n array is defined with the command DM The user must specify a name and the number of entries to be held in the array An array name can contain up to eight characters starting with an alphabetic character The number of entries in the defined array is enclosed in Example DM posx 7 Defines an array names posx with seven entries DM speed 100 Defines an array named speed with 100 entries DA posx 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 O 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 0 7650 2 Assigns the first element of the array speed the value 7650 2 speed 0 Returns array element value posx 9 _TPX Assigns the 10 element of the array posx the returned value from the tell position command con 1 COS pos 2 Assigns the second element of the array con the cosine of the variable POS multiplied by 2 timer 0 TIME Assigns the firs
187. n be plugged back in after the correct settings have been loaded back to the controller when necessary To perform a Master Reset find the jumper location labeled MR or MR on the controller and put a jumper across the two pins Power up with the jumper installed The Self Test will take slightly longer up to 5seconds After the error light shuts off it is safe to power down and remove the Master Reset jumper If performing a Master Reset does not get rid of the error light the controller may need to be sent back to the factory to be repaired Contact Galil for more information Chapter 9 Troubleshooting 149 DMC 30000 User Manual 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 Figure 10 1 COMPUTER CONTROLLER DRIVER ney The operation of such a system can be divided into three levels as illustrated in Figure 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
188. n counts and n1 is the phase shift 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 4 Specify the slave positions Next we specify the slave positions with the instruction ET n x where n indicates the order of the point The value n starts at zero and may go up to 256 The parameter x will indicate the corresponding slave position For this example the table may be specified by ET O 0 ET 1 3000 ET 2 2250 ET 3 1500 This specifies the ECAM table Step 5 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 6 Engage the slave motion To engage the slave motion use the instruction EG x where x is the master positions at which the corresponding 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 7 Disengage the slave motion To disengage the cam use the command EQ x where x is the master positions at which the corresponding slave axis is disengaged Chapter 6 Programming 81 DMC 30000 User Manual 3000 2250 1500 2000 4000 6000 Master X This disengages the slave axis at a specified master position If the parameter is outside the master cycle the stopping is i
189. n tools as well as several design examples will be provided TIME 8 hours 8 00 am 5 00 pm 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 Attendees must have a current application and recently purchased a Galil controller to attend this course TIME Two days 8 30 4 30pm http www galilmc com learning training at galil ph Appendices 182 DMC 30000 User Manual Contacting Us Galil Motion Control 270 Technology Way Rocklin CA 95765 Phone 916 626 0101 Fax 916 626 0102 E Mail Address support galilmc com Web http www galilmc com Appendices 183 DMC 30000 User Manual WARRANTY All controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship for a period of 18 months after shipment Motors and Power supplies are warranted for 1 year Extended warranties are available In the event of any defects in materials or workmanship Galil Motion Control will 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
190. nal AL command arms latch Input 1 is latch A Appendices 181 DMC 30000 User Manual 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 500 000 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 20 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 introduction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30 pm 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 desig
191. nal current limiting resistor Contact Galil if there is any uncertainty if your system requires the use of an additional resistor If a resistor is required a resistor of 1 2kO should be added in series with each input to limit the amount of current An example is shown with INCOM Bank 0 to power digital input 1 in Figure A 2 below where R is 1 2 kQ This covers the worst case scenario where INCOM is powered with the maximum 24 Vp and all 8 of it s inputs are normally closed To calculate the exact resistance required the table below includes the maximum power rating per resistor back and the maximum amount of inputs pins used per pack INCOM LSCOM Max number of pins used on single resistor pack 8 inputs 6 inputs Max power rating per resistor pack 1 25 W 1 00 W An example in the Input Current Limitation Calculations section below provides how to use this table to calculate the resistance required 5V PS2805 Gb Vs RETURN Input Current Limitation Calculations The follow calculations are based upon the most extreme condition where all 8 inputs of INCOM are active at all times Assumptions e The resistor pack has a 1 25 W total limitation e INCOM uses 8 resistors of a single resistor pack e All inputs are continuously on at the same time e The maximum voltage of 24 Voc is used 125 gap We 8 inputs input Appendices 176 DMC 30000 User Manual Using P IJV and assuming t
192. ncommitted and may be designated by the user to 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 Encoder MA MB Position 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 15 000 000 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 Encoder Index MI Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Encoder MA MB MI Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Auxiliary Encoder AA AB Aux A Aux B Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for step motors Abort A low input stops commanded motion instantly without a controlled deceleration Also aborts motion progra
193. nd 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 which 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 return a number representing the motion status See the command reference for further information Flash Memory Interrogation Commands For debugging the status of the program memory array memory or variable memory the DMC 30000 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 which can be currently defined For example a standard DMC 30000 will have a maximum of 3000 array elements in up to 6 arrays If an array of 100 elements is defined the command DM will return the value 2900 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 contents of the Program space use the interrogation command LS List To list th
194. nd no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or LM returns the available spaces for motion segments that can be sent to the buffer 31 returned means the buffer is empty and 31 segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional segments can be sent at PC bus speeds The operand _CS can be used to determine the value of the segment counter Additional commands The commands VS n VA n and VD n are used for specifying the vector speed acceleration and deceleration Specifying Vector Speed for Each Segment The vector speed may be specified by the immediate command VS It can also be attached to a motion segment with the instructions Chapter 6 Programming 76 DMC 30000 User Manual VP x y lt n gt m CR r e 6 lt n gt m The first command lt n is equivalent to commanding VS n at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a
195. nd output is greater than the OV threshold for more than than the 500ms defined by the OT command AND there has been less than 4 counts of change on the encoder then the controller will turn off that axis due to an encoder failure The motor will have moved some distance during this operation but it will be shut down before a full runaway condition occurs Using Encoder Failure to detect a hard stop or stalled motor The encoder failure detection can also be used to detect when an axis is up against a hard stop In this scenario the motor command will be commanded above the OV threshold but because the motor is not moving the controller will detect this scenario as an encoder failure Programmable Position Limits The DMC 30000 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 30000 will not accept position commands beyond the limit Motion beyond the limit is also prevented Example DP 0 Define Position BL 2000 Set Reverse position limit FL 2000 Set Forward position limit JG 2000 Jog BG X Begin motion stops at forward limits Off On Error The DMC 30000 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 for each axis specify 1 2 or 3 for that axis To disable this function specify 0 for the axes When this functi
196. nditional statement based on input 1 IF IN 2 0 2 IF conditional statement executed if 1 IF conditional true G INPUT 1 AND INPUT 2 ARE ACTIVE Message to be executed if 2 IF conditional is true ELSE ELSE command for 2 IF conditional statement G ONLY INPUT 1 IS ACTIVE Message to be executed if 2 IF conditional is false ENDIF End of 2 conditional statement ELSE ELSE command for 1 IF conditional statement G ONLY INPUT 2 IS ACTIVE Message to be executed if 1 IF conditional statement is false ENDIF End of 1 conditional statement WAIT Label to be used for a loop JP WAIT IN 1 0 IN 2 0 Loop until both input 1 and input 2 are not active RIO End Input Interrupt Routine without restoring trippoints 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 Example An example of a subroutine to draw a square 500 counts per side is given below The square is drawn at vector position 1000 1000 Chapter 7 Application Programming 113 DMC 30000 User Manual M Begin Main Program
197. ne 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 TEST Begin main program len 123456 Set len to a string value 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 lenl Flen amp 00FF Mask top byte of Flen and set this value to variable len1 len2 Flen S FF00 100 Let variable len2 top byte of Flen len3 len amp S000000FF Let variable len3 bottom byte of len len4 len amp SO000FF00 100 Let variable len4 second byte of len len5 len amp SO0OFF0000 10000 Let variable lenS third byte of len len6 len amp SFF000000 1000000 Let variable len6 fourth byte of len G leno S4 Display len6 as string message of up to 4 chars G len5 S4 Display len as string message of up to 4 chars G len4 S4 Display len4 as string message of up to 4 chars G len3 S4 Display len3 as string message of up to 4 chars G len2 S4 Display len as string message of up to 4 chars G len1 S4 Display len1 as string message of up to 4 chars EN
198. nfiguration and the inputs for those feedback options DMC 30000 Feedback Options DMC 3001x DMC 3001x SER DMC 3101x DMC 3101x SER Main Digital Encoder MA MB MA MB MA MB MA MB Aux Digital Encoder AA AB AA AB AA AB AA AB Analog Feedback 0 5V All All Al1 AQ Al1 AQ Analog Feedback 16 bit configurable 10V Al1 AQ Al1 AQ SSI BiSS Channel 0 MF 1 2 Main MF 1 2 Main SSI BiSS Channel 1 MF 3 4 Aux MF 3 4 Aux MA MB are the Main Encoder inputs AA AB are the Aux Encoder Inputs e Allis Analog Input 1 e MF 1 2 are Multi function Inputs 1 and 2 e ME 3 4 are Multi function Inputs 3 and 4 Main Encoder Inputs The main encoder inputs can be configured for quadrature default or pulse and direction inputs This configuration is set through the CE command The encoder connections are found on the 15 pin HD D sub Encoder connectors and are labeled MA MA MB MB The negative inputs are the differential inputs to the encoder inputs if the encoder is a single ended 5V encoder then the negative input should be left floating except for the DMC 31000 see AS DMC 31000 for details If the encoder is a single ended and outputs a 0 12V signal then the negative input should be tied to the 5V line on the DMC 30000 When the encoders are setup as step and direction inputs the MA channel will be the step or pulse input and the MB channel will be the direction input
199. ng 137 DMC 30000 User Manual 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 IMPORTANT Use the RI command not EN to return from the ININT subroutine Example Input Interrupt Instruction A H w 0000 20000 Sa wag A wW HUGH e p WO W Aq ININT G Interrupt has occurred ST AB LOOP JP LOOP IN 1 0 JG 15000 10000 WT 300 BG AB RI Interpretation Label A Enable input 1 for interrupt function Set speeds on A and B axes Begin motion on A and B axes Label B Report A and B axes positions Wait 1000 milliseconds Jump to B End of program Interrupt subroutine Displays the message Stops motion on A and B axes Loop until Interrupt cleared Specify new speeds Wait 300 milliseconds Begin motion on A and B axes Return from Interrupt subroutine Jumping back to main program with ININT To jump back to the main program using the JP command the RI command must be issued in a subroutine and then the ZS command must be issued prior to the JP command See Application Note 2418 for more information http www galilmc com support appnotes optima note2418 pdf Analog Inputs The DMC 30000 provides two analog inputs The value of these inputs in volts may be read using the AN n
200. ng example DMC 30010 CARD TRES SER Serial Encoder Interface The SER enables the DMC 30000 controller to interface to BiSS and SSI encoders Electrical specifications can be found in the Multi Function Pins MF section of Chapter 3 Connecting Hardware see the SS and SI commands in the DMC 30000 Command Reference for command information Part number ordering example DMC 30010 CARD SER HALLF Filtered Hall Sensor Inputs The HALLF option will place a capacitor between the hall input and digital GND to filter unwanted noise This results in cleaner more reliable hall sensor reads The HALLF option is only available for Galil s internal PWM amplifiers Part number ordering example DMC 30012 BOX HALLF Appendices 166 DMC 30000 User Manual Communication Options RS 422 Serial Port Serial Communication The default serial configuration for the DMC 30000 is to have RS 232 communication on the serial port The controller can be ordered to have RS 422 RS 422 communication is a differentially driven serial communication protocol that should be used when long distance serial communication is required in an application RS 422 Serial Port Pinout Standard connector and cable when DMC 30000 is ordered with RS 422 Option Pin Signal RTS TXD RXD CTS GND RTS TXD RXD CTS Oloo NIAI BR Wl N R JP2 RS 422 Termination Jumpers Label Function If jumpered
201. nge the ratio of outputting amps of the amplifier per commanded volts of the controller This is another way to limit the amount of current but can also maintain the resolution of the 10V motor command line Step B Set the Error Limit When ER error limit and OE off on error is set the controller will automatically shut down the motors when excess error TE gt ER has occurred This is an important safety feature during set up as wrong polarity can cause the motor to run away see Step C below for more information regarding runaway motors NOTE Off on error OE requires the amplifier enable signal to be connected from the controller to the amplifier This is automatic when using Galil s internal amplifiers see Step 9 Connecting External Amplifiers and Motors pg 26 for external amplifiers Step C Understanding and Correcting for Runaway Motors Chapter 2 Getting Started gt 24 DMC 30000 User Manual A runaway motor is a condition for which the motor is rotating uncontrollably near it s maximum speed in a single direction This is often caused by one of two conditions 1 The amplifier enable signal is the incorrect logic required by the amplifier This is only applicable to external amplifiers only If the motor is in a MO state when the motor runs away the MO command is toggling the amplifier on enabled and needs to be reconfigured The motor is running away because the controller is registering
202. ngerous voltages current temperatures and energy levels exist in this product and the associated amplifiers and servo motor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install set up and operate this equipment Never open the controller box when DC power is applied WARNING If the controller was ordered with Galil s internal amplifiers power to the controller and amplifier is typically supplied through the 2 pin amplifier power connector If the controller is ordered without internal amplifiers the power will come through a 2 or 4 pin connector on the bottom side of the controller depending on the option ordered See Power Wiring Diagrams pg 165 for the location of the power connections For pin outs and a list of connector part numbers to make a power cable see Power Connector Part Numbers pg 164 Different options may effect which connections and what bus voltages are appropriate If using an internal amplifier the ISCNTL Isolate Controller Power pg 162 option will require multiple connections one to power the controller board and another to power the amplifiers Table 2 1 below shows which power connectors are and required for powering the system based upon the options ordered X designates a connection these connectors are only populated if required Chapter 2 Getting Started gt 21 DMC 30000 User Manual
203. now at rate of 2 msec BG XY Begin motion A JP A _RC 1 Loop until done G DONE Print message EN End program PLAY Play back 0 Initial Counter JP DONE N gt 300 Exit if done Print Counter X POS N Print X position Y POS N Print Y position XERR N Print X error YERR N Print Y error N 1 Increment Counter DONE Done EN End Program De allocating Array Space Array space may be de allocated using the DA command followed by the array name DA 0 deallocates all the arrays Input of Data Numeric and String NOTE The IN command has been removed from the DMC 30000 firmware Variables should be entered by sending data directly from the host application Sending Data from a Host The DMC 30000 can accept ASCII strings from a host This is the most common way to send data to the controller such as setting variables to numbers or strings Any variable can be stored in a string format up to 6 characters by simply specifying defining that variable to the string value with quotes for example varS STRING Will assign the variable varS to a string value of STRING To assign a variable a numerical value the direct number is used for example varN 123456 Will assign the variable varN to a number of 123 456 All variables on the DMC 30000 controller are stored with 6 bytes of integer and 4 bytes of fractional data Chapter 7 Application Programming 129 DMC 30000 User Manual Opera
204. nstantaneous ECAM Example To illustrate the complete process consider the cam relationship described by the equation X 0 5 xN 100 sin 0 18 N where N virtual axis 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 instruction EA N defines virtual axis as the master axis The cycle of the master is 2000 Over that cycle the slave varies by 1000 This leads to th e instructions MMN 2000 and EMA 1000 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 Y according to the equation and assigns the values to the table with the instruction ET i x INSTRUCTION INTERPRETATION SETUP Label EAN Select X as master EMA 1000 Slave Modulus MN 2000 EP 20 0 Master position increments i 0 Index LOOP Loop to construct table from equation p i 3 6 Note 3 6 0 18 20 s SIN p 100 Define sine position x i 10 s Define slave position ET i x Define table i i 1 JP LOOP i lt 100 Repeat the process EN Chapter 6 Programming 82 DMC 30000 User Manual PVT Mode The DMC 30000 controllers now supports a mode of motion referred to as PVT This mode allows arbitrary motion pro
205. nt along the trajectory To illustrate the ability to interrogate the motion status consider the first motion segment of our example LMOVE where the X axis moves toward the point X 5000 Suppose that when X 3000 the controller is interrogated using the command MG _AV The returned value will be 3000 The value of _CS and _VPA will be zero Chapter 6 Programming 75 DMC 30000 User Manual Vector Mode Linear and Circular Interpolation Motion he DMC 30000 provides a vector mode that allows the buffering of absolute moves from the starting position for a single axis The coordinated motion mode is similar to the linear interpolation mode but the linear segments are specified as absolute positions from the starting position of the A axis The command VM AN where A is the A axis and N is the virtualy axis Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence Note This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y
206. ntiate response from the command line and unsolicited messages The command CW1 causes the controller to set the high bit of ASCII characters to 1 of all unsolicited characters This may cause characters to appear garbled to some terminals This function can be disabled by issuing the command CW2 For more information see the CW command in the Command Reference RS 232 Port Cable requirements The RS 232 port on the DMC 30000 requires a straight through serial cable The pinout for this cable is indicated below RS232 Main Port P1 DATATERM 1 No Connect 6 No Connect 2 Transmit Data output 7 Clear To Send input 3 Receive Data input 8 Request To Send output 4 No Connect 9 No connect 5 Ground Configuration The GalilTools software will automatically configure your PC for 8 bit data one start bit one stop bit full duplex and no parity The baud rate for the RS 232 communication can be selected by setting the proper switch configuration on the front panel according to the table below Baud Rate Selection JP1 JUMPER SETTINGS 19 2 BAUD RATE ON 19200 OFF recommended 115200 Chapter 4 Software Tools and Communication 51 DMC 30000 User Manual Handshaking The RS 232 main port is set for hardware handshaking Hardware Handshaking uses the RTS and CTS lines The CTS line will go high whenever the DMC 30000 is not ready to receive additional characters The RTS line will inhibit the DMC 3000
207. ntroller transparent to the user The library is conceptually divided into six categories 1 Connecting and Disconnecting functions to establish and discontinue communication with a controller 2 Basic Communication The most heavily used functions for command and response and unsolicited messages Programs Downloading and uploading embedded programs Arrays Downloading and uploading array data Advanced Lesser used calls Ou le or igo Data Record Access to the data record in both synchronous and asynchronous modes Chapter 4 Software Tools and Communication 62 DMC 30000 User Manual C Library Windows and Linux Both Full and Lite versions of GalilTools ship with a native C communication library The Linux version libGalil so is compatible with g and the Windows version Galil1 dll with Visual C 2008 Contact Galil if another version of the C library is required See the getting started guide and the hello cpp example in lib COM Windows To further extend the language compatibility on Windows a COM Component Object Model class built on top of the C library is also provided with Windows releases This COM wrapper can be used in any language and IDE supporting COM Visual Studio 2005 2008 etc The COM wrapper includes all of the functionality of the base C class See the getting started guide and the hello examples in lib for more info For more information on the GalilTools Communica
208. nual Consider a system with the following parameters K 0 2 Nm A Torque constant jJ 2 1074 kg m2 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 theDMC 30000 outputs 10V for a 16 bit command of 32768 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of w 200 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 Kt Js 1000 s2 Amp K 2 Amp V DAC Ky 10 32768 0003 Encoder K 4N 2n 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 L s M s K Ky Ky H s 3 17 10 s 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 w 500 L j500 3 17 10 j500 2 j500 2000 This function has a magnitude of L j500 0 00625 and a phase Arg L j500 180 tan 4500 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 m
209. o ao ao ao ao t 100 ms 4 42765 GCODVANHS 0 442765 iv 0 221363 0 z EJ E EJ E a 2 0 221383 3 0 221383 4 o Trigger Channel Wi RPE Edge x Level 1000 count Mode Repeat v READY Stop didt_RPA ddt RPS Scope l A Scale fdlv Offset div i 100000 eci 1 S oe m 100000 cciS 4 ao Mj 2 S 1 E A ao m 0 221383 0 g D ao w 4 42765 E l 1 S gt ao w ose E ao m 0 221383 3 ao x ozaises g 4 e t 100ms lo Trigger Channel M _RPEw Edge j a Level 1000 count i i Mode Repeat u READY dA RPA dE AP The slave axis for each figure is shown on the bottom portion of the figure the master axis is shown on the top portion The shock to the slave axis will be significantly less in Figure 6 7 than in Figure 6 6 The ramped gearing does have one consequence There isn t a true synchronization of the two axes until the gearing ramp is complete The slave will lag behind the true ratio during the ramp period If exact position synchronization is required from the point gearing is initiated then the position must be commanded in addition to the gearing The controller keeps track of this position phase lag with the _GP operand The following example will demonstrate how the command is used Chapter 6 Programming 79 DMC 30000 User Manual Command Summary Electronic Gearing
210. o obtain the parameters necessary for operation in an Internet Protocol network ARP is an application that determines the Ethernet hardware address of a device at a specific IP address BOOT P is an application that determines which devices on the network do not have an IP address and assigns the IP address you have chosen to it Ping is used to check the communication between the device at a specific IP address and the host computer The DMC 30000 can communicate with a host computer through any application that can send TCP IP or UDP IP packets A good example of this is Telnet a utility that comes with most Windows systems Chapter 4 Software Tools and Communication 54 DMC 30000 User Manual Modbus An additional protocol layer is available for speaking to I O devices Modbus is an RS 485 protocol that packages information in binary packets that are sent as part of a TCP IP packet In this protocol each slave has a 1 byte slave address The DMC 30000 can use a specific slave address or default to the handle number The port number for Modbus is 502 The Modbus protocol has a set of commands called function codes The DMC 30000 supports the 10 major function codes Function Code Definition 01 Read Coil Status Read Bits 02 Read Input Status Read Bits 03 Read Holding Registers Read Words 04 Read Input Registers Read Words 05 Force Single Coil Write One Bit 06 Preset Single Register Write One Word
211. 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 and for products within warranty Call Galil to receive a Return Materials Authorization RMA number prior to returning product to Galil 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 3 97 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 Appendices 184 DMC 30000 User Manual A1 DMC 30012 Description The DMC 30012 includes a sinusoidally commutated PWM amplifier for driving 3 phase brushless servo motors or a brushed motor Each amplifier drives motors operating at up to 10 Amps continuous 15 Amps peak 20 80 VDC The gain settings of the amplifier are user programmable at 0 4 Amp Volt 0 8 Amp Volt and 1 6 Amp Volt The switching frequency is 33 kHz The amplifier offers protection for over voltage under voltage ov
212. oller is not receiving enough voltage to power up Under Current If the power supply does not have enough current the red LED will cycle on and off along with the green power LED Position Error If any axis that is set up as a servo MT command has a position error value TE that exceeds the error limit ER the error light will come on to signify there is an axis that has exceeded the position error limit Use a DP 0 to set all encoder positions to zero or a SH Servo Here command to eliminate position error Invalid Firmware If the controller is interrupted during a firmware update or an incorrect version of firmware is installed the error light will come on The prompt will show up as a greater than sign gt instead of the standard colon prompt Use GalilTools software to install the correct version of firmware to fix this problem Chapter 9 Troubleshooting 148 DMC 30000 User Manual Self Test During the first few seconds of power up it is normal for the red LED to turn on while it is performing a self test If the self test detects a problem such as corrupted memory or damaged hardware the error light will stay on to signal a problem with the board To fix this problem a Master Reset may be required The Master Reset will set the controller back to factory default conditions so it is recommended that all motor and I O cables be removed for safety while performing the Master Reset Cables ca
213. on a number of things If a device queries the controller it will receive the response unless it explicitly tells the controller to send it to another device If the command that generates a response is part of a downloaded program the response will route to whichever port is specified as the default unless explicitly told to go to another port with the CF command To designate a specific destination for the information add Eh to the end of the command Ex MG EC Hello will send the message Hello to handle 3 TP EF will send the z axis position to handle 6 Multicasting A multicast may only be used in UDP IP and is similar to a broadcast where everyone on the network gets the information but specific to a group In other words all devices within a specified group will receive the information that is sent in a multicast There can be many multicast groups on a network and are differentiated by their multicast IP address To communicate with all the devices in a specific multicast group the information can be sent to the multicast IP address rather than to each individual device IP address All Galil controllers belong to a default multicast address of 239 255 19 56 The controller s multicast IP address can be changed by using the IA gt u command Using Third Party Software Galil supports DHCP ARP BOOT P and Ping which are utilities for establishing Ethernet connections DHCP is a protocol used by networked devices clients t
214. on is enabled the specified 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 A hardware limit is reached Chapter 8 Hardware amp Software Protection 145 DMC 30000 User Manual 3 The abort command is given 4 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 Automatic 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 a encoder failure is detected or the abort input is triggered 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 cleared Example A JP A EN Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor AMX After motor stops SHX Servo motor here to clear error RE Return to main program Limit Switch Routine The DMC 30000 provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automat
215. on sequence Cs S Clear sequence AV s Trippoint for After Relative Vector distance AMST Holds execution of next command until Motion Sequence is complete LM Return number of available spaces for linear and circular segments in DMC 30000 sequence buffer Zero means buffer is full 31 means buffer is empty Operand Summary Coordinated Motion Sequence OPERAND DESCRIPTION _VPA The absolute coordinate of the axis at the last intersection along the sequence _AV Distance traveled _L Number of available spaces for linear and circular segments in DMC 30000 sequence buffer Zero means buffer is full 31 means buffer is empty _CS Segment counter Number of the segment in the sequence starting at zero _VE Vector length of coordinated move sequence When AV is used as an operand AV returns the distance traveled along the sequence Chapter 6 Programming 77 DMC 30000 User Manual The operand _VPX can be used to return the coordinates of the last point specified along the path Example Sine Wave Output The CR command can be used to command sinusoidal motion to the axis The below code and scope output shown in Figure 6 5 show an example of how this can be achieved The frequency and amplitude of the output can be modified by changing the radius in the CR command and by changing the vector speed REM frequency output Hz VS pi 2 r 10 REM ex VS 12000 and r 1590 REM frequen
216. ons that communicate with a Galil controller the HelloGalil library of quick start projects immediately gets you communicating with the controller from the programming language of your choice In the Hello World tradition each project contains the bare minimum code to demonstrate communication to the controller and simply prints the controller s model and serial numbers to the screen Figure 4 1 GalilClass1 dil 1 5 0 0 Gailil1 dll 1 6 0 445 192 168 1 26 DMC30010 Rev 1 0 26 IHA IHB MG TIME 818000 http www galil com learn api examples Galil Communication Libraries The Galil Communication Library Galil class provides methods for communication with a Galil motion controller over Ethernet USB RS 232 or PCI buses It consists of a native C Library and a similar COM interface which extends compatibility to Windows programming languages e g VB CH etc A Galil object usually referred to in sample code as g represents a single connection to a Galil controller For Ethernet controllers which support more than one connection multiple objects may be used to communicate with the controller An example of multiple objects is one Galil object containing a TCP handle to a DMC 30000 for commands and responses and one Galil object containing a UDP handle for unsolicited messages from the controller If recordsStart is used to begin the automatic data record function the library will open an additional UDP handle to the co
217. ontents i Contents Contents iii Chapter 1 Overview 1 Chapter 2 Getting Started 10 Domom a Mounting Instructions Ekne ee n tees ene neta rer rer Installing the DMC Amplifiers and Motors 15 Chapter 3 Connecting Hardware 29 OVELVICW eccccessesnsscccssssenceccoessanscessescsnsnecsessssssssesssssnssesessnsnsssossosses Overview of Optoisolated Inputs Feedback Inputs and Multi Function MF Pins 38 TUL OUS coat secaases sca A 40 Pia TN ere Cate tie aE 41 Analog OUPO aaa 42 Extermal Aroplifier Veer hae occa sass casiavees rest aac testeneyy 43 Chapter 4 Software Tools and Communication 45 Unsolicited Messages Generated by Controller 46 he Eee A E a eee Oe Cr eee Oe EE MELO PAOA A AEE 46 Chapter 5 Command Basics 59 DMC 30000 Contents ii ph 190d 101616 0 See ee ne eet SERIE a em renee mE ee tame EE 59 Command Syntat ASCI a Pe ee Oar ete er ee eee err err 59 Controller Response to WIA Accs e se ais ca ceeehces Jinbetrosatinig the Controller cassed a 60 Chapter 6 Programming 62 REE i yo es E AASE 62 Independent Axis POsST ODINE a cscustatcesstiseasisisransaises gs iaatvssserasises cas 63 Independent Jogging Dual Loop Auxiliary Encoder sioiias 90 Motion Sonno Mina eion ao o 92 Chapter 7 Application Programming 98 CEN O o a E 98
218. op and DV 0 disables dual loop NOTE 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 KPA 0 KIA 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 necessary Sampled Dual Loop Example In this example we consider a linear slide which 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 X axis and connect the linear encoder to the auxiliary encoder of X Assume that the required motion distance is one inch and 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 CE 0 Configure encoder DEO Set initial value PR 40000 Main move BGX Start motion Correct Correction loop AMX Wait for motion completion V1 10000 DEX Find linear encoder error V2 _TEX 4 V1 Compensate for
219. or provides power to DI 8 1 digital inputs the abort input ABRT reset RST and electric lock out ELO Table 3 1 shows all the input banks power commons and their corresponding inputs Common Signal Common Signal Location Powers Inputs Labeled INC I O D Sub Connector DI 8 1 ABRT RST ELO LSC I O D Sub Connector FLS RLS HOM Table 3 1 1 4 axis controller INCOM and LSCOM banks and corresponding inputs powered The full pin outs for each bank can be found in the J5 I O 44 pin HD D Sub Connector Female pg 173 Wiring the Optoisolated Digital Inputs To take full advantage of optoisolation an isolated power supply should be used to provide the voltage at the input common connection Connecting the ground of the isolated power to the ground of the controller will bypass optoisolation and is not recommended if true optoisolation is desired If there is not an isolated supply available the 5 Voc 12 Voc and GND controller references may be used to power INC LSC The current supplied by the controller references are limited see 5 12V Power Output Specifications pg 158 in the Appendices for electrical specifications Using the controller reference power completely bypasses optoisolation and is not recommended for most applications Banks of inputs can be used as either active high or low Connecting V to INC LSC will configure the inputs for active low as current will flow through the diode when the inp
220. or detailed information on bit status during error conditions Under Voltage Protection If the supply to the amplifier drops below 18 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 18V threshold NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 20 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the DMC 30012 is a trans conductance amplifier the amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the
221. ot make any connections to the MA and MB inputs Check CE command Contact Galil Chapter 9 Troubleshooting 147 DMC 30000 User Manual Encoder Position Drifts Swapping cables fixes the problem 1 Poor Connections intermittent cable Review all connections and connector contacts Encoder Position Drifts Significant noise can be seen on MA and or MB encoder signals 1 Noise Shield encoder cables Avoid placing power cables near encoder cables Avoid Ground Loops Use differential encoders Use 12V encoders Stability SYMPTOM DIAGNOSIS CAUSE REMEDY 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 too little damping Decrease KI and KP Increase KD Operation SYMPTOM DIAGNOSIS CAUSE REMEDY Controller rejects Response of controller 1 Anything Correct problem reported by TC1 commands from TC1 diagnoses error Motor Doesn t Move Response of controller from 2 Anything Correct problem reported by SC TC1 diagnoses error Error Light Red LED The red error LED has multiple meanings for Galil controllers Here is a list of reasons the error light will come on and possible solutions Under Voltage If the contr
222. ote Closed loop operation with a stepper motor is not possible Chapter 6 Programming 91 DMC 30000 User Manual Command Summary Stepper Motor Operation COMMAND DESCRIPTION DE Define Encoder Position When using an encoder DP Define Reference Position and Step Count Register IT Motion Profile Smoothing Independent Time Constant KS Stepper Motor Smoothing MT Motor Type 2 2 2 5 or 2 5 for stepper motors RP Report Commanded Position TD Report number of step pulses generated by controller TP Tell Position of Encoder Operand Summary Stepper Motor Operation OPERAND DESCRIPTION _DEA Contains the value of the step count register _DPA Contains the value of the main encoder _ITA Contains the value of the Independent Time constant _KSA Contains the value of the Stepper Motor Smoothing constant _MTA Contains the motor type value _RPA Contains the commanded position generated by the profiler _TDA Contains the value of the step count register _TPA Contains the value of the main encoder Stepper Position Maintenance Mode SPM The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle the event of stepper motor position error The mode looks at position feedback from the main encoder and compares it to the commanded step pulses The position information is used to determine if there is any significan
223. otion EN Example Joystick Jogging The jog speed can also be changed using an analog input such as a joystick Assume that for a 10 Volt input the speed must be 50000 counts sec JOY Label JGO Set in Jog Mode BGX Begin motion B Label for loop V1 AN 1 Read analog input VEL V1 50000 10 Compute speed JG VEL Change JG speed JP B Loop Position Tracking The Galil controller may be placed in the position tracking mode to support changing the target of an absolute position move on the fly New targets may be given in the same direction or the opposite direction of the current position target The controller will then calculate a new trajectory based upon the new target and the acceleration deceleration and speed parameters that have been set The motion profile in this mode is trapezoidal There is not a set limit governing the rate at which the end point may be changed however at the standard TM rate the controller updates the position information at the rate of 1msec The controller generates a profiled point every other sample and linearly interpolates one sample between each profiled point Some examples of applications that may use this mode are satellite tracking missile tracking random pattern polishing of mirrors or lenses or any application that requires the ability to change the endpoint without completing the previous move The PA command is typically used to command the axis to a specific absolute position
224. otor 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 a standard quadrature type or it may provide pulse and direction The controller also offers the provision for inverting the direction of the encoder rotation The main and the auxiliary encoders are configured with the CE command The command form is CE x where the parameter x is the sum of two integers m and n m configures the main encoder and n configures the auxiliary encoder Using the CE Command m Main Encoder n Second Encoder 0 Normal quadrature 0 Normal quadrature 1 Pulse amp direction 4 Pulse amp direction 2 Reverse quadrature 8 Reversed quadrature 3 Reverse pulse amp direction 12 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 for the X axis is CE 6 Additional Commands for the Auxiliary Encoder The command DE can be used to define the position of the auxiliary encoders For example DE 500 sets the value to 500 The positions of the auxiliary encoders may be interrogated with the command DE or the operand _DEA The command TD X returns the current position of the auxiliary encoder The command DV 1 configures the auxiliary encoder to be used for backlash compensation Backla
225. otor power leads and halls if required to the internal amplifiers Table 2 5 lists each of Galil s internal amplifiers and where to find documentation for pin outs of the amplifier connections and electrical specifications In addition it describes the commutation method and whether halls are required Chapter 2 Getting Started gt 26 DMC 30000 User Manual Amplifier Commutation Halls Required DMC 30012 Brusheg 3 Halls optional for 3 phased sinusoidal mode 3 phased sinusoidal DMC 30016 N A Stepper No Brushed DMC 30017 2 and 3 phased Sinusoidal Halls optional for 3 phased sinusoidal mode N A stepper Table 2 5 Amplifier documentation location commutation and hall requirements for each internal amplifier E Only available if 2PB option is ordered Pin outs for the hall signals are found on the 15 pin encoder connector J4 Encoder 15 pin HD D Sub Connector Female pg 174 or if the DMC 31000 option is ordered the hall pin outs are found here DMC 31000 Encoder 15 pin HD D Sub Connector Female pg 202 If wiring 3 phased brushless motors Skip to the additional instructions provided in Step 8a Commutation of 3 phased Brushless Motors pg 23 to find proper commutation NOTE If wiring 2 phased brushless motors Skip to the additional instructions provided in Step 8b Commutation of 2 phased Brushless Motors pg 25 to find proper commutation Step C Issue the appropriate conf
226. pecified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided in half Command Summary Linear Interpolation COMMAND DESCRIPTION IM A Enable linear interpolation LM or _LMS_ Returns number of available spaces for linear segments in DMC 30000 sequence buffer Zero means buffer full 31 means buffer empty LI x lt n gt m Specify incremental distances relative to current position and assign vector speed n and m VS n Specify vector speed VA n Specify vector acceleration VD n Specify vector deceleration VR n Specify the vector speed ratio BG S Begin Linear Sequence CS Clear sequence LE Linear End Required at end of LI command sequence LE Returns the length of the vector resets after 2147483647 AM S Trippoint for After Sequence complete AV Trippoint for After Relative Vector distance n Operand Summary Linear Interpolation OPERAND DESCRIPTION _AV Return distance traveled _CS Segment counter returns number of the segment in the sequence starting at zero _LE Returns length of vector resets after 2147483647 _L Returns number of available spaces for linear segments in DMC 30000 sequence buffer Zero means buffer full 31 means buffer empty _VPA Return the absolute coordinate of the last data poi
227. plete 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 Using If Else and Endif Commands The DMC 30000 provides a structured approach to conditional statements using IF ELSE and ENDIF commands Using the IF and ENDIF Commands An IF conditional statement is formed by the combination of an IF and ENDIF command The IF command has as it s arguments one or more conditional statements If the conditional statement s evaluates true the command interpreter will continue executing commands which follow the IF command If the conditional statement evaluates false the controller will ignore commands until the associated ENDIF command is executed OR an ELSE command occurs in the program see discussion of ELSE command below NOTE An ENDIF command must always be executed for every IF command that has been executed It is recommended that the user not include jump commands inside IF conditional statements since this causes re direction of command execution In this case the command interpreter may not execute an ENDIF command Chapter 7 Application Programming 112 DMC 30000 User Manual Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command and has no arguments If the argument of the I
228. pping drive for an axis with a 1 8 step motor and 4000 count rev encoder Note the necessary difference is with the YA command Full Stepping Drive X axis SETUP OE1 Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA1 Step resolution of the full step drive YB200 Motor resolution full steps per revolution Y C4000 Encoder resolution counts per revolution SHX Enable axis WT50 Allow slight settle time YS1 Enable SPM mode Chapter 6 Programming 93 DMC 30000 User Manual Half Stepping Drive X axis SETUP OE1 Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA2 Step resolution of the half step drive YB200 Motor resolution full steps per revolution Yc4000 Encoder resolution counts per revolution SHX Enable axis WT50 Allow slight settle time YS1 Enable SPM mode 1 64 Step Microstepping Drive X axis SETUP OE1 Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA64 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WT50 Allow slight settle time YS1 Enable SPM mode Example Error Correction The following code demonstrates what is necessary to set up SPM mode in order to detect the error stop the motor corr
229. r TB Tell Status TG Tell Error Code TD Tell Dual Encoder TE Tell Error TI Tell Input TP Tell Position TR Trace TS Tell Switches TE Tell Torque TV Tell Velocity For example the following example illustrates how to display the current position of the A axis TP A Tell position A 0 Controllers Response interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier PR Request PR setting The controller can also be interrogated with operands Operands Most DMC 30000 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 A axis can be assigned to the variable V with the command V _TPA The Command Reference denotes all commands which have an equivalent operand as Operand Usage Also see description of operands in Chapter 7 Application Programming Chapter 5 Command Basics 66 DMC 30000 User Manual Chapter 6 Programming Overview The DMC 30000 provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing
230. r individual configurations in the Appendices rr lo O OJ Q 5 SH ENCODER a5 A s o gt eg woo 000m goi Genin Q Poe oe els 2 S8s2ssd EDELT olo aE oa assisa PRO S i z 2 CN 5 o N P pa z o NO z E Q 3 a POoo000000000000 0w Q v ia i taaie Atataa Q 3020 N O O LO ko v O m pasl n Cc U v lt H Z O a 8 I mm W me 272 m aes IF Z m Appendices 174 DMC 30000 User Manual DMC 30012 BOX ISCNTL DMC 30016 BOX ISCNTL and DMC 30017 BOX ISCNTL Requires two DC power supplies see power requirements for individual configurations in the Appendices Appendices 175 DMC 30000 User Manual Input Current Limitations Each bank of inputs uses a current limiting resistor pack These resistor packs have a maximum power rating that should never be exceeding during use Over time damage can occur to the resistor pack resulting in non functional inputs For most applications this is not an issue but applications using greater than 18 5 Voc with normally closed switches should consider placing an additio
231. ram CMDERR Command error utility JP DONE ED lt gt 2 Check if error on line 2 JP DONE TC lt gt 6 Check if out of range G SPEED TOO HIGH Send message G TRY AGAIN Send message ZS1 Adjust stack JP BEGIN Return to main program DONE End program if other error ZSO Zero stack EN End program The above program prompts 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 In multitasking applications there is an alternate method for handling command errors from different threads Using the XQ command along with the special operands described below allows the controller to either skip or retry invalid commands OPERAND FUNCTION _EDI Returns the number of the thread that generated an error _ED2 Retry failed command operand contains the location of the failed command _ED3 Skip failed command operand contains the location of the command after the failed command The operands are used with the XQ command in the following format XQ_ED2 or _ED3 ED1 1 Where the 1 at the end of the command line indicates a restart therefore the existing program stack will not be removed when the above format executes The following example shows an error correction routine which uses the operands Chapter 7 Application Programming 116 DMC 30000 User Manual Example
232. rcing output option HSRC Outputs 1 is the brake output The BW command sets the delay between when the brake is turned on and when the amp is turned off When the controller goes into a motor off MO state this is the time in samples between when the brake digital output changes state and when the amp enable digital output changes state The brake is actuated immediately upon MO and the delay is to account for the time it takes for the brake to engage mechanically once it is energized electrically The brake is released immediately upon SH See the BW command in the DMC 30000 Command Reference for more information Chapter 3 Connecting Hardware 39 DMC 30000 User Manual Standard 4mA Sinking Optoisolated Outputs Description The default outputs of the DMC 30000 are capable of 4mA and are configured as sinking outputs The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output PWR Max Voltage 24 VDC Output PWR Min Voltage 5 VDC ON Voltage No Load Output PWR 5VDC 0 1 VDC Max Drive Current per Output 4mA Sinking Wiring the Standard 4mA outputs With this configuration the output power supply will be connected to Output PWR labeled OPB and the power supply return will be connected to Output GND labeled OPA Note that the load is wired between Output PWR and DO The wiring diagram for Bank 0 is shown in Figure 3 4 Refer to P
233. re upgraded to 16 bit 10V configurable see the Analog Inputs section in Chapter 3 Connecting Hardware for more information A5 DMC 31000 206 DMC 30000 User Manual DMC 31000 Encoder 15 pin HD D Sub Connector Female Pin Label Sin Cos Feedback Standard Quadrature 1 MI Vot Index Pulse Input I Index Pulse Input 2 MB V Main Encoder Input B Main Encoder Input 3 MA V Main Encoder Input A Main Encoder Input 4 AB B Aux Encoder Input 5 GND Digital Ground 6 MI Vo Index Pulse Input Index Pulse Input 7 MB Vz Main Encoder Input B Main Encoder Input 8 MA V Main Encoder Input A Main Encoder Input 9 AA A Aux Encoder Input 1 HALA A Channel Hall Sensor 11 AA A Aux Encoder Input 12 AB B Aux Encoder Input 13 HALB B Channel Hall Sensor 14 HALC C Channel Hall Sensor 15 5V 5V Theory of Operation Traditional quadrature rotary encoders work by having two sets of lines inscribed radially around the circumference of an optical disk A light is passed through each of these two sets of lines On the other side of the gratings photo sensors detect the presence or absence of these lines These two sets of lines are offset from each other such that one leads the other by one quarter of a complete cycle as shown in Figure A4 1 below These signals are commonly referred to as the Channels A and B The direction of rotation of the encoder can be inferred by which of
234. 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 HX Halt all tasks The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 30000 provides commands and operands which 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 which 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 TR1 TRO turns the trace function off Note When the trace Chapter 7 Application Programming 105 DMC 30000 User Manual function is enabled the line numbers as well as the command line will be displayed as each command line is executed 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 Error Code Command When there is a program error the DMC 30000 halts the program execution at the point where the error occurs To display the last line number of program execution issue the comma
235. rent 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 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 over damped 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 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 filt
236. rical Specifications Supply Voltage Maximum Current Maximum Step Frequency Step Resolution Switching Frequency Minimum Inductance Mating Connectors 20 80 VDC 6 0 Amps 3 MHz 256 steps full step 33 kHz Vsupply 24VDC 0 75 mH Vsupply 48VDC 1 2 mH On Board Connector Terminal Pins POWER 2 pin Molex Mini Fit Jr MOLEX 39 31 0020 MOLEX 44476 3112 A B C D 4 pin Motor Power Connectors 4 pin Molex Mini Fit Jr MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Motor Connector Power Connector Power Connector Pin Number Connection 1 DC Power Supply Ground 2 VS DC Power Motor Connector 1 B 2 B 3 A 4 A Note The stepper motor wiring on the DMC 30017 is not compatible with other Galil stepper drivers such as the SDM 44140 and SDM 44040 A4 DMC 30017 202 DMC 30000 User Manual Operation Stepper Mode With the DMC 30017 the controller will default to MT 2 stepper motor To set the controller for servo mode set MT1 See A1 DMC 30012 for further information regarding running in servo mode Setting the Current AG The DMC 30017 has 4 amplifier gain current settings The gain is set with the AG command as shown in Table A3 1 for AG m AG setting Gain Value m 0 0 75 A Phase m 1 1 5 A Phase m 2 3 A P
237. rned 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 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 VF 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 Chapter 7 Application Programming 134 DMC 30000 User Manual Instruction v1 10 vl 0000000010 0000 VF2 2 Local Formatting of Variables Interpretation Assign v1 Return v1 Response Default format Change format Return v1 Response New format Specify hex format Return v1 Response Hex value Change format Return v1 Response Overflow 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 Sn m following the variable
238. rror 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 CMDERR to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the LIMSWI routine to function the DMC 30000 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 HLOOP JP HLOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed LOOP JP LOOP LIMSWI LIMIT OCCURRED EN M R HQ CGI XQ LOOP JG 5000 BGX Dummy Program Jump to Loop Limit Switch Label Print Message Return to main program Download Program Execute Dummy Program Jog Begin Motion Now when a forward limit switch occurs on the X axis the LIMSWI subroutine will be executed Notes regarding the LIMSWI Routine 1 2 The RE command is used to return from the LIMSWI subroutine The LIMSWI subroutine will be re executed if the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error
239. s cogs or runs away after BZ turn off the controller and amplifier and swap motor phases A and B and retry steps 3 6 b If commutation is still not successful after 6 a issue the appropriate BA BM and BZ commands but do not servo Check the hall state with QH If QH shows either of the two values shown below then turn off the controller and amplifier and rewire the motor based on the following and then retry step 3 6 elf QH mreturns 5 Turn off the controller and amplifier and swap motor phases A and B then B and C elf QH mreturns 6 Turn off the controller and amplifier and swap motor phases A and C then B and C 7 The motor should now be wired for sine commutation using the BI BC method Once BI 1 is issued the motor is in a pseudo trapezoidal state you can enable sine commutation by issuing the BC command and commanding a slow jog move Once a hall transition is found the commutation will be in sinusoidal mode Step 8b Commutation of 2 phased Brushless Motors If a motor is not correctly commutated it will not function as expected Commutation is the act of properly switching each of the 2 phases of a servo motor at the correct time to allow smooth 360 degree rotation or linear motion in both directions The following sections provide a brief description and guide on how to perform sinusoidal commutation with the DMC 30017 with the 2PB option Wiring 2 phased brushless motors are wired the same way as stepper mo
240. s based on its own status or external events without intervention from a host computer Chapter 7 Application Programming 107 DMC 30000 User Manual DMC 30000 Event Triggers Command Function AM A or S Halts program execution until motion is complete on the specified axes or motion sequence s This command is useful for separating motion sequences in a program ADA Halts program execution until position command has reached the specified relative distance from the start of the move AR A Halts program execution until after specified distance from the last AR or AD command has elapsed AP A Halts program execution until after absolute position occurs MF A 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 MR A Halt program execution until after reverse motion reached absolute position If position is already past the point then MR will trip immediately Will function on geared axis or aux inputs MC A Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW x 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 HMCTIME AI tn Halts program execut
241. s same example with an additional condition JP TEST v1 lt v2 amp v3 lt v4 v5 lt v6 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 MOVEZ if input 1 is logic level high After the subroutine MOVE2 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 v1l 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 JP A 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 BEGIN Begin Program count 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec PA 0 Position absolute 0 BGX Begin move AMX Wait for motion com
242. sa BSSQESRCRESESS FREES SASSSNRERGSRVSS anoo Z aE 5 Sba5ShSe2228E88 O ARETE 5 q wanar8 eStNSEG anona BRSUSSReSBESES3 PE E XOE OlLOOS ON 00 0000000000000 fecvcccccceeecs OLOOE ONNG E i0 0000000000000 ca l eea Acl GNO AGF ACL H Z m ddJAvd g AVTI YO H Z m Appendices 171 DMC 30000 User Manual DMC 30011 CARD Requires a 9VDC to 48VDC power supply ee lt O CN O CD og U Zz oa lt lt on IF Z m O A ae J 7 m gt H Z m odA8r 6 ddJAyvJ g l JE oo0000000000 Ow pPOO000000000000 Om 00000000000000 cad E Appendices 172 DMC 30000 User Manual DMC 30011 BOX Requires a 9VDC to 48VDC power supply g egseeesessasat YSNNI JAVIN TOULNOO NOILOW TITV9 BSRENSSCREEESS FREES sissekSPReness y onoo e GFF eaanor8 e SI BESGRSRSESEGaS3 ESESS f ws000000000000 80000000000000 0m 90000000 oa lt C GN C O UJ O gt lt og V A oo lt lt L F H Z m AVT3Y X0 H Z m 9dA8r 6 d4yvsdd Appendices 173 DMC 30000 User Manual DMC 30012 BOX DMC 30016 BOX and DMC 30017 BOX See power requirements fo
243. se value upon the first hall transition The motor is then running in a sinusoidally commutated mode and the use of the halls are no longer required Commands required BA BM BI BC BZ and QH are used to aid in the wiring process and initial set up for this method Note These list the minimum required commands to provide commutation There are many more commutation configuration commands available not discussed here See the Command Reference for details Method PRO CON e Can be used with vertical or unbalanced loads e Can cause significant motor movement e Less sensitive to noise than BX e May fail at hard stops BZ p e Does not require halls e Quick first time set up e Provides the least amount of movement If no e Not recommended with vertical or unbalanced loads BX hall sensors are available e Sensitive to noise on feedback lines e Does not require halls e Requires some movement e Quick first time set up e may fail at hard stops e No unnecessary movement required e Requires halls BI BC e Best option with a vertical or unbalanced load e Longer first time set up due to additional wiring Table 2 7 Pros and cons of each commutation method tif your motor has halls it is recommended to use the BI BC method The following sections discuss how to wire and configure a motor for sinusoidal commutation using the different commutation methods Chapter 2 Getting Started 28 DMC 30000 User M
244. setting For example if the filter parameters of the DMC 30000 are KP 16 KD 144 Kl 2 PL 0 75 T 0 001 s the digital filter coefficients are K 160 A 0 9 C 2 a 250 rad s and the equivalent continuous filter G s is G s 16 0 144s 2000 s 250 s 250 The notch filter has two complex zeros z and and two complex poles p and The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of the resonance poles The notch poles P and p are programmable and are selected to have sufficient damping It is best to select the notch parameters by the frequency terms The poles and zeros have a frequency in Hz selected by the command NF The real part of the poles is set by NB and the real part of the zeros is set by NZ The most simple procedure for setting the notch filter identify the resonance frequency and set NF to the same value Set NB to about one half of NF and set NZ to a low value between zero and 5 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 Chapter 10 Theory of Operation 156 DMC 30000 User Manual 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 sys
245. sh Compensation There are two methods for backlash compensation using the auxiliary encoders 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 and 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 Chapter 6 Programming 96 DMC 30000 User Manual 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 The dual loop method is activated with the instruction DV Dual Velocity where DV 1 activates dual lo
246. t EPA x Time constant for independent motion smoothing AM X Trippoint for profiler complete MC A Trippoint for in position The lower case specifiers x represent position values for each axis The DMC 30000 also allows use of explicit notation such as PRX 2000 Chapter 6 Programming 68 DMC 30000 User Manual Operand Summary Independent Axis OPERAND DESCRIPTION _ACA Return acceleration rate _DCA Return deceleration rate _SPA Returns the speed _ PAA Returns current destination if the axis is moving otherwise returns the current commanded position if in a move _ PRA Returns current incremental distance Example Absolute Position Movement PA 10000 Specify absolute position AC 1000000 Acceleration DC 1000000 Deceleration SP 50000 Speed BG X Begin motion Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion 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 command 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 a accelerated or decelerated change to the new speed An instant change to the motor position can be made with
247. t Fields Header Information Byte 0 1 of Header Bytes 2 3 of Header BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT9 BIT8 1 N A N A N A N A Block N A S Block Present in Present in Data Data Record Record BIT 7 BIT6 BITS BIT 4 BIT 3 BIT 2 BIT 1 BITO N A N A N A N A N A N A N A A Block Present in Data Record Bytes 2 and 3 make a word which represents the Number of bytes in the data record including the header Byte 2 is the low byte and byte 3 is the high byte NOTE The header information of the data records is formatted in little endian reversed network byte order BIT 15 Thread Status 1 Byte BIT5 Coordinated BIT 14 Thread 5 Running Motion Status 2 Byte BIT 13 BIT 4 BIT 3 Thread 4 Running Thread 3 Running BIT 12 BIT 11 BIT 2 Thread 2 Running BIT 1 Thread 1 Running BITO Thread 0 Running Move in N A N A N A N A N A Progress BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT O N A N A Motion is Motion is Motion is N A N A N A slewing stopping making final due to ST decel or Limit Switch Axis Status 1 Word BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 2 Phase of Mode of Move in Mode of More or EE Ping Home HM 1 Phase of HM complete Motion Motion PA Motion Edge in f or FI Progress in Progress HM complete Coord or PR PA only Progress command i iccuad Motion Negative Direction
248. t difference between the commanded and the actual motor positions If such error is detected it is updated into a command value for operator use In addition the SPM mode can be used as a method to correct for friction at the end of a microstepping move This capability provides closed loop control at the application program level SPM mode can be used with Galil and non Galil step drives SPM mode is configured executed and managed with seven commands This mode also utilizes the H POSERR automatic subroutine allowing for automatic user defined handling of an error event Internal Controller Commands user can query Qs Error Magnitude pulses User Configurable Commands user can query amp change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status A pulse is defined by the resolution of the step drive being used Therefore one pulse could be a full step a half step or a microstep When a Galil controller is configured for step motor operation the step pulse output by the controller is internally fed back to the auxiliary encoder register For SPM the feedback encoder on the stepper will connect to the main Chapter 6 Programming 92 DMC 30000 User Manual encoder port Enabling the SPM mode ona controller with YS 1 exec
249. t element of the array timer the returned 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 Example A Begin Program count 0 DM pos 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec pos count _TPX Record position into array element pos count Report position count counttl 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 The GalilTools software is recommended for downloading and uploading array data from the controller The GalilTools Communication library also provides function calls for downloading and uploading array data from the controller to from a buffer or a file Chapter 7 Application Programming 127 DMC 30000 User Manual Arrays may also 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
250. t 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 or JG commands or VP or LI Ramped Gearing In some applications especially when the master is traveling at high speeds it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave when the gearing is engaged For example if the master is already traveling at 500 000 counts sec and the slave will be geared at a ratio of 1 1 when the gearing is engaged the slave will instantly develop following error and command maximum current to the motor This can be a large shock to the system For many applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame Galil allows the user to specify an interval of the master axis over which the gearing will be engaged For example the same master X axis in this case travels at 500 000 counts sec and the gear ratio is 1 1 but the gearing is slowly engaged over 30 000 counts of the master axis greatly diminishing the initial shock to the slave axis Figure 6 6 below shows the velocity vs time profile for instantaneous gearing Figure 6 7 shows the velocity vs time profile for the gradual gearing engagement Scope a Yertical Horizontal didt Source Scale div Offset div i RPA Axis A ref 100000 cc 1 a RPB Axis B ref 100000 cc s 4 ao x 2 S 1 a
251. t return gt is used to terminate the instruction for processing by the DMC 30000 command interpreter NOTE If you are using a Galil terminal program commands will not be processed until an lt return 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 return gt command IMPORTANT All DMC 30000 commands are sent in upper case For example the command PR 4000 lt return gt Position relative Chapter 5 Command Basics 64 DMC 30000 User Manual Implicit Notation PR is the two character instruction for position relative 4000 is the argument which represents the required position value in counts The lt return gt terminates the instruction The space between PR and 4000 is optional To view the current values for each command type the command followed by a PR 1000 Specify a relative move of 1000 PR Request relative move value Explicit Notation The DMC 30000 provides an alternative method for specifying data Here data is specified individually using the single axis specifier A An equals sign is used to assign data to that axis For example PRA 1000 Specify a position relative movement for the A axis of 1000 ACA 200000 Specify acceleration as 200000 Controller Response to DATA The DMC 30000 returns a for valid commands and a for invalid commands For example if the command BG is sent in lower case the DMC 300
252. tage 5 VDC Max Drive Current per Output 25mA Sourcing Wiring the 25mA Sourcing Outputs With this configuration the output power supply will be connected to Output PWR labeled OPA and the power supply return will be connected to Output GND labeled OPB Note that the load is wired between DO and Output GND The wiring diagram for Bank 0 is shown in Figure 3 6 Refer to Pin outs in the Appendix for pin out information 3 3V Output GND Chapter 3 Connecting Hardware 41 DMC 30000 User Manual 500mA Sourcing Optoisolated Outputs HSRC Description The 500mA sourcing option refereed to as high power sourcing HSRC is capable of sourcing up to 500mA per output and up to 1 5 A per bank The voltage range for the outputs is 12 24 VDC These outputs are capable of driving inductive loads such as solenoids or relays The outputs are configured for hi side sourcing Electrical Specifications Output PWR Max Voltage 24 VDC Output PWR Min Voltage 12 VDC Max Drive Current per Output 0 5 A not to exceed 1 5 A for all 4 outputs Wiring the 500mA Sourcing Optoisolated Outputs With this configuration the output power supply will be connected to Output PWR labeled OPA and the power supply return will be connected to Output GND labeled OPB Note that the load is wired between DO and Output GND The wiring diagram for Bank 0 is shown in Figure 3 7 Refer to Pin outs in the Appendix for pin out information Output PWR OPA
253. tal outputs 1 Begin by opening a connection to the RIO which in our example has IP address 192 168 1 120 IHB 192 168 1 120 lt 502 gt 2 Issued to DMC 30000 2 Dimension an array to store the commanded values Set array element 0 equal to 170 and array element 1 equal to 85 array element 1 configures digital outputs 15 8 and array element 0 configures digital outputs 7 0 Chapter 4 Software Tools and Communication 55 DMC 30000 User Manual DM myarray 2 myarray 0 170 which is 10101010 in binary myarray 1 85 which is 01010101in binary 3 a Send the appropriate MB command Use function code 15 Start at output 0 and set clear all 16 outputs based on the data in myarray MBB 15 0 16 myarray 3 b Set the outputs using the SB command B2001 SB2003 SB2005 SB2007 SB2008 SB2010 SB2012 SB2014 Results Both steps 3a and 3b will result in outputs being activated as below The only difference being that step 3a will set and clear all 16 bits where as step 3b will only set the specified bits and will have no affect on the others Bit Number Status Bit Number Status 0 0 8 1 1 1 9 0 2 0 10 1 3 1 11 0 4 0 12 1 5 1 13 0 6 0 14 1 7 1 15 0 Example 2 DMC 30000 connected as a Modbus master to a 3rd party PLC The DMC 30000 will read the value of analog inputs 3 and 4 on the PLC located at addresses 40006 and 40008 respectively The PLC stores values as 32 bit float
254. tegrated when using DMC 30012 DMC 30016 DMC 30017 3 Power Supply for Amplifiers and Controller 4 Brush or Brushless Servo motors with Optical Encoders or stepper motors a Cables for connecting to the DMC 30000 PC Personal Computer Serial or Ethernet for DMC 30000 6 GalilTools or GalilTools Lite Software package gi GalilSuite is highly recommended for first time users of the DMC 30000 Chapter 2 Getting Started gt 19 DMC 30000 User Manual Installing the DMC Amplifiers and Motors Installation of a complete operational motion control system consists of the following steps Step 1 Determine Overall Motor Configuration pg 15 Step 2 Install Jumpers on the DMC 30000 pg 15 Step 3 Install the Communications Software pg 16 Step 4 Connect Power to the Controller pg 16 Step 5 Establish Communications with Galil Software pg 17 Step 6 Connecting Encoder Feedback pg 17 Optional for steppers Step 7 Setting Safety Features before Wiring Motors pg 19 Servo motors only Step 8 Wiring Motors to Galil s Internal Amps pg 21 Internal amplifiers only Step 8a Commutation of 3 phased Brushless Motors pg 23 3 phased brushless servo motors only Step 8b Commutation of 2 phased Brushless Motors pg 25 2 phased brushless servo motors only Step 9 Connecting External Amplifiers and Motors pg 26 External amplifiers only Step 10 Tune the Servo System pg 28 Servo motors only Electronics are dangerous Only a certified e
255. tem elements Next we discuss the system analysis 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 30000 controller and the following parameters K 0 1 Nm A J 2 1074 kg m R 2 Q K 4 Amp Volt KP 12 5 KD 245 KI 0 N 500 Counts rev T 1 ms The transfer function of the system elements are Motor M s P I K Js 500 s rad A Amp K 4 Amp V DAC Ky 0 0003 V count Encoder K 4N 2n 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 T 0 001 Therefore D z 1030 z 0 95 Z Accordingly the coefficients of the continuous filter are P 50 D 0 98 The filter equation may be written in the continuous equivalent form G s 50 0 98s 098 s 51 The system elements are shown in Figure 10 7 Torque constant System moment of inertia Motor resistance Current amplifier gain Digital filter gain Digital filter zero No integrator Encoder line density Sample period Chapter 10 Theory of Operation 157 DMC 30000 User Manual FILTER ZOH DAC AMP MOTOR V D 2000 500 ji gt x 50 0 980s 512000 0 0003 4 32 ENCODER 318 The open loop transfer function A s is the product of all the elements in the loop
256. that may be commanded by the controller in the position tracking mode In this example there is a host program that will generate the absolute position Chapter 6 Programming 70 DMC 30000 User Manual targets The absolute target is determined based on the current information the host program has gathered on the object that it is tracking The controller must be placed in the position tracking mode to allow on the fly absolute position changes This is performed with the PT command To place the X axis in this mode the host would issue PT1 to the controller The next step is to begin issuing PA command to the controller The BG command isn t required in this mode the SP AC and DC commands determine the shape of the trapezoidal velocity profile that the controller will use Example Motion 1 The host program determines that the first target for the controller to move to is located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 countts sec2 and the velocity is set to 50 000 counts sec The command sequence to perform this is listed below EX1 PT 1 Place the X axis in Position tracking mode AC 150000 Set the X axis acceleration to 150000 counts sec2 DC 150000 Set the X axis deceleration to 150000 counts sec2 SP 50000 Set the X axis speed to 50000 counts sec PA 5000 Command the X axis to absolute position 5000 encoder counts EN The output from this code can be seen in Figure 6 1
257. the A and B signals leads the other Each rising or falling edge indicates one quadrature count Thus for a complete cycle of the square wave there are a total of four encoder counts Channel A Channel B A sinusoidal encoder is similar to a quadrature encoder in that it produces two signals that are read from two sets of lines inscribed on an optical disk The difference is that the two signals are output as analog sinusoidal waves as shown in Figure A4 2 A5 DMC 31000 207 DMC 30000 User Manual Vb When the DMC is ordered with the DMC 31000 option the position is tracked on two levels First the number of coarse cycles is counted much like is done with a quadrature encoder On the fine level the precise position inside the cycle is determined from the two sinusoidal signals using bit wise interpolation This interpolation can be set by the user in the range of 2 through 2 points per sinusoidal cycle via AF command See the AF command in the command reference for more information The unique position within one cycle can be read using the following equation Fine tan V 360 V a The overall position can be determined using Position Coarse_cycles 2 Fine Where nis the number of bits of resolution that were used in the conversion Coarse_cycles is the whole number of cycles counted Fine is the interpolated position within one cycle Vb and Va are the two signals as indicated in Figure
258. the axis is in an inactive and is not attempting to control it s movement See Step 9 Connecting External Amplifiers and Motors pg 26 for configuring the amplifier enable signal 2 The motor and encoder are in opposite polarity causing a positive feedback loop Reversed polarity is when a positive voltage on the motor command line results in negative movement of the motor This will result in a positive feedback loop and a runaway motor The following steps can be taken to detect reverse polarity 1 After connecting your servo motor using either Step 8 Wiring Motors to Galil s Internal Amps pg 21 or Step 9 Connecting External Amplifiers and Motors pg 26 issue the following commands MO A KIA 0 KPA 0 KDA 0 SHA 2 Check the current position by issuing TP A 3 Seta small positive voltage on the motor command line using the OF command use a high enough voltage to get the motor to move This will cause a runaway like condition so have an appropriate OE set see Step B Example OFA 0 5 4 Ifthe motor has not been disabled by OB disable it by issuing MO A 5 Check the position again by using TP A 6 If TP has increased the the motor command line and encoder are in correct polarity If TP has decreased then the motor command line is in opposite polarity with the encoder If the system has reverse polarity take the following steps to correct for it Brushed Motor Choose one of the following 1 Reverse the dir
259. the limit switch will not be possible until the logic state of the switch returns back to an inactive state Any attempt at further motion before the logic state has been reset will result in the following error 22 Begin not possible due to limit switch error The operands LFA and _LRA contain the state of the forward and reverse limit switch respectively 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_LFA or MG_LRA 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 Chapter 3 Connecting Hardware 34 DMC 30000 User Manual 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 30000 Find Edge FE
260. the motor in an MO state Move the motor shaft manually in the direction desired for positive movement a If TP is decreasing reverse encoder direction See Step 6 Connecting Encoder Feedback pg 17 Chapter 2 Getting Started gt 29 DMC 30000 User Manual 2 Continue to move the motor in the positive direction by hand but now monitor the state of QH QH should change as the motor continues to rotate in the positive direction QH should return the sequence 132645 a If the order is reversed swap Hall A and Hall C b If all 6 states are not seen one of the hall inputs is miswired or not connected 3 Select which axis will be using sinusoidal commutation by issuing the BA command 4 Set brushless modulus using the BM configuration command BM is the distance in counts of a single magnetic cycle of the motor This can be calculated by dividing counts revolution of the encoder by the number of pole pairs of the motor For a linear motor the number of encoder counts per magnetic phase may need to be calculated from motor and encoder manufacturers information 5 Initialize the motor for hall commutation BI 1 6 Test the motor for proper commutation by enabling the motor SH and jogging the motor slowly JG 1000 BG A If the motor rotates 360 degrees without cogging running away or stalling skip to step 7 a If the motor stalls cogs or runs away issue an MO and try initialization using BZ If the motor stall
261. tically prescribed profiles such as sine or cosine trajectories Teaching or Record and Play Back Contour Mode with Teach Record and Play Back CM CD DTI RA RD RC Backlash Correction Dual Loop Auxiliary Encoder DV Following a trajectory based on a master Electronic Cam EA EM EP ET EB encoder position EG EQ Smooth motion while operating in Motion Smoothing IT independent axis positioning Smooth motion while operating in vector or Motion Smoothing LT linear interpolation positioning Chapter 6 Programming 67 DMC 30000 User Manual Smooth motion while operating with stepper Stepper Motion Smoothing KS motors Independent Axis 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 30000 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 30000 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 Begin
262. time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 0 5 results in the specification VS 2000 to be divided by two Trippoints The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION VM AN Enable Vector Mode VP m n Specify the Vector segment CR r 9 lt n gt m Specifies arc segment where r is the radius P is the starting angle and PAR is the travel angle Positive direction is CCW VS s Specify vector speed or feed rate of sequence VA s Specify vector acceleration along the sequence VD s Specify vector deceleration along the sequence VR s Specify vector speed ratio BG S Begin moti
263. tines error handling subroutines and command error subroutines See section on AMPERR Label for Amplifier error routine AUTO Label that will automatically run upon the controller exiting a reset power on AUTOERR Label that will automatically run if there is an FLASH error out of reset CMDERR Label for incorrect command subroutine COMINT Label for Communications Interrupt See CC Command ININT Label for Input Interrupt subroutine See II Command LIMSWI Label for Limit Switch subroutine MCTIME Label for timeout on Motion Complete trippoint POSERR Label for excess Position Error subroutine TCPERR Label for errors over a TCP connection error code 123 Commenting Programs Using the command NO or Apostrophe The DMC 30000 provides a command NO for commenting programs or single apostrophe 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 NOTE The NO and commands are actual controller commands Therefore inclusion of the NO or commands will require process time by the controller see General Program Flow and Timing information for more details Difference between NO and using the GalilTools software The GalilTools software will treat an apostrophe commend different from an NO when the compression algorithm is activated upon a program download line gt 80 characters or program memory gt 1
264. tion The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 2 or 3 The command will return an eight bit number representing specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label HAMPERR in their program to handle amplifier errors As long as a program is executing in thread zero and the AMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition See the TA command for detailed information on bit status during error conditions See the the DMC 30012 Error Monitoring and Protection section for information regarding functionality of the specific types of protection on the DMC 30017 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO followed by a WT 2 and SH must be issued
265. tions Library see the online user manual http www galilmc com support manuals galiltools library html Chapter 4 Software Tools and Communication 63 DMC 30000 User Manual Chapter 5 Command Basics Introduction The DMC 30000 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands are sent in ASCII The DMC 30000 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 communications port for immediate execution by the DMC 30000 or an entire group of commands can be downloaded into the DMC 30000 memory for execution at a later time 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 30000 instruction set and syntax A summary of commands as well as a complete listing of all DMC 30000 instructions is included in the Command Reference http www galilmc com support manuals ph Command Syntax ASCII DMC 30000 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 l
266. tions and wiring of output 4 is dependent on the outputs ordered NOTE Many amplifiers designate the enable input as inhibit Electrical Specifications AEN Default Max Amplifier Enable Voltage 5V Max Amplifier Enable Current sink source 20 mA Output 4 Specifications Optoisolated Outputs pg 34 and CN in the command reference fore details Chapter 3 Connecting Hardware 49 DMC 30000 User Manual Chapter 4 Software Tools and Communication Introduction The default configuration DMC 30000 has one RS 232 port and two Ethernet ports The RS 232 port baud rate defaults to 115200 bps and can be configured for 19200 bps via jumpers on the side of the controller The Ethernet ports are 100BASE T connections that auto negotiate half or full duplex The GalilTools software package is available for PC computers running Microsoft Windows or Linux to communicate with the DMC 30000 controller This software package has been developed to operate under Windows and Linux and include all the necessary drivers to communicate to the controller In addition GalilTools includes a software development communication library which allows users to create their own application interfaces using programming environments such as C C Visual Basic and LabVIEW The following sections in this chapter are a description of the communications protocol and a brief introduction to the software tools and communication techniques used by Galil At t
267. toisolated inputs These inputs can be read individually using the function IN x where x specifies the input number 1 thru 8 These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller For example the user may wish to have the motor move 1000 counts in the positive direction when the logic state of DI1 goes high Digital Input 1 can be used has a high speed position latch see High Speed Position Capture The Latch Function for more information This can be accomplished by connecting a voltage in the range of 5V to 28V into INC of the input circuitry from a separate power supply Chapter 3 Connecting Hardware 36 DMC 30000 User Manual Optoisolated Input Electrical Information Electrical Specifications INC LSC Max Voltage 24 Voc INC LSC Min Voltage 0 Voc Internal resistance of inputs 2 2 kQ The current limiting resistors chosen for the inputs allow for the flexibility to have 5 24V optoisoalated inputs Because of this added range applications powering the inputs with 18 5 Voc or greater with normally closed switches may need an additional resistor to limit the current to the inputs see the Input Current Limitations pg 171 for more details or simply place a 1 2kQ resistor in series with INCOM LSCOM as shown in Figure A 2 in the 171 The optoisolated inputs are powered in banks For example INC located on the 44 pin I O D sub connect
268. tor Data Entry Mode The Operator Data Entry Mode provides for un buffered data entry through the main RS 232 port In this mode the DMC 30000 provides a buffer for receiving characters This mode may only be used when executing an applications program The Operator Data Entry Mode may be specified for Port 2 only This mode may be exited with the or lt escape gt key NOTE Operator Data Entry Mode cannot be used for high rate data transfer To capture and decode characters in the Operator Data Mode the DMC 30000 provides special the following keywords Keyword Function P1CH Contains the last character received P1ST Contains the received string P1NM Contains the received number P1CD Contains the status code 1 mode disabled 0 nothing received 1 received character but not lt enter gt 2 received string not a number 3 received number NOTE The value of P1CD returns to zero after the corresponding string or number is read These keywords may be used in an applications program to decode data and they may also be used in conditional statements with logical operators Example Instruction Interpretation JP LOOP P1CD lt gt 3 Checks to see if status code is 3 number received JP P P1CH V Checks if last character received was a V PR P1NM Assigns received number to position JS XAXIS P1ST x Checks to see if received string is X Using Communication Interrupt The DMC 30000 provides a specia
269. tors for the DMC 30017 For motor phase wiring pin outs see A4 DMC 30017 pg 196 Sinusoidal Commutation The BZ method of sinusoidal commutation is used to commutate 2 phased brushless servo motors A brief description of how the method works is provided below and the pros and cons of this method are provided in Table 2 7 BZ Method The BZ method forces the motor into a zero degree magnetic phase by exciting only two of the phases in a fixed configuration The location of the motor within its magnetic cycle is then known and sinusoidal commutation is initialized Chapter 2 Getting Started gt 30 DMC 30000 User Manual Commands required BA BM BZ The BZ command will move the motor to find the zero commutation phase This movement is sudden WARNING 2 i H and will cause the motor to jerk Larger applied voltages will cause more severe motor jerk The BZ command requires encoder feedback to the controller and the motor phases to the drive 1 Check encoder position with the TP command Ensure the motor is in an MO state and move the motor manually in the desired positive direction while monitoring TP If TP reports a smaller or more negative number reverse encoder direction see Step 6 Connecting Encoder Feedback pg 17 2 Configure the A axis for sinusoidal commutation by issuing the BA A 3 Set brushless modulus using the BM configuration command BM is the distance in counts of a single magnetic
270. tput pulse and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought 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 ba
271. trolled deceleration LM or _LM returns the available spaces for LI segments that can be sent to the buffer 31 returned means the buffer is empty and 31 LI segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent The instruction CS returns the segment counter As the segments are processed CS increases starting at zero This function allows the host computer to determine which segment is being processed Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration An Example of Linear Interpolation Motion LMOVE label DP 0 Define position of 0 LM X Enable LM mode LI 5000 Specify first linear segment LI 10000 Specify second linear segment E End linear segments VS 4000 Specify vector speed BG S Begin motion sequence E Program end Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications it is necessary to attach various speeds to different motion segments This can be done by two functions lt n and gt m For example LI x lt n gt m The first command lt n is equivalent to commanding VS n at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function
272. troller will default to MT 2 stepper motor To set the controller for external servo mode set MT1 The DMC 30016 should be setup for Active High step pulses MT 2 or MT 2 5 Current Level Setup AG Command AG configures how much current the DMC 30016 delivers to each motor It is settable in 7mMA increments from 0 5 to 1 4 Amps Low Current Mode LC LC configures the behavior when holding position when RP is constant The settings are shown in Table A2 1 for LC m LC Setting Mode Description m 0 Full Current Motor uses 100 of current at all times when enabled m 1 Low Current Motor uses 25 of current while at resting state m 2 32767 Delayed Low Current m specifies the number of samples to wait between the end of the move and when the current is cut to 25 Table A2 1 LC settings for DMC 30016 Step Drive Resolution Setting YA command When using the DMC 30016 the step drive resolution can be set with the YA command as shown in Table A2 2 for YAm YA setting Step Resolution m 1 Full 70 holding current m 2 Half m 4 1 4 m 16 1 16 Table A2 2 YA settings A3 DMC 30016 199 DMC 30000 User Manual ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered
273. uaranteed to be accurate but it is important to remember that the required path to obtain the position and velocity in the specified time may be different based on the PVT values Mismatched values for PVT can result in different interpolated profiles than expected but the final velocity and position will be accurate The t value is entered in samples which will depend on the TM setting With the default TM of 1000 one sample is 976us This means that a t value of 1024 will yield one second of motion The velocity value v will always be in units of counts per second regardless of the TM setting Chapter 6 Programming 83 DMC 30000 User Manual Command Summary PVT COMMAND DESCRIPTION PVA r rt Specifies the segment for an incremental PVT segment of p counts an end speed of v counts sec in a total time of t samples PVA Contains the number of PV segments available in the PV buffer Begin PVT mode Contains the number PV segments that have executed PVT Examples Parabolic Velocity Profile In this example we will assume that the user wants to start from zero velocity accelerate to a maximum velocity of 1000 counts second in 1 second and then back down to 0 counts second within an additional second The velocity profile would be described by the following equation and shown in Figure 6 9 v t 1000 1 1000 Velocity counts second 1200 1000
274. ucted To move the constrained axes simply command the N axis in the jog mode or with the PR and PA commands For example PAN 2000 BGN will cause the XY axes to move to the corresponding points on the motion cycle Chapter 6 Programming 89 DMC 30000 User Manual Sinusoidal Motion Example The x axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a frequency of 20 Hz This can be performed by commanding the X and N axes to perform circular motion Note that the value of VS must be VS 2n R F where R is the radius or amplitude and F is the frequency in Hz Set VA and VD to maximum values for the fastest acceleration INSTRUCTION INTERPRETATION VM XN Select Axes VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten Cycles VE BGS 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 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 ou
275. until user enters new value for n1 PR n1 2000 Convert to counts G ENTER SPEED IN RPM s1 1 Prompt for RPMs spd JP spd sl 1 Wait for user to enter new value for s1 SP s1 2000 60 Convert to counts sec G ENTER ACCEL IN RAD SEC2 al 1 Prompt for ACCEL acc JP acc al 1 Wait for user to enter new value for a1 AC al 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program Hardware I O Digital Outputs The DMC 30000 has 4 bit uncommitted digital outputs output port Each bit may be set and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit Example Set Bit and Clear Bit Instruction Interpretation SB3 Sets bit 3 of output port CB4 Clears bit 4 of output port Example Output Bit 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 Interpretation 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 OB 3 QIN 1 amp IN 2 Set Output 3 only if Input 1 and Input 2 are high OB 4 COUNT 1 Set Output 4 if element 1 in the array COUNT is non zero The output port can be set by specifying an 16 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entir
276. us move sequence making the linear interpolation mode ideal for following a piece wise linear path There is no limit to the total move length The LM LM A command selects the Linear Interpolation mode Specifying Linear Segments The command LI x specifies the incremental move distance This means motion is prescribed with respect to the current axis position Up to 31 incremental move segments may be given prior to the Begin Sequence BGS command Once motion has begun additional LI segments may be sent to the controller The clear sequence CS command can be used to remove LI segments stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or AB The command ST causes a decelerated stop The Chapter 6 Programming 73 DMC 30000 User Manual command AB causes an instantaneous stop and aborts the program and the command AB1 aborts the motion only The Linear End LE command must be used to specify the end of a linear move sequence This command tells the controller to decelerate to a stop following the last LI command If an LE command is not given an Abort AB1 must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 30000 sequence buffer to ensure continuous motion If the controller receives no additional LI segments and no LE command the controller will stop motion instantly at the last vector There will be no con
277. utes an internal monitoring of the auxiliary and main encoder registers for that axis or axes Position error is then tracked in step pulses between these two registers QS command TPxYAx YB YC QS TD Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally YA defines the step drive resolution where YA 1 for full stepping or YA 2 for half stepping The full range of YA is up to YA 9999 for microstepping drives Error Limit The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor steps Once the value of QS exceeds this limit the controller then performs the following actions 1 The motion is maintained or is stopped depending on the setting of the OE command If OEA 0 the axis stays in motion if OEA 1 the axis is stopped 2 YSis set to 2 which causes the automatic subroutine labeled POSERR to be executed Correction A correction move can be commanded by assigning the value of QS to the YR correction move command The correction move is issued only after the axis has been stopped After an error correction move has completed and QS is less than three full motor steps the YS error status bit is automatically reset back to 1 indicating a cleared error Example SPM Mode Setup The following code demonstrates what is necessary to set up SPM mode for a full step drive a half step drive and a 1 64th microste
278. utput 1 Wait 40 msec from reference and reset reference Set Output 1 Loop End Program Using AT WT with non default TM rates By default both WT and AT are defined to hold up program execution for n number of milliseconds WT n or AT n The second field of both AT and WT can be used to have the program execution be held up for n number of samples rather than milliseconds For example WT 400 or WT 400 0 will hold up program execution for 400 msec regardless of what is set for TM By contrast WT 400 1 will hold up program execution for 400 samples For the default TM of 1000 the servo update rate is 976us per sample so the difference between WT n 0 and WT n 1 is minimal The difference comes when the servo update rate is changed With a low servo update rate it is often useful to be able to time loops based upon samples rather than msec and this is where the unscaled WT and AT are useful For example MAIN TM 250 MOVE PRX 1000 BGX Cx WE 257 SBI EN Label 250us update rate Label Position Relative Move Begin Motion Wait for motion to complete Wait 2 samples 500us Set bit 1 End Program In the above example without using an unscaled WT the output would either need to be set directly after the motion was complete or 2 ms after the motion was complete By using WT n 1 and a lower TM greater delay resolution was achieved Chapter 7 Application Programming 110 DMC 30000 User
279. uts are pulled to the isolated ground Connecting the isolated ground to INC LSC will configure the inputs for active high as current will flow through the diode when the inputs are pulled up to V Figure 3 1 Figure 3 3 are the optoisolated wiring diagrams for powering INC LSC Chapter 3 Connecting Hardware 37 DMC 30000 User Manual 5V INC 2 2K CPU DI 8 1 PS2805 LSC CPU FLS RLS HOM PS2805 5V INC 2 2K CPU ELO ABRT RST PS2805 Chapter 3 Connecting Hardware 38 DMC 30000 User Manual Optoisolated Outputs The DMC 30000 has several different options for the uncommitted digital outputs labeled as DO The default outputs are 4mA sinking which are ideal for interfacing to TTL level devices Additional options include 25mA sinking lower power sinking LSNK 25mA sourcing low power sourcing LSRC 500mA sourcing high power sourcing HSRC and 500mA sinking outputs high power sinking HSNK Please refer to your part number to determine which option you have The DMC 30000 has only has a single bank Bank 0 of 4 optoisolated outputs powered through the Output PWR and Output GND pins located on J5 I O 44 pin HD D Sub Connector Female Please see the Pin outs in the Appendix for pin outs Wiring diagrams electrical specifications and details for each output type are provided below Brake Output When using the brake outputs it is recommended to order the controller with 500mA sou
280. value other than zero The conditional statement can be any valid DMC 30000 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 vl v7 6 ABS v1 gt 10 Array Element vi lt count 2 Variable vi lt v2 Internal Variable _TPX 0 _TVX gt 500 I O v1l gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 30000 will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and 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 30000 executes operations from left to right See Mathematical and Functional Expressions for more information For example using variables named v1 v2 v3 and v4 JP TEST v1 lt v2 amp v3 lt v4 Chapter 7 Application Programming 111 DMC 30000 User Manual 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 consider thi
281. w WATCHDOG TIMER ISOLATED LIMITS AND i HOME INPUTS ETHERNET RISC BASED HIGH SPEED MAIN ENCODER MICROCOMPUTER MOTOR ENCODER AUXILIARY ENCODER INTERFACE gt 10 VOLT OUTPUT FOR RS 232 SERVO MOTORS RS 422 _ p PULSE DIRECTION OUTPUT FOR STEP MOTORS re HIGH SPEED ENCODER VO INTERFACE COMPARE OUTPUT 2 UNCOMMITTED PROGRAMMABLE OPTOISOLATED OUTPUTS ANALOG INPUTS OPTOISOLATED INPUTS HIGH SPEED LATCH Microcomputer Section The main processing unit of the controller is a specialized Microcomputer with RAM and Flash FLASH The RAM provides memory for variables array elements and application programs The flash FLASH provides non volatile storage of variables programs and arrays The Flash also contains the firmware of the controller which is field upgradeable Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 15 MHz For standard servo operation the controller generates a 10 volt analog signal 16 Bit DAC For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the DMC 30000 consists of a daisy chainable Ethernet 100 Base T port and a 115kbaud RS 232 programming port General I O The DMC 30000 provides interface circuitry for 8 bi directional optoisolated inputs 4 optoisolated outputs and 2 analog inputs with 12 Bit ADC 16 Bit optional Unused auxiliary en
282. which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AEN which can be used to switch the amplifiers off in the event of a serious DMC 30000 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 will also turn on at this stage A reset is required to restore the DMC 30000 to normal operation Consult the factory for a Return Materials Authorization RMA Number if the DMC 30000 is damaged Chapter 1 Overview 14 DMC 30000 User Manual Chapter 2 Getting Started imensions D DMC 30010 CARD nT i 4 00 3 00 10 0000000000000m 20000000000000 0000000000000 D m b E l M3x0 5 THREAD 2 528 2 650 DMC 30000 User Manual Chapter 2 Getting Started gt 15 DMC 30011 CARD 3 00 4 00 A woodod0000000000CGS xooo0000000000o0lg 2 663 M3x0 5 THREAD 4PLCS 18 DMC 30000 User Manual Chapter 2 Getting Started gt 16 DMC 30010 BOX and DMC 30011 BOX
283. which makes them very easy to program GalilTools software further simplifies system set up with one button servo tuning and real time display of position and velocity information Designed to solve complex motion problems the DMC 30000 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences contouring and PVT Mode The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 30000 provides continuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with as well as a gantry mode of operation For synchronization with outside events the DMC 30000 provides uncommitted I O including 8 optoisolated digital inputs 4 optically isolated outputs 2 analog inputs for interface to joysticks sensors and pressure transducers and 1 uncommitted analog output Further I O is available if the auxiliary encoders are not being used 2 inputs each axis Dedicated optoisolated inputs are provided for forward and reverse limits abort home Input interrupts can be defined to work with uncommitted inputs Commands are sent in ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen and program development using many environments such as Visual Basic C C etc Drivers for Windows XP Vist
284. xis This is done with the instruction EAp where p DAorN p is the selected master axis For the given example since the master is the aux encoder input we specify EA DA Step 2 Specify the master cycle and the change in the slave axis or axes In the electronic cam mode the position of the master is always expressed modulo one cycle In this example the position of the master axis 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 x and y are redefined as zero The MM command specifies the master modulus and the EM command specifies the slave modulus 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 instructions MM 6000 EM 1500 Chapter 6 Programming 80 DMC 30000 User Manual Step 3 Specify the master interval and starting point 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 n0 n1 where n0 is the interval width i

DMC-30000 User Manual - Galil Motion Control

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