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DMC-2x00 User Manual

1. Figure 10 5 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Fig 10 6 DMC 40x0 Chapter 10 Theory of Operation e 179 VOLTAGE SOURCE E see W P K M EL ST 1 ST 1 S lt CURRENT SOURCE V W P VELOCITY LOOP Figure 10 6 Mathematical model of the motor and amplifier in three operational modes 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 Kf 4N 20 count rad For example a 1000 lines rev encoder is modeled as Kf 638 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers 1s 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 180 e Chapter 10 Theory of Operation DMC 40x0 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 D z ER F ES 1 B Low pass L z 7_B Notch N z PESE Z pIZ p The filter parameters K A C and B ar
2. 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 DMC 40x0 Chapter 10 Theory of Operation e 175 X VELOCITY Y VELOCITY X POSITION Y POSITION TIME Figure 10 3 Velocity and Position Profiles 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 1s 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 feedbac
3. LC configures each motor s behavior when holding position when RP is constant and multiple configurations LC command set to 0 Full Current Mode causes motor to use 100 of peak current AG while at a resting state profiler is not commanding motion This is the default setting LC command set to 1 Low Current Mode causes motor to use 25 of peak current while at a resting state This is the recommended configuration to minimize heat generation and power consumption LC command set to an integer between 2 and 32767 specifying the number of samples to wait between the end of the move and when the amp enable line toggles Percentage of full AG current used while holding position with LC n n n n n n n n 100 The LC command must be entered after the motor type has been selected for stepper motor operation e M T 2 2 2 2 LC is axis specific thus LC1 will cause only the X axis to operate in Low Current mode Step Drive Resolution Setting YA command When using the SDM 44040 the step drive resolution can be set with the YA command Step Drive Resolution per Axis YA n n n n n n n n n 1 n 2 n 4 n 16 242 e A3 SDM 44040 Full Half 1 4 1 16 DMC 40x0 ELO Input If the ELO input on the controller is triggered then 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 FAMPERR routine will run whe
4. the controller will return the state of the least significant bit of block 2 assuming block 2 1s configured as an input 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 Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 27 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Fig 7 1 The program starts at a state that we define as A Here the controller waits for the input pulse on I1 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 ATI Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion
5. 50 0 98s 098 s 51 The system elements are shown in Fig 10 7 FILTER ZOH DAC AMP MOTOR V 50 0 980s a 0 0003 4 2 S 2000 S ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s is the product of all the elements in the loop A 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency c at which AO wc equals one This can be done by the Bode plot of AG wc as shown in Fig 10 8 Magnitude 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s DMC 40x0 Chapter 10 Theory of Operation e 183 Next we determine the phase of A s at the crossover frequency A j200 390 000 200 51 j200 4 5200 2000 a Arg A j200 tan 200 51 180 tan 1 200 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 degrees and 45 degrees The phase margin of 70 degrees given above indicated overdamped 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
6. BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Latch State of State of State of Stepper Occurred Forward Reverse Home Mode Limit Limit Input 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 1s 32767 Maximum positive torque is 32767 Zero torque is 0 QZ Command The QZ command can be very useful when using the QR command since it provides information about the controller and the data record The QZ command returns the following 4 bytes of information INFORMATION Number of axes present number of bytes in general block of data record number of bytes in coordinate plane block of data record Number of Bytes in each axis block of data record Controller Response to Commands Most DMC 40x0 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon DMC 40x0 Chapter 4 Software Tools and Communication e 61 Instructions are sent in ASCII and the DMC 40x0 decodes each ASCII character one byte one at a time It takes approximately 0 05 msec for the controller to decode each command After the instruction is decoded the DMC 40x0 r
7. DM SPEED 10 Dimension Speed Array SPEED 1 7650 2 Assigns the first element of the array SPEED the value 7650 2 SPEED 1 Returns array element value POSX 10 _TPX Assigns the 10 element of the array POSX the returned value from the tell position command CON 2 0COS POS 2 Assigns the second element of the array CON the cosine of the variable POS multiplied by 2 TIMER 1 TIME Assigns the first element of the array timer the returned 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 FA Begin Program COUNT 0 DM POS 10 Initialize counter and define array LOOP Begin loop WI 10 Wait 10 msec POS COUNT _TPX Record position into array element POS COUNT Report position COUNT COUNT 1 Increment counter JP LOOP COUNT lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named POS The variable COUNT is used to increment the array element counter The above example can also be executed with the automatic data capture feature described below 146 e Chapter 7 Application Programming DMIC 40X0 Uploading and Downloading Arrays to On Board Memory Arrays may be uploaded and downloaded using the QU and QD commands QU array start end delim QD array
8. ICM 42200 Encoder 26 pin HD D Sub Connector Female Ping S S 5V From Controller Reverse Limit Switch Input B Aux Encoder Input ENBL Amp Enable Return A Aux Encoder Input STP PWM Step A Main Encoder Input ICM 42200 Analog 15 pin D sub Connector Male A 5 Digital Ground E ret L B M M GN y e A M 2 Ps ar osmo ICON INEA Anos Ground ES o AGN Ansog Ground 14 No Connect 12V from Controller 11 13 I5 IR 5V from Controller D 14 16 Notes 1 Negative differential motor command output when DIFF option is ordered on ICM Ex DMC 4040 C012 1200 DIFF Hall Input 2 when ordered with internal amplifier AMP 43040 Ex DMC 4040 C012 1200 D3040 Connected to GND in standard configuration 2 Hall Input 1 when ordered with internal amplifier AMP 43040 Ex DMC 4040 C012 1200 D3040 Connected to GND in standard configuration 3 Hall Input 0 when ordered with internal amplifier AMP 43040 Ex DMC 4040 C012 1200 D3040 Connected to GND in standard configuration DMC 40x0 Appendices e 197 Connectors for CMB 41012 Interconnect Board CMB 41012 Extended I O 44 pin HD D Sub Connector Male Pint Label Seet Pint abel Descripion Pn Label Description Ps ion Gegscgtgn 21 1031 Confgwabievovisr 36 GND DigialGroms Ps ose Connew v0 wiss 23 Les Configwnbievionnas 3s Nic Nocom Po Le confignatie nora 28 1037 Conguadie vomis 39 GND Di
9. start end where array is an array name such as A start is the first element of array default 0 end is the last element of array default last element delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 The file 1s terminated using lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 40x0 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 eight types of data can be captured and stored in eight 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 RA nf m Lol Lol 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 typel 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 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 el
10. AXIS SPEED N NUMLOOP CI 1 NMLP JP NMLP P2CD lt 2 JP ERROR P2CD 2 val P2NM EN ERROR CI 1 MG INVALID TRY AGAIN JP NMLP EN Inputting String Variables Interrupt routine Check for A Check for B Check for S Jump if not X Y S New X speed Jump to Print New Y 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 String variables with up to six characters may be input using the specifier Sn where n represents the number of string characters to be input Ifn is not specified six characters will be accepted For example IN Enter A B or C V S specifies a string variable to be input The DMC 40x0 stores all variables as 6 bytes of information When a variable is specified as a number the value of the variable is represented as 4 bytes of integer and 2 bytes of fraction When a variable is specified as a string the variable can hold up to 6 characters each ASCII character is 1 byte When using the IN command for string input the first input character 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 see section Bit wise Operators
11. AY 20000 1000000 1000000 4000 0 94 e Chapter 6 Programming Motion Specify Specify Specify Speci fy Segment motion vector vector vector AB plane speed acceleration deceleration DMC 40x0 CR 1500 270 180 Segment BC VP 0 3000 Segment CD CR 1500 90 180 Segment DA VE End of sequence BGS Begin Sequence The resulting motion starts at the point A and moves toward points B C D A Suppose that we interrogate the controller when the motion is halfway between the points A and B The value of AV is 2000 The value of CS is 0 _VPX and_VPY contain the absolute coordinate of the point A Suppose that the interrogation 1s repeated at a point halfway between the points C and D The value of AV is 4000 15002 2000 10 712 The value of CS is 2 _VPX VPY contain the coordinates of the point C C 4000 3000 B 4000 0 A 0 0 Figure 6 8 The Required Path Electronic Gearing This mode allows up to 8 axes to be electronically geared to some master axes The masters may rotate in both directions and the geared axes will follow at the specified gear ratio The gear ratio may be different for each axis and changed during motion The command GAX yzw or GA ABCDEFGH specifies the master axes GR x y z w specifies the gear ratios for the slaves 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 mod
12. Compensating for Differences in Encoder Resolution By default the DMC 40x0 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in the Command Reference 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 Tangent Motion Several applications such as cutting require a third axis 1 e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 40x0 allows one axis to be specified as the tangent axis The VM command provides parameter specifications for describing the coordinated axes and the tangent axis VM m n p m n specifies coordinated axes p specifies tangent axis such as X Y Z W p N turns off tangent axis Before the tangent mode can operate it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m n command m defines the scale factor in counts degree and n defines the tangent position that equals zero degrees in the coordinated motion plane The operand TN can be used to return th
13. NOTE This function requires the AMPEN signal to be connected from the controller to the amplifier Step C Set Torque Limit as a Safety Precaution To limit the maximum voltage signal to your amplifier the DMC 40x0 controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to the velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt on the X axis TL 1 lt return gt NOTE Once the correct polarity of the feedback loop has been determined the torque limit should in general be increased to the default value of 9 99 The servo will not operate properly if the torque limit is below the normal operating range See description of
14. ST AB Stops motion on A and B axes FLOOP JP LOOP IN 1 0 Loop until Interrupt cleared JG 15000 10000 Specify new speeds WT 300 Wait 300 milliseconds BG AB Begin motion on A and B axes RI Return from Interrupt subroutine Analog Inputs The DMC 40x0 provides eight analog inputs The value of these inputs in volts may be read using the AN n function where n is the analog input through 8 The resolution of the Analog to Digital conversion is 12 bits 16 bit ADC is available as an option 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 10V motor must move 10000 counts Method Read the analog input and command A to move to that point 158 e Chapter 7 Application Programming DMC 40x0 Instruction POINTS SP 7000 AC 80000 DC 80000 LOOP VP AN 1 1000 PA VP BGA AMA JP LOOP EN Interpretation Label Speed Acceleration Read and analog input compute position Command position Start motion After completion Repeat End Example Position Follower Continuous Move Method Read the analog input compute the commanded position and the position error Command
15. 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 FTWOMOVE 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 10000 PA 20000 Specify Absolute position BGX Begin motion AD 1000 Wait until 1000 counts SB1 Set output bit 1 EN End program Event Trigger Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR trippoint is used as shown in the next example TRIP Label JG 50000 Specify Jog Speed BGX n 0 Begin Motion REPEAT Repeat Loop AR 10000 Wait 10000 counts TPX Tell Position SB1 Set output 1 WT50 Wait 50 msec CB1 Clear output 1 n n 1 Increment counter JP REPEAT n lt 5 Repeat 5 times DMC 40x0 Chapter 7 Application Programming e 131 STX EN Stop End Event Trigger Start Motion on Input This example waits for input 1 to go low and then starts motion Note The AI command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Input Interrupt
16. The reverse limit switch RLSx 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 When a forward or reverse limit switch 1s 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 1s 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 the limit switch will not be possible until the logic state of the switch returns back to an inactive state This usually involves physically opening the tripped switch Any attempt at further motion before the logic state has been reset will result in the following error 022 Begin not possible due to limit switch error The operands LFx and LRx contain the state of the forward and reverse limit switches respectively x represents the axis X Y Z W etc The value of the operand is either a 0 or 1
17. USER MANUAL DMC 40x0 Manual Rev 1 0c By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Rev 12 08 Using This Manual This user manual provides information for proper operation of the DMC 40x0 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller Y our DMC 40x0 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 1s shown below Attention Pertains to servo motor use Attention Pertains to stepper motor use Attention Pertains to controllers with more than 4 axes H H Please note that many examples are written for the DMC 4040 four axes controller or the DMC 4080 eight axes controller Users of the DMC 4030 3 axis controller DMC 4020 2 axes controller or DMC 4010 1 axis controller should note that the DMC 4030 uses the axes denoted as XYZ the DMC 4020 uses the axes denoted as XY and the
18. 2 The abort command is given 3 The abort input is activated with a low signal Note If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Examples E byl Enable off on error for X Y Z and W QEU do Ud Enable off on error for Y and W axes and disable off on error for W and Z axes 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 The error routine must be closed with the RE command The RE command returns from the error subroutine to the main program NOTE The Error Subroutine will be entered again unless the error condition is gone Example HA 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 170 e Chapter 8 Hardware amp Software Protection DMC 40x0 Limit Switch Routine The DMC 40x0 provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automatic execution of a limit switch subroutine The FLIMSWI label specifies the start of the limit switch subroutine This label causes the statements following to be automatically executed 1f any limit
19. 294 297 SL new F User defined variable ZA 298 299 UW G axis status see bit field map below 300 UB G axis switches see bit field map below 301 UB G axis stop code 302 305 SL G axis reference position 306 309 SL G axis motor position 310 313 SL G axis position error 314 317 SL G axis auxiliary position 318 321 SL G axis velocity 322 325 SL new size G axis torque 326 327 SW G axis analog input 328 UB new G Hall Input Status 329 UB Reserved 330 333 SL new G User defined variable ZA 334 335 UW H axis status see bit field map below 336 UB H axis switches see bit field map below 337 UB H axis stop code 338 341 SL H axis reference position 342 345 SL H axis motor position 346 349 SL H axis position error 350 353 SL H axis auxiliary position 354 357 SL H axis velocity 358 361 SL new size H axis torque 362 363 SW H axis analog input 364 UB new H Hall Input Status 365 UB Reserved 366 369 SL new H User defined variable ZA DMC 40x0 Chapter 4 Software Tools and Communication e 59 Explanation Data Record Bit Fields Header Information Byte 0 1 of Header BIT BITIS BIT BIT14 BIT pr BIT BITI2 BIT BTI BIT BITIO BIT 9 BIT 8 I cs T Block S Block Present Present Present in Data in Data in Data Record Record Record G EN F Block E Block D Block C Block B Block A Block Present Present Present Present Present Present Present Present in Data in Data in Data in Data in Data in
20. 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 DMC 40x0 Chapter 7 Application Programming e 161 START PULSE l1 ee MOTOR VELOCITY OUTPUT PULSE q q AAA AAA output TIME INTERVALS move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals X Y Table Controller An X Y Z system must cut the pattern shown in Fig 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool The solid curves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate is 0 1 g The motion starts at point A with the Z axis raised An X Y motion to point B is followed by lowering the Z axis and performing a cut along the circle Once the circular motion is completed the Z axis is raised and the motion continues to point C etc Assume that all of the 3 axes are driven by lead screws with 10 turns per inch pitch Also assume encoder resolution of 1000 lines per revolution This results in the relationship 1 inch 40 000 counts and the speeds of 1 in sec 40 000 count sec 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 2 0 1g 38 6 in s2 1 544 000 count s Note that the circular path has a radius
21. DMC 4010 uses the X axis only Examples for the DMC 4080 denote the axes as A B C D E F G H Users of the DMC 4050 5 axes controller DMC 4060 6 axes controller or DMC 4070 7 axes controller should note that the DMC 4050 denotes the axes as A B C D E the DMC 4060 denotes the axes as A B C D E F and the DMC 4070 denotes the axes as A B C D E F G The axes A B C D may be used interchangeably with A B C D 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 machinery Galil shall not be liable or responsible for any incidental or consequential damages Contents Contents i Chapter 1 Overview 1 PARE OAC HoN E l OVERVIEW OF Eed 2 Standard Servo Motor with 10 Volt Command Senal 2 Brushless Servo Motor with Sinusoidal Commutanon 2 Stepper Motor with Step and Direction Signals ccccccccnnnnnnncnnnnnnnnnnnnnnnnnnnnnninonoss 2 OVA VE OLEA AO A EE 3 Amplifiers CUE Mo icon 3 Amplifiers im Velocity Mid cards 3 SEPPE MIOtOr Ama ICTS PAN ROA OE UU O see 3 Overview of Galil Aimplitters and DAVE Ses 3 Pllc MIP A 3 O40 GDS OX O a ad 3 AD AMP AS AO EDS it 3 ASAS DIME ADO D404 st 3 AA SOME AO CIDA TAO td 3 DMC A00 Funciona B16 me tS alii 4 Microcomputer Sec ON daa dabas 4 eet 4 CONANT ALON NEE 4 Genera E ele 4 A ee ne 5 e EE 5 Pomp er COTY GE a 5 EE 6 Watch DOS TIN ot 6 Chapter 2 Getting Started 7 DALE IA
22. 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 HMxX read 1 initially and a normally closed switch will make HMX read zero Furthermore with CN 1 a normally open switch will make HMX read 0 initially and a normally closed switch will make HMxX 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 1s in the opposite direction of Stage 2 the motor will stop immediately at th
23. I O points will be configured as an input For example if block 4 and 5 is to be configured as an output CO 12 is issued DMC 40x0 Chapter 7 Application Programming e 159 8 Bit I O Block Binary Decimal Value for Representation Block 25 32 33 40 41 48 The simplest method for determining n Step 1 Determine which 8 bit I O blocks to be configured as outputs Step 2 From the table determine the decimal value for each I O block to be set as an output Step 3 Add up all of the values determined in step 2 This is the value to be used for n For example if blocks 2 and 3 are to be outputs then n is 3 and the command CO3 should be issued NOTE This calculation is identical to the formula n n2 2 n3 4 n4 5 n5 where nx represents the block Saving the State of the Outputs in Non Volatile Memory The configuration of the extended I O and the state of the outputs can be stored in the non volatile flash memory with the BN command Ifno value has been set the default of CO 0 1s used all blocks are inputs Accessing Extended I O When configured as an output each I O point may be defined with the SBn and CBn commands where n 1 through 8 and 17 through 48 Outputs may also be defined with the conditional command OBn where n 1 through 8 and 17 through 48 For 5 8 axis controllers each I O point may be defined with the SBn and CBn commands where n 1 4080 through 48 The command OP may also be used to set ou
24. and ST stops the motion In binary commands are represented by a binary code ranging from 80 to FF ASCII commands can be sent live over the communications port for immediate execution by the DMC 40x0 or an entire group of commands can be downloaded into the DMC 40x0 memory for execution at a later time Combining commands into groups for later execution is referred to as Applications Programming and 1s discussed in the following chapter Binary commands cannot be used in Applications programming This section describes the DMC 40x0 instruction set and syntax A summary of commands as well as a complete listing of all DMC 40x0 instructions is included in the Command Reference Command Syntax ASCII DMC 40x0 instructions are represented by two ASCII upper case characters followed by applicable arguments A space may be inserted between the instruction and arguments A semicolon or lt return gt is used to terminate the instruction for processing by the DMC 40x0 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 40x0 commands are sent in upper case For example the command PR 4000 lt return gt Position relative PR is the two character instruction for position relative 4000 is the argument
25. 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 DUALOOP CE 0 DEO PR 40000 BGX Correct AMX v1 10000 _DEX V2 _TEX 4 V1 JP END ABS V2 lt 2 PR V2 4 BGX JP CORRECT END EN 116 e Chapter 6 Programming Motion INTERPRETATION Label Configure encoder Set initial value Main move Start motion Correction loop Wait for motion completion Find linear encoder error Compensate for motor error Exit if error is small Correction move Start correction Repeat DMC 40x0 Motion Smoothing The DMC 40x0 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 Using the IT Command gt When operating with servo motors motion smoothing can be accomplished with the IT command This command filters the acceleration and deceleration fu
26. 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 command AB causes an instantaneous stop and aborts the program and the command AB 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 AR must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 40x0 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 controlled deceleration LM or LM returns the available spaces for LI segments that can be sent to the buffer 511 returned means the buffer 1s empty and 511 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 at PC bus speeds 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 86 e Chapter 6 Programming Motion DMC 40x0 Addi
27. e0000000 000000000 000000000 5V 5V 10K AEN TO DRIVE PIN 2 CPU AEN SHn 5V MOn V 12V Bi 10K AEN TO DRIVE PIN 2 CPU AEN SHn 5V MOn ON AMP ENABLE POWER PIN 20 EN 10K AEN TO DRIVE PIN 2 CPU AEN SHn 5V d AMP ENABLE RETURN MOn V PIN 11 DMC 40x0 5V LOW AMP ENABLE SINKING 12V LOW AMP ENABLE SINKING ISOLATED SUPPLY LOW AMP ENABLE SINKING DMC 40x0 AXIS A AXIS A AXIS A O O O O O O O O 00000000 000000000 00000000 000000000 000000000 000000000 000000000 000000000 5V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn V 12V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V AMP ENABLE POWER PIN 20 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware e 45 5V HIGH AMP ENABLE SOURCING 12V HIGH AMP ENABLE SOURCING ISOLATED SUPPLY HIGH AMP ENABLE SOURCING 46 e Chapter 3 Connecting Hardware AXIS A AXIS A AXIS A O0000 0000 000000000 O O O O O O O O o o o O O O o O 000000000 000000000 000000000 O O O O Oo O O o 000000000 123456 CPU AEN SHn 5V MOn 0V CPU AEN SHn 5V MOn V CPU AEN SHn 5V MOn 0V 5V 10K 12V 10K AMP ENABLE POWER PIN 20 10K AMP ENABLE RETURN PIN 11 AEN TO DRIVE PIN 2 AEN TO DRIVE PIN 2 AEN TO DRIVE PI
28. expression following the completed MG statement n m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is result F5 2 If the value of the variable result is equal to 4 1 this statement returns the following The Final Value is 00004 10 If the value of the variable result is equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppressed by sending N at the end of the statement This is useful when a text string needs to surround a numeric value Example A JG 50000 BGA ASA MG The Speed is _TVA F5 1 N MG counts sec EN When A is executed the above example will appear on the screen as The speed is 50000 counts sec Using the MG Command to Configure Terminals The MG command can 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 Me COD T7239 sends the ASCII characters represented by 7 and 255 to the bus 152 e Chapter 7 Application Programming DMC 40x0 Summary of Message Functions function description S Surround
29. ms for TM1000 m is number of records to be captured Returns a 1 if recording Chapter 6 Programming Motion e 107 FRECORD DM XPOS 501 RA XPOS RD _TPX MOX RC2 HA JP A RC 1 COMPUTE DM DX 500 C 0 L D C 1 DELTA XPOS D XPOS C DX C DELTA C C 1 JP L C lt 500 Record and Playback Example Begin Program Dimension array with 501 elements Specify automatic record Specify X position to be captured Turn X motor off Begin recording 4 msec interval at TM1000 Continue until done recording Compute DX Dimension Array for DX Initialize counter Label Compute the difference Store difference in array Increment index Repeat until done PLAYBCK Begin Playback CMX Specify contour mode DT2 Specify time increment I 0 Initialize array counter B Loop counter CD DX I I I 1 Specify contour data I I 1 Increment array counter JP B I lt 500 Loop until done CD 0 0 End countour buffer Wait DP Wait _CM lt gt 511 Wait until path is done EN End program For additional information about automatic array capture see Chapter 7 Arrays Virtual Axis The DMC 40x0 controller has two additional virtual axes designated as the M and N axes These axes have no encoder and no DAC However they can be commanded by the commands Rees Dey TES SP PRs PA EC TT Ck UM VP CR STS DB RE The main use of the virtual axes is to serve as a virtual master in ECAM modes and to perform an unnecessary part
30. 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 constructed 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 108 e Chapter 6 Programming Motion DMC 40x0 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 21 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 VMXN Select Axes VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz GCR LODOS 90 2000 Ten Cycles VE BGS Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently
31. this pin 1s not used and should be left open The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM 64kHz signal is 2 duty cycle for full negative voltage 50 for 0 Voltage and 99 8 for full positive voltage 64kHz Switching Frequency In the Sign Magnitude Mode MT1 5 the PWM 128 kHz signal is 0 for 0 Voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output 128kHz Switching Frequency PWM Step For stepper motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Sign Direction Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors 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 8 The high power optically isolated outputs are uncommitted and E may be designated by the user to toggle relays and trigger external SE HEET events The output lines are toggled by Set Bit SB and Clear Bit DMC 4050 thru 4080 CB instructions The OP instruction 1s used to define the state of all the bits of the Output port 204 e Appendices DMC 40x0 DMC 40x0 Inputs Encoder MA MB Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any
32. 07 specifies stop X bit 0 Y bit 1 and Z bit 2 2 2 2 7 Binary command table Command No Command No Command No ANA o a ema a IC Peed Se FE s m w aa TJ w m Je s s ew s po e Oc gt a o e IE s s o eea w w CU m o fema id FC S DMC 40x0 Chapter 5 Command Basics e 73 w Js TA TR o o e Jo ra om a RRE ea o ena EC e EC E E enea og pam IEC E enea ve mc o EC eea of tw IE E EE EE ER ERR REES Pas e paid oa e m o e e em e Pre Ja e o mene SSC d ao s s id wi mene e KS Je a a E e fice w rn mo o ea o rene s rene s if SS Controller Response to DATA The DMC 40x0 returns a for valid commands and a for invalid commands For example if the command BG is sent in lower case the DMC 40x0 will return a bg lt return gt invalid command lower case DMC 40x0 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 TC 1 lt return gt Tell Code command 1 Unrecognized 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 a
33. 1 The load is coupled with a 2 pitch lead screw A 2000 count rev encoder is on the motor resulting in a resolution of 4000 counts inch The program below uses the variable len to length The IN command is used to prompt the operator to enter the length and the entered value 1s assigned to the variable len BEGIN AC 800000 DC 800000 SP 5000 len 3 4 CUT All IN enter Length IN len PR len 4000 BGX AMX SB1 WT100 CB1 JP CUT EN LABEL Acceleration Deceleration Speed Initial length in inches Cut routine Wait for start signal Prompt operator for length in inches Specify position in counts Begin motion to move material Wait for motion done Set output to cut Wait 100 msec then turn off cutter Repeat process End program Operator Data Entry Mode The Operator Data Entry Mode provides for un buffered data entry through the auxiliary RS 232 port In this mode the DMC 40x0 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 Set the third field of the CC command to one to set the Operator Data Entry Mode To capture and decode characters in the Operator Data Mode the DMC 40x0 provides special the following keywords Contains the la
34. 1000000 1000000 Acceleration for X Y DC 1000000 1000000 Deceleration for X Y SP 50000 30000 Speeds for X Y BG XY Begin motion Example Multiple Move Sequence Required Motion Profiles X Axis 500 counts Position 20000 count sec Speed 500000 counts sec2 Acceleration Y Axis 1000 counts Position 10000 count sec Speed 500000 counts sec2 Acceleration Z Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on X Y and Z axes The movement on each axis will be separated by 20 msec Fig 6 0 shows the velocity profiles for the X Y and Z axis Begin Program 20 00 50 0 20 0 Specify relative position movement of 1000 500 and 100 counts for X Y and Z axes 20000 10000 5000 Specify speed of 20000 10000 and 5000 counts sec 500000 500000 500000 Specify acceleration of 500000 counts sec for all axes 500000 500000 500000 Specify deceleration of 500000 counts sec for all axes X Begin motion on the X axis 20 Wait 20 msec Y Begin motion on the Y axis 20 Wait 20 msec Z Begin motion on Z axis End Program DMC 40x0 Chapter 6 Programming Motion e 79 VELOCITY COUNTS SEC X axis velocity profile 20000 Y axis velocity profile 15000 Z axis velocity profile 10000 5000 TIME ms 0 20 40 60 80 100 Figure 6 0 Velocity Profiles of XYZ Notes on figure 6 0 The X and Y axis have a trapezoidal velocity profile while the Z ax
35. 139 172 o ee ented merece 77 105 107 146 148 E ee a Pee Ye ee 5 75 121 Position Apesta 121 ES EE 107 AG EE 15 16 145 Reset 2 14 19 22 23 32 39 52 62 134 169 171 201 205 Scaling Epos Cale negri adas 94 A O 87 117 Motion Smoothing cccccccccnnnnnnnnnnnnnnnnno 77 117 118 SDK 124 Selecta AUTE tal otto uri 147 48 Serial Port 16 17 141 142 151 153 202 203 204 Servo Design Kit SDE a ne ee A 124 A 157 204 Sine 77 101 144 Single Ended cccccsscssessseeseesssessseeses 6 19 21 189 Slew 24 25 78 98 131 133 162 Smoothing s000000a 1 24 77 87 88 92 94 117 18 Software SDE Eege 124 Index e 249 AA EE 16 20 Special La aR 126 172 Specification tii 87 88 92 Stability oo 115 16 166 173 74 178 184 AC EE 137 140 141 159 DAO UAC Is on 140 159 SEH EE 148 o A 89 95 EE geet ees 148 Step Mot ride 2 3 5 13 24 118 KS Smoothing 24 77 87 88 92 94 117 18 Stepper Position Maintenance 000000000000 2 24 111 Stop A NER AM 86 92 169 171 204 5 Stop Code 75 138 145 142 49 148 162 63 165 67 SLOP MOU OM dla 86 92 139 172 Subroutine 32 91 124 126 134 39 151 158 170 71 Automatic Subroutine oocccnnncccnoniccnononiconon 126 138 Synchronization EE 1 6 48 99 A A 70 71 MAINO E 77 91 93 94 E aa ae dais 107 Dira AAA tere ne mt Serene ee 147 48 Ee 5 73121 A A 77 149 Position Capture zean de ei
36. 34 144 Digital CPU laos 144 Dip Switch AES eege 147 48 MY ONY THO ad tediosa 147 IR Eiter 116 148 ET E EE 77 115 16 166 Dual Loop 77 109 16 109 16 109 16 166 Index e 247 Dual Loop 77 109 16 109 16 109 16 166 ET WE E 77 115 16 166 A A AN 100 103 Electronic Cam 76 77 99 101 Echo 49 62 ELC Hie ME A O ESTE ENE ere 28 138 Ire re EE 28 FEPRO EE 1 4 14 161 201 Electroni Camada idas liado 76 77 99 101 Electronic Gearmg 1 76 77 95 99 A O E 94 Enable AMplifer eege 169 Amplifier Eno 6 18 41 Encoder Auxiliary Encoder 1 5 19 24 37 98 109 16 109 16 109 16 158 190 205 Differential 6 19 21 37 158 189 190 Dual Encoder iii 75 116 148 MAEL PUE AAA esti ig aban as 19 33 Quadrature 4 6 115 156 162 170 181 189 Error Code 53 74 75 138 145 14249 162 63 165 67 Error Handling 11 32 126 13738 170 72 Error Lamm 18 20 25 39 41 138 169 71 Of On Error a 18 33 41 169 171 Example Communication Interrupt ccceee 141 151 Weston Exp dia 25 Ethernet Communication Error 142 input Interruprta ia 159 A A E E A 55 224 BI eng E E 157 SN ee 157 Position Follower 159 Printing Eelere 154 Set Bit and Clear Bitoon 157 Sinusoidal Commutati0N ccccnoccccnnniccnnnninonnn 17522 Start Motion on Switch 158 Turn on output after MOVE oooooooooooonnnnnnnnnnnnnnnoss 157 Usine TOUS eege 158 W
37. 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 40x0 provides 510 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 value of 5000 to the variable posx PR poss Assigns variable posx to PR command JG rpmy 70 Assigns variable rpmY multiplied by 70 to JG command Programmable Variables The DMC 40x0 allows the user to create up to 510 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 40x0 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 Val
38. 7 Application Programming e 165 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 once the motor settles This implies that the correction needs to
39. A and C axes are configured for sinusoidal commutation The first phase of the A axis will be the motor command A signal The second phase of the A axis will be the motor command F signal The first phase of the C axis will be the motor command C signal The second phase of the C axis will be the motor command G signal Step C Specify the Size of the Magnetic Cycle Use the command BM to specify the size of the brushless motors magnetic cycle in encoder counts For example if the X axis is a linear motor where the magnetic cycle length 1s 62 mm and the encoder resolution is micron the cycle equals 62 000 counts This can be commanded with the command BM 62000 On the other hand if the C axis is a rotary motor with 4000 counts per revolution and 3 magnetic cycles per revolution three pole pairs the command is BMG 4 13335339 Step D part 1 Systems with or without Hall Sensors Test the Polarity of the DACs Use the brushless motor setup command BS to test the polarity of the output DACs This command applies a certain voltage V to each phase for some time T and checks to see if the motion is in the correct direction The user must specify the value for V and T For example the command BSA 2 700 will test the A axis with a voltage of 2 volts applying it for 700 millisecond for each phase In response this test indicates whether the DAC wiring 1s correct and will indicate an approximate value of BM If the wiring 1s correc
40. DMC 4050 4060 4070 4080 are five thru eight axes controllers All eight axes have the ability to use Galil s integrated amplifiers or drivers and connections for integrating external devices Designed to solve complex motion problems the DMC 40x0 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences and contouring The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 40x0 provides continuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with multiple master axes as well as gantry mode operation For synchronization with outside events the DMC 40x0 provides uncommitted I O including 8 opto isolated digital inputs 16 inputs for DMC 4050 thru DMC 4080 8 high power optically isolated outputs 16 outputs for DMC 4050 thru DMC 4080 and 8 analog inputs for interface to joysticks sensors and pressure transducers The DMC 40x0 also has an additional 32 I O at 3 3V logic 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 and definable input interrupts Commands can be sent in either Binary or ASCII Additional software 1s available for automatic tuning trajectory viewing
41. Drifts Significant noise can be 1 Noise Shield encoder cables seen on MA and or Avoid placing power cables near MB encoder signals encoder cables Avoid Ground Loops Use differential encoders Use 12V encoders Stability symptom DIAGNOSIS CAUSE mer Servo motor runs away Reversed Motor Type 1 Wrong feedback Reverse Motor or Encoder Wiring when the loop is closed corrects situation MT 1 polarity remember to set Motor Type back to default value MT 1 Motor oscillates 2 Too high gain or Decrease KI and KP Increase KD too little damping Operation SYMPTOM CAUSE REMEDY EDY ur UN rejects Response um controller mu Correct A reported by TC commands from TC1 diagnoses error Motor Doesn t Move Response of controller 2 Anything Correct problem reported by SC from TC1 diagnoses error DMC 40x0 Chapter 9 Troubleshooting e 173 Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Fig 10 1 COMPUTER CONTROLLER The operation of such a system can be divided into three levels as illustrated in Fig 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming ENCODER DRIVER Figure 10 1 Elements of Servo Systems The first level the closing of the loop assures that the motor
42. ENDIF EN Begin thread 1 Create new variable Set KP to value of N an invalid value Issue invalid command End of thread 1 Begin command error subroutine If error is out of range KP 1 Set N to a valid number Retry KP N command If error is invalid command TY Skip invalid command End of command error routine Example Communication Interrupt A DMC 4010 is used to move the A axis back and forth from 0 to 10000 This motion can be paused resumed and stopped via input from an auxiliary port terminal Instruction BEGIN CC 9600 0 1 0 CI 2 MG P2 Type 0 to stop motion MG P2 Type 1 to pause motion MG P2 Type 2 to resume motion rate 2000 SPA rate LOOP PAA 10000 BGA AMA PAA 0 BGA AMA JP LOOP EN COMINT JP STOP P2CH 0 JP PAUSE P2CH 1 JP RESUME P2CH 2 EN1 1 STOP STA ZS EN PAUSE rate _SPA SPA 0 ENT 1 140 e Chapter 7 Application Programming Interpretation Label for beginning of program Setup communication configuration for auxiliary serial port A Setup communication interrupt for auxiliary serial port es Message out of auxiliary port A Message out of auxiliary port 4 Message out of auxiliary port Variable to remember speed Set speed of A axis motion Label for Loop Move to absolute position 10000 Begin Motion on A axis Wait for motion to be complete Move to absolute position 0 Begin Motion on A axis Wait for motion to be complete Continual
43. 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 52 e Chapter 4 Software Tools and Communication DMC 40x0 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 to 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 addr
44. I I I I I I I I I I I I A ere aL oro ep eee ee oe ee ee ee en rm em rm rm rm rm mm rm KEE EEGEN Aen ees e ei dl ea eene ci SI Figure 6 1 Position vs Time msec Motion 1 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 cts at that time Figure 6 1 shows what the position profile would look like if the move was allowed to complete to 5000 cts The position was modified when the robot was at a position of 4200 cts Note that the robot actually travels to a distance of almost 5000 cts 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 3 the velocity profile is triangular because the controller doesn t have sufficient time to reach the set speed of 50000 cts sec before it is commanded to change direction l Se oo nen en en e Den nenn nen e ne e e e e E E WT ee eee A a ze e e e e e zm ll ze zm rm e e rm rm rm re lee E EE HU Figure 6 2 Position vs Time msec Motion 2 DMC 40x
45. If the Off On Error function is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no longer under servo control If the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running are terminated when a transition in the Abort input is detected This can be configured with the CN command For information see the Command Reference OE and CN DMC 40x0 Chapter 3 Connecting Hardware e 33 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 Integrated Amplifiers and Drivers in the Appendices Reset Input When this input 1s driven low the controller will reset This 1s the same as pressing the RESET button on the controller Uncommitted Digital Inputs The DMC 40x0 has 8 opto isolated 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 x axis motor move 10
46. Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WI 100 Wait 100 msec PA 0 Position absolute 0 BGX Begin move AMX Wait for motion complete WI 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 40x0 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 Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only wh
47. Interpretation Distances of A B C D Accelerations Decelerations Start A and C Start B and D Example 4 Independent Moves Slew speeds of A B C D of A B C D Of A BED motion motion The motion parameters may be specified independently as illustrated below Instruction PR SP DC AC AC 300 600 2000 80000 100000 r 100000 DC 150000 BG BG C B Interpretation Distances of B and C Slew speed of B Decel Accel Accel Decel A erati A E erati ab erati E erati on on on on OF of OF of Start C motion Start B motion Example 5 Position Interrogation The position of the four axes may be interrogated with the instruction TP Instruction LP The position error which is the difference between the ER Q W P interrogated with the instruction TE Instruction TE J Q W P Tell Tell Tell Tell Tell posit posit posit posit a i posit ion ion ion ion ion Interpretation Q QA W wW all four axes Interpretation Tell Example 6 Absolute Position error Srror error error error Objective Command motion by specifying the absolute position Instruction 26 e Chapter 2 Getting Started Interpretation A axis only B axis only C axis only D axis only commanded position and the actual position can be all axes A axis
48. 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 YSE Enable SPM mode Example Error Correction The following code demonstrates what is necessary to set up SPM mode for the X axis detect error stop the motor correct 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 OE1 Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 LA HZ Motor type set to stepper YA2 Step resolution of the drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WT100 Allow slight settle time MOTION Perform motion SP12 Set the speed PR1000 Prepare mode of motion BGX Begin motion LOOP JP LOOP Keep thread zero alive for POSERR to run in 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 POSERR Automatic subroutine is called when YS 2 WT100 Wait helps user see the correction spsave _SPX Save current speed setting JP RETURN YSX lt gt 2 Return to thread zero if invalid error SP 64 Set slow speed setting for correctio
49. Output of Data Numeric and String Numerical and string data can be output from the controller using several methods The message command MG can output string and numerical data Also the controller can be commanded to return the values of variables and arrays as well as other information using the interrogation commands the interrogation commands are described in chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen DMC 40x0 Chapter 7 Application Programming e 151 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 2s result In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Position of A is _TPA Specifying the Port for Messages The port can be specified with the specifier P1 for the main serial port P2 for auxiliary serial port or En for the Ethernet port MG P2 Hello World Sends message to Auxiliary Port Formatting Messages String variables can be formatted using the specifier Sn where n 1s 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
50. PP ace aac ere ce eee ee ee 7 PNAC EOS ODay OU sss pss ea T E EE 8 DMC 40x0 Power Connections do 9 IVIC 404 0 Dimensions ss osteo teas eed do 10 IONIC A080 Ee 11 Elements Yon Need gerrnana a O ea a 12 AMM the DMA a EEES 13 Step 1 Determine Overall Motor Configuration cccccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnninininnninos 13 Step 2 Install Jumpers on the eessen a aa a 14 Step 3 Install the Communications Software 14 Step 4 Connect 20 80VDC Power to the Controller oooocoocccccccnnnnnnnnnnnnns 15 DMC 40x0 Contents e i Step 5 Establish Communications with Galil Software 15 Step 6 Determine the Axes to be Used for Sinusoidal Commutation 17 Step 7 Make Connections to Amplifier and Encoder ooccccccccnnccccnnnnnnnnnnnnnnnnnnnnnnos 18 Step 8a Connect Standard Servo Motors 19 Step 8b Connect Sinusoidal Commutation Motors 21 Step Sc Connect Step MOLES art nn 24 Step 92 Tune the ENEE an 24 PEST OME AMID ICS aras 25 Example 1 System e EE 25 Example 2 Profiled MOVE a 25 Example 3 Moltiple ARES a 26 Example 4 Independent MOVES ria t 26 Example 5 Position Interrogaton 26 Example 6 Absolute Position scr 26 Example Velocity Ee 2a Example 8 Operation Under Torque Limit cooooocccccccncnananananononanonnno nono nono ono no nono nnn nono 21 Example 9 Initio EE 2 Example 10 Operation in the Buffer Mode 28 Example 11 Using the On Board Editor
51. 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 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 Selective Abort The controller can be configured to provide an individual abort for each axis Activation of the selective abort signal will act the same as the Abort Input but only on the specific axis To configure the controller for selective abort issue the command CN 1 This configures the inputs 5 6 7 8 13 14 15 16 to act as selective aborts for axes A B C D E F G H respectively 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 1s triggered see Integrated Amplifiers and Drivers 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 ac
52. Step 3 Step 3 Configure Circuit Reference the instructions below for the desired configuration and then proceed to Step 4 5V High Amp Enable Sinking Configuration Default pg 211 5V Low Amp Enable Sinking Configuration pg 211 5V High Amp Enable Sourcing Configuration pg 212 5V Low Amp Enable Sourcing Configuration pg 212 12V High Amp Enable Sinking Configuration pg 213 12V Low Amp Enable Sinking Configuration pg 213 12V High Amp Enable Sourcing Configuration pg 214 12V Low Amp Enable Sourcing Configuration pg 214 Isolated Power High Amp Enable Sinking Configuration pg 215 Isolated Power Low Amp Enable Sinking Configuration pg 215 Isolated Power High Amp Enable Sourcing Configuration pg 216 Isolated Power Low Amp Enable Sourcing Configuration pg 216 210 e Appendices DMC 40x0 5V High Amp Enable Sinking Configuration Default JP 2 SHUNT AT GND SHUNT AT 5 Default Configuration Shipped with controller when no specific setup is ordered RP PIN 1 i ESTATE ON NNN Ne Q U4 PIN 1 TL E CH CO Cl ii les O Je z E 5V Low Amp Enable Sinking Configuration SHUNT AT GND JP 2 JP1 SHUNT AT 5 From Default Configuration Reverse RP2 aiy ER Opa d TEDEGO DGO GUDD oD Gopopopopopoopoog 1921100000200 0 SE SH U4 PIN 1 RP2 PIN 1 WS T T QE Appendices e 211 DMC 40x0 5V High Amp Enable Sourcing Configurat
53. TL in the command reference Step D Connect the Motor Once the parameters have been set connect the analog motor command signal MCMn where n is A H to the amplifier input To test the polarity of the feedback command a move with the instruction PR 1000 lt CR gt Position relative 1000 counts BGA lt CR gt Begin motion on A axis 20 e Chapter 2 Getting Started DMC 40x0 When the polarity of the feedback is wrong the motor will attempt to run away The controller should disable the motor when the position error exceeds 2000 counts If the motor runs away the polarity of the loop must be inverted Inverting the Loop Polarity When the polarity of the feedback is incorrect the user must invert the loop polarity and this may be accomplished by several methods If you are driving a brush type DC motor the simplest way is to invert the two motor wires typically red and black For example switch the M1 and M2 connections going from your amplifier to the motor When driving a brushless motor the polarity reversal may be done with the encoder If you are using a single ended encoder interchange the signal MA and MB If on the other hand you are using a differential encoder interchange only MA and MA The loop polarity and encoder polarity can also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section To Invert Polarity using Hall Comm
54. V4 In this example this statement will cause the program to jump to the label TEST if V1 is less than V2 and V3 is less than V4 To illustrate this further consider this same example with an additional condition JP AFTES IS d EM amp AVIV AVS 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 VS 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 MOVE2 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 V1I 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 134 e Chapter 7 Application Programming DMC 40x0 COUNT 10
55. a 0 to VS PWM to the motor when moving in the forward direction and a 0 to VS PWM to the motor when moving in the negative direction This mode is useful when using low inductance motors because it reduces the losses due to switching voltages across the motor windings It 1s recommended to use chopper mode when using motors with 200 500uH inductance DMC 40x0 A1 AMP 43040 e 233 Astorage Scope oom 078 016 005 797 Figure Al 2 Peak Current Operation With the AMP 43040 and 43020 the user 1s also given the ability to choose between normal and high current bandwidth AU In addition the user can calculate what the bandwidth of the current loop is for their specific combination AW To select normal current loop gain for the X axis and high current loop gain for the Y axis issue AU 0 1 The command AW is used to calculate the bandwidth of the amplifier using the basic amplifier parameters To calculate the bandwidth for the X axis issue AW X v n where v represents the DC voltage input to the card represents the inductance of the motor in millihenries and n represents 0 or 1 for the AU setting Note For most applications unless the motor has more than 5 mH of inductance with a 24V supply or 10 mH of inductance with a 48 volts supply the normal current loop bandwidth option should be chosen AW will return the current loop bandwidth in Hertz Brush Amplifier Operation The AMP 43040 and AMP 43020 also allow for brush op
56. an SH command is sent to the controller or the controller is reset RS command or power cycle Rev C Amplifiers began shipping in December 2008 ELO Input If the ELO input on the controller is triggered then 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 FAMPERR 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 236 e A1 AMP 43040 DMC 40x0 A2 AMP 43140 Introduction The AMP 43140 contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 DC Volt input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at A maximum current The typical current loop bandwidth is 4 kHz The AMP 43140 can be ordered to have a 100mA maximum current output where the gain of the amplifier is 10mA V Order as D3140 100mA HABAS Figure A2 1 DMC 4040 C012 1000 D3140 DMC 4040 with AMP 43140 DMC 40x0 A2 AMP 43140 e 237 Electrical Specifications The amplifier is a brush type trans conductance linear amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input DC Supply Voltage 12 30 VDC bipola
57. 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 166 e Chapter 7 Application Programming DMC 40x0 THIS PAGE LEFT BLANK INTENTIONALLY DMC 40x0 Chapter 7 Application Programming e 167 Chapter 8 Hardware amp Software Protection Introduction The DMC 40x0 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 40x0 1s an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 40x0 Galil shall not be liable or respo
58. both X and Y when Master 0 Begin jog on Z axis Loop until the variable is set Disengage X and Y when Master 2000 Wait until the Master goes to 2000 Stop the Z axis motion Exit the ECAM mode End of the program The above example shows how the ECAM program is structured and how the commands can be given to the controller The next page provides the results captured by the WSDK program This shows how the motion will be seen during the ECAM cycles The first graph 1s for the X axis the second graph shows the cycle on the Y axis and the third graph shows the cycle of the Z axis DMC 40x0 Chapter 6 Programming Motion e 103 Three Storage Scopes EJ File Collection Graph First Scope x Actual Position oom Normal Second Scope y Actual Position oom Normal Third Scope E Actual Position oom Normal Command String Figure 6 12 Three Storage Scopes Contour Mode The DMC 40x0 also provides a contouring mode This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes 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 For example CMXZ specifies contouring on the X and Z axes Any axes that are not being used in the co
59. cccccscsssssseseessseseesesseeseeseeeseeeeeeees 28 Example 12 Motion Programs with Loops 28 Example 13 Motion Programs with Trippoints cccccccccccceseeeeeeeeeeeeeeeeeeeeeeeees 29 Example 14 gt Control Vara Ole td T 29 Example 15 Linear Interpol a oes Cee Sa ee 30 Example 16 Circular Interpolation cccccccccccccseseeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 30 Chapter 3 Connecting Hardware 32 CDV CVG A A Selec sant AS 32 Usine OP EE BEER 32 e EE A 32 a A 33 ADO AU 33 ELO Electronice Lock QUID ie 34 o EE 34 Uncommitted Digital plis bi 34 Wiring the Optoisolated Inputs said dd ii 34 Electrical SPE Cit Call ONS eegene 34 BieDirectional E E 34 Using an Isolated Power Supp 36 Bypassing the Opto solation ccccccccccccnnnnininnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnn nn nn rn 37 e e EE 37 The Auxiliary Encoder PUES A A A AA AA 37 High Power Opto Isolated Outpnuts cccccccccccceeccceeeeeessesseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 38 Electrical PEACE A A A 38 Wiring the Opto Isolated Outputs oocccnnnnncnnccccnnnonononinnnnninininininnnnnnnnnnnnnnnnnnnannnnnos 38 EE EES e Ee ee Eege 39 PSE ns EN o e a 39 Electrical SPECI CALLOUS eege egener aaa 39 REES SEET 39 UU OA A cca eegend ege 39 PURO dol a 39 Extended LO of the DMC 40x0 Controller sara ia 40 Electrical Specifications 3 3V Standard 40 Electrical Specifications 5V Option id sienna 40 Amper IMENICE add 41 Electri
60. 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 1t 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 40x0 is used to jog the A and B axis This program automatically begins upon power up and allows the user to input values from the main serial port terminal 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 Instruction Interpretation AUTO Label for Auto Execute speedA 10000 Initial A speed speedB 10000 Initial B speed CE 2 Set Port 2 for Character Interrupt JG speedA speedB Specify jog mode speed for A and B axis BGXY Begin motion PRINT Routine to print message to terminal MG P2 TO CHANGE SPEEDS Print message MG P2 TYPE A OR B MG P2 TYPE S TO STOP JOGLOOP Loop to change Jog speeds JG speedA speedB Set new jog speed JP JOGLOOP EN End of main program 150 e Chapter 7 Application Programming DMC 40x0 COMINT JP A P2CH A JP By P2CH B JP HE P2CH 5 ZS1 C1I2 JIP JOGLOOP A JS NUM speedX val Z281 C12 JPR PRINT B JS NUM speedY val ZS1 C1I2 JIP PRINT C ST AMX CI 1 MG 8 THE END ZS EN 1 NUM MG ENTER P2CH S
61. command must move the motor to find the zero commutation phase This movement is instantaneous and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The applied voltage will typically be sufficient for proper operation of the BZ command For systems with significant friction this voltage may need to be increased and for systems with very small motors this value should be decreased For example BZ 2 0 1 will drive both A and C axes to zero will apply 2V and 1V respectively to A and C and will end up with A in SH and C in MO Step F part 2 Systems with Hall Sensors Only Set Zero Commutation Phase With Hall sensors the estimated value of the commutation phase is good to within 30 This estimate can be used to drive the motor but a more accurate estimate is needed for efficient motor operation There are 3 possible methods for commutation phase initialization Method 1 Use the BZ command as described above Method 2 Drive the motor close to commutation phase of zero and then use BZ command This method decreases the amount of system jerk by moving the motor close to zero commutation phase before executing the BZ command The controller makes an estimate for the number of encoder counts between the current position and the position of zero commutation phase This value is stored in the operand BZn Using this operand the controller can be commanded to move the motor The BZ command is then i
62. commutated motor requires two DACs In standard servo operation the DMC 40x0 has one DAC per axis In order to have the additional DAC for sinusoidal commutation the controller must be designated as having one additional axis for each sinusoidal commutation axis For example to control two standard servo axes and one axis of sinusoidal commutation the controller will require a total of four DACs and the controller must be a DMC 4040 Sinusoidal commutation is configured with the command BA For example BAA sets the A axis to be sinusoidally commutated The second DAC for the sinusoidal signal will be the highest available DAC on the controller For example Using a DMC 4040 the command BAA will configure the A axis to be the main sinusoidal signal and the D axis to be the second sinusoidal signal The BA command also reconfigures the controller to indicate that the controller has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAA is given to a DMC 4040 controller the controller will be re configured to a DMC 4030 controller By definition a DMC 4030 controls 3 axes A B and C The D axis is no longer available since the output DAC is being used for sinusoidal commutation Further instruction for sinusoidal commutation connections are discussed in Step 6 DMC 40x0 Chapter 2 Getting Started e 13 Stepper Motor Operation To configure the DMC 40x0 for stepper motor operation the co
63. corresponding axis 1s unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input corresponding to that axis The commanded position of the stepper can be interrogated with RP or TD The encoder position can be interrogated with TP 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 Programming Motion for more information The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a range between 0 25 and 64 where 64 implies the largest amount of smoothing See Command Reference regarding KS The DMC 40x0 profiler commands the step motor amplifier All DMC 40x0 motion commands apply such as PR PA VP CR and JG The acceleration deceleration slew speed and smoothing are also used Since step motors run open loop the PID filter does not function and the position error is not generated To connect step motors with the DMC 40x0 you must follow this procedure If you have a Galil integrated stepper driver skip Step A the step and direction lines are already connected to the driver Step A Connect step and direction signals from controller to motor amplifier From the controller to respective signals on your step motor amplifier These signals are labele
64. 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 _ LFx or MG LRx This prints the value of the limit switch operands for the x axis The logic state of the limit switches can also be interrogated with the TS command For more details on TS see the Command Reference 32 e Chapter 3 Connecting Hardware DMC 40x0 Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states O 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 40x0 Find Edge FE Find Index FI and Standard Home HM The Find Edge routine 1s initiated by the command sequence FEX lt return gt BGX lt return gt 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 hom
65. describe the 500mA optically isolated outputs that are used on the ICM 42x00 Electrical Specifications Output Common Max Voltage 30 VDC Output Common Min Voltage 12 VDC Max Drive Current per Output 0 5 A not to exceed 3A for all 8 outputs Wiring the Opto Isolated Outputs The ICM 42x00 module allows for opto isolation on all of the digital inputs and outputs The digital outputs are optically isolated and are capable of sourcing up to 0 5 A per pin with a 3 A limit for the group of 8 outputs The outputs are configured for hi side drive only The supply voltage must be connected to output supply voltage OPWR and the supply return must be connected to output return ORET Figure 3 3 shows the manner in which the load should be connected The output will be at the voltage that 1s supplied to the OPWR pin Up to 30 VDC may be supplied to OPWR 3 3W OPwR VO A D O DO 8 1 CPU IRF Tae fs MMBD1204 40 LOAD ORET VO A D rA AW CPW 1 0 E H d Ay a df DO 16 5 EH GPU 1 IRF7342 7 MMED1204 10K ORET 1 0 E H Figure 3 3 ICM 42x00 General Purpose Digital Output Opto Isolation 4080 For controllers with 5 8 axes outputs 9 16 are located on the I O E H D Sub connector The OPWR and ORET for these outputs are also found on the I O E H D Sub connector Connections to the OPWR and ORET on the I O E H as described above are required for operation of outputs 9 16 38 e Chapter 3 C
66. element has a numeric range of 4 bytes of integer 231 followed by two bytes of fraction 2 147 483 647 9999 DMC 40x0 Chapter 7 Application Programming e 145 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 Defining Arrays An array 1s 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 uppercase 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 DM POSX 0 Frees array space Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the POSX array defined with the DM command DM POSX 7 would be specified as POSX 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples
67. field may be used MF x y z w Trippoint for forward motion past specified value Only one field may be used Example Simple Master Slave Master axis moves 10000 counts at slew speed of 100000 counts sec Y is defined as the master X Z W are geared to master at ratios of 5 5 and 10 respectively GA Y Y Y Specify master axes as Y CR Syy s DLO Set gear ratios PR 10000 Specify Y position SP 100000 Specify Y speed BGY Begin motion Example Electronic Gearing Objective Run two geared motors at speeds of 1 132 and 0 045 times the speed of an external master The master is driven at speeds between 0 and 1800 RPM 2000 counts rev encoder Solution Use a DMC 4030 controller where the Z axis is the master and X and Y are the geared axes MO 2 Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GR 1 132 045 Specify gear ratios Now suppose the gear ratio of the X axis is to change on the fly to 2 This can be achieved by commanding GR 2 Specify gear ratio for X axis to be 2 Example Gantry Mode In applications where both the master and the follower are controlled by the DMC 40x0 controller it may be desired to synchronize the follower with the commanded position of the master rather than the actual position This eliminates the coupling between the axes which may lead to oscillations For example assume that a gantry is driven by two axes X Y on both sides This requires the g
68. for Monitoring Conditions ccccccccnncnnnnncnnnnnnnnnnnnninininininanos 137 Mathematical and Functional Expressions viii id iaa 141 Mathematical Operators earn ia 141 Bit WSS TE 142 FONCIONS eane a E ATA 142 O satay see wal EE 143 Programmable Variables Amirna ee ee 143 BUT EE 145 Special Operands AE aia 145 Eege 145 Det AS a 146 ASSionment O Array ENE a a 146 Automatic Data Capture into Arrays ii ia 147 Desallocatino ATi Ay Space ra ea 148 Input of Data Numeric and Smng nono nono nono nono nono nono nono n nn nn ono n o nn n nn nnnnnss 148 rte eg E 148 Operator Data Entry e E 149 Using Communication Interrupt 150 Output of Data Numeric and String ooooooooooooooonnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnon ono n nono nn nro nn nro nnnnnnnnnnos 151 Sendo MESES a 151 Displaying Variables and Arraws 153 Interrogation Commands eise esst geesde dee 153 Formatting Variables and Array Elements 154 Conyertino to User EC 155 Eech 156 Dita ege Gegend 156 EEN Eegeregie 157 The Auxiliary Encoder pulsar 157 Input interrupt FUNCION a ae obs 158 A T iit te tated 158 Extended I O of the DMC 40x0 Controller casados ia less 159 Configuring the I O of the Eeer iere 159 Saving the State of the Outputs in Non Volatile Memor 160 Accessmo EE DE EE 160 enee 161 Contents e v E E 161 A Lab CAM dos 162 Speed Control Dy Joy ska tos 164 Position Control by Jovspck 165 Backlash Compensation by Sampled Dua Loop 165 Chapter 8 Hardware amp Softw
69. function II or use a conditional jump on an input such as JP GO QIN 1 INPUT AI 1 PR 10000 BGX EN E ls 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 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 1s measured from the start of the move or from the last AV command VECTOR VMXY 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 MOVES PR 12000 SP 20000 AC 100000 BGX AD 10000 SP 5000 AMX WT 200 PR 10000 132 e Chapter 7 Application Programming 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 DMC 40x0 SP 30000 New Speed AC 150000 New Acceleration BGX Start Motion EN End Define Output Waveform Using
70. go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the AMPERR routine Bit 0 of TAO will be set 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 DMC 40x0 A1 AMP 43040 e 235 Over Temperature Protection The controller is also equipped with over temperature protection Rev A and Rev B amplifiers If the average heat sink temperature rises above 100 C then the amplifier will be disabled Bit 2 of TAO will be set when the over temperature occurs on the A D axis amplifier and Bit 6 of TAO will be set when the over temperature occurs on the E H axis amplifier The over temperature condition will trigger the AMPERR routine if included in the program on the controller The amplifier will re enable when the temperature drops below 100 C Rev C and newer amplifiers If the average heat sink temperature rises above 80 C then the amplifier will be disabled Bit 2 of TAO will be set when the over temperature occurs on the A D axis amplifier and Bit 6 of TAO will be set when the over temperature occurs on the E H axis amplifier The over temperature condition will trigger the AMPERR 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
71. is triggered then 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 FAMPERR 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 246 e A4 SDM 44140 DMC 40x0 Index ADO oie tose ies toed 1 86 92 169 171 189 204 5 OTT Opn Frror 33 169 171 Stop Motion eoo 86 92 139 172 Absolute Positl0M c om 26 78 79 13031 135 Absolute Value cc ooncccnnnocccnnnioconnn 100 135 144 170 Acceleranon 2 24 133 150 156 222 23 EE cidos 147 48 Amp litter Earle es 6 18 41 169 Amplifier Cam 3 5 20 179 183 185 Analog Input 1 4 32 39 81 144 45 146 159 166 189 224 Analysis A A E a 124 SA A O 16 20 Arithmetic Functions ooocccnnnnoccnnnnoccnnnicccnonosos 134 142 Ambas 122 Array 1 4 14 77 90 106 8 128 134 142 55 191 Automatic Subroutine ccooocccnnniccnnnnnocononicinnonas 126 138 CMDERR usada 126 138 140 INN aio 158 159 IKEA WEE 32 126 137 38 170 72 A ERD EE 126 130 138 139 POSERR ica 126 137 39 170 71 Ee EE 142 Auxiliary Encoder 98 109 16 109 16 109 16 Poal ENCOCEE ere e e 116 148 Baek EE 77 115 16 166 Backlash Compensation Dual Loop 77 109
72. limit to maximum 9 998 volts The maximum level of 9 998 volts provides the full output torque Example 9 Interrogation The values of the parameters may be interrogated Some examples Instruction Interpretation DMC 40x0 Chapter 2 Getting Started e 27 KP Return gain of A axis KP Return gain of C axis KP e Py Return gains of all axes Many other parameters such as KI KD FA can also be interrogated The command reference denotes all commands which can be interrogated Example 10 Operation in the Buffer Mode The instructions may be buffered before execution as shown below Instruction Interpretation PR 600000 Distance SP 10000 Speed WI 10000 Wait 10000 milliseconds before reading the next instruction BG A Start the motion Example 11 Using the On Board Editor Motion programs may be edited and stored in the controller s on board memory When the command ED is given from the Galil DOS terminal such as DMCTERM the controllers editor will be started The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited The editor provides the line number For example in response to the first ED command the first line 1s zero Line Instruction Interpretation 000 FA Define label 001 PR 700 Distance 002 SP 2000 Speed 003 BGA Start A motion 004 EN End program To exit the editor mode input lt cntrl gt Q The program may be executed with the comma
73. numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 80 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below 124 e Chapter 7 Application Programming DMC 40x0 Edit Mode Commands lt RETURN gt Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of lt RETURN gt will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a lt return gt 1s given lt cntrl gt P The lt cntrl gt P command moves the editor to the previous line lt cntrl gt I The lt cntrl gt I command inserts a line above the current line For example 1f the editor is at line number 2 and lt cntrl gt I is applied a new line will be inserted between lines 1 and 2 This new line will be labeled line 2 The old line number 2 1s renumbered as line 3 lt entr1 gt D The lt cntrl gt D command deletes the line currently being edited For example if the editor is at line number 2 and lt cntri gt D is applied line 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q The lt cntrl gt Q quits
74. 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 40x0 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 FLOOP JP LOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed SED Edit Mode DMC 40x0 Chapter 7 Application Programming e 137 000 LOOP Dummy Program 001 JP FLOOP EN Jump to Loop 002 LIMSWI Limit Switch Label 003 MG LIMIT OCCURRED Print Message 004 RE Return to main program lt control gt Q Quit Edit Mode XQ LOOP Execute Dummy Program JG 5000 Jog BGX 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 The RE command is used to return from the LIMSWI subroutine 2 The LIMSWI subroutine will be re executed 1f the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error ED Edit Mode 000 LOOP Dummy Program 001 JP LOOP EN Loop 002 FPOSERR Position Error Routine 003 Vl1l _ TEX Read Position Error 004 MG EXCESS POSITION ERROR Print Mes
75. oe 606606 506500000059 Poe o 00 0 aje o o o tja ale oo o dl RP PIN 1 12V Low Amp Enable Sourcing Configuration SHUNT AT 12V JP2 SHUNT AT GND From Default Configuration Move U4 up one pin location on socket Change JP1 to GND Ze Change JP2 to 12V CEP di cl l a lo rajado E U4 PIN 1 AAA O c6066506500600005909 RP2 PIN 1 a l o cy CH Cal Y Gs EN y a DMC 40x0 214 e Appendices Isolated Power High Amp Enable Sinking Configuration JP 2 M SHUNT AT AEC SHUNT AT AECI V AEC2 820 Ohms RPS FOr FOV EO Flav For FLV to 247 4 7K Ohms RP 6 From Default Configuration Change JP1 to AECI RP2 PIN 1 2 O o O 22 a N O n tE SE O lt Zz e y 6 SN af E oY o 7 om Us cd D 3 lt d di 5 O e N co RP6 PIN 1 AAA PHM O 60606 5060000006059 U4 PIN 1 Isolated Power Low Amp Enable Sinking Configuration JP2 SHUNT AT AEC SHUNT AT AECI V AEC2 820 Ohms RP 6 FOr VEO 12V FOr LSV to 24 4 7K Ohms RP 6 From Default Configuration Reverse RP2 U4 PIN 1 Change JP1 to AECI 2 Change JP2 to AEC2 If AECI is 13V to 24V Replace RP6 with 4 7K Resistor Pack 4 AAA e SERA TO OOS Ts FF 60665065006006005909 RP PIN 1 ES E d ng 200 Appendices e 215 DMC 40x0 Isolated Power High Amp Enable Sourcing Configuration al JP2 SHUNT AT AECI
76. on a PC screen CAD translation and program development using many environments such as Visual Basic C C etc Drivers for Windows XP 32 amp 64 bit DMC 40x0 Chapter 1 Overview e 1 Overview of Motor Types The DMC 40x0 can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Brushless servo motors with sinusoidal commutation 3 Step motors with step and direction signals 4 Other actuators such as hydraulics For more information contact Galil The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 40x0 achieves superior precision through 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 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 Brushless Servo Motor with Sinusoidal Commutation The DMC 40x0 can provide sinusoidal commutation for brushless motors BLM In this configuration the controller generates two sinusoidal signals for connection with amplifiers specifically designed for this purpose Note The task of generating sinusoidal commutation may be accomplishe
77. once This example code illustrates the use of DMCOpen and DMCCommand A connection is made to controller 1 in the Galil registry upon launching the application Then the controller is sent the command TPX whenever a command button is pressed The response is then placed in a text box When the application is closed the controller is disconnected To use this example start a new Visual Basic project place a Text Box and a Command Button on a Form add the DMCCOMA40 BAS module and type the following code Dim m_nController As Integer Dim m_hDmc As Long Dim m_nRetCode As Long Dim m_nResponseLength As Long Dim m_sResponse As String 256 Private Sub Command1_Click m_nRetCode DMCCommand m_hDmc TPX m_sResponse m_nResponseLength Textl Text Val m_sResponse End Sub Private Sub Form _ Load m_nResponseLength 256 m_nController 1 m_nRetCode DMCOpen m_nController 0 m_hDmc End SILO Private Sub Form_Unload Cancel As Integer m_nRetCode DMCClose m_hDmc End Sub Where m_nController is the number for the controller in the Galil registry m hDmce is the DMC handle used to identify the controller It is returned by DMCOpen m_nRetCode is the return code for the routine m_nResponseLength is the response string length which must be set to the size of the response string m_sResponse is the string containing the controller response to the command 68 e Chapter 4 Sof
78. only B axis only C axis only D axis only DMC 40x0 DP 0 2000 Define the current positions of A B as 0 and 2000 PA 7000 4000 Sets the desired absolute positions BG A Start A motion BG B Start B motion After both motions are complete the A and B axes can be command back to zero PA 0 0 Move to 0 0 BG AB Start both motions Example 7 Velocity Control Objective Drive the A and B motors at specified speeds Instruction Interpretation JG 10000 20000 Set Jog Speeds and Directions AC 100000 40000 Set accelerations DC 50000 50000 Set decelerations BG AB Start motion after a few seconds command JG 40000 New A speed and Direction TV A Returns A speed and then JG 20000 New B speed TV B Returns B speed These cause velocity changes including direction reversal The motion can be stopped with the instruction ST Stop Example 8 Operation Under Torque Limit The magnitude of the motor command may be limited independently by the instruction TL Instruction Interpretation TETU z2 Set output limit of A axis to 0 2 volts JG 10000 Set A speed BG A Start A motion In this example the A motor will probably not move since the output signal will not be sufficient to overcome the friction Ifthe motion starts it can be stopped easily by a touch of a finger Increase the torque level gradually by instructions such as Instruction Interpretation TI LO Increase torque limit to 1 volt TL 9 998 Increase torque
79. 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 Galil recommends that the user wait for an acknowledgement of receipt of a packet 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 40x0 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 40x0 unit use the TH command A sample is shown here with a unit that has a serial number of 3 Sample MAC Ethernet Address 00 50 4C 20 04 AF The second level of addressing is the IP address This is a 32 bit or 4 byte number that usually 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 40x0 controller can be done in a number of ways The first method for setting the IP address 1s using a DHCP server The DH command controls whether the DMC 40x0 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
80. please contact Galil DOMC 4040 Figure Al 1 DMC 4040 C012 I000 D3040 DMC 4040 with AMP 43040 DMC 40x0 A1 AMP 43040 e 231 Electrical Specifications The amplifier is a brush brushless trans conductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage 18 80 VDC Continuous Current 7 Amps Peak Current 10 Amps Nominal Amplifier Gain 0 7 Amps Volt Switching Frequency 60 kHz up to 140 kHz available contact Galil Minimum Load Inductance 0 5 mH Inverter mode 0 2 mH Chopper Mode Brushless Motor Commutation angle 120 60 option available Mating Connectors POWER 6 pin MATE N LOK MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector 232 e A1 AMP 43040 DMC 40x0 Operation Brushless Motor Setup Note If you purchased a Galil motor with the amplifier it is ready for use No additional setup is necessary To begin the setup of the brushless motor and amplifier it is first necessary to have communications with the motion controller Refer to the user manual supplied with your controller for questions regarding controller communications It is also necessary to have the motor hardware connected and the amplifier powered to begin the setup pha
81. position These commands are detailed below Current Level Setup AG Command AG configures how much current the SDM 44140 delivers to each motor Four options are available 0 5A 1 0A 2 0A and 3 0Amps Note when using the 3 0A setting mounting the unit to a metal or heat dissipating surface is recommended Drive Current Selection per Axis AG n n n n n n n n n 0 OSA n 1 1 A default n 2 2A n 3 30A Low Current Setting LC Command LC configures each motor s behavior when holding position when RP is constant and multiple configurations LC command set to 0 Full Current Mode causes motor to use 100 of peak current AG while at a resting state profiler is not commanding motion This is the default setting LC command set to 1 Low Current Mode causes motor to use 25 of peak current while at a resting state This is the recommended configuration to minimize heat generation and power consumption LC command set to an integer between 2 and 32767 specifying the number of samples to wait between the end of the move and when the amp enable line toggles Percentage of full AG current used while holding position with LC n n n n n n n n 100 The LC command must be entered after the motor type has been selected for stepper motor operation e M T 2 2 2 2 LC is axis specific thus LC1 will cause only the X axis to operate in Low Current mode ELO Input If the ELO input on the controller
82. 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 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 Data which is output from the controller is stored in the output UART The UART buffer can store up to 512 characters of information In normal operation the controller places output into the FIFO buffer When the trace mode is enabled the controller will send information to the UART buffer at a very high rate In general the UART will become full because the hardware handshake line will halt serial data until the correct data is read When the UART becomes full program execution will be delayed until it is cleared If the user wants to avoid this delay the command CW 1 can be given This command causes the controller to throw away the data which can not be placed into the FIFO In this case the controller does not delay program execution Error Code Command When there is a program error the DMC 40x0 halts the program execution at the p
83. stored in the array DIF Finally the motors are run in the contour mode 106 e Chapter 6 Programming Motion DMC 40x0 Contour Mode Example INSTRUCTION POINTS DM POS 16 DM DIF 15 C 0 T 0 A VI 50 T V2 3 T V3 955 SIN V2 V1 V4 INT V3 POS C v4 T T 8 C C 1 JP A C lt 16 B C 0 C D C 1 DIF C POS D POS C C C 1 JP C C lt 15 RUN CMX DT3 C 0 E CD DIF C C C 1 JP AR Gelb CD 0 0 Wait JDP Wait CM lt gt 511 EN INTERPRETATION Program defines X points Allocate memory set initial conditions C is index T is time in ms Argument in degrees Compute position Integer value of V3 Store in array POS Program to find position differences Compute the difference and store Program to run motor Contour Mode 8 millisecond intervals Contour Distance is in DIF End contour buffer Wait until path is done End the program Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 40x0 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 Clin RA C RD _TPX RC n m RC or Re DMC 40x0 Dimension array Specify array for automatic record up to 4 for DMC 4040 Specify data for capturing such as _TPX or _TPZ Specify capture time interval where n is 2 sample periods 1
84. 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 FLIMSWI Limit Switch Utility V1 _LFX Check if forward limit V2 _LRX Check 1f 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 LE LF MG FORWARD LIMIT Send message STX AMX Stop motion PR 1000 BGX AMX Move in reverse JP END End LR LR MG REVERSE LIMIT Send message STX AMX Stop motion PR1000 BGX AMX Move forward END End RE Return to main program DMC 40x0 Chapter 8 Hardware amp Software Protection e 171 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 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 Adjusting offset causes the 1 Amplifier has an Adjust amplifier offset Amplifier co
85. table which summarizes the relationship between the various filters Equivalent Filter Form DMC 40x0 Digital D z K z A z Cz z 1 1 B Z B Digital D z KP KD 1 71 KI 2 1 z7 1 B Z B KP KD KI PL K KP KD A KD KP KD C KI 2 B PL Continuous G s P Ds I s a sta PID T P KP D T KD I KI 2T a 1 T In 1 PL 186 e Chapter 10 Theory of Operation DMC 40x0 THIS PAGE LEFT BLANK INTENTIONALLY DMC 40x0 Chapter 10 Theory of Operation e 187 Appendices Electrical Specifications Servo Control MCMn Amplifier Command 10 volt analog signal Resolution 16 bit DAC or 0 0003 volts 3 mA maximum Output impedance 500Q MA MA MB MB MI MI Encoder andTTL compatible but can accept up to 12 volts Auxiliary Stepper Control STPn Step DIRn Direction Input Output Limit Switch Inputs Home Inputs DII thru DIS Uncommitted Inputs and Abort Input DI9 thru DI16 Uncommitted Inputs DMC 4050 through DMC 4080 only AII thru AI8 Analog Inputs DO1 thru DOS Outputs DO9 thru DO16 Outputs DMC 4050 through DMC 4080 only 188 e Appendices Quadrature phase on CHA CHB Can accept single ended A B only or differential A A B B Maximum A B edge rate 12 MHz Minimum IDX pulse width 80 nsec TTL 0 5 volts level at 50 duty cycle 3 000 000 pulses sec maximum frequency TTL 0 5 volts 2 2K ohm in series with opto isolator A
86. 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 1s as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step output pulses 2 5 specifies a stepper motor with active low step output pulses and reversed direction 2 5 specifies a stepper motor with active high step output pulse and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought 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 1s 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 Moni
87. that the serial port on the controller must be set for handshake mode for proper communication with Galil software The user must also insure that a straight through serial cable is being used NOT a Null Modem cable see appendix for pin out of serial cable Using Non Galil Communication Software The DMC 40x0 main serial port is configured as DATASET Your computer or terminal must be configured as a DATATERM for full duplex no parity 8 data bits one start bit and one stop bit Check to insure that the baud rate jumpers have been set to the desired baud rate as described above Your computer needs to be configured as a dumb terminal which sends ASCII characters as they are typed to the DMC 40x0 Sending Test Commands to the Terminal After you connect your terminal press lt return gt or the lt enter gt key on your keyboard In response to carriage return lt return gt the controller responds with a colon Now type TPA lt return gt This command directs the controller to return the current position of the A axis The controller should respond with a number such as 20 Step 6 Determine the Axes to be Used for Sinusoidal Commutation This step is only required when the controller will be used to control a brushless motor s with sinusoidal commutation The command BA is used to select the axes of sinusoidal commutation For example BAAC sets A and C as axes with sinusoidal commutation Notes on Configuring
88. the editor mode In response the DMC 40x0 will return a colon After the Edit session is over the user may list the entered program using the LS command If no operand follows the LS command the entire program will be listed The user can start listing at a specific line or label using the operand n A command and new line number or label following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation Sis List entire program ES 5 Begin listing at line 5 LS 579 List lines 5 thru 9 LS A 9 List line label A thru line 9 IS RA A 5 List line label A and additional 5 lines Program Format A DMC 40x0 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 conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 40x0 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 40x0 programs must begin with a label and
89. too high The delay in servo systems 1s 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 filter 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 1t 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 whet
90. value of the step count register for the x axis OTP Contains the value of the main encoder for the x axis _DEx _DPx _ITx _KSx _MTx _RPx _TDx _TPx 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 significant 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 FPOSERR 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 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 Mai
91. 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 40x0 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and 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 511 returned means the buffer is empty and 511 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 IT is the s curve smoothing constant used with coordinated motion Specifying Vector Speed for Each Segment The vector speed may be specified by the immed
92. whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 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 m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 200070 Step 4 Specify the slave positions Next we specify the slave positions with the instruction ET n x y Z w where n indicates the order of the point The value n starts at zero and may go up to 256 The parameters x y z w indicate the corresponding slave position For this example the table may be specified by ET O 0 ET 1L 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 EB Ti 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 SX Sop Zo where x y z w are the mast
93. will be F signal The first phase of the C axis will be the motor command C signal The second phase of the C axis will be the motor command G signal Step 7 Make Connections to Amplifier and Encoder If the system is run solely by Galil s integrated amplifiers or drivers skip this section the amplifier is already connected to the controller Once you have established communications between the software and the DMC 40x0 you are ready to connect the rest of the motion control system The motion control system typically consists of the controller with interconnect module an amplifier for each axis of motion and a motor to transform the current from the amplifier into torque for motion System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 40x0 There can also be a combination of axes running from Galil integrated amplifiers and drivers and external amplifiers or drivers If sinusoidal commutation 1s to be used special attention must be paid to the reconfiguration of axes see above section for more information Connecting to External Amplifiers Here are the first steps for connecting a motion control system Step A Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply Ifthe amplifiers are operating properly
94. will take place on all axes Here are some examples of syntax for requesting action BG A Begin A only BG B Begin B only BG ABCD Begin all axes BG BD Begin B and D only BG Begin all axes 4080 For controllers with 5 or more axes the axes are referred to as A B C D E F G H The specifiers X Y Z W and A B C D may be used interchangeably BG ABCDEFGH Begin all axes BG D Begin D only Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S or T is used to specify the coordinated motion This allows for coordinated motion to be setup for two separate coordinate systems Refer to the CA command in the Command Reference for more information on specifying a coordinate system For example BG S Begin coordinated sequence S BG TW Begin coordinated sequence T and D axis DMC 40x0 Chapter 5 Command Basics e 71 Command Syntax Binary advanced Some commands have an equivalent binary value Binary communication mode can be executed about 20 faster than ASCII commands Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format All binary commands have a 4 byte header and 1s followed by data fields The 4 bytes are specified in hexadecimal format Header Format Byte 1 specifies the command number between 80 to FF The complete binary command number table is listed below Byte 2 specifies the of bytes in e
95. 0 Chapter 6 Programming Motion e 83 Figure 6 3 Velocity vs Time msec Motion 2 Example Motion 4 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 4 shows the plot of position vs time Figure 6 5 plots velocity vs time and Figure 6 6 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 Figure 6 4 Position vs Time msec Motion 4 84 e Chapter 6 Programming Motion DMC 40x0 Figure 6 5 Velocity vs Time Motion 4 Figure 6 6 Velocity cts sec vs Time msec with IT 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 Trip Points Most trip points 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 MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position DMC 40x0 Chapter 6 Programming Motion e 85 Command Summary Position Tracking Mode MF n n n n n n n n Trip point to hold up program execution until n number of counts have passed in the f
96. 00 000 counts sec servo 6 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1 10 4 16000 elements 30 arrays 2000 lines x 80 characters DMC 40x0 Fast Update Rate Mode The DMC 40x0 can operate with much faster servo update rates than the default of every millisecond This mode is known as fast mode and allows the controller to operate with the following update rates DMC 4010 DMC 4020 DMC 4030 DMC 4040 DMC 4050 DMC 4060 DMC 4070 DMC 4080 31 25 usec 31 25 usec 62 5 usec 62 5 usec 93 75 usec 93 75 usec 125 usec 125 usec In order to run the DMC 40x0 motion controller in fast mode the fast firmware must be uploaded This can be done through the Galil terminal software such as DMCTERM and WSDK The fast firmware is included with the original DMC 40x0 utilities In order to set the desired update rates use the command TM When the controller is operating with the fast firmware the following functions are disabled Gearing mode Ecam mode Pole PL Analog Feedback AF Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in thread 2 8 Tell Velocity Interrogation Command TV Aux Encoders TD Dual Velocity DV Peak Torque Limit TK Notch Filter NB NF NZ DMC 40x0 Appendices e 191 Power Connectors for the DMC 40x0 Overview The DMC 40x0 uses Molex Pitch Mini Fit Jr Receptacle Housing connectors for connecting DC Power to the Amplifiers Controll
97. 00 counts in the positive direction when the logic state of DI goes high This can be accomplished by connecting a voltage in the range of 5V to 28V into INCOM of the input circuitry from a separate power supply A080 Controllers with more than 4 axes have an additional 8 general opto isolated inputs inputs 9 16 The INCOM for these inputs is found on the I O E H D Sub connector An additional 32 I O are provided at 3 3V 5V option through the extended I O These are not opto isolated NOTE INCOM and LSCOM for Inputs 9 16 and Limit and Home Switches for axes 5 8 are found on the connectors for the E H axes These are NOT the same INCOM and LSCOM for axes 1 4 DI9 DI16 INCOM I O E H D Sub connectors FLSE RLSE HOME LSCOM I O E H D Sub connector FLSF RLSF HOMF FLSG RLSG HOMG FLSH RLSH HOMH Wiring the Optoisolated Inputs Electrical Specifications Input Common INCOM Max Voltage 28 VDC Limit Common LSCOM Max Voltage 28 VDC Minimum Current to turn on Inputs mA Bi Directional Capability All inputs can be used as active high or low If you are using an isolated power supply you can connect the positive voltage of the supply Vs to INCOM or supply the isolated ground to INCOM Comnecting Vs to INCOM will configure the inputs for active low Connecting the isolated ground to INCOM will configure the inputs for active high If there is not an isolated available the Galil 5V or 12V and GND may be used It is recomme
98. 000 CR 0000 60 90 VP 200007 20000 20000 10000 10000 20000 Figure A 1 X Y Motion Path DMC 40x0 Appendices e 221 The first line describes the straight line vector segment between points A and B The next segment is a circular arc which starts at an angle of 180 and traverses 90 Finally the third line describes the linear segment between points C and D Note that the total length of the motion consists of the segments A B Linear 10000 units R A d2 T B C Circular 15708 360 C D Linear 10000 Total 35708 counts In general the length of each linear segment is Lx v Xk Yk Where Xk and Yk are the changes in X and Y positions along the linear segment The length of the circular arc is Li RiJA x 277 360 The total travel distance 1s given by p S k 1 The velocity profile may be specified independently in terms of the vector velocity and acceleration For example the velocity profile corresponding to the path of Fig A 2 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Fig A 2 Velocity 10000 time s d 0 05 A 0 357 qT 0 407 Figure A 2 Vector Velocity Profile The acceleration time Ta is given by _ VS 100000 VA 2000000 The slew time Ts is given by 0 055 222 e Appendices DMC 40x0 di Dc a OS a 0 05 0 307 s VS 100000 The total motion tim
99. 040 240 TO lee 240 EEC CAL EEN 241 Matina EE 241 EEN 242 Current Level Setup AG O A O eee 242 Low Current Setting LE Command iia 242 Step Drive Resolution Setting YA Command ooccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnnos 242 Fei ote a career o A anole tre 243 A4 SDM 44140 244 Mtro Tee EN 244 eelere ele Ehe 245 Matine Connectors oran 245 OD 210 00 ea E OO O A eegener 246 Current Level Setup AG Commande 246 Low Current Setting LC Commande 246 Eeer 246 Index 247 viii e Contents DMC 40x0 Chapter 1 Overview Introduction The DMC 40x0 Series are Galil s highest performance stand alone controller The controller series offers many enhanced features including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 40x0 provides two communication channels high speed RS 232 2 channels up to 115K Baud and 10BaseT Ethernet The controllers allow for high speed servo control up to 22 million encoder counts sec and step motor control up to 6 million steps per second Sample rates as low as 31 25 usec per axis are available A Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field The DMC 40x0 is available with up to eight axes in a single stand alone unit The DMC 4010 4020 4030 4040 are one thru four axes controllers and the
100. 16 109 16 109 16 166 E EE 16 49 Begin Motion 20 23 131 33 139 145 142 49 TAL yo ds 1 53 70 73 160 A Os ues Sabo EE 142 152 Burn 22 48 EEPROM raid 1 4 161 201 Bypassing Optolsolati0ON ooooccnnnncnooooooononanooooonnnnnonnnoos 37 Capture Data RECO eege 77 105 107 146 148 o eebe 163 64 Circular Interpolation 30 91 94 96 148 163 Bi EE 157 204 Clear Soquente ais 86 88 92 94 DMC 40x0 Ee E 146 EMDERR ee ees ege 126 138 140 Code138 145 14249 162 63 165 67 Command Summary oocccccccnnnnnnnnnnnnnns 78 80 88 94 148 Commanded Position 79 80 96 98 140 148 175 77 Compensation Backlash ce 77 115 16 166 Conditional JUMP cccccccccnnnnnnnnncnnnnnns 34 129 133 35 Configuration dE 174 Contour Mods iaa ida 76 77 104 8 Control Filter IR Er 178 Et e 145 TAO eege Ee een 178 Proportional CUM aa 178 Coordinated Motion occcnocccnnniccnnnnorcnnniccononanos 76 91 94 A A ete nen 91 94 96 148 163 Contour Mode 76 77 104 8 Se E 100 103 Electronic Cam 76 77 99 101 Electronic Gearing oooccccncnnnnnnnnnnnnnnnnnnnos 76 77 95 99 Eh RE 76 77 95 99 Linear Interpolation 30 76 81 88 90 96 104 COSI eege 77 142 44 147 Cycle Time Keen 146 DAC178 181 83 185 Daw aecawars nT 178 Dat e aPC e aaa a 147 48 Data Record tad ii 56 60 61 A Cece setatebeee 128 DCCC ler aOR eiii etc 150 Digital Feiere Ae 182 83 185 87 Digital e cernere
101. 166 sn A CO 173 Integrator eiee EEE 24 25 178 Internal Variable onccnnnnnnnninn 30 135 144 145 Interrogati0n 24 26 27 74 75 89 95 154 155 A oie wate 133 137 39 A O 21 TES Jog 1 80 81 95 103 122 131 33 139 40 145 151 166 171 NOY SUC O A E E Hates 81 145 165 66 JOD ere 13 14 174 201 EAO E E E 134 142 144 146 47 EIME tra r 146 47 DMC 40x0 Label 24 81 87 91 101 3 108 116 122 130 39 145 46 150 164 166 67 171 EE a a onto 170 72 EE 170 71 Special GA DEL taa 126 172 E EE 5 75 121 Arm Bale EE 122 Data Capu Oi S 147 48 Position CAPI es 121 Record EE 77 105 107 146 148 KE WEE 107 Dn 138 146 170 72 TEINS WVU aereo 32 126 137 38 170 72 Linear Interpolation 30 76 81 88 90 96 104 Icaro ae 86 88 92 94 Logical Operatoren asera 134 150 Masking SE eieiei 142 152 Math Function Absolute Value ccconncccnnncccnn 100 135 144 170 BI Wisin 142 COSMO deed 77 142 44 147 MAA E 134 GE Mee 77 101 144 Mathematical Expression 0oooononnccooonooooooonnnnnnoss 142 144 METE dada 126 130 138 139 Memory 1 2 21 22 28 70 107 124 128 134 138 146 147 161 Amay nnnnnnn 4 77 90 106 8 128 134 142 55 191 Download isa ii 147 A A 124 Message 49 52 62 91 128 138 39 143 142 53 152 153 171 72 MODUS asen 52 53 54 55 225 A ete ee 175 178 79 183 Motion Complete LR WEE 126 130 13
102. 4 WV lhe CO We EE 162 KREE 16 20 e e Te EE 140 159 DMC 40x0
103. 8 139 Motion Smootbng 77 117 118 Ss A PTR AE EO PER ae 87 117 Motor Command 2 18 20 21 22 183 204 Moving Acce 133 150 222 23 Begin Moon 131 33 139 145 142 49 EE ee 91 94 96 148 163 Home OPUS Eesen 118 kreeg 127 Pala 87 133 34 OE OO EOL less 169 171 RE RE E ala 18 33 41 169 171 Operand Internal Variable nnnn 30 135 144 145 Operators E EE 142 Optoisolation Home MPU basar 33 146 DMC 40x0 Output Amplifier Enable 00000000000000aaaaeaeaao 6 18 41 169 DistalOttipPutlrai ao 1157 Ertor Opus ida cial 39 Motor Command 2 18 20 21 22 183 204 Step and Dmrectpon 2 PID 178 187 Een 77 149 POSERR gate these e rod 126 137 39 170 71 Position Error 126 138 39 145 148 166 Position CAP tad 121 E Ce 121 Fer EEN 107 Position Error116 126 138 39 145 148 166 169 71 177 POSERR dci 126 137 39 Poston ee asa 171 Program Flo W oooccnnnnnnninnnnnnnnonconarcocoronononoos 125 129 158 Interrupt 1 133 137 39 141 151 158 159 O O O AA TEEN 137 140 141 159 Programmable iris 144 46 166 170 A A eee N a 4 PROSCAR dada 24 70 76 eee mae ee 87 133 34 Proportional Cam 24 178 Protection Error Limit 18 20 25 39 41 138 169 71 Eege Er EE 20 27 e BEE 5 204 Quadrature 4 6 115 156 162 170 181 189 Quit A DOM EE 1 86 92 169 171 189 204 5 Stop MOU dias 86 92
104. 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 Program label ATO Initialize time reference SB1 Set Output 1 FLOOP Loop AT 10 After 10 msec from reference CB1 Clear Output 1 AT 40 Wait 40 msec from reference and reset reference SB1 Set Output 1 JP LOOP Loop EN Conditional Jumps The DMC 40x0 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 40x0 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 1f 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 wit
105. D Sub Connector Female 193 ICM 42000 External Driver A D 44 pin D Sub Connector Malen 194 ICM 42000 External Driver E H 44 pin D Sub Connector Male 194 vi e Contents DMC 40x0 ICM 42000 Encoder 15 pin D Sub Connector Femalei nos 195 ICM 42000 Analog 15 pin D sub Connector Male oooonnnnnnicicicanonnonanananananananonoss 195 Connectors for ICM 42200 Interconnect Board 196 ICM 42200 I O A D 44 pin D Sub Connector Female 196 ICM 42200 DMC 40x0 I O E H 44 pin D Sub Connector Female 196 ICM 42200 Encoder 26 pin D Sub Connector Femalei 197 ICM 42200 Analog 15 pin D sub Connector Male ooonnnnnnnicicicicnonannonananananana conos 197 Connectors for CMB 41012 Interconnect Board 198 CMB 41012 Extended I O 44 pin D Sub Connector Malen 198 RS 232 Mala Port Mala 198 RS 232 Auxihary POR Female anat 199 RS 422 Main Port Non Standard Option 199 RS 422 Auxiliary Port Non Standard Cptpon 200 r 200 Jumper Description for ICM 42000 and CMR AIOI 201 Cable Connections for DNC A OKO iscsi ad dad 202 Standard RS 232 Specifications E 202 DMC 40x0 Serial Cable Ee e 203 PinzOut Description tor WiC A OKO a asioin E ya 204 Configuring the Amplifier Enable Circula da 206 IC M42000 and IC NA DV OO ice sled dd 206 DMC 404 OC Steps 1 ANG did 206 RITTER 208 DMC 4040 and DMC 4080 Step 2 210 DMC 4040 Steps and ii a lake Se 217 DIMC 4080 Steps 4 and5 DE 219 Co
106. Data in Data in Data Record Record Record Record Record Record Record Record Bytes 2 3 of Header 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 Thread Status 1 Byte pri pri BIT BIT6 BITS BITS BIT BIT4 BIT BIT3 BIT BIT2 BIT BIT BIT BITO Thread 7 EN 6 Thread 5 EZ 4 E 3 E 2 E l E 0 Running Running Running Running Running Running Running Running Coordinated Motion Status for S or T Plane 2 Byte BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in N A N A 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 0 Motion Motion iS iS slewing stopping due to ST or Limit Switch 60 e Chapter 4 Software Tools and Communication DMC 40x0 Axis Status 1 Word BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in Mode of Mode of FE Home 1 Phase 2 Phase Mode of Progress Motion Motion Find HM in of HM of HM Motion PA or PA only Edge in Progress complete complete Coord PR Progress or FI Motion command issued BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Negative Mode of Motion Motion i Latch is 3rd Phase Motor Direction Motion 1S iS i armed of HM in Off Move slewing stopping i Progress due to Contour ST of Limit Axis Switches 1 Byte
107. ELSE MG ONLY INPUT 1 IS ACTIVE ENDIF ELSE MG ONLY INPUT 2 IS ACTIVE ENDIF WAIT JP WAIT IN 1 0 IN 2 0 RIO Subroutines Begin Main Program TEST Enable input interrupts on input 1 and input 2 Output message Label to be used for endless loop Endless loop End of main program Input Interrupt Subroutine IF conditional statement based on input 1 20 TF conditional statement executed if 1 TF conditional true Message to be executed if 2 IF conditional is true ELSE command for 2 IF conditional statement Message to be executed if 2 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 1 IF conditional statement is false End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 2 are not active End Input Interrupt Routine without restoring trippoints 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 1s manipulated as described in the following section Example An example of a subroutine to draw a s
108. 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 the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy 1s 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 controller commands the motor to move to a new rotary position which eliminates the position error DMC 40x0 Chapter
109. EX F INDEX PULSES POSITION POSITION Figure 6 16 Homing Sequence for Normally Closed Switch and CN 1 120 e Chapter 6 Programming Motion DMC 40x0 Example Find Edge HEDGE Label AC 2000000 Acceleration rate DC 2000000 Deceleration rate SP 8000 Speed FE Find edge command BG Begin motion AM After complete MG FOUND HOME Send message DP 0 Define position as 0 EN End Command Summary Homing Operation FE XYZW Find Edge Routine This routine monitors the Home Input FI XYZW Find Index Routine This routine monitors the Index Input HM XYZW Home Routine This routine combines FE and FI as Described Above SC XYZW Stop Code TS XYZW Tell Status of Switches and Inputs Operand Summary Homing Operation operand Description _HMx Contains the value of the state of the Home Input _SCx Contains stop code _TSx 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 The DMC 40x0 provides a position latch feature This feature allows the position of the main or auxiliary encoders of X Y Z or W to be captured within 25 microseconds of an external low input signal or index pulse The general inputs 1 through 4 and 9 thru 12 correspond to each axis 1 through 4 9 through 12 IN1 X axis latch IN9 E axis latch IN2 Y axis latch IN10 F axis latch IN3 Z axis la
110. If at any time the Halls are in an invalid state the appropriate bit of TAI will be set The state of the Hall inputs can also be monitored through the QH command Hall errors will cause the amplifier to be disabled if OE 1 is set and will cause the controller to enter the FAMPERR subroutine if it is included in a running program Under Voltage Protection If the supply to the amplifier drops below 12 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 12V threshold bit 3 of the error status TAO will tell the user whether the supply is in the acceptable range Note If there is an AMPERR routine and the controller is powered before the amplifier then the FKAMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 92 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V This error is monitored with bit 1 of the TAO command 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 AMP 43040 is a trans conductance amplifier the amplifier will never
111. Input Voltage 5 25 VDC Guarantee High Voltage 2 0 VDC Guarantee Low Voltage 0 8 VDC Inputs are internally pulled up to 5V through a 4 7kQ resistor Outputs Sink Source 20mA 40 e Chapter 3 Connecting Hardware DMC 40x0 Amplifier Interface Electrical Specifications Max Amplifier Enable Voltage 24V Max Amplifier Enable Current 24V sink source 25 mA Motor Command Output Impedance 500 Q Overview The DMC 40x0 command voltage ranges between 10V and is output on the motor command line MCMn where nis A H 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 Note The DMC 40x0 controller has an option for differential motor command outputs For more information contact Galil The DMC 40x0 also provides an amplifier enable signal AENn where n is A H This signal changes under the following conditions the motor off command MO is given the watchdog timer activates or the OE command Enable Off On Error is set and the position error exceeds the error limit or a limit switch is reached see OE command in the Command Reference for more information For all versions of the ICM 42x00 the standard configuration of the amplifier enable si
112. LUE T I 1 224 e Appendices Interpretation Label Establish connection Wait 10 milliseconds Jump to subroutine Configure digital outputs Configure analog outputs Configure analog inputs Save configuration to OPTO 22 End Label Set variable Set variable Set variable Jump to subroutine Label Set variable Set variable Set variable Jump to subroutine Label Set variable Set variable Set variable Jump to subroutine Label Dimension array Set variable Loop subroutine Set array element Increment Set array element Increment DMC 40x0 JP CFGLOOP I lt 2 NUMOF IO Conditional statement MBF 6 16 632 MODULE 8 NUM Configure I O using Modbus function code 16 where OFIO 2 A the starting register is 632 MODULE 8 number of registers is NUMOFIO 2 and A contains the data EN end CFERR Label MG UNABLE TO ESTABLISH Message CONNECTION EN End Using the equation I O number Handlenum 1000 Module 1 4 Bitnum 1 MG IN 6001 display level of input at handle 6 module 1 bit 2 SB 6006 set bit of output at handle 6 module 2 bit 3 or to one OB 60061 AO 608 3 6 set analog output at handle 6 module 53 bit 1 to 3 6 volts MG AN 6017 display voltage value of analog input at handle6 module 5 bit 2 DMC 40x0 Appendices e 225 DMC 40x0 DMC 2200 Comparison Faster servo operation good for very 22 MHz encoder speed for servos 12 MHz high resolution sensors Fas
113. MAS Ne SNS Cos ote te Sy eege 70 Coordinated Motion with more than 1 as 71 Command Syntax Binary Godhvanced nono non nnn nono cnn nn non nn cnn conos TZ Binary Command DIAM I2 Binary command table lat 73 Controller Respons eto DA LA A A AA eee 74 tere Cont lt OS 74 Interrogation Command ss sire eee eee ee ee 74 Summary of Interrogation Commands eeneneeesessseenssersrresrrrrrrrrrrrsrrrrrrrrrrrrrreeens 75 Interrogating Current Commanded Values 00000000ooosooonnnnenennenenennennnneressseeeesesesees 75 Operan EE 75 Command SUMM ee 75 Chapter 6 Programming Motion 76 ONES Ee Eege 76 AE EUA fo AXIS KEIER eegene 78 Command Summary Independent AXIS 00oooocooooooooooooonnnnnnnnnnononononnnononnnno nono nonnnnnnnnnos 78 Operand Summary Independent AXIS 0ooooncccononooaooonooonono nono nnnn nono nono nono nnnnn nono nnnnn conos 78 Eet Wee e EE 80 Contents e iii iv e Contents Command Summary Jogging ooooocoooooooooooooooononnnnnnnnnnonnononnn nn non nono nono nono nn n non nono nnnnnnos 80 Operand Summary Independent AXIS 0ooooocccccononaooooooonono nono nono nono nono nono non nn nono nnnnnnonnos 81 Position Er E 81 Example MOON ere Ee 83 Example Motonet added dede coo 84 A ance ceed A 85 Command Summary Position Tracking Mode 86 Linear interpolat n Mode Eelere 86 Specifyin Lincar Com ads 86 Command Summary Linear Interpolati0M ooooncnnccuunanaoanananonononoooronrrn ono nnnnnnnnonon
114. MCMH Motor Command H 1 Negative differential motor command outputs when DIFF option is ordered on ICM Ex DMC 4040 C012 I000 DIFF These pins may be used for other functions when DIFF option is not ordered 194 e Appendices DMC 40x0 ICM 42000 Encoder 15 pin HD D Sub Connector Female Pin l 2 S A E ICM 42000 Analog 15 pin D sub Connector Male DMC 40x0 Pine taba Description Ps aonn sier CO TT Ps aonn EEUU E 7 14 Analog Input 8 Appendices e 195 Connectors for ICM 42200 Interconnect Board ICM 42200 I O A D 44 pin HD D Sub Connector Female Ping Label Description Pint Label Description Ping Label Description 3 pi Digital input 4 D latch Digital Input 3 C latch Digital Input 5 ELO Electronic Lock Out ABRT Abort Input Digital Ground HOMA Home Switch A Reverse Limit Switch A FLSB Forward Limit Switch B A HOMB Home Switch B Reverse Limit Switch B FLSC Forward Limit Switch C nu HOMC Home Switch C RLSC Reverse Limit Switch C FLSD Forward Limit Switch D HOMD Home Switch D RLSD Reverse Limit Switch D Digital Ground Dis fv TA ICM 42200 DMC 40x0 I O E H 44 pin HD D Sub Connector Female A080 For DMC 4050 thru DMC 4080 controllers only Pint Label Description Em Label Description Pint Label Seege 1 Um L ec eg RST L t ano iil o pw beams ewn 17 INCOM renge 32 ono Genie CMP a fw a jw wi 196 e Appendices DMC 40x0
115. N 2 DMC 40x0 lt oh Sch 5V 5V 5V 990 O_O LOW AMP ENABLE 990 CPU AEN AEN TO DRIVE SOURCING odo i STEE PIN 2 MOn 0V 10K Si 626 z 000 5V 12V 12V 288 O_O LOW AMP ENABLE z o CPU AEN AEN TO DRIVE SOURCING odo SECH PIN 2 MOn 0V 10K lt f 0 AMP ENABLE POWER a oso EN PIN 20 de O 9 Q ISOLATED SUPPLY 020 LOW AMP ENABLE 990 CPU AEN AEN TO DRIVE SOURCING oie SEN PIN 2 MOn 0V 10K AMP ENABLE RETURN PIN 11 DMC 40x0 Chapter 3 Connecting Hardware e 47 Chapter 4 Software Tools and Communication Introduction The default configuration DMC 40x0 has two RS232 ports and 1 Ethernet port The main RS 232 port is the data set and can be configured through the jumpers on the top of the controller The auxiliary RS 232 port is the data term and can be configured with the software command CC The auxiliary RS 232 port can be configured either for daisy chain operation or as a general port This configuration can be saved using the Burn BN instruction The RS232 ports also have a clock synchronizing line that allows synchronization of motion on more than one controller Galil software is available for PC computers running Microsoft Windows to communicate with the DMC 40x0 controller Standard Galil communications software utilities are available for Windows operating systems which includes SmartTERM and WSDK These software packages are developed to operate under Windows XP and include all the
116. O 0343538 m m a foo oO ONS Sack HIM BS 2 538 538 fh 3415 90 H 3 H3AINO TUNE d 300003 J a a w DN Y 8 WI DAH 26 Haddals Hal HEAIHO TN ETEEN 0 4 HANH TWNHSLX Sp iv HaHa TNA Wiss 0 L3NH3HI3 101 9 01 03003106 YSN NI IOWA T0OHLNOS NOLLOW MIO O807 OWG DI OJONILXS Figure 2 2 Outline of the of the DMC 4080 DMC 40x0 8 e Chapter 2 Getting Started DMC 40x0 Power Connections Power Connectors for Galil integrated Amplifiers Power Connector for Controller without Galil Amplifiers DMC 4080 GALIL MOTION CONTROL MADE IN USA p EXTENDED VO AUX SERIAL RESERVED SAN y sy EXTERNAL DRIVER A D EXTERNAL DRIVER E H EXTENDED IO EXTERNAL DRIVER A D EXTERNAL DRIVER E H hn name 6ST 1RES name ISTE 1RES mb snes zem RRES AES astra LA sexo 3 RES momo JESIH snes 201028 3 DIRS 4 RES 7 HORF an arg 4RES A Se snes AMES 50IRG woe 2 woe ZIOAN GRES 37 AENS gt AEN 37 AENS ZE uge 38 AEC2 BAEC AENG sage seg 7 A 39 GNO DIS 11018 21081 31 1019 ETHERNET YD 20 80 A DC GROUMD Figure 2 4 Power Connector used when controller is ordered without Galil Amplifiers Also used for powering the controller when using the Linear Amplifier See Power connector information for specific amplifiers in the Integrated Amplifiers and Drivers section of the Appendices For more information on Co
117. O FLSX RLSX HOME X FLSY RLSY HOMY INCOM 2 2kQ RPACK KA e RK Ss ge ge e e e H DI1 DIZ DIS DI4 DES DI6 DIA DIS ABRT XLATCH YLATCH ZLATCH WLATCH Figure 3 1 The Optoisolated Inputs Using an Isolated Power Supply To take full advantage of opto isolation an isolated power supply should be used to provide the voltage at the input common connection When using an isolated power supply do not connect the ground of the isolated power to the ground of the controller A power supply in the voltage range between 5 to 28 Volts may be applied directly see Figure 3 2 For voltages greater than 28 Volts a resistor R is needed in series with the input such that 1 mA lt V supply R 2 2KQ lt 11 mA 36 e Chapter 3 Connecting Hardware DMC 40x0 External Resistor Needed for External Resistor Needed for Voltages gt 28V LSCOM Voltages gt 28V LSCOM 2 2K 2 2K Na Ki Na Ne FLSX FLSX Configuration to source current at the Configuration to sink current at The LSCOM terminal and sink Current at LSCOM terminal and source current at switch inputs switch inputs Figure 3 2 Connecting a single Limit or Home Switch to an Isolated Supply This diagram only shows the connection for the forward limit switch of the X axis Bypassing the Opto Isolation If no isolation is needed the internal 5 Volt supply may be used to power the switches This can be done by connecting LSCOM or INCOM to 5V To close the circuit wire th
118. P 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 GNX 2 is invalid Special Operands Keywords The DMC 40x0 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 40x0 commands Keyword Function Returns a if motion on axis n is complete otherwise returns 0 In O JL Returns status of Home Switch equals 0 or 1 Returns status of Forward Limit switch input of axis n equals 0 or 1 Returns status of Reverse Limit switch input of axis n equals 0 or 1 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 V1 _LFX Assign V1 the logical state of the Forward Limit Switch on the X axis V3 TIME Assign V3 the current value of the time clock V4 _HMW Assign V4 the logical state of the Home input on the W axis Arrays For storing and collecting numerical data the DMC 40x0 provides array space for 16000 elements The arrays are one dimensional and up to 30 different arrays may be defined Each array
119. RS 422 Main Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option RS 422 Auxiliary Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option 50 e Chapter 4 Software Tools and Communication DMC 40x0 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 40x0 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 must be connected to the slave in order to begin communicating Each packet sent is acknowledged when received If no acknowledgement is received the information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connection This protocol is similar to communicating via RS232 If information 1s lost the controller does not return a colon or question mark Because the protocol does not provide for lost information the sender must re send the packet Although UDP IP is more efficient and simple Galil recommends using the TCP IP protocol TCP IP insures that if a packet is lost or destroyed while in transit it will be resent Ethernet communication transfers information in packets The
120. S nl DMC 40x0 Interpretation Label Prompt for revs Chapter 7 Application Programming e 155 PR n1 2000 Convert to counts IN ENTER SPEED IN RPM s1 Prompt for RPMs SP s1 2000 60 Convert to counts sec IN ENTER ACCEL IN RAD SEC2 al Prompt for ACCEL AC al 200074273414 Convert to counts sec2 BG Begin motion EN End program Hardware I O Digital Outputs The DMC 40x0 has an 8 bit uncommitted output port and an additional 32 I O which may be configured as inputs or outputs with the CO command for controlling external events The DMC 4050 through DMC 4080 has an additional 8 outputs Each bit on the output port 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 SB6 Sets bit 6 of output port CB4 Clears bit 4 of output port Example Output Bit The Output Bit OB instruction 1s 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 QIN 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 s
121. SHUNT AT AEC AEC1 V AEC2 V For 5V to 12V RP6 820 Ohms For 13V to 24V RP6 4 7K Ohms From Default Configuration U4 PIN 1 l Move U4 up one pin location on socket pre re zc 2 Reverse RP2 sse 3 Change JP1 to AECI E A Change JP2 to AEC2 RP2 PIN 1 2 5 If AEC2 is 13V to 24V Replace RP6 O with 4 7K Resistor Pack E R EE Dau REV G Isolated Power Low Amp Enable Sourcing Configuration JP 4 JP2 SHUNT AT AECI SHUNT AT AEC AECI V ABCZ Vt For 5V to 12V RP6 820 Ohms For 13V to 24V RP6 4 7K Ohms E From Default Configuration U4 PIN 1 RPG PIN 1 e Be l Move U4 up one pin location on socket zee o 2 Change JP1 to AECI 23 Se S 3 Change JP2 to AEC2 8 030 4 If AEC2 is 13V to 24V Replace RP6 RP2 PIN 1 ot ees with 4 7K Resistor Pack EA FSFICM 42000 GALIL REV E 216 e Appendices DMC 40x0 For Steps 4 and 5 with a DMC 4080 refer to DMC 4080 Steps 4 and 5 section below DMC 4040 Steps 4 and 5 Step 4 Replace ICM REPLACE ICM DMC 40x0 Appendices e 217 Step 5 Replace Cover Notes l Cover Installation A Install Jack Screws 20 Places B Install 6 32x3 16 Button Head Cover Screws 4 Places REPLACE JACK SCREWS ZU PLCS PREPLACE COVER SCREWS 4 PLCS 218 e Appendices DMC 40x0 DMC 4080 Steps 4 and 5 Step 4 Replace ICM s REPLACE ICM S Appendices e 219 DMC 40x0 Step 5 Replace Cover Notes l Cover Installation A Install Ja
122. Sinusoidal Commutation The command BA reconfigures the controller such that 1t has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAA is given to a DMC 4040 controller the controller will be re configured to be a DMC 4030 controller In this case the highest axis is no longer available except to be used for the 2 phase of the sinusoidal commutation Note that the highest axis on a controller can never be configured for sinusoidal commutation The DAC associated with the selected axis represents the first phase The second phase uses the highest available DAC When more than one axis is configured for sinusoidal commutation the controller will assign the second phases to the DACs which have been made available through the axes reconfiguration The highest sinusoidal commutation axis will be assigned to the highest available DAC and the lowest sinusoidal commutation axis will be assigned to the lowest available DAC Note that the lowest axis 1s the A axis and the highest axis is the highest available axis for which the controller has been configured Example Sinusoidal Commutation Configuration using a DMC 4070 BAAC DMC 40x0 Chapter 2 Getting Started e 17 This command causes the controller to be reconfigured as a DMC 4050 controller The A and C axes are configured for sinusoidal commutation The first phase of the A axis will be the motor command A signal The second phase of the A axis
123. WI Label for Limit Switch subroutine POSERR Label for excess Position Error subroutine MCTIME Label for timeout on Motion Complete trip point CMDERR Label for incorrect command subroutine Commenting Programs Using the command NO or Apostrophe The DMC 40x0 provides a command NO for commenting programs or single apostrophe This command allows the user to include up to 78 characters on a single line after the NO command and can be used to include comments from the programmer as in the following example PATH 2 D CIRCULAR PATH VMXY VECTOR MOTION ON X AND Y vs 10000 VECTOR SPEED IS 10000 VP 4000 0 BOTTOM LINE CR 1500 270 180 126 e Chapter 7 Application Programming DMC 40x0 HALF CIRCLE MOTION VP 0 3000 TOP LINE CR 1500 90 180 HALF CIRCLE MOTION VE END VECTOR SEQUENCE BGS BEGIN SEQUENCE MOTION EN END OF PROGRAM Note The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Executing Programs Multitasking The DMC 40x0 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 through 7 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 Only the main thread thread 0 may use the input command IN 2 When input inter
124. abilize JP LOOP Keep correcting until error is within tolerance END End CORRECT subroutine returning to code SPX spxX EN 114 e Chapter 6 Programming Motion DMC 40x0 Dual Loop Auxiliary Encoder The DMC 40x0 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation and axis used in circular compare When used the second encoder 1s typically mounted on the motor or the load but may be mounted in any position The most common use for the second encoder is backlash compensation described below The second encoder may be a standard quadrature type or 1t 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 y z w or a b c d e f g h for controllers with more than 4 axes where the parameters x y z w each equal 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 Normal quadrature Normal quadrature Pulse amp direction Pulse amp direction Reverse pulse direction Reversed pulse 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 1s 6 and the command for the X axis 1s CE 6 Additional Commands for the Auxili
125. ach field as 0 1 2 4 or 6 as follows 00 No data fields i e SH or BG 01 One byte per field 02 One word 2 bytes per field 04 One long word 4 bytes per field 06 Galil real format 4 bytes integer and 2 bytes fraction Byte 3 specifies whether the command applies to a coordinated move as follows 00 No coordinated motion movement 01 Coordinated motion movement For example the command STS designates motion to stop on a vector move S coordinate system The third byte for the equivalent binary command would be 01 Byte 4 specifies the axis or data field as follows Bit 7 H axis or 8 data field Bit 6 G axis or 7 data field Bit 5 F axis or 6 data field Bit 4 E axis or 5 data field Bit 3 D axis or 4 data field Bit 2 C axis or 3 data field Bit 1 B axis or 2 data field Bit 0 A axis or 1 data field Data fields Format Data fields must be consistent with the format byte and the axes byte For example the command PR 1000 500 would be Az OD OO OS OS Eo FE UC where A7 is the command number for PR 02 specifies 2 bytes for each data field 72 e Chapter 5 Command Basics DMC 40x0 00 S is not active for PR 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 2 5 03 E8 represents 1000 FE OC represents 500 Example The command ST XYZS would be AL OU 0L OF where Al is the command number for ST 00 specifies 0 data fields 01 specifies stop the coordinated axes S
126. ain encoder port 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 For example the DMC 4080 controllers may have one master and up to seven slaves To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis Y when the master is X Such a graphic relationship is shown in Figure 6 11 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master axis This is done with the instruction EAp where p X Y Z W E F G H p is the selected master axis For the given example since the master is x we specify EAX 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 x 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 To specify the master cycle and the slave cycle change we use the instruction EM DMC 40x0 Chapter 6 Programming Motion e 99 EM E ZW where x y z w specify the cycle of the master and the total change of the slaves over one cycle The cycle of the master is limited to 8 388 607
127. alil Controller model eg DMC 40x0 Pressing the down arrow to the right of this field will reveal a menu of valid controller types You then need to choose serial or Ethernet connection The registry information will show a default Comm Port of 1 and a default Comm Speed of 115200 appears This information can be changed as necessary to reflect the computers Comm Port and the baud rate set by the jumpers found on the communications board The registry entry also displays timeout and delay information These are advanced parameters which should only be modified by advanced users see software documentation for more information Once you have set the appropriate Registry information for your controller Select OK and close the registry window You will now be able to communicate with the controller 16 e Chapter 2 Getting Started DMC 40x0 To establish communication to the controller open up the Terminal and hit the Enter key You should receive a colon prompt Communicating with the controller is described in later sections If you are not properly communicating with the controller the program will pause for 3 15 seconds and an error message will be displayed In this case there is most likely an incorrect setting of the serial communications port or the serial cable is not connected properly The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller Please note
128. alog input B Hall Input Status Reserved B User defined variable ZA C axis status see bit field map below C axis switches see bit field map below C axis stop code C axis reference position C axis motor position C axis position error C axis auxiliary position C axis velocity C axis torque C axis analog input C Hall Input Status Reserved C User defined variable ZA D axis status see bit field map below D axis switches see bit field map below D axis stop code D axis reference position D axis motor position D axis position error D axis auxiliary position D axis velocity D axis torque D axis analog input D Hall Input Status Reserved D User defined variable ZA E axis status see bit field map below E axis switches see bit field map below E axis stop code E axis reference position E axis motor position E axis position error E axis auxiliary position E axis velocity E axis torque E axis analog input E Hall Input Status Reserved E User defined variable ZA F axis status see bit field map below F axis switches see bit field map below DMC 40x0 265 UB F axis stop code 266 269 SL F axis reference position 270 273 SL F axis motor position 274 277 SL F axis position error 278 281 SL F axis auxiliary position 282 285 SL F axis velocity 286 289 SL new size F axis torque 290 291 SW F axis analog input 292 UB new F Hall Input Status 293 UB Reserved
129. ample 14 Control Variables Objective To show how control variables may be utilized Instruction A DPO PR 4000 SP 2000 BGA AMA WT 500 B Vl _TPA PR V1 2 BGA AMA WT 500 V1 JP C V1 0 JP B C DMC 40x0 Interpretation Label Define current position as zero Initial position Set speed Move A Wait until move is complete Wait 500 ms Determine distance to zero Command A move 1 2 the distance Start A motion After A moved Wait 500 ms Report the value of V1 Exit if position 0 Repeat otherwise Label C Chapter 2 Getting Started e 29 EN End of Program To start the program command XQ A Execute Program A This program moves A to an initial position of 1000 and returns it to zero on increments of half the distance Note _TPA is an internal variable which returns the value of the A position Internal variables may be created by preceding a DMC 40x0 instruction with an underscore _ Example 15 Linear Interpolation Objective Move A B C motors distance of 7000 3000 6000 respectively along linear trajectory Namely motors start and stop together Instruction Interpretation LM ABC Specify linear interpolation axes LI O00 300056000 Relative distances for linear interpolation LE Linear End VS 6000 Vector speed VA 20000 Vector acceleration VD 20000 Vector deceleration BGS Start motion Example 16 Circular Interpolation Objective Move the AB axes in circular mode to f
130. antry mode for strong coupling between the motors The X axis is the master and the Y axis is the follower To synchronize Y with the commanded position of X use the instructions 98 e Chapter 6 Programming Motion DMC 40x0 GA CX Specify the commanded position of X as master for Y GR 1 Set gear ratio for Y as 1 1 GM 1 Set gantry mode PR 3000 Command X motion BG X Start motion on X axis You may also perform profiled position corrections in the electronic gearing mode Suppose for example that you need to advance the slave 10 counts Simply command LE Specify an incremental position movement of 10 on Y axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on Y axis BGY Begin motion on Y axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity correction GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 7 axes can be slaved to one master axis The master axis encoder must be input through a m
131. aracter 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 IN ENTER len S6 Input character string Of up to 6 characters into variable Len Flen FRAC len Define variable Flen as fractional part of variable len Flen 10000 Flen Shift Flen by 32 bits IE convert fraction Flen to integer lenl Flens 00FF Mask top byte of Flen and set this value to variable lenl len2 Flen amp FF00 100 Let variable len2 top byte of Flen len3 len amp 000000FF Let variable len3 bottom byte of len len4 len 50000FFO00 100 Let variable len4 second byte of len len5 len 00FF0000 10000 Let variables Lens third byes 06 Len len6 lens FF000000 1000000 Let variable len6 fourth byte of len MG len6 S4 Display len6 as string message of up to 4 chars MG len5 S4 Display len5 as string message of up to 4 chars MG L n S4 Display len4 as string message of up to 4 chars MG len3 S4 Display len3 as string message of up to 4 chars MG len2 S4 Display len2 as string message of up to 4 chars MG len S4 Display Leni as string message of up to 4 chars This program will accept a string input of up to 6 characters parse each character and then display each character Notice also
132. are Protection 168 tte 168 E A een Cate Tener en 168 Output Protection dies ee 168 Ni ET 169 EE EEN 169 Programmable Position LES eas aa eae 170 EE EE ee 170 Automatic Error Routine o ES 170 egent HE FR OLIN aese E E 171 Chapter 9 Troubleshooting 172 Eeer leiere 172 A eee O eC ee ge E E oe ee 172 SEI EE 173 A E 173 Chapter 10 Theory of Operation 174 EE RRR eM Ream Tener ae enue ans PR ate On ee 174 Operation of Closed Loop Systems ron died 176 System MOI ita 177 le ee TE 178 O 180 asta eC mer ene ee ene eer Pe ica ies iio tic en ene nee eer ce ee 180 A Seen aera erger ner Meant oe eee een et 181 A eer eee ee eye eee nen ree rere ee ree eee eee eee nee ee ere eee eer 182 O SUS fesse ai fie a etc hears a old le ccc taal cee cued dia ned 182 System Desion and C OM Pens an jiestiio ccs cas areadnesneds dates dido 184 The Analytical Med AA A 184 Appendices 188 Electical PACA EE 188 SR E 188 IA A O Oder OE 188 PE E 188 POW Et I CQULl TC EE 189 Max Power OUDOT tddi 189 Pertormance SPE CIM CANONS eege 190 Minimum Servo Loop Update Didi iaa aos 190 Fast Update Rate MOGE passie TE A A a dona 191 Power Connectors for the DMC 40x0 ooooocccncnnnnnnnononanonnonnnononnn nono nono nono nono nono ono nono non nn nn nro nana nono 192 EE 192 Molex Part Numbers EE 192 Connectors for ICM 42000 Interconnect Board 193 ICM 42000 I O A D 44 pin D Sub Connector Female occccccncccnncnnninnnnnnnnnno 193 ICM 42000 DMC 40x0 I O E H 44 pin
133. are for Windows Registering controllers in the Windows registry is no longer required when using the GalilTools software package A simple connection dialog box appears when the software is opened that shows all available controllers Any available controllers with assigned IP addresses can be found under the Available tab in the Connections Dialog Box Ifthe controller is not connected to a DHCP enabled network or the DH command 1s set to 0 and the controller has not been assigned an IP address the controller can be found under the No IP Address tab For more information on establishing communication to the controller via the GalilTools software see the GalilTools user manual http www galilmc com support manuals galiltools index html Using DMC SmartTerminal or WSDK Software for Windows NOTE For new applications Galil recommends using the GalilTools software package The controller must be registered in the Windows registry for the host computer to communicate with it The registry may be accessed via Galil software such as WSDK or GALIL Smart Terminal A dedicated network card with a static IP address is recommended To set your NIC card to a static IP go to the Control Panel gt Network Connections gt Local Area Connection gt Properties gt TCP IP and choose use the DMC 40x0 Chapter 2 Getting Started e 15 following IP address If a Dynamic IP address is used make sure there is a DHCP Server on yo
134. ary Encoder The command DE x y z w can be used to define the position of the auxiliary encoders For example DE Ehe a ag sets their initial values The positions of the auxiliary encoders may be interrogated with the command DE For example DE 29757 returns the value of the X and Z auxiliary encoders The auxiliary encoder position may be assigned to variables with the instructions VIs _DEX The command TD XYZW returns the current position of the auxiliary encoder The command DV 1 1 1 1 configures the auxiliary encoder to be used for backlash compensation Backlash 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 DMC 40x0 Chapter 6 Programming Motion e 115 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 syste
135. at 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 RS232 by entering RS The only reset that will not cause the controller to disconnect is a software reset via the Ethernet 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 1s 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 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
136. ates motion into electrical pulses which are fed back into the controller The DMC 40x0 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as CHA and CHB This type of encoder 1s known as a quadrature encoder Quadrature encoders may be either single ended CHA and CHB or differential CHA CHA and CHB CHB The DMC 40x0 decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization The DMC 40x0 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 5 500 000 full encoder cycles second 22 000 000 quadrature counts sec For example if the encoder line density is 10 000 cycles per inch the maximum speed is 300 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 40x0 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 40x0 can accept analog feedback 10v instead of an encoder for any axis For more information see the command AF in the command reference To int
137. ation commands may be formatted locally To format locally use the command Fn m or n m on the same line as the interrogation command The symbol F specifies that the response should be returned in decimal format and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal TP F2 2 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 00 Response from Interrogation Command TP 94 2 Tell Position in hexadecimal format 4 2 FFFB 00 9 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 VE men 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 4 154 e Chapter 7 Application Programming DMC 40x0 A negative sign for m specifies hexadecimal format The default format for VF 1s VF 10 4 Hex values are returned preceded by a and in 2 s complement Instruction Interpretation v1 10 Assign vl vl Return vl 0000000010 0000 Response Default format VF2 2 Change format vl Return vl 10 00 Response New format VF 2 2 Specify hex format vl Return vl SOA 00 Response Hex value VF 1 Change format vl Return vl 9 Response Overflow Local Formatting of Variables PF and VF commands ar
138. bel 001 PR1000 Position Relative 1000 002 BGX Begin 003 PR5000 Position Relative 5000 004 EN End lt cntrl gt Q Quit Edit Mode XQ A Execute A 2003 PR5000 Error on Line 3 ICL Tell Error Code 7 Command not valid Command not valid while running while running ED 3 Edit Line 3 003 AMX PR50000 BGX Add After Motion Done SE Q Quit Edit Mode XQ A Execute A Program Flow Commands The DMC 40x0 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 DMC 40x0 Chapter 7 Application Programming e 129 Event Triggers amp Trippoints To function independently from the host computer the DMC 40x0 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 40x0 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
139. c DMC 4020 31 25 usec DMC 4030 62 5 usec DMC 4040 62 5 usec DMC 4050 93 75 usec DMC 4060 93 75 usec DMC 4070 125 usec DMC 4080 125 usec In order to run the DMC 40x0 motion controller in fast mode the fast firmware must be uploaded This can be done through the Galil terminal software such as DMCTERM and WSDK The fast firmware is included with the original DMC 40x0 utilities In order to set the desired update rates use the command TM When the controller is operating with the fast firmware the following functions are disabled Gearing mode Ecam mode Pole PL Analog Feedback AF Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in thread 2 8 Tell Velocity Interrogation Command TV Aux Encoders TD Dual Velocity DV Peak Torque Limit TK Notch Filter NB NF NZ DMC 40x0 Chapter 6 Programming Motion e 123 Chapter 7 Application Programming Overview The DMC 40x0 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 40x0 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 40x0 provides commands that allow the DMC 40x0 to make its own decisions These commands include conditional jumps event
140. cal pecas a 41 ii e Contents DMC 40x0 DMC 40x0 DS A A EE 41 ICM 42000 and ICM 42100 Amplifier Enable Creut 41 ICM 42200 Amplifier Enable Circuit ooccccnnnnnininininnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 44 Chapter 4 Software Tools and Communication 48 Introduciendo 48 Ro Zand RSL PO Ss aa T Po Sted Ge Reads ale a staan eet eats 48 A ON EIN AL OL pata ee ed pee eee 49 EE ee ee ee 50 Ethernet C onora oeng rae Ne reer Ee 51 Communi CatiOn Protocols ee ee ee 51 Se 51 Communicating with Multiple DeviceS ooooooocnoonooonooonoooooonnnnnonnnnnnnnnnnnnnnnnnnnnonononoos 52 Te A a ial ee 52 Usine Third Par e do 53 eeler EE KE ee E ene 54 Data RECO dicas S6 Explanation Data Record Bit Fields cda costuras ida Sees 60 Notes Regarding Velocity and Torque Information cccccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 61 OFC OMIM AIG 3 cas easciss ous deze sani a saints oia 61 Controller Response to Lomas o ico 61 Unsolicited Messages Generated by Control iia 62 Galilkools Windows and Li A a ees 63 Creatine Custom Software Interface Senisi a cen chte E coeanasataec E E 65 HelloGalil Quick Start to PC programming coococcccconanonanannnnononnnnno nono nono non anna nana 65 GalilTools Communication Librares nono a aa 65 NI SA se oe E 66 DMC Win Programmers Toolkit ao 66 Galil Communications API with CC 67 Galil Communications API with Visual Basic 67 DOS and EE eg 69 Chapter 5 Command Basics 70 PICO Lee 70 CO
141. cation Programming e 157 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Input Interrupt Function The DMC 40x0 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 A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RI command is used to return from this subroutine to the place in the program where the interrupt had occurred If it is desired to return to somewhere else in the program after the execution of the ININT subroutine the Zero Stack ZS command is used followed by unconditional jump statements Important Use the RI command not EN to return from the ININT subroutine Example Input Interrupt Instruction Interpretation FA Label A II 1 Enable input 1 for interrupt function JG 30000 20000 Set speeds on A and B axes BG AB Begin motion on A and B axes B Label B TP AB Report A and B axes positions WT 1000 Wait 1000 milliseconds JP B Jump to B EN End of program ININT Interrupt subroutine MG Interrupt has occurred Displays the message
142. ck Screws 34 Places B Install 6 32x3 16 Button Head Cover Screws 4 Places REPLACE JACK SCREWS 34 PLCS REPLACE COVER SCREWS 4 PLCS 220 e Appendices DMC 40x0 Coordinated Motion Mathematical Analysis The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which 1s also known as the feed rate is the vector sum of the velocities along the X and Y axes Vx and Vy Vs 4 Vx Vy The vector distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle corresponds to the positive direction of the X axis and the CCW direction of rotation is positive Angles are expressed in degrees and the resolution is 1 256th of a degree For example the path shown in Fig A 1 is specified by the instructions VP 0 10
143. ction 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 2 e Chapter 1 Overview DMC 40x0 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 1s 10A the amplifier gain should be 1 A V Amplifiers in Velocity Mode For velocity mode amplifiers a command signal of 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 ru For step motors the amplifiers should accept step and direction signals Overview of Galil Amplifiers and Drivers With the DMC 40x0 Galil offers a variety of Servo Amplifie
144. ctive 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 Voltages above 24 volts require an additional resistor gt 1mA 0ON lt 0 5 mA OFF Standard configuration is 10 volts 12 Bit Analog to Digital converter 16 bit optional High power Opto Isolated 500mA souring High power Opto Isolated 500mA sourcing DMC 40x0 1017 thru 1048 DIS1 DI82 DI83 DI84 DMC 4020 through DMC 4080 only DI85 DI86 DMC 4030 through DMC 4080 only DI87 DI88 DMC 4040 through DMC 4080 only DI89 DI90 DMC 4050 through DMC 4080 only DI91 DI92 DMC 4060 through DMC 4080 only DI93 DI94 DMC 4070 through DMC 4080 only DI95 DI96 DMC 4080 only Power Requirements 20 80 VDC 12 16W at 25C Max Power Output 5V LIA 12V 40mA OV 40mA DMC 40x0 Extended configurable I O Standard 3 3V logic with 5V option Auxiliary Encoder Inputs for A X axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for B Y axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for C Z axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliar
145. d 32 bit number e g IA 124 51 29 31 or IA 2083724575 Type in BN to save the IP address to the DMC 40x0 non volatile memory NOTE Galil strongly recommends that the IP address selected 1s not one that can be accessed across the Gateway The Gateway 1s 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 1t connects to the DMC 40x0 board Typical port numbers for applications are Port 23 Telnet Port 502 Modbus Communicating with Multiple Devices The DMC 40x0 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 client The term Slave is equivalent to the internet server An Ethernet handle is a communication resource within a device The DMC 40x0 can have a maximum of 8 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 8 handles are in use and a 9 master tries to connect it will be sent a reset packet th
146. d STPA and DIRA for the A axis on the EXTERNAL DRIVER A D D Sub connector top of the controller Consult the documentation for connecting these signals to your step motor amplifier Step B Configure DMC 40x0 for motor type using MT command You can configure the DMC 40x0 for active high or active low pulses Use the command MT 2 or 2 5 for active low step motor pulses and MT 2 or 2 5 for active high step motor pulses See description of the MT command in the Command Reference Step 9 Tune the Servo System Adjusting the tuning parameters is required when using servo motors standard or sinusoidal commutation The system compensation provides fast and accurate response and the following section suggests a simple and easy way for compensation More advanced design methods are available with software design tools from Galil such as the Windows Servo Design Kit WSDK software The filter has three parameters the damping KD the proportional gain KP and the integrator KI The parameters should be selected in this order To start set the integrator to zero with the instruction Ki 0 lt return gt Integrator gain and set the proportional gain to a low value such as KP 1 lt return gt Proportional gain KO 100 lt return gt Derivative gain For more damping you can increase KD maximum is 4095 875 Increase gradually and stop after the motor vibrates A vibration is noticed by audible sound or by interrogation If you send the com
147. d in the brushless motor amplifier If the amplifier generates the sinusoidal commutation signals only a single command signal 1s required and the controller should be configured for a standard servo motor described above Sinusoidal commutation in the controller can be used with linear and rotary BLMs However the motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds with a standard update rate of 1 millisecond For faster motors please contact the factory To simplify the wiring the controller provides a one time automatic set up procedure When the controller has been properly configured the brushless motor parameters may be saved in non volatile memory The DMC 40x0 can control BLMs equipped with Hall sensors as well as without Hall sensors If Hall sensors are available once the controller has been setup the brushless motor parameters may be saved in non volatile memory In this case the controller will automatically estimate the commutation phase upon reset This allows the motor to function immediately upon power up The Hall effect sensors also provide a method for setting the precise commutation phase Chapter 2 describes the proper connection and procedure for using sinusoidal commutation of brushless motors Stepper Motor with Step and Direction Signals ru The DMC 40x0 can control stepper motors In this mode the controller provides two signals to connect to the stepper motor Step and Dire
148. d to change the active state of the amplifier enable output However the polarity of RP6 must not be changed a different resistor value may be needed to limit the current to 6 mA The default value for RP6 is 820 ohms which works at 5V When using 24 V RP6 should be replaced with a 4 7 kQ resistor pack NOTE For detailed step by step instructions on changing the Amplifier Enable configuration on the ICM 42000 or ICM 42100 see the Configuring the Amplifier Enable Circuit section in the Appendices DMC 40x0 Chapter 3 Connecting Hardware e 41 Amplifier Enable Circuit Sinking Output Configuration Pin 1 of LTV8441 in Pin 2 of Socket U4 Socket U4 of se o Amp Enable Output to Drive AENn RP2 470 Ohm RP6 8200hm 3 a gt 2 PIN 1 TTL level Amp Enable signal from controller SH 5V MO OV SHoHSHS AECOM2 Figure 3 4 Amplifier Enable Circuit Sinking Output Configuration Sinking Configuration pinl of LT V8441 chip in pin2 of socket U4 RP2 Logic State JP1 JP2 square pin next to RP2 label is 5V 5V HAEN Default Configuration SV AECOM1 GND AECOM2 Dot on R pack next to RP2 label SV LAEN SV AECOM1 GND AECOM2 Dot on R pack opposite RP2 label 12V HAEN 12V AECOMI GND AECOM2 Dot on R pack next to RP2 label 12V LAEN 12V AECOM GND AECOM2 Dot on R pack opposite RP2 label Isolated 24V HAEN AECI AECOMI1 AEC2 AECOM2 Do
149. d to the active coordinate system until changed with the CA command 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 DMC 40x0 Chapter 6 Programming Motion e 91 This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y specifies the coordinates of the end points of the vector movement with respect to the starting point Non sequential axis do not require comma delimitation 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 Up to 511 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
150. dy to receive additional characters The RTS line will inhibit the DMC 40x0 from sending additional characters Note the RTS line goes high for inhibit The auxiliary port of the DMC 40x0 can be configured either as a general port or for the daisy chain When configured as a general port the port can be commanded to send ASCII messages to another DMC 40x0 controller or to a display terminal or panel CC Command Configure Communication at port 2 The command is in the format of See CC in the Command Reference for more information CC m n ak p where m sets the baud rate n sets for either handshake or non handshake mode r sets for general port or the auxiliary port and p turns echo on or off m Baud Rate 9600 19200 38400 1 15200 DMC 40x0 Chapter 4 Software Tools and Communication e 49 n Handshake O No 1 Y es r Mode 0 Disabled 1 enabled p Echo 0 Off 1 On Valid only if r 0 NOTE for the handshake of the auxiliary port the roles for the RTS and CTS lines are reversed Example CC 19200 0 1 1 Configure auxiliary communication port for 19200 baud no handshake general port mode and echo turned on RS 422 Configuration The DMC 40x0 can be ordered with the main and or 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
151. e Tt is given by ess Ta 0 4075 VS The velocities along the X and Y axes are such that the direction of motion follows the specified path yet the vector velocity fits the vector speed and acceleration requirements For example the velocities along the X and Y axes for the path shown in Fig A 1 are given in Fig A 3 Fig A 3a shows the vector velocity It also indicates the position point along the path starting at A and ending at D Between the points A and B the motion is along the Y axis Therefore Vy Vs Between the points B and C the velocities vary gradually and finally between the points C and D the motion is in the X direction B C time Figure A 3 Vector and Axes Velocities DMC 40x0 Appendices e 223 Example Communicating with OPTO 22 SNAP B3000 ENET Controller is connected to OPTO 22 via handle F The OPTO 22 s IP address is 131 29 50 30 The Rack has the following configuration Module 1 Digital Outputs Module 2 Analog Outputs 10V Module 3 Analog Inputs 10V Module 4 Digital Inputs Instruction FCONF IG THF 131 29 50 30 lt 502 gt 2 wWI10 JP FCEGERR _IHF2 0 JS FCEGDOUT JS FCEGAOUT JS FCEGAIN MBF 6 6 1025 1 EN FCEGDOUT MODULE 2 CFGVALUE 180 NUMOF IO 4 JP CFGJOIN CFGAOUT MODULE 3 CFGVALUE SA7 NUMOF LO 2 JP CFGJOIN CFGAIN MODULE 5 CFGVALUE 12 NUMOF IO 2 JP CFGJOIN CFGJOIN DM A 8 I 0 CFGLOOP A I 0 I I 1 A 1 CFGVA
152. e enabled with the command GM allows the gearing to stay enabled even if a limit is hit or an ST command is issued GR 0 0 0 0 turns off gearing in both modes The command GM x y z w select the axes to be controlled under the gantry mode The parameter 1 enables gantry mode and 0 disables it GR causes the specified axes to be geared to the actual position of the master The master axis is commanded with motion commands such as PR PA or JG When the master axis is driven by the controller in the jog mode or an independent motion mode it is possible to define the master as the command position of that axis rather than the actual position The designation of the DMC 40x0 Chapter 6 Programming Motion e 95 commanded position master 1s by the letter C For example GACX indicates that the gearing 1s the commanded position of X An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the X and Y motor form a circular motion the Z axis may move in proportion to the vector move Similarly if X Y and Z perform a linear interpolation move W can be geared to the vector move Electronic gearing allows the geared motor to perform a second independent or coordinated 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 Geari
153. e DMC 40x0 circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed ISOLATED LIMITS AND below WATCHDOG TIMER HOME INPUTS ETHERNET RISC BASED HIGH SPEED MAIN ENCODERS MICROCOMPUTER MOTOR ENCODER AUXILIARY ENCODERS INTERFACE 10 VOLT OUTPUT FOR RS 232 FOR SERVO MOTORS RS 422 Ee PULSE DIRECTION OUTPUT FOR STEP MOTORS gt HIGH SPEED ENCODER 8 PROGRAMMABLE 8 UNCOMMITTED 8 PROGRAMMABLE HIGH POWER OPTOISOLATED ANALOG INPUTS OPTOISOLATED OUTPUTS INPUTS HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 40x0 Functional Elements Microcomputer Section The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM The RAM provides memory for variables array elements and application programs The flash EEPROM 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 12 MHz For standard servo operation the controller generates a 10 volt analog signal 16 Bit DAC For sinusoidal commutation operation the controller uses two DACs to generate two 10 volt analog signals For stepper motor operation the controller generates a step and direction signal Commu
154. e desired input to any ground GND pin on the controller TTL Inputs The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 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 Loof the full voltage range for example connect the input to 6 volts if the signal is a 0 12 volt logic Example A DMC 4010 has one auxiliary encoder This encoder has two inputs channel A and channel B Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal will be connected to AA and the second to AB AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor DMC 40x0 Chapter 3 Connecting Hardware e 37 High Power Opto Isolated Outputs The DMC 40x0 has different interconnect module options this section will
155. e global format commands that affect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m or n m following the variable name and the symbol F specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal Instruction Interpretation v1 10 Assign vl vl Return v1 0000000010 0000 Default Format vl F4 2 Specify local format 7001000 New format vl S4 2 Specify hex format 000A 00 Hex value vl ALPHA Assign string ALPHA to v1 vl S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 40x0 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 1s converted into counts by multiplying 1t by the number of counts revolution Instruction RUN IN ENTER OF REVOLUTION
156. e initial position of the tangent axis Example Assume an XY table with the Z axis controlling a knife The Z axis has a 2000 quad counts rev encoder and has been initialized after power up to point the knife in the Y direction A 180 circular cut is desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion is CCW ending at 3000 0 Note that the 0 position in the XY plane is in the X direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First X Y and Z are driven to the starting point and later the cut is performed Assume that the knife is engaged with output bit 0 EXAMPLE Example program VM XYZ XY coordinate with Z as tangent TN 2000 360 500 2000 360 counts degree position 500 is 0 degrees in XY plane CR 300050 180 3000 count radius start at 0 and go to 180 CCW VE End vector CBO Disengage knife BA 3000 0 EN Move X and Y to starting position move Z to initial tangent position BG XYZ Start the move to get into position AM XYZ When the move is complete SBO Engage knife WT50 Wait 50 msec for the knife to engage BGS Do the circular cut AMS After the coordinated move is complete CBO Disengage knife MG ALL DONE EN End program DMC 40x0 Chapter 6 Programming Motion e 93 Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION VM m n Specifies the axes for the planar motion where m and n re
157. e magnitude and phase of L s at the frequency w 500 L 500 3 17 106 5500 j500 2000 This function has a magnitude of LG500 0 00625 and a phase Arg LG500 180 tan 1 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that A j500 1 Arg A j500 135 However since A s L s G s then it follows that G s must have magnitude of GG500 AG500 LG500 160 and a phase arg G j500 arg A 500 arg LG500 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 o 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as GG500 P G500D 160 and arg G j500 tan 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 2744s The function G is equivalent to a digital filter of the form D z KP KD 1 71 where DMC 40x0 Chapter 10 Theory of Operation e 185 P KP D KD T and KD D T Assuming a sampling period of T 1 ms the parameters of the digital filter are KP 82 4 KD 247 4 The DMC 40x0 can be programmed with the instruction KP 82 4 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following
158. e 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 KI 2 B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD I s a s a where P KP D T KD I KIT where T is the sampling period and B is the pole setting For example if the filter parameters of the DMC 40x0 are KP 16 KD 144 KI 2 PL 0 75 T 0 001 s the digital filter coefficients are K 160 A 0 9 C 1 a 250 rad s and the equivalent continuous filter G s 1s G s 16 0 144s 1000 s 250 s 250 The notch filter has two complex zeros Z and z and two complex poles P and p The effect of the notch filter 1s 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 DMC 40x0 Chapter 10 Theory of Operation e 181 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
159. e 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 lt return gt BGX lt return gt Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command 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 1s dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HMX lt return gt BGX lt return gt Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detectin
160. e the commutation phase of the brushless motor In this case the controller could become unstable until the commutation phase has been set using the BZ command see next step It is highly recommended that the motor off command be given before executing the BN command In this case the motor will be disabled upon power up or reset and the commutation phase can be set before enabling the motor Step F part 1 Systems with or without Hall Sensors Set Zero Commutation Phase 22 e Chapter 2 Getting Started DMC 40x0 When an axis has been defined as sinusoidally commutated the controller must have an estimate for commutation phase When Hall sensors are used the controller automatically estimates this value upon reset of the controller If no Hall sensors are used the controller will not be able to make this estimate and the commutation phase must be set before enabling the motor To initialize the commutation without Hall effect sensor use the command BZ This function drives the motor to a position where the commutation phase is zero and sets the phase to zero The BZ command is followed by real numbers in the fields corresponding to the driven axes The number represents the voltage to be applied to the amplifier during the initialization When the voltage 1s specified by a positive number the initialization process ends up in the motor off MO state A negative number causes the process to end in the Servo Here SH state WARNING This
161. ead 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 Imsec 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 DMC 40x0 Chapter 6 Programming Motion e 81 The PA command is typically used to command an axis or multiple axes to a specific absolute position 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 mo
162. ecify first linear segment with a vector speed of 4000 and end speed 1000 DMC 40x0 Chapter 6 Programming Motion e 87 LI 1000 1000 lt 4000 Specify second linear segment with a vector speed of 4000 and end speed gt 1000 1000 LI 0 5000 lt 4000 Specify third linear segment with a vector speed of 4000 and end speed 1000 gt 1000 LE End linear segments BGS Begin motion sequence EN Program end 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 to be scaled VR also applies when the vector speed 1s specified 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 LM xyzw LM abcdefgh LM LI x y z w lt n LI a b c d e f g h lt n UN PIO u YN 5 ES es o AMS eg i DESCRIPTION Specify axes for linear interpolation same controllers with 5 or more axes Returns number of available spaces for linear segments in DMC 40x0 sequence buffer Zero means buffer full 511 means buffer empty Specify incremental distances relative to current position and assign vector speed n Specify vector speed Specify vector acceleration Operand Summary Linear Interpolation OPERAND LE ES DESCRIPTION Re
163. ements defaults to the smallest array defined by DM When m is a negative number the recording is done continuously in a circular manner _RD is the recording pointer and indicates the address of the next array element n 0 stops recording Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Recording Controller time as reported by the TIME command Analog input n X Y Z W E F G H for AN inputs 1 8 2 encoder position dual encoder DMC 40x0 Chapter 7 Application Programming e 147 _TPX _TSX TTX Switches only bit 0 4 valid Torque reports digital value 32544 Note X may be replaced by Y Z or W for capturing data on other axes Operand Summary Automatic Data Capture 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 DM XPOS 300 YPOS 300 DM XERR 300 YERR 300 RA XPOS XERR YPOS YERR RD _TPX _TEX _TPY PR TODO 20000 RC1 BG XY FA JP A _RC 1 MG DONE EN PLAY N 0 JP DONE N gt 300 N X POS N Y POS N XERR N YERR N N N 1 DONE EN De allocating Array Space _TEY Begin program Define X Y position arrays Define X Y error arrays Select arrays for capture Select data types Specify move d
164. en or the OE3 command Enable Off On Error is given and the position error exceeds the error limit AMPEN can be used to disable the amplifier for these conditions The AMPEN signal from the DMC 40x0 is shipped as a default of 5V active high or high amp enable In other words the AMPEN signal will be high when the controller expects the amplifier to be enabled If your amplifier requires a different configuration it is highly recommended that the DMC 40x0 is ordered with the desired configuration See the DMC 40x0 ordering information in the catalog http www galilmc com catalog cat40x0 pdf or contact Galil for more information on ordering different configurations If the amplifier enable needs to be changed see the ICM 42000 and ICM 42100 Amplifier Enable Circuit section in Chapter 3 Connecting Hardware 18 e Chapter 2 Getting Started DMC 40x0 4080 When ordered with ICM 42000 s or ICM 42100 s the AEN signal is configurable for axes 1 4 and axes 5 8 Ex axes 1 4 could be ordered as 5V high amp enable and axes 5 8 could be ordered as 12V low amp enable When ordered with ICM 42200 s each axis is individually configurable Step C Connect the encoders For stepper motor operation an encoder 1s optional For servo motor operation if you have a preferred definition of the forward and reverse directions make sure that the encoder wiring is consistent with that definition The DMC 40x0 accepts single ended or differential encoder
165. en 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 IF 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 40x0 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 40x0 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 S 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 DMC 40x0 Chapter 7 Application Programming e 135 Example using IF ELSE and ENDIF TEST Dias MG WAITING FOR INPUT 1 INPUT 2 LOOP JP LOOP EN FININT IF IN 1 0 IF IN 2 0 MG INPUT 1 AND INPUT 2 ARE ACTIVE
166. end with an End EN statement Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted The maximum number of labels which may be defined is 510 DMC 40x0 Chapter 7 Application Programming e 125 Valid labels BEGIN SQUARE X1 FBEGIN1 Invalid labels 1Square 123 A Simple Example Program START Beginning of the Program PR 10000 20000 Specify relative distances on X and Y axes BG XY Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves X and Y 10000 and 20000 units 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 40x0 have some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines See section on Auto Start Routine The DMC 40x0 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 by beginning the program with the label AUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions ININT Label for Input Interrupt subroutine LIMS
167. ent configures digital outputs 15 8 and array element 0 configures digital outputs 7 0 DM myarray 2 myarray 0 170 which is 10101010 in binary myarray 1 85 which is 010101011n 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 SB2Z00175B20037 5820057 5B2007 7 SBZ20087SB20107 SB201275B2014 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 54 e Chapter 4 Software Tools and Communication DMC 40x0 Example 2 DMC 4040 connected as a Modbus master to a 3rd party PLC The DMC 4040 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 floating 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 THB 192 168 1 10 lt 502 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 mya
168. entiioeas 121 RO des 77 105 107 146 148 Tell Error Position Error 126 138 39 145 148 166 TELEFE e beca 74 75 TEMP died docsters 26 62 75 155 MUL OR GUC tin ck tasccedi cessed bocaceat N 21 75 Terminal 14 15 16 17 20 28 32 70 124 145 TEON EE 25 175 RENE 24 178 Dicta Tater ies 70 1892 83 185 87 250 e Index Modelo aaa 175 178 79 183 PID RE 2 21 24 25 178 187 Stability 115 16 166 173 74 178 184 Time Diere 146 RK E 146 47 Time ler all xe a 104 5 107 148 SIMCO acc eis escocia 16 126 130 138 139 METI Esto 126 130 138 139 TOP Que EE 20 27 A ar nin 124 129 131 33 177 204 Trippoint oooococcccccc 29 78 87 88 93 94 130 31 137 Troubleshoot rindas 173 TTL 4 32 37 39 41 169 189 204 TONINO tiese A easiest 12 21 25 A cence eebe 124 Stability 115 16 166 173 74 178 184 SR A 16 20 e EE 28 124 IS E 156 Varlable 14 29 75 124 152 153 154 156 JERITE AR O A 135 144 145 Internal Vanable 30 Vector Acceleration oocccnnnncccninoc 30 88 89 94 164 Vector Deceleration oocccnnnncccnoniocccnnnocos 30 88 89 94 Vector Mode A does nsec eene 163 64 Circular Interpolation 30 91 94 96 148 163 Clear SEQUE dis 86 88 92 94 FUN PSE Scale docs 94 Se e er a 88 92 94 133 163 64 Linear Intempolanon 30 KT 77 91 93 94 VECO PESO ies treed ina 30 86 92 94 133 16
169. er and Motors This section gives the specifications of these connectors For information specific to your Galil amplifier or driver refer to the specific amplifier driver in the Integrated Amplifiers and Drivers section Molex Part Numbers Used There are 3 different Molex connectors used with the DMC 40x0 The type of connectors on any given controller will be determined be the Amplifiers Drivers that were ordered Below are tables indicating the type of Molex Connectors used and the specific part numbers used on each Amplifier or Driver For more information on the connectors go to http www molex com Note These part numbers list the connectors that are found on the controller For more information see the Molex website Galil Amplifier Driver Molex Part Number AMP 43040 AMP 43140 SDM 44040 SMD 44140 192 e Appendices DMC 40x0 Connectors for ICM 42000 Interconnect Board ICM 42000 I O A D 44 pin HD D Sub Connector Female Pint Label Description Ping Label Description Ping Label Description 3 bu Digital mput4 D latch Digital Input 3 C latch Digital Input Electronic Lock Out ABRT Abort Input Digital Ground LSCOM Limit Switch Common FLSA Forward Limit Switch A 7 HOMA Home Switch A RLSA Reverse Limit Switch A FLSB Forward Limit Switch B HOMB Home Switch B RLSB Reverse Limit Switch B FLSC Forward Limit Switch C HOMC Home Switch C Reverse Limit Switch C FLSD Forward Limit Switch D HOMD Home Switch D R
170. er may be configured in the torque or the velocity mode In the torque mode the amplifier gain should be such that a 10 volt signal generates the maximum required current In the velocity mode a command signal of 10 volts should run the motor at the maximum required speed For Galil amplifiers see Integrated Amplifiers and Drivers Step by step directions on servo system setup are also included on the WSDK Windows Servo Design Kit software offered by Galil See section on WSDK for more details Step A Check the Polarity of the Feedback Loop It is assumed that the motor and amplifier are connected together and that the encoder is operating correct Step 7 Before connecting the motor amplifiers to the controller read the following discussion on setting Error Limits and Torque Limits Note that this discussion only uses the A axis as an examples Step B Set the Error Limit as a Safety Precaution Usually there is uncertainty about the correct polarity of the feedback The wrong polarity causes the motor to run away from the starting position Using a terminal program such as DMC Smart Terminal the following parameters can be given to avoid system damage Input the commands ER 2000 lt return gt Sets error limit on the A axis to be 2000 encoder counts OE 1 lt return gt Disables A axis amplifier when excess position error exists If the motor runs away and creates a position error of 2000 counts the motor amplifier will be disabled
171. er positions at which the corresponding slaves 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 Xy Vp Zp W 100 e Chapter 6 Programming Motion DMC 40x0 where x y z w are the master positions at which the corresponding slave axes are disengaged 3000 2250 1500 2000 4000 6000 Master X Figure 6 11 Electronic Cam Example This disengages the slave axis at a specified master position Ifthe parameter is outside the master cycle the stopping is instantaneous To illustrate the complete process consider the cam relationship described by the equation Y 0 5 xX 100 sin 0 184X where X is the master with a cycle of 2000 counts The cam table can be constructed manually point by point or automatically by a program The following program includes the set up The instruction EAX defines X as the master axis The cycle of the master is 2000 Over that cycle Y varies by 1000 This leads to the instruction EM 2000 1000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18X and X varies in increments
172. eration To configure an axis for brush type operation connect the 2 motor leads to Phase A and Phase B connections for the axis Connect the encoders homes and limits as required Set the controller into brush axis operation by issuing BR n n n n By setting n 1 the controller will operate in brushed mode on that axis For example BRO 1 0 0 sets the Y axis as brush type all others as brushless If an axis is set to brush type the amplifier has no need for the Hall inputs These inputs can subsequently be used as general use inputs queried with the QH command The gain settings for the amplifier are identical for the brush and brushless operation The gain settings can be set to 0 4 0 7 or 1 0 A V represented by gain values of 0 1 and 2 e g AG 0 0 2 1 The current loop gain AU can also be set to either 0 for normal or for high current loop gain Using External Amplifiers Use connectors on top of controller to access necessary signals to run external amplifiers In order to use the full torque limit make sure the AG setting for the axes using external amplifiers are set to O or 1 For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 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 also monitor for illegal Hall states 000 or 111 with 120 phasin
173. erface with other types of position sensors such as absolute encoders Galil can customize the controller and command set Please contact Galil to talk to one of our applications engineers about your particular system requirements Watch Dog Timer The DMC 40x0 provides an internal watch dog timer which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AMPEN which can be used to switch the amplifiers off in the event of a serious DMC 40x0 failure The AMPEN output is normally high During power up and if the microprocessor ceases to function properly the AMPEN output will go low The error light will also turn on at this stage A reset is required to restore the DMC 40x0 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 40x0 is damaged 6 e Chapter 1 Overview DMC 40x0 Chapter 2 Getting Started DMC 4040 Layout The following layouts assume either an ICM 42000 1000 or ICM 42100 1100 interconnect modules are installed For layouts of systems with ICM 42200 s I200 installed please contact Galil Overall dimensions and footprint are identical the only differences are in connector type and location de A B C D POWER ENCODER STEPPER SERVO POWER DMC 4040 5a wua SEND si i 14HALG 4 ABs As OJO Ba A 0 A ANS OOS TAA A OJO 8 BIO GND OOS O 13 HALB 3 MAS GALIL MOTION CONTROL ee ama oe MADE IN USA 11 AAs A og 1 Mls emm eg lt o
174. es 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 Mib for more info For more information on the GalilTools Communications Library see the online user manual http www galilmc com support manuals galiltools library html ActiveX Toolkit Galil recommends the GalilTools Communication Library for all new applications Galil s ActiveX Toolkit is useful for the programmer who wants to easily create a custom operator interface to a Galil controller The ActiveX Toolkit includes a collection of ready made ActiveX COM controls for use with Visual Basic Visual C Delphi LabVIEW and other ActiveX compatible programming tools The most common environment is Visual Basic 6 but Visual Basic NET Visual C Wonderware LabVIEW and HPVEE have all been tested by Galil to work with the OCX controls The ActiveX Toolkit can be purchased from Galil at http www galilmc com buy index html The ActiveX toolkit can save many hours of programming time Built in dialog boxes are provided for quick parameter setup selection of color size location and text The toolkit controls are easy to use and provide context sensitive help making it ideal for even the novice programmer ActiveX Toolkit Includes a terminal control for sending commands and editing programs a pol
175. ess and the host computer The DMC 40x0 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 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 40x0 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 40x0 supports the 10 major function codes Function Code Definition OU con Read Coil Status Read Bits Hi dead Input Status Read Bits nn Ui Ad Holding Registers Read Words OA Lead Input Registers Read Words Un Orce Single Coil Write One Bit nn Up e reset Single Register Write One Word O7 Read Exception Status Read Error Code In Force Multiple Coils Write Multiple Bits In Breser Multiple Registers Write Words 17 Report Slave ID The DMC 40x0 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 incor
176. eturns a response to the port from which the command was generated If the instruction was valid the controller returns a colon or a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the main 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 40x0 will return the data followed by a carriage return line feed and It is good practice to check for after each command is sent to prevent errors An echo function is provided to enable associating the DMC 40x0 response with the data sent The echo 1s enabled by sending the command EO 1 to the controller Unsolicited Messages Generated by Controller When the controller is executing a program 1t may generate responses which will be sent via the main RS 232 port or Ethernet ports This response could be generated as a result of messages using the MG command OR as a result of a command 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 de
177. everse Limit Switch D Digital Ground ICM 42000 DMC 40x0 I O E H 44 pin HD D Sub Connector Female A080 For DMC 4050 thru DMC 4080 controllers only Pint Label Description Pine Label Description pe Label Description Pi eee tier Owe In RST Reset o mp Let 2 os TTD 17 INCOM InputCommon 32 pno Disiet mour 1077 ieh EA bisama amen i8 on visiem amen 33 ons L it s ro tesrnis tock Ow 20 ABRT avona 3s GND Digna Groma ua timieswien Common 21 Nc woCom e nome Home swiene 3 Lag Ps pou disiwtoupre pos L tz a CMP s av evoco o Pr A GND Digital Ground 34 y o momo Home swien 4 aso y ES 43 DMC 40x0 Appendices e 193 ICM 42000 External Driver A D 44 pin HD D Sub Connector Male Im reses OO RES mm Rend Pm Pine c ES S E a l 12V from Controller 12V from Controller MCMA Motor Command A MCMB Motor Command B Reserved MCMDA N i Reserved MCMDB N Motor Command C MCMD Motor Command D c Sp l Reserved MCMDC N R l Pm E E w EC o CR 2 EE 0 2 Das AIR 4 Ne l ICM 42000 External Driver E H 44 pin HD D Sub Connector Male 4080 For DMC 4050 thru DMC 4080 controllers only D ND C E EC wm 10 12V from Controller 25 12V 12V from Controller 40 MCME Motor Command E 11 MCMF Motor Command F 26 Reserved MCMDE N 41 Reserved MCMDF_N Reserved MCMDG_N 27 MCMG Motor Command G 42
178. fault port is the main serial port The controller has a special command CW which can affect the format of unsolicited messages This command is used by Galil Software to differentiate response from the command line and unsolicited messages The command CW 1 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 When handshaking is used hardware and or software handshaking characters which are generated by the controller are placed in a FIFO buffer before they are sent out of the controller The size of the RS 232 buffer is 512 bytes When this buffer becomes full the controller must either stop executing commands or ignore additional characters generated for output The command CW 1 causes the controller to ignore all output from the controller while the FIFO is full The command CW 0 causes the controller to stop executing new commands until more room is made available in the FIFO This command can be very useful when hardware handshaking is being used and the communication line between controller and terminal will be disconnected In this case characters will continue to build up in the controller until the FIFO is full For more information see the CW command in the Command Reference 62 e Chapter 4 Software To
179. feedback with or without an index pulse The encoder signals are wired to that axis associated 15pin DSub connector found on top of the controller The signal leads are labeled MA channel A MB channel B and MI For differential encoders the complement signals are labeled MA MB and MI For complete pin out information see Connectors for ICM 42000 Interconnect Board in the Appendices NOTE When using pulse and direction encoders the pulse signal is connected to CHA and the direction signal is connected to CHB The controller must be configured for pulse and direction with the command CE See the command summary for further information on the command CE Step D Verify proper encoder operation Start with the A encoder first Once it is connected turn the motor shaft and interrogate the position with the instruction TPA lt return gt The controller response will vary as the motor is turned At this point if TPA does not vary with encoder rotation there are three possibilities 1 The encoder connections are incorrect check the wiring as necessary 2 The encoder has failed using an oscilloscope observe the encoder signals Verify that both channels A and B have a peak magnitude between 5 and 12 volts Note that if only one encoder channel fails the position reporting varies by one count only If the encoder failed replace the encoder If you cannot observe the encoder signals try a different encoder 3 There is a hardwa
180. follows the commanded position This is done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling is the generation of the desired position function This function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the 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 174 e Chapter 10 Theory of Operation DMC 40x0 LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000 SP 20000 20000 AC 200000 00000 BG X AD 2000 BG Y EN This program corresponds to the velocity profiles shown in Fig 10 3 Note that the profiled positions show where the motors must be at any instant of time
181. g The controller will monitor the error conditions and respond as programmed in the application The errors are monitored 234 e A1 AMP 43040 DMC 40x0 via the TA command TA n may be used to monitor the errors with n 0 1 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 TA1 will return hall errors on the appropriate axes TA2 will monitor 1f 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 AMPERR in their program to handle soft or hard 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 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 Hall Error Protection During normal operation the controller should not have any Hall errors Hall errors can be caused by a faulty Hall effect sensor or a noisy environment
182. g 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 HMX 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 the abort input is activated the controller stops generating motion commands immediately whereas the limit switch response causes the controller to make a decelerated stop NOTE The effect of an Abort input is dependent on the state of the off on error function for each axis
183. general output block 2 outputs 17 24 general output block 3 outputs 25 32 general output block 4 outputs 33 40 general output block 5 outputs 41 48 general output block 6 outputs 49 56 general output block 7 outputs 57 64 general output block 8 outputs 65 72 general output block 9 outputs 73 80 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved 56 e Chapter 4 Software Tools and Communication DMC 40x0 42 UB Ethernet Handle A Status 43 UB Ethernet Handle B Status 44 UB Ethernet Handle C Status 45 UB Ethernet Handle D Status 46 UB Ethernet Handle E Status 47 UB Ethernet Handle F Status 48 UB Ethernet Handle G Status 49 UB Ethernet Handle H Status 50 UB error code 51 UB thread status see bit field map below 52 55 UL new Amplifier Status 56 59 UL new Segment Count for Contour Mode 60 61 UW new Buffer space remaining Contour Mode 62 63 UW segment count of coordinated move for S plane 64 65 UW coordinated move status for S plane see bit field map below 66 69 SL distance traveled in coordinated move for S plane 70 71 UW new Buffer space remaining S Plane 72 73 UW segment count of coordinated move for T plane 74 75 UW Coordinated move status for T plane see bit field map below 76 79 SL distance traveled in coordinated move for T plane 80 81 UW new Buffer space remaining T Plane Axis information 82 83 UW A axis status see bit field map below 84 UB A axis
184. ghalGromi ris res reno fw aw fav RS 232 Main Port Male Standard connector and cable 9Pin Notes 1 5V when 5V option is ordered on CMB Ex DMC 4040 C012 5V 1200 2 Reserved when 5V option is ordered on CMB 198 e Appendices DMC 40x0 Baud Rate Jumper Settings RS 232 Auxiliary Port Female Standard connector and cable 9Pin RS 422 Main Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option DMC 40x0 Appendices e 199 RS 422 Auxiliary Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option Ethernet 100 BASE T 10 BASE T Kycon GS NS 88 3 5 10 BASE 2 AMP 227161 7 10 BASE F HP HFBR 1414 TX Transmitter HP HFBR 2416 RX Receiver 200 e Appendices DMC 40x0 Jumper Description for ICM 42000 and CMB 41012 Communications Reserved 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 Baud Rate setting see table above Baud Rate setting see table above Used to upgrade controller firmware when resident firmware is corrupt Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated DMC 40x0 Appendices e 201 Cable Connections for DMC 40x0 The DMC 40x0 requires the transmit receive and ground for slow communication
185. gnal is SV active high amp enable HAEN sinking In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed by configuring the Amplifier Enable Circuit on the ICM 42x00 If your amplifier requires a different configuration than the default 5V HAEN sinking it is highly recommended that the DMC 40x0 is ordered with the desired configuration See the DMC 40x0 ordering information in the catalog http www galilmc com catalog cat40x0 pdf or contact Galil for more information on ordering different configurations Notel Many amplifiers designate the enable input as inhibit ICM 42000 and ICM 42100 Amplifier Enable Circuit This section describes how to configure the ICM 42000 and ICM 42100 for different Amplifier Enable configurations It is advised that the user order the DMC 40x0 with the proper Amplifier enable configuration The ICM 42000 and ICM 42100 gives the user a broad range of options with regards to the voltage levels present on the enable signal The user can choose between High Amp Enable HAEN Low Amp Enable LAEN 5V logic 12V logic external voltage supplies up to 24V sinking or sourcing Tables 3 2 and 3 3 found below illustrate the settings for jumpers resistor packs and the socketed optocoupler IC Refer to Figures 3 4 and 3 5 for precise physical locations of all components Note that the resistor pack located at RP2 may be reverse
186. h logical operators Logical operators oooi i o less than or equal to greater than or equal to DMC 40x0 Chapter 7 Application Programming e 133 Conditional Statements The conditional statement is satisfied 1f 1t evaluates to any value other than zero The conditional statement can be any valid DMC 40x0 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 Vil V 76 RABS V1 gt 10 Array Element VL lt Count 2 Variable V1 lt V2 Internal Variable TP X G _TVX gt 500 I O V1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 40x0 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 40x0 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 V3 lt
187. he DMC 40x0 controller with an ICM 42000 or ICM 42100 For detailed instruction on changing the amplifier enable configuration on a DMC 40x0 with an ICM 42200 see the section in Chapter 3 labeled ICM 42200 Amplifier Enable Configuration For electrical details about the amplifier enable circuit see the ICM 42000 and ICM 42100 Amplifier Enable Circuit section in Chapter 3 For DMC 4080 refer to DMC 4080 Steps 1 and 2 section below NOTE From the default configuration the configuration for 12V High Amp Enable Sinking Configuration does not require the remove of the metal cover This can be achieved by simply changing the jumpers DMC 4040 Steps 1 and 2 Step 1 Remove Cover Notes l Cover Removal A Remove Jack Screws 20 Places B Remove 6 32x3 16 Button Head Cover Screws 4 Places e Lift Cover Straight Up and Away from Unit REMOVE JACK SCREWS 20 PLCS REMOVE COVER SCREWS a 4 PLCS 206 e Appendices DMC 40x0 Step 2 Remove ICM REMOVE ICM For DMC 4040 Proceed to Step 3 Configure Circuit DMC 40x0 Appendices e 207 DMC 4080 Steps 1 and 2 Step 1 Remove Cover Notes l Cover Removal A Remove Jack Screws 34 Places B Remove 6 32x3 16 Button Head Cover Screws 4 Places 2 Lift Cover Straight Up and Away from Unit REMOVE JACK SCREWS 34 PLCS REMOVE COVER SCREWS 4 PLCS 208 e Appendices DMC 40x0 Step 2 Remove ICM s Appendices e 209 DMC 40x0 DMC 4040 and DMC 4080
188. he DMC 40x0 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 by beginning the program with the label AUTO 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 40x0 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 1s enabled by inserting a special predefined label in the applications program The pre defined labels are Automatically executes on power up AUTOERR Automatically executes when a checksum is encountered during AUTO start up Check error condition with RS bit 0 for variable checksum error bit 1 for parameter checksum error bit 2 for program checksum error bit 3 for master reset error there should be no program For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the POSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt subroutine When the specified input
189. her rotary or linear is measured by a sensor The resulting signal called position feedback is returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Fig 10 4 The mathematical model of the various components is given below CONTROLLER R A DIGITAL Y V E FILTER M ZOH DAC kt AMP MOTOR C P ENCODER Figure 10 4 Functional Elements of a Motion Control System DMC 40x0 Chapter 10 Theory of Operation e 177 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 1s as follows Voltage Drive The amplifier is a voltage source with a gain of Kv V V The transfer function relating the input voltage V to the motor position P is P V K K S ST 1 ST 1 where T RJ K s and T E R Is and the motor parameters and units are Kt Torque constant Nm A R Armature Resistance J Combined inertia of motor and load kg m2 L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to MKS units For example consider a mot
190. his example assigns the system filter parameters error limits and enables the automatic error shut off Instruction Interpretation KP10 10 10 10 Set gains for a b c d or A B C D axes KP 10 Alternate method for setting gain on all axes KPA 10 Method for setting only A or X axis gain KPX 10 Method for setting only X or A axis gain KP 20 Set B axis gain only Instruction Interpretation E eh eech gs cl ge Enable automatic Off on Error function for all axes ER 1000 Set error limit for all axes to 1000 counts KP10 10 10 10 10 10 10 10 Set gains for a b c d e f g and h axes KP 10 Alternate method for setting gain on all axes KPA 10 Alternate method for setting A axis gain Ka LO Set C axis gain only KPD 10 Alternate method for setting D axis gain KPH 10 Alternate method for setting H axis gain Example 2 Profiled Move Rotate the A axis a distance of 10 000 counts at a slew speed of 20 000 counts sec and an acceleration and deceleration rates of 100 000 counts s2 In this example the motor turns and stops Instruction Interpretation PR1000 Distance DMC 40x0 Chapter 2 Getting Started e 25 SP20000 DC AC BG 100000 100000 A Example 3 Multiple Axes Objective Move the four axes independently Instruction PR SP AC DC BG BG 500 1000 600 400 10000 12000 20000 10000 10000 10000 80000 40000 30000 AC BD 10000 10000 30000 Speed Deceleration Acceleration Start Motion
191. iate command VS It can also be attached to a motion segment with the instructions VP x y lt n gt m CR r 0 0 lt n gt m The first command lt n is equivalent to commanding Van 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 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 92 e Chapter 6 Programming Motion DMC 40x0
192. id Variable Names posx posl speedz DMC 40x0 Chapter 7 Application Programming e 143 Invalid Variable Names RealLongName 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 1s 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 40x0 function can be used to assign a value to a variable For example v ABS v2 or v2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters 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 v1 v3 v4 Assigns the value of vl 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 GN or PR PR v1 Assign vl to PR command SP vS 2000 Assign vS 2000 to SP command Display
193. ilable 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 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 DMC 40x0 Appendices e 229 Integrated Amplifiers and Drivers Overview A1 AMP 43040 D3040 The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless amplifiers that are capable of handling 500
194. ill immediately enable the motor upon power up The MO command will need to be issued to turn the motor off unless an error occurs that will turn the motors off The MO jumper is located on JP1 the same block as the Master Reset and Upgrade jumpers Communications Jumpers for DMC 40x0 The baud rate for RS232 communication can be set with jumpers found on JP1 of the communication board same set of jumpers where MO MRST and UPGD can be found To set the baud rate to the desired value see Table 2 below BAUD RATE 9600 19200 38400 115200 Table 2 1 Baud Rate Jumper Settings Other serial communication protocols such as RS 485 can be implemented as a special consult Galil Step 3 Install the Communications Software After applying power to the computer you should install the Galil software that enables communication between the controller and PC Using Windows XP 32 amp 64 bit Install the Galil Software Products CD ROM into your CD drive A Galil htm page should automatically appear with links to the software products Select the correct version of GalilTools software for your particular operating system and click Install Follow the installation procedure as outlined 14 e Chapter 2 Getting Started DMOO The most recent copy of the GalilTools software can be downloaded from the Galil website http www galilmc com products software galiltools html All other Galil software 1s also available for d
195. ing the value of variables at the terminal Variables may be sent to the screen using the format variable For example vl 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 0 Set in Jog mode BGXY Begin Motion LOOP Loop VX AN 1 20000 Read joystick X VY AN 2 20000 Read joystick Y JG VX VY Jog at variable vX vyY JP LOOP Repeat EN End 144 e Chapter 7 Application Programming DMCA Operands Operands allow motion or status parameters of the DMC 40x0 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 40x0 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 40x0 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 GAIN _GNZ 2 Assigns value from GNZ multiplied by two to variable GAIN JP LOOP _TEX gt 5 Jump to LOOP if the position error of X is greater than 5 J
196. ion SHUNT AT 5V JP2 SHUNT AT GND From Default Configuration Move U4 up one pin location on socket Reverse RP2 Change JP1 to GND Change JP2 to 5V gt 4 SogG00000000 ene PARDO Doo oe 606065060000 _ Bes pss gu Sr ee FENE CEA aa DOETE 065 RP2 PIN 1 es d n 1001 5V Low Amp Enable Sourcing Configuration SHUNT AT 5V JP2 SHUNT AT GND From Default Configuration Move U4 up one pin location on socket Change JP1 to GND Change JP2 to 5V 2 3 EE dE E U4 PIN 1 AAA O 606650650060000909 RP2 PIN 1 Ed R em A0 DMC 40x0 212 e Appendices 12V High Amp Enable Sinking Configuration Does not require the removal of Metal JP 2 SHUNT AT GND SHUNT AT 12Y From Default Configuration Change JP1 to 12V RP PIN 1 A EC rer G G eGoeGoGoGoGo U4 PIN 1 E ae C3 Ca b BE E 12V Low Amp Enable Sinking Configuration JP 2 SHUNT AT GND SHUNT AT 12Y From Default Configuration Reverse RP2 Change JP1 to 12V Zz i Porras Dopopopopopopooel c6506606500600600909 Ed E em 00 U4 PIN 1 RP PIN 1 Appendices e 213 DMC 40x0 12V High Amp Enable Sourcing Configuration SHUNT AT 4 12V JP2 SHUNT AT GND From Default Configuration Move U4 up one pin location on socket Reverse RP2 Change JP1 to GND Change JP2 to 12V 4 y AAA 250500005 DOTE TE
197. ion Subroutine Vector Mode Linear and Circular Interpolation Motion The DMC 40x0 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments The DMC 40x0 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specified for coordinated motion at any given time The command VM m n p where m and n are the coordinated pair and p is the tangent axis Note the commas which separate m n and p are not necessary For example VM XWZ selects the XW axes for coordinated motion and the Z axis as the tangent Specifying the Coordinate Plane The DMC 40x0 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T To specify vector commands the coordinate plane must first be identified This is done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applie
198. ire Ee 162 CGR ALC serne e 88 92 94 133 163 64 AA A AR ne SRE eterna 62 128 Filter Parameter Dad 24 178 EE 24 25 28 145 Wat EE 24 25 178 A O 2 21 24 25 178 187 eet Ai a 24 25 Proportional Cam 178 El EE 115 16 166 173 74 178 184 PS A a a 33 FOMA NIN esre a e a 153 155 156 PREQUCHOY aries 24 118 184 86 189 248 e Index Function 86 106 116 17 121 133 134 138 142 47 164 166 67 AAE as 124 156 Functions AIMO ls 134 142 Gain 3 5 20 24 25 28 145 Proportional sennen A caaa s 178 A T 95 98 A Ee 1 76 77 95 99 Halt 87 133 34 ADO A 86 92 169 171 204 5 Off On Error cooocccnnniccnnnnioccnnoniocinnninicnnos 33 169 171 Stop Moon 86 92 139 172 SEN 32 Ke 147 48 Amper Pra 169 1 0157 uge E 174 TEE 169 Hardware Handshake oocccncncccnnnnoccnoniccnnonanoss 49 62 Home l pte asesore mecmemenc acne tye 33 146 189 Home ES 118 FOMINS sina An 33 Find E 33 I O Amplifier Enable 6 18 19 41 169 A AlOG PU dad 81 Digtal TU acid cet dad 1 34 144 158 Digital Output ccccnnnnnnnnnnncncninonininininono 1 144 157 Home PUT 33 146 189 Limit Won dis 205 TT dais ata 169 Independent Motion Jog80 81 95 103 122 131 33 13940 145 166 171 oe EE 19 33 Ee Wie WEE 126 138 39 158 159 Input A A 81 Input Interrupt 126 133 138 39 158 159 TINTING EE 126 138 39 NI en ere ane ene R 149 Inputs EE Ee 144 45 146
199. is has a triangular velocity profile The X and Y axes accelerate to the specified speed move at this constant speed and then decelerate such that the final position agrees with the command position PR The Z axis accelerates but before the specified speed is achieved must begin deceleration such that the axis will stop at the commanded position All 3 axes have the same acceleration and deceleration rate hence the slope of the rising and falling edges of all 3 velocity profiles are the same 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 for each axis 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 1s 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 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 lo
200. is 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 40x0 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 Switch Type CN Setting Initial HMX state Normally Open Normally Open ont o Forward Revese Fomvard Normally Closed Normally Closed Example Homing Instruction Interpretation HOME Label CN yk Configure the polarity of the home input AC 1000000 Acceleration Rate DMC 40x0 Chapter 6 Programming Motion e 119 DC SP HM BG AM MG EN 1000000 5000 AT HOME Deceleration Rate Speed for Home Search Home Begin Motion After Complete Send Message End Figure 6 16 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 HOME SWITCH _HMX 1 VELOCITY MOTION BEGINS IN FORWARD DIRECTION gt POSITION VELOCITY MOTION CHANGES DIRECTION lt POSITION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD IND
201. istance Start recording now at rate of 2 msec Begin motion Loop until done Print message End program Play back Initial Counter Exit if done Je Print Counter Print X position Print Y position Print X error A Print Y error Increment Counter Done End Program 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 Input of Data The command IN is used to prompt the user to input numeric or string data Using the IN command the user may specify a message prompt by placing a message in quotations When the controller executes an IN command the controller will wait for the input of data The input data is assigned to the specified variable or array element 148 e Chapter 7 Application Programming DMC 40x0 An Example for Inputting Numeric Data A IN Enter Length EN lenX In this example the message Enter Length 1s displayed on the computer screen The controller waits for the operator to enter a value The operator enters the numeric value which is assigned to the variable lenX Cut to Length Example In this example a length of material is to be advanced a specified distance When the motion is complete a cutting head is activated to cut the material The length is variable and the operator is prompted to input it in inches Motion starts with a start button which 1s connected to input
202. k is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way 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 176 e Chapter 10 Theory of Operation DMC 40x0 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 1s 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
203. le of multiple objects is one Galil object containing a TCP handle to a DMC 40x0 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 controller 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 oe ae E i Data Record Access to the data record in both synchronous and asynchronous modes 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 d11 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 DMC 40x0 Chapter 4 Software Tools and Communication e 65 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 releas
204. ling window for displaying responses from the controller such as position and speed a storage scope control for plotting real time trajectories such as position versus time or X versus Y a send file control for sending contour data or vector DMC files a continuous array capture control for data collection and for teach and playback a graphical display control for monitoring a 2 D motion path a diagnostics control for capturing current configurations a display control for input and output status a vector motion control for tool offsets and corner speed control For more detailed information on the ActiveX Toolkit please refer to the user manual at http www galilmc com support manuals activex pdf DMCWin Programmers Toolkit Galil recommends the GalilTools Communication Library for all new applications DMCWin is a programmer s toolkit for C C and Visual Basic users The toolkit includes header files for the Galil communications API as well as source code and examples for developing Windows programs that communicate to Galil Controllers The Galil communications API includes functions to send commands download programs download upload arrays access the data record etc For a complete list of all the functions refer to the DMCWin user manual at http www galilmc com support manuals dmcwin pdf This software package is free for download and is available at http www galilmc com support download html 66 e Chapter 4 Softwa
205. ll codes is listed in the TC command in the Command Reference section Interrogating the Controller Interrogation Commands The DMC 40x0 has a set of commands that directly interrogate the controller When the command is entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and Leading Zeros LZ command See Chapter 7 and the Command Reference 74 e Chapter 5 Command Basics DMC 40x0 Summary of Interrogation Commands For example the following example illustrates how to display the current position of the X axis TP A lt return gt Tell position A 0 Controllers Response TP AB lt return gt Tell position A and B 0 0 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PR Request A B C D values PR Request B value only The controller can also be interrogated with operands Operands Most DMC 40x0 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
206. lop their own custom software interfaces to a Galil controller These tools include the Galil Tools Communication Library ActiveX Toolkit NET API and DMCWin For new applications Galil recommends the GalilTools Communication Libraries HelloGalil Quick Start to PC programming For programmers developing Windows applications 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 w Formi Sel Connected to 001842 Rev 1 00 Denel number 2039 0000 Figure 4 2 Sample program output http www galilmc com support hello_galil html GalilTools Communication Libraries The GalilTools Communication Library Galil class provides methods for communication with a Galil motion controller over Ethernet 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 C 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 examp
207. ly loop to make back and forth motion End main program Interrupt Routine Check for S stop motion Check for P pause motion Check for R resume motion Do nothing Routine for stopping motion Stop motion on A axis Zero program stack End Program Routine for pausing motion Save current speed setting of A axis motion Set speed of A axis to zero allows for pause Re enable trip point and communication interrupt DMC 40x0 FRESUME Routine for resuming motion SPA rate Set speed on A axis to original speed BNI 1 Re enable trip point and communication interrupt For additional information see section on Using Communication Interrupt Example Ethernet Communication Error This simple program executes in the DMC 40x0 and indicates via the serial port when a communication handle fails By monitoring the serial port the user can re establish communication if needed Instruction Interpretation LOOP Simple program loop JP LOOP EN TCPERR Ethernet communication error auto routine MG P1 _IA4 Send message to serial port indicating which handle did not receive proper acknowledgment RE Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 40x0 provides the use of the following mathematical operators IT Tosa or On some computes a solid vena ne appear ava broken Ting The numeric range for addition subtraction and multiplication operations is 2 147 483 647 9999 The p
208. mand TE A lt return gt Tell error a few times and get varying responses especially with reversing polarity 1t indicates system vibration When this happens simply reduce KD by about 20 24 e Chapter 2 Getting Started DMC 40x0 Next you need to increase the value of KP gradually maximum allowed is 1023 875 You can monitor the improvement in the response with the Tell Error instruction KP 10 lt return gt Proportion gain TE A lt return gt Tell error As the proportional gain is increased the error decreases Again the system may vibrate if the gain is too high In this case reduce KP by about 20 Typically KP should not be greater than KD 4 only when the amplifier is configured in the current mode Finally to select KI start with zero value and increase it gradually The integrator eliminates the position error resulting in improved accuracy Therefore the response to the instruction TE A lt return gt becomes zero As KI is increased its effect is amplified and it may lead to vibrations If this occurs simply reduce KI Repeat tuning for the B C and D axes Note For a more detailed description of the operation of the PID filter and or servo system theory see Chapter 10 Theory of Operation Design Examples Here are a few examples for tuning and using your controller These examples have remarks next to each command these remarks must not be included in the actual program Example 1 System Set up T
209. moothes 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 y Z W where x y z W is an integer from 0 25 to 64 and represents the amount of smoothing The smoothing parameters x y z w and n are numbers between 0 25 and 64 and determine the degree of filtering The minimum value of 0 25 implies no 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 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 1s used to define the polarity of the home input 118 e Chapter 6 Programming Motion DMC 40x0 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
210. ms which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies the KP proportional and KI integral terms to the position error based on the load encoder and applies the KD derivative term to the motor encoder This method results in a stable system The dual loop method is activated with the instruction DV Dual Velocity where DV ge es E activates the dual loop for the four axes and DV Oy 0 00 disables the dual loop Note that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if 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 1s 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
211. n MG ERROR _QSX YRX _QSX Else error is valid use QS for correction MCX Wait for motion to complete MG CORRECTED ERROR NOW _QSX DMC 40x0 Chapter 6 Programming Motion e 113 WT100 Wait helps user see the correction RETURN SPX spsave Return the speed to previous setting REO Return from POSERR Example Friction Correction The following example illustrates how the SPM mode can be useful in correcting for X axis friction after each move when conducting a reciprocating motion The drive is a 1 64th microstepping drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to continue upon error KS 16 Set step smoothing Miya A AS 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 Wok 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 MCX JS CORRECT Move to correction JP MOTION CORRECT Correction code spx _5PX FLOOP 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 MCX WT100 St
212. n 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 DMC 40x0 A3 SDM 44040 e 243 A4 SDM 44140 Introduction The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis i Figure Al 1 DMC 4040 C012 1000 D4140 DMC 4040 with SDM 44140 244 e A4 SDM 44140 DMC 40x0 Electrical Specifications The amplifier is a brush type trans conductance linear amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input DC Supply Voltage 12 60 VDC Max Current per axis 3 0 Amps Selectable with AG command Max Step Frequency 6 MHz Motor Type Bipolar 2 Phase Switching Frequency 60 kHz Minimum Load Inductance 0 5 mH Mating Connectors POWER 6 pin MATE N LOK MOLEX 39 01 2065 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 01 2045 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Motor Connector CE DMC 40x0 A4 SDM 44140 e 245 Operation The AG command sets the current on each axis and the LC command configures each axis s behavior when holding
213. nalog 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 3 13107 0x3333 myanalog Analog input 3 0x401CCCCD 2 45V Analog input 4 0xC0C33333 6 1V Example 3 DMC 4040 connected as a Modbus master to a hydraulic pump The DMC 4040 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 THB 192 168 1 100 lt 502 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 function code 16 Start at address 30000 and write to 2 registers using the data in the array pump MBB 16 30000 2 pumpl 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 Example Communicating with OPTO 22 SNAP B3000 ENET in the Appendices DMC 40x0 Chapter 4 Software Tools and Communication e 55 Data Record The DMC 40x0 can provide a block of status information with the use of a single command QR This comma
214. nctions 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 commands IT x y z w 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 parameters x y z w and n are numbers 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 The following example illustrates the effect of smoothing Fig 6 15 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 E Filter for smoothing BG X Begin DMC 40x0 Chapter 6 Programming Motion e 117 ACCELERATION O Cc E 2 VELOCITY U O A ee ACCELERATION VELOCITY O S C O O E OI H Ge O Bn o d q lt x Figure 6 15 Trapezoidal velocity and smooth velocity profiles Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command s
215. nd XQ A Start the program running If the ED command is issued from the Galil Windows terminal software such as Smart TERM the software will open a Windows based editor From this editor a program can be entered edited downloaded and uploaded to the controller Example 12 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction Interpretation A Label DP 0 Define current position as zero v1 1000 Set initial value of V1 LOOP Label for loop PA V1 Move A motor V1 counts BG A Start A motion AM A After A motion is complete 28 e Chapter 2 Getting Started DMC 40x0 WT 500 TP A v1 V1 1000 JP LOOP V1 lt 10001 EN Wait 500 ms Tell position A Increase the value of V1 Repeat if V1 lt 10001 End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ A Execute Program A Example 13 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction B DP 0 0 PR 30000 60000 SP 5000 5000 BGA AD 4000 BGB AP 6000 SP 2000 50000 AP 50000 SP 10000 EN To start the program command XQ B Interpretation Label Define initial positions Set targets Set speeds Start A motion Wait until A moved 4000 Start B motion Wait until position A 6000 Change speeds Wait until position B 50000 Change speed of B End program Execute Program B Ex
216. nd along with the QZ command can be very useful for accessing complete controller status The QR command will return 4 bytes of header information and specific blocks of information as specified by the command arguments OR ABCDEFGHST Each argument corresponds to a block of information according to the Data Record Map below If no argument is given the entire data record map will be returned Note that the data record size will depend on the number of axes Note UB Unsigned Byte 1 UW Unsigned Word 2 SW Signed Word 2 SL Signed Long Word 4 UL Unsigned Long Word 4 ADDR 00 01 02 03 04 05 06 07 08 09 10 11 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 TYPE UB UB UB UB UW UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB UB SW new SW new SW new SW new SW new SW new SW new SW new ITEM 1 Byte of Header 2 Byte of Header 3 Byte of Header A Byte of Header sample number general input block 0 inputs 1 8 general input block 1 inputs 9 16 general input block 2 inputs 17 24 general input block 3 inputs 25 32 general input block 4 inputs 33 40 general input block 5 inputs 41 48 general input block 6 inputs 49 56 general input block 7 inputs 57 64 general input block 8 inputs 65 72 general input block 9 inputs 73 80 general output block 0 outputs 1 8 general output block 1 outputs 9 16
217. nded to use an isolated supply for the optoisolated inputs The optoisolated inputs are configured into groups For example the general inputs DI1 DI8 inputs 1 8 the ABRT abort input and RST reset and ELO electronic lock out inputs are one group Figure 3 1 illustrates the internal circuitry The INCOM signal is a common connection for all of the inputs in each group 34 e Chapter 3 Connecting Hardware DMC 40x0 4080 The ELO ABRT and RST pins are found on the I O A D D Sub and are duplicated on the I O E H D Sub Le There is only one ELO ABRT and RST input for an 8 axis controller The common is the INCOM found on the I O A D D Sub connector The optoisolated inputs are connected in the following groups DMC 40x0 Group Controllers with 1 4 Axes Common Signal DI DIS ABRT RST ELO INCOM I O A D D Sub Connectors FLSA RLSA HOMA LSCOM I O A D D Sub Connectors FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD DI1 DI8 ABRT RST ELO INCOM I O A D D Sub Connectors FLSA RLSA HOMA LSCOM I O A D D Sub Connectors FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD DI9 DI16 INCOM I O E H D Sub Connectors FLSE RLSE HOME LSCOM I O E H D Sub Connectors FLSF RLSF HOMF FLSG RLSG HOMG FLSH RLSH HOMH Table 3 1 INCOM and LSCOM information Chapter 3 Connecting Hardware e 35 ECON A i hs gt Additional Limit Switches Dependent on Number of Axes 2 2KQ RPACK SC e s lt u O O O O O
218. necessary drivers to communicate In addition Galil offers software development tools CToolkit and ActiveX Toolkit to allow users to create their own application interfaces using programming environments such as C C Visual Basic and LabVIEW Galil also offers some basic software drivers and utilities for non Windows environments such as DOS Linux and QNX 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 the application level SmartTERM and WSDK are 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 Galil provides software tools ActiveX and API functions for advanced 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 or use our ActiveX COM objects The ActiveX controls can simplify programming and offer additional functionality over using the communication DLL s directly At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers RS232 and RS422 Ports The RS232 pin out description for the main and auxiliary port is given below Note that the a
219. ner the speed is increased back to 4000 cts s 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 such as CNC 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 y z w lt n gt m The first command lt n is equivalent to commanding VSn 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 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 ALT Label for alternative program DP 0 0 Define Position of X and Y axis to be 0 LMXY Define linear mode between X and Y axes LI 4000 0 lt 4000 gt 1000 Sp
220. ng 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 axis when the gearing is engaged For example if the master axis is already traveling at 1 000 000 cts 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 1 000 000 counts sec and the gear ratio is 1 1 but the gearing is slowly engaged over 30 000 cts of the master axis greatly diminishing the initial shock to the slave axis Figure 1 below shows the velocity vs time profile for instantaneous gearing Figure 6 9 shows the velocity vs time profile for the gradual gearing engagement p p p I I I I I I I I I I I I I I I Le r Le I I I I I I I I I I I I Figure 6 9 Velocity cts sec vs Time msec Instantaneous Gearing Engagement 96 e Chapter 6 Programming Motion DMC 40x0 I I I I I I I I I I I I L i I I I I I I I I I I I I U I I Figure 6 10 Velocity cts sec vs Time msec Ramped Geari
221. ng The slave axis for each figure is shown on the bottom portion of the figure the master axis 1s shown on the top portion The shock to the slave axis will be significantly less in figure 6 10 than in figure 6 9 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 Example Electronic Gearing Over a Specified Interval Objective Run two geared motors at speeds of 1 132 and 045 times the speed of an external master Because the master is traveling at high speeds it is desirable for the speeds to change slowly Solution Use a DMC 4030 controller where the Z axis is the master and X and Y are the geared axes We will implement the gearing change over 6000 counts 3 revolutions of the master axis MO Z Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GD6000 6000 Specify ramped gearing over 6000 counts of the master axis GR 1 132 045 Specify gear ratios Question What is the effect of the ramped gearing Answer Below in the example titled Electronic Gearing gearing w
222. nication The communication interface with the DMC 40x0 consists of high speed RS 232 and Ethernet The Ethernet is 10 100Bt and the two RS 232 channels can generate up to 115K General I O The DMC 40x0 provides interface circuitry for 8 bi directional optoisolated inputs 8 high power optoisolated outputs and 8 analog inputs with 12 Bit ADC 16 Bit optional The DMC 40x0 also has an additional 32 I O 3 3V 4eChapter1Overview see DMCA logic and unused auxiliary encoder inputs may also be used as additional inputs 2 inputs each axis The general inputs can also be used as high speed latches for each axis A high speed encoder compare output is also provided 4080 The DMC 4050 through DMC 4080 controller provides an additional 8 optoisolated inputs and 8 high power optoisolated outputs System Elements As shown in Fig 1 2 the DMC 40x0 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Power Supply Computer DMC 40x0 Controller Amplifier Driver Figure 1 2 Elements of Servo systems Motor 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 you with motor sizing www galilmc com support motorsizer The motor may be a step or servo motor and can be brush type or brushles
223. nnections from controller to amplifier input Motor is enabled even when MO command is given Unable to read main or auxiliary encoder input 172 e Chapter 9 Troubleshooting motor to change speed The SH command disables the motor The encoder does not work when swapped with another encoder input internal offset 2 Damaged amplifier 1 The amplifier requires the a different Amplifier Enable setting on the Interconnect Module 1 Wrong encoder connections 2 Encoder is damaged 3 Encoder configuration incorrect offset may also be compensated by use of the offset configuration on the controller see the OF command Replace amplifier Refer to Chapter 3 or contact Galil 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 DMC 40x0 Unable to read main or The encoder works 1 Wrong encoder Check encoder wiring For single auxiliary encoder input correctly when swapped connections ended encoders MA and MB with another encoder input only do not make any connections eo Faeoder to the MA and MB inputs configuration incorrect Check CE command 3 Encoder input or Contact Galil controller is damaged Encoder Position Drifts Swapping cables fixes the 1 Poor Connections Review all connections and problem intermittent cable connector contacts Encoder Position
224. nnectors mfg PN s and diagrams see the Power Connector Section in the Appendix DMC 40x0 Chapter 2 Getting Started e 9 DMC 4040 Dimensions 20 201 4 PLCS DMC 4040 GALIL MOTION CONTROL MADE IN USA hizo 6 7 5 1 Eed 100 LS 1063 pr its Eo ca HT Cii AS Figure 2 5 Dimensions of DMC 4040 10 e Chapter 2 Getting Started DMC 40x0 mensions DMC 4080 D ooo a EEY S 9 GeL IT i Wan Ni dowry gt a TOHLNOO NOLON TYD Kach cet 080r OWG DO D sol y LOZ Oe Figure 2 6 Dimensions of DMC 4080 Chapter 2 Getting Started e 11 DMC 40x0 Elements You Need For a complete system Galil recommends the following elements 1 DMC 4010 4020 4030 or DMC 4040 Motion Controller or DMC 4050 4060 4070 or DMC 4080 2 Motor Amplifiers Integrated when using Galil amplifiers and drivers 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 40x0 s integrated ICM s 5 PC Personal Computer RS232 or Ethernet for DMC 40x0 6 GalilTools Software package GalilTools is highly recommended for first time users of the DMC 40x0 It provides step by step instructions for system connection tuning and analysis 12 e Chapter 2 Getting Started DMC 40x0 Installing the DMC 40x0 Installation of a complete operational DMC 40x0 system consists of 9 steps Step 1 Determine overall motor configuration S
225. nnoos 110 Operand Summary Stepper Motor Operatnon nono nnnnnnnnonnnnnos 111 Stepper Position Maintenance Mode GPM 111 Internal Controller Commands user Can query ccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 111 User Configurable Commands user can query amp change occcccncnccnnccnncnoconininos 111 A O A 112 COMO ollas 112 Dual Loop Auxiliary EnCOGe ii veaveeureedveseurseetoeveroveotarsentouness 115 Backlash Compensation ad EE 115 M t SOO E dad 117 Use tic IT COmMent Sta 117 Using the KS Command Step Motor Smoothing 0000000000000000000000000000000000ssee 118 EE 118 DAS EE 119 EE 119 EE 119 Command Summary Homing Operation 121 Operand Summary Homing Operaton nono nono nono nono ono no nnnnnnoos 121 High Speed Position Capture The Latch Funcnon nooo nono nono nnnnnnos 121 DMC 40x0 DMC 40x0 Fast Update Rate E 123 Chapter 7 Application Programming 124 EE a eet 124 Using the DMC 40x0 Editor to Enter Progerams 124 EditMode Command a dia 125 PPO OU AMUN Wt OTIIVAL seats oss Gece sk escent a 125 Usina ENEE 125 en RER RE E 126 EIERE 126 Executing Programs MUI A A A 127 Eege 128 PEO Flow O A a EA 129 Event TALES A oie ae eee ae 130 Event Tigger Examples sc j iiss eee tite oret dete a ee ee 131 Conditional Se LEN 133 Using MElsg and Endi Commands a 135 SUD FOULING eegene een 136 Sta kari ll Al OM aces 25sec tei a a a aa aa 137 e Lali ROUD O ii tiza 137 Automatic Subroutines
226. 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 1s 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 The lower case specifiers x y z w represent position values for each axis The DMC 40x0 also allows use of single axis specifiers such as PRY 2000 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x 78 e Chapter 6 Programming Motion DMC 40x0 A PR SP AC DE BG WT BG WT BG EN Returns the speed for the axis specified by x Returns current destination if x axis is moving otherwise returns the current commanded position if in a move Returns current incremental distance specified for the x axis Example Absolute Position Movement PA 10000 20000 Specify absolute X Y position AC
227. nsible for any incidental or consequential damages Hardware Protection The DMC 40x0 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 Each axis amplifier has separate amplifier enable lines This signal also goes low when the watch dog timer is activated or upon reset Note The standard configuration of the AEN signal is TTL active low Both the polarity and the amplitude can be changed To make these changes see section entitled Amplifier Circuit in Chapter 3 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 one of the following error 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 168 e Chapter 8 Hardware amp Software Protection DMC 40x0 Input
228. nt is prescribed Independent Jogging JG Motion stops on Stop command AC DC ST Absolute positioning mode where absolute position targets Position Tracking PA may be sent to the controller while the axis is in motion PT SP AC DC Motion Path described as incremental position points versus Contour Mode CM time CD DT LM 2 3 or 4 axis coordinated motion where path is described by Linear Interpolation linear segments 76 e Chapter 6 Programming Motion DMC 40x0 2 D motion path consisting of arc segments and linear Coordinated Motion segments such as engraving or quilting Third axis must remain tangent to 2 D motion path such as Coordinated motion with tangent axis specified VM knife cutting VP CR VS VA VD TN VE Electronic gearing where slave axes are scaled to master axis Electronic Gearing GA which can move in both directions GD _GP GR GM if gantry Master slave where slave axes must follow a master such as Electronic Gearing conveyer speed Moving along arbitrary profiles or mathematically Contour Mode prescribed profiles such as sine or cosine trajectories Teaching or Record and Play Back Contour Mode with Automatic Array Capture Backlash Correction Dual Loop Following a trajectory based on a master encoder position Electronic Cam EQ Smooth motion while operating in independent axis Independent Motion Smoothing IT positioning Smooth motion while operating in vector or linear Vect
229. ntenance 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 encoder port Enabling the SPM mode on a controller with YS 1 executes 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 DMC 40x0 Chapter 6 Programming Motion e 111 TPxYA x YB S TD KR YC Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally Y A 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 1f 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 OE 0 the axis stays in motion if OE 1 the axis is stopped 2 YS is set to 2 which causes the automatic subroutine labeled FPOSERR to be executed Co
230. nterval 2 ms CD 0 0 End Contour buffer Wait JP Wait CM lt gt 511 Wait until path is done EN POSITION COUNTS SE Jee E 240 192 96 48 ptei TIME ms S 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 13 The Required Trajectory Additional Commands _ CM gives the amount of space available in the contour buffer 511 maximum Zero parameters for DT followed by zero parameters for CD exit the contour mode If no new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a Command Summary Contour Mode COMMAND DESCRIPTION CM XYZW Specifies which axes for contouring mode Any non contouring axes may be operated in other modes CM Contour axes for DMC 4080 ABCDEFGH CD x y z w Specifies position increment over time interval Range is 32 000 CD 0 0 0 0 ends the contour buffer This is much like the LE or VE commands DMC 40x0 Chapter 6 Programming Motion e 105 CD Position increment data for DMC 4080 a b c d e f g h Specifies time interval 2 sample periods 1 ms for TM1000 for position increment where n is an integer between and 8 Zero ends contour mode If n does not change it does not need to be specified with each CD Amount of space left in contour buffer 511 maximum General Velocity Profiles The Contour M
231. ntouring mode may be operated in other modes A contour is described by position increments which are described with the command CD x y z w over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2n 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 sample If the time interval changes for each segment use CD x y z w n where n is the new DT value Consider for example the trajectory shown in Fig 6 13 The position X may be described by the points Point 1 X 0 at T Oms Point 2 X 48 at T 4ms Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 DX 48 Time 4 DT 2 Increment 2 DxX 240 Time 8 DT 3 Increment 3 DX 48 Time 16 DT 4 104 e Chapter 6 Programming Motion DMC 40x0 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 i
232. ntroller requires that the command MT must be given Further instruction for stepper motor connections are discussed in Step 8c Step 2 Install Jumpers on the DMC 40x0 Master Reset and Upgrade Jumpers JP1 on the main board contains two jumpers MRST and UPGRD The MRST jumper is the Master Reset jumper When MRST is connected the controller will perform a master reset upon PC power up or upon the reset input going low Whenever the controller has a master reset all programs arrays variables and motion control parameters stored in EEPROM will be ERASED The UPGRD jumper enables the user to unconditionally update the controller s firmware This jumper is not necessary for firmware updates when the controller is operating normally but may be necessary in cases of corrupted EEPROM EEPROM corruption should never occur however it is possible if there is a power fault during a firmware update If EEPROM corruption occurs your controller may not operate properly In this case install the UPGRD Jumper and use the update firmware function on the Galil Terminal to re load the system firmware Motor Off Jumpers The state of the motor upon power up may be selected with the placement of a hardware jumper on the controller With a jumper installed at the MO location the controller will be powered up in the motor off state The SH command will need to be issued in order for the motor to be enabled With no jumper installed the controller w
233. o Galil Controllers with C Windows and Linux and COM enabled languages such as VB C and Labview Windows only GalilTools runs on Windows and Linux platforms as standard with other platforms available on request GalilTools Lite is available at no charge and contains the Editor Terminal Watch and Communcition Library tools only The latest version of GalilTools can be downloaded from the Galil website at http www galilmc com products software galiltools html For information on using Galil Tools see the help menu in Galil Tools or the GalilTools user manual http www galilmc com support manuals galiltools index html DMC 40x0 Chapter 4 Software Tools and Communication e 63 Galillools 192 168 1 2 DMC4080 Rev 1 0 1 IHC Hard5topHoming dme 5 File Edit Window Controller Tools Help New Open Save Connect Upload Download Execute Watch Tuner Scope Terminal Tuner OI x Step Amplitude 100 counts Step Time 100 ms hard stop Terminal a x Home DCX 6 7107 Source Value Units AN 1 2 5781 ii MG Lookir JGA 1 00H e d wl Hi HI oe A Gi Scope Source Scale idiv Offset div EECHER Zeg AE A O EE A A CS EPT EI A A a _TTA Axis A torque DAC w m Trigger Figure 4 1 GalilTools 64 e Chapter 4 Software Tools and Communication DMC 40x0 Creating Custom Software Interfaces Galil provides programming tools so that users can deve
234. o o o DC x ce DE a Gei S E S 3 SG E i 1 i E ef Zen ER B oe MAM DND GHD ATAM EY S APWE 121 2124 AECI AEC ANALOG CH E es CH L St St 9 AGND Vente E T 8 1 10 AB D a us E gt CH 3 An Ge Dei a 5 z NAK a z x pr i iaa f 1 Hi 5 Al cc Di 1341 n D GI 6 AGND 14 NC E sey TIE o 5 se B4 5V EXTENDED VO EXTERNAL DRIVER 4 0 JO A D B aa ET 1058 m aisteg JEE ipes 1 gran Seay Jr 17 1020 17 RES 44 CMP 14 ORET 321022 21021 JRS amp 2STPC Ge 29008 16 1023 Tr en uereg EN 43 DOT 13006 ao eer 3102 Y HGD Gen FRES por ae 0 3441087 20 4 10126 Lu T MORE ams 4AES H a pp SUGE e 351090 TH siga 35 RES 5 DIAG n SNC 21 1091 DAD PES apen S 10 HOMD O 36 GND 81032 mun GRES on SALS Ju some 9 D mue P 99 FLSD 3 HOMO ZE an TA E TAEMA aner SEALSE ao RESET WNE 8 1036 AECE gt B AEMD 23 ALSB 24 10137 24 WIC 37 FLSB 7 HOMA 39 GND 24 om OPT 39 GND ONC III 99 ALGA 25 NIC LINKACT mm 7 IBFLSA 77 BLSCOM 401009 10 NC MO 20 MEMA TEES STT 26 040 RES 35 GND 5 ELO 411042 Srpg MION 38 4K 41 RES Sy yeup 1 MEME og DABRT o 421045 se 12 1044 ER Ji ERROR 42MCMD 12 RES e 19 De 98 oc appes ZY ao 3 Da 43 GND 13 1047 UPGD GND So we gt 8013 AN d met 14 NC MAST Oh POWER 44 NIC gt A 14 NIC e od 17 INCOM z md i 15 RES 1545 ener Figure 2 1 Outline of the of the DMC 4040 DMC 40x0 Chapter 2 Getting Started e 7 DMC 4080 Layout 5 iHa
235. ode is ideal for generating any arbitrary velocity profiles The velocity profile can be specified as a mathematical function or as a collection of points The design includes two parts Generating an array with data points and running the program Generating an Array An Example Consider the velocity and position profiles shown in Fig 6 14 The objective is to rotate a motor a distance of 6000 counts in 120 ms The velocity profile 1s 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 Q27 B Note is the angular velocity X is the position and T is the variable time in milliseconds In the given example A 6000 and B 120 the position and velocity profiles are X 50T 6000 27 sin 27n T 120 Note that the velocity in count ms is 50 1 cos 27 T 120 Figure 6 14 Velocity Profile with Sinusoidal Acceleration The DMC 40x0 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 1s computed and is
236. of 2 or 80000 counts and the motion starts at the angle of 270 and traverses 360 in the CW negative direction Such a path is specified with the instruction CR SS 0000 20 gt 200 162 e Chapter 7 Application Programming DMC 40x0 DMC 40x0 INSTRUCTION A VM XY VP 160000 160000 VE VS 200000 VA 1544000 BGS AMS PR 80000 SP 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ PR 21600 SP 20000 BGX AMX PR 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ VP 37600 16000 VE VS 200000 BGS AMS EN Further assume that the Z must move 2 at a linear speed of 2 per second The required motion is performed by the following instructions FUNCTION Label Circular interpolation for XY Positions End Vector Motion Vector Speed Vector Acceleration Start Motion When motion is complete Move Z down Z speed Start Z motion Wait for completion of Z motion Circle Feed rate Start circular move Wait for completion Move Z up Start Z move Wait for Z completion Move X Speed X Start X Wait for X completion Lower Z Z second circle move Raise Z Return XY to start Chapter 7 Application Programming e 163 0 4 9 3 X Figure 7 2 Motor Velocity and the Associated Input Output signals Speed Control by Joystick The speed of a motor is controlled by a joystick The joystick produces a signal in
237. 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 N Y DMC 40x0 INSTRUCTION INTERPRETATION FSETUP Label EAX Select X as master EM 2000 1000 Cam cycles EP 20 0 Master position increments N 0 Index LOOP Loop to construct table from equation P N 3 6 Note 3 6 0 18 20 S SIN P 100 Define sine position Y N 10 S Define slave position Define table Chapter 6 Programming Motion e 101 JP LOOP N lt 100 Repeat the process EN Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center of the cycle X 1000 and Y 500 This implies that Y must be driven to that point to avoid a jump This is done with the program INSTRUCTION INTERPRETATION RUN Label EB1 Enable cam PA 500 starting position SP 50 0 0 Y speed BGY Move Y motor AM After Y moved AI1 Wait for start signal EG 1000 Engage slave AE a Wait for stop signal EQ 1000 Disengage slave EN End Command Summary Electronic CAM EA p Specifies master axes for electronic cam where p X Y Z or W or A B C D E F G H for main encoder as master or M or N a for virtual axis master Enables the ECAM ECAM counter sets the index into the ECAM table EG x y Z W Engages ECAM o eines the CAM bt es OOOO EW Widen Segment se Aplcai
238. oint where the error occurs To display the last line number of program execution issue the command MG ED The user can obtain information about the type of error condition that occurred by using the command TC1 This command reports back a number and a text message 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 RAM Memory Interrogation Commands For debugging the status of the program memory array memory or variable memory the DMC 40x0 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 14010 will have a maximum of 16000 array elements in up to 30 arrays If an array of 100 elements is defined the command DM will return the value 15900 and the command DA will return 29 128 e Chapter 7 Application Programming DMC 40x0 To list the contents of the variable space use the interrogation command LV List Variables To list the contents of array s
239. ols and Communication DMC 40x0 GalilTools Windows and Linux Galil Tools is Galil s set of software tools for current Galil controllers It is highly recommended for all first time purchases of Galil controllers as it provides easy set up tuning and analysis GalilTools replaces the WSDK Tuning software with an improved user interface real time scopes and communications utilities The Galil Tools set contains the following tools Scope Editor Terminal Watch and Tuner and a Communication Library for development with Galil Controllers The powerful Scope Tool is ideal for system analysis as 1t captures numerous types of data for each axis in real time Up to eight channels of data can be displayed at once and additional real time data can be viewed by changing the scope settings This allows literally hundreds of parameters to be analyzed during a single data capture sequence A rising or falling edge trigger feature 1s also included for precise synchronization of data The Program Editor Tool allows for easy writing of application programs and multiple editors to be open simultaneously The Terminal Tool provides a window for sending and receiving Galil commands and responses The Watch Tool displays controller parameters in a tabular format and includes units and scale factors for easy viewing The Tuning Tool helps select PID parameters for optimal servo performance The Communication Library provides function calls for communicating t
240. ommand Position Format is specified by DMC 40x0 Chapter 7 Application Programming e 153 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 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 1s PF 10 0 If the number of decimal places specified by PF 1s less than the actual value a nine appears in all the decimal places Example Instruction Interpretation DEAL 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 PF2 Format 2 places TPA Tell Position 99 Returns 99 if position greater than 99 Removing Leading Zeros from Response to Interrogation Commands The leading zeros on data returned as a response to interrogation commands can be removed by the use of the command LZ LZO 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 g co Response Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrog
241. on tE SSS CN CTC Operand Summary Electronic CAM Command Description Contains State of ECAM Contains current ECAM index Km Contains ECAM status for each axis EM o Contains size of cycle for each axis 102 e Chapter 6 Programming Motion DMC 40x0 Contains value of the ECAM table interval _EQx EY Example Electronic CAM Contains ECAM status for each axis Set ECAM cycle count The following example illustrates a cam program with a master axis Z and two slaves X and Y INSTRUCTION FA V1 0 PA 0 0 BGXY AMXY EA Z EM 0 0 400 EP400 0 ET 0 0 0 ET 1 40 2 ET 2 120 ET 3 240 ET 4 280 ET 5 280 ET 6 280 ET 7 240 ET 8 120 ET 9 40 2 ET 10 0 0 EB 1 JGZ 4000 EG 0 0 BGZ LOOP JP LOOP V1 0 EQ2000 200 MF 2000 ST Z EB O EN 0 O 60 120 140 140 140 120 60 O 0 INTERPRETATION Label Initialize variable Go to position 0 0 on X and Y axes Z axis as the Master for ECAM Change for Z is 4000 zero for X Y ECAM interval is 400 counts with zero start When master is at 0 positions 1 point 2 point in the ECAM table 3 point in the ECAM table 4 point in the ECAM table 5 point in the ECAM table 6 point in the ECAM table 7 point in the ECAM table m 8 point in the ECAM table Or point in the ECAM table 10 point in the HCAM table Starting point for next cycle Enable ECAM mode Set Z to jog at 4000 Engage
242. onnecting sinusoidal commutation motors the servos must be tuned as described in Step 9 Step A Disable the motor amplifier Use the command MO to disable the motor amplifiers For example MOA will turn the A axis motor off Step B Connect the motor amplifier to the controller The sinusoidal commutation amplifier requires 2 signals usually denoted as Phase A amp Phase B These inputs should be connected to the two sinusoidal signals generated by the controller The first signal is the axis specified with the command BA Step 6 The second signal is associated with the highest analog command signal available on the controller note that this axis was made unavailable for standard servo operation by the command BA When more than one axis is configured for sinusoidal commutation the controller will assign the second phase to the command output which has been made available through the axes reconfiguration The 2 phase of the highest sinusoidal commutation axis will be the highest command output and the 2 phase of the lowest sinusoidal commutation axis will be the lowest command output It is not necessary to be concerned with cross wiring the 1 and 2 signals If this wiring is incorrect the setup procedure will alert the user Step D DMC 40x0 Chapter 2 Getting Started e 21 Example Sinusoidal Commutation Configuration using a DMC 4070 BAAC This command causes the controller to be reconfigured as a DMC 4050 controller The
243. onnecting Hardware DMC 40x0 Analog Inputs The DMC 40x0 has eight analog inputs configured for the range between 10V and 10V The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 005V A 16 bit ADC is available as an option Ex DMC 4020 16bit C012 1000 The analog inputs are specified as AN x where x is a number 1 thru 8 AQ settings The analog inputs can be set to a range of 10V 5V 0 5V or 0 10V The inputs can also be set into a differential mode where analog inputs 2 4 6 and 8 can be set to the negative differential inputs for analog inputs 1 3 5 and 7 respectivally See the AQ command in the command reference for more information Electrical Specifications Input Impedance 12 and 16 bit Single Ended Unipolar 42kQ Differential Bipolar 31kQ TTL Outputs Output Compare The output compare signal is TTL and is available on the I O A D D Sub connector as CMP Output compare is controlled by the position of any of the main encoders on the controller The output can be programmed to produce an active low pulse 250 nsec based on an incremental encoder value or to activate once when an axis position has been passed For further information see the command OC in the Command Reference A080 For controllers with 5 8 axes a second output compare signal is available on the I O E H D Sub connector Error Output The controller provides a TTL signal ERR to indicate a controlle
244. onnos 88 Operand Summary Linear Interpolati0N oooonnnnncccucuananonononononononrono non onnnnnonnnonnnnnnnos 88 Example e Linear MOVE atari ta 89 Example Multiple MOVES ts 90 Vector Mode Linear and Circular Interpolation Moon 91 Speciiyine the Coordinate Plane aaa 91 Specifying Vector SCO IME IIS adas 91 Additional command ani dsc 92 Command Summary Coordinated Motion Sequence ssnneeeeeeeseeseeeeseseerseen 94 Operand Summary Coordinated Motion Sequence cccceceeeeeseeeessssssssesseees 94 Electromecanica Se 95 Ramped Oca td dd 96 Example Electronic Gearing Over a Specified Internal 97 Command Summary Electronic Gearing ooooconnnnnnnnnnonononnoonnnonnn nono nono nono nono nn nnnnnnnnnnos 98 Example Simple Master Ma ta 98 Example Electronic EA a 98 Example Gantry Mode ic aid 98 Electronice Card E 99 Command Summary Electronic CAM 102 Operand Summary Electronic CAM 102 Examples Electronic CAM ee 103 Comtour Mod caia 104 Specitiyina C OMOUR SC OMNIS 5 5 ceet dentist e 104 Additonal ommand S ee 105 Command Summary Contour Mode oooooooococononononononononnnnnnnnnnnnononononnn no nono nono nnnnnnoos 105 SLL MOOC ne fer 109 Specifying Stepper Motor OperatlON cocccccccccnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 109 Using an Encoder with stepper Motors amesem ienne eara 110 Command Summary Stepper Motor OperatlOM ooooconcncconananonananonooooorn nono nonononn
245. op position controller while in the jog mode The DMC 40x0 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 80 e Chapter 6 Programming Motion DMC 40x0 Parameters can be set with individual axes specifiers such as JGY 2000 set jog speed for Y axis to 2000 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the jog speed for the axis specified by x _TVx Returns the actual velocity of the axis specified by x averaged over 0 25 sec Example Jog in X only Jog X motor at 50000 count s After X motor is at its jog speed begin jogging Z in reverse direction at 25000 count s FA AC 200007 20000 Specify X Z acceleration of 20000 cts sec DC 20000 20000 Specify X Z deceleration of 20000 cts sec JG 50 0007 23000 Specify jog speed and direction for X and Z axis BG X Begin X motion AS X Wait until X is at speed BG Z Begin Z motion 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 R
246. or Smoothing IT interpolation positioning Smooth motion while operating with stepper motors Stepper Motor Smoothing Gantry two axes are coupled by gantry Gantry Mode GM DMC 40x0 Chapter 6 Programming Motion e 77 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 40x0 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 40x0 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 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
247. or with the parameters Kt 14 16 oz in A 0 1 Nm A R 20 J 0 0283 oz in s2 2 10 4 kg mi L 0 004H Then the corresponding time constants are Tm 0 04 sec and Te 0 002 sec Assuming that the amplifier gain is Kv 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of Ka The resulting transfer function in this case is P V Ka Kt Js where Kt and J are as defined previously For example a current amplifier with Ka 2 A V with the motor described by the previous example will have the transfer function 178 e Chapter 10 Theory of Operation DMC 40x0 P V 1000 s2 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 1s fed back to the amplifier Such a system is illustrated in Fig 10 5 Note that the transfer function between the input voltage V and the velocity is V K KyJs 1 K Ky Kg Js 1 Ko sT7 1 where the velocity time constant T1 equals T1 J K K Kg This leads to the transfer function P V I Kg s sT1 1 K bc Kt Js
248. ordinated Motion Mathematical Analvsis 221 Example Communicating with OPIO Z3SNAP RBIOOO ENET 224 DMC 40x0 DMC 2200 Comparison ti 226 Listot EEN eege EE 221 Tranne Se E 22i EE e ee e 228 WARRANTY ia 229 Integrated Amplifiers and Drivers 230 Sa eege 230 Al AMP 43040 D3040 o ooocccccccnnnononononoccnonanonnnonnnonnnnonnnnnnnnnnnanononnnnnnnnnnononnnannnnos 230 A2 AMP 43140 D3140 ooooncccnnnnnooononnnccnononoonnnnnnnnnononnnnnnnnonnnnrnnnnnncnnnnnnonnnnnnnnos 230 A3 SDM 44040 CG DAOU 230 A4 SDM 44140 D4140 oocccccnnnococonnnocononononnnnnnononnnnonnnnnnnnnnnnnnnnnnnncnnnnnnonnnnnnnnos 230 A1 AMP 43040 231 odu 01 e 231 PVC CHICAS PC CII CATIONS dd 232 Mating COUN CClOIS a aden eee eee 232 OT sie C215 0 0 PRR ne mre ree Eege 233 Brushless Motor Se is 233 Brushless Amplifier Software Setup 233 CAI eli Kao Vos doo 233 Brush Amplifier Opa hinted a EEA i 234 Uso Pxterival Amp ee 234 Error Monitoring and Protection cccccccccccccceceeeseeseeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 234 lal BIGOT PLOLeC LON a 235 Under Voldag Protectoras ia 235 Over Voltage Proteccion 235 DMC 40x0 Contents e vii Over Current Protec et ea 235 Over Temperature Protecti n ati 236 SES 236 A2 AMP 43140 237 rue Tee 237 Electrical SPC CHIC AOS a e sl 238 ENEE ee teeta ened cee ene AA 238 ODIO 6 aaRen re nen er ene ny ee Eege 239 Using Extemal Amps iia 239 EE 239 A3 SDM 44
249. orm the path shown on Fig 2 8 Note that the vector motion starts at a local position 0 0 which is defined at the beginning of any vector motion sequence See application programming for further information Instruction Interpretation VM AB Select AB axes for circular interpolation VP 4000 0 Linear segment CR 200032 eh SE Circular segment VP 0 4000 Linear segment CR 2000 90 180 Circular segment vs 1000 Vector speed VA 50000 Vector acceleration VD 50000 Vector deceleration VE End vector sequence BGS Start motion 30 e Chapter 2 Getting Started DMC 40x0 4000 4000 0 4000 R 2000 4000 0 0 0 local zero Figure 2 7 Motion Path for Circular Interpolation Example DMC 40x0 Chapter 2 Getting Started e 31 Chapter 3 Connecting Hardware Overview The DMC 40x0 provides opto isolated digital inputs for forward limit reverse limit home and abort signals The controller also has 8 opto isolated uncommitted inputs for general use as well as 8 high power opto isolated outputs and 8 analog inputs configured for voltages between 10 volts 4080 Controllers with 5 or more axes have an additional 8 opto isolated inputs and an additional 8 high power opto isolated outputs This chapter describes the inputs and outputs and their proper connection Using Optoisolated Inputs Limit Switch Input The forward limit switch FLSx inhibits motion in the forward direction immediately upon activation of the switch
250. orward direction Only one axis at a time may be specified Trip point to hold up program execution until n number of counts have passed in the reverse direction Only one axis at a time may be specified Command Used to specify the absolute position target Linear Interpolation Mode The DMC 40x0 provides a linear interpolation mode for 2 or more axes In linear interpolation mode motion between the axes is coordinated to maintain the prescribed vector speed acceleration and deceleration along the specified path The motion path is described in terms of incremental distances for each axis An unlimited number of incremental segments may be given in a continuous 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 command selects the Linear Interpolation mode and axes for interpolation For example LM YZ selects only the Y and Z axes for linear interpolation When using the linear interpolation mode the LM command only needs to be specified once unless the axes for linear interpolation change Specifying Linear Segments The command LI x y z w or LI a b c d e f g h specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis position Up to 511 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
251. ould take effect immediately From the start of gearing if the master traveled 6000 counts the slaves would travel 6792 counts and 270 counts Using the ramped gearing the slave will engage gearing gradually Since the gearing is engaged over the interval of 6000 counts of the master the slave will only travel 3396 counts and 135 counts respectively The difference between these two values is stored in the GPn operand If exact position synchronization is required the IP command is used to adjust for the difference DMC 40x0 Chapter 6 Programming Motion e 97 Command Summary Electronic Gearing Specifies master axes for gearing where n X Y Z or W or A B C D E F G H for main encoder as master n CX CY CZ CW or CA CB CC CD CE CF CG CH for commanded position n DX DY DZ or DW or DA DB DC DD DE DF DG DH for auxiliary encoders n S or T for gearing to coordinated motion GD a b c d e f g Sets the distance the master will travel for the gearing change to take full effect _GPn h 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 h GR a b c d e f g Sets gear ratio for slave axes 0 disables electronic gearing for specified axis GM a b c d e f g h X 1 sets gantry mode 0 disables gantry mode Trippoint for reverse motion past specified value Only one
252. ownload at the Galil software downloads page http www galilmc com support download html Using Linux 32 amp 64 bit The GalilTools software package is fully compatible with a number of Linux distributions See the GalilTools webpage and user manual for downloads and installation instructions http www galilmc com products software galiltools html Step 4 Connect 20 80VDC Power to the Controller If the controller was ordered with Galil Amplifiers or Drivers then power to the controller will be supplied through those power connectors Otherwise the power will come through the connector on the side of the controller See DMC 40x0 Power Connections WARNING Dangerous 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 to it The green power light indicator should go on when power is applied Step 5 Establish Communications with Galil Software Communicating through an Ethernet connection The DMC 40x0 motion controller is equipped with DHCP If the controller is connected to a DHCP enabled network an IP address will automatically be assigned to the controller See Ethernet Configuration in Chapter 4 for more information Using GalilTools Softw
253. pace use the interrogation command LA List Arrays To list the contents of the Program space use the interrogation command LS List To list the application program labels only use the interrogation command LL List Labels Operands In general all operands provide information 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 _ UE 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 _ ERx 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 ED Edit Mode 000 A Program La
254. pecifying an 16 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 16 bit output port where bit 0 is output 1 bitl 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 24 6 OPO Clears all bits of output port to zero OP 255 Sets all bits of output port to one A th pbg gA OS E aT The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move Instruction Interpretation 156 e Chapter 7 Application Programming DMC 40x0 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 through 48 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 po
255. porates 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 1s not necessary the I O number to be used can be calculated with the following I O Number HandleNum 1000 Module 1 4 BitNum 1 DMC 40x0 Chapter 4 Software Tools and Communication e 53 Where HandleNum is the handle number from 1 A to 6 F 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 If an explicit slave address 1s to be used the equation becomes I O Number SlaveAddress 10000 HandleNum 1000 Module 1 4 Bitnum 1 Modbus Examples Example 1 DMC 4040 connected as a Modbus master to a RIO 47120 via Modbus The DMC 4040 will set or clear all 16 of the RIO s digital outputs 1 Begin by opening a connection to the RIO which in our example has IP address 192 168 1 120 THB 192 168 1 120 lt 502 Issued to DMC 4040 2 Dimension an array to store the commanded values Set array element 0 equal to 170 and array element 1 equal to 85 array elem
256. present the planar axes and p is the tangent axis Return coordinate of last point where m X Y Z or W Specifies arc segment where r is the radius is the starting angle and AO is the travel angle Positive direction is CCW CR 1 0 AO Specify vector speed or feed rate of sequence Specify vector acceleration along the sequence Specify vector deceleration along the sequence S curve smoothing constant for coordinated moves Return number of available spaces for linear and circular segments in DMC 40x0 ae sequence buffer Zero means buffer is full 511 means buffer is empty CAS or CAT Specifies which coordinate system 1s to be active S or T Operand Summary Coordinated Motion Sequence OPERAND DESCRIPTION The absolute coordinate of the axes at the last intersection along the sequence Distance traveled Number of available spaces for linear and circular segments in DMC 40x0 sequence buffer Zero means buffer is full 511 means buffer is empty OS Segment counter Number of the segment in the sequence starting at zero EVE Vector length of coordinated move sequence _VPM AN LM CS VE When AV is used as an operand AV returns the distance traveled along the sequence The operands VPX and VPY can be used to return the coordinates of the last point specified along the path Example Traverse the path shown in Fig 6 8 Feed rate is 20000 counts sec Plane of motion is XY VM VS VA VD VP
257. quare 500 counts per side is given below The square 1s drawn at vector position 1000 1000 M CB1 VP 1000 1000 LE BGS AMS SB1 JS Square CBl EN Square v1 500 UJS L Vl1 V1 JS L EN L PR V1 V1 BGX AMX BGY AMY EN 136 e Chapter 7 Application Programming Begin Main Program Clear Output Bit 1 pick up pen Define vector position move pen Wait for after motion trippoint Set Output Bit 1 put down pen Jump to square subroutine End Main Program Square subroutine Define length of side Switch direction End subroutine Define X Y Begin X After motion on X Begin Y End subroutine DMC 40x0 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 T
258. r Max Current per axis 1 0 Amps 100mA option Amplifier gain 0 1 A V 10mA V option Power output per channel 20 W Total max power output 60 W Mating Connectors On Board Connector Terminal Pins POWER 4 pin MATE N LOK MOLEX 39 01 2045 MOLEX 44476 3112 A B C D 4 pin Motor 2 pin MATE N LOK Power Connectors MOLEX 39 01 2025 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector 4 VS DC Power Motor Connector 238 e A2 AMP 43140 DMC 40x0 Operation Using External Amplifiers Use connectors on top of controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 ELO Input If the ELO input on the controller is triggered then 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 FAMPERR 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 DMC 40x0 A2 AMP 43140 e 239 A3 SDM 44040 Introduction The SDM 44040 is a stepper driver module capable of driving up to four bipolar two phase stepper motors The current is selectable with options of 0 5 0 75 1 0 and 1 4 Amps Phase The
259. r error 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 A080 For controllers with 5 8 axes the ERR signal is duplicated on the I O E H D Sub connector DMC 40x0 Chapter 3 Connecting Hardware e 39 Extended I O of the DMC 40x0 Controller The DMC 40x0 controller offers 32 extended TTL I O points which can be configured as inputs or outputs in 8 bit increments Configuration is accomplished with command CO see Extended I O of the DMC 40x0 Controller The I O points are accessed through the 44 pin D Sub connector labeled EXTENDED I O See the appendix for a complete pin out of CMB 41012 Extended I O 44 pin HD D Sub Connector Electrical Specifications 3 3V Standard Inputs Max Input Voltage 3 4 VDC Guarantee High Voltage 2 0 VDC Guarantee Low Voltage 0 8 VDC Inputs are internally pulled up to 3 3V through a 4 7kQ resistor Outputs Sink Source 4mA per output Electrical Specifications 5V Option Inputs Max
260. r to move the X axis 1000 encoder counts Remember to add DMC32 LIB to your project prior to compiling include lt windows h gt include lt dmccom h gt long lRetCode HANDLEDMC hDmc HWND hWnd int main void d Connect to Gont roller number 1 lRetCode DMCOpen 1 hWnd amp hDmc if rc DMCNOERROR char szBurter 64 gt Move the X axis 1000 counts 1RetCode DMCCommand hDmc PR1000 BGX szBuffer SEPZeECOTUSZBUELEY 3 Disconnect from controller number 1 as the last action lRetCode DMCClose hDmc teruri dls Galil Communications API with Visual Basic Declare Functions Galil recommends the GalilTools Communication Library for all new applications To use the Galil communications API functions add the module file included in the C ProgramFiles Galil DMCWIN VB directory named DMCCOM40 BAS This module declares the routines making them available for the VB project To add this file select Add Module from the Project menu in VB5 6 DMC 40x0 Chapter 4 Software Tools and Communication e 67 Sending Commands in VB Most commands are sent to the controller with the DACCommand function This function allows any Galil command to be sent from VB to the controller The DMCCommand function will return the response from the controller as a string Before sending any commands the DMCOpen function must be called This function establishes communication with the controller and is called only
261. rates 1 e 9600 baud For faster rates the handshake lines are required The connection tables below contain the handshake lines Standard RS 232 Specifications 25 pin Serial Connector Male D type This table describes the pinout for standard serial ports found on most computers 202 e Appendices DMC 40x0 9 Pin Serial Connector Male D type Standard serial port connections found on most computers DMC 40x0 Serial Cable Specifications Cable to Connect Computer 25 pin to Main Serial Port Cable to Connect Computer 9 pin to Main Serial Port Cable 9 pin Cable to Connect Computer 25 pin to Auxiliary Serial Port Cable 9 pin 25 Pin Male terminal 9 Pin male controller 4 RTS 8 CTS DMC 40x0 Appendices e 203 Cable to Connect Computer 9 pin to Auxiliary Serial Port Cable 9 pin 9 Pin FEMALE terminal 9 Pin MALE Controller Pin Out Description for DMC 40x0 Outputs Motor Command 10 Volt range signal for driving amplifier In servo mode motor command output is updated at the controller sample rate In the motor off mode this output is held at the OF command level Amplifier Enable Signal to disable and enable an amplifier Amp Enable goes low on Abort and OE1 PWM Step PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a conventional amplifier that accepts a 10 Volt analog signal
262. re B to Terminal A Ifthe controller finds that the commutation order 1s correct but the motor would run away due to positive feedback the controller will prompt the user to Wire Phase B to C and C to B Exchange Hall Sensors A and B After making any necessary changes to the motor phase wiring confirm correct operation by reissuing the BS command Once the axis is wired correctly the controller is ready to perform closed loop motion Brushless Amplifier Software Setup Select the amplifier gain that 1s appropriate for the motor The amplifier gain command AG can be set to 0 1 or 2 corresponding to 0 4 0 7 and 1 0 A V In addition to the gain 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 The following figure captured with WSDK 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 Chopper Mode The AMP 43040 can be put into what is called a Chopper mode The chopper mode is in contrast to the normal inverter mode in which the amplifier sends PWM power to the motor of VS In chopper mode the amplifier sends
263. re Tools and Communication DMC 40x0 Galil Communications API with C C Galil recommends the GalilTools Communication Library for all new applications When programming in C C the communications API can be used as included functions or through a class library All Galil communications programs written in C must include the DMCCOM H file and access the API functions through the declared routine calls C programs can use the DMCCOM H routines or use the class library defined in DMCWIN H After installing DMCWin into the default directory the DMCCOM H header file is located in C Program Files Galil DMCWIN INCLUDE C programs that use the class library need the files DMCWIN H and DMCWIN CPP which contain the class definitions and implementations respectively These can be found in the C ProgramFiles Galil DMCWIN CPP directory To link the application with the DLL s the DMC32 lib file must be included in the project and is located at C Program Files Galil DMCWIN LIB Example A simple console application that sends commands to the controller To initiate communication declare a variable of type HANDLEDMC a long integer and pass the address of that variable in the DMCOpen function If the DMCOpen function is successful the variable will contain the handle to the Galil controller which is required for all subsequent function calls The following simple example program written as a Visual C console application tells the controlle
264. re failure in the controller connect the same encoder to a different axis If the problem disappears you may have a hardware failure Consult the factory for help Step E Connect Hall Sensors if available Hall sensors are only used with sinusoidal commutation and are not necessary for proper operation The use of Hall sensors allows the controller to automatically estimate the commutation phase upon reset and also provides the controller the ability to set a more precise commutation phase Without Hall sensors the commutation phase must be determined manually The Hall Effect sensors are connected to the digital inputs of the controller These inputs can be used with the general use inputs bits 1 8 the auxiliary encoder inputs bits 81 96 or the extended I O inputs of the DMC 40x0 controller bits 17 80 NOTE The general use inputs are optoisolated and require a voltage connection at the INCOM point for more information regarding the digital inputs see Chapter 3 Connecting Hardware Each set of sensors must use inputs that are in consecutive order The input lines are specified with the command BI For example if the Hall sensors of the C axis are connected to inputs 6 7 and 8 use the instruction BI 6 or BIC 6 Step 8a Connect Standard Servo Motors The following discussion applies to connecting the DMC 40x0 controller to standard servo motors DMC 40x0 Chapter 2 Getting Started e 19 The motor and the amplifi
265. recision for division is 1 65 000 Mathematical operations are executed from left to right Calculations within parentheses have precedence Examples speed 7 5 V1 2 The variable speed is equal to 7 5 multiplied by V1 and divided by 2 count count 2 The variable count is equal to the current value plus 2 result _TPX COS 45 40 puts the position of X 28428 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 DMC 40x0 lt lt i Chapter 7 Application Programming e 141 Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The operator 1s a Logical Or These operators allow for bit wise operations on any valid DMC 40x0 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 one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last ch
266. represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 sT 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis 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 40x0 controller and the following parameters Kt 0 1 Nm A Torque constant J 2 10 4 kg m2 System moment of inertia R 2 Q Motor resistance Ka 4 Amp Volt Current amplifier gain KP 12 5 Digital filter gain KD 245 Digital filter zero KI 0 No integrator N 500 Counts rev Encoder line density T 1 ms Sample period The transfer function of the system elements are Motor M s P I Kt Js2 500 s2 rad A Amp K 4 Amp V DAC Kg 0 0003 V count Encoder Kf 4N 2x 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 182 e Chapter 10 Theory of Operation DMC 40x0 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
267. resolution encoder may be used as long as the maximum frequency does not exceed 22 000 000 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 Auxiliary Encoder AA AB Aux A Aux B Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for step motors Abort A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program Electronic Lock Out Forward Limit Switch Reverse Limit Switch Input Input 8 isolated Input 9 Input 16 isolated 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 Input that when triggered will shut down the amplifiers at a hardware level Usef
268. rrection 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 microstepping 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 YAL Step resolution of the full step drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WT50 Allow slight settle time YSL Enable SPM mode Half Stepping Drive X axis SETUP OE1 Set the profiler to stop axis upon error KS16 Set step smoothing Mis 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 112 e Chapter 6 Programming Motion DMC 40x0 OL Enable SPM mode 1 64 Step Microstepping Drive X axis FSETUP
269. rs and Stepper Drivers that are integrated into the same enclosure as the controller Using the Galil Amplifiers and Drivers provides a simple straightforward motion control solution in one box A1 AMP 43040 D30x0 The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless amplifiers that are capable of handling 500 watts of continuous power per axis The AMP 43040 43020 Brushless drive modules are connected to a DMC 40x0 The standard amplifier accepts DC supply voltages from 18 80 VDC A2 AMP 43140 D3140 The AMP 43140 contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 DC Volt input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 kHz A3 SDM 44040 D4040 The SDM 44040 is a stepper driver module capable of driving up to four bipolar two phase stepper motors The current is selectable with options of 0 5 0 75 1 0 and 1 4 Amps Phase The step resolution is selectable with options of full half 1 4 and 1 16 A4 SDM 44140 D4140 The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution the SDM 44140 drives two The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis DMC 40x0 Chapter 1 Overview e 3 DMC 40x0 Functional Elements Th
270. rupts 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 FTASK1 Task1 label ATO Initialize reference time CBI 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 Loopl TASK2 Task2 label XQ TASK1 1 Execute Taskl LOOP 2 Loop2 label PR 1000 Define relative distance BGX Begin motion DMC 40x0 Chapter 7 Application Programming e 127 AMX After motion done WI 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 1 e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 40x0 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
271. s 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 40x0 Amplifier Driver For each axis 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 meet 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 40x0 See the Integrated Amplifiers and Drivers section in the DMC 40x0 Chapter 1 Overview e 5 Appendices or http galilmc com products accelera dmc40x0 html for more information Encoder An encoder transl
272. s text string Fn m Formats numeric values in decimal n digits to the left of the decimal point and m digits to the right P1 P2 or E Send message to Main Serial Port Auxiliary Serial Port or Ethernet Port Displaying Variables and Arrays Variables and arrays 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 vl posA 1 _TPA Assign the first entry vl Print et Interrogation Commands The DMC 40x0 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 DP PR EM TN FL VE IP TE TP The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the decimal point using the PF c
273. sage 005 MG ERROR V1 Print Error 006 RE Return from Error lt control gt Q Quit Edit Mode XQ LOOP Execute Dummy Program JG 100000 Jog at High Speed BGX Begin Motion Example Input Interrupt A Label ELL Input Interrupt on 1 JG 30000 60000 Jog BGXW Begin Motion LOOP JP LOOP EN Loop ININT Input Interrupt STXW AM Stop Motion TEST JP TEST IN 1 0 Test for Input 1 still low JG 30000 6000 Restore Velocities BGXW Begin motion RIO Return from interrupt routine to Main Program and do not re enable trippoints Example Motion Complete Timeout BEGIN Begin main program TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command 138 e Chapter 7 Application Programming DMC 40x0 BGX Begin motion MCX Motion Complete trip point EN End main program MCTIME Motion Complete Subroutine MG X fell short Send out a message EN 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 IN ENTER SPEED SPEED JG SPEED BGX JP BEGIN EN CMDERR JP DONE _ED lt gt 2 JP DONE _TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN ASI JP BEGIN DONE ZS0 EN Begin main program Prompt for speed Begin motion Repeat End main program Command error utility Check if error on line 2 Check if ou
274. se After the encoders and motor leads are connected the controller and amplifier need to be configured correctly in software Take all appropriate safety precautions For example set a small error limit ER 1000 a low torque limit TL 3 and set off on Error to 1 for all axes OE 1 Review the command reference and controller user manual for further details There are 3 settings for the amplifier gain 0 4 A V 0 7 A V and 1 0 A V corresponding to AG amplifier gain 0 1 and 2 If the gain is set to 0 7 A V a torque limit of 3 TLn 3 will allow the amplifier to output no more than 2 1 amps of current on the specified axis The controller has been programmed to test whether the Hall commutation order is correct To test the commutation for the X axis issue the BS command BSX n m The controller will attempt to move the motor through one revolution If the motor is unable to move the controller will return unknown Hall transition check wiring and execute BS again It may be necessary to issue more voltage to create motion The default for the BS command is BSn 0 25 1000 which will send 0 25 volts to the amplifier for 1 second BSX 0 5 300 will issue 0 5 volts from the controller for 300 milliseconds If the controller is able to move the motor and the Hall transitions are not correct the controller will alert the operator and recommend which motor phases to change For example the controller might return Wire A to Terminal B Wi
275. sition motor A must stop turning Solution Connect panel switch to input 1 of DMC 40x0 High on input 1 means switch is 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 For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 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 oof the full voltage range for example connect the input to 6 volts if the signal is a 0 12 volt logic Example A DMC 4010 has one auxiliary encoder This encoder has two inputs channel A and channel B Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal will be connected to AA and the second to AB AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 DMC 40x0 Chapter 7 Appli
276. specifies the vector speed VS and not the actual axis speeds VZ and VW The axis speeds are determined by the controller from VS VVZ VW The result is shown in Figure 6 7 DMC 40x0 Chapter 6 Programming Motion e 89 30000 2 000 POSITION W 3000 0 4000 36000 40000 POSITION Z FEEDRATE 0 0 1 0 5 0 6 TIME sec VELOCITY Z AXIS TIME sec VELOCITY W AXIS Figure 6 7 Linear Interpolation TIME sec Example Multiple Moves This example makes a coordinated linear move in the XY plane The Arrays VX and VY are used to store 750 incremental distances which are filled by the program LOAD LOAD Load Program DM VX 750 VY 750 COUNT 0 Define Array Initialize Counter 90 e Chapter 6 Programming Motion DMC 40x0 N 0 LOOP VX COUNT N VY COUNT N N N 10 COUNT COUNT 1 JP LOOP COUNT lt 750 A LM XY COUNT 0 LOOP2 JP LOOP2 _LM 0 JS C COUNT 500 LI VX COUNT VY COUNT COUNT COUNT 1 JP LOOP2 COUNT lt 750 LE AMS MG DONE EN C BGS EN Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full wait Begin motion on 500 segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Mot
277. ssued as described above For example to initialize the A axis motor upon power or reset the following commands may be given SHA Enable A axis motor PRA 1 _BZA Move A motor close to zero commutation phase BGA Begin motion on A axis AMA Wait for motion to complete on A axis BZA 1 Drive motor to commutation phase zero and leave motor on Method 3 Use the command BC This command uses the Hall transitions to determine the commutation phase Ideally the Hall sensor transitions will be separated by exactly 60 and any deviation from 60 will affect the accuracy of this method Ifthe Hall sensors are accurate this method is recommended The BC command monitors the Hall sensors during a move and monitors the Hall sensors for a transition point When that occurs the controller computes the commutation phase and sets it For example to initialize the A axis motor upon power or reset the following commands may be given SHA Enable A axis motor BCA Enable the brushless calibration command PRA 50000 Command a relative position movement on A axis BGA Begin motion on A axis When the Hall sensors detect a phase transition the commutation phase is reset DMC 40x0 Chapter 2 Getting Started e 23 Step 8c Connect Step Motors In Stepper Motor operation the pulse output signal has a 50 duty cycle Step motors operate open loop and do not require encoder feedback When a stepper 1s used the auxiliary encoder for the
278. st character received Contains the received number P2ST Contains the received string PCD o o Contains the status code DMC 40x0 Chapter 7 Application Programming e 149 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 P2CD 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 P2CD 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 P2NM Assigns received number to position JS XAXIS P1ST X Checks to see if received string is X Using Communication Interrupt The DMC 40x0 provides a special interrupt for communication allowing the application program to be interrupted by input from the user The interrupt is enabled using the CI command The syntax for the command is CI n n 0 Don t interrupt Port 2 n 1 Interrupt on lt enter gt Port 2 n 2 Interrupt on any character Port 2 n 1 Clear any characters in buffer The COMINT label is used for the communication interrupt For example the DMC 40x0 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
279. step resolution is selectable with options of full half 1 4 and 1 16 Figure A3 1 DMC 4040 C012 I000 D4040 DMC 4040 with SDM 44040 240 e A3 SDM 44040 DMC 40x0 Electrical Specifications The amplifier is a brush type trans conductance linear amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input DC Supply Voltage 12 30 VDC Max Current per axis 1 4 Amps Phase Amps Selectable with AG command Maximum Step Frequency 6 MHz Motor Type Bipolar 2 Phase Mating Connectors POWER 6 pin MATE N LOK MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com naa a Power Connector Motor Connector Motor Connector CE DMC 40x0 A3 SDM 44040 e 241 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 Current Level Setup AG Command AG configures how much current the SDM 206x0 delivers to each motor Four options are available 0 5A 0 75A 1 0A and 1 4 Amps Drive Current Selection per Axis AG n n n n n n n n n 0 n 1l n 2 n 3 0 5 A 0 75 A default LOA 14 A Low Current Setting LC Command
280. switches see bit field map below 85 UB A axis stop code 86 89 SL A axis reference position 90 93 SL A axis motor position 94 97 SL A axis position error 98 101 SL A axis auxiliary position 102 105 SL A axis velocity 106 109 SL new size A axis torque 110 111 SW A axis analog input 112 UB new A Hall Input Status 113 UB Reserved 114 117 SL new A User defined variable ZA 118 119 UW B axis status see bit field map below 120 UB B axis switches see bit field map below 121 UB B axis stop code 122 125 SL B axis reference position 126 129 SL B axis motor position 130 133 SL B axis position error 134 137 SL B axis auxiliary position 138 141 SL B axis velocity 142 145 SL new size B axis torque DMC 40x0 Chapter 4 Software Tools and Communication e 57 146 147 148 149 150 153 154 155 156 157 158 161 162 165 166 169 170 173 174 177 178 181 182 183 184 185 186 189 190 191 192 193 194 197 198 201 202 205 206 209 210 213 214 217 218 219 220 221 222 225 226 227 228 229 230 233 234 237 238 241 242 245 246 249 250 253 254 255 256 231 258 261 262 263 264 SW UB new UB SL new UW UB UB SL SL SL SL SL SL new size SW UB new UB SL new UW UB UB SL SL SL SL SL SL new size SW UB new UB SL new UW UB UB SL SL SL SL SL SL new size SW UB new UB SL new UW UB 58 e Chapter 4 Software Tools and Communication B axis an
281. system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 AEN Output Line Goes low DMC 40x0 Chapter 8 Hardware amp Software Protection e 169 The Jump on Condition statement 1s 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 Programmable Position Limits The DMC 40x0 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 40x0 will not accept position commands beyond the limit Motion beyond the limit is also prevented Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog BG XYZ Begin motion stops at forward limits Off On Error The DMC 40x0 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 for X Y Z and W axis To disable this function specify O for the axes When this function 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
282. t the approximate value for BM will agree with the value used in the previous step NOTE In order to properly conduct the brushless setup the motor must be allowed to move a minimum of one magnetic cycle in both directions NOTE When using Galil Windows software the timeout must be set to a minimum of 10 seconds time out 10000 when executing the BS command This allows the software to retrieve all messages returned from the controller Step D part 2 Systems with Hall Sensors Only Test the Hall Sensor Configuration Since the Hall sensors are connected randomly it is very likely that they are wired in the incorrect order The brushless setup command indicates the correct wiring of the Hall sensors The Hall sensor wires should be re configured to reflect the results of this test The setup command also reports the position offset of the Hall transition point and the zero phase of the motor commutation The zero transition of the Hall sensors typically occur at 0 30 or 90 of the phase commutation It is necessary to inform the controller about the offset of the Hall sensor and this is done with the instruction BB Step E Save Brushless Motor Configuration It is very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configured the burn command BN should be given NOTE Without Hall sensors the controller will not be able to estimat
283. t of range Send message Send message Adjust stack Return to main program End program if other error Zero stack End program The above program prompts the operator to enter a jog speed Ifthe operator enters a number out of range greater than 8 million the FCMDERR 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 Example Command Error w Multitasking A JP A EN DMC 40x0 Begin thread 0 continuous loop End of thread O Chapter 7 Application Programming e 139 B N 1 KP N TY EN CMDERR EP TC 6 N 1 xO EB D2 se BDL ENDIF Te eet XO EDS BDL I
284. t on R pack next to RP2 label Isolated 24V LAEN AECI AECOM1 AEC2 AECOM2 Dot on R pack opposite RP2 label For 24V isolated enable tie 24V of external power supply to AEC1 at the D sub tie common return to AEC2 Replace RP6 with a 4 7 KQO resistor pack For Axes A D AEC1 and AEC2 are located on the EXTERNAL DRIVER A D D Sub connector For Axes E H AECI and AEC2 are located on the EXTERNAL DRIVER E H D Sub connector Note AEC1 and AEC2 for axes A D are NOT connected to AEC and AEC2 for axes E H Table 3 2 Sinking Configuration 42 e Chapter 3 Connecting Hardware DMC 40x0 Amplifier Enable Circuit Sourcing Output Configuration Pin 1 of LTV8441 in Pin 1 of Socket U4 Socket U4 S lt JP2 S TTL level Amp Enable signal from controller SH 5V MO OV Pin 1 of socket Amp Enable Output to Drive AENn RP2 470 Ohm 5V or GND JP1 PIN 1 AECOM1 Figure 3 5 Amplifier Enable Circuit Sourcing Output Configuration Sourcing Configuration pm of LTV8441 chip in pin1 of socket U4 RP2 Logic State JP1 JP2 square pin next to RP2 label is 5V 5V HAEN GND AECOM1 SV AECOM2 Dot on R pack opposite RP2 label SV LAEN GND AECOM1 SV AECOM2 Dot on R pack next to RP2 label 12V HAEN GND AECOM1 12V AECOM2 Dot on R pack opposite RP2 label 12V LAEN GND AECOM1 12V AECOM2 Dot on R pack next to RP2 label Isola
285. tch IN11 G axis latch IN4 W axis latch IN12 H axis latch Note To insure a position capture within 25 microseconds the input signal must be a transition from high to low The DMC 40x0 software commands AL and RL are used to arm the latch and report the latched position The steps to use the latch are as follows DMC 40x0 Chapter 6 Programming Motion e 121 l Give the AL XYZW command or ABCDEFGH for DMC 4080 to arm the latch for the main encoder and ALSXSYSZSW for the auxiliary encoders 2 Test to see if the latch has occurred Input goes low by using the AL X or Y or Z or W command Example V1 _ALX returns the state of the X latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the RL XYZW command or RL XYZW Note The latch must be re armed after each latching event Example Latch Latch program JG 5000 Jog Y BG Y Begin motion on Y axis AL Y Arm Latch for Y axis Wait Wait label for loop JP Wait _ALY 1 Jump to Wait label if latch has not occurred Result _RLY Set value of variable Result equal to the report position of y axis Result Print result EN End 122 e Chapter 6 Programming Motion DMC 40x0 Fast Update Rate Mode The DMC 40x0 can operate with much faster servo update rates than the default of every millisecond This mode is known as fast mode and allows the controller to operate with the following update rates DMC 4010 31 25 use
286. ted 24V HAEN AECI AECOMI1 AEC2 AECOM2 Dot on R pack opposite RP2 label Isolated 24V LAEN AECI AECOM1 AEC2 AECOM2 Dot on R pack next to RP2 label For 24V isolated enable tie 24V of external power supply to AEC2 at the D sub tie common return to AEC1 Replace RP6 with a 4 7 KQ resistor pack For Axes A D AEC1 and AEC2 are located on the EXTERNAL DRIVER A D D Sub connector For Axes E H AECI and AEC2 are located on the EXTERNAL DRIVER E H D Sub connector Note AECI and AEC2 for axes A D are NOT connected to AEC and AEC2 for axes E H Table3 3 Sourcing Configuration DMC 40x0 Chapter 3 Connecting Hardware e 43 ICM 42200 Amplifier Enable Circuit This section describes how to configure the ICM 42200 for different Amplifier Enable outputs The ICM 42200 1s designed to be used with external amplifiers As a result the amplifier enable circuit for each axis 1s individually configurable through jumper settings The user can choose between High Amp Enable HAEN Low Amp Enable LAEN 5V logic 12V logic external voltage supplies up to 24V sinking or sourcing Every different configuration is described below with jumper settings and a schematic of the circuit AXIS A 5V HIGH AMP ENABLE SINKING AXIS A 12V HIGH AMP ENABLE SINKING AXIS A ISOLATED SUPPLY HIGH AMP ENABLE SINKING 44 e Chapter 3 Connecting Hardware 000000000 O o O o O O je O 00000O000O 00000000 000000000 000000000
287. tems 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 design 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 DMC 40x0 Appendices e 227 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 URL http galilmc com FTP http galilmc com ftp 228 e Appendices DMC 40x0 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 ava
288. tep 2 Install Jumpers on the DMC 40x0 Step 3 Install the communications software Step 4 Connect DC power to controller Step 5 Establish communications with the Galil Communication Software Step 6 Determine the Axes to be used for sinusoidal commutation Step 7 Make connections to amplifier and encoder Step 8a Connect standard servo motors Step 8b Connect sinusoidal commutation motors Step 8c Connect step motors Step 9 Tune the servo system Step 1 Determine Overall Motor Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 40x0 can control any combination of standard servo motors sinusoidally commutated brushless motors and stepper motors Other types of actuators such as hydraulics can also be controlled please consult Galil The following configuration information is necessary to determine the proper motor configuration Standard Servo Motor Operation Unless ordered with stepper motor drivers or in a non standard configuration the DMC 40x0 has been setup by the factory for standard servo motor operation providing an analog command signal of 10V No hardware or software configuration is required for standard servo motor operation Sinusoidal Commutation Sinusoidal commutation is configured through a single software command BA This configuration causes the controller to reconfigure the number of available control axes Each sinusoidally
289. ter reverse motion A or BorC or D or E or F or Gor H reached absolute position Only one axis may be specified If position is already past the point then MR will trip immediately Will function on geared axis or aux inputs MC X or Y or Z or W Halt program execution until after the motion profile A or Bor Cor DorE orF or G or H has been completed and the encoder has entered or passed the specified position TW x y z w 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 4 MCTIME Halts program execution until after specified input is at specified logic level n specifies input line Positive is high logic level negative is low level n 1 through 8 for DMC 4010 4020 4030 4040 n 1 through 16 for DMC 4050 4060 4070 4080 Also n 17 48 130 e Chapter 7 Application Programming DMC 40x0 ASXYZWS Halts program execution until specified axis has ABCDEFGH reached its slew speed 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 AVn Halts program execution until specified distance along a coordinated path has occurred WT n Halts program execution until specified time in msec has elapsed Event Trigger Examples Event Trigger Multiple Move Sequence
290. ter stepper operation 6 MHz stepper rate Improved EMI Connections broken out through D Sub 100 pin high density connector connectors and high power amps run and cable away from control lines Contour Buffer 511 elements New commands features ALAK PW OV OT OA ALTX TR1 1 HV LD M axis EY ZA OE2 TM scaling NO LC1000 MT1 5 4POSERR LIMSWI FMCTIME and ININT run without a thread 226 e Appendices DMC 40x0 List of Other Publications Step by Step Design of Motion Control Systems by Dr Jacob Tal U 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 sys
291. that the values used for masking are represented in hexadecimal as denoted by the preceding SL 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 A Response from command MG leno S4 E Response from command MG lend 94 S Response from command MG len4 94 T Response from command MG len3 54 M Response from command MG Leni 54 E Response from command MG lenl 94 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 ofn 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 142 e Chapter 7 Application Programming DMIC 40X0 men STOEN acom BER Se Sg Sg Sg Sa TOUT SES 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 1s from left to right and can be over ridden by using parentheses Examples vl ABS V7 The variable vl is equal to the absolute value of variable v7 V2
292. the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller you need to verify that the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 kQ resistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal is used by the controller to disable the motor When configured with the ICM 42000 or ICM 42100 this signal is labeled AENA for the A axis and is found on the 15 pin Dsub connector associated with the A axis if configured with the ICM 42200 the AENA signal is located on the 26 pin Dsub associated with the A axis Note that many amplifiers designate this signal as the INHIBIT signal Use the command MO to disable the motor amplifiers check to insure that the motor amplifiers have been disabled often this is indicated by an LED on the amplifier This signal changes under the following conditions the watchdog timer activates the motor off command MO is giv
293. the motor to run at a speed in proportions to the position error Instruction CONT AC 80000 DC 80000 JG 0 BGX LOOP vp AN 1 1000 ve vp _TPA vel ve 20 JG vel JP LOOP EN Interpretation Label Acceleration rate Start job mode Start motion Compute desired position Find position error Compute velocity Change velocity Change velocity End Extended I O of the DMC 40x0 Controller The DMC 40x0 controller offers 32 extended I O points which can be configured as inputs or outputs in 8 bit increments through software The I O points are accessed through 1 44 pin high density connector Configuring the I O of the DUC 40x0 The 32 extended I O points of the DMC 40x0 series controller can be configured in blocks of 8 The extended I O is denoted as blocks 2 5 or bits 17 48 The command CO is used to configure the extended I O as inputs or outputs The CO command has one field COn where n is a decimal value which represents a binary number Each bit of the binary number represents one block of extended I O When set to 1 the corresponding block is configured as an output The least significant bit represents block 2 and the most significant bit represents block 5 The decimal value can be calculated by the following formula n n2 2 n3 4 n4 5 n5 where nx represents the block If the nx value is a one then the block of 8 I O points is to be configured as an output If the nx value is a zero then the block of 8
294. the range between 10V and 10V The objective 1s 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 1ts 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 164 e Chapter 7 Application Programming DMC 40x0 The corresponding velocity for the motor 1s assigned to the VEL variable Instruction FA JGO BGX B VIN AN 1 VEL VIN 20000 JG VEL JP B EN 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 Change the speed JP B Repeat the process
295. 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 Used as an Operand Also see description of operands in Chapter 7 Command Summary For a complete command summary see Command Reference manual DMC 40x0 Chapter 5 Command Basics e 75 Chapter 6 Programming Motion Overview The DMC 40x0 provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 4010 are single axis controllers and use X axis motion only Likewise the DMC 4020 use X and Y the DMC 4030 use X Y and Z and the DMC 4040 use X Y Z and W The DMC 4050 use A B C D and E The DMC 4060 use A B C D E and F The DMC 4070 use A B C D E F and G The DMC 4080 use the axes A B C D E F G and H The example applications described below will help guide you to the appropriate mode of motion A080 For controllers with 5 or more axes the specifiers ABCDEFGH are used XYZ and W may be interchanged with ABCD EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each axis is Independent Axis Positioning PA PR independent and follows prescribed velocity profile SP AC DC Velocity control where no final endpoi
296. tion Communicating through the Main Serial Communications Port Connect the DMC 40x0 MAIN serial port to your computer via the Galil CABLE 9PIN D RS 232 Cable This is a straight through serial cable NOT a NULL modem Using GalilTools Software for Windows Registering controllers in the Windows registry is no longer required when using the GalilTools software package A simple connection dialog box appears when the software is opened that shows all available controllers The serial ports are listed as COMn communication speed ex COM 115200 The default serial communication speed on the DMC 40x0 is 115200Bps For more information on establishing communication to the controller via the GalilTools software see the GalilTools user manual http www galilmc com support manuals galiltools index html Using DMC SmartTerminal or WSDK Software for Windows NOTE For new applications Galil recommends using the GalilTools software package In order for the windows software to communicate with a Galil controller the controller must be registered in the Windows Registry To register a controller you must specify the model of the controller the communication parameters and other information The registry is accessed through the Galil software under the File menu in WSDK or under the Tools menu in the Galil Smart Terminal Use the New Controller button to add a new entry to the Registry You will need to supply the G
297. tion 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 The default value for KS is 1 313 which corresponds to a time constant of 3 939 sample periods Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver The pulses which are generated by the smoothing filter 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 Motion Profiler Stepper Smoothing Filter Output Buffer Output 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 usef
298. tion the host program has gathered on the object that it is tracking The position tracking mode does allow for all of the axes on the controller to be in this mode but for the sake of discussion it is assumed that the robot is tracking only in the X dimension 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 if both X and Y axes were desired the command would be PT 1 1 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 1s located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 cts sec2 and the velocity is set to 50 000 cts sec The command sequence to perform this is listed below Command Description AC150000 Set the X axis acceleration to 150000 cts sec DC150000 Set the X axis deceleration to 150000 cts sec SP50000 Set the X axis speed to 50000 cts sec PA5000 Command the X axis to absolute position 5000 encoder counts 82 e Chapter 6 Programming Motion DMC 40x0 I I I I I I I I I I I I I I I I F I I I I I I I I I I I I I I I I i L I I I I I I
299. tional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 40x0 computes the vector speed based on the axes specified in the LM mode For example LM XYZ designates linear interpolation for the X Y and Z axes The vector speed for this example would be computed using the equation VS2 XS82 YS82 ZS2 where XS YS and ZS are the speed of the X Y and Z axes The controller always uses the axis specifications from LM not LI to compute the speed IT is used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trippoint which halts program execution until the vector distance of n has been reached An Example of Linear Interpolation Motion LMOVE label DP 0 0 Define position of X and Y axes to be 0 LMXY Define linear mode between X and Y axes LI 5000 0 Specify first linear segment LI 0 5000 Specify second linear segment LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector distance of 4000 is reached vs 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached VS 4000 Change vector speed EN Program end In this example the XY system is required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trippoint which slows the speed to 1000 count s Once the motors reach the cor
300. tivated 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 FLIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Software Protection The DMC 40x0 provides a programmable error limit 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 200 300 400 500 Set X axis error limit for 200 Y axis error limit to 300 Z axis error limit to 400 counts W axis error limit to 500 counts ER Lyp A Set Y axis error limit to 1 count set W axis error limit to 10 counts The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position Ifthe absolute value of the error exceeds the value specified by ER the controller will generate several signals to warn the host
301. 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 40x0 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 CAUTION 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 IP address to the DMC 40x0 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 DMC 40x0 Chapter 4 Software Tools and Communication e 51 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 signe
302. toring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving back and forth For example when operating with servo motors the trippoint AM After Motion is used to determine when the motion DMC 40x0 Chapter 6 Programming Motion e 109 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 posi
303. tput bits specified as blocks of data The OP command accepts 3 parameters The first parameter sets the values of the main output port of the controller Outputs 1 8 block 0 The additional parameters set the value of the extended I O as outlined OP m a b where m is the decimal representation of the bits 1 8 values from 0 to 255 and a b c d represent the extended I O in consecutive groups of 16 bits values from 0 to 65535 Arguments which are given for I O points which are configured as inputs will be ignored The following table describes the arguments used to set the state of outputs Argument Blocks Bits Description m 0 1 8 General Outputs a 2 3 17 32 Extended I O b 4 5 33 48 Extended I O For example if block 8 is configured as an output the following command may be issued OP 7 7 This command will set bits 1 2 3 block 0 and bits 33 34 35 block 4 to 1 Bits 4 through 8 and bits 36 through 48 will be set to 0 All other bits are unaffected When accessing I O blocks configured as inputs use the TIn command The argument n refers to the block to be read n 0 2 3 or 4 The value returned will be a decimal representation of the corresponding bits 160 e Chapter 7 Application Programming DMC 40x0 Individual bits can be queried using the VIN n function where n 1 through 8 or 17 through 48 If the following command is issued Individual bits can be queried using the IN n function where n 1 through 48 MG IN 17
304. 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 40x0 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 2000 lines Using the DMC 40x0 Editor to Enter Programs Galil s SmartTerminal and WSDK software provide an editor and UPLOAD and DOWNLOAD utilities Application programs for the DMC 40x0 may also be created and edited locally using the DMC 40x0 The DMC 40x0 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number or label by specifying a line number or label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN Line
305. turn distance traveled Segment counter returns number of the segment in the sequence starting at zero Returns length of vector resets after 2147483647 Returns number of available spaces for linear segments in DMC 40x0 sequence buffer Zero means buffer full 511 means buffer empty 88 e Chapter 6 Programming Motion DMC 40x0 Return the absolute coordinate of the last data point along the trajectory m X Y Z or W or A B C D E F G or H 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 VPX and VPY will be zero Now suppose that the interrogation is repeated at the second segment when Y 2000 The value of AV at this point is 7000 CS equals 1 VPX 5000 and VPY 0 Example Linear Move Make a coordinated linear move in the ZW plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 counts sec2 LM ZW AR o e 40000 30000 LE VS VA VD BGS 100000 1000000 1000000 Speci fy Specify Speci fy Specify Specify Speci fy axes for linear interpolation ZW distances end move vector speed vector acceleration vector deceleration Begin sequence Note that the above program
306. tware Tools and Communication DMC 40x0 DOS and QNX tools Galil offers unsupported code examples that demonstrate communications to the controller using the following operating systems DOS DOS based utilities amp Programming Libraries for Galil controllers which includes a terminal utilities to upload and download programs and source code for BASIC and C programs Download DMCDOS at http www galilmc com support download html dos QNX Galil offers sample drivers for ISA and PCI cards for the QNX 4 24 operating system We also offer drivers and utilities for QNX 6 2 for PCI only Download at http www galilmc com support download html linux Linux Galil now offers full support to Linux users through the Galil Tools software package For more information see the previous section on GalilTools or visit the Galil website http www galilmc com products software galiltools html DMC 40x0 Chapter 4 Software Tools and Communication e 69 Chapter 5 Command Basics Introduction The DMC 40x0 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 can be sent in ASCII or binary In ASCH the DMC 40x0 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
307. 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 decisions based on its own status or external events without intervention from a host computer DMC 40x0 Event Triggers AMX YZWorS Halts program execution until motion is complete on ABCDEFGH the specified axes or motion sequence s AM with no parameter tests for motion complete on all axes This command is useful for separating motion sequences in a program AD X or Y or Z or W Halts program execution until position command has A or BorC or D or Eor F or Gor H reached the specified relative distance from the start of the move Only one axis may be specified at a time AR X or Y or Z or W Halts program execution until after specified distance A or BorC or Dor E or F or G or H from the last AR or AD command has elapsed Only one axis may be specified at a time AP X or Y or Z or W Halts program execution until after absolute position A or B or Cor D or E or F or G or H occurs Only one axis may be specified at a time MF X or Y or Z or W Halt program execution until after forward motion A or BorC or D or EorF or Gor H reached absolute position Only one axis may be specified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs MR X or Y or Z or W Halt program execution until af
308. ul for safety applications where amplifiers must be shut down at a hardware level 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 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 Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Uncommitted inputs May be defined by the user to trigger events Inputs are checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input 1 is latch X Input 2 is latch Y Input 3 1s latch Z and Input 4 is latch W if the high speed position latch function is enabled High speed position latch to capture axis position on occurrence of latch signal AL command arms latch Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W Input 9 is latch E input 10 is latch F input 11 is latch G input 12 is latch H Appendices e 205 Configuring the Amplifier Enable Circuit ICM 42000 and ICM 42100 The following section details the steps needed to change the amplifier enable configuration for t
309. ul 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 1t must be connected to the main encoder input Note The auxiliary encoder is not available while operating with stepper motors The position of the encoder can be interrogated by using the command TP The position value can be defined by using the command DE Note Closed loop operation with a stepper motor 1s not possible Command Summary Stepper Motor Operation COMMAND DESCRIPTION Define Encoder Position When using an encoder mp Define Reference Position and Step Count Register 110 e Chapter 6 Programming Motion DMC 40x0 Report number of step pulses generated by controller Tell Position of Encoder ij vJ Operand Summary Stepper Motor Operation OPERAND DESCRIPTION DEX Contains the value of the step count register for the x axis DPx o Contains the value of the main encoder for the x axis ET Contains the value of the Independent Time constant for the x axis KS Contains the value of the Stepper Motor Smoothing Constant for the x axis MTx Contains the motor type value for the x axis bp Contains the commanded position generated by the profiler for the x axis TDx Contains the
310. ur network or you will encounter an error Use the New Controller button to add a new entry in the registry or alternatively click on the Find Ethernet Controller to have the software search for controllers connected to the network When adding a new controller choose DMC 40x0 as the controller type Enter the IP address obtained from your system administrator Select the button corresponding to the UDP or TCP protocol in which you wish to communicate with the controller Ifthe IP address has not been already assigned to the controller click on ASSIGN IP ADDRESS ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do not have an IP address The program will then ask you whether you would like to assign the IP address you entered to the controller with the specified serial number Click on YES to assign 1t NO to move to next controller or CANCEL to not save the changes If there are no controllers on the network that do not have an IP address assigned the program will state this When done registering click on OK If you do not wish to save the changes click on CANCEL Once the controller has been registered select the correct controller from the list and click on OK If the software successfully established communications with the controller the registry entry will be displayed at the bottom of the screen in the Status window NOTE The controller must be registered via an Ethernet connec
311. utated brushless motors invert motor phases B amp C exchange Hall A with Hall B and invert encoder polarity as described above Sometimes the feedback polarity is correct the motor does not attempt to run away but the direction of motion is reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals If the motor moves in the required direction but stops short of the target it is most likely due to insufficient torque output from the motor command signal MCMn This can be alleviated by reducing system friction on the motors The instruction TTA lt return gt Tell torque on A reports the level of the output signal It will show a non zero value that is below the friction level Once you have established that you have closed the loop with the correct polarity you can move on to the compensation phase servo system tuning to adjust the PID filter parameters KP KD and KI It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section Step 8b Connect Sinusoidal Commutation Motors When using sinusoidal commutation the parameters for the commutation must be determined and saved in the controller s non volatile memory The setup for sinusoidal commutation is different when using Hall Sensors Each step which is affected by Hall Sensor Operation is divided into two parts part 1 and part 2 After c
312. uxiliary port is essentially the same as the main port except inputs and outputs are reversed The DMC 40x0 may also be configured by the factory for RS422 These pin outs are also listed below 48 e Chapter 4 Software Tools and Communication DMC 40x0 RS 232 Configuration NOTE If you are connecting the RS232 auxiliary port to a terminal or any device which is a DATASET it is necessary to use a connector adapter which changes a dataset to a dataterm This cable is also known as a null modem cable 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 RS232 Auxiliary Port P2 DATASET 1 No Connect 6 No Connect 2 Receive Data input 7 Request To Send output 3 Transmit Data output 8 Clear To Send input 4 No Connect 9 No Connect Can be connected to 5V with APWR jumper 5 Ground Configuration Configure your PC for 8 bit data one start bit one stop bit full duplex and no parity The baud rate for the RS232 communication can be selected by setting the proper switch configuration on the front panel according to the table below Baud Rate Selection SWITCH SETTINGS BAUD RATE 9600 19200 38400 115200 Handshaking The RS232 main port is set for hardware handshaking Hardware Handshaking uses the RTS and CTS lines The CTS line will go high whenever the DMC 40x0 is not rea
313. ve 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 1t would also need to constantly update the position target 1t 1s 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 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 targets The absolute target is determined based on the current informa
314. watts of continuous power per axis The AMP 43040 43020 Brushless drive modules are connected to a DMC 40x0 The standard amplifier accepts DC supply voltages from 18 80 VDC A2 AMP 43140 D3140 The AMP 43140 contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 DC Volt input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 kHz A3 SDM 44040 D4040 The SDM 44040 is a stepper driver module capable of driving up to four bipolar two phase stepper motors The current is selectable with options of 0 5 0 75 1 0 and 1 4 Amps Phase The step resolution is selectable with options of full half 1 4 and 1 16 A4 SDM 44140 D4140 The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution the SDM 44140 drives two The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis 230 e Integrated Amplifiers and Drivers DMC 40x0 Al AMP 43040 Introduction The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless amplifiers that are capable of handling 500 watts of continuous power per axis The AMP 43040 43020 Brushless drive modules are connected to a DMC 40x0 The standard amplifier accepts DC supply voltages from 18 80 VDC If higher voltages are required
315. which is preprogrammed in the DMC 40x0 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 c with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Consider a system with the following parameters Kt Nm A Torque constant J 2 10 4 kg m2 System moment of inertia R 2 Q Motor resistance Ka 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of theDMC 40x0 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 0 500 rad s and a phase margin of 45 degrees The first step is to develop a mathematical model of the system as discussed in the previous system Motor M s P I Kt Js2 1000 s2 Amp Ka 2 Amp V DAC Kd 10 32768 0003 Encoder Kf 4N2 636 ZOH H s 2000 s 2000 184 e Chapter 10 Theory of Operation DMC 40x0 Compensation Filter G s P sD The next step 1s to combine all the system elements with the exception of G s into one function L s L s M s K Kg Kf H s 3 17 10 s2 s 2000 Then the open loop transfer function A s is A s L s G s Now determine th
316. which represents the required position value in counts The lt return gt terminates the instruction The space between PR and 4000 is optional For specifying data for the A B C and D axes commas are used to separate the axes If no data is specified for an axis a comma is still needed as shown in the examples below If no data is specified for an axis the previous value is maintained To view the current values for each command type the command followed by a for each axis requested 70 e Chapter 5 Command Basics DMC 40x0 PR 1000 Specify A only as 1000 PR 2000 Specify B only as 2000 PR 3000 Specify C only as 3000 PR 4000 Specify D only as 4000 PR 2000 4000 6000 8000 Specify A B C and D PR 800077 9000 Specify B and D only PR Request A B C D values PR Request B value only The DMC 40x0 provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as A B C or D 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 ACB 200000 Specify acceleration for the B axis as 200000 Instead of data some commands request action to occur on an axis or group of axes For example ST AB stops motion on both the A and B axes Commas are not required in this case since the particular axis is specified by the appropriate letter A B C or D If no parameters follow the instruction action
317. y Encoder Inputs for D W axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for E axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for F axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for G axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for H axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Appendices e 189 Performance Specifications Minimum Servo Loop Update Time Minimum Servo Loop Update Time DMC 4010 DMC 4020 DMC 4030 DMC 4040 DMC 4050 DMC 4060 DMC 4070 DMC 4080 Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Array Size Program Size 190 e Appendices Normal Fast Firmware 62 5 usec 31 25 usec 62 5 usec 31 25 usec 125 usec 62 5 usec 125 usec 62 5 usec 156 25 usec 93 75 usec 156 25 usec 93 75 usec 187 5 usec 125 usec 187 5 usec 125 usec 1 quadrature count Phase locked better than 0 005 System dependent 2147483647 counts per move Up to 22 0

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