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1. 0 queue empty no element taken 1 element taken unsigned int qu_avail queue_t q This routine interrogates the number of available elements in the queue q Response value Number of available elements unsigned int qu_used queue_t q This routine interrogates the number of occupied queue elements in the queue q Response value Number of occupied addresses Example include lt stdio h gt include queue h define QUEUEELEMENTS 10 define ELEMENTSIZE 10 define OUT BUF ADR define IN BUF ADR main char i queue_t outqueue_ptr queue_t inqueue_ptr char data_ptr 10 0x853000 0x854000 counter variable pointer to output queue pointer to input queue pointer to data buffer Generate a pointer to a queue generated by another process The queue begins with the queue header pointing to address OUT BUF ADR outqueue_ptr queue t OUT_BUF_ADR Open a queue at address IN_BUF_ADR The queue should have 10 elements of 10 Bytes each eh inqueue ptr queueopen QUEUEELEMENTS ELEMENTSIZE void IN BUF ADR an attempt is made to read data from the queue e if dequeue outqueue ptr char data ptr printf Data for i 0 i lt 10 i printf c data_ptr i printf n else printf Queue empty The previously read date are written to another queue i if enqueue inqueue ptr char data ptr printf Data writte
2. 4 2 Motor Direction of Motion If the motor is correctly connected the motor turns in a clockwise direction when a positive velocity values is output This sense of orientation can be reversed by means of the instruction USR Using this instruction the direction of motor motion can be synchronised with direction of counting of the position measurement system i e the output of a positive velocity value causes the actual position value to increase The initialised condition of motor direction orientation is re established by repeating the instruction USN The instruction USR has no effect in the mode test gt The correct motor encoder connections should be established during the commissioning phase Otherwise the controller may respond falsely on reaching the hardware limit switches 4 3 Axes 4 3 1 Axis Types Source MACB ENG DOC Status 04 06 99 Page 35 MACCONTROLLER USER Manual Version 1 2e of 82 The following axis types can be set up e linear axes circular axes 360 e circular optimised axes 360 This axis type is identified by the parameter 5 7 4 3 1 1 Linear Axes Linear axes are limited by the parameter In in the negative direction and lt p gt in the positive direction Diagram 4 1 The positive software limit switch must be above the negative limit Ip In Hardware limits are defined by the limit switches All target positions must lie between the range defined by lt n gt an
3. If the axis lies within the target radius after the period sw the axis controller turn off the BOOST signal The axis resets the time value zero and the time measurement is restarted The basic function of the servomode is illustrated in Diagram 5 11 The waiting period sw should be chosen such that oscillations of the motor encoder system have time to damp The parameter tr must allow for the achievable step accuracy as well as the ratio of the position encoder resolution to motor steps Source MACB ENG DOC Status 04 06 99 Page 58 MACCONTROLLER USER Manual Version 1 2e of 82 generate profile see Fig 5 12 start to increment servotime counter lt sw gt servotime no counter lt sw gt complete actual position outside target radius lt tr gt turn on Boost position lt ap gt target position lt ap gt reached no reset servotime counter lt sw gt Diagram 5 11 Basic Functions of the Servomode Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e move to turn off target Boost lt bt gt movement Page 59 of 82 Position Target Postition tr actual X mcXx ue dv Ws 4 servo counter servo counter complet servo counter i complete position correct BOOST l active Significance of lt sw gt Diagram 5 12 Significance
4. search index coarse search index home find edge All other modes operate exclusively on fly Two examples illustrate the behaviour of the axis in on fly operation 1st Example The axis moves in the mode find edge and looks for the positive hardware limit switch During movement the user issues the instruction code for the mode brake and the execute command In on fly operation the axis switches to the mode brake immediately and stops without having found the limit switch 2nd Example Another axis is positioning to the target position 20 000 Currently it is at the position 0 The input and activation of the new target position 10 000 causes the axis to already stop at the new target without have first moved to the position 20 000 After deactivation of the on fly operation by means of the command FLYOFF the axis controller processes each command in series The axis can then only be directly accessed and stopped via the stop bits in the DPRAM see Section 3 The behaviour of the axes for the above examples changes as follows 1st Example The axis looks for the limit It only transfers to the mode brake after the switch has been found 2nd Example The other axis moves to the position 20 000 only then does it accept the new command and starts to generate a ramp It moves to the position 10 000 for the second time and stops there on fly operation is activated with the command FLYON The axis controller go
5. 39 Mode Search Index Coarse 48 encoder_f 62 Mode Speed 45 Source MACB_ENG DOC Status 04 06 99 Page 80 MACCONTROLLER USER Manual Version 1 2e of 82 Mode Test 52 Mode Velocity Tracking 52 Modes 44 Monitoring 59 Negative limit switch 17 off fly 44 on fly 44 On fly Operation 53 operating modes 10 pole 55 position information in the DPRAM 31 Position measurement 16 Positive limit switch 17 Queue Description 66 queues 28 reset 14 sampling periods 44 Scaling of the Command Signal 43 serial interface 28 Software Stop 30 SSI clock rate 20 SSI Absolute encoder 19 Start Stop Frequency 32 Step Number 32 switch settings 12 syn_f 60 target position 46 target radius 47 Technical Data 72 telegramme 29 Torque Force Limitation 56 TURBO Signal 33 Units Conversion 39 User Status 63 velocity profile 46 Version Coding 59 via the DPRAM 30 VMEbus 12 Watchdog 41 zero 55 Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e Page 81 of 82 11 Hardware Drawings Circuit diagrammes are included with this document These may help the user to analyse the hardware functions of the MAC4 series of axis control cards There may also be of assistance when interface circuits are to be specified for these cards MAC4 INC CP PANDMNPWN PE aren m Ww N ST2 Connector ST2 Stecker Microprocessor Interface Rechner Interface Opto couplers Optokoppler Counter
6. MACASTP Trennung 3 Opto couplers Axis 4 MACASTP Trennung 4 Component Layout Component Side Rev A Component Layout Solder Side Rev A Source MACB ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e Page 82 of 82
7. Status 04 06 99 Mnemonic UWMS WSSF WBT UWSH UWLP UWLN UWET WIRQ3 WMF WAA Mnemonic A2 2000 500 30 80 1 1000000 0 A0 1000 2000 2000000 2000000 NNN WY A4 Page 67 of 82 Setting Controller set up Controller amplification 20 Zero 0 5 Pole 0 Integral amplification 0 02 Emergency braking ramp 5 000 Inc SP SP Justification velocity 20 Inc SP Axis initialisation MAC4 SSI Setting Circular axis with the size 10 000 Inc Absolute encoder resolution 10 000 connected via the VMEbus access via address 80C000 No switches connected off fly operation Maximum following error 500 Controller set up Controller amplification 50 Zero 0 99 Pole 0 Integral amplification 0 05 Emergency braking ramp 5 000 Inc SP SP Set watchdog to minute Axis initialisation 7 3 Queue Description Mnemonic WGA WZE WPO UWKISC WKI WAA INIT Mnemonic UWSH UWCR WGA WZE WPO UWKISC WKI WAA WWD INIT 7 3 1 Message Structure for VMEbus or RS 232 Source MACB ENG DOC E Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e 80 200 128 41 5000 20 10000 4 80C000 14 o ooo 500 253 13 5000 60000 Page 68 of 82 The conversion of commands into corresponding queue entries or serial messages is explained using examples The following commands have to be transferred to the axis controller MAC4 INC M
8. a negative limit switch a reference switch and a drive fault signal see Section 2 The active signal level can be configured separately for each switch The following parameters are available for this purpose setting of ps positive hardware limit switch ns negative hardware limit switch rs Reference switch df drive fault Signal Source MACB ENG DOC Status 04 06 99 Page 42 MACCONTROLLER USER Manual Version 1 2e of 82 gt The configuration of the limit and reference switches has no influence on the corresponding LED display see Section 2 The settings are made by the commands UWPS UWNS UWRS and UWSO see Reference Manual URPS URNS URRS URSO 4 6 Interrupt Vectors The axis controller is able to generate interrupts dependent on various events see Tab 4 4 The interrupt vectors can be configured accordingly The interrupt generation can be turned off by choosing vector 0 Default Only axis controllers with interrupt vectors defined as greater than 0 actually initiate interrupts The interrupts 1 4 and 6 can be set up separately for each axis The interrupt 5 is effective for all axes Nr queue empty command buffer that came from the VMEbus buffer to a command from the VMEbus The signal drive fault is active RIROS end of positioning The actual positioning or justification is completed The emergency stop switch has been activated encoder value demand A new position com
9. as possible at the target position This justification velocity may not exceed the start stop frequency lt ssf gt in the case of MAC4 STP If the start stop frequency is reduced to a value below lv this is then automatically reduced to the start stop frequency value 4 8 4 Scaling of the Command Signal The axis controller only accepts integer values Velocities with fractional values may be realised by binary shifting by the parameter sf Scaling obeys the equation lt Parameter scaled gt Parameter 2 gt The output values for all modes velocity acceleration and braking values can be scaled 4 9 Axis Initialisation Source MACB_ENG DOC Status 04 06 99 Page 44 MACCONTROLLER USER Manual Version 1 2e of 82 The system and parameter settings are activated by the INIT command This command acts on each axis individually Parameters which are not defined by the user are set to their default values on initialisation When the internal position measurement system is set by the parameter et the additional parameters ea eb and ec are automatically generated These parameters which are activated by the E command have no effect prior to axis initialisation as the controller and the profile generator are disabled Exceptions are the axis independent parameters e watchdog wd e vector for the emergency stop interrupt lt irg_vec5 gt After basic initialisation the axis controller starts to monitor
10. automatically selected returns the position at the axis limits to the base value motion over 360 repeats infinitely Positioning is only possible within the range of one load revolution Digital to analogue Converter Dual Port RAM Reference signal z track of an incremental encoder Intelligent peripheral controller The process of aligning the axis to a marker usually the reference pulse The justification velocity is a low speed used to approach the final position in order that the axis can stop immediately on recognition of the target Axis movement is linear instead of rotary The range of movement is physically limited The range of operation is limited by software limits and limit switches Commands and responses in communication between the axis controller and the host Instructions transmitted to the axis controller are executed individually The instructions that follow wait until completion Cause the immediate execution of instructions The axis controller receives the position information via the VMEbus or the DRAM There is no position sensor at the peripheral connector P2 The axis controller receives its position information from an encoder connected to peripheral connector P2 Ring buffer for the intermediate storage of messages between the axis Addresses for the attributes read and write pointer of a queue Start address for the messages in a queue Generator sampling period Status 04 06 99 Page
11. ensured that the hardware limit switch remain active over the complete forbidden range There is no protection against movement in the forbidden direction if the axis overruns a hardware limit switch and comes to halt behind the switch 2 3 4 Fault Signals The MAC4 SSI can interrogate three fault code signals FC Signals via the connector P2 These codes can be made available to the host system for all axes as joint status information Source MACB_ENG DOC Status 04 06 99 Page 22 MACCONTROLLER USER Manual Version 1 2e of 82 These inputs can also be used to interrogate other user signals Signal level FC 0 2 TTL Table 2 11 MAC4 SSI FC Signals 2 4 Peripheral Connections MAC4 STP The axis interface of the MAC4 STP consists of the functional blocks shown in Diagram2 7 Peripheral Interface Status register Potential Isolation Frequency Synthesizer Connector P2 Diagram 2 7 MAC4 STP Block Diagram of Axis Interface The connection of the axis controller to the stepper drivers is made via the connector P2 Diagram2 8 The pin allocation is given in the appendix 2 4 1 Motor The control of the stepper drives is made by means of the signals listed in Tab 2 12 Reset oc negative oc axis disabled c negative pulse oc run oc Open collector Output open Table 2 12 MAC4 STP Motor Signals Source MACB_ENG DOC Status 04 06 99 Page 23 MACCONTROLLER USER Manual Versi
12. of lt sw gt Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e position correct positioning sw 100 mS 0 1 2 3 4 servo counter servo counter complete complete l TERE S I servo position counter O correct lt bt gt 80mS time in SP Page 60 of 82 6 Diagnosis and Monitoring 6 1 System Displays Version The hard and software version of the axis controller can be read with the instruction VER A 32 bit value is returned with the version coded according to Tab 6 1 Bit 0 7 software release number Bit 8 15 Bit 16 23 hardware release umber coded as a letter Bit 24 31 card type 0 INC 1 SSI 2 STP Table 6 1 Version Coding System Data The read instructions listed in Tab 6 2 have been implemented to monitor motor motion The direct output of the position measurement systems can be accessed as well as the actual position of the motor This option allows the internal processing of the position measurement system to be checked by the user Abbrev Meaning Units Units Units MAC4 INC MAC4 SSI MAC4 STP Inc SSP Inc SSP Steps SSP ae actual enaps o ooa Eie IRCPI actual actual position O O e T T measurement system after bit suppression a MN UN RU hardware counter RFE actual following error factualfollowingerror ne _ nce Steps ROUT Joupuvale TS Step s SP Inc SP Inc
13. of parameters In addition the axis is influenced by the settings e on fly or e off fly as well as the controller parameter in the servo mode The setting of a mode as well as changes of the parameter values only become effective after execution of an execute command A motion mode can only be activated when an axis is in the mode enable or brake The axis controller reads the position generates a command value and controls or monitors the motion of each axis within the set system sampling period Within each system sampling period a profile generator calculates the command value for each axis 1 System sampling period Controller for the axes 1 2 3 and 4 Profile generator for axis 1 Command interpreter 2 System sampling period Controller for the axes 1 2 3 and 4 Profile generator for axis 2 Command interpreter 3 System sampling period Controller for the axes 1 2 3 and 4 Profile generator for axis 3 Command interpreter 4 System sampling period Controller for the axes 1 2 3 and 4 Profile generator for axis 4 Command interpreter The following sampling periods are set up eee MAC4 INC MAC4 SSI MAC4 STP system sampling period generator sampling period Table 5 1 Sampling Periods In the following the generator sampling period is simply called sampling period SP 5 1 Mode Reset Axis controllers MAC4 INC MAC4 SSI MAC4 STP With a reset all axes are brought to a stand still with the em
14. performed either closed loop MAC4 INC SSD or open loop with the option of feedback position correction MACA STP Source MACB ENG DOC Status 04 06 99 Page 11 MACCONTROLLER USER Manual Version 1 2e of 82 Disable Brake Diagram 1 2 State Change Diagram simplified MD ME UE MB MC MF MH MI MP MS PT VT nABWN Pe Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e Page 12 of 82 2 Hardware 2 1 Processor Module IPC The processor module of the axis controllers consists of the functional blocks illustrated in Diagram2 1 VMEbus A24 D16 Status Reset Clock Voltage Monitor VMEbus DRAM Driver Interrupt Handler 8 Kwords Data and Address and Requester MC68000 RAM Boot ROM FERRUM MC68010 256 KWords 256 KWords Connector to Peripheral Interface Module Diagram 2 1 Block Diagram of IPC The necessary set up conditions for the operation of the overall module on the VMEbus are described in the following sections Detailed information is provided in 1 2 1 1 Address Allocation The axis controller DPRAM occupies 64 KByte of address space on the VMEbus The base address of the DPRAM space can be adjusted within the address range of the VMEbus 100000 to BEFFFF with switches S1 and S2 on the IPC Diagram2 2 The address is defined by the switch settings as follows S1 S2 0000 Before commissioning the card it is necessary to check whether the DPRAM a
15. position measurement systems can be employed in addition to the systems mentioned in Tab 1 1 The axis position is transferred via the VMEbus to the axis controller or read autonomously by the controller over the bus All axis controllers of the family possess very similar features with the exception of their drive interface functions The master capability of the VMEbus Interfaces of both types of CPU modules used IPC and APC extends the possibility for system integration This also applies for the upward scaling of the APC when implementing the DSP option In addition to the powerful communications capability via VMEbus the APC offers a CAN Interface for the close integration of further measurement systems or process I O Source MACB ENG DOC Status 04 06 99 Page 8 MACCONTROLLER USER Manual Version 1 2e of 82 The axis interfaces of the controller are potentially isolated from the processor module in order to ensure a high level of safety and noise immunity Further the similar connector pinning employed by all the types of the controller ensure the greatest possible standardisation in the application and wiring of the drives and the axes when using these cards A number of display functions on the front panel of the controller indicate the state of the control of the individual axes in order to assist in commissioning and fault finding This documentation specifically describes the axis controller types MAC4 INC MAC4 SSI and MAC4 ST
16. the emergency stop condition All other connected switches are first interrogated after axis initialisation This only happens when no emergency stop condition is recognised The signals to the FC inputs 0 2 are available immediately after basic initialisation The same applies for the status display of the gray binary jumpers on MAC4 SSI controllers Axis initialisation activates the position measurement After this actual position values are available that may be read by commands RCP or RCPI MACA STP Until then only the position value 0 is seen A repeat initialisation causes the position value to be reset in the case of incremental position measurement This must be allowed for when using the software limit switches The axis controller responds to the INIT command with the user status after axis initialisation has been completed The init bit in the user status is set The axis initialisation process can be reversed with the command DEINIT The axis is then brought to a stand still and deactivated disable The axis controller clears the init bit in the user status The system parameters may now be changed Source MACB ENG DOC Status 04 06 99 Page 45 MACCONTROLLER USER Manual Version 1 2e of 82 5 Operating Modes In addition to the modes listed in Section 1 there is the mode reset which strictly speaking is not a mode at all The behaviour of the axis controllers in the various modes is defined by a differing number
17. the interrupts and their use is provided in Section 4 x closed open Table 2 1 Setting of interrupt levels The axis controller does not support interrupts generated by the host gt The jumper J7 on the IPC must be in position A B Source MACB_ENG DOC Status 04 06 99 Page 15 MACCONTROLLER USER Manual Version 1 2e of 82 2 2 Peripheral Connector MAC4 INC The axis interface of the MAC4 INC comprises the functional blocks shown in Diagram2 3 Peripheral Interface Address 16 Bit Counter register Potential Isolation Connector P2 Diagram 2 3 MAC4 INC Block Diagram of Axis Interface The connection of the axis controllers to the drive is made via the peripheral connector P2 Diagram2 4 The Pin allocation is given in the appendix IPC Drive Interface Logic IC31 MAC4 INC Rev D Connector P2 component view Diagram 2 4 MAC4 INC Component view Source MACB_ENG DOC Status 04 06 99 Page 16 MACCONTROLLER USER Manual Version 1 2e of 82 2 2 1 Motor The motors are controlled by means of the signals listed in Tab 2 2 Designation Signal name Signal level Signal level after Reset Enable EN 1 4 0 V axis enabled H o c axis disabled o c open Collector Output open Table 2 2 MAC4 INC Motor Signals 2 2 2 Position Measurement S ystems There are three ways of measuring position Direct connection of an incremental encoder via the P2 c
18. 79 of 82 SSI Synchronous serial interface interface standard for absolute encoders start stop frequency is the maximum possible acceleration or braking step from or to velocity Zero of a stepper motor 9 References 1 Dorsch Mikrosystem GmbH IPC V4 0 Technical Manual in German Ref Nr 942 1346 50 10 Index External Position Information 30 axis_f 60 fault code 17 drive fault 17 Fault Processing 60 FC Signals 17 7 segment display 24 ferr_f 62 find edge 51 absolute encoder 36 Following error 42 actual position 19 Address Allocation in the DPRAM 28 gain 55 address space 12 Global Parameters 42 AOUT 16 Axis Initialisation 43 h_stop 61 Axis Offset 35 host computer 14 base address 12 incremental encoder 16 36 BOOST 22 instructions 8 BOOST Signal 33 integral gain 55 interlocking flag 31 check sum 29 Interrupt Vectors 41 circular axes 34 interrupts 14 Circular optimised axes 34 IPC 7 Commands messages 30 Communication 28 Justification Velocity 42 controller coefficients 55 controller structure 54 Lead Lag Filter 54 limit switch 17 DF 17 Linear Axes 34 Diagnosis 59 logo_F 61 DIR 22 DLE 29 Message Structure 29 DPRAM Mode Brake 45 Address for position information 30 Mode Disable 45 Address space 12 Mode Enable 45 dr_f 61 Mode Find Edge 51 drive fault 41 Mode Home 49 Mode Position Tracking 52 Emergency Braking 42 Mode Positioning 45 emergency stop 17 Mode Reset 44 EN 16 Mode Search Index 48 encoder resolution
19. 9 Page 38 MACCONTROLLER USER Manual Version 1 2e of 82 If there is no position measurement system connected the output pulse counts generated by the axis controller are counted and used for the value of the actual position The real position is not monitored by the controller The position value is available in units of motor or driver steps The solder bridges selecting the counting of the outputs steps must be closed for the individual axes see Section 2 4 4 1 2 Incremental Encoder at the Peripheral Connector P2 An incremental encoder is directly connected at the peripheral connector P2 The signals received from the incremental encoder are counted in the axis controller and are used to generate the value of position In the case of MAC4 STP the axis solder bridges for the counting of increments must remain open see Section 2 The position value is now in units of the incremental encoder and must be converted to motor or driver steps The ratio of steps increment lt ms gt lt es gt must be known 4 4 1 3 Absolute Encoder at the Peripheral Connector P2 An absolute encoder with SSI interface is connected via the peripheral connector P2 directly to the axis controller The position received from the sensor can be registered either as absolute or relative position information In the case of relative registration only the change is position value since the last postion interrogation is processed In the case of absolute position measur
20. MOTION UNDER CONTROL USER Manual MACCONTROLLER MAC MAC4 INC Version 4 2 MAC4 SSI Version 4 2 MAC4 STP Version 2 2 MACCON GmbH June 1996 MACCON GmbH Kuehbachstr 9 D 81543 Munich Tel 49 89 651220 0 Fax 49 89 655217 Change Status 30 09 96 03 03 98 Maccon port ESO Source MACB_ENG DOC Status 04 06 99 Page 1 MACCONTROLLER USER Manual Version 1 2e of 82 All rights reserved The contents of this documentation was generated and checked carefully by engineers of MACCON and port GmbH in following MACCON MACCON can however accept no responsibility for damage caused by the use of this documentation In particular named performance characteristics and technical data may not be constituted to be guaranteed product features in any legal sense MACCON has the right to change the products described or their documentation at any time without prior warning as long as these changes are made for reasons of reliability or technical improvement All rights of this documentation lie with MACCON The transfer to third parties or duplication in any form whole or in part is subject to written approval by MACCON Copies of this document may however be made exclusively for the use of the user and his engineers The user is thereby responsible that third parties do not obtain access to these copies The soft and hardware designations used are mostly registered and are subject to copyright MACCON would like to thank po
21. Mode Positioning Axis controllers MAC4 INC MAC4 SSI MAC4 STP The axis moves to the target position defined with the parameter lt ap gt Source MACB_ENG DOC Status 04 06 99 Page 47 MACCONTROLLER USER Manual Version 1 2e of 82 Velocity Speed Position Time in sampling periods Diagram 5 1 Mode positioning MACA INC SST The axis controller accelerates the axis with the acceleration pa to the velocity pv Thereafter the axis moves with the velocity pv until it enters the braking phase Braking is made with the braking ramp pd The velocity profile is trapezoidal Depending on the velocity set the acceleration and braking ramps as well as the move distance the velocity profile may be triangular or rectangular In the case of MAC4 STP the braking ramp is followed by creep phase Diagram 5 2 In the creep phase the axis moves lt stc gt steps with the justification velocity v Each pulse generated is counted by means of an interrupt This ensures that the axis positions exactly to one step Boost Signal time bt bt Velocity Speed LVS sp m MR Target Position ap ess ec LE I emu IE WS p me cme em time creep speed justification phase stc Diagram 5 2 Mode positioning MAC4 STP The direction of the motion depends on the target position Source MACB_ENG DOC Status 04 06 99 Page 48 MACCONTROLLER USER Manual Version 1 2e o
22. P 1 2 Software Concept The extensive system software with more than 250 instructions with and without parameters for the control and parameterisation of motions functions is addressed by means of a numerical command set which has been optimised for field bus applications The functionality of the firmware is illustrated in the signal flow chart of Diagram 1 1 The CAN interface is not implemented in all versions of the MAC family The instructions that have been implemented in these axis controllers may be split into 6 groups 1 General instructions Initialisation confirmation of parameter changes error confirmation 2 Instructions for mode change Positioning etc 3 Instructions for system set up Direction of motor rotation on the fly operation etc 4 Instructions to read write system specific parameters position measurement systems axis type etc 5 Instructions to read write mode dependent parameters mode specific velocities accelerations delays etc 6 Diagnosis instructions reading of status and position information etc Source MACB ENG DOC Status 04 06 99 Page 9 MACCONTROLLER USER Manual Version 1 2e of 82 Command RS232 VME Parameter Serve Interfaces 1 Special commands andparameters I VME bus only Interpret Commands 2 Read actual values Write command values 5 Calculate control algorithm Diagram 1 1 Data flow Cha
23. R USER Manual Version 1 2e of 82 5 12 Mode Position Tracking 5 13 Mode Test 5 14 Special Characteristics of the Profile Generator in the MAC4 STP 5 15 On fly Operation 5 16 Position Controller of MAC4 INC SSI 5 16 1 Controller 5 16 2 Torque Force Limitation 5 17 Servomode 6 DIAGNOSIS AND MONITORING 6 1 System Displays 6 2 Status Information 6 3 Fault Processing 6 3 1 False Axis Number 6 3 2 Syntax Error 6 3 3 Limit Value Error 6 3 4 Drive Fault 6 3 5 Hardware Emergency Stop 6 3 6 Watchdog Error 6 3 7 Logical Error 6 3 8 Error of Position Measurement System 6 3 9 Following Error Overflow 7 APPENDIX 7 1 Status 7 1 1 User Status 7 1 2 System Status 7 1 3 Overall Status 7 2 Example Configuration 7 3 Queue Description 7 3 1 Message Structure for VMEbus or RS232 7 3 2 Queue Implementation under OS 9 7 3 3 Queue Address List 7 4 Technical Data 7 5 MAC4 INC Pin Allocation of the Peripheral Connector P2 7 6 MAC4 SSI Pin Allocation of the Peripheral Connector P2 7 7 MAC4 STP Pin Allocation of the Peripheral Connector P2 8 GLOSSARY 9 REFERENCES Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e 54 54 55 55 56 56 58 58 61 61 62 62 62 62 62 63 63 63 63 63 65 65 RAF 67 68 68 70 74 75 76 77 78 79 80 Page 6 of 82 10 INDEX 80 11 HARDWARE DRAWINGS 82 Source MACB_ENG DOC Status 04 06 99 Page 7 MACCONTROLLER USER Manual Ve
24. SER Manual Version 1 2e of 82 gt A too high integral component will cause stability problems 5 16 2 Torque Force Limitation The command signal generated by the controller is converted by the 12 bit out DAC and the motor amplifier into a current value in the motor which generates a torque or force The torque is limited by the controller to the value It A too strong limitation of the command value or torque may lead to an overflow of following error gt If the motor driver is set to voltage mode instead of current the command values output via the DAC are converted to a voltage at the driver output and thus to a velocity The torque limit then has the significance of velocity limit 5 17 Servomode Axis controller MAC4 STP Stepper drives are usually controlled without a control loop Step loss may occur and the motor target position then lost If a position measurement system at the motor is connected to the axis controller it recognises the discrepancy and can correct it The servomode is active after motion in the modes enable positioning search index coarse search index home find edge brake In the servomode the actual and target positions are compared after the time lt sw gt has lapsed If the axis is not within the set tolerance band tr around the target position a new position command is started The waiting time sw becomes effective after reaching the target position
25. SP Steps SP SSP System sampling period Instruction does not exist NO units Table 6 2 System Data Using the instruction RFE read following error it is possible to identify by how much the position of the motor differs from the target value A detailed description of each instruction is provided in the Reference Manual Source MACB ENG DOC Status 04 06 99 Page 61 MACCONTROLLER USER Manual Version 1 2e of 82 6 2 Status Information The operating condition of the axis controller can be read by using the following status commands Overall Status RAS User status RBS System status RSS axis independent information specific axis information for the user specific information for internal control Table 6 3 Status Information A detailed description of status is provided in the appendix 6 3 Fault Processing If the axis controller recognises an error it returns a different code to the received instruction excepting read instructions In addition an error dependent bit is set in the user or overall status A reported error must first be acknowledged with the instruction C before the axis controller can accept further commands Read commands are an exception these are always executed 6 3 1 False Axis Number returned instruction code user status cause of error effect of error 6 3 2 Syntax Error returned instruction code user status cause of error effect of error 6 3 3 Lim
26. a gt is defined by the parameter lt ec gt This storage address can be the register of a counter or the register of an encoder with SSI interface In the relative counting mode this value is important to be able to recognise counter overflow In the absolute encoder mode this value limits the axis range values outside this range lt ec gt can be recognised as errors The width of the position information in bits is identified by the parameter lt eb gt It indicates the number of significant bits of the values read All higher value bits are ignored Source MACB_ENG DOC Status 04 06 99 Page 39 MACCONTROLLER USER Manual Version 1 2e of 82 If the axis controller reads the position information externally over the VMEbus lt et gt 3 4 the parameter eb further defines whether the axis controller accesses one or two 16 bit words via the VMEbus When two 16 bit accesses are made it must be ensured that the measurement values does not change between them The first 16 bit access reads the LSW least significant word of the position measurement value at the address ea 2 and the second 16 bit access reads the MSW most significant word at the address ea Tab 4 3 summarises all the settings needed The counter of the axis controller is used when output steps are counted or an incremental encoder is used at the peripheral connector P2 All necessary information address of the counter registers counter range are automatically g
27. asurement of the index pulse employs interrupts 5 9 Mode Home Axis controllers MAC4 INC MAC4 STP The axis is positioned to the first index pulse following as shown the left active signal transition of the reference switch Diagram 5 7 Source MACB_ENG DOC Status 04 06 99 Page 51 MACCONTROLLER USER Manual Version 1 2e of 82 Velocity Speed Direction of Motion 1 Phase hd Move to reference switch hv Position Reference Switch Position active l NE Velocity Speed 3 1 i i Direction of Motion l Aly 2 Phase l Position to left edge lv of reference switch Position Velocity Speed Direction of Motion 3 Phase Position to index pulse lv Position Index Pulse active Position Diagram 5 7 Mode home MAC4 INC gt These mode is only executable when an incremental encoder is connected to the peripheral connector P2 In the first phase the reference switch is looked for with the acceleration lt ha gt and the velocity lt hv gt The axis is then braked with the braking ramp Ad In the second phase the left signal transition of the reference switch is sought for The left signal transition of the reference switch lies closest to the negative limit of axis movement Source MACB ENG DOC Status 04 06 99 Page 52 MACCONTROLLER USER Manual V
28. at this structure is observed Source MACB ENG DOC Status 04 06 99 Page 31 MACCONTROLLER USER Manual Version 1 2e of 82 The contents of the field Source indicate to the axis controller via which interface the command was received i e where the response must be sent to When accessing via the VMEbus the user must take care that a zero is put in the Source field In all other cases the interface driver enters the Source Commands messages usually include parameter values which are associated with the instruction code If the command requires no parameters the remaining bytes for the message parameter remain empty The response of the axis controllers include the instruction code of the command received The user status is included in the message parameters see Section 6 If the axis controller received a read command the recognised value is repeated in the message parameters instead of the user status In the case of an error the appropriate error code is included in the response of the axis controller in place of the instruction code the user or general status is included in the message parameters see Section 6 3 5 Direct Access to the DPRAM There are two further possibilities of accessing the controller directly over the VMEbus via the DPRAM These possibilities are in addition to communication via the queue 3 5 1 Software Stop The instruction brake see Section 5 serves to bring the axis to a stand still As t
29. d Ip total axis travel If the axis is moved out of this range the motor is braked and the axis disabled These settings are made with the commands UWSH UWLP UWLN see Reference Manual URSH URLP URLN Drive Neg Pos Hardware cin Hardware Limit Switch Limit Switch Neg Pos Software Software Limit Switch Limit Switch In o p Axis operating range v ae ee ee m Diagram 4 1 Linear Axes 4 3 1 2 Circular and Circular optimised axes In the case of circular axes there are no limits that may cause the axis to be disabled Diagram 4 2 Source MACB_ENG DOC Status 04 06 99 Page 36 MACCONTROLLER USER Manual Version 1 2e of 82 0 lt cr gt 2000 1500 500 1000 Diagram 4 2 Circular Axes The travel of the circular axis one revolution is defined in the parameter lt cr gt This value must be greater than zero lt cr gt gt 0 The position counter is set to zero when the position of the axis arrives at the value lt cr gt during motion in the positive direction During movement in the negative direction the position counter is set to lt cr gt 1 when the position value drops below zero Circular optimised axes differ from circular axes in that the shortest distance for an absolute move is automatically selected by the axis controller The settings are made with the commands UWSH UWCR see Reference Manual URSH URCR 4 3 2 Axis Offset The position information read normally identifies th
30. ddress space lies within the addressable address space of the host system and whether possible address conflicts may occur Source MACB ENG DOC Status 04 06 99 Page 13 MACCONTROLLER USER Manual Version 1 2e of 82 CPU VMEbus IRQ to IPC B ABdisable C BC enable not for MAC4 A Resvavwens N EPROM B AB enable IC26 odd C BC disable VMEbus P1 Ji A CPU watchdog active un VMEbus address Axis Interface according to type Front panel Connector P2 component view IPC HEBR 1 2 3 4 6 6 7 rear view J Jumper designation of set jumpers Diagram 2 2 Front and Rear View of the IPC Source MACB_ENG DOC Status 04 06 99 Page 14 MACCONTROLLER USER Manual Version 1 2e of 82 2 1 2 HostReset Jumper J4 see Diagram2 2 allows the user to define whether a reset of host computer causes the axis controller to reset or not A B A host reset causes the axis controller to reset B C A host reset has no influence on the axis controller 2 1 3 Software R eset The axis controller can also be reset with the instruction MR see Reference manual This command uses the watchdog of the IPC and functions only when the Jumper J11 is in place see Diagram2 2 2 1 4 Interrupts The axis controller supports interrupt vectors at the VMEbus The interrupt level can be selected by means of the solder bridges LB1 and LB2 on the IPC Diagram2 2 according to Tab 2 1 A detailed description of
31. e index pulse a braking phase with the braking ramp cd follows The axis is thus brought to a stand still near to the index pulse The final deviation of the stationary axis position from the index pulse depends on the parameter settings The direction of motion is determined by the sign of the velocity cv 5 8 Mode Search Index Axis controllers MAC4 INC MAC4 STP The mode search index executes a fine justification alignment to the index pulse Diagram 5 6 gt These mode is only executable when an incremental encoder is connected at the peripheral connector P2 Source MACB_ENG DOC Status 04 06 99 Page 50 MACCONTROLLER USER Manual Version 1 2e of 82 Velocity Speed Direction of motion 1 Phase Move to index pulse and brake iv id Position Index Pulse active Position Velocity Speed Direction of motion 2 Phase Retern to index pulse Position Diagram 5 6 Mode search index MAC4 INC The first phase is the same as for the mode search index coarse however search index uses acceleration ia maximum velocity iv and braking ramp id In the first phase of motion the axis is driven over and beyond the index pulse In the second phase it moves with the creep velocity Iv back to the index pulse On reaching the index pulse the axis is halted A braking ramp is not generated The direction of motion depends on the sign of the parameter iv The me
32. e position of the axis This value may be modified with an offset defined by the parameter ao axis offset see Diagram 4 3 The position information processed by the axis controller is the sum of the actual measured position information and the axis offset The axis offset can also be set indirectly by allocating a user value to the actual position by means of the instruction WZP Source MACB ENG DOC Status 04 06 99 Page 37 MACCONTROLLER USER Manual Version 1 2e of 82 Position 0 after initialisation ao UWAO1000 E Position 1000 PF ao 1000 WZP2000 E Position 2000 lt ao gt 2000 UWAO_R1000 E Position 3000 H lt ao gt 3000 Diagram 4 3 Axis Offset 4 4 Position Measurement System 4 4 1 Types of Position Measurement There are various possibilities of measuring the axis position Position measurement step counter P2 measurement mode Attribute internal internal external measurement mode measurement mode position sensor over the DPRAM in absolute measurement mode position sensor over the VMEbus in relative measurement mode external external oL x L aha hs Co a absolute encoder at the peripheral connector P2 x internal in absolute measurement mode X position measurement available Table 4 2 Types of Position Measurement 4 4 1 1 Step Counter Source MACB ENG DOC Status 04 06 9
33. eaning 70 16 o MP mode positioning pO E activate positioning EE RCP actual axis position is read non implemented command These commands should be transferred to axis 1 axis number 0 Entry in the Command Queue via the VMEbus When directly accessing the queue via the VMEbus the following entries must be made in sequence in the command queue address area p pu EA The entries marked with a may be chosen freely These entries are ignored by the axis controller Entries in the Response Queue over the VMEbus The responses of the axis controller as a reaction to commands are entered in sequence in the response queue address area 0 0o v se so sor 0 O0 s 0 0 SO 01 0 o f me 0 00 03 SEB o o i 0 00 23 S08 pot pnwl 39 ipo BEUNDEESONEORVOENERCUONUE NEGRO ORO SENE DEREN gy are E A Explanation of the responses e atthe start of the instruction sequence the axis is in the mode enable e the change to the mode positioning is made with the execute instruction e the position read by the fourth instruction is 1 000 Inc A syntax error is shown as the response to the last instruction Transmit Message over the Serial Interface When communicating via the serial interface the queue entries given above are made by the interface driver of the axis controller In the field Source there is a One instead of a Zero The message to
34. ed with the emergency braking ramp ed and transferred to the mode disable In the mode test the axis is disabled without a braking ramp the error message is given as the response to the next instruction 165 bit h stop set the emergency stop switch was activated all axes are disabled without braking ramp and put in the mode disable the error message is given as the response to the next instruction 164 bit watch f set the set watchdog time has expired without communications between host and axis controller all axes are braked with the emergency braking ramp ed and are put in the mode disable In the mode test the axis is disabled without a braking ramp the error message is given as the response to the next instruction 163 bit logo F a system parameter has been set although the axis is not deinitialised or in the mode disable a justification to the index pulse has been commanded although an incremental encoder has not been specified and connected at the peripheral connector P2 an error has not been acknowledged with the clear command a change to a motion mode is only possible from the modes enable or brake a circular axis cannot be justified to the limit switch the axis position can only be set when the axis is in the stand still condition the mode find edge was requested with a condition that was declared OFF for the switch the mode home was requested although the r
35. eference switch was declared OFF the parameter ec may not be set in circular axes using an absolute encoder the transmitted command is ignored 6 3 8 Error of Position Measurement S ystem Source MACB ENG DOC Status 04 06 99 Page 63 MACCONTROLLER USER Manual Version 1 2e of 82 returned instruction code user status cause of error effect of error 6 3 9 Following Error Overflow returned instruction code 163 user status cause of error effect of error Source MACB_ENG DOC 163 bits encoder f logo f set the position value read from an externally connected position sensor or the SSI absolute encoder exceeds the value range given by ec the affected axis is disabled without braking ramp and remains in the mode disable bit ferr_f set the difference between the actual position of the axis and the commanded position exceeds the maximum values mf allowed The cause can be a bad cable connection the value of velocity or acceleration is too large the motor cannot follow an error of the position measurement system MAC4 STP a false input value for the motor steps lt ms gt or the encoder lines lt es gt e MAC4 STP a bad ratio of es to ms that leads to rounding errors bad mechanical connection between motor and encoder e afalsely connected motor or encoder i e in the positive direction of motion the encoder counts downwards e MAC4 INC SSI insufficient controller
36. ement the operating range of the absolute encoder may not be exceeded 4 4 1 4 External Position Encoder Any position measurement system of choice is connected to the host system Position measurement is not made by the axis controller but by another module The transfer of the position information to the axis controller is made either via the DPRAM see Section 3 or the axis controller reads the measurement value over the VMEbus as a bus master The position read can either be processed in absolute or relative form The position value is now in units of the incremental encoder and must be converted in the case of MAC4 STP to motor or driver steps 4 4 2 Configuration of the Position Measurement System 4 4 2 1 Address and Range Settings The following parameters are used to set the address and range settings of the position measurement system lt et gt encoder type lt ea gt encoder address lt eb gt encoder bit size lt ec gt encoder counter range The type of position measurement system is defined by the parameter lt et gt The parameter ea indicates the address from which the axis controller should read the position information gt Before initialisation INIT it must be ensured that plausible measurement values are present at these address as the axis controller will immediately start processing these values after initialisation The counting range of the storage address identified by the parameter lt e
37. en the distance between target and actual positions becomes too large a following error overflow may occur The axis controller generates a braking ramp depending on the distance This also applies on recognising the limit switches the signal drive fault a communication or an encoder error 5 13 Mode Test Axis controllers MAC4 INC MAC4 SSI MAC4 STP In this mode it is possible to recognise whether the axis is correctly connected To this purpose the axis is activated and the command value given in the parameter lt da gt is output to the motor The profile generator and the position controller servomode are not active in this mode The instruction USR has no effect in the mode test Source MACB_ENG DOC Status 04 06 99 Page 54 MACCONTROLLER USER Manual Version 1 2e of 82 5 14 Special Characteristics of the Profile Generator in the MAC 4 STP The BOOST signal is generated before each motor move and deactivated after move completion The MAC4 STP uses the start stop frequency in all modes as the first and last acceleration value in a profile Diagram5 2 5 15 On fly Operation If the axis controller receives a new instruction it normally executes it immediately even when the instruction currently being processed has not been completed This behaviour is known as on fly operation Alternatively off fly operation in which instructions are strictly processed in series can be selected in the modes positioning
38. enerated during initialisation INIT and need not be set by the user These settings are made by the commands UWET UWEA UWEC and UWEB see Reference Manual URET UREA UREC UREB Eno LI NM steps connector P2 increments P2 in relative counting mode increments P2 in absolute counting mode increments counting mode address increments position sensor over the DPRAM in relative counting mode address increments absolute counting mode address increments lt e Eeo oe mod address increments Default value automatic entry i Parameter value within the permissible limits Table 4 3 Settings of the Position Measurement System 4 4 2 2 Scaling of the SSI Encoders MAC4 SSI The protocol of the SSI encoders must be specified in order to be able to connect different SSI encoders to the axis controller MAC4 SSI The protocol is dependent on the manufacturer and can be identified in the encoder documentation An example is shown in Diagram4 4 Source MACB ENG DOC Status 04 06 99 Page 40 MACCONTROLLER USER Manual Version 1 2e of 82 Pause CLOCK Standby 20 21 22 23 24 25 26 standby 18 significant data bits Total data word 25 bits Diagram 4 4 Signals of the SSI As a rule the axis controller does not read position information from the register with right handed justification so that a binary shift operation is needed before further processing The axis controller can only process the position information
39. ergency braking ramp lt ed gt and are transferred to the mode disable All parameters are set to their default values If a reset is made in the mode test the axes are disabled without first being braked A reset is executed without the need for an execute command After a reset all axes are deinitialised This function is only guaranteed when the jumper J11 on the IPC is set Section 2 Source MACB ENG DOC Status 04 06 99 Page 46 MACCONTROLLER USER Manual Version 1 2e of 82 5 2 Mode Disable Axis controllers MAC4 INC MAC4 SSI MAC4 STP The addressed axis is disabled and an output motor command of zero is generated 5 3 Mode Enable Axis controllers MAC4 INC MAC4 SSI MAC4 STP The addressed axis is enabled It is held at its actual position Only after an enable can a motion mode be selected The axis remains enabled until it is transferred again to the mode disable 5 4 Mode Speed Axis controllers MAC4 INC MAC4 SSI MAC4 STP The axis moves with the velocity given by the parameter lt sv gt This velocity is reached with an acceleration ramp defined by lt sa gt Thereafter the axis moves continuously with the velocity lt sv gt The sign of the velocity lt sv gt determines the direction of motion of the axis 5 5 Mode Brake Axis controllers MAC4 INC MAC4 SSI MAC4 STP The axis is brought to a stand still with the brake ramp lt sd gt Thereafter the axis is held at the actual position 5 6
40. ersion 1 2e of 82 Finally in the third phase the axis is positioned to the next index pulse in a positive direction In the latter two phases the velocity lt v gt is used Braking from velocity lt v gt occurs without a braking ramp The direction or search is determined by the sign of the velocity lt hv gt 5 10 Mode Find Edge Axis controllers MAC4 INC MAC4 SSI MAC4 STP With this mode it is possible to justify align an axis to a switch defined by the parameter lt dl gt Diagram5 8 Direction of Motion o 1 Phase lt fd gt Move to left edge of reference switch and brake Velocity Speed Position Switch selected Position active P Velocity Speed i aT i Direction of Motion _ i 2 Phase lv Move to left edge of reference switch Position Diagram 5 8 mode find edge MAC4 INC The following switches can be selected dl 0 reference switch dl 1 negative hardware limit switch dl 2 positive hardware limit switch In the case of circular axes it is only possible to justify to the reference switch The mode find edge is executed in two phases The axis controller accelerates the axis with the acceleration lt fa gt to the maximum permissible velocity lt fv gt The axis moves with constant velocity lt fv gt to the switch transition and brakes with lt fd gt The justification to the switch tran
41. es automatically to on fly operation on switch on Source MACB ENG DOC Status 04 06 99 Page 55 MACCONTROLLER USER Manual Version 1 2e of 82 5 16 Position Controller of MAC 4 INC SSI 5 16 1 Controller A Lead Lag Filter with PD behaviour and a parallel integrator I behaviour has been implemented in these controllers Lead Lag Drive Command Following Command Position Error output Integrator Actual Position Diagram 5 10 Controller Structure The basic controller structure is shown in Diagram5 10 The z transfer function of the controller is Lead Lag Filter GZ K 1 Az 1 Bz with the corresponding recursive algorithm u k K e k K A e k 1 B uj k 1 Integrator G C 1 z with the corresponding recursive algorithm u2 k Ce k 1 u k 1 Source MACB_ENG DOC Status 04 06 99 Page 56 MACCONTROLLER USER Manual Version 1 2e of 82 The output command value of the controller is given by the following expression Up k zu kK Uy k where e k is the following error and u k the command value at the sampling time k The integral component of the controller is limited to avoid excessive command values anti wind up The controller coefficients can set by the parameters lt ga gt gain lt ze gt zero lt po gt pole lt ki gt integral gain These values are converted as follows lt ga gt 4 K lt ze gt 256 A po 256 B
42. esponds to a down count of the encoder MAC4 INC SSI bad set of control parameters e MAC4 SSI false shift factor lt sc gt The parameter mf indicates the size of the following error that may be tolerated The axis is braked and disabled on exceeding the given value The error message Following error overflow is generated gt MAC4 STP A following error can also occur when counting position pulses internally This effect results from the time delay between position measurement and command output In this case the following error does not truly indicate an error in motor motion only the generated steps to the motor driver have been counted 4 8 2 Emergency Braking Emergency braking lt ed gt serves to stop the axis as quickly as possible It is employed in the following cases reset instruction watchdog error software or hardware limit switch activated following error overflow signal drive fault active The emergency braking ramp is used in all other modes for the above exception conditions with the exception of the mode test In the test mode the axis is stopped without a ramp 4 8 3 J ustification Velocity The justification velocity lt v gt serves for the final and exact positioning to switch transitions or to the encoder index pulse in the modes search index home find edge and positioning The value should be chosen to be as low as possible in order that the axis can stop as precisely
43. ess Table 7 1 Queue Address List Source MACB_ENG DOC Status 04 06 99 Page 74 MACCONTROLLER USER Manual Version 1 2e of 82 7 4 Technical Data 6HE VMEbus card for the control of OR 4 DC servodrives brush and brushless MACA INC SST 4 stepper drives MAC4 STP local Motorola CPU 68000 with 16 MHz clock and 64 kByte DPRAM to VMEbus VMEbus Master Slave A24 D16 standard EPROM firmware or user programmable generates and processes interrupts process peripherals potentially isolated from the CPU supply voltage 5 V current consumption 2 5 A temperature range operational environment 0 45 C storage and transport 25 80 C VMEbus connection via connector VMEbus P1 peripheral connections via a two row peripheral connector P2 according to DIN 41612 style C via a backplane or a 64 pole flat band cable RS232 with SUB D 9m connector at the front panel 4 enable outputs 3 user definable inputs error code inputs TTL 1 emergency stop input with LED display 6 Status LEDs per axis reset switch at the front panel or reset via the VMEbus MAC4 INC 8 inputs limit switches 24 V 4 inputs reference switches 24 V 4 inputs drive fault signal 24 V 4 analog motor outputs 10 V 12 bit 6 incremental encoder inputs unipolar or bipolar with index pulse controller sampling rate 2 5 ms all axes cycle time of the profile generator 10 ms all axes MAC4 SSI 8 inputs limit switches 24 V 4 inputs re
44. f 82 On arriving at the target oscillations around this position must be avoided A time variable recognition of the target serves to dampen oscillations and thereby stabilises the recognition of the end of the move see Diagram 54 Target Position d Axis 2 x Target Radius Diagram 5 3 Target Position and Radius Position Target Radius Target Position tin SP sampling periods p 7 Actual Value of trt Counter A arp asi euism opc erare seine o CERTA C EE a Grea N pos_end at lt trt gt 10 Diagram 5 4 Significance of lt trt gt The parameter target radius lt tr gt puts a window around the target position lt ap gt see Diagram5 3 After reaching the target position a target time counter is started During each SP of the axis controller the actual position is compared with the target position If the actual position lies within the target radius the target time counter is increased by one In all other cases the contents of the target time counter are reset If the counter for the target time reaches the value given by the parameter lt trt gt the axis controller recognises that the positioning move has been completed In the case of MAC4 STP tolerances resulting from the ratio lt es gt to lt ms gt are allowed for automatically For a target radius of zero the axis controller only recognises the end of the po
45. f the type queue_t to define the absolute start address of the queue Response values loc is returned The axis controller defines with this function a command and response queue of 10 queue elements of each 10 byte length Example Define a queue of 10 elements each of 10 bytes at address 0x854700 define NUMBER 10 define SIZE 10 define LOCATION 0x854700 queue_t myqueue myqueue queueopen NUMBER SIZE void LOCATION void queueclose queue_t q With this function the queue q is cleared Elements that are not yet in the queue are lost Response value none The routine queue close should only be called by a process after other communication processes have ceased to access the queue int enqueue queue t q char s The same number of bytes are written from the buffer s in the queue q as were given as the size of an element width on opening the queue Response value 0 queue full no entry possible 1 entry possible Of the maximum predefined number of storage addresses in the queue nel only a maximum of nel 1 may actually be occupied with data For programming reasons one element must remain free between the read and write pointers of a queue int dequeue queue t q char s The same number of bytes are written from the queue in the buffer s as were given as the size of an element width Source MACB ENG DOC Status 04 06 99 Page 71 MACCONTROLLER USER Manual Version 1 2e of 82 Response value
46. ference switches 24 V 4 inputs drive fault signals 24 V 4 analog motor outputs 10 V 12 bit 4 SSl inputs bipolar TTL 4 SSI outputs bipolar to the clock TTL Gray binary sensor can be connected configuration per jumper SSI clock rates 750 375 187 5 or 93 75 kHz selectable per jumper controller sampling rate 2 5 ms all axes cycle time of the profile generator 10 ms all axes Source MACB_ENG DOC Status 04 06 99 Page 75 MACCONTROLLER USER Manual Version 1 2e of 82 MAC4 STP 8 inputs limit switches 5 24 V 4 inputs reference switches 5 24 V 4 inputs drive fault signals 5 24 V 4 motor outputs with boost direction and pulse output maximum step frequency 500 kHz 4 incremental encoder inputs unipolar or bipolar with index pulse controller sampling period 8 ms all axes cycle time of the profile generator 32 ms all axes 7 5 MAC4 INC Pin Allocation of the Peripheral Connector P2 Row A Af 1 a O 142 o k O Ss M k PAR OUTS O a5 AOA A6 ChBi Pee 4 Hu ee 7 A8 ChA2 p AIO LA s ENT PEN a i mec NEN EET SEU B e Oo 6 Cp B 30549 O az CO OE All a a NND NN aB C2 ChB3 CB ha a Cia 4e i4 ga p 0 1 E oo n O HEN O0 CH B k 8 _ 4 5 k 6 PENNE C CONNU a 09
47. ge of the DPRAM 3 2 Communication via Queues 3 3 Communication via the Serial Interface 3 4 Message Structure 3 5 Direct Access to the DPRAM 3 5 1 Software Stop Source MACB ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e 11 13 13 13 15 15 15 16 17 17 17 18 19 21 21 22 22 23 23 24 26 26 26 28 29 29 30 30 31 32 32 Page 4 of 82 3 5 2 External Position Information via the DPRAM 32 4 SYSTEM SETTINGS 34 4 1 Motor and Drive Parameters for the MAC4 STP 34 4 1 1 Step Number of the Motor 34 4 1 2 Start Stop Frequency 34 4 1 3 TURBO Signal 35 4 1 4 BOOST Signal 35 4 2 Motor Direction of Motion 35 4 3 Axes 35 4 3 1 Axis Types 35 4 3 2 Axis Offset 37 4 4 Position Measurement System 38 4 4 1 Types of Position Measurement 38 4 4 2 Configuration of the Position Measurement System 39 4 5 Switch Configuration per Software 42 4 6 Interrupt Vectors 43 4 7 Watchdog 43 4 8 Global Parameters 43 4 8 1 Maximum Following Error 43 4 8 2 Emergency Braking 44 4 8 3 Justification Velocity 44 4 8 4 Scaling of the Command Signal 44 4 9 Axis Initialisation 44 5 OPERATING MODES 46 5 1 Mode Reset 46 5 2 Mode Disable 47 5 3 Mode Enable 47 5 4 Mode Speed 47 5 5 Mode Brake 47 5 6 Mode Positioning 47 5 7 Mode Search Index Coarse 50 5 8 Mode Search Index 50 5 9 Mode Home 51 5 10 Mode Find Edge 53 5 11 Mode Velocity Tracking 54 Source MACB_ENG DOC Status 04 06 99 Page 5 MACCONTROLLE
48. his command is entered in the queue and is not immediately executed there is a possibility to stop the axis immediately per software The user must set the corresponding stop bit in the DPRAM at address 4600 Tab 3 2 The stop bits are reset by the axis controller The software stop does not disable the axis instead it executes the mode brake If the software stop is initiated in the mode test the axis is disabled mode disable Table 3 2 Stop by Means of Software 3 5 2 External Position Information via the DPRAM When the position information is made available via the DPRAM the host must write this information directly in the DPRAM of the axis controller The addresses for the entry of the position information are fixed see Tab 3 3 and must be identified by the parameter ea in the initialisation phase Further explanations regarding the configuration of the position measurement system can be found in Section 4 There is an interlocking flag in order to avoid access conflicts between host and axis controller when entering the position information in the DPRAM Source MACB ENG DOC Status 04 06 99 Page 32 MACCONTROLLER USER Manual Version 1 2e of 82 Table 3 3 DPRAM Addresses for the Position Information The length of the position information is always 4 bytes The flag field has a length of 2 bytes Example The position information for axis has to be supplied by the host 1 The host checks whether
49. in the form of mnemonics is given in capitals INSTRUCTION e Instructions which write parameters to the controller are designated with an additional _R if these are relative write instructions WRITE_R relative parameter value e The given abbreviations for the instructions only serve to simplify documentation Transmission of instructions to the axis controllers is performed always as a number code e Special notes and warning indications are provided as number codes and are provided in a box with an arrow gt WARNING e Descriptions of abbreviations and designations are provided in the glossary Source MACB ENG DOC Status 04 06 99 Page 3 MACCONTROLLER USER Manual Version 1 2e of 82 List of Contents 1 OVERVIEW OF THE VMEBUS AXIS CONTROLLER FAMILY MAC 1 1 Hardware Concept 1 2 Software Concept 1 3 Axis Control 2 HARDWARE 2 1 Processor Module IPC 2 1 1 Address Allocation 2 1 2 Host Reset 2 1 3 Software Reset 2 1 4 Interrupts 2 2 Peripheral Connector MAC4 INC 2 2 1 Motor 2 2 2 Position Measurement Systems 2 2 3 Input Signals 2 2 4 Fault Signals 2 3 Peripheral Connector MAC4 SSI 2 3 1 Motor 2 3 2 Position Measurement Systems 2 3 3 Input signals 2 3 4 Fault Signals 2 4 Peripheral Connections MAC4 STP 2 4 1 Motor 2 4 2 Position Measurement Systems 2 4 3 Input Signals 2 4 4 Fault Signals 2 5 Front Panel 2 5 1 Reset 2 5 2 7 Segment Display 2 5 3 LED Display 3 COMMUNICATIONS 3 1 Address Ran
50. it Value Error returned instruction code user status cause of error effect of error Source MACB_ENG DOC 160 bit axis f set input of a false axis number the transmitted command is ignored the interrupt command buffer empty is not generated The response with the error code 160 includes the falsely given axis number the interrupt answer available is generated with the interrupt vector of the last valid axis continued operation of all axes is only possible after an error acknowledgement for any axis 161 bit syn_f set the instruction code does not exist the transmitted command is ignored 162 bit limit_f set the parameter value lies outside of the permissible limits the given target position lies outside of the software axis limits the given position is outside of the value range of the absolute encoder the transmitted command is ignored Status 04 06 99 Page 62 MACCONTROLLER USER Manual Version 1 2e of 82 6 3 4 Drive Fault returned instruction code user status cause of error effect of error 6 3 5 Hardware Emergency Stop returned instruction code user status cause of error effect of error 6 3 6 Watchdog Error returned instruction code user status cause of error effect of error 6 3 7 Logical Error returned instruction code user status cause of error effect of error bit dr f set the drive fault signal is active the axis is brak
51. itch Neg Limit Switch Reference Switch Axis Disabled Axis in Position Drive Fault Signal 1 Axis Status LED Indicators muU axis controller operational basic initialisation of the CPU performed 3 calculation of the CR check sum for the EPROM axis controller ready for communication error of the position measurement system Source MACB ENG DOC Status 04 06 99 Page 27 MACCONTROLLER USER Manual Version 1 2e of 82 axis disabled by watchdog hardware emergency stop condition Table 2 16 7 Segment Display 2 5 3 LED Display The hardware emergency stop is effective for all axes and is displayed by the LED STOP The display of the switch positions and of the axis operating conditions is made by six LEDs per axis see Diagram2 9 The LEDs for the limit switch and the reference switch light up when the signal level drops to 0 V They are disabled or extinguished at a signal level of 5 V MACA STP or 24 V The LED D is turned on when the axis is disabled It is turned off when the axis controller is instructed to go in to the enable mode During a position move the LED P indicates that the target position has been reached The LED turns off on changing to another mode or commanding a new target position The user can modify the polarity of the drive fault signal according to his application However the LED always turns on when the system recognises the signal condition as switch on Sou
52. ki 256 C In order to influence the integral amplification more exactly it is possible to shift the integral coefficient ki internally a number ki sc of binary steps to the right Each shift corresponds to a halving of the value ki sc Integral factor 2 ki 2 Example The actual integral amplification is 8 256 2 2 with ki 8 and ki sc 2 gt The default value of lt ki_sc gt is 8 The qualitative relationship between the values of the controller parameters and system behaviour is shown in Tab 5 2 Increase of the parameter Stability Stiffness zero pole less better integral gain worse shorter increased gain worse shorter increased Table 5 2 Influence of the Controller Parameters In setting of controller parameter the following procedure is recommended 1 Increase gain until the motor starts to oscillate gently 2 Reduce the gain parameter about 20 3 Reduce the zero during continuous motion until no further improvement in the following error can be recognised 4 Again increase the zero value slightly 5 The parameter pole can be set up in a similar way to the zero However this may reduce the stiffness of the system 6 As the last step the integral amplification is set up as high as possible in order that the target position is reached as quickly as possible with minimum following error Source MACB ENG DOC Status 04 06 99 Page 57 MACCONTROLLER U
53. mand value may be written to the DPRAM Table 4 4 Interrupts gt Interrupt 2 is not generated when the output queue is full The response is lost 4 7 Watchdog A watchdog generated by software surveys communications between the host and axis controller It disables all axes if the axis controller receives no instruction from the host during a period set in the parameter lt wd gt This facility is to ensure that the axes do not go out of control if there is a fault in the host system or in the connection between the host and axis controller The set value is valid for all axes 4 8 Global Parameters The following parameters are used in various modes 4 8 1 Maximum Following Error The following error is defined as the difference between the commanded position and the actual position of the axis There may be several reasons why the axis does not reach the commanded position Source MACB_ENG DOC Status 04 06 99 Page 43 MACCONTROLLER USER Manual Version 1 2e of 82 cable breakage the commanded velocity or acceleration may be too high for the motor error of the position measurement system MAC4 STP the given value for motor steps lt ms gt or encoder lines lt es gt is false MAC4 STP the ratio of lt es gt to lt ms gt has led to rounding errors bad mechanical connection between motor and encoder the motor or encoder are incorrectly connected i e in the positive motor direction of motion counts corr
54. n in queue M else printf Queue full close queue queueclose inqueue ptr Source MACB ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e Page 72 of 82 Source MACB_ENG DOC Status 04 06 99 Page 73 MACCONTROLLER USER Manual Version 1 2e of 82 7 3 3 Queue Address List The command queue of the axis controllers is the basis for the address list in Tab 7 1 po Value is always 18 Offset to queue base address This value may notbechanged Sesc Stee o ooo This value may not be changed 7 This value may notbe changed 5 Endorf the queue header Begin of the queue base address xx4718 Axisnumber xx4719 Pee oo Sxx471A po MS instruction code xx471B Po LSB instruction code xx471C MS parameter value xx471D I parameter value Sxx47IE xx471F LSB parameter value xx4720 Po Source xx4721 o fem ty Eo femtry o o xx4722 pO aiser O xx4723 Sxx4724 xx4725 xx4726 xx4727 pe parametervalue xx4728 PSB parametervalue SSS O xx4729 pf Source ooo Sxx472A o y y ew S xdT2Cenry3 analogue entry tand xx4736entry4 Jandogueenryland2 S O xx4740entry5 Jandogueenryland2 o xx474A entry6 Jandogueenryland2 xx4754entry7 Jandogueenryland2 o xx475Eentry8 Jandogueenryland2 S x4768enryO Jandogueenryland2 x4772enry 10 Janalogueenryland2 o xx477C Po End ofthe queue base addr
55. n the appendix 3 3 Communication via the Serial Interface The serial connection SUB D Opin at the front panel can be used for communication with the axis controller The transmission rate is fixed at 4800 Baud one stop bit no parity The serial interface is served by a software driver which transfers messages to the queue From there they are read by the axis controller and processed accordingly The protocol employed is based on BSC protocol binary synchronous communication IBM GA 27 3004 2 Each telegram consists of three component parts Diagram3 3 Telegram header Data Check sum 2 Byte n Byte 1 Byte Diagram 3 3 Structure of a Serial Telegram Source MACB ENG DOC Status 04 06 99 Page 30 MACCONTROLLER USER Manual Version 1 2e of 82 Telegram Header The telegram header Diagram3 4 introduces a new telegram and begins with DLE Data Link Escape 10 followed by a STX Start type of TeXt 02 DLE STX 1 Byte 2 Byte Diagram 3 4 Structure of the Telegram Header Data The data field Diagram3 5 includes the axis number the instruction code and possible parameters for the axis controller This dictates the length of 7 bytes If a byte with the value 10 DLE has to be transmitted this character must be repeated and the length of the data field increases by one byte 2 3 Byte 4 7 Byte Diagram 3 5 Structure of the Data Fields excl transmitted DLE Check sum A check sumis added at the end of the serial
56. not used MAC4 STP internal control bit otherwise not used MAC4 STP internal control bit otherwise not used 7 1 3 Overall Status pO hstp 0 0 0 0 harwareemergencystp O axis f false axis number mE Mo EEMEMNMM GGG signal FC active signalFC2 active po q serven internal controlbit Source MACB ENG DOC Status 04 06 99 Page 66 MACCONTROLLER USER Manual Version 1 2e of 82 7 2 Example Configuration The various configuration possibilities of the axis controllers are illustrated below with the help of examples Default values apply for parameters not listed MAC4 STP Setting Motor with 500 steps per revolution Start stop frequency of the motor 30 Hz BOOST time 80 ms Linear axis with limits of 0 and 1 000 000 Steps Internal counting of steps generated no position sensor connected Activation of the interrupt drive fault Vector A0 Maximum following error 1 000 steps Emergency braking ramp 2 000 Hz SP Justification velocity 8 Hz Axis initialisation MAC4 INC Setting Motor to turn in anti clockwise direction Linear axis with the limits of 2 000 000 and 2 000 000 Inc All switch levels active high Activation of the interrupt drive fault Vector A2 and end of positioning Vector A4 on fly operation Maximum following error 2 000 Inc Source MACB_ENG DOC MACCONTROLLER USER Manual Version 1 2e INIT WIRQ3 WMF
57. oE po XO X STO SB R4 a not implemented Source MACB_ENG DOC Status 04 06 99 Page 76 MACCONTROLLER USER Manual Version 1 2e of 82 7 6 MAC4 SSI Pin Allocation of the Peripheral Connector P2 A32 Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e 15 V Input AOUTI AIT WU DA um DAT4 END Page 77 of 82 7 7 MAC4 STP Pin Allocation of the Peripheral Connector P2 8 3 1 N1 N2 F1 F2 0 1 F C DIR2 TESP4 A32 RS4 IESNA Source MACB ENG DOC Status 04 06 99 Page 78 MACCONTROLLER USER Manual Version 1 2e of 82 8 Glossary APC axis initialisation basic initialisation circular optimised circular axis DAC DPRAM Index pulse IPC justification linear axis message off_fly on_fly position measurement external position measurement internal queue queue administration queue base address SP Source MACB_ENG DOC MACCONTROLLER USER Manual Version 1 2e Advanced peripheral controller Adaptation of the axis controller to a specific application by means of configuring system parameters After switch on the axis controller initialises the internal data fields enters the default values in the parameter fields and sets the status and displays Returns the position at the axis limits to the base value motion over 360 repeats infinitely When positioning the shortest route to the target is
58. on 1 2e of 82 2 4 2 Position Measurement S ystems There are three ways of measuring position e Direct connection of an incremental encoder via the peripheral connector P2 connector internal position measurement e Position measurement by counting the number of steps generated internal position measurement e Position measurement incremental or absolute by access through the VMEbus to an external position counter external position measurement e Supply of the position information incremental or absolute by a host via the DPRAM of the axis controller external position measurement IPC Drive Interface Logic PALI 1 MAC4 STP MACH1 MACH2 MACH4 MACH3 Connector P2 x Pulse counting Encoder Counting Component View BR Bridge Jumper LB Solder bridge x closed open Diagram 2 8 MAC4 STP Component View Using the solder bridge BR1 4 Diagram2 8 it is possible to distinguish whether the actual position is measured by counting the steps generated by the controller axis or by the encoder signals from the peripheral connector P2 If position measurement is made via a separate position encoder the position of the solder bridge BR 1 4 is not relevant In the mode Internal position measurement an internal position counter is used to count the input steps or the incremental encoder signals Source MACB ENG DOC Status 04 06 99 Page 24 MACCONTROLLER USER Manual Ver
59. onnector internal position measurement Position measurement incremental or absolute by access through the VMEbus to an external position counter external position measurement e Supply of the position information incremental or absolute by a host via the DPRAM of the axis controller 2 external position measurement The connection of an incremental encoder to the axis controller is made according to Tab 2 3 See appendix for the pin allocation of the connectors P2 connectors Signal level Encoder inputs Ch A 1 4 TTL differential or unipolar Ch A 1 4 Ch B 1 4 Ch_B 1 4 Ch_Z 1 4 Ch_Z 1 4 Table 2 3 MAC4 INC Inputs of Position Counter The A and B tracks supply the basic counting pulses The position counter can however generate a four times higher resolution by decoding the 90 shift between the two signals The Z or reference input index pulse however can only register a single pulse per encoder revolution This signal serves for referencing or justification of the absolute position information within the axis controller The index pulse is recognised per interrupt 2 2 3 Input Signals Various switches can be connected via the P2 connector see Tab 2 4 The emergency stop signal must be present The signal level of all other switches are configurable see Section 4 Source MACB_ENG DOC Status 04 06 99 Page 17 MACCONTROLLER USER Manual Version 1 2e of 82 Designation Signal name Signal le
60. parameters e MAC4 SSI a false shift factor sc the axis is braked with the emergency braking ramp ed and put in the mode disable Status 04 06 99 Page 64 MACCONTROLLER USER Manual Version 1 2e of 82 7 Appendix 7 1 Status 7 1 1 User Status fee ei ee 8 dren axis enabled 9 tev reversing ofthe output i O positioning completed i e axis is in the target radi ee ee C o a A E e a S Aes vU positive hardware limit switch on free not used negative software limit switch on positive software limit switch on Im n Im m fee o meued O Im m Im n emble 8 J postioing search index coarse velocity tracking jG epee 0 0 p 0 0 fp s 0 0 0 5 Source MACB ENG DOC Status 04 06 99 Page 65 MACCONTROLLER USER Manual Version 1 2e of 82 7 1 2 System Status pO mrdy command operational S phase fee eG 6 q zsop internal controlbit S O AN P eee a 8 j int MAC4 STP internal control bit otherwise notused MAC4 STP BOOST signal permits move otherwise not used MAE NEN MER ONU EH i3 11 _ boost MAC4 STP BOOST signal on otherwise notused _ sum Oe gt o cU i a Ee 10 10 i i 11 i 12 i A i 13 turbo Me eS ee eee 32 phase5 phase6 N T i 23 j F 23 brake_stop MAC4 STP internal control bit otherwise not used MAC4 STP LED F on otherwise
61. r the operating modes All non configurable parameters retain their default values After completion of the configuration each axis of the controller must be initialised with the instruction INIT Operation can first begin after the initialisation 4 1 Motor and Drive Parameters for the MAC4 STP The parameters of the connected stepper drives and their configuration must be communicated to the axis controller 4 1 1 Step Number of the Motor The step number of the motors indicates how many steps it executes per revolution This number is stored in the parameter lt ms gt The step number of the motor is an important factor for the conversion of units in position measurement The setting is made using the command UWMS see Reference Manual URMS 4 1 2 Start Stop Frequency The start stop frequency lt ssf gt indicates what maximum velocity jump the motor can follow from stand still without loosing steps or from what velocity the motor can be brought to an abrupt halt This value is dependent on the motor load Velocities above the start stop frequency can only be reached using the acceleration ramps When stopping braking ramp is used The setting is made by means of command WSSF see Reference Manual RSSF Source MACB_ENG DOC Status 04 06 99 Page 34 MACCONTROLLER USER Manual Version 1 2e of 82 4 1 3 TURBO Signal A distinction is made between two operating conditions normal and TURBO operation in order to achie
62. ram 2 5 MAC4 SSI Block Diagram of the Axis Interface The connection of the axis controller to the drives is made via the connector P2 Diagram 2 6 The pin allocation is provided in the appendix IPC Drive Interface Logic D C31 MAC4 SSI IC5 Axis 1 Rev A B Axis 2 e Axis 3 D Axis 4 J1 x Binary Gray 93 75 kHz B 187 5 kHz 375 kHz IC17 IC16 D 750 kHz Axis4 Axis3 J2 SSI clock Connector P2 D y B IC14 IC15 Axis1 Axis 2 component view J Jumper designation of set jumpers see Diagram 2 2 x closed open Source MACB_ENG DOC Status 04 06 99 Page 19 MACCONTROLLER USER Manual Version 1 2e of 82 Diagram 2 6 MAC4 SSI Component View Source MACB_ENG DOC Status 04 06 99 Page 20 MACCONTROLLER USER Manual Version 1 2e of 82 2 3 1 Motor The control of the motors is made by means of the signals listed in Tab 2 6 Signal level Signal level after Reset Enable EN 1 4 0 V axis enabled H o c axis disabled DAC Output AOUT 4 o c Open collector Output open Table 2 6 MAC4 SSI Motor Control Signals 2 3 2 Position Measurement S ystems There are three possibilities of measuring the actual position of the motor Direct connection of a SSI absolute encoder via the connector P2 internal position measurement Position measurement incremental or absolute by access over the VMEbus to a separate position counter ex
63. rce MACB ENG DOC Status 04 06 99 Page 28 MACCONTROLLER USER Manual Version 1 2e of 82 3 Communications The axis controller executes instructions that must be transmitted to it in sequence Communication can either be via e the VMEbus or e the serial communication interface Communications are bidirectional Each command transmitted is acknowledged by the axis controller 3 1 Address Range of the DPRAM Communications between the host and the axis controller is made over a special address range in the DPRAM Access to other address can lead to an unexpected reaction of the axis controller Addressing is made in hexadecimal form without including the base address defined by the switches S1 and S2 The axis controller uses the range of 3000 to FFEE in the DPRAM The range of 0000 to 3000 is reserved for local IRQ vectors monitor and debugger variables The axis controller is based on a Motorola CPU A 32 bit number in the DPRAM is used according to Diagram3 1 to define the byte sequence Address Address 1 Address 2 gt Address 3 gt Diagram 3 1 Byte Sequence 3 98 flag field host o 330 countercontentofanexternalposition measurement system host pip pU 3400 3708 flag field Host 370A counter content of an external position measurement system host 3800 5E Flag Field Host Ooo 3B0A counter content of an external position measurement system ho
64. rovided by the axis controller via the Jumper J2 at the clock rates stated in Tab 2 8 Diagram2 6 26 clock pulses are always generated gt Only one Jumper for the SSI Baud rate may be set The maximum permissible Clock rate is conditioned by the cable length Source MACB_ENG DOC Status 04 06 99 Page 21 MACCONTROLLER USER Manual Version 1 2e of 82 Clock rate in kHz Cable lengths in m 93 75 Huc jode E S 58 1 98 qq H 0 e Table 2 8 MAC4 SSI Setting of the Clock Rate The required SSI clock rate is chosen by closing the appropriate the corresponding jumper The position information can be coded in Binary or Gray code The selection is made for each axis separately with the jumper J1 Diagram2 6 according to Tab 2 9 Gray Code Binary Code Table 2 9 Setting of the Code Selection 2 3 3 Input signals Various switches can be connected via the connector P2 see Tab 2 10 The emergency stop signal must be connected The signal levels of all other switches are configurable see Section 4 Signal level Signal level Signal level Signal level switch Eu mer m switch REID drive fault IDF 1 4 Emergency stop STOP 0 12 V 12 247 yd Ne P S E Table 2 10 MAC4 SSI Switch Signal Levels The emergency stop signal is effective for all axes simultaneously Activation of the emergency stop switch causes all axes to be disabled immediately gt It must be
65. rsion 1 2e of 82 1 Overview of the VME bus axis Controller Family MAC The MAC VMEbus Controller Family consists of initially three flexible and readily configurable servo and stepper axis positioning controllers for application in open control system architectures These components were mainly developed by MACCON this means that we are in a position to extend and adapt the functionality and firmware at any time to match specific application requirements MACCON offers engineering capacity alongside normal product support in order to provide optimum solutions for demanding motion control tasks 1 1 Hardware Concept An overview over all axis controllers of the MAC family of 6HE VMEbus cards is given in Tab 1 The controllers consist of two sub cards the first being a 3HE CPU Module which is either an IPC intelligent peripheral controller or an APC advanced peripheral controller the second being an adapter interface module for interface to the motor power stages and the axes This interface module also includes interfaces to a position measurement system reference and limit switches as well as additional binary inputs and outputs One controller can serve 4 axes Each axis can be programmed independently of the others CPU MC 68000 MC68332 DSP MC68000 MC68332 DSP MC68000 BEEN UO MC68332 DSP Step counter MAC4 UNI MC68332 DSP REEL SSL Absolute encoder SS Table 1 1 MAC Axis Controller Family External
66. rt for MAC Firmware The parameter set includes approx 50 parameters that are needed for the definition or change of values such as Motion definition Measurement system parameters Limit switches Servocontrol coefficients and Interrupt vectors Source MACB_ENG DOC Status 04 06 99 MACCONTROLLER USER Manual Version 1 2e Page 10 of 82 A number of different operating modes have been implemented Axis disabled disable Axis enabled enable Velocity control speed Axis stopped brake Positioning positioning Coarse search for the index pulse search index coarse Fine search for the index pulse search index Search for reference switch home Search for reference switch edge find edge Velocity trajectory velocity tracking Position trajectory position tracking Test test An overview over the operating modes that can be activated by a corresponding command is provided by the state change Diagram 1 2 The term Move covers all motion modes 1 3 Axis Control The MAC4 family can control the following motor and encoder configurations e DC Servomotor with incremental encoder MACA INC or e DC Servomotor with absolute SSI encoder MAC4 SSI or e Stepper and microstepper drives in normal or TURBO operation incremental encoder feedback is possible MAC4 STP The axes can be e linear rotary or e 360 rotary with shortest path algorithm Motion control is
67. rt for their development work on the MAC series of position controllers and the engineers of the European Southern Observatory ESO for their part in the generation and correction of this documentation Copyright 1996 MACCON GmbH port Automation Kuehbachstr 9 Antonienstr 3 D 81543 Munich D 06749 Bitterfeld Tel 49 89 651220 0 Tel 49 3493 743 10 Fax 49 89 655217 Fax 49 3493 743 15 e mail sales maccon de e mail service port de Source MACB_ENG DOC Status 04 06 99 Page 2 MACCONTROLLER USER Manual Version 1 2e of 82 General This documentation of the motor axis controller family MAC4 consists of a User and a Reference Manual This User Manual serves as an introduction in the use of the MAC series of axis controllers The procedure for the integration of axis controllers in the user system is described here The Reference Manual includes an instruction description for each command The page references given in the index refer to this User Manual only Please also refer to index of Reference Manual Differentiation is made between the manuals by the roman numbers I User Manual and IH Reference Manual Conventions e Parameter for the axis controllers are designated in the text as follows lt abbreviation for parameter gt A summary of all these abbreviations is given in the appendix e Hexadecimal numbers are designated in the text as follows hexadecimal number e Abbreviation for instructions
68. s Zaehler Enable Logic Freigabe Absolute Position Sensor Absolutgeber Selection Logic Select DC DC Converter DC DC Wandler DAC Output to Drives Sollertgeber Axis Interface and Status Synchro Axis Status Synchro Interconnections Processor Peripherals MAC 64POL Stecker Component Layout Rev D MAC4 SSI CPANDAMPWNH PE rere m Uo N ST2 Connector ST2 Stecker Microprocessor Interface Rechner Interface Opto couplers Optokoppler SSI Clock and Receivers Pulsgenerator und Empf nger Enable Logic Freigabe SSI Counter Selection Logic Select DC DC Converter DC DC Wandler DAC Output to Drives Sollertgeber Axis Interface and Status Synchro Axis Status Synchro Interconnections Processor Peripherals MAC 64POL Stecker Component Layout Rev A MAC4 STP CS PANDMFWNP m m m QN tA RU F2 Block Diagramme MACASTP Microprocessor Interface Rechner Interface Block Diagramme Axis Control MACASTP Achsen Drive Interface Axis 1 MACASTP Achsteuerung 1 Drive Interface Axis 2 MACASTP Achsteuerung 2 Drive Interfcae Axis 3 MACASTP Achsteuerung 3 Drive Interface Axis 4 MACASTP Achsteuerung 4 Block Diagramme Connector VME P2 MACASTP Axis Input Circuits MACASTP Lesevestirker Status Inputs MACASTP Status Opto couplers Axis 1 MACASTP Trennung 1 Opto couplers Axis 2 MACASTP Trennung 2 Opto couplers Axis 3
69. sed with absolute addresses i e the access must be made to fixed storage space An absolute address must be made available to the queue management function gt The user must ensure that other data address ranges are not overwritten by the queue The following steps are necessary when transmitting messages via the queue generate queue enter message read message close queue A C routine is available for each step that can be obtained through MACCON GmbH queue_t queueopen unsigned int nel int width void loc Source MACB_ENG DOC Status 04 06 99 Page 70 MACCONTROLLER USER Manual Version 1 2e of 82 This function generates a queue initialises the queue header and returns a pointer of the data type queue_t queue_t is the structure definition for the queue header queue h typedef struct int base Offset queue header queue address range int front Write index int rear Read index int free frei int width Size of a queue entry in Bytes int nel max number of elements in the queue queue_t The absolute start address of the queue is transferred to the routine by means of the parameter loc The queue header must follow the queue base address directly gt This function is executed by the axis controller It may not be called by the host system This ensures that only one process can write to the queue header The other communications process only needs a pointer o
70. sion 1 2e of 82 The connection of an incremental encoders to the axis controller is made according to Tab 2 13 The pin allocation of the peripheral connector P2 is in the appendix Signal level Encoder inputs Ch_A 1 4 TTL differential or unipolar Ch_A 1 4 Ch_B 1 4 Ch_B 1 4 Ch_Z 1 4 Ch Z 1 4 Table 2 13 MAC4 STP Inputs of Position Counter The index pulse of the incremental encoder is generally monitored per interrupt However during positioning moves the stepper pulse outputs are monitored by the interrupt inputs to ensure a high positioning accuracy no output pulse is lost 2 4 3 Input Signals Various switches can be connected via the peripheral connector P2 see Tab 2 14 The emergency stop signal must be connected The signal levels of all other switches are configurable see Section 4 Designation Signal name Signal level Signal level Signal level Signallevel low active low active high active high active on off on off switch switch RSC 5 24 V 52A V DF A 5 24 V 5 24 V Emergency stop STOP 0 12 V i34 a Table 2 14 MAC4 STP Switch Signals The emergency stop signal is effective on all axes simultaneously Activation of the emergency stop switch causes all axes to be disabled immediately gt It must be ensured that the hardware limit switch remain active over the complete forbidden range There is no protection against movement in the forbidden direction if the axis o
71. sition is made in opposite direction of motion with the velocity lt v gt Braking from the velocity lt v gt is made without a braking ramp Source MACB_ENG DOC Status 04 06 99 Page 53 MACCONTROLLER USER Manual Version 1 2e of 82 The direction of motion during a justification move to the reference switch is determined by the sign of the parameter fv In the other configurations the direction of motion depends on the switch positions On moving to the reference switch the axis controller justifies to the first recognised switch transition Diagram 5 9 Reference Switch Position active Search from Search from neg direction pos direction Diagram 5 9 Reference Switch Transition find edge 5 11 Mode Velocity Tracking Axis controllers MAC4 INC MAC4 SSI MAC4 STP The user can generate his own ramps in this mode The velocity is defined by the parameter vt and can be changed at any time gt The acceleration is not monitored it is the responsibility of the user to remain within the permissible acceleration limits 5 12 Mode Position Tracking Axis controllers MAC4 INC MAC4 SSI MAC4 STP The position that the axis should reach within the next SP is defined by the parameter lt at gt This position is held until the parameter lt at gt receives a new value gt Velocity and acceleration are not limited the user is responsible for ensuring that not too large position jumps are made Wh
72. sitioning move when the actual position has been the same as the target position for the time duration lt trt gt If the parameter lt trt gt is set to zero the end of a positioning move is therefore recognised immediately on reaching the target position lt trt gt can be set up in steps of the sampling period The effective value is automatically adapted to this time frame through rounding up Source MACB_ENG DOC Status 04 06 99 Page 49 MACCONTROLLER USER Manual Version 1 2e of 82 The end of a position move is indicated by the bit pos end in the user status The LED POS at the display of the axis controller is turned on If the interrupt vectors end of positioning has been selected this is generated once at the VMEbus The LED display and the bit pos end are cleared only at the next execute instruction 5 7 Mode Search Index Coarse Axis controllers MAC4 INC MAC4 STP The axis is approximately positioned to the next index pulse of the incremental encoder Diagram 5 5 gt These mode is only executable when an incremental encoder is connected at the peripheral connector P2 Velocity speed Direction of motion cv Position Index Pulse activ Position Diagram 5 5 Mode search index coarse The axis controller moves the axis with the acceleration ca to the maximum permissible velocity cv Then the axis moves with this constant velocity cv to the next index pulse After registration of th
73. st 3CO0 flag field Host 3F0A counter content of an external position measurement system host Source MACB ENG DOC Status 04 06 99 Page 29 MACCONTROLLER USER Manual Version 1 2e of 82 4700 command buffer queue administration Ps 4718 queue base address 4800 output buffer queue administration E 4818 queue base address Table 3 1 Address Allocation in the DPRAM 3 2 Communication via Queues Communication with the axis controller is made via the command and output buffer in the DPRAM Both are implemented and structured as ring storage so called queues A queue consists of a queue administration and a queue base address The elements of the queue included in queue base address are numbered in sequence For administration purposes two pointers are used which point to the start and end address of the actual queue contents The start address of the command or output queue in the DPRAM is fixed see Tab 3 1 The administration structure for the queue is held at this address the so called queue header The actual queue begins after the header with an offset of 24 byte 18 to the start address Each queue can accommodate a maximum of 10 messages The basic structure of the queue is shown in Diagram3 2 Offset to Element Number of queue Base address size elements 18 10 Byte 10 Element je o Element 10 Diagram 3 2 Queue Structure A detailed description of the queue is included i
74. telegram This check sum is generated by adding the contents of all bytes of the data fields with the exception of the repeated DLE character The result is truncated to one byte i e the more significant bytes are ignored If the check sum does not agree with the contents of the telegram the receiver responds with a NAK character 15 Negative AcKnowledgement 3 4 Message Structure Parameters and modes of the axis controller are set by means of commands that are acknowledged by the axis controller Commands and responses possess the same structure and are designated in the following as messages A message Diagram3 6 consists of a message header Diagram3 7 a message parameter and a definition of origin Message header Message parameter Source empty 4 Byte 4 Byte Byte Byte Diagram 3 6 Structure of a Message Axis number empty Instruction code Byte 1 Byte 2 Byte Diagram 3 7 Structure of the Message Header The empty bytes are needed for reasons of portability The axis controller counts the axes 0 3 In this documentation the axes are counted from the number 1 When communicating with the axis controller 1 must be deducted from the axis number All messages are entered in the queue exactly as stated If communications are made via the serial interface the interface software driver generates the structure When communicating via the VMEbus i e by means of a direct write access to the DPRAM the user must ensure th
75. ternal position measurement e Supply of the position information incremental or absolute by the host to the DPRAM of the axis controller external position measurement An absolute position sensor with a resolution of up to 24 Bit can be connected to the axis controller using internal position measurement The connection of the Clock and Data lines is via the peripheral connector P2 see Tab 2 7 The pin allocation of the connectors P2 is given in the appendix Signal level SSI Clock T 1 4 TTL differential T 1 4 SSI Data DAT 1 4 TTL differential DAT I 4 Table 2 7 SSI Encoder Connections The MAC4 SSI transmits clock signals to the connected position sensor Diagram4 4 At the first H L transition high low the position information is buffered and then transmitted over the data lines to the MAC4 SSI with the most significant data bit first starting at the first L H transition At each following L H transition the next less significant bit is transmitted until the last bit has been sent After completion of transmission and an additional recovery time the position sensor returns to its original condition Thereafter the next read cycle can be initiated The time period between two position interrogations by the axis controller lies well above the recovery time Diagrams for the recovery time of an SSI encoder are provided in the data sheet of the sensor manufacturer The clock signal to the absolute encoder is p
76. the axis controller must be structured as follows Source MACB ENG DOC Status 04 06 99 Page 69 MACCONTROLLER USER Manual Version 1 2e of 82 6 Bah OSG d poss Oye SOG 2 te 6 27 4 eS 9 p c oom iu As the parameter 16 is identical with the value for DLE this byte must be transmitted twice in the first message Response Message via the Serial Interface By means of the source entry the axis controller recognises that it must return the message in the response queues via the serial Interface The response message has the form do a A wu xcoq 9 qo udesp de x ie 2 0 o 3 2 0 1 1 60 Bue Des a 00 meii cm jpg dq oup tl ocmE c0 o TER y Sara aa e a EE REIECTA ERE 6 2 o o 121 2 o 3 8 a Control Characters in Serial Protocol Control character DLE 10 NAK 15 STX 02 7 3 2 Queue Implementation under OS 9 C functions under the operation system OS 9 are available for the entry of the messages in the command queue that may be easily transferred to another platform A queue is implemented as ring store array The elements of the queue are numbered in sequence Two pointers a read and a write pointer are used for administration of the queue gt Only one process write or read may access the queue at one time A simultaneous write access falsifies the message Simultaneous reading may also lead to false values The queues of the axis controller must be acces
77. the interlocking flag at address 3308 is set to 0000 If this is the case the axis controller has already read out the current position information 2 Now the host writes the new value for the position information to address 330A of the DPRAM In this case the base addresses set with the switches S1 and S2 of the IPC have to be observed Afterwards the host sets the interlocking flag at addresses 3308 to 8000 3 The axis controller reads the value of position information at the address 330A and resets the interlocking flag to 0000 Source MACB_ENG DOC Status 04 06 99 Page 33 MACCONTROLLER USER Manual Version 1 2e of 82 4 System Settings After switch on or reset the axis controller executes a basic initialisation in which all of the parameters are set to their default values The axis controller is operational when e A 5 is shown in the LED status display and e The copyright statement MACCON 1993 appears in the output queue at address 4818 The command interface is now active The axis controller must be configured and initialised before actual operation axis initialisation The configuration process includes MAC4 STP setting of motor and drive parameters setting of the motor direction of motion setting of the axis type and definition of the axis parameters description of the position measurement system identification of switches and their settings entry of interrupt vectors setting of parameters fo
78. ured that the quotient es ms and ms es should not go beyond two significant bits behind the decimal point 1st Example A motor driver with 25 000 steps rev is directly connected to an incremental encoder with 1 000 lines rev after quadrature discrimination 4 000 increments rev The following parameter values are set up in the initialisation phase lt es gt 1 000 lt ms gt 25 000 The axis controller derives the following coefficients ms 4 lt es gt 25 000 4 1 000 6 25 or 4 es ms 4 1 000 25 000 0 16 There is no rounding error as there is no third figure behind the decimal point 2nd Example A motor driver with 25 000 step rev is connected with an external positioning system with 2 500 inc rev via a gearbox with a reduction of 5 1 After five revolutions of the motor the encoder has made just one 1 motor revolution corresponding to 25 000 steps 5 motor revolutions correspond to 125 000 steps 1 encoder revolution corresponds to 2 500 increments 625 lines The relation for the conversion factor is es 625 ms 125 000 ms 4 lt es gt 125 000 4 625 50 or 4 es ms 4 2 000 125 000 0 02 The settings are made by the commands UWES and UWMS see Reference Manual URES URMS 4 5 Switch Configuration per Software Connections are available for each axis at the peripheral connector P2 of the axis controller for a positive limit switch
79. ve a greater dynamic velocity range If the axis is in the TURBO mode velocities are multiplied internally by the factor 10 This property must only be allowed for when generating user velocity profiles in the modes velocity tracking and position tracking The possible velocity range in the operational modes normal TURBO operation are summarised in Tab 4 1 po TURBO Lowest frequency Highest frequency Frequency steps 7 629 Hz 0 7629 Hz Length of output pulses Table 4 1 Normal and TURBO Operation Only the frequencies that lie exactly on the frequency steps i e 0 7629 Hz 1 5258 Hz etc in normal operation are generated precisely All other values are subject to rounding effects with a minimum of modulation which is however practically insignificant The setting is made by means of the command TURBO see Reference Manual The bit Turbo in the system status is set or deleted accordingly 4 1 4 BOOST Signal The BOOST signal is generated before each motor move and cleared during stand still The application of the signal increases the torque output of the stepper motor during the critical acceleration and deceleration phases of movement The bit boost is set in the system status The signal must be generated for a period prior to motion depending on the drive Diagram5 2 This time is variable and can be set by means of the parameter bt The setting is made by means of the command WBT see Reference Manual RBT
80. vel Signal level Signal level Signal level low active low active high active low active on off on off Positive limit IESP 1 4 0V 24 V 24 V OV switch Negative limit IESN 1 4 0V 24 V 24 V OV switch RS 1 4 DF 1 4 Emergency stop STOP 0 12 V iow ia A 10 3 Table 2 4 MAC4 INC Switch Signals The emergency stop signal is effective for all axes Activation of the emergency stop switch causes all axes to be deactivated immediately gt It must be ensured that the hardware limit switch remain active over the complete forbidden range There is no protection against movement in the forbidden direction if the axis overruns a hardware limit switch and comes to halt behind the switch 2 2 4 Fault Signals The MAC4 INC can recognise three fault code signals FC Signals at the P2 connector This information can be made available to the host system by reading the axes general status information They do not indicate any status of the axis controller itself These inputs can also be used for other signals according to the user s choice typically the status of the drives being controlled Signal level FCO 2 Table 2 5 MAC4 INC FC Signals Source MACB_ENG DOC Status 04 06 99 Page 18 MACCONTROLLER USER Manual Version 1 2e of 82 2 3 Peripheral Connector MAC4 SSI The axis interface of the MAC4 SSI consists of the functional blocks shown in Diagram 2 5 Peripheral Interface Connector P2 Diag
81. verruns a hardware limit switch and comes to halt behind the switch The setting of the positive signal levels of the switches 5 V or 24 V is made for each signal by using the solder bridges BR5 20 Diagram2 8 2 4 4 FaultSignals The MAC4 STP can interrogate three fault code signals FC Signals via the peripheral connector P2 These codes can be made available to the host system for all axes as joint status information These inputs can also be used to interrogate other user signals Signal level Source MACB ENG DOC Status 04 06 99 Page 25 MACCONTROLLER USER Manual Version 1 2e of 82 FC 0 2 TTL Table 2 15 MAC4 STP FC Signals 2 5 Front Panel There is a 7 segment display at the front panel of the axis controller Diagram2 9 including specific LED displays a reset button and a connector for the serial communication interface 2 5 1 Reset After a reset of the axis controller all output signals return to the default states given in tables Tab 2 2 Tab 2 6 or Tab 2 12 In addition the velocity command register is reset i e no signals are sent to the motor driver 2 5 2 7 Segment Display The 7 segment display indicates the operating condition of the axis controllers by displaying a hexadecimal number between 0 and F Tab 2 16 Source MACB_ENG DOC Status 04 06 99 Page 26 MACCONTROLLER USER Manual Version 1 2e of 82 7 Segment Display Status z mo Ooo0o090 g99g000 62 o 8 Pos Limit Sw
82. when it is correctly justified see Diagram 4 5 O000XXXXXXXXXXXXXXXXXx0O Significant data bits Shifting 2 bits to the right lt sc gt 2 OOOOOOxxxxxXXXXXXXXXXXXXX Position information Diagram 4 5 Shifting of the Position Information for SSI Encoder The parameter 5c indicates the number of the binary shift steps required The setting is made by the command UWSC see Reference Manual URSC 4 4 2 3 Units Conversion for MAC4 STP The position units used by the MAC4 STP are motor or driver steps Position measurement systems that generate increments can be connected to MAC4 STP see Tab 4 3 The ratio of increments step is needed for the conversion between the two frames of reference This ratio is defined by means of the parameter encoder resolution es and number of motor steps ms The encoder resolution is defined as the number of encoder lines per revolution The 90 phase difference between the A and B tracks allow the effective resolution to be multiplied by four The number of lines before quadrature multiplication is entered in the parameter es The axis controller multiplies this value by four internally 4 lt es gt is the number of increments that correspond to ms step Source MACB ENG DOC Status 04 06 99 Page 41 MACCONTROLLER USER Manual Version 1 2e of 82 gt Rounding errors can occur if the ratio of motor steps to encoder resolution in non integral As a guideline it should be ens

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