Home

DMC-1600 User Manual - Galil Motion Control

1. Kj Js2 2 0 Amp V DAC 10 32768 0003 Encoder 4 2 6 ZOH H s 2000 s 2000 Compensation Filter G s P sD The next step is to combine all the system elements with the exception of G s into one function L s L s M s Ka Kg Kp H s 3 17 106 52 5 2000 Then the open loop transfer function A s is A s L s G s Now determine the magnitude and phase of L s at the frequency c 0 L j500 3 17 106 0 500 2 j500 2000 This function has a magnitude of L j500 0 00625 and a phase Arg L j500 180 tan 1 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that A j500 1 Arg A j500 135 However since Chapter 10 Theory of Operation e 175 A s L s G s then it follows that G s must have magnitude of GG500 A j500 L 500 160 and a phase arg G j500 arg AGj500 arg LG500 135 194 59 In other words we need to select a filter function G s of the form G s P sD so that at the frequency o 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as GG500 j500D 160 arg G j500 tan 500D P 59 The solution of these equations leads to P 160008 59 82 4 500D 160sin 59 137 Therefore D 0 274 and G 824 0 2744s
2. 909 2 2 ee e st 88 5 gt gt n me 2u0f qria X gt gt gt 3 Filter 3 Chokes 5 A gt gt gt gt DC Power Supply Encoder Figure 2 2 System Connections with the AMP 1900Amplifier Note this figure shows a Galil Motor and Encoder which uses a flat ribbon cable for connection to the AMP 1900 unit 18 e Chapter 2 Getting Started DMC 1600 DMC 1600 AUX encoder input connector input connector Error LED DB25 female 26 pin header AUX encoder Reset Switch 100 pin high density connector part 2 178238 9 4 gt L 00 d 5 5 ADG202 buffer circuit VCC ee LSCOM VCC 99 INCOM MAX MBX 0 INX buffer circuit 5 VDC GND AN o MBX gt 7407 TMAX rot ee Amp enable a Encoder Wire Connections Signal Gnd 2 Ref In 4 BRUSH TYPE PWM SERVO mhibit 11 x 6 ICM 1900 t a 2 85 o 85 Channel A MAX az MBX gt 5 5 MBX Index Channel INX Index Channel INX 5 DC Brush 8 Servo Motor 9 AMPLIFIER MSA 12 80 Motor 1 Motor 2 Pow
3. Example Motion Complete Timeout BEGIN Begin main program TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command BGX Begin motion MCX Motion Complete trip point EN End main program MCTIME Motion Complete Subroutine MG X fell short Send out a message EN End subroutine This simple program will issue the message fell short if the X axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error BEGIN IN ENTER SPEED SPEED JG SPEED BGX JP BEGIN EN CMDERR JPHDONE ED 2 JP DONE TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN 781 JP DONE 750 Begin main program Prompt for speed Begin motion Repeat End main program Command error utility Check if error on line 2 Check if out of range Send message Send message Adjust stack Return to main program End program if other error Zero stack End program The above program prompts the operator to enter a jog speed If the operator enters a number out of range greater than 8 million the CMDERR routine will be executed prompting the operator to enter a new number In multitasking applications there is an alternate method for handling command errors from different threads Using the XQ command along with the special operands described below allows the controller to either skip or retry invalid commands OPERAND FUNCTION Returns the number of
4. The DMC 1600 has a set of commands that directly interrogate the controller When these command are entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF and Leading Zeros LZ command For a complete description of interrogation commands see chapter 5 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by theses interrogation commands BL LE DE PA DP PR EM TN FL VE IP TE TP The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the decimal point using the PF command Position Format 15 specified by PF m n 146 e Chapter 7 Application Programming DMC 1600 DMC 1600 where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format Hex values are returned preceded by a and in 2 s complement Hex values should be input as signed 2 s complement where negative numbers have a negative sign The default format is PF 10 0 If the number of decimal places specified by PF 15 less than the actual value a nine appears in all the decimal places Examples DP21 Define position TPX Tell position 0000
5. The closing of the servo loop is very similar Suppose that we want the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop 166 e Chapter 10 Theory of Operation DMC 1600 The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called overdamped response The results may be worse if we turn the faucet too fast The overreaction results in temperature oscillations When the response of the system oscillates we say that the system is unstable Clearly unstable responses are bad when we want a constant level What causes the oscillations The basic cause for the instability is a combination of delayed reaction and high gain In the case o
6. USER MANUAL DMC 1600 Manual Rev 1 0h By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet Address support galilmc com URL www galilmc com Rev 8 2011 Using This Manual lt Your DMC 1600 motion controller has been designed to work with both servo and stepper type motors Installation and system setup will vary depending upon whether the controller will be used with stepper motors or servo motors To make finding the appropriate instructions faster and easier icons will be next to any information that applies exclusively to one type of system Otherwise assume that the instructions apply to all types of systems The icon legend is shown below Attention Pertains to servo motor use Attention Pertains to stepper motor use Please note that many examples are written for the DMC 1640 four axes controller or the DMC 1680 eight axes controller Users of the DMC 1630 3 axis controller DMC 1620 2 axes controller or DMC 1610 1 axis controller should note that the DMC 1630 uses the axes denoted as XYZ the DMC 1620 uses the axes denoted as XY and the DMC 1610 uses the X axis only WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machine Galil shall not be liable or responsible for any incidental or consequentia
7. sss enne nnne 80 Example Multiple Moves nennen enne enne nnns 82 Coordinated Motion 83 83 Specifying Vector Segment cccececsseesseescesseeeeceeeceeceseceseceaecaecaeecaeeeseeeaeeeeeeneees 84 Additional 4 84 Command Summary Coordinated Motion Sequence sss 86 Operand Summary Coordinated Motion Sequence 86 Electronic Gearing cecidere cete e hb eee ei derit de ede ees 88 7 88 Electronic Cam 2 oce tete eter tere p eder ri e ptm e ieu 90 93 Contout Modi oreet ge Pe n tei eicere eie ee pet iei ee 95 Specifying Contour Segment 55 97 Command Summary Contour Mode seen 97 Stepper Motor Oper tion icec etes eet e eee REA eti nte de e Reid 101 Specifying Stepper Motor Operation sess 101 102 Command Summary Stepper Motor Operation sese 102 Operand Summary Stepper Motor 103 103 Error Litt eae Rd Bea ee eons 104 6 104 Dual Loop Auxiliary Encodet eie Re ede etie adea eed 107 Backlash gt 5010 108 Motion Smoothing ji A oh aee ide te Ri et eek Mee 110 Using the IT and VT Commands S curve profiling ss
8. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 4 50 Analog GND Ground T5V Error Output Reset Encoder Compare Output Ground Ground Motor command W Sign W Dir W PWM W Step W Motor command Z Sign Z Dir Z PWM Z Step Z Motor command Y Sign Y Dir Y PWM Y Step Y Motor command X Sign X Dir X PWM 8 Step X Amp enable W Amp enable Z Amp enable Y Amp enable X pr 2225 NNNN y T 2 180 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 nc Ground 5V Limit common Home W Reverse limit W Forward limit W Home Z Reverse limit Z Forward limit Z Home Y Reverse limit Y Forward limit Y Home X Reverse limit X Forward limit X Ground 5V Input common Latch X Latch Y Latch Z Latch W Input 5 Input 6 Input 7 Input 8 Abort Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 87 45V 88 89 90 91 92 93 94 95 96 97 98 99 Ground Ground Ground Analog In 1 Analog In 2 Analog In 3 Analog In 4 Analog In 5 Analog In 6 Analog In 7 Analog In 8 12V 100 12V J5 DMC 1640 AUXILIARY ENCODERS 36 PIN HIGH DENSITY AMP 178238 00 gt T5V Ground Aux X A Aux X Aux X B Aux X At Aux Y A Aux Y B Aux Y B Aux Y At AuxZ A Aux Z B
9. 4000 0 0 0 local zero Figure 2 4 Motion Path for Example 16 30 e Chapter 2 Getting Started DMC 1600 THIS PAGE LEFT BLANK INTENTIONALLY DMC 1600 Chapter 2 Getting Started e 1 Chapter 3 Connecting Hardware Overview The DMC 1600 provides optoisolated digital inputs for forward limit reverse limit home and abort signals The controller also has 8 optoisolated uncommitted inputs for general use as well as 8 TTL outputs and 8 analog inputs configured for voltages between 10 volts The DMC 1610 1620 1630 and 1640 controllers have an additional 64 I O which can be connected to OPTO 22 racks This chapter describes the inputs and outputs and their proper connection If you plan to use the auxiliary encoder feature of the DMC 1600 you must also connect a 26 pin IDC cable from the 26 pin J5 Auxiliary encoder connector on the DMC 1600 to the 26 pin header connector on the AMP 19X0 or ICM 1900 This cable is not shipped unless requested when ordering Using Optoisolated Inputs Limit Switch Input The forward limit switch FLSx inhibits motion in the forward direction immediately upon activation of the switch The reverse limit switch RLSx inhibits motion in the reverse direction immediately upon activation of the switch If a limit switch is activated during motion the controller will make a decelerated stop using the deceleration rate previously set with the DC command The motor will remain on in a servo state af
10. AMP 19X0 Mating Power Amplifiers The 19 0 series are mating brush type servo amplifiers for the DMC 1600 The AMP 1910 contains 1 amplifier the AMP 1920 2 amplifiers the AMP 1930 3 amplifiers and the AMP 1940 4 amplifiers Each amplifier is rated for 7 amps continuous 10 amps peak at up to 80 V The gain of the AMP 19X0 is 1 amp V The AMP 19X0 requires an external DC supply The AMP 19X0 connects directly to the DMC 1600 and screw terminals are provided for connection to motors encoders and external switches Features e 7 amps continuous 10 amps peak 20 to 80V e Available with 1 2 3 or 4 amplifiers Connects directly to DMC 1600 series controllers Screw type terminals for easy connection to motors encoders and switches Steel mounting plate with 1 4 keyholes Specifications Minimum motor inductance 1 mH PWM frequency 30 kHz Ambient operating temperature 0 to 70 Dimensions Weight Mounting Keyholes 1 4 Gain 1 amp V 194 e Appendices DMC 1600 Coordinated Motion Mathematical Analysis The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which 15 also known as the feed rate is the vector sum of the velocities along the X and Y axes Vx and Vy Vs Vx Vy The vector distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the
11. Accuracy is 0001 IN n Return digital input at general input n where n starts at 1 OUT n Return digital output at general output n where n starts at 1 AN n Return analog input at general analog in n where n starts at 1 Note that these functions are multi valued An application program may be used to find the correct band Functions may be combined with mathematical expressions The order of execution of mathematical expressions is from left to right and can be over ridden by using parentheses Examples V1 ABS V7 The variable V1 is equal to the absolute value of variable V7 V2 5 SIN POS variable V2 is equal to five times the sine of the variable POS V3 IN 1 The variable V3 is equal to the digital value of input 1 V4 2 5 AN 5 variable V4 is equal to the value of analog input 5 plus 5 then multiplied by 2 DMC 1600 Chapter 7 Application Programming e 137 Variables For applications that require a parameter that is variable the DMC 1600 provides 254 variables These variables can be numbers or strings program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by program calculations For example a cut to length application may require that a cut length be variable Example PR POSX Assigns variable POSX to PR command JG RPMY 70 Assigns variable RPMY multiplied by 70
12. Aux Z B Aux Z At Aux W A Aux W Aux W AuxW 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 NC 36 2 2 2 2 2 OO GO OG O0 OO QOO CO DMC 1600 Notes X Y Z W are interchangeable designations for A B C D axes For A Description of the Connectors of the Extended I O see section below Extended I O of the DMC 1600 Controller Pin Out Description for DMC 1600 Outputs Analog Motor Command Amp Enable PWM STEP OUT PWM STEP OUT Sign Direction Error Output 1 Output 8 DMC 1600 10 Volt range signal for driving amplifier In servo mode motor command output is updated at the controller sample rate In the motor off mode this output is held at the OF command level Signal to disable and enable an amplifier Amp Enable goes low on Abort and OEI PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a conventional amplifier that accepts a 10 Volt analog signal this pin is not used and should be left open The switching frequency is 16 7 kHz The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM signal is 2 duty cycle for full negative voltage 5096 for 0 Voltage and 99 896 for full positive voltage In the Sign Magnitude Mode Jumper SM the PWM signal is 0 for 0 Voltage 99 6
13. GM Independent Axis Positioning In this mode motion between the specified axes is independent and each axis follows its own profile The user specifies the desired absolute position PA or relative position PR slew speed SP acceleration ramp AC and deceleration ramp DC for each axis On begin BG the DMC 1600 profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory The controller determines a new command position along the trajectory every sample period until the specified profile is complete Motion is complete when the last position command is sent by the DMC 1600 profiler Note The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified DMC 1600 Chapter 6 Programming Motion e 73 The Begin BG command can be issued for all axes either simultaneously or independently XYZ or W axis specifiers are required to select the axes for motion When no axes are specified this causes motion to begin on all axes The speed SP and the acceleration AC can be changed at any time during motion however the deceleration DC and position PR or PA cannot be changed until motion 1s complete Remember motion is complete when the profiler is finished not when the actual motor is in position The Stop command ST can be issued at any time to decelerate the motor to a stop before it reaches its final position An
14. Once motion has begun additional LI segments may be sent to the controller The clear sequence CS command can be used to remove LI segments stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or AB The command ST causes a decelerated stop The command AB causes an instantaneous stop and aborts the program and the command ABI aborts the motion only The Linear End LE command must be used to specify the end of a linear move sequence This command tells the controller to decelerate to a stop following the last LI command If an LE command is not given an Abort ABI must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 1600 sequence buffer to ensure continuous motion If the controller receives no additional LI segments and no LE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM LM returns the available spaces for LI segments that can be sent to the buffer 511 returned means the buffer is empty and 511 LI segments can be sent zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent at PC bus speeds The instruction CS returns the segment counter As the segments are processed CS increases starting at zero This function allows the host computer to determine which segment is
15. SP 20000 20000 AC 200000 00000 BGX AD 2000 BG Y EN This program corresponds to the velocity profiles shown in Fig 10 3 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The following section explains the operation of the servo system First it 15 explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined DMC 1600 Chapter 10 Theory of Operation e 165 X VELOCITY Y VELOCITY X POSITION Y POSITION Pd TIME Figure 10 3 Velocity and Position Profiles Operation of Closed Loop Systems To understand the operation of a servo system we may compare it to a familiar closed loop operation adjusting the water temperature in the shower One control objective is to keep the temperature at a comfortable level say 90 degrees F To achieve that our skin serves as a temperature sensor and reports to the brain controller The brain compares the actual temperature which is called the feedback signal with the desired level of 90 degrees F The difference between the two levels is called the error signal If the feedback temperature is too low the error is positive and it triggers an action which raises the water temperature until the temperature error is reduced sufficiently
16. The function G is equivalent to a digital filter of the form D z 4 4KD 1 z7 where P 4 D 4 KD T and 4 KD D T Assuming a sampling period of T 1ms the parameters of the digital filter are KP 20 6 KD 68 6 The DMC 1600 can be programmed with the instruction KP 20 6 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters 176 e Chapter 10 Theory of Operation DMC 1600 DMC 1600 Equivalent Filter Form DMC 1600 Digital D z K z A z Cz z 1 1 B Z B Digital D z 4 KP 4 1 271 2 1 271 1 7 KP KD KI PL K KP KD 4 A KD KP KD C KI2 B PL Continuous G s P Ds I s 8 PID T 4 D 4T KD I KI2T 1 7 In 1 PL Chapter 10 Theory of Operation e 177 Appendices Electrical Specifications Servo Control ACMD Amplifier Command A A B B IDX IDX Encoder and Auxiliary Stepper Control Pulse Direction Input Output Uncommitted Inputs Limits Home Abort Inputs AN 1 thru AN 8 Analog Inputs OUT 1 thru OUT 8 Outputs 178 Appendices 10 Volts analog signal Resolution 16 bit DAC or 0003 Volts 3 mA maximum TTL compatible but can accept up to 12 Volts Quadrature phase on CHA CHB Can accept single ended A B only or differential A A B B Maximum A B edge rate 12 MHz
17. and applies the KD derivative term to the motor encoder This method results in a stable system The dual loop method is activated with the instruction DV Dual Velocity where activates the dual loop for the four axes and DV LLLI DV 0 disables the dual loop Note that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if necessary Sampled Dual Loop Example In this example we consider a linear slide which is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it is best to use a rotary encoder on the motor Connect the rotary encoder to the X axis and connect the linear encoder to the auxiliary encoder of X Assume that the required motion distance is one inch and that this corresponds to 40 000 counts of the rotary encoder and 10 000 counts of the linear encoder The design approach is to drive the motor a distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program Instruction DUALOO
18. asa command The amplifier gain should be set so that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers a command signal of 10 Volts should run the motor at the maximum required speed Set the velocity gain so that an input signal of 10V runs the motor at the maximum required speed For step motors the amplifiers should accept step and direction signals For start up of a step motor system refer to Connecting Step Motors on page 20 The WSDK software is highly recommended for first time users of the DMC 1600 It provides step by step instructions for system connection tuning and analysis 8 e Chapter 2 Getting Started DMC 1600 Installing the DMC 1600 DMC 1600 Installation of a complete operational DMC 1600 system consists of 9 steps Step 1 Determine overall motor configuration Step 2 Install Jumpers on the DMC 1600 Step 3 Install the communications software Step 4 Install the DMC 1600 in the PC Step 5 Establish communications with the Galil Communication Software Step 6 Determine the Axes to be used for sinusoidal commutation Step 7 Make connections to amplifier and encoder Step 8a Connect standard servo motors Step 8b Connect sinusoidal commutation motors Step 8c Connect step motors Step 9 Tune the servo system Step 1 Determine Overall Motor Configuration Before setting up the motion
19. disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AEN signal note the state of the resistor pack on the ICM 1900 When Pin 1 1s on the 5V mark the output voltage is 0 5V To change to 12 volts pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side If you remove the resistor pack the output signal is an open collector allowing the user to connect an external supply with voltages up to 24V The user should provide current limiting resistors in this case Step C Connect the encoders For stepper motor operation an encoder is optional For servo motor operation if you have a preferred definition of the forward and reverse directions make sure that the encoder wiring is consistent with that definition The DMC 1600 accepts single ended or differential encoder feedback with or without an index pulse If you are not using the AMP 19x0 or the ICM 1900 you will need to consult the appendix for the encoder pinouts for connection to the motion controller The AMP 19x0 and the ICM 1900 can accept encoder feedback from a 10 pin ribbon cable or individual signal leads For a 10 pin ribbon cable encoder connect the cable to the protected header connector labeled X ENCODER repeat for each axis necessary For individual wires simply match the leads from the encoder you are using t
20. the DMC 1600 controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting servo system When operating an amplifier in torque mode the v voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to the velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt on the X axis TL 1 lt CR gt Note Once the correct polarity of the feedback loop has been determined the torque limit should in general be increased to the default value of 9 99 The servo will not operate properly if the torque limit is below the normal operating range See description of TL in the command reference Step C Enable Off On Error as a safety precaution To limit the maximum distance the motor will move from the commanded position enable the Off On Error function
21. 15 to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe the position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner A 5 1 cos 2z B X 4 sin 2zj B Note is the angular velocity X is the position and T is the variable time in milliseconds In the given example A 6000 and B 120 the position and velocity profiles are X 501 6000 27 sin 27 T 120 Note that the velocity in count ms is 6 50 1 cos 27 T 120 Chapter 6 Programming Motion e 97 Figure 6 7 Velocity Profile with Sinusoidal Acceleration The DMC 1600 can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X 501 955 sin 1 A complete program to generate the contour movement in this example is given below To generate an array we compute the position value at intervals of 8 ms This is stored at the array POS Then the difference between the positions is computed and is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example Instruction Interpretation POINTS Program defines X points DM POS 16 Allocate memory DM DIF 15 C 0 Set initial conditions C is index T 0 T is time in ms A V1 50 T V2 3 T Argument in degrees V3 955 SIN V2 V1 Compute
22. 172 e Chapter 10 Theory of Operation DMC 1600 K4 4 Amp V DAC Kg 0 0003 V count Encoder 4N 2n 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 0 001 Therefore D z 1030 z 0 95 Z Accordingly the coefficients of the continuous filter are P 50 0 98 The filter equation be written in the continuous equivalent form G s 50 0 985 098 5 51 The system elements are shown in Fig 10 7 FILTER ZOH DAC AMP MOTOR i 50 0 980s 2000 0 0003 4 Sen f 2000 Sg ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s is the product of all the elements in the loop A 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency c at which AG equals one This can be done by the Bode plot of AG as shown in Fig 10 8 DMC 1600 Chapter 10 Theory of Operation e 173 Magnitude 50 200 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s Next we determine the phase of A s at the crossover frequency A j200 390 000 200 51 200 2 3200 2000 Arg A j200 tan 1 200 51 180 tan 1 200 2000 a 76 180 6 110 Finally the phase margin PM equ
23. 40000 Slew speed of Z AC 100000 Acceleration of Z DC 150000 Deceleration of Z BGZ Start Z motion BG Y Start Y motion Example 5 Position Interrogation The position of the four axes may be interrogated with the instruction TP Instruction Interpretation TP Tell position all four axes TPX Tell position X axis only TP Y Tell position Y axis only TPZ Tell position Z axis only TPW Tell position W axis only The position error which is the difference between the commanded position and the actual position can be interrogated with the instruction TE Instruction Interpretation TE Tell error all axes TEX Tell error X axis only TE Y Tell error Y axis only TEZ Tell error Z axis only TEW Tell error W axis only DMC 1600 Chapter 2 Getting Started 25 Example 6 Absolute Position Objective Command motion by specifying the absolute position Instruction Interpretation DP 0 2000 Define the current positions of X Y as 0 and 2000 PA 7000 4000 Sets the desired absolute positions BGX Start X motion BG Y Start Y motion After both motions are complete the X and Y axes can be command back to zero PA 0 0 Move to 0 0 BG XY Start both motions Example 7 Velocity Control Objective Drive the X and Y motors at specified speeds Instruction Interpretation JG 10000 20000 Set Jog Speeds and Directions AC 100000 40000 Set accelerations DC 50000 50000 Set decelerations BG XY Start motion after a
24. 74 73 GND GND GND GND GND GND GND GND GND GND GND GND GND GND 70 72 74 76 78 80 82 84 86 88 90 92 94 DMC 1600 186 gt Appendices 96 GND 98 GND 100 GND Note for Interfacing to External I O Racks The extended I O connector can be made compatible with external I O mounting racks such as Grayhill 70GRCM32 HL and OPTO 22 G4PB24 by using the CB 50 80 and a 80 pin high density cable By connecting the CB 50 80 the user will be provided with 2 50pin IDC connectors which are directly compatible with specific I O mounting racks When using the OPTO 22 G4PB24 I O mounting rack the user will only have access to 48 of the 64 I O points available on the controller Block 5 and Block 9 must be configured as inputs and will be grounded by the I O rack DMC 1600 Appendices e 187 Jumper Description for DMC 1600 JUMPER LABEL FUNCTION IF JUMPERED JP20 SMX For each axis the SM jumper selects the SM SMY magnitude mode for servo motors or selects SMZ stepper motors If you are using stepper SMW motors SM must always be jumpered The Analog motor command is not valid with SM jumpered SME SMF SMG SMH OPT Reserved JP21 MRST Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated 188 e Appendices DMC 1600 Accessories and Options DMC 1610 DMC 1620 DMC 1
25. 91 92 93 94 95 96 97 98 99 100 103 104 107 108 111 112 115 116 119 120 121 122 123 124 125 GE COR EHS qx dtu m eue c 2 70 7 53 general output block 4 outputs 33 40 general output block 5 outputs 41 48 general output block 6 outputs 49 56 general output block 7 outputs 57 64 general output block 8 outputs 65 72 general output block 9 outputs 73 80 error code general status segment count of coordinated move for S plane coordinated move status for S plane distance traveled in coordinated move for S plane segment count of coordinated move for T plane coordinated move status for T plane distance traveled in coordinated move for T plane axis status x a axis switches X a axis stopcode axis reference position X a axis motor position X a axis position error axis auxiliary position 8 axis velocity X a axis torque axis analog input y b axis status y b axis switches y b axis stopcode y b axis reference position y b axis motor position y b axis position error y b axis auxiliary position y b axis velocity y b axis torque y b axis analog input z c axis status z c axis switches z c axis stopcode z c axis reference position z c axis motor position 2 0 axis position error z c axis auxiliary position z c axis velocity z c axis torque z c axis analog input w d axis status 60 e Chapter 4 S
26. Chapter 1 Overview DMC 1600 DMC 1600 Functional Elements The DMC 1600 circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed below WATCHDOG TIMER ISOLATED LIMITS AND HOME INPUTS 6833 HIGH SPEED MAIN ENCODERS 2ND FIFO MICROCOMPUTER MOTOR ENCODER AUXILIARY ENCODERS WITH INTERFACE 10 VOLT OUTPUT FOR 2 Meg RAM FOR Primary SERVO MOTORS FIFOS EEPROM XYZW PULSE DIRECTION OUTPUT FOR STEP MOTORS PLUG amp PLAY HIGH SPEED ENCODER INTERFACE COMPARE OUTPUT INTERRUPTS DMA BUS 8 8 PROGRAMMABLE 8 PROGRAMMABLE ANALOG INPUTS OPTOISOLATED OUTPUTS ISA BUS m HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 1600 Functional Elements Microcomputer Section The main processing unit of the DMC 1600 is a specialized 32 bit Motorola 68331 Series Microcomputer with 256K RAM and 256K Flash EEPROM The RAM provides memory for variables array elements and application programs The flash EEPROM provides non volatile storage of variables programs and arrays It also contains the DMC 1600 firmware Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 12 MHz generates a 10 Volt analog signal 16 Bit D to A for input to a servo amp
27. Connect Hall Sensors if available 14 Chapter 2 Getting Started DMC 1600 Hall sensors are only used with sinusoidal commutation and are not necessary for proper operation The use of hall sensors allows the controller to automatically estimate the commutation phase upon reset and also provides the controller the ability to set a more precise commutation phase Without hall sensors the commutation phase must be determined manually The Hall effect sensors are connected to the digital inputs of the controller These inputs can be used with the general use inputs bits 1 8 the auxiliary encoder inputs bits 81 96 or the extended I O inputs of the DMC 1600 controller bits 17 80 Note The general use inputs are optoisolated and require a voltage connection at the INCOM point for more information regarding the digital inputs see Chapter 3 Connecting Hardware Each set of sensors must use inputs that are in consecutive order The input lines are specified with the command BI For example if the Hall sensors of the Z axis are connected to inputs 6 7 and 8 use the instruction BI 6 Or BIZ 6 Step 8a Connect Standard Servo Motors The following discussion applies to connecting the DMC 1600 controller to standard servo motor amplifiers The motor and the amplifier may be configured in the torque or the velocity mode In the torque mode the amplifier gain should be such that a 10 Volt signal generates the maximum required
28. NO command and can be used to include comments from the programmer as in the following example PATH NO 2 D CIRCULAR PATH VMXY NO VECTOR MOTION ON X AND Y VS 10000 NO VECTOR SPEED IS 10000 VP 4000 0 NO BOTTOM LINE CR 1500 270 180 NO HALF CIRCLE MOTION VP 0 3000 NO TOP LINE CR 1500 90 180 NO HALF CIRCLE MOTION VE NO END VECTOR SEQUENCE BGS NO BEGIN SEQUENCE MOTION EN NO END OF PROGRAM Note The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Using REM Statements with the Galil Terminal Software If you are using Galil software to communicate with the DMC 1600 controller you may also include REM statements REM statements begin with the word and may be followed by any comments which are on the same line The Galil terminal software will remove these statements when the program is downloaded to the controller For example PATH REM 2 D CIRCULAR PATH VMXY REM VECTOR MOTION ON X AND Y VS 10000 Chapter 7 Application Programming 119 REM VECTOR SPEED IS 10000 VP 4000 0 REM BOTTOM LINE CR 1500 270 180 REM HALF CIRCLE MOTION VP 0 3000 REM TOP LINE CR 1500 90 180 REM HALF CIRCLE MOTION VE REM END VECTOR SEQUENCE BGS REM BEGIN SEQUENCE MOTION EN REM END OF PROGRAM These REM statements will be removed when this program is downloaded to the controller Executing Programs Multit
29. Read Write IRQ enable Write 1 to enable IRQ Write 0 to disable IRQ Read 1 IRQ enabled 5 Read Write IRQ status Write 1 to clear IRQ Read 1 IRQ pending 4 Read Write Freeze Status of Secondary FIFO Write 1 to freeze 2 FIFO Write 0 to clear freeze of 2 FIFO Read 1 2 FIFO frozen B Read Only If 1 Secondary FIFO is busy updating 2 Read Only If 1 DMC to PC Buffer empty No data to be read _ If 0 PC to DMC buffer not half full Can write at least 255 bytes If 1 buffer is more than half full fo Read Only If 1 PC to DMC Buffer full Do not write data Half Full Flag The Half Full flag Bit 1 of the control register can be used to increase the speed of writing large blocks of data to the controller When the half full bit is zero the write buffer is less than half full In this case up to 255 bytes can be written to the controller at address N without checking the buffer full status bit 0 of the control register Reading the Data Record from the Secondary FIFO To read the data record from the secondary FIFO first the freeze bit bit 4 of N 4 of the control register must be set Then wait for the controller to finish updating the last data record by monitoring the busy status bit bit3 of N 4 When bit 3 is 0 the data record can be read Since the Secondary FIFO at N C is 4 bytes wide data may be read in 1 byte 2 byte or 4 byte increments Read the data at N C until bit 7 of N 4 is
30. Variables te alia adr nb Oen REC RR 138 Programmable Variables sense egre esie des 138 Operands eI RE HE RR REG 139 140 Lure 140 Defining Arrays ede ee e De e RE Ha E Ee Ee EH E ia 140 141 Automatic Data Capture into 2 142 Deallocating Array 2 0866 143 Input of Data Numeric and String eene 143 Input of eoe a ERR eed 143 144 Sending Messages cesare et ee 144 Displaying Variables and Arrays 146 Interrogation Commands 6 6 ra e ISO PS etg e ee rediret 146 148 9 Converting to User Units e E RHET 148 Programmable Hardware 149 Digital ME 149 Digital Inputs aaepe EO IO EH 150 Input Interrupt Function 150 Amnaloe TInputs eto sa eau a Oo eie ete ect eti e creta 151 Example Applications e e ORIGEN IER aud 152 Mare GUUE Ies o Elem fh estos toss te f cep oras 152 X Y Table Controller oett boo etia ea e EE td ed 153 15 156 Backlash Compensation by Sampled Dual Loop 156 Chapter 8 Hardware amp Software Protection 158 Introduction 2s hae SERRE tte dn rete ns RU ertet 158 Hardware Protection uo een eoe eene a REPE Ra 158 Output Protection Lines
31. WT 100 COUNT COUNT 1 IP LOOP COUNT 10 EN Program Editor Window 1054000 Get Responses Here HEHH Line 0 Col 4 C Testing dme Status connected with Galil DMC 1842 6 axis controller revision 1 0 A Filename Cursor Line and Column Info Display Area Controller Revision Info amp Serial Figure 4 1 Galil SmartTERM layout The following SmartTERM File menu items describe basic features of the application Download File Launches a file open dialog box that selects a file usually a DMC file to be downloaded to the controller This command uses the DL command to download the file clearing all programs in the controller s RAM Upload File Opens a file save as dialog that creates a file for saving the DMC program that is in the controller s RAM This command uses the UL command to upload the file Send File Launches a file open dialog box that selects a file usually a DMC file to be sent to the controller Each line of the file is sent to the controller as a command and is executed immediately 40 e Chapter 4 Software Tools and Communications DMC 1600 Download Array Upload Array Convert File ASCII to Binary Convert File Binary to ASCII Send Binary File Opens the Download Array dialog box that allows an array in the controller s RAM to be defined and populated with data The dialog box uses the DMC32 dll s DMCArrayDownload function
32. advanced users who wish to develop their own custom application programs to communicate to the controller Custom application programs can utilize API function calls directly to our DLL s or use our ActiveX COM objects which simplifies programming At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers 38 e Chapter 4 Software Tools and Communications DMC 1600 SmartTERM WSDK Application a RECTE D ER Galil ActiveX Controls DMCShell ocx DMCReg ocx DMCTerm ocx etc DMC32 dll Ed EI JL Galil API Level DMEBUSS2 di GLWDMPCI sys Driver Level 1 Hardware DMC 1600 FIFO IRQ Interface Figure 1 Software Communications Hierarchy Galil SmartTERM SmartTERM is Galil s basic communications utility that allows the user to perform basic tasks such as sending commands directly to the controller editing downloading and executing DMC programs uploading and downloading arrays and updating controller firmware The latest version of SmartTERM can be downloaded from the Galil website at http www galilmc com support download html DMC 1600 Chapter 4 Software Tools and Communications e 39 File Edit Tools View e 3E fE 2 T File Edit On Off MSG Type Commands Terminal Options MG
33. and IRQ Chapter 2 Getting Started e 11 After providing the setup information the terminal should indicate Attempting to connect to controller followed by the colon being sent This indicates a successful connection Note The BIOS for your PC when using DOS should be set for Non Plug and Play OS for successful communication Using Windows98SE ME NT 2000 XP In order for the windows software to communicate with a Galil controller the controller must be registered in the Galil Registry listing the controller information and address Under Windows NT 2000 the DMC 1600 controller is registered by initializing the Galil Driver To do this install the DTERM32 software program DMCWIN32 exe or the Galil Servo Design Kit Software WSDK32 exe Begin the software and add the DMC 1600 controller to the registry The registry is available from the pull down menu Registry from DTERM32 and from the pull down menu File from the WSDK software After registering the controller re boot the system Under the Options Menu select Start Device Driver Then select the terminal to begin communicating directly with the controller Dterm32 will find the DMC 1600 controller and automatically insert the controller information into the registry The registry entry also displays timeout and delay information These are advanced parameters that should only be modified by advanced users see software documentation for more information Communi
34. any current connections to a controller and open a new connection to the selected controller DMCTerminal only connects to a single controller at a time However multiple Chapter 4 Software Tools and Communications e 41 Disconnect from Controller Controller Registration DMC Program Editor Reset Controller Device Driver Diagnostics Update Firmware Display Data Record 42 Chapter 4 Software Tools and Communications instances of the application can be open at once Causes the currently open connection to a Galil Motion Controller to be closed Opens the Edit Registry dialog box which allows the Galil Registry entries to be edited or new entries for non Plug and Play controllers to be created or deleted Causes the terminal to enter Smart Terminal with Editor mode This is the same as clicking on the Smart Terminal with Editor mode button on the terminal window s toolbar Offers three reset options Reset Controller sends an RS command to the controller The RS command does not clear burned variables programs or parameters Master Reset performs a master reset on the controller A Master Reset does clear burned saved variables programs or parameters Clear Controller s FIFO causes the controller s output FIFO to be cleared of data The Device Driver menu selection is available to operating systems and or controllers that have device drivers that can be stopped and starte
35. as well as source code and examples for developing Windows programs that communicate to Galil Controllers The Galil communications API includes functions to send commands download programs download upload arrays access the data record etc For a complete list of all the functions refer to the DMCWin user manual at http www galilmc com support manuals dmcwin pdf This software package is free for download and is available at http www galilmc com support download html Galil Communications API with When programming in C C the communications API can be used as included functions or through a class library All Galil communications programs written in C must include the DMCCOM H file and access the API functions through the declared routine calls C programs can use the DMCCOM H routines or use the class library defined in DMCWIN H After installing DMCWin into the default directory the DMCCOM H header file is located in C Program Files Galil DMCWIN INCLUDE C programs that use the class library need the files DMCWIN H and DMCWIN CPP which contain the class definitions and implementations respectively These can be found in the C ProgramFiles Galil DMCWIN CPP directory To link the application with the DLL s the DMC32 lib file must be included in the project and is located at C Program Files Galil DMCWIN LIB Example A simple console application that sends commands to the controller To initiate communication
36. being processed Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 1600 computes the vector speed based on the axes specified in the LM mode For example LM XYZ designates linear interpolation for the X Y and Z axes The vector speed for this example would be computed using the equation vs xs vvs zs where XS YS and ZS are the speed of the X Y and Z axes The controller always uses the axis specifications from LM not LI to compute the speed VT 15 used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trippoint which halts program execution until the vector distance of n has been reached An Example of Linear Interpolation Motion LMOVE label DP 0 0 Define position of X and Y axes to be 0 LMXY Define linear mode between X and Y axes LI 5000 0 Specify first linear segment 78 Chapter 6 Programming Motion DMC 1600 DMC 1600 LI 0 5000 Specify second linear segment LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector distance of 4000 is reached VS 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached VS 4000 Change vector speed EN Program end In this example the XY system is required to perform a 90 turn In order to slow the speed around the corner we use the AV
37. between the input voltage V and the velocity is Ka Ky Js 1 K Ky Kg Js 1 Kg sT1 1 where the velocity time constant T1 equals T1 Ky Kg This leads to the transfer function I Kg s sT1 1 K Figure 10 5 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Fig 10 6 Chapter 10 Theory of Operation e 169 VOLTAGE SOURCE V E W P E zr a ST_ 1 ST 1 S CURRENT SOURCE V W VELOCITY LOOP V W P K ST S Figure 10 6 Mathematical model of the motor and amplifier in three operational modes Encoder The encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the position resolution is increased to 4N quadrature counts rev The model of the encoder can be represented by a gain of 4 2 count rad For example a 1000 lines rev encoder is modeled as Kp 638 170 gt Chapter 10 Theory of Operation DMC 1600 DMC 1600 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65536 and the output voltage range is 10V or 20V Therefore the effective gain of the DAC
38. by Galil to work with the OCX controls The ActiveX Toolkit can be purchased from Galil at http store yahoo com galilmc actoolsoffor html The ActiveX toolkit can save many hours of programming time Built in dialog boxes are provided for quick parameter setup selection of color size location and text The toolkit controls are easy to use and provide context sensitive help making it ideal for even the novice programmer ActiveX Toolkit Includes DMC 1600 Chapter 4 Software Tools and Communications e 49 a terminal control for sending commands and editing programs a polling window for displaying responses from the controller such as position and speed a storage scope control for plotting real time trajectories such as position versus time or X versus Y a send file control for sending contour data or vector DMC files a continuous array capture control for data collection and for teach and playback a graphical display control for monitoring a 2 D motion path a diagnostics control for capturing current configurations a display control for input and output status a vector motion control for tool offsets and corner speed control For more detailed information on the ActiveX Toolkit please refer to the user manual at http www galilmc com support manuals activex pdf DMCWin Programmers Toolkit DMCWin is a programmer s toolkit for C C and Visual Basic users The toolkit includes header files for the Galil communications API
39. c eo e eae tede eq e a dett at 158 Input Protection Lines es ee NORRIS R GR ween At 159 Software Protection ud ec e teneo Oa eem Ritt e des ent 159 Programmable Position 159 uiuat ee oe Deae Ee ests Rede aser xt end 160 Automatic Error Rou ne x eee ede ode 160 DMC 1600 DMC 1600 Limit Switch Routine Chapter 9 Troubleshooting OVERVIEW Rts halite taker een i ipe REIR T Installation 35 feces irt Communic ation Operation oo t ede tesi Chapter 10 Theory of Operation OVERVIEW avec Operation of Closed Loop System Modeling tees tes 8 7 Encoder teet tte exo RR System Analysis nennen System Design and The Analytical 1 1010 Appendices Index Electrical Specifications sse Servo Controler atn phan es Stepper Control 25 onis tud RO Taput Power Requirement sese Performance Specifications sse Connectors for DMC 1600 Main Board Pin Out Description for 1600 Extended I O of the DMC 1600 Controller Accessories and 2 7 PC AT Interrupts and Their IC
40. command IMPORTANT All DMC 1600 commands are sent in upper case For example the command PR 4000 lt enter gt Position relative PR is the two character instruction for position relative 4000 is the argument which represents the required position value in counts The lt enter gt terminates the instruction The space between PR and 4000 is optional For specifying data for the X Y Z and W axes commas are used to separate the axes If no data is specified for an axis a comma is still needed as shown in the examples below If no data is 64 Chapter 5 Command Basics DMC 1600 specified for an axis the previous value is maintained The space between the data and instruction Is optional To view the current values for each command type the command followed by a for each axis requested PR 1000 Specify X only as 1000 PR 2000 Specify Y only as 2000 3000 Specify Z only as 3000 PR 4000 Specify W only as 4000 PR 2000 4000 6000 8000 Specify X Y Z and W PR 8000 9000 Specify Y and W only PR Request X Y Z W values PR Request Y value only The DMC 1600 provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as X Y Z or W An equals sign is used to assign data to that axis For example PRX 1000 Specify a position relative movement for the X axis of 1000 ACY 200000 Specify acceleration for the Y axis as 200000 Instead of data some commands r
41. commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during 84 e Chapter 6 Programming Motion DMC 1600 DMC 1600 previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function 2100000 is followed by 75000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point Changing Feed rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided by two Compensating for Differences in Encoder Resolution By default the DMC 1600 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES comman
42. control system the user must determine the desired motor configuration The DMC 1600 can control any combination of standard servo motors sinusoidally commutated brushless motors and stepper motors Other types of actuators such as hydraulics can also be controlled please consult Galil The following configuration information 1s necessary to determine the proper motor configuration Standard Servo Motor Operation The DMC 1600 has been setup by the factory for standard servo motor operation providing an analog command signal of 10V No hardware or software configuration is required for standard servo motor operation Sinusoidal Commutation Sinusoidal commutation is configured through a single software command BA This configuration causes the controller to reconfigure the number of available control axes Each sinusoidally commutated motor requires two DAC s In standard servo operation the DMC 1600 has one DAC per axis In order to have the additional DAC for sinusoidal commutation the controller must be designated as having one additional axis for each sinusoidal commutation axis For example to control two standard servo axes and one axis of sinusoidal commutation the controller will require a total of four DAC s and the controller must be a DMC 1640 Sinusoidal commutation is configured with the command BA For example BAX sets the X axis to be sinusoidally commutated The second DAC for the sinusoidal signal will be the
43. editor window File menu allows an application program to be downloaded with compression 80 characters wide This allows the user to write an application program in the editor window that is longer than the normal line limitation 1000 lines and download it to the controller Additionally dynamic syntax help is available by activating the syntax help button A gt icon DMC Data Record Display The DMC SmartTERM utility program includes a Data Record display window that is useful for observing the current status of all the major functions of the controller including axis specific data I O status application program status and general status The data record 1s available through a secondary communications channel To display the Data Record shown in Fig 4 2 select Display Data Record under the Tools menu of DMC SmartTERM DMC 1600 Chapter 4 Software Tools and Communications e 43 El Galil DMC 1840 Data Record General Status Axis Status Pro g Ww Move in Progress oF Motion PA or Mode of Motion PA Find Edge in Progress O Error 1118 Input Bank 4 Moton is Making Final Deceleration 5 put Bank 5 Motor Coordinated Motion Status T a Ac Stute of Latch i s sens State of Forward Lim Motion is Stoppina ST LimSwtch State of Reverse Limit SM Jumper Installed Figure 4 2 Data Record
44. few seconds command JG 40000 New X speed and Direction TVX Returns X speed and then JG 20000 New Y speed TV Y Returns Y speed These cause velocity changes including direction reversal The motion can be stopped with the instruction ST Stop Example 8 Operation Under Torque Limit The magnitude of the motor command may be limited independently by the instruction TL Instruction Interpretation TL 0 2 Set output limit of X axis to 0 2 volts JG 10000 Set X speed BGX Start X motion In this example the X motor will probably not move since the output signal will not be sufficient to overcome the friction If the motion starts it can be stopped easily by a touch of a finger Increase the torque level gradually by instructions such as Instruction Interpretation TL 1 0 Increase torque limit to 1 volt TL 9 98 Increase torque limit to maximum 9 98 Volts The maximum level of 9 998 volts provides the full output torque 26 e Chapter 2 Getting Started DMC 1600 DMC 1600 Example 9 Interrogation The values of the parameters may be interrogated Some examples Instruction Interpretation KP Return gain of X axis Return gain of Z axis KP Return gains of all axes Many other parameters such as KI KD FA can also be interrogated The command reference denotes all commands which can be interrogated Example 10 Operation in the Buffer Mode The instructions may be buffered before execution as
45. in real time They allow the DMC 1600 to make decisions without a host computer For example the DMC 1600 can decide between two motion profiles based on the state of an input line DMC 1600 Chapter 7 Application Programming e 127 Command Format JP and JS FORMAT DESCRIPTION JS destination logical condition Jump to subroutine if logical condition is satisfied JP destination logical condition Jump to location if logical condition is satisfied The destination is a program line number or label where the program sequencer will jump if the specified condition is satisfied Note that the line number of the first line of program memory is 0 The comma designates IF The logical condition tests two operands with logical operators Logical operators less than or equal to greater than or equal to Conditional Statements The conditional statement is satisfied 1f it evaluates to any value other than zero The conditional statement can be any valid DMC 1600 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions If no conditional statement is given the jump will always occur Examples Number 1 6 Numeric Expression V1 V7 6 ABS V1 gt 10 Array Element V1 lt Count 2 Variable 1 lt 2 Internal Variable TPX 0 _TVX gt 500 T O V1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 1600 will accept multiple conditions in a single jump state
46. included with the controller utilities In order to set the desired update rates use the command TM When operating the controller with the fast firmware some functionality is limited The following functions are disabled Chapter 6 Programming Motion e 115 Chapter 7 Application Programming Overview The DMC 1600 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 1600 memory freeing the host computer for other tasks However the host computer can send commands to the controller at any time even while a program is being executed Only ASCII commands can be used for application programming In addition to standard motion commands the DMC 1600 provides commands that allow the DMC 1600 to make its own decisions These commands include conditional jumps event triggers and subroutines For example the command JP LOOP n 10 causes a jump to the label ZLOOP if the variable n is less than 10 For greater programming flexibility the DMC 1600 provides user defined variables arrays and arithmetic functions For example with a cut to length operation the length can be specified as a variable in a program which the operator can change as necessary The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 80 characters x 1000 lines Using the DMC 1600 Editor to Ente
47. initial value of V1 Label for loop Move X motor V1 counts Start X motion After X motion is complete Wait 500 ms Tell position X Increase the value of V1 Repeat if V1 lt 10001 End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ A Execute Program A Example 13 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction ZB DP 0 0 PR 30000 60000 SP 5000 5000 BGX AD 4000 BGY AP 6000 SP 2000 50000 AP 50000 SP 0 EN Interpretation Label Define initial positions Set targets Set speeds Start X motion Wait until X moved 4000 Start Y motion Wait until position X 6000 Change speeds Wait until position Y 50000 Change speed of Y End program To start the program command XQ B Execute Program 4B Example 14 Control Variables Objective To show how control variables may be utilized Instruction ZA DPO PR 4000 SP 2000 BGX AMX WT 500 ZB 28 Chapter 2 Getting Started Interpretation Label Define current position as zero Initial position Set speed Move X Wait until move is complete Wait 500 ms DMC 1600 DMC 1600 V1 _TPX Determine distance to zero PR V1 2 Command X move 1 2 the distance BGX Start X motion AMX After X moved WT 500 Wait 500 ms Report the value of V1 JP V1 0 Exit if position 0 JP B Repeat otherwise C Label C EN En
48. instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18X and X varies in increments of 20 the phase varies by increments of 3 6 The program then computes the values of Y according to the equation and assigns the values to the table with the instruction ET N Y Instruction Interpretation ZSETUP Label EAX Select X as master EM 2000 1000 Cam cycles EP 20 0 Master position increments N 0 Index LOOP Loop to construct table from equation 3 6 Note 3 6 0 18 20 S SIN P 100 Define sine position xl0 S Define slave position ET N Y Define table 1 JP LOOP N lt 100 Repeat the process EN Command Summary Electronic CAM Specifies master axes for electronic cam where P X Y Z or W or A B C D E F G H for main encoder as master ECAM counter sets the index into the ECAM table EG x y z w Engages ECAM Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center of the cycle X 1000 and Y 500 This implies that Y must be driven to that point to avoid a jump Chapter 6 Programming Motion e 93 This is done with the program Instruction ZRUN EBI PA 500 SP 5000 BGY AM All EG 1000 AI 1 EQ 1000 EN Interpretation Label Enable cam starting position Y speed Move Y motor After Y moved Wait for start signal Engage slave Wait
49. of the binary number represents one block of extended I O When set to 1 the corresponding block is configured as an output The least significant bit represents block 2 and the most significant bit represents block 9 The decimal value can be calculated by the following formula n n 2 n 4 n 4 8 n5 16 ng 32 n 64 ng 128 no where n represents the block If the n value is a one then the block of 8 I O points is to be configured as an output If the n value is a zero then the block of 8 I O points will be configured as an input For example if block 4 and 5 are to be configured as outputs CO 12 is issued 8 Bit I O Block Binary Representation Decimal Value of Bit 3 4 5 f 73 80 2 128 The simplest method for determining n Step 1 Choose which 8 bit I O blocks that should be configured as outputs Step 2 From the table determine the decimal value for each I O block to be set as an output Step 3 Add up all of the values determined in step 2 This is the value to be used for n For example if blocks 1 and 2 are to be outputs then n is 3 and the command CO3 should be issued Note This calculation is identical to the formula n n 2 n3 4 n4 8 n5 16 ne F32 n 64 ng 128 where n represents the block Appendices e 183 Saving the State of the Outputs in Non Volatile Memory The configuration of the extended I O and the state of the outputs can be stored in the EEPROM with
50. operate a stepper motor must have the corresponding stepper motor jumper installed For a discussion of SM jumpers see Step 2 Step B Connect step and direction signals from controller to motor amplifier from the controller to respective signals on your step motor amplifier These signals are labeled PULSX and DIRX for the x axis on the ICM 1900 Consult the documentation for your step motor amplifier Step C Configure DMC 1600 for motor type using MT command You can configure the DMC 1600 for active high or active low pulses Use the command MT 2 for active high step motor pulses and MT 2 for active low step motor pulses See description of the MT command in the Command Reference Step 9 Tune the Servo System Adjusting the tuning parameters is required when using servo motors standard or sinusoidal commutation The system compensation provides fast and accurate response and the following presentation suggests a simple and easy way for compensation More advanced design methods are available with software design tools from Galil such as the Servo Design Kit SDK software The filter has three parameters the damping KD the proportional gain KP and the integrator KI The parameters should be selected in this order To start set the integrator to zero with the instruction KIO CR Integrator gain and set the proportional gain to a low value such as KP 1 CR Proportional gain KD 100 CR Derivative gain For more dampin
51. or the load but may be mounted in any position The most common use for the second encoder is backlash compensation described below DMC 1600 The second encoder may be a standard quadrature type or it may provide pulse and direction The controller also offers the provision for inverting the direction of the encoder rotation The main and the auxiliary encoders are configured with the CE command The command form is CE 2 or a b c d e f g h for controllers with more than 4 axes where the parameters x y z w each equal the sum of two integers m and n m configures the main encoder and n configures the auxiliary encoder Using the CE Command Normal quadrature Normal quadrature Pulse amp direction Pulse amp direction Chapter 6 Programming Motion e 107 Reverse pulse amp direction Reversed pulse amp direction For example to configure the main encoder for reversed quadrature m 2 and a second encoder of pulse and direction n 4 the total is 6 and the command for the X axis is CE 6 Additional Commands for the Auxiliary Encoder The command DE x y z w can be used to define the position of the auxiliary encoders For example DE 0 500 30 300 sets their initial values The positions of the auxiliary encoders may be interrogated with the command DE For example DE returns the value of the X and Z auxiliary encoders The auxiliary encoder position may be assigned to variables with the instruct
52. position V4 INT V3 Integer value of V3 POS C V4 Store in array POS T T 8 C C 1 JP A C lt 16 B Program to find position differences C 0 C 98 e Chapter 6 Programming Motion DMC 1600 DMC 1600 D CH DIF C POS D POS C 1 JP lt 15 RUN CMX DT3 C 0 HE CD DIF C WC 1 JP lt 15 DTO Compute the difference and store End first program Program to run motor Contour Mode 4 millisecond intervals Contour Distance is in DIF Wait for completion Stop Contour End the program Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 1600 automatic array capture feature to capture position data The captured data may then be played back in the contour mode The following array commands are used DM RD TPX RC n m RC or RC Dimension array Specify array for automatic record up to 4 for DMC 1640 Specify data for capturing such as _TPX TPZ Specify capture time interval where n is 2n msec m is number of records to be captured Returns a 1 if recording Record and Playback Example RECORD DM XPOS 501 RA XPOS RD TPX MOX RC2 A JPHA RC 1 COMPUTE DM DX 500 0 L D C 1 DELTA XPOS D XPOS C DX C DELTA Begin Program Dimension array with 501 elements Specify automatic record Specify X position to be captured Turn
53. radius of 2 or 80000 counts and the motion starts at the angle of 270 and traverses 360 in the CW negative direction Such a path is specified with the instruction CR 80000 270 360 Further assume that the Z must move 2 at a linear speed of 2 per second The required motion is performed by the following instructions Instruction Function A Label VM XY Circular interpolation for XY VP 160000 0 Positions VE End Vector Motion VS 200000 Vector Speed VA 1544000 Vector Acceleration BGS Start Motion AMS When motion is complete PR 80000 Move Z down SP 80000 Z speed BGZ Start Z motion AMZ Wait for completion of Z motion CR 80000 270 360 Circle VE VS 40000 Feed rate BGS Start circular move AMS Wait for completion PR 80000 Move Z up BGZ Start Z move AMZ Wait for Z completion PR 21600 Move X SP 20000 Speed X BGX Start X AMX Wait for X completion PR 80000 Lower Z BGZ AMZ CR 80000 270 360 Z second circle move VE VS 40000 BGS AMS PR 80000 Raise Z 154 e Chapter 7 Application Programming DMC 1600 DMC 1600 BGZ AMZ VP 37600 16000 Return XY to start VE VS 200000 BGS AMS EN 4 9 3 X Figure 7 2 Motor Velocity and the Associated Input Output signals Speed Control by Joystick The speed of a motor 1s controlled by a joystick The joystick produces a signal in the range between 10V and 10V The objective is to drive the motor at a speed proportional to the
54. shown below Instruction Interpretation PR 600000 Distance SP 10000 Speed WT 10000 Wait 10000 milliseconds before reading the next instruction BG X Start the motion Example 11 Using the On Board Editor Motion programs may be edited and stored in the controller s on board memory When the command ED is given from the Galil DOS terminal such as DMCTERM the controller s editor will be started The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited The editor provides the line number For example in response to the first ED command the first line is zero Line Instruction Interpretation 000 A Define label 001 PR 700 Distance 002 SP 2000 Speed 003 BGX Start X motion 004 EN End program To exit the editor mode input lt gt 0 The program may be executed with the command XQ Start the program running If the ED command is issued from the Galil Windows terminal software such as DTERM32 the software will open a Windows based editor From this editor a program can be entered edited downloaded and uploaded to the controller Example 12 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction Interpretation HA Label Chapter 2 Getting Started 27 V1 1000 Loop PA VI BGX AMX WT 500 TPX V1 V1 1000 JP Loop V1 lt 10001 EN Define current position as zero Set
55. the filter is applied to a digital to analog converter DAC The resulting output signal in the range between 10 and 10 Volts is then applied to the amplifier and the motor The motor position whether rotary or linear is measured by a sensor The resulting signal called position feedback 1s returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Fig 10 4 The mathematical model of the various components is given below DMC 1600 Chapter 10 Theory of Operation e 167 CONTROLLER R X DIGITAL Y V E FILTER ZOH DAC MOTOR ENCODER Figure 10 4 Functional Elements of a Motion Control System Motor Amplifier The motor amplifier may be configured in three modes 1 Voltage Drive 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Drive The amplifier is a voltage source with a gain of Kv V V The transfer function relating the input voltage V to the motor position P is P V K K S ST 1 ST 1 where T RJ K s and T 1 s and the motor parameters and units are Torque constant Nm A R Armature Res
56. the point A Suppose that the interrogation 1s repeated at a point halfway between the points C and D The value of AV is 4000 15007 2000 10 712 The value of CS is 2 _ VPY contain the coordinates of the point C C 4000 3000 D 0 3000 B 4000 0 A 0 0 Figure 6 3 The Required Path DMC 1600 Chapter 6 Programming Motion e 87 Electronic Gearing This mode allows up to 8 axes to be electronically geared to some master axes The masters may rotate in both directions and the geared axes will follow at the specified gear ratio The gear ratio may be different for each axis and changed during motion The command yzw GA ABCDEFGH specifies the master axes GR x y z w specifies the gear ratios for the slaves where the ratio may be a number between 127 9999 with a fractional resolution of 0001 There are two modes standard gearing and gantry mode The gantry mode is enabled with the command GM GR 0 0 00 turns off gearing in both modes A limit switch or ST command disable gearing in the standard mode but not in the gentry mode The command GM x y z w select the axes to be controlled under the gantry mode The parameter 1 enables gantry mode and 0 disables it GR causes the specified axes to be geared to the actual position of the master The master axis is commanded with motion commands such as PR PA or JG When the master axis is driven by the controller in the jog mode or an independent motion mode it is p
57. the thread that generated an error 134 e Chapter 7 Application Programming DMC 1600 Retry failed command operand contains the location of the failed command Skip failed command operand contains the location of the command after the failed command The operands are used with the XQ command in the following format XQ ED2 or ED3 ED1 1 Where the 1 at the end of the command line indicates a restart therefore the existing program stack will not be removed when the above format executes The following example shows an error correction routine which uses the operands Example Command Error w Multitasking HA Begin thread 0 continuous loop End of thread 0 B Begin thread 1 N Create new variable KPN Set KP to value of N an invalid value TY Issue invalid command EN End of thread 1 CMDERR Begin command error subroutine IF TC 6 If error is out of range KP 1 N21 Set N to a valid number XQ ED2 EDI I ENDIF IF _ 1 XQ ED3 EDI I Retry KP N command If error is invalid command TY Skip invalid command ENDIF EN End of command error routine Mathematical and Functional Expressions DMC 1600 Mathematical Operators For manipulation of data the DMC 1600 provides the use of the following mathematical operators OPERATOR FUNCTION Subtraction Multiplication Chapter 7 Application Programming e 135 Logical And Bit wise Logical Or On some computers a solid
58. to JG command Programmable Variables The DMC 1600 allows the user to create up to 254 variables Each variable is defined by a name which can be up to eight characters The name must start with an alphabetic character however numbers are permitted in the rest of the name Spaces are not permitted Variable names should not be the same as DMC 1600 instructions For example PR is not a good choice for a variable name Examples of valid and invalid variable names are Valid Variable Names POSX POSI SPEEDZ Invalid Variable Names REALLONGNAME Cannot have more than 8 characters 123 Cannot begin variable name with a number SPEED Z Cannot have spaces in the name Assigning Values to Variables Assigned values can be numbers internal variables and keywords functions controller parameters and strings The range for numeric variable values is 4 bytes of integer 2 followed by two bytes of fraction 2 147 483 647 9999 Numeric values can be assigned to programmable variables using the equal sign Any valid DMC 1600 function can be used to assign a value to a variable For example V1 ABS V2 or V2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters which must be in quotation Examples POSX TPX Assigns returned value from TPX command to variable POSX SPEED 5 75 Assigns value 5 75 to variable SPEED INPUT IN 2 A
59. will use this value to send the appropriate DR command to the controller when a communications session is opened Additionally for DMC 1700 users the dialog box shown in Fig 4 6 allows the user to select between two Data Record Access methods DMA or Secondary FIFO DMC 1600 Chapter 4 Software Tools and Communications e 47 Controller Communications Parameters I 1 General Parameters PCI Bus Parameters Communication Method BaselBPot amp ddess Interrupt Vector Apply x Figure 4 7 DMC 1600 Data Record Parameters Windows Servo Design Kit WSDK The Galil Windows Servo Design Kit includes advanced tuning and diagnostic tools that allows the user to maximize the performance of their systems as well as aid in setup and configuration of Galil controllers WSDK is recommended for all first time users of Galil controllers WSDK has an automatic servo tuning function that adjusts the PID filter parameters for optimum performance and displays the resulting system step response A four channel storage scope provides a real time display of the actual position velocity error and torque WSDK also includes impulse step and frequency response tests which are useful for analyzing system stability bandwidth and resonances can be purchased from Galil via the web at http store yahoo com galilmc wsdk32 html Features Include Automatic tuning for optimizing controller PID filter parameters Pro
60. 00 500 Set X axis error limit for 200 Y axis error limit to 300 Z axis error limit to 400 counts W axis error limit to 500 counts ER 1 10 Set Y axis error limit to 1 count set W axis error limit to 10 counts The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position If the absolute value of the error exceeds the value specified by ER the DMC 1600 will generate several signals to warn the host system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 AEN Output Line Goes low The Jump on Condition statement is useful for branching on a given error within a program The position error of X Y Z and W can be monitored during execution using the TE command Programmable Position Limits The DMC 1600 provides programmable forward and reverse position limits These are set by the BL and FL software commands Once a position limit is specified the DMC 1600 will not accept position commands beyond the limit Motion beyond the limit is also prevented Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog DMC 1600 Chapter 8 Hardware amp Software Protection 159 BG XYZ Begin motion stops at forward limits
61. 00 provides eight analog inputs The value of these inputs in volts may be read using the AN n function where n is the analog input 1 through 8 The resolution of the Analog to Digital conversion is 12 bits 16 bit ADC is available as an option Analog inputs are useful for reading special sensors such as temperature tension or pressure The following examples show programs which cause the motor to follow an analog signal The first example is a point to point move The second example shows a continuous move Example Position Follower Point to Point Objective The motor must follow an analog signal When the analog signal varies by 10V motor must move 10000 counts Method Read the analog input and command X to move to that point Instruction Points SP 7000 Interpretation Label Speed Chapter 7 Application Programming e 151 AC 80000 DC 80000 Acceleration Loop VP AN 1 1000 Read analog input and compute position PA VP Command position BGX Start motion AMX After completion JP Loop Repeat EN End Example Position Follower Continuous Move Method Read the analog input compute the commanded position and the position error Command the motor to run at a speed in proportions to the position error Instruction Interpretation Cont Label AC 80000 DC 80000 Acceleration rate 100 Start job mode BGX Start motion Loop VP AN 1 1000 Compute desired position VE VP _TPX Find position error VEL VE 20 Compu
62. 000021 Default format PF4 Change format to 4 places TPX Tell position 0021 New format PF 4 Change to hexadecimal format TPX Tell Position 0015 Hexadecimal value PF2 Format 2 places TPX Tell Position 99 Returns 99 if position greater than 99 Removing Leading Zeros from Response to Interrogation Response The leading zeros on data returned as a response to interrogation commands can be removed by the use of the command LZ Example Using the LZ command LZO Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 0000000000 0000000007 Response from Interrogation Command With Leading Zeros 121 Enables the LZ function TP Tell Position Interrogation Command 9 5 0 7 Response from Interrogation Command Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrogation commands may be formatted locally To format locally use the command Fn m or n m on the same line as the interrogation command The symbol F specifies that the response should be returned in decimal format and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal For example Examples TP 2 2 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 00 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from I
63. 1 signifying that the FIFO is empty After the data has been read un freeze the secondary FIFO by setting bit 4 of N 4 to 0 which allows the controller to continue to refresh the data record at the defined rate specified by the DR command 58 e Chapter 4 Software Tools and Communications DMC 1600 Enabling and Reading IRQ s In order to service interrupts from the IRQ line the IRQ control register Status Byte must first be enabled This is done by setting bit 6 of the control register N 4 equal to 1 When interrupted first the interrupt routine must verify that the interrupt originated from the DMC 1600 controller This is done by checking that the IRQ enable and IRQ status bits bit 5 and 6 of N 4 are high The Status Byte can then be read by reading the IRQ register at N 8 The returned Status Byte indicates what event generated the interrupt for more information on specific interrupt events see the EI and UI commands in the Command Reference or the previous section Controller Event Interrupts in this chapter Once the Status Byte has been read the interrupt must be cleared by writing a 1 to bit 5 of N 4 Note to preserve values of other bits the interrupt service routine should read N 4 and write this value back to N 4 to clear the interrupt Resetting the PC to DMC FIFO To reset the output FIFO write data to address N 8 where bit 2 is high and all other bits are low Resetting the DMC to PC
64. 1 Overview e 1 Overview of Motor Types The DMC 1600 can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Brushless servo motors with sinusoidal commutation 3 Step motors with step and direction signals 4 Other actuators such as hydraulics For more information contact Galil The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 1600 achieves superior precision through use of a 16 bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feedforward an extra pole filter and integration limits The controller is configured by the factory for standard servo motor operation In this configuration the controller provides an analog signal 10Volt to connect to a servo amplifier This connection is described in Chapter 2 Brushless Servo Motor with Sinusoidal Commutation The DMC 1600 can provide sinusoidal commutation for brushless motors BLM In this configuration the controller generates two sinusoidal signals for connection with amplifiers specifically designed for this purpose Note The task of generating sinusoidal commutation may be accomplished in the brushless motor amplifier If the amplifier generates the sinusoidal commutation signals only a single command signal is required and the controller should be config
65. 2 10 183 191 193 Dual Encoder 70 109 143 Backlash 74 108 10 157 58 Backlash Compensation Dual Loop 74 102 10 102 10 102 10 157 Begin Motion 1 19 22 126 27 134 140 144 45 150 152 Binary 1 54 65 68 Bit Wise 129 137 Burn 202 e Index EEPROM 3 Bypassing Optoisolation 37 C Capture Data Record 74 98 100 141 144 Circle 154 55 Circular Interpolation 84 87 89 143 154 55 Clear Bit 150 Clear Sequence 79 81 85 87 Clock 141 CMDERR 120 133 135 Code 54 133 140 143 45 153 54 156 58 Command Syntax 65 66 Command Summary 71 75 77 81 87 141 143 Commanded Position 76 77 89 90 135 143 153 165 67 Communication 3 Almost Full Flag 59 FIFO 3 Compare Function 4 Compensation Backlash 74 108 10 157 58 Conditional jump 35 117 124 127 30 152 Configuration Jumper 37 164 Contour Mode 73 74 96 101 Control Filter Damping 164 168 Integrator 168 Proportional Gain 168 Coordinated Motion 66 73 84 87 Circular 84 87 89 143 154 55 Contour Mode 73 74 96 101 Ecam 91 92 95 Electronic Cam 73 74 91 93 Electronic Gearing 73 74 89 91 Gearing 73 74 89 91 Linear Interpolation 73 78 81 83 89 96 DMC 1600 Cosine 74 137 38 142 Cycle Time Clock 141 D DAC 168 172 74 176 Damping 164 168 Data Capture 142 43 Data Output Set Bit 150 Debugging 122 Deceleration 145 Differential Encoder 15 18 164 Digital Filter 65 172 73 175 7
66. 2147483647 VPm Returns number of available spaces for linear segments in DMC 1600 sequence buffer Zero means buffer full 512 means buffer empty 2 Return the absolute coordinate of the last data point along the trajectory m X Y Z or W or A B C D E F G or H To illustrate the ability to interrogate the motion status consider the first motion segment of our example ZLMOVE where the X axis moves toward the point X 5000 Suppose that when X 3000 the controller is interrogated using the command MG The returned value will be 3000 The value of CS VPX and VPY will be zero Now suppose that the interrogation is repeated at the second segment when Y 2000 The value of AV at this point is 7000 CS equals 1 VPX 5000 VPY 0 Example Linear Move Make a coordinated linear move in the ZW plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 counts sec LM ZW Specify axes for linear interpolation LI 40000 30000 Specify ZW distances LE Specify end move 80 e Chapter 6 Programming Motion DMC 1600 DMC 1600 VS 100000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration BGS Begin sequence Note that the above program specifies the vector speed VS and not the actual axis speeds VZ and VW The axis speeds are determined by the DMC 1600 from VS JVZ VW The resulting profile is shown in Figu
67. 3 34 60 79 85 159 161 179 182 83 Off On Error 15 35 38 159 161 Stop Motion 79 85 135 162 Hardware 33 56 150 159 Address 142 43 164 191 201 Amplifier Enable 37 159 Clear Bit 150 Jumper 37 164 Offset Adjustment 163 Output of Data 145 Set Bit 150 TTL 5 33 159 Home Input 34 112 141 Homing 34 112 Find Edge 34 112 VO Amplifier Enable 37 159 Analog Input 78 Clear Bit 150 Digital Input 33 35 138 151 Digital Output 138 150 Home Input 34 112 141 e 203 Output of Data 145 Set Bit 150 TTL 5 33 159 ICM 1100 15 37 38 159 Independent Motion Jog 77 78 89 95 115 126 27 134 35 140 157 160 Index Pulse 15 34 112 ININT 120 133 35 151 52 Input Analog 78 Input Interrupt 57 119 127 133 34 151 52 ININT 120 151 52 Input of Data 144 Inputs Analog 4 33 37 138 40 141 146 152 53 157 179 Installation 163 Integrator 168 Interconnect Module ICM 1100 15 37 38 159 Interface Terminal 65 Internal Variable 129 139 140 Interrogation 69 70 81 88 145 147 Interrupt 119 21 127 133 34 151 52 Invert 108 164 J Jog 77 78 89 95 115 126 27 134 35 140 157 160 Joystick 78 140 156 57 Jumper 37 164 K Keyword 129 137 139 141 42 TIME 141 42 L Label 37 78 80 84 94 95 100 110 113 115 117 23 125 34 140 41 145 147 150 53 155 157 58 161 LIMSWI 160 62 POSERR 160 61 Special Label 119 161 Latch 70 115 Arm Latch 115 Data Cap
68. 4 160 61 Position Error 17 120 133 34 140 143 153 158 Position Capture 115 Latch 70 115 Teach 100 Position Error 15 17 38 110 120 133 34 140 143 153 158 159 61 164 167 POSERR 120 133 34 Position Follow 152 53 Position Limit 160 Program Flow 119 124 Interrupt 56 119 21 127 133 34 151 52 Stack 132 135 152 Programmable 139 40 150 157 160 EEPROM 3 Programming Halt 79 121 25 127 28 151 Proportional Gain 168 Protection Error Limit 15 17 38 133 159 61 Torque Limit 17 PWM 4 Q Quadrature 5 108 150 153 160 171 Quit Abort 33 34 60 79 85 159 161 179 182 83 Stop Motion 79 85 135 162 R Record 74 98 100 141 144 Latch 70 115 Position Capture 115 Teach 100 Register 140 Reset 33 60 128 159 161 S SB Set Bit 150 Scaling Ellipse Scale 87 S Curve 79 111 Motion Smoothing 74 111 SDK 117 DMC 1600 Selecting Address 142 43 164 191 201 Servo Design Kit SDK 117 Set Bit 150 Sine 74 94 138 Single Ended 5 15 18 Slew 74 89 112 125 127 153 Smoothing 74 79 81 85 87 111 12 Software SDK 117 Terminal 65 Special Label 119 161 Specification 79 80 86 Stability 109 10 158 163 64 168 174 Stack 132 135 152 Zero Stack 135 152 Status 65 70 81 123 24 140 143 Interrogation 69 70 81 88 145 147 Stop Code 70 143 164 Tell Code 69 Step Motor KS Smoothing 74 79 81 85 87 111 12 Stepper Position Maintenance 104 Stop Abort 33 34
69. 4000 trippoint which slows the speed to 1000 count s Once the motors reach the corner the speed 15 increased back to 4000 cts s Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications such as CNC it is necessary to attach various speeds to different motion segments This can be done by two functions lt n and gt For example LI x y Z w lt n gt m The fist command n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function 7100000 is followed by 75000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point As an example consider the following program ALT Label for alternative program DP 0 0 Define Position of X and Y axis to be 0 LM
70. 60 79 85 159 161 179 182 83 Stop Code 54 70 133 140 143 45 143 153 54 156 58 164 Stop Motion 79 85 135 162 Subroutine 33 84 120 128 35 152 160 61 Automatic Subroutine 133 Synchronization 5 91 Syntax 65 66 Tangent 74 84 86 87 Teach 100 Data Capture 142 43 Latch 70 115 Play Back 74 144 Position Capture 115 Record 74 98 100 141 144 Tell Code 69 Tell Error 70 Position Error 17 120 133 34 140 143 153 158 Tell Position 70 Tell Torque 70 Terminal 33 37 65 117 140 146 Theory 165 Damping 164 168 Digital Filter 65 172 73 175 77 Modelling 165 168 69 173 PID 18 168 178 Stability 109 10 158 163 64 168 174 Time Clock 141 e 205 TIME 141 42 Time Interval 96 98 100 143 Timeout 12 13 120 125 133 135 MCTIME 120 125 133 135 Torque Limit 17 Trigger 117 124 126 28 167 Trippoint 75 79 81 86 87 98 125 26 132 Troubleshooting 163 TTL 5 33 159 Tuning SDK 117 Stability 109 10 158 163 64 168 174 U Upload 117 User Unit 149 V Variable 206 e Internal 129 139 140 Vector Acceleration 81 82 155 Vector Deceleration 81 82 87 Vector Mode Circle 5 Circular Interpolation 84 87 89 143 154 55 Clear Sequence 79 81 85 87 Ellipse Scale 87 Feedrate 80 86 87 127 154 55 Tangent 74 84 86 87 Vector Speed 78 85 87 127 155 W Wire Cutter 153 Z Zero Stack 135 152 DMC 1600
71. 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change 15 a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 Step 3 Specify the master interval and starting point Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are specified by the instruction 90 e Chapter 6 Programming Motion DMC 1600 DMC 1600 EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0 Step 4 Specify the slave positions Next we specify the slave positions with the instruction ET n x y z w where n indicates the order of the point The value n starts at zero and may go up to 256 The parameters x y z w indicate the corresponding slave position For this example the table may be specified by ET 0 0 1 3000 2 2250 ET 3 1500 This specifies the ECAM table Step 5 Enable the ECAM To enable the ECAM mode use the command EBn where n 1 enables ECAM mode and n 0 disables ECAM mode Step 6 Engage the slave motion To engage the slav
72. 630 DMC 1640 Cable 1600 1M Cable 1600 4M CB 50 100 Starter Kit 16 Bit ADC Sinusoidal Commutation Option ICM 1900 ICM 1900 Opto AMP 1910 AMP 1920 AMP 1930 AMP 1940 DMC 1600 Utilities WSDK 16 WSDK 32 VBX Tool Kit Setup 16 Setup 32 CAD to DMC HPGL DMC 1600 axis motion controller 2 axes motion controller 3 axes motion controller 4 axes motion controller 100 pin high density cable 1 meter 100 pin high density cable 4 meter 50 pin to 100 pin converter board includes two 50 pin ribbon cables Includes DMC 1600 ICM 1900 or AMP 19 0 cable utilities WSDK software and manual Increased resolution for analog inputs Sinusoidal Commutation for brushless motors Interconnect module Optoisolated digital outputs Interconnect module with 1 axis power amplifier Interconnect module with 2 axes power amplifier Interconnect module with 3 axes power amplifier Interconnect module with 4 axes power amplifier Utilities for Plug amp Play firmware Servo Design Kit for Windows 3 X Servo Design Kit for Windows NT or Windows 95 98 2000 ME XP Visual Basic Tool Kit includes VBXs and OCXs Set up software for Windows 3 X Set up software for Windows NT or Windows 95 AutoCAD DXF translator HPGL translator Appendices 189 Interrupts and Their Vectors These occur on the first 8259 IRQ VECTOR USAGE 0 8 or 08h Timer chip DON T USE THIS 1 9 or 09h Keyboard DON T USE THIS 2 10 or O
73. 7 Digital Input 33 35 138 151 Digital Output 138 150 Clear Bit 150 Dip Switch Address 142 43 191 201 Download 65 117 142 Dual Encoder 70 109 143 Backlash 74 108 10 157 58 Dual Loop 74 102 10 102 10 102 10 157 Dual Loop 74 102 10 102 10 102 10 157 Backlash 74 108 10 157 58 E Ecam 91 92 95 Electronic Cam 73 74 91 93 Echo 54 Edit Mode 117 189 134 Editor 117 18 EEPROM 3 Electronic Cam 73 74 91 93 Electronic Gearing 73 74 89 91 Ellipse Scale 87 Enable Amplifer Enable 37 159 Encoder Auxiliary Encoder 33 89 102 10 102 10 102 10 183 191 193 Differential 15 18 164 Dual Encoder 70 109 143 Index Pulse 15 34 112 Quadrature 5 108 150 153 160 171 Error Code 54 133 140 143 45 153 54 156 58 Error Handling 33 120 133 160 62 Error Limit 15 17 38 133 159 61 Off On Error 15 35 38 159 161 Example Wire Cutter 153 DMC 1600 F Feedrate 80 86 87 127 154 55 FIFO 3 Filter Parameter Damping 164 168 Integrator 168 PID 18 168 178 Proportional Gain 168 Stability 109 10 158 163 64 168 174 Find Edge 34 112 Flags Almost full 59 Formatting 146 147 49 Frequency 5 6 Function 34 35 54 65 79 98 99 109 11 115 117 121 25 127 129 133 136 42 146 47 150 53 155 157 58 Functions Arithmetic 117 129 137 139 149 G Gain Proportional 168 Gear Ratio 89 90 Gearing 73 74 1 H Halt 79 121 25 127 28 151 Abort 3
74. BP 5 WW WWW WN NN NNN NN NY e Be Re Be Re Re eS Nn A LU Ne DO DN d t l2 DO ANANDA BPW l2 C ND DN FW l2 DMC 1600 ABW ABW GND VCC OUTCOM ERROR RESET CMP MOCMDW SIGNW PWMW MOCMDZ SIGNZ PWMZ MOCMDY SIGNY PWMY MOCMDX SIGNX PWMX GND VCC A AMPENZ MPENY MPENX LSCOM HOMEW RLSW FLSW HOMEZ RLSZ A A 0 0 0 0 0 0 0 0 0 0 9 0 Oo om X Auxiliary encoder A X Auxiliary encoder B X Auxiliary encoder B Y Auxiliary encoder A Y Auxiliary encoder A Y Auxiliary encoder B Y Auxiliary encoder B Z Auxiliary encoder A Z Auxiliary encoder A Z Auxiliary encoder B Z Auxiliary encoder B W Auxiliary encoder A W Auxiliary encoder A W Auxiliary encoder B W Auxiliary encoder B Signal Ground 5 Volts Output Common for use with the opto isolated output option Error signal Reset Circular Compare output W axis motor command to amp input w respect to ground W axis sign output for input to stepper motor amp W axis pulse output for input to stepper motor amp Z axis motor command to amp input w respect to ground Z axis sign output for input to stepper motor amp Z axis pulse output for input to stepper motor amp Y axis motor command to amp input w respect to ground Y axis sign output for input to stepper motor amp Y axis pulse output for input to stepper motor am
75. Capability All inputs can be used as active high or low If you are using an isolated power supply you can connect 5 to INCOM or supply the isolated ground to INCOM Connecting 5V to INCOM configures the inputs for active low Connecting ground to INCOM configures the inputs for active high The optoisolated inputs are configured into groups For example the general inputs IN1 IN8 and the ABORT input are one group Figure 3 1 illustrates the internal circuitry The INCOM signal is a common connection for all of the inputs in this group 34 e Chapter 3 Connecting Hardware DMC 1600 The optoisolated inputs are connected in the following groups Group Controllers with 1 4 Axes Group Controllers with 5 9 Axes Signal IN1 IN8 ABORT IN1 IN16 ABORT INCOM FLX RLX HOMEX FLX RLX HOMEX FLY RLY HOMEY LSCOM FLY RLY HOMEY FLZ RLZ HOMEZ FLW RLW HOMEW FLZ RLZ HOMEZ FLE RLE HOMEE FLF RLF HOMEF FLW RLW HOMEW FLG RLG HOMEG FLH RLH HOMEH LSCOM A AY 4 Or OO FO FLSX HOMEX RLSY RLSX FLSY HOMEY INCOM O YA 4 OO 0 Or 3 09 INT IN2 IN3 IN4 IN5 IN6 IN7 IN8 ABORT Figure 3 1 The Optoisolated Inputs Using an Isolated Power Supply To take full advantage of opto isolation an isolated power supply should be used to provide the voltage at the input common conn
76. DMC 1600 The individual jumpers are labeled SMX SMY SMZ and SMW for axes 1 through 4 Optional Motor Off Jumper The state of the motor upon power up may be selected with the placement of a hardware jumper on the controller With a jumper installed at the OPT location next to the stepper motor jumpers the controller will be powered up in the motor off state The SH command will then need to be issued in order for the motor s to be enabled With no jumper installed the controller will immediately enable the motor s upon power up 10 e Chapter 2 Getting Started DMC 1600 DMC 1600 Step 3 Install the Communications Software After applying power to the computer you should install the Galil software that enables communication between the controller and PC Using Dos Using the Galil Software CD ROM go to the directory DMCDOS Type INSTALL at the DOS prompt and follow the directions Using Windows SE 98 NT ME XP or 2000 32 bit versions The Galil Software CD ROM will automatically begin the installation procedure when the CD ROM is installed After installing the Galil CD ROM software on your computer you can easily install other software components as desired To install the basic communications software run the Galil Software CD ROM and choose DMCWIN32 Windows Utilities and Programming Libraries WIN95 98 NT This will install the Galil Terminal that can be used for communication Step 4 Inst
77. DMC 1600 decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization For stepper motors the DMC 1600 can also interface to encoders with pulse and direction signals There is no limit on encoder line density however the input frequency to the controller must not exceed 3 000 000 full encoder cycles second 12 000 000 quadrature counts sec For example 1f the encoder line density is 10000 cycles per inch the maximum speed is 300 inches second If higher encoder frequency is required please consult the factory The standard voltage level is TTL zero to five volts however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 1600 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 1600 can accept analog feedback instead of an encoder for any axis For more information see description of analog feedback in Chapter 2 under section entitled Test the encoder operation To interface with other types of position sensors such as resolvers or absolute encoders Galil can customize the controller and command set Please contact Galil to talk to one of our applications engineers about your particular system requirements Watch Dog Timer The DMC 1600 provides an internal watch dog timer which checks for proper microprocessor operation The timer t
78. Display for a DMC 1840 The Data Record display is user customizable so that all or just parts of the record can be displayed To modify the display right click on an object to access the options For detailed information about the features of the Galil DMC SmartTERM including the Data Record please consult Help Topics under the Help menu Communication Settings The Galil SmartTERM application installation as well as WSDK ActiveX and DMCWIN32 installations includes the necessary drivers and DLL files required to communicate with the Galil controller The drivers are automatically installed and default communications settings are applied 44 e Chapter 4 Software Tools and Communications DMC 1600 to the device by the driver when a card is installed as per the installation procedure outlined in Ch 2 However some advanced settings are available to modify the communications methods and data record access These settings are accessed through the Galil Registry Editor after the card is properly installed Galil Registry Editor The Edit Registry dialog box shown in Fig 4 3 can be accessed by selecting Controller Registration under the Tools menu or by selecting the toolbar icon with the magnifying glass within DMC SmartTERM The Edit Registry dialog shows the current controller models installed to the PC along with their associated I O addresses interrupt lines and controller serial numbers The Galil Registry is part of the DMC
79. End program Play back Initial Counter Exit if done Print Counter Print X position Print Y position Print X error Print Y error Increment Counter Done Array space may be deallocated using the DA command followed by the array name DA 0 deallocates all the arrays Input of Data Numeric and String Input of Data The command IN is used to prompt the user to input numeric or string data Using the IN command the user may specify a message prompt by placing a message in quotations When the controller executes an IN command the controller will wait for the input of data The input data is assigned to the specified variable or array element An Example for Inputting Numeric Data HA IN Enter Length LENX EN DMC 1600 Chapter 7 Application Programming 143 In this example the message Enter Length is displayed on the computer screen The controller waits for the operator to enter a value The operator enters the numeric value which is assigned to the variable LENX Cut to Length Example In this example a length of material is to be advanced a specified distance When the motion is complete a cutting head is activated to cut the material The length 1s variable and the operator is prompted to input it in inches Motion starts with a start button which is connected to input 1 The load is coupled with a 2 pitch lead screw 2000 count rev encoder is on the motor resulting in a resolution of 4000
80. FIFO To reset the input FIFO write data to address N 8 where bit 1 is high and all other bits are low Resetting the Controller Clearing the FIFO is useful for emergency resets or Abort For example to reset the controller clear the FIFO then send the RS command If the controller is not responding it may be necessary to provide a hardware reset to the controller This can be accomplished by writing data to address N 8 where bit 7 is high Reset Register at N 8 Secondary FIFO Memory Map ADDR 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 DMC 1600 TYPE ITEM W sample number general input block 0 inputs 1 8 general input block 1 inputs 9 16 general input block 2 inputs 17 24 general input block 3 inputs 25 32 general input block 4 inputs 33 40 general input block 5 inputs 41 48 general input block 6 inputs 49 56 general input block 7 inputs 57 64 general input block 8 inputs 65 72 general input block 9 inputs 73 80 general output block 0 outputs 1 8 general output block 1 outputs 9 16 general output block 2 outputs 17 24 Cic G56 occ c c cuc vv vv v ww w general output block 3 outputs 25 32 Chapter 4 Software Tools and Communications e 59 16 17 18 19 20 21 22 23 24 25 26 27 28 31 32 33 34 35 36 39 40 41 42 43 44 47 48 51 52 55 56 59 60 63 64 65 66 67 68 69 70 71 72 75 76 79 80 83 84 87 88
81. FIFO Memory Maps ette ett ein eg Ree 59 Explanation of Status Information and Axis Switch Information 62 Chapter 5 Command Basics 64 Introduction eee nde iit ge CH D HE Rp He HIER 64 Command Syntax ere ide eit eee eed 64 65 Command Syntax Binary iie eade ee au ee 66 Binary Command 1 e c cedet ERE erede one 66 Binary command tablei 2 eei durer ere ert eed a re ie eroe ded cag 67 Controller Response to DATA raone A O O REA enne nennen 68 Interrogating the Controller eiie res ce ere eee niin credere ences 68 ii e Contents DMC 1600 DMC 1600 Interrogation Commands on Rad ee S RR Uie deret ten 68 Interrogating Current Commanded Values sss 69 Operands ueteres e en dieantue ege ees FO EN Pte E eed 69 Command Summary gece eke dtu eed tede GH HA e ie diee ep ade ue 70 Chapter 6 Programming Motion 72 OVERVIEW RR EE 72 ee RE RO Ge RH Ee n det 73 Command Summary Independent Axis sse 74 Independent Jogettg s soni beatam a o aded d wa qute 76 Command Summary Jogging 76 Operand Summary Independent Axis 77 Linear Interpolation Mode nennen eren ener nnne nnns 77 Specifying Linear Segments essere enne nnne 78 80 Operand Summary Linear 1 80 Example Linear Move
82. Label PR 2000 Position Command BG Begin AM After move SBI Set Output 1 WT 1000 Wait 1000 msec Clear Output 1 EN End Digital Inputs The DMC 1600 has eight digital inputs for controlling motion by local switches The IN n function returns the logic level of the specified input 1 through 8 For example a Jump on Condition instruction can be used to execute a sequence if a high condition is noted on an input 3 To halt program execution the After Input AT instruction waits until the specified input has occurred Example JP A IN 1 0 Jump to A if input 1 is low JP B IN 2 1 Jump to B if input 2 is high AIT Wait until input 7 is high AI 6 Wait until input 6 is low Example Start Motion on Switch Motor X must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor X must stop turning Solution Connect panel switch to input 1 of DMC 1600 High on input 1 means switch is in on position Instruction Function S JG 4000 Set speed AI 1 BGX Begin after input 1 goes high AI 1 STX Stop after input 1 goes low AMX JP S After motion repeat EN Input Interrupt Function The DMC 1600 provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the II m n o command The m specifies the beginning input and n specifies the final input in the range The 150 e Chapt
83. M 1900 Interconnect Module sss ICM 1900 Drawing esee AMP 19X0 Mating Power Amplifiers Coordinated Motion Mathematical Analysis DMC 1600 DMC 1000 Comparison List of Other Publications sese Training Semin rs 4 iir Contacting Us sc eee ede WARRANTY sees ettet hebetes Contents ev Chapter 1 Overview Introduction DMC 1600 The DMC 1600 series motion control cards install directly into a compact PCI bus This controller series offers many enhanced features including high speed communications non volatile program memory fast encoder speeds and improved cabling for EMI reduction The DMC 1600 provides two communication channels a high speed FIFO for sending and receiving commands and a secondary channel which gives high speed access to status and parameters The DMC 1600 allows for high speed servo control up to 12 million encoder counts sec and step motor control up to 3 million steps per second Sample rates as low as 62 5usec per axis are available A 2 Meg Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field without removing the controller from the system The DMC 1600 can be used with step motors servo motors and hydraulics on any combination of axes Each axis is configurable by the user for optimum flexibility The DMC 1600 achieves superior precisio
84. Minimum IDX pulse width 0 nsec TTL 0 5 Volts level at 50 duty cycle 3 000 000 pulses sec maximum frequency TTL 0 5 Volts 2 2K ohm in series with optoisolator Active high or low requires at least 2mA to activate Can accept up to 28 Volts without additional series resistor Above 28 Volts requires additional resistor Standard configuration is 10 Volt 12 Bit Analog to Digital converter 16 bit optional TTL DMC 1600 Power Requirement 5V 750 mA 12V 40 mA 12V 40mA Performance Specifications Minimum Servo Loop Update Time DMC 1610 DMC 1620 DMC 1630 DMC 1640 Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Array Size Program Size DMC 1600 Normal Firmware Fast Firmware 250 usec 125 usec 250 usec 125 usec 375 usec 250 usec 375 usec 250 usec 1 quadrature count Phase locked better than 005 System dependent 2147483647 counts per move Up to 12 000 000 counts sec servo 3 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1 104 8000 elements 30 arrays 1000 lines x 80 characters Appendices 179 Connectors for DMC 1600 Main Board J1 DMC 1640 A D AXES MAIN 100 PIN HIGH DENSITY AMP 2 178238 9 5 00 tn 15 002 Hose 13 14 15 16 17 18 19 20 21 22 23 24 25 26
85. Next the table is constructed To move the constrained axes simply command the N axis in the jog mode or with the PR and PA commands For example PAN 2000 BGN will cause the XY axes to move to the corresponding points on the motion cycle Sinusoidal Motion Example The x axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a frequency of 20 Hz This can be performed by commanding the X and N axes to perform circular motion Note that the value of VS must be VS 2r R F where R is the radius or amplitude and F is the frequency in Hz Set VA and VD to maximum values for the fastest acceleration INSTRUCTION INTERPRETATION VMXN Select axes VA 68000000 Maximum Acceleration 100 e Chapter 6 Programming Motion DMC 1600 VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten cycles VE BGS Stepper Motor Operation DMC 1600 When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation In order to command stepper motor operation the appropriate stepper mode jumpers must be installed See chapter 2 for this installation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step ou
86. Off On Error The DMC 1600 controller has a built in function which can turn off the motors under certain error conditions This function is know as Off On Error To activate the OE function for each axis specify 1 for X Y Z and W axis To disable this function specify 0 for the axes When this function is enabled the specified motor will be disabled under the following 3 conditions 1 The position error for the specified axis exceeds the limit set with the command ER 2 The abort command is given 3 The abort input is activated with a low signal Note If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Examples OE 1 1 1 1 Enable off on error for X Y Z and W OE 0 1 0 1 Enable off on error for Y and W axes and disable off on error for W and Z axes Automatic Error Routine The POSERR label causes the statements following to be automatically executed if error on any axis exceeds the error limit specified by ER The error routine must be closed with the RE command The RE command returns from the error subroutine to the main program NOTE The Error Subroutine will be entered again unless the error condition is gone Example A JP Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor AMX After motor stops SHX Servo
87. P CE 0 DEO PR 40000 BGX Correct AMX V1 10000 DEX V2 _TEX 4 V1 JP END ABS V2 lt 2 PR V2 4 BGX JP CORRECT END EN Interpretation Label Configure encoder Set initial value Main move Start motion Correction loop Wait for motion completion Find linear encoder error Compensate for motor error Exit if error is small Correction move Start correction Repeat Chapter 6 Programming Motion 109 Motion Smoothing The DMC 1600 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value The discontinuous acceleration results in jerk which causes vibration The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration Using the IT and VT Commands S curve profiling S When operating with servo motors motion smoothing can be accomplished with the IT and VT command These commands filter the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile known as S curve has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following commands IT x y z w Independent time constant n Vector time constant The command IT is used for smoothing independent moves of the type JG
88. PR PA and the command VT is used to smooth vector moves of the type VM and LM The smoothing parameters x y z w and n are numbers between 0 and 1 and determine the degree of filtering The maximum value of 1 implies no filtering resulting in trapezoidal velocity profiles Smaller values of the smoothing parameters imply heavier filtering and smoother moves The following example illustrates the effect of smoothing Fig 6 8 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT 5 Filter for S curve BG X Begin 110 e Chapter 6 Programming Motion DMC 1600 ACCELERATION VELOCITY ACCELERATION VELOCITY Figure 6 8 Trapezoidal velocity and smooth velocity profiles Homing DMC 1600 The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference This reference is connected to the Home input line The HM command initializes the motor to the encoder index pulse in addition to the Home input The configure command CN is used to define the polarity of the home input The Find Edge FE instruction is useful for initializing the motor to a home switch The home switch is connected to the Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew s
89. Reg ocx ActiveX object refer to Fig 4 1 This ActiveX control is used to create maintain and modify the critical communication parameters which are discussed next Edit Registry E x Controller DMC 1800 PCI Address 41 76 Interrupt Level 16 Serial 8922 EISE Controller DMC 1800 PCI Address 4160 Interrupt Level 16 Serial 2275 ETOP Controller3 DMC 1740 ISA Address 824 Serial 1 m Non PnP Tools New Controller T s Ae Find Ethemet Controller Plug and Play Device B Non Plug and Play Device Close Figure 4 3 Galil Registry Editor Setting Communications Parameters and Methods To access the Controller Communication Parameters dialog highlight the desired controller in the Galil Registry Editor accessed through Smart TERM and select the Properties command button The timeout property under the General Parameters tab shown in Fig 4 4 allows the user to select the timeout period that the Galil software waits for a response from the controller before generating an error If the controller does not reply with the data response and a colon or just a colon for commands that do not invoke responses then the Galil software API will generate the timeout error code 1 time out occurred while waiting for a response from the controller The default setting for the timeout is 5000ms which should be sufficient for most cases DMC 1600 Chapter 4 Software Tools and Communicat
90. S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM 148 e Chapter 7 Application Programming DMC 1600 The DMC 1600 position parameters such as PR and VP have units of quadrature counts Speed parameters such as SP JG and VS have units of counts sec Acceleration parameters such as AC DC VA and VD have units of counts sec2 The controller interprets time in milliseconds All input parameters must be converted into these units For example an operator can be prompted to input a number in revolutions A program could be used such that the input number is converted into counts by multiplying it by the number of counts revolution Example RUN Label IN ENTER OF REVOLUTIONS N1 Prompt for revs PR N1 2000 Convert to counts IN ENTER SPEED IN RPM S1 Prompt for RPMs SP 51 2000 60 Convert to counts sec IN ENTER ACCEL IN RAD SEC2 AI Prompt for ACCEL AC A1 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program Programmable Hardware I O DMC 1600 Digital Outputs The DMC 1600 has an 8 bit uncommitted output port for controlling external events The DMC 1650 through DMC 1680 has an additional 8 outputs The DMC 1600 has an additional 64 I O configured as inputs or outputs with CO command Each bit on the output port may be se
91. SCII or binary In ASCH the DMC 1600 instruction set is BASIC like and easy to use Instructions consist of two uppercase letters that correspond phonetically with the appropriate function For example the instruction BG begins motion and ST stops the motion In binary commands are represented by a binary code ranging from 80 to FF ASCII commands can be sent live over the bus for immediate execution by the DMC 1600 or an entire group of commands can be downloaded into the DMC 1600 memory for execution at a later time Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter Binary commands cannot be used in Applications programming This section describes the DMC 1600 instruction set and syntax A summary of commands as well as a complete listing of all DMC 1600 instructions is included in the Command Reference chapter Command Syntax ASCII DMC 1600 instructions are represented by two ASCII upper case characters followed by applicable arguments A space may be inserted between the instruction and arguments A semicolon or lt enter gt is used to terminate the instruction for processing by the DMC 1600 command interpreter Note If you are using a Galil terminal program commands will not be processed until an enter command is given This allows the user to separate many commands on a single line and not begin execution until the user gives the enter
92. SP 8000 Speed FEY Find edge command BG Y Begin motion AM Y After complete MG FOUND HOME Send message DP 0 Define position as 0 EN End 112 e Chapter 6 Programming Motion DMC 1600 DMC 1600 MOTION BEGINS TOWARD HOME DIRECTION MOTION REVERSE TOWARD HOME DIRECTION MOTION TOWARD INDEX DIRECTION INDEX PULSES HOME SWITCH POSITION POSITION POSITION do POSITION pO POSITION Figure 6 9 Motion intervals in the Home sequence Chapter 6 Programming Motion e 113 High Speed Position Capture The Latch Function Often it 1s desirable to capture the position precisely for registration applications The DMC 1600 provides a position latch feature This feature allows the position of the main or auxiliary encoders of X Y Z or W to be captured within 25 microseconds of an external low input signal Faster latch times are available to 1 usec Please contact Galil The general inputs 1 through 4 and 9 thru 12 correspond to each axis through 4 IN1 X axis latch IN2 Y axis latch IN3 Z axis latch INA W axis latch 9 through 12 IN9 E axis latch INIO F axis latch IN11 latch IN12 latch Note To insure a position capture within 25 microseconds the input signal must be a transition from high to low The DMC 1600 software commands AL and RL are used to arm the latch and report the latched position The steps to use the latch are as foll
93. SZ alalu Q reserved reserved B ESI 2 reserved gt a 45 rs Jajo lt J reserved fn Q lt DMC 1600 Chapter 5 Command Basics e 67 reserved reserved reserved s im 2 Controller Response to DATA The DMC 1600 returns a for valid commands The DMC 1600 returns a for invalid commands For example if the command BG is sent in lower case the DMC 1600 will return a bg lt enter gt invalid command lower case DMC 1600 returns a When the controller receives an invalid command the user can request the error code The error code will specify the reason for the invalld command response To request the error code type the command For example TC1 lt enter gt Tell Code command 1 Unrecognized command Returned response There are many reasons for receiving an invalid command response The most common reasons are unrecognized command such as typographical entry or lower case command given at improper time such as during motion or a command out of range such as exceeding maximum speed A complete listing of all codes is listed in the TC command in the Command Reference section Interrogating the Controller Interrogation Commands The DMC 1600 has a set of commands that directly interrogate the controller When the command is entered the requested data is returne
94. Specify relative distances on X and Y axes BG XY Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves X and Y 10000 and 20000 units After the motion is complete the motors rest for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 1600 has some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines See section on Auto Start Routine The DMC 1600 has a special label for automatic program execution A program which has been saved into the controller s non volatile memory can be automatically executed upon power up or reset by beginning the program with the label ZAUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions on page on page 132 118 Chapter 7 Application Programming DMC 1600 DMC 1600 ININT Label for Input Interrupt subroutine LIMSWI Label for Limit Switch subroutine POSERR Label for excess Position Error subroutine Label for timeout on Motion Complete trip point ZCMDERR Label for incorrect command subroutine Commenting Programs Using the command NO The DMC 1600 provides a command NO for commenting programs This command allows the user to include up to 78 characters on a single line after the
95. TURN gt Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of RETURN will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a lt return gt is given lt cntrl gt P The lt cntrl gt P command moves the editor to the previous line lt entrl gt I The lt cntrl gt I command inserts a line above the current line For example if the editor is at line number 2 and lt cntrl gt I is applied a new line will be inserted between lines 1 and 2 This new line will be labeled line 2 The old line number 2 is renumbered as line 3 lt cntr1 gt D The lt cntrl gt D command deletes the line currently being edited For example if the editor is at line number 2 and lt cntrl gt D is applied line 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q The lt cntrl gt Q quits the editor mode In response the DMC 1600 will return a colon After the Edit session is over the user may list the entered program using the LS command If no operand follows the LS command the entire program will be listed The user can start listing at a specific line or label using the operand n A command and new line number or label following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation 18 List ent
96. Used for Z axis latch input Input 4 Used for W axis latch input Input 5 Input 6 Input 7 Input 8 Abort Input Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Signal Ground Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 Analog Input 5 Analog Input 6 Analog Input 7 Analog Input 8 Main encoder Main encoder A Main encoder Main encoder B X X X X X Main encoder Index X Main encoder Index Signal Ground 5 Volts Y Main encoder DMC 1600 92 93 MBY 94 MBY 95 TINY 96 INY 97 MAZ 98 MAZ 99 MBZ 100 MBZ 101 INZ 102 INZ 103 GND 104 VCC 105 MAW 106 MAW 107 MBW 108 MBW 109 INW 110 INW 111 12V 112 12V Specifications Dimensions 13 5 x 2 675 x 6 88 DMC 1600 e e Y Main encoder A Y Main encoder B Y Main encoder B Y Main encoder Index Y Main encoder Index Z Main encoder A Main encoder A Z Z Main encoder Z Main encoder B Z Z Main encoder Index Main encoder Index Signal Ground 5 Volts W Main encoder Main encoder A W W Main encoder B W Main encoder B W W Main encoder Index Main encoder Index 12 Volts 12 Volts Appendices 193 ICM 1900 Drawing 13 500 5 12 560 mo 1 1 620 0 220 6 880 4 940 2 000 Figure A 1 ICM 1900 Drawing
97. X After motion is complete SBI Set output bit 1 WT 20 Wait 20 ms Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process START PULSE 11 EN MOTOR VELOCITY OUTPUT PULSE output TIME INTERVALS DMC 1600 move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals X Y Table Controller An X Y Z system must cut the pattern shown in Fig 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool The solid curves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate 1s 0 1 g The motion starts at point A with the Z axis raised An X Y motion to point B is followed by lowering the Z axis and performing a cut along the circle Once the circular motion is completed the Z axis is raised and the motion continues to point C etc Assume that all of the 3 axes are driven by lead screws with 10 turns per inch pitch Also assume encoder resolution of 1000 lines per revolution This results in the relationship inch 40 000 counts and the speeds of Chapter 7 Application Programming e 153 1 in sec 40 000 count sec 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 0 1g 38 6 in s2 1 544 000 count s2 Note that the circular path has a
98. X axis motor BCX Enable the brushless calibration command PRX 50000 Command a relative position movement on X axis BGX Begin motion on X axis When the hall sensors detect a phase transition the commutation phase is re set 22 e Chapter 2 Getting Started DMC 1600 DMC 1600 Step 8c Connect Step Motors In Stepper Motor operation the pulse output signal has a 50 duty cycle Step motors operate open loop and do not require encoder feedback When a stepper is used the auxiliary encoder for the corresponding axis is unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input corresponding to that axis The commanded position of the stepper can be interrogated with RP or DE The encoder position can be interrogated with TP The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a range between 0 5 and 8 where 8 implies the largest amount of smoothing See Command Reference regarding KS The DMC 1600 profiler commands the step motor amplifier All DMC 1600 motion commands apply such as PR PA VP CR and JG The acceleration deceleration slew speed and smoothing are also used Since step motors run open loop the PID filter does not function and the position error is not generated To connect step motors with the DMC 1600 you must follow this procedure Step A Install SM jumpers Each axis of the DMC 1600 that will
99. X motor off Begin recording 4 msec interval Continue until done recording Compute DX Dimension Array for DX Initialize counter Label Compute the difference Store difference in array Chapter 6 Programming Motion e 99 1 Increment index JP L C lt 500 Repeat until done PLAYBCK Begin Playback CMX Specify contour mode DT2 Specify time increment I 0 Initialize array counter B Loop counter CD XPOS I WC Specify contour data I I 1 Increment array counter JP 2B I 500 Loop until done DT 0 CDO End contour mode EN End program For additional information about automatic array capture see Chapter 7 Arrays Virtual Axis The DMC 1600 controller has an additional virtual axis designated as the N axis This axis has no encoder and no DAC However it can be commanded by the commands AC DC JG SP PR PA BG IT GA VM VP CR ST DP RP The main use of the virtual axis is to serve as a virtual master in ECAM modes and to perform an unnecessary part of a vector mode These applications are illustrated by the following examples ECAM Master Example Suppose that the motion of the XY axes is constrained along a path that can be described by an electronic cam table Further assume that the ecam master is not an external encoder but has to be a controlled variable This can be achieved by defining the N axis as the master with the command EAN and setting the modulo of the master with a command such as EMN 4000
100. XY Define linear mode between X and Y axes LI 4000 0 4000 gt 1000 Specify first linear segment with a vector speed of 4000 and end speed 1000 LI 1000 1000 lt 4000 gt 1000 Specify second linear segment with a vector speed of 4000 and end speed 1000 LI 0 5000 lt 4000 gt 1000 Specify third linear segment with a vector speed of 4000 and end speed 1000 LE End linear segments BGS Begin motion sequence EN Program end Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS to be scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided in half Chapter 6 Programming Motion e 79 Command Summary Linear Interpolation COMMAND LM abcdefgh same controllers with 5 or more axes Returns number of available spaces for linear segments in DMC 1600 sequence buffer Zero means buffer full 512 means buffer empty LI x y zw n Specify incremental distances relative to current position and assign vector speed n LI a b c d e f g h n Operand Summary Linear Interpolation OPERAND DESCRIPTION Return distance traveled Segment counter returns number of the segment in the sequence starting at zero Returns length of vector resets after
101. YS 1 executes an internal monitoring of the auxiliary and main encoder registers for that axis or axes Position error is then tracked in step pulses between these two registers QS command TPxYAxYB 5 TD gt YC Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally defines the step drive resolution where YA 1 for full stepping or YA 2 for half stepping The full range of YA is up to 9999 for microstepping drives Error Limit The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor steps Once the value of QS exceeds this limit the controller then performs the following actions 1 The motion is maintained or is stopped depending on the setting of the OE command If OE 0 the axis stays in motion if OE 1 the axis is stopped 2 YS is set to 2 which causes the automatic subroutine labeled ZPOSERR to be executed Correction A correction move can be commanded by assigning the value of QS to the YR correction move command The correction move is issued only after the axis has been stopped After an error correction move has completed and QS is less than three full motor steps the YS error status bit is automatically reset back to 1 indicating a cleared error Example SPM Mode Setup The following code demonstrates what is necessary to set up SPM mode for a full step drive a half step drive an
102. ah Cascade from second 8259 DON T USE THIS 3 11 or Obh COM2 4 12 or Och COMI 5 13 or Odh LPT2 6 14 or Oech Floppy DON T USE THIS 7 15 or 0fh LPTI These occur on the second 8259 IRQ VECTOR USAGE 8 104 or 70h Real time clock DON T USE THIS 9 105 or 71h Redirect cascade DON T USE THIS 10 106 or 72h 11 107 or 73h 12 108 or 74h Mouse DSR 13 109 or 75h Math Co processor exception 14 110 or 76h Fixed Disk DON T USE THIS 15 111 or 77h ICM 1900 Interconnect Module The ICM 1900 interconnect module provides easy connections between the DMC 1600 series controllers and other system elements such as amplifiers encoders and external switches The ICM 1900 accepts the 100 pin main cable and 25 pin auxiliary cable and breaks them into screw type terminals Each screw terminal 1s labeled for quick connection of system elements An ICM 1900 is required for each set of 4 axes The ICM 1900 is contained in a metal enclosure A version of the ICM 1900 is also available with servo amplifiers see AMP 19X0 Features Breaks out DMC 1600 cables into individual screw type terminals Clearly identifies all terminals Provides jumper for connecting limit and input supplies to 5 V supply from PC Available with on board servo drives see AMP 19X0 Can be configured for AEN high or low Terminal Label 1 0 Description 1 1 X Auxiliary encoder 190 gt Appendices DMC 1600 O tU BW NY BR A A HR HR
103. all the DMC 1600 in the PC The DMC 1600 is installed directly into the Compact PCI bus The procedure is outlined below 1 Make sure the host computer is in the power off condition 2 Remove unit cover 3 Remove the metal plate covering the expansion bus slot where the DMC 1600 will be inserted 4 Insert DMC 1600 card in the expansion bus and secure with screw 5 Attach 100 pin cable to your controller card If you are using a Galil ICM 1900 or AMP 19X0 this cable connects into the J2 connection on the interconnect module If you are not using a Galil interconnect module you will need to appropriately terminate the cable to your system components see the appendix for cable pin outs The auxiliary encoder connections are accessed through the 36 pin connector J5 Note The part number for the 100 pin connector is 2 178238 9 from AMP 6 Turn power on to computer 7 The operating system should recognize the DMC 1600 as a new device 8 The Plug and Play feature will automatically configure the controller for your computers available resources The installation will also automatically add this information to the Galil Registry Step 5 Establish Communication using Galil Software DMC 1600 DOS Users All that is required for installation of the DMC 1600 in DOS is the DMCTERM software Within DMCTERM the DMC 1600 should be selected from the card options and the DOS drivers will automatically register the card with a correct address
104. als PM 180 a 70 As long as PM is positive the system is stable However for a well damped system PM should be between 30 degrees and 45 degrees The phase margin of 70 degrees given above indicated overdamped response Next we discuss the design of control systems System Design and Compensation The closed loop control system can be stabilized by a digital filter which is preprogrammed in the DMC 1600 controller The filter parameters can be selected by the user for the best compensation The following discussion presents an analytical design method The Analytical Method The analytical design method is aimed at closing the loop at a crossover frequency o with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Consider a system with the following parameters Kt Nm A Torque constant 174 e Chapter 10 Theory of Operation DMC 1600 DMC 1600 1 kg m System moment of inertia R 2 Q Motor resistance 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of the DMC 1600 outputs 10V for a 14 bit command of 8192 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of cy 500 rad s and a phase margin of 45 degrees The first step is to develop a mathematical model of the system as discussed in the previous system Motor M s
105. also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section 16 e Chapter 2 Getting Started DMC 1600 DMC 1600 Sometimes the feedback polarity 1s correct the motor does not attempt to run away but the direction of motion is reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals If the motor moves in the required direction but stops short of the target it is most likely due to insufficient torque output from the motor command signal ACMD This can be alleviated by reducing system friction on the motors The instruction TTX CR Tell torque on X reports the level of the output signal It will show a non zero value that is below the friction level Once you have established that you have closed the loop with the correct polarity you can move on to the compensation phase servo system tuning to adjust the PID filter parameters KP KD and KI It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section Chapter 2 Getting Started e 17 AUX encoder AUX encoder Reset Switch Error LED 100 pin high density connector input connector input connector AMP part 2 178238 9 DB25 female 26 pin header ae TEE NI gt gt gt lt gt
106. and 8 and designates 2 msec between data m is optional and specifies the number of elements to be captured If m is not defined the number of elements defaults to the smallest array defined by DM When m is a negative number the recording is done continuously in a circular manner RD is the recording pointer and indicates the address of the next array element n 0 stops recording Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Recording Lo om E Note X may be replaced by Y Z or W for capturing data on other axes Operand Summary Automatic Data Capture Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Returns address of next array element 142 e Chapter 7 Application Programming DMC 1600 Example Recording into An Array During a position move store the X and Y positions and position error every 2 msec RECORD DM XPOS 300 YPOS 300 DM XERR 300 YERR 300 RA XPOS XERR YPOS YERR RD TPX TEX TPY TEY PR 10000 20000 RCI BG XY A JP ZA RC 1 MG DONE EN PLAY N 0 JP DONE N gt 300 N X POS N Y POS N XERR N YERR N N N 1 DONE EN Deallocating Array Space Begin program Define X Y position arrays Define X Y error arrays Select arrays for capture Select data types Specify move distance Start recording now at rate of 2 msec Begin motion Loop until done Print message
107. aptured by the WSDK program This shows how the motion will be seen during the ECAM cycles The first graph is for the X axis the second graph shows the cycle on the Y axis and the third graph shows the cycle of the Z axis Three Storage Scopes File Collection Graph First Scope x Actual Position Zoom Normal Second Scope v Position Zoom Normal Y Third Scope z Position Zoom Normal Command String iStart Collecting Figure 6 5 WSDK program results Three Storage Scopes Contour Mode DMC 1600 The DMC 1600 also provides a contouring mode This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes This is ideal for following computer generated paths such as parabolic spherical or user defined profiles The path 1s not limited to straight line and arc segments and the path length may be infinite Specifying Contour Segments The Contour Mode is specified with the command CM For example CMXZ specifies contouring on the X and Z axes Any axes that are not being used in the contouring mode may be operated in other modes A contour is described by position increments which are described with the command CD x y z w over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2 ms where n is a number between 1 and 8 The controller performs linear interpolation betwe
108. ar segment is Le Xk Yk Where Xk and Yk are the changes in X and Y positions along the linear segment The length of the circular arc is Lx Ri A i 2 2 360 The total travel distance is given by D Y Lk k l The velocity profile may be specified independently in terms of the vector velocity and acceleration For example the velocity profile corresponding to the path of Fig A 2 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Fig A 3 Velocity 10000 time s T 0 05 T 0 357 Ta 0 407 a S Figure A 3 Vector Velocity Profile 196 e Appendices DMC 1600 DMC 1600 The acceleration time is given by VS 100000 VA 2000000 The slew time Ts is given by D _ 35708 VS 100000 The total motion time Tt is given by T d Ta 0 4075 VS 0 05s 0 05 0 3075 The velocities along the X and Y axes such that the direction of motion follows the specified path yet the vector velocity fits the vector speed and acceleration requirements For example the velocities along the X and Y axes for the path shown in Fig A 2 are given in Fig AA Fig A 4a shows the vector velocity It also indicates the position point along the path starting at A and ending at D Between the points A and B the motion is along the Y axis Therefore Vy Vs and Vx 0 Between the points B and C the velociti
109. are terminated when a transition in the Abort input is detected For information on setting the Off On Error function see the Command Reference OE Uncommitted Digital Inputs The DMC 1600 has 8 opto isolated inputs These inputs can be read individually using the function IN x where x specifies the input number 1 thru 8 These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller For example the user may wish to have the x axis motor move 1000 counts in the positive direction when the logic state of INI goes high IN9 IN16 INCOM 2 FLE RLE HOMEE LSCOM 2 FLF RLF HOMEF FLG RLG HOMEG FLH RLH HOMEH Note When using the ICM 1100 the INCOM is different for IN9 IN16 from IN1 IN8 A logic zero is generated when at least 1mA of current flows from the common to the input A positive voltage with respect to the input must be supplied at the common This can be accomplished by connecting a voltage in the range of 5V to 28V into INCOM of the input circuitry from a separate power supply DMC 1610 1620 1630 1640 controllers have 64 additional TTL I O The CO commands configures each set of 8 I O as inputs or outputs The DMC 16X8 use two 50 pin headers which connect directly via ribbon cable to an OPTO 22 24 I O or Grayhill Opto rack 32 I O The INI thru IN80 function checks the state of the inputs 1 thru 80 Wiring the Optoisolated Inputs Bi Directional
110. asking The DMC 1600 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 through 7 where 0 is the main thread Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The main thread differs from the others in the following ways 1 Only the main thread thread 0 may use the input command IN 2 When input interrupts are implemented for limit switches position errors or command errors the subroutines are executed as thread 0 To begin execution of the various programs use the following instruction XQ A Where n indicates the thread number To halt the execution of any thread use the instruction HXn where n is the thread number Note that both the XQ and HX commands can be performed by an executing program The example below produces a waveform on Output 1 independent of a move Task1 label ATO Initialize reference time CBI Clear Output 1 LOOP1 Loop label AT 10 Wait 10 msec from reference time SBI Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference Clear Output 1 JP ZLOOPI Repeat Loop1 120 e Chapter 7 Application Programming DMC 1600 TASK2 Task2 label XQ TASKI 1 Execute Task LOOP2 Loop label PR 1000 Define relative distance BGX Begin motion AMX After motion done WT 10 Wait 10 msec JP LOOP2 IN 2 1 Repeat motion unless Input 2 is lo
111. asy or equivalent is required Analysis and design tools as well as several design examples will be provided TIME 8 hours 8 00 am 5 00 pm PRODUCT WORKSHOP WHO SHOULD ATTEND Current users of Galil motion controllers Conducted at Galil s headquarters in Rocklin CA students will gain detailed understanding about connecting systems elements system tuning and motion programming This is a hands on seminar and students can test their application on actual hardware and review it with Galil specialists TIME Two days 8 30 am 5 00 pm Appendices e 199 Contacting Us Galil Motion Control 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 Internet address support galilmc com URL www galilmc com FTP galilmc com 200 Appendices DMC 1600 WARRANTY DMC 1600 All products manufactured by Galil Motion Control are warranted against defects in materials and workmanship The warranty period for controller boards is 1 year The warranty period for all other products is 180 days In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship a
112. at of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 kO resistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal 15 used by the controller to disable the motor This signal is labeled AMPENX for the X axis on the ICM 1900 and should be connected to the enable signal on the amplifier Note that many amplifiers designate this signal as the INHIBIT signal Use the command MO to disable the motor amplifiers check to insure that the motor amplifiers have been disabled often this is indicated by an LED on the amplifier This signal changes under the following conditions the watchdog timer activates the motor off command MO is given or the 1 command Enable Off On Error is given and the position error exceeds the error limit As shown in Figure 3 4 AEN can be used to disable the amplifier for these conditions DMC 1600 Chapter 2 Getting Started 13 The standard configuration of the AEN signal is TTL active high In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed if you are using the ICM 1900 interface board To change the polarity from active high 5 volts enable zero volts
113. ater efficiency and response time since the drivers do not have to poll the buffers for the data Additionally the interrupt method allows for data record caching The interrupt method uses bus level interrupts IRQ from the controller to notify the PC that data is available This requires that the Controller be configured with a valid interrupt line For DMC 1600 controllers the interrupt is configured automatically Firmware version 2 0m and greater is required for the communications interrupt method to be available For complete information on the different communications methods select the More Info button on the Communications parameters dialog box Data Record Cache Depth With the interrupt communications method enabled the driver will cache data records for retrieval via API function calls This makes it possible to not miss any data records even if the DR command has been configured to refresh the data record every two milliseconds For example a program could poll at a relatively long frequency say every 50 milliseconds and not miss any data The cache depth can be set when the interrupt communication method is selected The data record cache functions like a FIFO Reading the data records removes them from the cache If the cache is full and a new data record arrives from the controller the new data record is placed in the cache and the oldest data record in the cache is discarded If multiple handles to a contr
114. ates to a stop and defines this position as 0 The logic state of the Home input can be interrogated with the command MG HMX This command returns a 0 or 1 if the logic state is low or high respectively The state of the Home input can also be interrogated indirectly with the TS command For examples and further information about Homing see command HM FI FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state NOTE The response of the abort input is significantly different from the response of an activated limit switch When the abort input is activated the controller stops generating motion Chapter 3 Connecting Hardware e 33 commands immediately whereas the limit switch response causes the controller to make decelerated stop NOTE The effect of an Abort input is dependent on the state of the off on error function for each axis If the Off On Error function is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no longer under servo control If the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running
115. can be added on either the ICM 1900 J52 or the DMC 1600 This can also be done by connecting wires between the 5V supply and common signals using the screw terminals on the ICM 1900 or AMP 19X0 To close the circuit wire the desired input to any ground GND terminal or pin out Analog Inputs The DMC 1600 has eight analog inputs configured for the range between 10V and 10V The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 005 A 16 bit ADC is available as an option The impedance of these inputs is 10 KQ The analog inputs are specified as AN x where x is a number thru 8 Amplifier Interface The DMC 1600 analog command voltage AC MD ranges between 10V This signal along with GND provides the input to the power amplifiers The power amplifiers must be sized to drive the motors and load For best performance the amplifiers should be configured for a current mode of operation with no additional compensation The gain should be set such that a 10 Volt input results in the maximum required current The DMC 1600 also provides an amplifier enable signal AEN This signal changes under the following conditions the watchdog timer activates the motor off command MO is given or the 36 e Chapter 3 Connecting Hardware DMC 1600 OElcommand Enable Off On Error is given and the position error exceeds the error limit As shown in Figure 3 4 AEN can be used to disable the amplifier for these
116. cation is established by selecting the Terminal Menu Select the controller by highlighting it Once the entry has been selected click on the OK button If communication is established the terminal window will open and a colon prompt will be displayed From the top line of the terminal commands can be sent to the controller Command syntax 15 described in the Command Reference and later sections If you are not properly communicating with the controller the program will pause for 3 15 seconds The top of the screen will display the message Status not connected with Galil motion controller and the following error will appear STOP Unable to establish communication with the Galil controller A time out occurred while waiting for a response from the Galil controller If this message appears you must click OK Contact Galil if you are unable to communicate with your controller Step 6 Determine the Axes to be Used for Sinusoidal Commutation This step is only required when the controller will be used to control a brushless motor s with sinusoidal commutation The command BA is used to select the axes of sinusoidal commutation For example BAXZ sets X and Z as axes with sinusoidal commutation Notes on Configuring Sinusoidal Commutation The command BA reconfigures the controller such that it has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAX is given to a DMC 1640 c
117. ccurred C8 Excess position error D8 All axis motion complete D7 H axis motion complete D6 G axis motion complete D5 F axis motion complete D4 E axis motion complete D3 W axis motion complete D2 Z axis motion complete DI Y axis motion complete DO X axis motion complete The recommended method to utilize the interrupts in a host application is to use a pre defined interrupt service routine which on interrupt will automatically execute and return the Status Byte For example when using the ActiveX toolkit DMCShell control with VB the DMCShelll DMCInterrupt event procedure shown below will automatically execute and return the StatusByte in the argument This StausByte can then be used in a case structure as the key to notify the host application of a specific event or condition In this VB example below the event procedure will display a message box every time the X axis motion is complete assuming the command was sent to the controller Note the argument is returned as 208 since the status byte is returned as an integer i e DO hex 208 decimal Private Sub DMCShelll DMCInterrupt StatusByte As Integer If StatusByte 208 Then MsgBox X axis complete End If End Sub 56 e Chapter 4 Software Tools and Communications DMC 1600 Hardware Level Communications This section of the chapter describes in detail the structures used to communicate with the controller at the register interface level The information in this
118. ch a system can be divided into three levels as illustrated in Fig 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming The first level the closing of the loop assures that the motor follows the commanded position This is done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling is the generation of the desired position function This function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the loop forces the motor to follow the commanded position 164 e Chapter 10 Theory of Operation DMC 1600 The highest level of control is the motion program This can be stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000
119. command these remarks must not be included in the actual program Example 1 System Set up This example shows various ways to assign parameters Instruction Interpretation KP10 10 10 10 Set gains for a b c d or X Y Z W axes KP 10 Alternate method for setting gain on all axes KPX 10 Alternate method for setting X or A axis gain KPA 10 Alternate method for setting A or X axis gain KP 20 Set Y axis gain only Example 2 Profiled Move Objective Rotate the X axis a distance of 10 000 counts at a slew speed of 20 000 counts sec and an acceleration and deceleration rates of 100 000 counts s2 In this example the motor turns and stops Instruction Interpretation PR 10000 Distance SP 20000 Speed DC 100000 Deceleration AC 100000 Acceleration BG X Start Motion 24 e Chapter 2 Getting Started DMC 1600 Example 3 Multiple Axes Objective Move the four axes independently Instruction PR 500 1000 600 400 SP 10000 12000 20000 10000 AC 100000 10000 100000 100000 DC 80000 40000 30000 50000 Interpretation Distances of X Y Z W Slew speeds of X Y Z W Accelerations of X Y Z W Decelerations of X Y Z W Start X and Z motion Start Y and W motion BG XZ BG YW Example 4 Independent Moves The motion parameters may be specified independently as illustrated below Instruction Interpretation PR 300 600 Distances of Y and Z SP 2000 Slew speed of Y DC 80000 Deceleration of Y AC 100000 Acceleration of Y SP
120. conditions The standard configuration of the AEN signal is TTL active high In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be changed if you are using the ICM 1900 interface board To change the polarity from active high 5 volts enable zero volts disable to active low zero volts enable 5 volts disable replace the 7407 IC with a 7406 Note that many amplifiers designate the enable input as inhibit To change the voltage level of the AEN signal note the state of the resistor pack on the ICM 1900 When Pin 1 is on the 5V mark the output voltage is 0 5V To change to 12 volts pull the resistor pack and rotate 1t so that Pin 1 1s on the 12 volt side If you remove the resistor pack the output signal is an open collector allowing the user to connect an external supply with voltages up to 24V A resistor should be put in line with the 24V supply to regulate current to 15mA DMC 1600 100 PIN ICM 1900 ACMD INPUT ENABLE RIBBON Figure 3 4 Connecting AEN to an amplifier TTL Outputs DMC 1600 The DMC 1600 provides eight general use outputs an output compare and an error signal output The general use outputs are TTL and are accessible through the ICM 1900 as OUTI thru OUTS These outputs can be turned On and Off with the commands SB Set Bit CB Clear Bit OB Output Bit and OP Output Port For
121. counts inch The program below uses the variable LEN to length The IN command is used to prompt the operator to enter the length and the entered value is assigned to the variable LEN BEGIN LABEL AC 800000 Acceleration DC 800000 Deceleration SP 5000 Speed LEN 3 4 Initial length in inches CUT Cut routine All Wait for start signal IN enter Length IN LEN PR LEN 4000 Prompt operator for length in inches Specify position in counts BGX Begin motion to move material AMX Wait for motion done SBI Set output to cut WTI100 CBl Wait 100 msec then turn off cutter JP CUT Repeat process EN End program Inputting String Variables String variables with up to six characters may input using the specifier Sn where n represents the number of string characters to be input If n is not specified six characters will be accepted For example IN Enter X Y or Z V S specifies a string variable to be input Output of Data Numeric and String Numerical and string data can be output from the controller using several methods The message command MG can output string and numerical data Also the controller can be commanded to return the values of variables and arrays as well as other information using the interrogation commands the interrogation commands are described in chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data f
122. ction 100 pin high density connector 60 pin IDC 26 pin IDC 20 pin IDC 2 Binary and ASCII communication modes 198 e Appendices DMC 1600 List of Other Publications Step by Step Design of Motion Control Systems by Dr Jacob Tal Motion Control Applications by Dr Jacob Tal Motion Control by Microprocessors by Dr Jacob Tal Training Seminars DMC 1600 Galil a leader in motion control with over 200 000 controllers working worldwide has a proud reputation for anticipating and setting the trends in motion control Galil understands your need to keep abreast with these trends in order to remain resourceful and competitive Through a series of seminars and workshops held over the past 15 years Galil has actively shared its market insights in a no nonsense way for a world of engineers on the move In fact over 10 000 engineers have attended Galil seminars The tradition continues with three different seminars each designed for your particular skill set from beginner to the most advanced MOTION CONTROL MADE EASY WHO SHOULD ATTEND Those who need a basic introduction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30 pm ADVANCED MOTION CONTROL WHO SHOULD ATTEND Those who consider themselves a servo specialist and require an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of Motion Control Made E
123. cular cut is desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion is CCW ending at 3000 0 Note that the 0 position in the XY plane is in the X direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First X Y and Z are driven to the starting point and later the cut is performed Assume that the knife is engaged with output bit 0 Example program VM XYZ XY coordinate with Z as tangent TN 2000 360 500 2000 360 counts degree position 500 is 0 degrees in XY plane CR 3000 0 180 3000 count radius start at 0 and go to 180 CCW Chapter 6 Programming Motion e 85 VE End vector CBO Disengage knife PA 3000 0 TN Move X and Y to starting position move Z to initial tangent position BG XYZ Start the move to get into position AM XYZ When the move is complete SBO Engage knife WTS0 Wait 50 msec for the knife to engage BGS Do the circular cut AMS After the coordinated move is complete CBO Disengage knife MG ALL DONE EN End program Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION VM m n Specifies the axes for the planar motion where m and n represent the planar axes and p is the tangent axis Return coordinate of last point where m X Y Z or W Specifies arc segment where r is the radius is the starting angle and AO is the travel angle Positive direction is CCW sequence buffer Zero
124. current In the velocity mode a command signal of 10 Volts should run the motor at the maximum required speed Step by step directions on servo system setup are also included on the WSDK Windows Servo Design Kit software offered by Galil See section on WSDK for more details Check the Polarity of the Feedback Loop It is assumed that the motor and amplifier are connected together and that the encoder is operating correctly Step B Before connecting the motor amplifiers to the controller read the following discussion on setting Error Limits and Torque Limits Note that this discussion only uses the X axis as an example Step A Set the Error Limit as a Safety Precaution Usually there is uncertainty about the correct polarity of the feedback The wrong polarity causes the motor to run away from the starting position Using a terminal program such as DMCTERM the following parameters can be given to avoid system damage Input the commands ER 2000 lt CR gt Sets error limit on the X axis to be 2000 encoder counts OE 1 lt CR gt Disables X axis amplifier when excess position error exists If the motor runs away and creates a position error of 2000 counts the motor amplifier will be disabled Note This function requires the AEN signal to be connected from the controller to the amplifier Step B Set Torque Limit as a Safety Precaution DMC 1600 Chapter 2 Getting Started 15 To limit the maximum voltage signal to your amplifier
125. d A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Uncommitted inputs May be defined by the user to trigger events Inputs are checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W if the high speed position latch function is enabled High speed position latch to capture axis position within 20 nanoseconds on occurrence of latch signal AL command arms latch Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W Input 9 is latch E input 10 is latch F input 11 is latch G input 12 is latch H DMC 1600 Extended I O of the DMC 1600 Controller DMC 1600 The DMC 1600 controller offers 64 extended I O points which can be configured as inputs or outputs in 8 bit increments through software The I O points are accessed through a single 80 pin High Density connector Rev A amp B DMC 16x0 controllers used a 100 pin HD connector Configuring the I O of the DMC 1600 The 64 extended I O points of the DMC 1600 series controller can be configured in blocks of 8 The extended I O is denoted as bits 17 80 and blocks 2 9 The command CO is used to configure the extended I O as inputs or outputs in blocks of 8 bits The CO command has one field COn n is a decimal value which represents a binary number Each bit
126. d This includes drivers on NT4 0 and serial and Ethernet controllers on all operating systems The Diagnostics menu allows diagnostics to be stopped and started It also will load the diagnostics output file specified in the Tools Options menu to be loaded into the editor window for analysis The Test Controller command tests the current controller with a series of standard communication tests The Update Firmware command allows new firmware to be downloaded to the currently connected controller Selecting this command will cause a file open dialog box to open allowing the user to specify a HEX file to be specified for download The latest firmware files can be downloaded from Galil s website Causes the Data Record dialog box to be DMC 1600 displayed for the currently connected controller The dialog automatically configures itself to display the data record for each type of Galil Motion Controller Options The Options menu command causes the Options dialog to be displayed The Options dialog box allows several application options to be set These option settings are preserved between uses DMC Program Editor Window The Program Editor Window is used to create application programs DMC that are downloaded to the controller The editor window is also useful for uploading and editing programs already residing in the controller s memory This window has basic text editing features such as copy cut paste etc Also the
127. d a 1 64 microstepping drive for an axis with a 1 8 step motor and 4000 count rev encoder Note the necessary difference is with the YA command Full Stepping Drive X axis SETUP Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper 1 Step resolution of the full step drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis 104 e Chapter 6 Programming Motion DMC 1600 DMC 1600 WTS50 Allow slight settle time YSI Enable SPM mode Half Stepping Drive X axis SETUP OEI Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA2 Step resolution of the half step drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WTS50 Allow slight settle time YSI Enable SPM mode 1 64 Step Microstepping Drive X axis 5 OEI Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 Motor type set to stepper YA64 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WTS50 Allow slight settle time YSI Enable SPM mode Example Error Correction The following code demonstrates what is necessary to set up SPM mode for the X axis detect error stop t
128. d accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in Chapter 11 Command Summary Trippoints The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Tangent Motion Several applications such as cutting require a third axis i e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 1600 allows one axis to be specified as the tangent axis The VM command provides parameter specifications for describing the coordinated axes and the tangent axis m n p m n specifies coordinated axes p specifies tangent axis such as X Y Z W p N turns off tangent axis Before the tangent mode can operate it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m n command m defines the scale factor in counts degree and n defines the tangent position that equals zero degrees in the coordinated motion plane The operand TN can be used to return the initial position of the tangent axis Example Assume an XY table with the Z axis controlling a knife The Z axis has a 2000 quad counts rev encoder and has been initialized after power up to point the knife in the direction A 180 cir
129. d in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position 68 Chapter 5 Command Basics DMC 1600 DMC 1600 Format PF Variable Format VF and Leading Zeros LZ command See Chapter 7 and the Command Reference Summary of Interrogation Commands sc T n Ts For example the following example illustrates how to display the current position of the X axis TP X lt enter gt Tell position X 0000000000 Controllers Response TP XY lt enter gt Tell position X and Y 0000000000 0000000000 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PR 1000 Specify X only as 1000 PR 0 Specify Y only as 2000 PR 3000 Specify Z only as 3000 PR 4000 Specify W only as 4000 PR 2000 4000 6000 8000 Specify X Y Z and W PR 8000 9000 Specify Y and W only PR Request X Y Z W values PR Request Y value only The controller can also be interrogated with operands Operands Most DMC 1600 commands have corresponding operands that can be used for interrogation Operands must be used inside of valid DMC expressions For example to display the value of an operand the user could use the command MG operand Chapter 5 Command Basics e 69 of the co
130. d of Program To start the program command XQ Execute Program This program moves X to an initial position of 1000 and returns it to zero on increments of half the distance Note TPX is an internal variable which returns the value of the X position Internal variables may be created by preceding a DMC 1600 instruction with an underscore Example 15 Linear Interpolation Objective Move X Y Z motors distance of 7000 3000 6000 respectively along linear trajectory Namely motors start and stop together Instruction Interpretation LM XYZ Specify linear interpolation axes LI 7000 3000 6000 Relative distances for linear interpolation LE Linear End VS 6000 Vector speed VA 20000 Vector acceleration VD 20000 Vector deceleration BGS Start motion Example 16 Circular Interpolation Objective Move the XY axes in circular mode to form the path shown on Fig 2 4 Note that the vector motion starts at a local position 0 0 which is defined at the beginning of any vector motion sequence See application programming for further information Instruction Interpretation VM XY Select XY axes for circular interpolation VP 4000 0 Linear segment CR 2000 270 180 Circular segment VP 0 4000 Linear segment CR 2000 90 180 Circular segment VS 1000 Vector speed VA 50000 Vector acceleration VD 50000 Vector deceleration VE End vector sequence BGS Start motion Chapter 2 Getting Started 29 4000 4000 0 4000 2000
131. declare a variable of type HANDLEDMC a long integer and pass the address of that variable in the DMCOpen function If the DMCOpen function is successful the variable will contain the handle to the Galil controller which is required for all subsequent function calls The following simple example program written as a Visual C console application tells the controller to move the X axis 1000 encoder counts Remember to add DMC32 LIB to your project prior to compiling include windows h include dmccom h long rc HANDLEDMC hDmc HWND hWnd int main void Connect to controller number 1 50 e Chapter 4 Software Tools and Communications DMC 1600 rc DMCOpen 1 hWnd amp hDmc if rc DMCNOERROR char szBuffer 64 Move the X axis 1000 counts rc DMCCommand hDmc PR1000 BGX szBuffer sizeof szBuffer Disconnect from controller number 1 as the last action rc DMCClose hDmc return 0 Galil Communications with Visual Basic Dim Dim Dim Dim DMC 1600 Declare Functions To use the Galil communications API functions add the module file included in the C ProgramFiles Galil DMCWIN VB directory named DMCCOMAO BAS This module declares the routines making them available for the VB project To add this file select Add Module from the Project menu in VB5 6 Sending Commands in VB Most commands a
132. e command KS As mentioned earlier there will always be some amount of stepper motor smoothing The default value for KS is 2 which corresponds to a time constant of 6 sample periods Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver The pulses which are generated by the smoothing filter can be monitored by the command TD Tell Dual TD gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position For example DP 0 defines the reference position of the X axis to be zero 2 k Stepper Smoothing Filter Output Motion Profiler Output Buffer EL 3 Adds a Delay Stepper Driver Reference Position RP Step Count Register TD Note Although steps can be missed by over lapping moves when the last stepper motion has been completed the stepper will be in the correct position Motion Complete Trippoint When used in stepper mode the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position The MC trippoint Motion Complete is generally more useful than AM trippoint After Motion since the step pulses can be delayed from the commanded po
133. e motion use the instruction EG 2 Chapter 6 Programming Motion e 91 where x y z w are the master positions at which the corresponding slaves must be engaged If the value of any parameter is outside the range of one cycle the cam engages immediately When the cam is engaged the slave position is redefined modulo one cycle Step 7 Disengage the slave motion To disengage the cam use the command EQ x y Zw where x y z w are the master positions at which the corresponding slave axes are disengaged 3000 2250 1500 0 2000 4000 6000 Master X Figure 6 4 Electronic Cam Example This disengages the slave axis at a specified master position If the parameter 1s outside the master cycle the stopping is instantaneous To illustrate the complete process consider the cam relationship described by the equation Y 0 5 gt X 100 sin 0 18 X where X is the master with a cycle of 2000 counts The cam table can be constructed manually point by point or automatically by a program The following program includes the set up 92 e Chapter 6 Programming Motion DMC 1600 DMC 1600 The instruction EAX defines X as the master axis The cycle of the master is 2000 Over that cycle Y varies by 1000 This leads to the instruction EM 2000 1000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required
134. e of certain events such as motion complete or excess position error The DMC 1600 uses only one of the PC s interrupts however it 1s possible to interrupt on multiple conditions For this reason the controller provides a status byte register that contains a byte designating each condition The DMC 1600 provides an interrupt buffer that is 16 deep This allows for multiple interrupt conditions to be stored in sequence of occurrence without loss of data The DMC 1600 provides two command forms of interrupt functionality EI and UI Specific interrupt conditions can be enabled using the EI command or explicit user defined interrupts can be sent using the UI command Enabling Event Interrupts EI command To enable certain conditions use the command EIm n Where the first field m represents 16 bit value of conditions described in the table below For example to enable interrupts on X and Y motion complete and position error set E1515 i e 515 2 2 2 Once the EI command is enabled for a specific condition an interrupt will occur for every instance of that condition except for the items marked with an asterisk they must be re enabled after every occurrence 0 X motion complete Y motion complete 2 2 motion complete 3 Wmotoncompee 4 Emotion complete 5 Fmotoncompete 6 6 motion complete 8 motion complete ___ 9 Exesspostionemo 0 Lmiswih 12 PRee
135. e waiting for motion to be complete waiting for a specified amount of time to elapse or waiting for an input to change logic levels The DMC 1600 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the DMC 1600 can make decisions based on its own status or external events without intervention from a host computer Chapter 7 Application Programming 123 DMC 1600 Event Triggers Command AMXYZWorS ABCDEFGH AD X or Y or Z or W A or B or C or D or E or F or Gor H AR X or Y or Z or W A or B or Cor Dor E or F or Gor H AP X or Y or Z or W A or B or Cor Dor E or F or Gor H MF Xor Y or Z or W A or B or Cor or E or F or or H MR X or Y or Z or W A or B or Cor Dor E or F or Gor H MC X or Y or Z or W A or B or C or D or E or F or G or H ASXYZWS ABCDEFGH AT n 124 e Chapter 7 Application Programming Halts program execution until motion is complete on the specified axes or motion se
136. each axis of motion and a motor to transform the current from the amplifier into torque for motion Galil also offers the AMP 19X0 series Interface Modules which are ICM 1900 s equipped with servo amplifiers for brush type DC motors If you are using an ICM 1900 connect the 100 pin ribbon cable to the DMC 1600 and to the connector located on the AMP 19x0 or ICM 1900 board The ICM 1900 provides screw terminals for access to the connections described in the following discussion System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 1600 If sinusoidal commutation is to be used special attention must be paid to the reconfiguration of axes Here are the first steps for connecting a motion control system Step Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are operating properly the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller you need to verify that the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than th
137. ecomes full program execution will be delayed until it is cleared If the user wants to avoid this delay the command can be given This command causes the controller to throw away the data which can not be placed into the FIFO In this case the controller does not delay program execution Break and Single Step Commands The commands BK and SL can be used to single step through an application program See the command reference for details Error Code Command When there is a program error the DMC 1600 halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG The user can obtain information about the type of error condition that occurred by using the command TC1 This command reports back a number and a text message which describes the error condition The command or TC will return the error code without the text message For more information about the command TC see the Command Reference Chapter 7 Application Programming 121 Stop Code Command The status of motion for each axis can be determined by using the stop code command SC This can be useful when motion on an axis has stopped unexpectedly The command SC will return a number representing the motion status See the command reference for further information RAM Memory Interrogation Commands For debugging the status of the program memory array memory or variable mem
138. ection When using an isolated power supply do not connect the ground of the isolated power to the ground of the controller A power supply in the voltage range between 5 to 28 Volts may be applied directly see Figure 3 2 For voltages greater than 28 Volts a resistor R is needed in series with the input such that 1 mA V supply R 2 2KQ lt 15 mA DMC 1600 Chapter 3 Connecting Hardware e 35 LSCOM For UT gt 28V LSCOM For Voltages 28V PES AN 2 2K 2 2 Isolated Supply Supply Isolated E gt L_ FLS FLS Configuration to source current at the LSCOM Configuration to sink current at the LSCOM terminal and sink current at switch inputs terminal and source current at switch inputs Figure 3 2 Connecting a single Limit or Home Switch to an Isolated Supply NOTE As stated in Chapter 2 the wiring is simplified when using the ICM 1900 or AMP 19X0 interface board This board accepts the signals from the ribbon cables of the DMC 1600 and provides phoenix type screw terminals A picture of the ICM 1900 can be seen on pg 18 If an ICM 1900 is not used an equivalent breakout board will be required to connect signals from the DMC 1600 Bypassing the Opto Isolation If no isolation is needed the internal 5 Volt supply may be used to power the switches This can be done by connecting a jumper between the pins LSCOM or INCOM and 5V labeled JP3 These jumpers
139. ed and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A Start is the first element of array default 0 End is the last element of array default last element Chapter 7 Application Programming 141 Delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 The file is terminated using lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 1600 provides a special feature for automatic capture of data such as position position error inputs or torque This is useful for teaching motion trajectories or observing system performance Up to four types of data can be captured and stored in four arrays The capture rate or time interval may be specified Recording can done as a one time event or as a circular continuous recording Command Summary Automatic Data Capture COMMAND DESCRIPTION RA n m o p Selects up to four arrays for data capture The arrays must be defined with the DM command RD typel type2 type3 type4 Selects the type of data to be recorded where typel type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command The RC command begins data collection Sets data capture time interval where nis an integer between 1
140. ed by sending at the end of the statement This is useful when a text string needs to surround a numeric value Example HA JG 50000 BGX ASX MG The Speed is TVX F5 1 MG counts sec EN When is executed the above example will appear on the screen as The speed 1s 50000 counts sec Using the MG Command to Configure Terminals The MG command can be used to configure a terminal Any ASCII character can be sent by using the format n where n is any integer between 1 and 255 Example MG 407 255 sends the ASCII characters represented by 7 and 255 to the bus Chapter 7 Application Programming e 145 Summary of Message Functions FUNCTION DESCRIPTION Fn m Formats numeric values in decimal n digits to the right of the decimal point and m digits to the left Sends ASCII character specified by integer N Suppresses carriage return line feed Sn Sends the first n characters of a string variable where n is 1 thru 6 Formats numeric values in hexadecimal Displaying Variables and Arrays Variables and arrays may be sent to the screen using the format variable or array x For example V1 returns the value of V1 Example Printing a Variable and an Array element DISPLAY Label DM POSX 7 Define Array POSX with 7 entries PR 1000 Position Command BGX Begin AMX After Motion 1 Assign Variable V1 POSX 0 TPX Assign the first entry 1 Print V1 Interrogation Commands
141. ell as retrieving the IRQ status byte The secondary FIFO for accessing the data record occupies address N C Communication Registers ON Rea wie we For FIFO satus convoi __ Read Wrie For IRO wats byte and controller reset N N 4 N 8 C Simplified Communication Procedure The simplest approach for communicating with the DMC 1800 is to check bits 0 and 2 of the CONTROL register at address N 4 Bit 0 is for WRITE STATUS and bit 2 is for READ STATUS Read Procedure To receive data from the DMC 1800 read the control register at address N 4 and check bit 2 If bit 2 is zero the DMC 1600 has data to be read in the READ register at address N Bit 2 must be checked for every character read DMC 1600 Chapter 4 Software Tools and Communications e 57 Write Procedure To send data to the DMC 1800 read the control register at address 4 and check bit 0 If bit 0 is zero the DMC 1600 FIFO buffer is not full and a character may be written to the WRITE register at address If bit 0 is one the buffer is full and any additional data will be lost Any high level computer language such as C Basic Pascal or Assembly may be used to communicate with the DMC 1600 as long as the READ WRITE procedure is followed as described above so long as the base address 15 known FIFO Control Register at N 4 Read Only If 1 Secondary FIFO empty
142. ement number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples DM SPEED 10 Dimension Speed Array SPEED 1 7650 2 Assigns the second element of the array SPEED the value 7650 2 SPEED 1 Returns array element value POSX 10 TPX Assigns the 11th element of the array POSX the returned value from the tell position command CON 2 QCOS POS 2 Assigns the third element of the array CON the cosine of the variable POS multiplied by 2 TIMER 1 TIME Assigns the second element of the array timer the returned value of the TIME keyword Using a Variable to Address Array Elements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter For example HA Begin Program COUNT 0 DM POS 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec POS COUNT TPX Record position into array element POS COUNT Report position COUNT COUNT 1 Increment counter JP LOOP COUNT lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named POS The variable COUNT is used to increment the array element counter The above example can also be executed with the automatic data capture feature described below Uploading and Downloading Arrays to On Board Memory Arrays may be upload
143. en the specified increments where one point is generated for each millisecond Consider for example the trajectory shown in Fig 6 4 The position X may be described by the points Chapter 6 Programming Motion e 95 Point 1 X 0 at T 0ms Point 2 X 48 at T 4ms Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 DX 48 Time 4 DT 2 Increment 2 DX 240 Time 8 DT 3 Increment 3 DX 48 Time 16 DT 4 When the controller receives the command to generate a trajectory along these points it interpolates linearly between the points The resulting interpolated points include the position 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are A CMX Specifies X axis for contour mode DT2 Specifies first time interval 2 ms CD 48 WC Specifies first position increment DT3 Specifies second time interval 2 ms CD 240 WC Specifies second position increment DT 4 Specifies the third time interval 2 ms CD 48 WC Specifies the third position increment Exits contour mode EN POSITION COUNTS ee 1 E 240 192 96 48 TIME ms 0 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 6 The Required Trajectory 96 e Chapter 6 Programming Motion DMC 1600 DMC 1600 Additional Commands The command WC is used as a trippoint When Comple
144. equest action to occur on an axis or group of axes For example ST XY stops motion on both the X and Y axes Commas are not required in this case since the particular axis is specified by the appropriate letter X Y Z or W If no parameters follow the instruction action will take place on all axes Here are some examples of syntax for requesting action BGX Begin X only BG Y Begin Y only BG XYZW Begin all axes BG YW Begin Y and W only BG Begin all axes BG ABCDEFGH Begin all axes BGD Begin D only Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S is used to specify the coordinated motion For example BGS Begin coordinated sequence BGSW Begin coordinated sequence and W axis DMC 1600 Chapter 5 Command Basics e 65 Command Syntax Binary Some commands have an equivalent binary value Binary communication mode can be executed much faster than ASCII commands Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format binary commands have a 4 byte header and are followed by data fields The 4 bytes are specified in hexadecimal format Header Format Byte 1 specifies the command number between 80 to FF The complete binary command number table 1s listed below Byte 2 specifies the of bytes in each field as 0 1 2 4 or 6 as follows 00 No data fields 1 e SH or BG 01 One byte per field 02 O
145. er 7 Application Programming DMC 1600 DMC 1600 parameter o is an interrupt mask If m and n are unused o contains a number with the mask A 1 designates that input to be enabled for an interrupt where 20 is bit 1 2 is bit 2 and so on For example II 5 enables inputs 1 and 3 20 22 5 A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RI command is used to return from this subroutine to the place in the program where the interrupt had occurred If it is desired to return to somewhere else in the program after the execution of the ININT subroutine the Zero Stack ZS command is used followed by unconditional jump statements IMPORTANT Use the RI instruction not EN to return from the ININT subroutine Examples Input Interrupt A JG 30000 20000 BG XY B TP XY WT 1000 JP 4B EN ININT MG Interrupt has occurred ST XY LOOP JP LOOP IN 1 0 JG 15000 10000 WT 300 BG XY RI Analog Inputs Label A Enable input 1 for interrupt function Set speeds on X and Y axes Begin motion on X and Y axes Label 4B Report X and Y axes positions Wait 1000 milliseconds Jump to B End of program Interrupt subroutine Displays the message Stops motion on X and Y axes Loop until Interrupt cleared Specify new speeds Wait 300 milliseconds Begin motion on X and Y axes Return from Interrupt subroutine The DMC 16
146. er Gnd 3 4 5 Power Gind High Volt DC Power Supply Figure 2 3 System Connections with a separate amplifier MSA 12 80 This diagram shows the connections for a standard DC Servo Motor and encoder Chapter 2 Getting Started 19 Step 8b Connect Sinusoidal Commutation Motors When using sinusoidal commutation the parameters for the commutation must be determined and saved in the controller s non volatile memory The servo can then be tuned as described in Step 9 Step A Disable the motor amplifier Use the command MO to disable the motor amplifiers For example MOX will turn the X axis motor off Step B Connect the motor amplifier to the controller The sinusoidal commutation amplifier requires 2 signals usually denoted as Phase A amp Phase B These inputs should be connected to the two sinusoidal signals generated by the controller The first signal is the axis specified with the command BA Step 6 The second signal is associated with the highest analog command signal available on the controller note that this axis was made unavailable for standard servo operation by the command BA When more than one axis is configured for sinusoidal commutation the controller will assign the second phase to the command output which has been made available through the axes reconfiguration The 2 phase of the highest sinusoidal commutation axis will be the highes
147. erpolation eese ener 29 Example 16 Circular Interpolation essere 29 Chapter 3 Connecting Hardware 32 OVet VIEW dst tM ot oe Mese ire ER 32 000000000 32 32 Home Switch Input eene nennen 33 33 Uncommitted Digital Inputs nennen ener 34 nennen nennen 34 Using an Isolated Power Supply cccccceccceesseessessceesceeecesecesecenecseecaeeeaeeeaeeeeeeneeeneeees 35 enne 36 Analog ee neret eei e eie De Ee e e eden 36 Amplifier Interface eh ape eee P o ge o des 36 TTLEQUutputsz2 iet ette te eere tr eth rete eei Hrs 37 Chapter 4 Software Tools and Communications 38 Introductio uode eb 2 38 Galil Smart TERM 2 gne ete gis ED UEM Me PEERS 39 Communication Settings ended ete eee deae esie eine de desee eR ua 44 Windows Servo Design Kit WSDK sss 48 Creating Custom Software 49 DOS Linux and QNX TOOIS ss ee ete RE ER LEV Ee E RETE URS 52 Command Format and Controller Response sess nnns 53 Binary Command Format e rne nete eg terre re erc eee 53 Controller Event Interrupts and User Interrupts esses 55 Hardware Level Communications esee eene nennen 57 Determining the Base Address sees 57 Communication 1 57 Secondary
148. errupt or automatic routine such as or ZLIMSWI is executed the subroutine stack is incremented by 1 Normally the stack 1s restored with an EN instruction Occasionally it is desirable not to return back to the program line where the subroutine or interrupt was called The ZS1 command clears 1 level of the stack This allows the program sequencer to continue to the next line The 750 command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is often desirable to restart the program sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of LIMSWI routine Auto Start Routine The DMC 1600 has a special label for automatic program execution A program which has been saved into the controllers non volatile memory can be automatically executed upon power up or reset by beginning the program with the label HAUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 1600 program sequences The DMC 1600 can monitor several important conditions in the background These conditions include checking for the occurrence of a limit switch a defined input position error or a command error Automatic monitoring is enabled by inserting a special predefined labe
149. es vary gradually and finally between the points C and D the motion is in the X direction B time Figure 4 Vector and Axes Velocities Appendices e 197 DMC 1600 DMC 1000 Comparison BENEFIT DMC 1600 DMC 1000 Higher Speed communication Frees host Two communication channels MAIN amp Only one channel FIFO Secondary FIFO Easy to install self configuring Plug and Play No Plug and Play Programs don t have to be downloaded from Non Volatile Program Storage No storage for programs PC but can be stored on controller Can capture and save array data Variable storage No storage for variables Parameters can be stored Array storage No storage for arrays Firmware can be upgraded in field without Flash memory for firmware EPROM for firmware which must be removing controller from PC installed on controller Faster servo operation good for very high 12 MHz encoder speed for servos 8 MHz resolution sensors Faster stepper operation 3 MHz stepper rate Higher servo bandwidth 62 usec axis sample time 125 usec axis Expanded memory lets you store more 1000 lines X 80 character program memory 500 line X 40 character programs Expanded variables 254 symbolic variables 126 variables Expanded arrays for more storage great for 8000 array elements in 30 arrays 1600 elements in 14 arrays data capture Higher resolution for analog inputs 8 analog inputs with 16 bit ADC option 7 inputs with 12 bit ADC only Better for EMI redu
150. escribed above Method 2 Drive the motor close to commutation phase of zero and then use BZ command This method decreases the amount of system jerk by moving the motor close to zero commutation phase before executing the BZ command The controller makes an estimate for the number of encoder counts between the current position and the position of zero commutation phase This value is stored in the operand _BZx Using this operand the controller can be commanded to move the motor The BZ command is then issued as described above For example to initialize the X axis motor upon power or reset the following commands may be given SHX Enable X axis motor PRX 1 _ BZX Move X motor close to zero commutation phase BGX Begin motion on X axis AMX Wait for motion to complete on X axis BZX 1 Drive motor to commutation phase zero and leave the motor on Method 3 Use the command BC This command uses the hall transitions to determine the commutation phase Ideally the hall sensor transitions will be separated by exactly 60 and any deviation from 60 will affect the accuracy of this method If the hall sensors are accurate this method is recommended The BC command monitors the hall sensors during a move and monitors the Hall sensors for a transition point When that occurs the controller computes the commutation phase and sets it For example to initialize the X axis motor upon power or reset the following commands may be given SHX Enable
151. f the temperature control the delay is due to the water flowing in the pipes When the human reaction is too strong the response becomes unstable Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which is designed to help the stability and accuracy Typically such a filter produces in addition to the proportional gain damping and integrator The combination of the three functions is referred to as a PID filter The filter parameters are represented by the three constants KP KI and KD which correspond to the proportional integral and derivative term respectively The damping element of the filter acts as a predictor thereby reducing the delay associated with the motor response The integrator function represented by the parameter KI improves the system accuracy With the KI parameter the motor does not stop until it reaches the desired position exactly regardless of the level of friction or opposing torque The integrator also reduces the system stability Therefore it can be used only when the loop is stable and has a high gain The output of
152. figured as an input Connector Description The extended I O connector is a single 100 pin High Density Connector used on Revs A amp B versions of the DMC 16x0 J101 100 PIN HIGH DENSITY Pin Signa Bloc Bit IN n Bit 1 k OUT n No 1 4 40 7 3 4 39 6 5 Vo 4 38 5 7 4 37 4 9 4 36 3 11 4 35 2 13 4 34 1 184 Appendices DMC 1600 33 32 31 IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO T5V IO IO IO IO IO IO IO IO 15 17 19 21 30 29 28 23 25 27 27 26 29 31 25 24 23 33 35 22 21 375 39 41 20 19 18 17 43 45 47 49 48 47 46 45 44 10 12 14 16 18 20 43 42 41 GND GND GND 22 GND 24 26 GND GND 28 GND 30 32 34 36 38 40 GND GND GND GND GND GND 42 GND 44 46 48 GND GND GND IO IO 50 5 72 71 53 Appendices 185 DMC 1600 70 69 68 67 66 65 IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO T5V IO IO IO IO IO IO IO IO 55 574 59 61 63 65 64 63 67 69 71 62 61 73 60 59 58 57 56 55 54 53 52 51 75 77 79 81 83 85 87 89 91 93 50 49 95 97 99 80 79 78 52 54 56 58 60 62 64 66 68 77 76 75
153. for full voltage and the sign of the Motor Command is available at the sign output For step motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Upon Reset the output will be low if the SM jumper is on If the SM jumper is not on the output will be tristate Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER These 8 TTL outputs are uncommitted and may be designated by the user to toggle relays and trigger external events The output lines are toggled by Set Bit SB and Clear Bit CB instructions The OP instruction is used to define the state of all the bits of the Output port Appendices e 181 Inputs Encoder Encoder Index I Encoder A B I Auxiliary Encoder Aux A Aux B Aux I Aux A Aux B Aux I Abort Reset Forward Limit Switch Reverse Limit Switch Home Switch Input 1 Input 8 Isolated Input 17 Input 80 TTL Latch 182 e Appendices Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximum frequency does not exceed 12 000 000 quadrature states sec The controller performs quadrature decoding
154. for stop signal Disengage slave End The following example illustrates a cam program with a master axis Z and two slaves X and Y Instruction A V1 0 PA 0 0 BGXY AMXY 7 0 0 4000 EP400 0 ET 0 0 0 ET 1 40 20 ET 2 120 60 ET 3 240 120 ET 4 280 140 ET 5 280 140 ET 6 280 140 ET 7 240 120 ET 8 120 60 ET 9 40 20 ET 10 0 0 EB 1 JGZ 4000 EG 0 0 BGZ ZLOOP JPZLOOP V1 0 EQ2000 2000 MF 2000 STZ EB 0 EN 94 e Chapter 6 Programming Motion Interpretation Label Initialize variable Go to position 0 0 on X and Y axes Z axis as the Master for ECAM Change for Z is 4000 zero for X Y ECAM interval is 400 counts with zero start When master is at 0 position 1st point 2nd point in the ECAM table 3rd point in the ECAM table 4th point in the ECAM table 5th point in the ECAM table 6th point in the ECAM table 7th point in the ECAM table 8th point in the ECAM table 9th point in the ECAM table 10th point in the ECAM table Starting point for next cycle Enable ECAM mode Set Z to jog at 4000 Engage both X and Y when Master 0 Begin jog on Z axis Loop until the variable is set Disengage X and Y when Master 2000 Wait until the Master goes to 2000 Stop the Z axis motion Exit the ECAM mode End of the program DMC 1600 The above example shows how the program is structured and how the commands can be given to the controller The next page provides the results c
155. g you can increase KD maximum is 4095 Increase gradually and stop after the motor vibrates A vibration is noticed by audible sound or by interrogation If you send the command TE X CR Tell error Chapter 2 Getting Started 23 a few times and get varying responses especially with reversing polarity it indicates system vibration When this happens simply reduce KD Next you need to increase the value of KP gradually maximum allowed is 1023 You can monitor the improvement in the response with the Tell Error instruction KP 10 CR Proportion gain TE X CR Tell error As the proportional gain is increased the error decreases Again the system may vibrate if the gain 1s too high In this case reduce Typically KP should not be greater than KD 4 Only when the amplifier is configured in the current mode Finally to select KI start with zero value and increase it gradually The integrator eliminates the position error resulting in improved accuracy Therefore the response to the instruction TE X CR becomes zero As KI is increased its effect is amplified and it may lead to vibrations If this occurs simply reduce KI Repeat tuning for the Y Z and W axes For a more detailed description of the operation of the PID filter and or servo system theory see Chapter 10 Theory of Operation Design Examples Here are a few examples for tuning and using your controller These examples have remarks next to each
156. he DMC 1600 in the PC sss 11 Step 5 Establish Communication using Galil Software sss 11 Step 6 Determine the Axes to be Used for Sinusoidal Commutation 12 Step 7 Make Connections to Amplifier and Encoder sss 13 Step 8a Connect Standard Servo Motors 15 Step 8b Connect Sinusoidal Commutation Motors sse 20 Step 8c Connect Step Motors 23 ene 23 Design Examples 2 o tene des testes rp Cdi ut t eso D tt 24 Example 1 System Set up sse ener 24 Example 2 Profiled Move sssssssssssssesseeeeeneneneeeren rennen enne 24 DMC 1600 Contents ei Example3 Multiple Axes eset hed 25 Example 4 Independent Moves 25 Example 5 Position Interrogation eese eene 25 Example 6 Absolute Position nee eerte er E eh deena bed 26 Example 7 Velocity Control nonae tenerte Re PIER diente A 26 Example 8 Operation Under Torque Limit eene 26 9 27 Example 10 Operation in the Buffer Mode esee 27 Example 11 Using the On Board Editor sse 27 Example 12 Motion Programs with Loops eene ene 27 Example 13 Motion Programs with Trippoints esee 28 Example 14 Control Variables 7 28 Example 15 Linear Int
157. he motor correct the error and return to the main code The drive is a full step drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to stop axis upon error KS16 Set step smoothing MT 2 2 2 2 Motor type set to stepper YA2 Step resolution of the drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution Chapter 6 Programming Motion e 105 SHX Enable axis WT100 Allow slight settle time Perform motion SP512 Set the speed PR1000 Prepare mode of motion BGX Begin motion ZLOOP JPZLOOP Keep thread zero alive for POSERR to run in REM When error occurs the axis will stop due to OE1 In REM POSERR query the status YS and the error QS correct REM and return to the main code POSERR Automatic subroutine is called when YS 2 WT100 Wait helps user see the correction spsave _SPX Save current speed setting JP RETURN YSX lt gt 2 Return to thread zero if invalid error SP 64 Set slow speed setting for correction MG ERROR QSX YRX QSX Else error is valid use QS for correction MCX Wait for motion to complete MG CORRECTED ERROR NOW QSX WT100 Wait helps user see the correction RETURN SPX spsave Return the speed to previous setting REO Return from POSERR Example Friction Correction The following example illustrates how the SPM mode can be useful in correcting for X axis friction after each
158. he phase to zero The BZ command argument is a real number which represents the voltage to be applied to the amplifier during the initialization When the voltage is specified by a positive number the initialization process will end in the motor off MO state A negative number causes the process to end in the Servo Here SH state Chapter 2 Getting Started e 21 Warning This command must move the motor to find the zero commutation phase This movement is instantaneous and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The applied voltage will typically be sufficient for proper operation of the BZ command For systems with significant friction this voltage may need to be increased and for systems with very small motors this value should be decreased For example BZ 2 will drive the X axis to zero using a 2V signal The controller will then leave the motor enabled For systems that have external forces working against the motor such as gravity the BZ argument must provide a torque 10x the external force If the torque is not sufficient the commutation zero may not be accurate If Hall Sensors are Available The estimated value of the commutation phase is good to within 30 This estimate can be used to drive the motor but a more accurate estimate 1s needed for efficient motor operation There are 3 possible methods for commutation phase initialization Method 1 Use the BZ command as d
159. highest available DAC on the controller For example Using a DMC 1640 the command BAX will configure the X axis to be the main sinusoidal signal and the W axis to be the second sinusoidal signal The BA command also reconfigures the controller to indicate that the controller has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAX is given to a DMC 1640 controller the controller will be re configured to a DMC 1630 controller By definition DMC 1630 controls 3 axes X Y and Z The W axis is no longer available since the output DAC is being used for sinusoidal commutation Chapter 2 Getting Started 9 Further instruction for sinusoidal commutation connections are discussed in Step 6 Stepper Motor Operation To configure the DMC 1600 for stepper motor operation the controller requires a jumper for each stepper motor and the command MT must be given The installation of the stepper motor jumper is discussed in the following section entitled Installing Jumpers on the DMC 1600 Further instructions for stepper motor connections are discussed in Step 8c Step 2 Install Jumpers on the DMC 1600 Master Reset and Upgrade Jumpers JP1 contains two jumpers MRST and UPGRD The MRST jumper is the Master Reset jumper With MRST connected the controller will perform a master reset upon PC power up or upon the reset input going low Whenever the controller has a master reset all
160. his constant speed and then decelerate such that the final position agrees with the command position PR The Z axis accelerates but before the specified speed 15 achieved must begin deceleration such that the axis will stop at the commanded position All 3 axes have the same acceleration and deceleration rate hence the slope of the rising and falling edges of all 3 velocity profiles are the same Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion The user specifies the jog speed JG acceleration AC and the deceleration DC rate for each axis The direction of motion is specified by the sign of the JG parameters When the begin command is given BG the motor accelerates up to speed and continues to jog at that speed until a new speed or stop ST command is issued If the jog speed is changed during motion the controller will make a accelerated or decelerated change to the new speed An instant change to the motor position can be made with the use of the IP command Upon receiving this command the controller commands the motor to a position which 1s equal to the specified increment plus the current position This command is useful when trying to synchronize the position of two motors while they are moving Note that the controller operates as a closed loop position controller while in the jog mode The DMC 1600 converts the velocity profile into a posi
161. if there is any significant difference between the commanded and the actual motor positions If such error is detected it is updated into a command value for operator use In addition the SPM mode can be used as a method to correct for friction at the end of a microstepping move This capability provides closed loop control at the application program level SPM mode can be used with Galil and non Galil step drives SPM mode is configured executed and managed with seven commands This mode also utilizes the POSERR automatic subroutine allowing for automatic user defined handling of an error event Internal Controller Commands user can query QS Error Magnitude pulses User Configurable Commands user can query amp change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status Chapter 6 Programming Motion e 103 A pulse is defined by the resolution of the step drive being used Therefore one pulse could be full step a half step or a microstep When a Galil controller is configured for step motor operation the step pulse output by the controller is internally fed back to the auxiliary encoder register For SPM the feedback encoder on the stepper will connect to the main encoder port Enabling the SPM mode on a controller with
162. ill accept a string input of up to 6 characters parse each character and then display each character Notice also that the values used for masking are represented in hexadecimal as denoted by the preceding For more information see section Sending Messages To illustrate further if the user types in the string at the input prompt the controller will respond with the following T Response from command MG LEN6 S41 E Response from command MG LENS 54 S Response from command MG LENA S4 T Response from command MG LEN3 54 M Response from command MG LEN2 S4 E Response from command MG LENI 54 Functions FUNCTION DESCRIPTION SIN n Sine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution COS n Cosine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution TAN n Tangent of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution ASIN n Arc Sine of n between 90 and 90 Angle resolution in 1 64000 degrees ACOS n Arc Cosine of n between 0 and 180 Angle resolution in 1 64000 degrees ATAN n Arc Tangent of n between 90 and 90 Angle resolution in 1 64000 degrees COM n 1 s Complement of n FRAC n Fraction portion of n INT n Integer portion of n RND n Round of n Rounds up if the fractional part of n is 5 or greater ABS n Absolute value of n SQR n Square root of n
163. in parentheses in hexadecimal format Binary communication mode can be executed much faster than ASCII commands since the controller does not have to first decode the ASCII characters Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format binary commands have a 4 byte header followed by data fields The 4 bytes are specified in hexadecimal format Binary Header Format Byte 1 specifies the hexadecimal command number between 80 to FF Byte 2 specifies the of bytes in each field as 0 1 2 4 or 6 as follows 00 No datafields i e SH or BG 01 One byte per field 02 One word 2 bytes per field 04 One long word 4 bytes per field 06 Galil real format 4 bytes integer and 2 bytes fraction Byte 3 specifies whether the command applies to coordinated motion on the S or axis as follows Bit l T axis coordinated motion movement Bit 0 S axis coordinated motion movement DMC 1600 Chapter 4 Software Tools and Communications e 53 For example the command STS commands motion to stop on the S axis vector motion The third byte for the equivalent binary command would then be 01 Byte 4 specifies the axis or data field as follows Bit 7 axis or 8 data field Bit 6 axis or 7 data field Bit 5 F axis or 6 data field Bit 4 E axis or 5 data field Bit 3 axis or 4 data field Bit 2 C axis or 3 data field B
164. incremental position movement IP may be specified during motion as long as the additional move is in the same direction Here the user specifies the desired position increment n The new target is equal to the old target plus the increment n Upon receiving the IP command a revised profile will be generated for motion towards the new end position The IP command does not require a begin Note If the motor is not moving the IP command is equivalent to the PR and BG command combination Command Summary Independent Axis COMMAND BG XYZ STXYZW MCXY2W The lower case specifiers x y z w represent position values for each axis The DMC 1600 also allows use of single axis specifiers such as PRY 2000 74 e Chapter 6 Programming Motion DMC 1600 DMC 1600 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the speed for the axis specified by x Pax Returns current destination if x axis is moving otherwise returns the current commanded position if in a move Returns current incremental distance specified for the x axis Example Absolute Position Movement PA 10000 20000 AC 1000000 1000000 DC 1000000 1000000 SP 50000 30000 BG XY Specify absolute X Y position Acceleration for X Y Deceleration for X Y Speeds for X Y Begin motion Examp
165. ing Command Format IF ELSE and ENDIF FORMAT DESCRIPTION IF conditional statement s Execute commands proceeding IF command up to ELSE command if conditional statement s is true otherwise continue executing at ENDIF command or optional ELSE command ELSE Optional command Allows for commands to be executed when argument of IF command evaluates not true Can only be used with IF command ENDIF Command to end IF conditional statement Program must have an ENDIF command for every IF command 130 e Chapter 7 Application Programming DMC 1600 DMC 1600 Example using IF ELSE and ENDIF TEST 3 MG WAITING FOR INPUT 1 INPUT 2 LOOP JP LOOP EN ININT IF N 1 0 IF IN 2 0 MG INPUT 1 AND INPUT 2 ARE ACTIVE ELSE MG ONLY INPUT 1 IS ACTIVE ENDIF ELSE MG ONLY INPUT 2 IS ACTIVE ENDIF WAIT JP4WAIT GIN 1 0 IN 2 0 RIO Subroutines Begin Main Program TEST Enable input interrupts on input 1 and input 2 Output message Label to be used for endless loop Endless loop End of main program Input Interrupt Subroutine IF conditional statement based on input 1 2 IF conditional statement executed if 1 IF conditional true Message to be executed if 2 IF conditional is true ELSE command for 2 IF conditional statement Message to be executed if 27 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 1 IF c
166. input voltage Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec Chapter 7 Application Programming e 155 The program reads the input voltage periodically and assigns its value to the variable VIN To get a speed of 200 000 ct sec for 10 volts we select the speed as Speed 20000 x VIN The corresponding velocity for the motor is assigned to the VEL variable Instruction HA JGO BGX B VIN AN 1 VEL VIN 20000 JG VEL JP B EN Position Control by Joystick This system requires the position of the motor to be proportional to the joystick angle Furthermore the ratio between the two positions must be programmable For example if the control ratio is 5 1 it implies that when the joystick voltage is 5 Volts corresponding to 1028 counts the required motor position must be 5120 counts The variable V3 changes the position ratio Instruction Function A Label V3 5 Initial position ratio DPO Define the starting position JGO Set motor in jog mode as zero BGX Start B V1 AN 1 Read analog input V2 V1 V3 Compute the desired position V4 V2 _TPX _TEX Find the following error V5 V4 20 Compute a proportional speed JG V5 Change the speed JP B Repeat the process EN End Backlash Compensation by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective wa
167. ions DEX The command TD XYZW returns the current position of the auxiliary encoder The command DV XYZW configures the auxiliary encoder to be used for backlash compensation Backlash Compensation There are two methods for backlash compensation using the auxiliary encoders 1 7Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies 108 Chapter 6 Programming Motion DMC 1600 DMC 1600 the KP proportional and KI integral terms to the position error based on the load encoder
168. ions e 45 Controller Communications Parameters x General Parameters PCI Bus Parameters Communication Method Controller DMC 1800 Timeout 5000 milliseconds Figure 4 4 General Communications Parameters Dialog Advanced communications settings are available under the Communications Method tab to allow different methods of communications to be utilized shown in Fig 4 5 The version 7 and higher drivers and DLL s allow for three different methods of communications Interrupt Stall and Delay Controller Communications Parameters General Parameters PCI Bus Parameters Communication Method Select the communication method that the device driver will use to send commands to the controller Use Communication Interrupts This is the best overall Data A he Dep 50 4 Data Record s c Stall Thread This method is fast but results in 100 CPU utilization if polling continuously Delay Thread This method in most cases is slower but is has negligible impact on CPU More Info utilization Figure 4 5 Controller Communications Method Dialog Box 46 e Chapter 4 Software Tools and Communications DMC 1600 Interrupt Communications Method The interrupt method overall is the most efficient of the three methods The software communications method uses a hardware interrupt to notify the application that a response or unsolicited data is available This allows for gre
169. ire program 15 5 Begin listing at line 5 15 5 9 List lines 5 thru 9 185 A 9 List line label A thru line 9 LS ZA A 5 List line label A and additional 5 lines Program Format A DMC 1600 program consists of DMC 1600 instructions combined to solve a machine control application Action instructions such as starting and stopping motion are combined with DMC 1600 Chapter 7 Application Programming 117 Program Flow instructions to form the complete program Program Flow instructions evaluate real time conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 1600 instruction in a program must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 80 characters A carriage return enters the final command on a program line Using Labels in Programs DMC 1600 programs must begin with a label and end with an End EN statement Labels start with the pound 7 sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted The maximum number of labels which may be defined is 254 Valid labels BEGIN SQUARE X1 BEGIN1 Invalid labels 1 Square 123 A Simple Example Program START Beginning of the Program PR 10000 20000
170. is K 20 65536 0 0003 V count Digital Filter The digital filter has three element in series PID low pass and a notch filter The transfer function of the filter The transfer function of the filter elements are K Z A CZ PID D z Z 2 11 1 Low pass 2 7 8 Z zyZ z Notch N z 2 Z pXZ The filter parameters K A C and B are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are K KP KD 4 A KD KP C KI2 B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD I s a S a P 4KP D 4T KD I KI 2T a 1 T In 1 B where T 1s the sampling period For example if the filter parameters of the DMC 1600 are 4 KD 36 2 PL 0 75 0 001 s the digital filter coefficients are K 160 A 0 9 Chapter 10 Theory of Operation e 171 1 250 rad s and the equivalent continuous filter G s 15 G s 16 0 1445 1000 5 250 s 250 The notch filter has two complex zeros Z z and two complex poles and p The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of the resonance poles The notch poles P and p are programmable and are selected to have sufficient damping It is best to select the notch parameters by the frequency terms The po
171. is prescribed Independent Jogging JG Motion stops on Stop command AC DC SP ST Motion Path described as incremental position points versus Contour Mode CM time CD DT WC LM 2 3 or 4 axis coordinated motion where path is described by Linear Interpolation linear segments 2 D motion path consisting of arc segments and linear Coordinated Motion segments such as engraving or quilting 72 Chapter 6 Programming Motion DMC 1600 Third axis must remain tangent to 2 D motion path suchas Coordinated motion with tangent axis specified VM knife cutting VP CR VS VA VD TN VE Electronic gearing where slave axes are scaled to master axis Electronic Gearing GA which can move in both directions GR GM if gantry Master slave where slave axes must follow a master such Electronic Gearing conveyer speed Moving along arbitrary profiles or mathematically Contour Mode prescribed profiles such as sine or cosine trajectories Teaching or Record and Play Back Contour Mode with Automatic Array Capture Backlash Correction Following a trajectory based on a master encoder position Electronic Cam EQ Smooth motion while operating in independent axis Independent Motion Smoothing IT positioning Smooth motion while operating in vector or linear Vector Smoothing VT interpolation positioning Smooth motion while operating with stepper motors Stepper Motor Smoothing Gantry two axes are coupled by gantry Gantry Mode
172. istance J Combined inertia of motor and load kg m L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to MKS units For example consider a motor with the parameters 14 16 oz 0 1 Nm A R 2 0 J 0 0283 oz in s2 2 1077 kg m L 0 004H 168 e Chapter 10 Theory of Operation DMC 1600 DMC 1600 Then the corresponding time constants are Tm 0 04 sec and 0 002 sec Assuming that the amplifier gain is Kv 4 the resulting transfer function 1s P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of Ka The resulting transfer function in this case is P V K Ky Js where Kt and J are as defined previously For example a current amplifier with K 2 A V with the motor described by the previous example will have the transfer function P V 1000 s2 rad V If the motor is a DC brushless motor it is driven by an amplifier that performs the commutation The combined transfer function of motor amplifier combination is the same as that of a similar brush motor as described by the previous equations Velocity Loop The motor driver system may include a velocity loop where the motor velocity is sensed by a tachometer and is fed back to the amplifier Such a system is illustrated in Fig 10 5 Note that the transfer function
173. it 1 B axis or 2 data field Bit 0 A axis or 1 data field Data Fields Format Data fields must be consistent with the format byte and the axes byte For example the command PR 1000 500 would be A7 02 00 05 03 E8 xx xx FE 0C where A7 is the command number for PR 02 specifies 2 bytes for each data field 00 coordinated motion is not active for PR 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 27 5 03 E8 represents 1000 xx xx represents inactive data for the B axis xx xx can be any values since byte 4 was configured to ignore it FE OC represents 500 Example The command STABC to stop motion on just axis A B and C would be A1 00 00 07 where Alis the command number for ST 00 specifies 0 data fields 00 specifies the command does not apply to the coordinated motion 07 specifies stop A bit 0 B bit 1 and C bit2 2942 2 7 For more information and a complete list of all Galil binary commands please refer to the Optima Series Bus Based Command Reference at http www galilmc com support manuals optcom pdf 54 e Chapter 4 Software Tools and Communications DMC 1600 Controller Event Interrupts and User Interrupts The DMC 1600 provides a hardware interrupt line that will when enabled interrupt the PC bus which will allow the controller to notify the host application of particular events occurring on the controller Interrupts free the host from having to poll for the occurrenc
174. l damages Contents Contents i Chapter 1 Overview 1 ie Laan nee AM anes baa Po cea a eol 1 Overview of Motor Types tette nte easy ipe e e RE A Eee NE Tee 2 Standard Servo Motor with 10 Volt Command 2 Brushless Servo Motor with Sinusoidal Commutation esses 2 Stepper Motor with Step and Direction Signals ssssssseeeee 2 DMC 1600 Functional Elements esee 3 Microcomputer Sectton oe dc an kane ecd st Re e ea Ue Oe Cg 3 Motor Initertac s lt caeca bee a eap e add n Rd 3 Communication x ens eter Ce RUE ein ae a e ee 3 General haec anb Co te bite tet tuos 4 System Elements ace ete Glade eee TI RR D ERE QUEUE IN 4 SEE NE teen 0 eta ette A iS 4 Amplifier Driver 4 nee ee e RR e t e e ER RERO Rd 4 Encoder 5o Rente nant aito te Rr ts a as DER Lc 5 Watch Dog Timer ian aec ue ee ete ane 5 Chapter 2 Getting Started 7 Th DMC 1600 Motion Controller tte te tn e Pene 7 Elements dM 8 Installmg the DMG 1I600 3 dere eere e p aeu e ae teris 9 Step 1 Determine Overall Motor Configuration sse 9 Step 2 Install Jumpers the 1600 10 Step 3 Install the Communications Software sss 11 Step 4 Install t
175. l in the applications program The pre defined labels are SUBROUTINE DESCRIPTION LIMSWI Limit switch on any axis goes low ININT Input specified by II goes low avCTIME For example the subroutine will automatically be executed when any axis exceeds its position error limit The commands in the ZPOSERR subroutine could decode which axis is in error and take the appropriate action In another example the ZININT label could be used to designate an input interrupt subroutine When the specified input occurs the program will be executed automatically NOTE An application program must be running for automatic monitoring to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the ZLIMSWI routine to function the DMC 1600 must be executing an applications program from memory This can be a very simple program that does nothing but loop on a statement such as LOOP JP 132 e Chapter 7 Application Programming DMC 1600 DMC 1600 ZLOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed ED Edit Mode 000 Dummy Program 001 JP LOOP EN Jump to Loop 002 ZLIMSWI Limit Switch Label 003 MG LIMIT OCCURRED Print Message 004 RE Return to main program control Q Quit Edit Mode XQ LOOP Execute Dummy Program JG 5000 Jog Begin Motion Now when a forward li
176. le Multiple Move Sequence Required Motion Profiles X Axis 500 counts Position 10000 count sec Speed 500000 counts sec Acceleration Y Axis 1000 counts Position 15000 count sec Speed 500000 counts sec Acceleration Z Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on X Y and Z axes The movement on each axis will be separated by 20 msec Fig 6 1 shows the velocity profiles for the X Y and Z axis HA Begin Program PR 2000 500 100 Specify relative position movement of 1000 500 and 100 counts for X Y and Z axes SP 15000 10000 5000 AC 500000 500000 500000 DC 500000 500000 500000 BGX WT 20 BG Y WT 20 BGZ EN Specify speed of 10000 15000 and 5000 counts sec Specify acceleration of 500000 counts sec for all axes Specify deceleration of 500000 counts sec for all axes Begin motion on the X axis Wait 20 msec Begin motion on the Y axis Wait 20 msec Begin motion on Z axis End Program Chapter 6 Programming Motion e 75 VELOCITY COUNTS SEC X axis velocity profile 20000 Y axis velocity profile 15000 Z axis velocity profile 10000 5000 TIME ms 0 20 40 60 80 100 Figure 6 1 Velocity Profiles of XYZ Notes on fig 6 1 The X and Y axis have a trapezoidal velocity profile while the Z axis has a triangular velocity profile The X and Y axes accelerate to the specified speed move at t
177. les and zeros have a frequency in Hz selected by the command NF The real part of the poles is set by NB and the real part of the zeros is set by NZ The most simple procedure for setting the notch filter identify the resonance frequency and set NF to the same value Set NB to about one half of NF and set NZ to a low value between zero and 5 ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 81 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 1600 controller and the following parameters K 0 1 Nm A Torque constant J 2404 kg m System moment of inertia R 2 Q Motor resistance K 4 Amp Volt Current amplifier gain KP 12 5 Digital filter gain KD 245 Digital filter zero KI 0 No integrator 0 Counts rev Encoder line density T 1 ms Sample period The transfer function of the system elements are Motor M s 2 1 Kt Js2 500 52 rad A Amp
178. lifier and generates step and direction signal for step motor drivers Communication The communication interface with the host PC contains a primary and secondary communication channel The primary channel uses a bi directional FIFO 470 and includes PC interrupt Chapter 1 Overview 3 handling circuitry The secondary channel can be enabled where data is placed into the DMC 1600 FIFO buffer General I O The DMC 1600 provides interface circuitry for 8 bidirectional optoisolated inputs 8 TTL outputs and 8 analog inputs with 12 Bit ADC 16 bit optional The general inputs can also be used as high speed latches for each axes A high speed encoder compare output is also provided System Elements As shown in Fig 1 2 the DMC 1600 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Computer Power Supply DMC 1600 Controller Figure 1 2 Elements of Servo systems Motor Amplifier Driver A motor converts current into torque which produces motion Each axis of motion requires a motor sized properly to move the load at the required speed and acceleration Galil s Motion Component Selector software can help you with motor sizing Contact Galil at 800 377 6329 if you would like this product The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step m
179. means buffer is full 512 means buffer is empty CAS or CAT Specifies which coordinate system is to be active S or T Operand Summary Coordinated Motion Sequence OPERAND DESCRIPTION VM The absolute coordinate of the axes at the last intersection along the sequence AV Distancetraveled _ 1 1 AV buffer Zero means buffer is full 512 means buffer is empty _CS starti _ 5 5 gt CS Segment counter Number of the segment in the sequence starting at zero ve Vector length of coordinated move sequence 86 e Chapter 6 Programming Motion DMC 1600 When AV is used as an operand AV returns the distance traveled along the sequence The operands VPX and can be used to return the coordinates of the last point specified along the path Example Traverse the path shown in Fig 6 3 Feed rate is 20000 counts sec Plane of motion is XY VM XY Specify motion plane VS 20000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration VP 4000 0 Segment AB CR 1500 270 180 Segment BC VP 0 3000 Segment CD CR 1500 90 180 Segment DA VE End of sequence BGS Begin Sequence The resulting motion starts at the point A and moves toward points B C D A Suppose that we interrogate the controller when the motion is halfway between the points A and B The value of AV is 2000 The value of CS is 0 _ VPY contain the absolute coordinate of
180. ment The conditional statements are combined in pairs using the operands amp and The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The operand between any two conditions requires that only one statement be true for the combined statement to be true Note Each condition must be placed in parenthesis for proper evaluation by the controller In addition the DMC 1600 executes operations from left to right For further information on Mathematical Expressions and the bit wise operators amp and see pg 135 For example using variables named V1 V2 V3 and V4 128 e Chapter 7 Application Programming DMC 1600 JP TEST V1 lt V2 amp V3 lt V4 In this example this statement will cause the program to jump to the label TEST if V1 is less than V2 and V3 is less than V4 To illustrate this further consider this same example with an additional condition JP ZTEST V1 lt V2 amp V3 lt V4 V5 V6 This statement will cause the program to jump to the label TEST under two conditions 1 If VI is less than V2 and V3 is less than V4 2 If V5 is less than V6 Using the JP Command If the condition for the JP command is satisfied the controller branches to the specified label or line number and continues executing commands from this point If the condition is not satisfied the controller continues to execute the ne
181. ments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence Note This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y specifies the coordinates of the end points of the vector movement with respect to the starting point The command CR r q d defines a circular arc with a radius starting angle of q and a traversed angle d The notation for q is that zero corresponds to the positive horizontal direction and for both q and d the counter clockwise CCW rotation is positive Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE The motion can be initiated with a Begin Sequence BGS command Once motion starts additional segments may be added The Clear Sequence CS command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or ABI ST stops motion at the specified deceleration ABI aborts the motion instantaneously The Vector End VE command must be used to specify the end of the coo
182. mit switch occurs on the X axis the ZLIMSWI subroutine will be executed Notes regarding the LIMSWI Routine 1 The RE command is used to return from the ZLIMSWI subroutine 2 The LIMSWI subroutine will be re executed if the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error ED 000 LOOP 001 JP ZLOOP EN 002 POSERR 003 V1 TEX 004 MG EXCESS POSITION ERROR 005 MG ERROR V1 006 RE control Q XQ LOOP JG 100000 BGX Edit Mode Dummy Program Loop Position Error Routine Read Position Error Print Message Print Error Return from Error Quit Edit Mode Execute Dummy Program Jog at High Speed Begin Motion Now if the position error on the X axis exceeds that specified by the ER command the POSERR routine will execute NOTE The RE command is used to return from the ZPOSERR subroutine NOTE The POSERR routine will continue to be executed until the position error is cleared is less than the ER limit Example Input Interrupt HA Label Input Interrupt on 1 JG 30000 60000 Jog BGXW Begin Motion LOOP JP LOOP EN Loop Chapter 7 Application Programming 133 ININT STXW AM TEST GIN 1 0 JG 30000 6000 BGXW RIO Input Interrupt Stop Motion Test for Input 1 still low Restore Velocities Begin motion Return from interrupt routine to Main Program and do not re enable trippoints
183. mmand For more details on TS see the Command Reference Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user There are three homing routines supported by the DMC 1600 Find Edge FE Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX lt return gt BGX return The Find Edge routine will cause the motor to accelerate then slew at constant speed until a transition is detected in the logic state of the Home input The direction of the FE motion is dependent on the state of the home switch High level causes forward motion The motor will then decelerate to a stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP It is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine i
184. mmand operands begin with the underscore character For example the value of the current position on the X axis can be assigned to the variable V with the command V TPX The Command Reference denotes all commands which have an equivalent operand as Used as an Operand Also see description of operands in Chapter 7 Command Summary For a complete command summary see Command Reference manual 70 Chapter 5 Command Basics DMC 1600 THIS PAGE LEFT BLANK INTENTIONALLY DMC 1600 Chapter 5 Command Basics e 71 Chapter 6 Programming Motion Overview The DMC 1600 provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 1610 is a single axis controller and uses X axis motion only Likewise the DMC 1620 uses X and Y the DMC 1630 uses X Y and Z and the DMC 1640 uses X Y Z W The DMC 1650 uses A B C D and E The DMC 1660 uses A B C D E and F The DMC 1670 uses A B C D E F and G The DMC 1680 uses the axes A B C D E F G and The example applications described below will help guide you to the appropriate mode of motion EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each axis is Independent Axis Positioning PA PR independent and follows prescribed velocity profile SP AC DC Velocity control where no final endpoint
185. more information about these commands see the Command Summary The value of the outputs can be checked with the operand and the function QOUTT see Chapter 7 Mathematical Functions and Expressions NOTE For systems using the ICM 1900 interconnect module the ICM 1900 has an option to provide optoisolation on the outputs In this case the user provides an isolated power supply 5volts to 24volts and ground For more information consult Galil The output compare signal is TTL and is available on the ICM 1900 as CMP Output compare is controlled by the position of any of the main encoders on the controller The output can be programmed to produce an active low pulse 1usec based on an incremental encoder value or to activate once when an axis position has been passed For further information see the command OC in the Command Reference The error signal output is available on the interconnect module as ERROR This is a TTL signal which is low when the controller has an error Note When the error signal 15 low the LED on the controller will be on which indicates an error condition one of the following error conditions 1 At least one axis has a position error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the outpu
186. motor here to clear error RE Return to main program NOTE An applications program must be executing for the YPOSERR routine to function Limit Switch Routine The DMC 1600 provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automatic execution of a limit switch subroutine The ZLIMSWI label specifies the start of the limit switch subroutine This label causes the statements following to be automatically executed 1f any limit switch is activated and that axis motor is moving in that direction The RE command ends the subroutine The state of the forward and reverse limit switches may also be tested during the jump on condition statement The LR condition specifies the reverse limit specifies the forward 160 e Chapter 8 Hardware amp Software Protection DMC 1600 limit X Y Z W following LR LF specifies the axis The CN command can be used to configure the polarity of the limit switches Limit Switch Example DMC 1600 A JP Dummy Program LIMSWI Limit Switch Utility V1 _LFX Check if forward limit V2 _LRX Check if reverse limit JP LF V1 0 Jump to LF if forward JPZLR V2 0 Jump to ZLR if reverse JP END Jump to end LF LF MG FORWARD LIMIT Send message STX AMX Stop motion PR 1000 BGX AMX Move in reverse JP END End LR LR MG REVERSE LIMIT Send message STX AMX Stop motion PR1000 BGX AMX Move forward END End RE Retu
187. move when conducting a reciprocating motion The drive is a 1 64 microstepping drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to continue upon error KS16 Set step smoothing MT 2 2 2 2 Motor type set to stepper Y A64 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WTS50 Allow slight settle time YSI Enable SPM mode 106 Chapter 6 Programming Motion DMC 1600 SP16384 PR10000 BGX MCX JS amp CORRECT MOTION2 SP16384 PR 10000 BGX MCX JS CORRECT JP MOTION CORRECT spx _SPX LOOP SP2048 WT100 JP END ABS _QSX lt 10 YRX QSX MCX WT100 JP LOOP END SPX spx EN Perform motion Set the speed Prepare mode of motion Begin motion Move to correction Set the speed Prepare mode of motion Begin motion Move to correction Correction code Save speed value Set a new slow correction speed Stabilize End correction if error is within defined tolerance Correction move Stabilize Keep correcting until error is within tolerance End CORRECT subroutine returning to code Dual Loop Auxiliary Encoder The DMC 1600 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation and axis used in circular compare When used the second encoder is typically mounted on the motor
188. n through use of a 16 bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feedforward an extra pole filter and integration limits Designed to solve complex motion problems the DMC 1600 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences and contouring The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 1600 provides continuous vector feed of an infinite number of linear and arc segments The DMC 1600 electronic gearing mode features operation for multiple masters axes as well as gantry For synchronization with outside events the DMC 1600 provides uncommitted I O including 8 general use digital inputs 72 general use digital outputs and 8 analog inputs for interface to Joysticks sensors and pressure transducers Dedicated optoisolated inputs are provided for forward and reverse limits abort home and definable input interrupts The DMC 1600 is a plug and play device making it easy to set up Commands can be sent in either Binary or ASCII Additional software is available to autotune view trajectories on a PC screen translate CAD DXF files into motion and create powerful application specific operator interfaces with Visual Basic Drivers for Dos Windows 3 1 95 98 2000 ME XP and NT are available Chapter
189. ne word 2 bytes per field 04 One long word 4 bytes per field 06 Galil real format 4 bytes integer and 2 bytes fraction Byte 3 specifies whether the command applies to a coordinated move as follows 00 No coordinated motion movement 01 Coordinated motion movement For example the command STS designates motion to stop on a vector motion The third byte for the equivalent binary command would be 01 Byte 4 specifies the axis or data field as follows Bit 7 axis or 8 data field Bit 6 G axis or 7 data field Bit 5 axis 6 data field Bit 4 E axis or 5 data field Bit3 D axis or 4 data field Bit 2 C axis or 3 data field Bit 1 axis or 2 data field Bit 0 A axis or 1 data field Data fields Format Data fields must be consistent with the format byte and the axes byte For example the command PR 1000 500 would be 7 02 00 05 03 E8 FE 0C where A7 is the command number for PR 02 specifies 2 bytes for each data field 00 S is not active for PR 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 22 5 66 Chapter 5 Command Basics DMC 1600 03 E8 represents 1000 FE OE represents 500 Example The command ST XYZS would be A1 00 01 07 where is the command number for ST 00 specifies 0 data fields 01 specifies stop the coordinated axes S 07 specifies stop X bit 0 Y bit 1 and Z bit 2 2 2 2 7 Binary command table reserved 5 lt
190. ng an analog input such as a joystick Assume that for a 10 Volt input the speed must be 50000 counts sec JOY Label JGO Set in Jog Mode BGX Begin motion B Label for loop AN I Read analog input VEL V1 50000 10 Compute speed JG VEL Change JG speed JP B Loop Linear Interpolation Mode The DMC 1600 provides a linear interpolation mode for 2 or more axes In linear interpolation mode motion between the axes is coordinated to maintain the prescribed vector speed acceleration and deceleration along the specified path The motion path is described in terms of DMC 1600 Chapter 6 Programming Motion e 77 incremental distances for each axis An unlimited number of incremental segments may be given in a continuous move sequence making the linear interpolation mode ideal for following a piece wise linear path There is no limit to the total move length The LM command selects the Linear Interpolation mode and axes for interpolation For example LM YZ selects only the Y and Z axes for linear interpolation When using the linear interpolation mode the LM command only needs to be specified once unless the axes for linear interpolation change Specifying Linear Segments The command LI x y z w or LI a b c d e f g h specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis position Up to 511 incremental move segments may be given prior to the Begin Sequence BGS command
191. ns These include Output Protection Lines Amp Enable This signal goes low when the motor off command is given when the position error exceeds the value specified by the Error Limit ER command or when off on error condition is enabled OE1 and the abort command is given Each axis amplifier has separate amplifier enable lines This signal also goes low when the watch dog timer is activated or upon reset Note The standard configuration of the AEN signal is TTL active low Both the polarity and the amplitude can be changed if you are using the ICM 1900 interface board To make these changes see section entitled Amplifier Interface pg 36 Error Output The error signal output is available on the interconnect module as ERROR This is a TTL signal which is low when the controller has an error Note When the error signal is low the LED on the controller will be on which indicates an error condition one of the following error conditions 1 At least one axis has a position error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is failure with the output IC which drives the error signal 158 e Chapter 8 Hardware amp Software Protection DMC 1600 Input Protection Lines Abort A low input stops commanded motion instantly without a co
192. nterrogation Command Chapter 7 Application Programming 147 Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by VF mn where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format The default format for VF is VF 10 4 Hex values are returned preceded by a and in 2 s complement V1 10 Assign V1 Return V1 0000000010 0000 Default format VF2 2 Change format Return V1 10 00 New format 2 2 Specify hex format Return V1 0A 00 Hex value 1 Change format Return V1 9 Overflow Local Formatting of Variables PF and VF commands are global format commands that effect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m n m following the variable name and the symbol specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal For example Examples V1 10 Assign V1 Return V1 0000000010 0000 Default Format V1 F4 2 Specify local format 0010 00 New format V1 4 2 Specify hex format 000 00 Hex value V1 ALPHA Assign string ALPHA to V1 V1
193. ntrolled deceleration For any axis in which the Off On Error function is enabled the amplifiers will be disabled This could cause the motor to coast to a stop If the Off On Error function is not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in this chapter Forward Limit Switch Low input inhibits motion in forward direction If the motor is moving in the forward direction when the limit switch 1s activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polanty of the limit switches Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch 1s activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine ZLIMSWI if such a routine has been written by the user The CN command can be used to change the polanty of the limit switches Software Protection The DMC 1600 provides a programmable error limit The error limit can be set for any number between 1 and 32767 using the ER n command The default value for ER is 16384 Example ER 200 300 4
194. nts _AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to specify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation ED Edit Mode 000 A Program Label 001 PR1000 Position Relative 1000 002 BGX Begin 003 PR5000 Position Relative 5000 004 EN End lt cntrl gt Q Quit Edit Mode XXQ ZA Execute ZA 122 e Chapter 7 Application Programming DMC 1600 003 PR5000 Error on Line 3 TCI Tell Error Code 27 Command not valid Command not valid while running while running ED 3 Edit Line 3 003 AMX PR5000 BGX Add After Motion Done lt cntrl gt Q Quit Edit Mode XQ A Execute A Program Flow Commands DMC 1600 The DMC 1600 provides instructions to control program flow The DMC 1600 program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements Event Triggers amp Trippoints To function independently from the host computer the DMC 1600 can be programmed to make decisions based on the occurrence of an event Such events includ
195. o the encoder feedback inputs on the interconnect board The signal leads are labeled CHA channel A CHB channel B and INDEX For differential encoders the complement signals are labeled CHA CHB and INDEX Note When using pulse and direction encoders the pulse signal is connected to CHA and the direction signal is connected to CHB The controller must be configured for pulse and direction with the command CE See the command summary for further information on the command CE Step D Verify proper encoder operation Start with the X encoder first Once it is connected turn the motor shaft and interrogate the position with the instruction TPX return The controller response will vary as the motor is turned At this point if TPX does not vary with encoder rotation there are three possibilities 1 The encoder connections are incorrect check the wiring as necessary 2 The encoder has failed using an oscilloscope observe the encoder signals Verify that both channels A and B have a peak magnitude between 5 and 12 volts Note that if only one encoder channel fails the position reporting varies by one count only If the encoder failed replace the encoder If you cannot observe the encoder signals try a different encoder 3 There is a hardware failure in the controller connect the same encoder to a different axis If the problem disappears you probably have a hardware failure Consult the factory for help Step E
196. of the encoder signals resulting in a resolution of quadrature counts 4 x encoder cycles Note Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses into CHA and direction into Channel B and using the CE command to configure this mode Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for step motors A low input stops commanded motion instantly without a controlled deceleration OE0 Also aborts motion program A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored When active inhibits motion in forward direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command When active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew spee
197. oftware Tools and Communications DMC 1600 DMC 1600 126 127 128 131 132 135 136 139 140 143 144 147 148 149 150 151 152 153 154 155 156 159 160 163 164 167 168 171 172 175 176 177 178 179 180 181 182 183 184 187 188 191 192 195 196 199 200 203 204 205 206 207 208 209 210 211 212 215 216 219 220 223 224 227 228 231 232 233 234 235 236 237 238 239 240 243 244 247 248 251 UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL SL SL SW SW UW UB UB SL SL SL w d axis switches w d axis stop code w d axis reference position w d axis motor position w d axis position error w d axis auxiliary position w d axis velocity w d axis torque w d axis analog input e axis status e axis switches e axis stop code e axis reference position e axis motor position e axis position error e axis auxiliary position e axis velocity e axis torque e axis analog input f axis status f axis switches f axis stopcode f axis reference position f axis motor position f axis position error f axis auxiliary position f axis velocity f axis torque f axis analog input g axis status g axis switches g axis stopcode g axis reference position g axis motor position g axis position error g axis auxiliary position g axis velocity g axis torque g axis analog input h axis status h axis switches h axis s
198. oggles the Amplifier Enable Output AEN which can be used to switch the amplifiers off in the event of a serious DMC 1600 failure The AEN output is normally high During power up and if the microprocessor ceases to function properly the AEN output will go low The error light for each axis will also turn on at this stage A reset is required to restore the DMC 1600 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 1600 is damaged Chapter 1 Overview gt 5 THIS PAGE LEFT BLANK INTENTIONALLY 6 Chapter 1 Overview DMC 1600 Chapter 2 Getting Started The DMC 1600 Motion Controller FON 0 000000000000000000000090 e 0 0 0 0 0 O 0 O0 0 O0 0 0 0 0 0 0 0 0 000900 7 0 oeoo eseee MAIN CONNECTOR AXES X W J1 AMP 2 178238 9 J5 AUX ENCODER SMX ee 55 U22 ss JP5 29 GL 1800 SMW ARRAY i vcc U2 JP7 23 Figure 2 1 Outline of the DMC 1600 DMC 1600 ERROR LED ee MRESET 9 UPGRADE 000000000000000000000009 0 a Y N e 0 0 0 8 0 0 0 0 0 6 0 0 0 6 60 6 6 6 0 6 EXTENDED I O AMP 2 178238 9 FLASH EEPROM GND e e KEY ee ee ee ee ee ee ee U9 RAM U21 RAM DAUGHTERBOARD J4 60000000000000000000000 8 00900000000000000000000000 Chapter 2 Get
199. oller are open the first handle to retrieve the data record s will possess the only copy available When an application needs only the most recent data record available the cache depth should be set to 1 Stall Thread and Delay Thread Methods Users can also choose between Delay and Stall methods These methods affect how the software waits for a response from the controller when a command is sent If a controller is configured with the Delay method the thread waiting for a command response gives up its time slice allowing other processes running on the operating system to proceed This method can slow communication but results in negligible CPU utilization The second method the Stall method uses the opposite strategy The thread that performs I O with the controller maintains ownership of the CPU and polls the controller until a response is received This approach is essentially the same method employed in previous versions V7 of the Galil communication DLLs and drivers While the Stall method does not have to wait for its thread to become eligible for execution it does result in 100 CPU utilization while communicating with the controller Data Record Refresh Rate Under the PCI Bus Parameters tab the rate at which the data record is sent to the software drivers can be configured The period between refreshes can be set from 2 256 ms assuming the standard TM setting of 1000 15 set The Galil communications DLL
200. oltage V to each phase for some time T and checks to see if the motion is in the correct direction The user must specify the value for V and T For example the command 20 e Chapter 2 Getting Started DMC 1600 DMC 1600 BSX 2 700 will test the X axis with a voltage of 2 volts applying it for 700 millisecond for each phase In response this test indicates whether the DAC wiring is correct and will indicate an approximate value of BM If the wiring is correct the approximate value for BM will agree with the value used in the previous step Note In order to properly conduct the brushless setup the motor must be allowed to move a minimum of one magnetic cycle in both directions Note When using Galil Windows software the timeout must be set to a minimum of 10 seconds time out 10000 when executing the BS command This allows the software to retrieve all messages returned from the controller If Hall Sensors are Available Since the Hall sensors are connected randomly it is very likely that they are wired in the incorrect order The brushless setup command indicates the correct wiring of the Hall sensors The hall sensor wires should be re configured to reflect the results of this test The setup command also reports the position offset of the hall transition point and the zero phase of the motor commutation The zero transition of the Hall sensors typically occur at 0 30 or 90 of the phase commutation It is necessary
201. onditional statement End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 2 are not active End Input Interrupt Routine without restoring trippoints A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program location where the subroutine was called unless the subroutine stack is manipulated as described in the following section Example An example of a subroutine to draw a square 500 counts per side is given below The square is drawn at vector position 1000 1000 M Begin Main Program 1 Clear Output Bit 1 pick up pen VP 1000 1000 LE BGS Define vector position move pen AMS Wait for after motion trippoint Set Output Bit 1 put down JS Square CB1 Jump to square subroutine EN End Main Program Square Square subroutine V1 500 JS 1 Define length of side 1 1 5 L Switch direction EN End subroutine Chapter 7 Application Programming 131 ZL PR V1 V1 BGX Define X Y Begin X AMX BGY AMY After motion on X Begin Y EN End subroutine Stack Manipulation It is possible to manipulate the subroutine stack by using the ZS command Every time a JS instruction int
202. ontroller the controller will be re configured to be a DMC 1630 controller In this case the highest axis is no longer available except to be used for the 2 phase of the sinusoidal commutation Note that the highest axis on a controller can never be configured for sinusoidal commutation The first phase signal is the motor command signal The second phase is derived from the highest DACX on the controller When more than one axis is configured for sinusoidal commutation the highest sinusoidal commutation axis will be assigned to the highest DAC and the lowest sinusoidal commutation axis will be assigned to the lowest available DAC Note the lowest axis 1s the X axis 12 e Chapter 2 Getting Started DMC 1600 Example Sinusoidal Commutation Configuration using a 1640 BAXY This command causes the controller to be reconfigured as a DMC 1620 controller The X and Y axes are configured for sinusoidal commutation The first phase of the X axis will be the motor command X signal The second phase of the X axis will be Z signal The first phase of the Y axis will be the motor command Y signal The second phase of the Y axis will be the motor command W signal Step 7 Make Connections to Amplifier and Encoder Once you have established communications between the software and the DMC 1600 you are ready to connect the rest of the motion control system The motion control system typically consists of an ICM 1900 Interface Module an amplifier for
203. ontroller has completed generating all step pulses before making additional moves If additional motion commands are given while step motor is already moving some steps may be missed This is most particularly important when moving back and forth For example when operating with servo motors the trippoint AM After Motion Is used to determine when the motion profiler is complete and is prepared to execute a new motion command However when operating in stepper mode the controller may still be generating step pulses when the motion profiler is complete This is caused by the stepper motor smoothing filter KS To understand this consider the steps the controller executes to generate step pulses First the controller generates a motion profile in accordance with the motion commands Chapter 6 Programming Motion e 101 Second the profiler generates pulses as prescribed by the motion profile The pulses that are generated by the motion profiler can be monitored by the command RP Reference Position RP gives the absolute value of the position as determined by the motion profiler The command DP can be used to set the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Third the output of the motion profiler is filtered by the stepper smoothing filter This filter adds a delay in the output of the stepper motor pulses The amount of delay depends on the parameter which is specified by th
204. or the controller in the Galil registry m hDmc is the DMC handle used to identify the controller It is returned by DMCOpen m nRetCode is the return code for the routine m nResponseLength is the response string length which must be set to the size of the response string m sResponse is the string containing the controller response to the command DOS Linux and QNX tools Galil offers unsupported code examples that demonstrate communications to the controller using the following operating systems DOS DOS based utilities amp Programming Libraries for Galil controllers which includes a terminal utilities to upload and download programs and source code for BASIC and C programs Download DMCDOS at http www galilmc com support download html dos Linux Galil has developed code examples for the Linux operating system The installation includes sample drivers to establish communication with Galil PCI and ISA controllers The current version of the software has been tested under Redhat 6 X O S Source code for the drivers and other utilities developed for Linux are available to customers upon request Linux drivers are available for ISA and PCI cards under Kernal 2 2 Drivers are also available for the PCI card only for Kernal 2 4 For more information on downloading and installing the Linux drivers for Galil controllers download the Linux manual at http www galilmc com support manuals Inxmanual pdf QNX Galil offers
205. ory the DMC 1600 has several useful commands The command DM will return the number of array elements currently available The command DA will return the number of arrays which can be currently defined For example a standard DMC 1610 will have a maximum of 8000 array elements in up to 30 arrays If an array of 100 elements is defined the command DM will return the value 7900 and the command DA will return 29 To list the contents of the variable space use the interrogation command LV List Variables To list the contents of array space use the interrogation command LA List Arrays To list the contents of the Program space use the interrogation command LS List To list the application program labels only use the interrogation command LL List Labels Operands In general all of the operands provide information which may be useful in debugging an application program Below is a list of operands which are particularly valuable for program debugging To display the value of an operand the message command may be used For example since the operand ED contains the last line of program execution the command MG _ED will display this line number ED contains the last line of program execution Useful to determine where program stopped DL contains the number of available labels UL contains the number of available variables _DA contains the number of available arrays _DM contains the number of available array eleme
206. ossible to define the master as the command position of that axis rather than the actual position The designation of the commanded position master 1s by the letter C For example GACX indicates that the gearing is the commanded position of X An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the X and Y motor form a circular motion the Z axis may move in proportion to the vector move Similarly if X Y and Z perform a linear interpolation move W can be geared to the vector move Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced an additional distance with PR or JG commands or VP or LI Command Summary Electronic Gearing COMMAND DESCRIPTION GAn Specifies master axes for gearing where n X Y Z or W or A B C D E F G H for main encoder as master n CX CY CZ or CW or CA CB CC CD CE CF CG CH for commanded position n DX DY DZ or DW or DA DB DC DD DE DF DG DH for auxiliary encoders Sets gear ratio for slave axes 0 disables electronic gearing for specified axis GR a b c d e f g Sets gear ratio for slave axes 0 disables electronic gearing for specified axis na h GM a b c d e f g h X 1 sets gantry mode 0 disables gantry mode Trippoint for reverse m
207. otion past specified value Only one field may be used Trippoint for forward motion past specified value Only one field may be used Example Simple Master Slave Master axis moves 10000 counts at slew speed of 100000 counts sec Y is defined as the master X Z W are geared to master at ratios of 5 5 and 10 respectively GA Y Y Y Specify master axes as Y GR 5 5 10 Set gear ratios PR 10000 Specify Y position SP 100000 Specify Y speed 88 e Chapter 6 Programming Motion DMC 1600 DMC 1600 BGY Begin motion Example Electronic Gearing Objective Run two geared motors at speeds of 1 132 and 0 045 times the speed of an external master The master is driven at speeds between 0 and 1800 RPM 2000 counts rev encoder Solution Use a DMC 1630 controller where the Z axis 1s the master and X and Y are the geared axes MOZ Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GR 1 132 045 Specify gear ratios Now suppose the gear ratio of the X axis is to change on the fly to 2 This can be achieved by commanding GR 2 Specify gear ratio for X axis to be 2 Example Gantry Mode In applications where both the master and the follower are controlled by the DMC 1600 controller it may be desired to synchronize the follower with the commanded position of the master rather than the actual position This eliminates the coupling between the axes which may lead to oscillations For example a
208. otors the controller can be configured to control full step half step or microstep drives An encoder is not required when step motors are used Amplifier Driver For each axis the power amplifier converts 10 Volt signal from the controller into current to drive the motor For stepper motors the amplifier converts step and direction signals into current The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation 1s required or the controller must be configured to provide sinusoidal commutation The amplifiers may be either pulse width modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 Volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 Volts should run the motor at the maximum speed DMC 1600 DMC 1600 Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 1600 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as CHA and CHB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended CHA and CHB or differential CHA CHA CHB CHB The
209. ows 1 Give the AL XYZW command or ABCDEFGH for DMC 1680 to arm the latch for the main encoder and ALSXSYSZSW for the auxiliary encoders 2 Test to see if the latch has occurred Input goes low by using the AL X or Y or Z W command Example 1 returns the state of the X latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the RL XYZW command or RL XYZW Note The latch must be re armed after each latching event Example Latch JG 5000 BG Y AL Y Wait JP Wait ALY 1 Result _RLY Result EN Latch program Jog Y Begin motion on Y axis Arm Latch for Y axis Wait label for loop Jump to Wait label if latch has not occurred Set value of variable Result equal to the report position of y axis Print result End Fast Firmware Operation The DMC 1600 motion controllers can operate in a mode which allows for very fast servo update rates This mode is known as fast mode and allows the following update rates DMC DMC DMC DMC DMC 1610 1620 1630 1640 1650 114 Chapter 6 Programming Motion 125 usec 125 usec 250 usec 250 usec 375 usec DMC 1600 DMC 1600 DMC 1660 375 usec DMC 1670 500 usec DMC 1680 500 usec In order to run the DMC 1600 motion controller in fast mode the fast firmware must be uploaded This can be done through the Galil terminal software such as DMCTERM and WSDK The fast firmware is
210. p X axis motor command to amp input w respect to ground X axis sign output for input to stepper motor amp X axis pulse output for input to stepper motor amp Signal Ground Volts W axis amplifier enable Z axis amplifier enable Y axis amplifier enable X axis amplifier enable Limit Switch Common W axis home input W axis reverse limit switch input W axis forward limit switch input Z axis home input Z axis reverse limit switch input Appendices e 191 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 FLSZ HOMEY RLSY FLSY HOMEX RLSX FLSX VCC GND INCOM XLATCH YLATCH ZLATCH WLATCH INS IN6 IN7 IN8 amp ABORT OUTI OUT2 OUT3 OUT4 OUTS OUT6 OUT7 Z uuu 4 o6 2 2 2 EB gom mo 9 D AE 2 MBX MBX INX INX GND VCC MAY 192 Appendices e e o LB on Z axis forward limit switch input Y axis home input Y axis reverse limit switch input Y axis forward limit switch input X axis home input X axis reverse limit switch input X axis forward limit switch input 5 Volts Signal Ground Input common Common for general inputs and Abort input Input 1 Used for X axis latch input Input 2 Used for Y axis latch input Input 3
211. path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle corresponds to the positive direction of the X axis and the CCW direction of rotation is positive Angles are expressed in degrees and the resolution is 1 256th of a degree For example the path shown in Fig A 2 15 specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 20000 10000 10000 20000 Figure A 2 X Y Motion Path DMC 1600 Appendices e 195 The first line describes the straight line vector segment between points and B The next segment is a circular arc which starts at an angle of 180 and traverses 90 Finally the third line describes the linear segment between points C and Note that the total length of the motion consists of the segments A B Linear 10000 units RJA 02 B C Circular 15708 360 C D Linear 10000 Total 35708 counts In general the length of each line
212. peed and slew until a transition is detected on the Homing line The motor will then decelerate to a stop A high deceleration value must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch The Home HM command can be used to position the motor on the index pulse after the home switch is detected This allows for finer positioning on initialization The command sequence HM and BG causes the following sequence of events to occur Chapter 6 Programming Motion e 111 Upon begin motor accelerates to the slew speed The direction of its motion is determined by the state of the homing input A zero GND will cause the motor to start in the forward direction 5V will cause it to start in the reverse direction The CN command is used to define the polarity of the home input 2 Upon detecting the home switch changing state the motor begins decelerating to a stop 3 The motor then traverses very slowly back until the home switch toggles again 4 The motor then traverses forward until the encoder index pulse is detected 5 The DMC 1600 defines the home position 0 as the position at which the index was detected Example HOME Label AC 1000000 Acceleration Rate DC 1000000 Deceleration Rate SP 5000 Speed for Home Search HM X Home X BGX Begin Motion AM X After Complete MG AT HOME Send Message EN End EDGE Label AC 2000000 Acceleration rate DC 2000000 Deceleration rate
213. placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The characters can be individually separated by using bit wise operations as illustrated in the following example TEST Begin main program IN ENTER LEN S6 Input character string of up to 6 characters into variable LEN FLEN FRAC LEN Define variable FLEN as fractional part of variable LEN FLEN 10000 FLEN Shift FLEN by 32 bits IE convert fraction FLEN to integer LENI FLEN amp SOOFF Mask top byte of FLEN and set this value to variable LEN1 LEN2 FLEN amp FF00 100 Let variable LEN2 top byte of FLEN LEN3 LEN amp 000000FF Let variable LEN3 bottom byte of LEN LEN4 LEN amp 0000FF00 100 Let variable LEN4 second byte of LEN LENS LEN amp SOOFF0000 10000 Let variable LENS third byte of LEN LEN6 LEN amp SFF000000 1000000 Let variable LEN6 fourth byte of LEN MG LEN6 S4 Display LEN6 as string message of up to 4 chars MG LENS 54 Display LENS as string message of up to 4 chars MG LENA 54 Display LEN4 as string message of up to 4 chars MG LEN3 54 Display LEN3 as string message of up to 4 chars MG LEN2 54 Display LEN2 as string message of up to 4 chars MG LEN 54 Display LEN1 as string message of up to 4 chars EN 136 e Chapter 7 Application Programming DMC 1600 This program w
214. position VE End vector BGS Begin sequence AV 5000 After vector distance VS 1000 Reduce speed EN End 126 e Chapter 7 Application Programming DMC 1600 Event Trigger Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves MOVES Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration BGX Start Motion AD 10000 Wait a distance of 10 000 counts SP 5000 New Speed AMX Wait until motion is completed WT 200 Wait 200 ms PR 10000 New Position SP 30000 New Speed AC 150000 New Acceleration BGX Start Motion EN End Define Output Waveform Using AT The following program causes Output to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec OUTPUT Program label ATO Initialize time reference Set Output 1 LOOP Loop AT 10 After 10 msec from reference 1 1 1 40 Wait 40 msec from reference and reset reference Set Output 1 JP LOOP Loop EN Conditional Jumps The DMC 1600 provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition The conditional jump determines if a condition is satisfied and then branches to a new location or subroutine Unlike event triggers the conditional jump instruction does not halt the program sequence Conditional jumps are useful for testing events
215. programs arrays variables and motion control parameters stored in EEPROM will be ERASED The UPGRD jumper enables the user to unconditionally update the controller s firmware This jumper is not necessary for firmware updates when the controller is operating normally but may be necessary in cases of corrupted EEPROM EEPROM corruption should never occur however it is possible if there is a power fault during a firmware update If EEPROM corruption occurs your controller may not operate properly In this case install the UPGRD Jumper and use the update firmware function on the Galil Terminal to re load the system firmware Opto Isolation Jumpers The inputs and limit switches are optoisolated If you are not using an isolated power supply the internal 5V supply from the PC may be used to power the optoisolators This is done by installing the jumpers on JP3 LSCOM to VCC will power the limit switch optoisolators and INCOM to VCC will power the general input optoisolators Note Using the PC s internal 5V supply to power the optoisolators will effectively bypass the optoisolation and fail to provide any isolation for the inputs and limit switches Stepper Motor Jumpers For each axis that will be used for stepper motor operation the corresponding stepper mode SM jumper must be connected The stepper motor jumpers labeled JP5 for axes X through W are located directly beside the GL 1800 IC s on the main board see the diagram for the
216. provides array space for 8000 elements The arrays are one dimensional and up to 30 different arrays may be defined Each array element has a numeric range of 4 bytes of integer Q by two bytes of fraction 2 147 483 647 9999 Arrays can be used to capture real time data such as position torque and analog input values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Defining Arrays An array is defined with the command DM The user must specify a name and the number of entries to be held in the array An array name can contain up to eight characters starting with an uppercase alphabetic character The number of entries in the defined array is enclosed in Example DM POSX 7 Defines an array names POSX with seven entries DM SPEED 100 Defines an array named speed with 100 entries DM POSX 0 Frees array space 140 e Chapter 7 Application Programming DMC 1600 DMC 1600 Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the POSX array defined with the DM command DM POSX 7 would be specified as POSX 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the el
217. put bit every 10000 counts during a move the AR trippoint is used as shown in the next example T TRIP JG 50000 BGX n 0 REPEAT AR 10000 TPX SBI WTS0 1 REPEAT n lt 5 STX EN DMC 1600 Label Specify Jog Speed Begin Motion Repeat Loop Wait 10000 counts Tell Position Set output 1 Wait 50 msec Clear output 1 Increment counter Repeat 5 times Stop End Chapter 7 Application Programming 125 Event Trigger Start Motion on Input This example waits for input 1 to go low and then starts motion Note The AI command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Input Interrupt function II or use a conditional jump on an input such as JP GO IN 1 1 INPUT Program Label Al 1 Wait for input 1 low PR 10000 Position command BGX Begin motion EN End program Event Trigger Set output when at speed ATSPEED Program Label JG 50000 Specify jog speed AC 10000 Acceleration rate BGX Begin motion ASX Wait for at slew speed 50000 Set output 1 EN End program Event Trigger Change Speed along Vector Path The following program changes the feed rate or vector speed at the specified distance along the vector The vector distance is measured from the start of the move or from the last AV command VECTOR Label VMXY VS 5000 Coordinated path VP 10000 20000 Vector position VP 20000 30000 Vector
218. quence s AM with no parameter tests for motion complete on all axes This command is useful for separating motion sequences in a program Halts program execution until position command has reached the specified relative distance from the start of the move Only one axis may be specified at a time Halts program execution until after specified distance from the last AR or AD command has elapsed Only one axis may be specified at a time Halts program execution until after absolute position occurs Only one axis may be specified at a time Halt program execution until after forward motion reached absolute position Only one axis may be specified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs Halt program execution until after reverse motion reached absolute position Only one axis may be specified If position is already past the point then MR will trip immediately Will function on geared axis aux inputs Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW x y z w sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stop code will be set to 99 An application program will jump to label Halts program execution until after specified input is at specified logic level n specifies input line Positive i
219. r Programs Application programs for the DMC 1600 may be created and edited either locally using the DMC 1600 editor or remotely using another editor and then downloading the program into the controller Galil s Terminal and SDK software software provide an editor and UPLOAD and DOWNLOAD utilities The DMC 1600 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number or label by specifying a line number or label following ED 116 Chapter 7 Application Programming DMC 1600 Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN Line numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 80 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below Edit Mode Commands lt RE
220. r should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000 count per revolution results in a rotary resolution of 0 25 micron This results in equal resolution on both linear and rotary sensors To illustrate the control method assume that the rotary encoder is used as a feedback for the X axis and that the linear sensor is read and stored in the variable LINPOS Further assume that at the start both the position of X and the value of LINPOS are equal to zero Now assume that the objective is to move the linear load to the position of 1000 The first step is to command the X motor to move to the rotary position of 1000 Once it arrives we check the position of the load If for example the load position is 980 counts it implies that a correction of 20 counts must be made However when the X axis is commanded to be at the position of 1000 suppose that the actual position is only 995 implying that X has a position error of 5 counts which will be eliminated once the motor settles This implies that the correction needs to be only 15 counts since 5 counts out of the 20 would be corrected by the X axis Accordingly the motion cor
221. rdinated motion This command requires the controller to decelerate to a stop following the last motion requirement Ifa VE command is not given an Abort AB1 must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 1600 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM LM returns the available spaces for motion segments that can be sent to the buffer 511 returned means the buffer is empty and 511 segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional segments can be sent at PC bus speeds The operand CS can be used to determine the value of the segment counter Additional commands The commands VS n VA n and VD n are used for specifying the vector speed acceleration and deceleration VT is the s curve smoothing constant used with coordinated motion Specifying Vector Speed for Each Segment The vector speed may be specified by the immediate command VS It can also be attached to a motion segment with the instructions VP x y lt n gt m CR r 0 8 lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new
222. re 6 2 Chapter 6 Programming Motion e 81 30000 27000 POSITION W 3000 0 4000 36000 40000 POSITION Z FEEDRATE 0 0 1 0 5 0 6 TIME sec VELOCITY Z AXIS TIME sec VELOCITY W AXIS TIME sec Figure 6 2 Linear Interpolation Example Multiple Moves This example makes a coordinated linear move in the XY plane The Arrays VX and VY are used to store 750 incremental distances which are filled by the program ZLOAD LOAD Load Program DM VX 750 VY 750 Define Array COUNT 0 Initialize Counter 82 e Chapter 6 Programming Motion DMC 1600 N 10 LOOP VX COUNT N VY COUNT N N N 10 COUNT COUNT 1 JP HLOOP COUNT lt 750 HA LM XY COUNT 0 LOOP2 JP LOOP2 LM 0 JS C COUNT 500 LI VX COUNT VY COUNT COUNT COUNT 1 JP LOOP2 COUNT lt 750 LE AMS MG DONE EN C BGS EN Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full wait Begin motion on 500th segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Motion Subroutine Coordinated Motion Sequences The DMC 1600 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the pre
223. re sent to the controller with the DMCCommand function This function allows any Galil command to be sent from VB to the controller The DMCCommand function will return the response from the controller as a string Before sending any commands the DMCCOpen function must be called This function establishes communication with the controller and is called only once This example code illustrates the use of DMCOpen and DMCCommand A connection is made to controller 1 in the Galil registry upon launching the application Then the controller is sent the command TPX whenever a command button is pressed The response is then placed in a text box When the application is closed the controller is disconnected To use this example start a new Visual Basic project place a Text Box and a Command Button on a Form add the DMCCOMAO BAS module and type the following code m nController As Integer m hDmc As Long m nRetCode As Long m nResponseLength As Long m sResponse As String 256 Private Sub Commandl Click m nRetCode DMCCommand m hDmc TPX m sResponse m nResponseLength Textl Text Val m sResponse End Sub Private Sub Form Load m nResponseLength 256 Chapter 4 Software Tools and Communications e 51 m nController 1 m nRetCode DMCOpen m nController 0 m hDmc End Sub Private Sub Form Unload Cancel As Integer m nRetCode DMCClose m hDmc End Sub Where m nController is the number f
224. rection should be Correction Load Position Error Rotary Position Error The correction can be performed a few times until the error drops below 2 counts Often this 1s performed in one correction cycle Example motion program Instruction Function HA Label DPO Define starting positions as zero LINPOS 0 PR 1000 Required distance BGX Start motion Wait for completion WT 50 Wait 50 msec LIN POS DEX Read linear position ER 1000 LINPOS Find the correction JP C ABS ER lt 2 Exit if error is small PR ER Command correction BGX JP B Repeat the process C EN Chapter 7 Application Programming e 157 Chapter 8 Hardware amp Software Protection Introduction The DMC 1600 provides several hardware and software features to check for error conditions and to inhibit the motor on error These features help protect the various system components from damage WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machine Since the DMC 1600 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 1600 Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 1600 includes hardware input and output protection lines for various error and mechanical limit conditio
225. rn to main program NOTE An applications program must be executing for LIMSWI to function Chapter 8 Hardware amp Software Protection e 161 Chapter 9 Troubleshooting Overview The following discussion may help you get your system to work Potential problems have been divided into groups as follows 1 Installation 2 Communication 3 Stability and Compensation 4 Operation The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM CAUSE REMEDY Motor runs away when connected to amplifier with Amplifier offset too Adjust amplifier offset no additional inputs large Same as above but offset adjustment does not stop Damaged amplifier Replace amplifier the motor Same as above but offset adjustment does not stop Damaged amplifier Replace amplifier the motor Controller does not read changes in encoder position Wrong encoder Check encoder wiring connections Same as above Bad encoder Check the encoder signals Replace encoder if necessary Same as above Bad controller Connect the encoder to different axis input If it works controller failure Repair or replace 162 e Chapter 9 Troubleshooting DMC 1600 Communication SYMPTOM CAUSE REMEDY Using the Galil provided terminal Address selection in Check address jumper positions cannot communicate with communication does not match and change if necessary The controller jumpers addre
226. rom variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is RESULT 144 e Chapter 7 Application Programming DMC 1600 DMC 1600 In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Value of KDX is KDX Formatting Messages String variables can be formatted using the specifier Sn where n is the number of characters 1 thru 6 For example MG STR 53 This statement returns 3 characters of the string variable named STR Numeric data may be formatted using the Fn mj expression following the completed MG statement n m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is RESULT F5 2 If the value of the variable RESULT is equal to 4 1 this statement returns the following The Final Value is 00004 10 If the value of the variable RESULT is equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppress
227. s 110 05 111 High Speed Position Capture The Latch Function 114 Fast Firmware Operation r E E eren nennen inen 114 Chapter 7 Application Programming 116 OVERVIEW C 116 116 Edit Mode Corimands pent e E re 117 PEO STAM 117 Using Labels 18 ueri e ere ER ERR Re A 118 Contents gt iii iv e Contents Special E bels i e RR eo 118 Commenting Programs eo e an eoo edet ede tette 119 Executing Programs enne 120 Debugging Programs sce Ret Re HERR ho ERROR ORE ER 121 Program Flow Commands 123 Event Triggers amp Trippoints sess 123 Event Trigger Examples ccccccccssesssesssesseeesceeseeeceseceeeceaecsaecaeecaeeeneeeeeeeeenerenseees 125 Conditional JUMPS eeii eren ener enne ener nennen nnne 127 Using If Else Endif Commands seen 129 SUDEIOULITIe AREE E REA SECUN E E RM E REESE 131 132 Aut zStart HURTS RM Ee A e REPERI Pete etui qp 132 Automatic Subroutines for Monitoring Conditions sse 132 Mathematical and Functional Expressions sese 135 135 Bit Wise sese eet eee dide e 136 137
228. s Information for S or T Plane 2 Byte BIT 14 N A 6 N A BIT 13 N A 5 Motion is slewing BIT 12 N A BIT 4 Motion is stopping 62 e Chapter 4 Software Tools and Communications BIT 11 N A BIT 3 Motion is making BIT 10 N A BIT 2 N A 9 N A BIT 1 N A BIT 0 Echo On BIT 0 SM Jumper Installed BIT 8 Mode of Motion Coord Motion BIT 0 Motor Off BIT 8 N A BIT 0 N A DMC 1600 due to final ST or decel Limit Switch Notes Regarding Velocity Torque and Analog Input Data The velocity information that is returned in the data record 1s 64 times larger than the value returned when using the command TV Tell Velocity See command reference for more information about TV The torque information is represented as a number in the range of 32544 Maximum negative torque of 9 9982 V is represented by 32544 Maximum positive torque of 9 9982 V is represented by 32544 Torque information is then scaled linearly as 1v 3255 The analog input is stored as a 16 bit value 32768 which represents an analog voltage range of 10V DMC 1600 Chapter 4 Software Tools and Communications e 63 Chapter 5 Command Basics Introduction The DMC 1600 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands can be sent in A
229. s high logic level negative is low level n 1 through 8 for DMC 1610 1720 1730 1740 1 through 24 for DMC 1650 1760 1770 1780 n 1 through 80 for DMC 17X8 Halts program execution until specified axis has reached its slew speed Halts program execution until n msec from reference time AT 0 sets reference AT n waits n msec from reference AT n waits n msec from reference and sets new reference after elapsed time Halts program execution until specified distance along a coordinated path has occurred Halts program execution until specified time in msec has elapsed DMC 1600 Event Trigger Examples Event Trigger Multiple Move Sequence The AM trippoint is used to separate the two PR moves If AM is not used the controller returns a for the second PR command because a new PR cannot be given until motion is complete TWOMOVE PR 2000 BGX AMX PR 4000 BGX EN Label Position Command Begin Motion Wait for Motion Complete Next Position Move Begin 2nd move End program Event Trigger Set Output after Distance Set output bit after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period SETBIT SP 10000 PA 20000 BGX AD 1000 Label Speed is 10000 Specify Absolute position Begin motion Wait until 1000 counts Set output bit 1 End program Event Trigger Repetitive Position Trigger To set the out
230. s initiated by the command sequence FIX return BGX lt return gt Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HMX lt return gt BGX retur Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detecting the transition in the logic state on the Home Input the motor will decelerate to a stop at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of 256 counts sec When the logic state changes again the motor moves forward in the direction of increasing encoder count at the same speed until the controller senses the index pulse After detection it deceler
231. sample drivers for ISA and PCI cards for the QNX 4 24 operating system We also offer drivers and utilities for QNX 6 2 for PCI only Download at http www galilmc com support download html linux 52 e Chapter 4 Software Tools and Communications DMC 1600 Command Format and Controller Response Instructions may be sent in Binary or ASCII format Binary communication allows for faster data processing since the controller does not have to first decode the ASCII characters ASCII Command mode In the ASCII mode instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon The controller decodes each ASCII character one byte one at a time It takes approximately 350 sec for the controller to decode each command and execute it After the instruction is decoded the controller returns a colon if the instruction was valid or a question mark if the instruction was not valid For instructions that return data such as Tell Position TP the controller will return the data followed by a carriage return line feed and colon An echo function is also provided to enable associating the response with the command sent The echo is enabled by sending the command EO 1 to the controller Binary Command Mode Some commands have an equivalent binary value for the controllers These values are listed in the Command Reference next to the command
232. scribed vector speed even at transitions between linear and circular segments The DMC 1600 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task DMC 1600 The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specified for coordinated motion at any given time The command VM m n p where m and n are the coordinated pair and p is the tangent axis Note the commas which separate m n and p are not necessary For example VM XWZ selects the XW axes for coordinated motion and the Z axis as the tangent Specifying the Coordinate Plane The DMC 1600 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T To specify vector commands the coordinate plane must first be identified This is done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applied to the active coordinate system until changed with the CA command Chapter 6 Programming Motion e 83 Specifying Vector Segments The motion segments are described by two commands VP for linear seg
233. section is intended for advanced programmers with extensive knowledge of ISA and PCI bus operation For main bi directional communication the DMC 1600 features a 512 character write FIFO buffer and a 512 character read buffer This permits sending commands at high speeds ahead of their actual processing by the DMC 1600 The DMC 1600 also provides a secondary FIFO for access to the data record Note This chapter provides an in depth look at how the controller communicates over the PCI bus at the register interface level For most users we recommend using the drivers supplied by Galil to provide the necessary tools for communicating with the controller Determining the Base Address The base address N is assigned its value by the BIOS and or Operating System The FIFO address N is referenced in the PCI configuration space at BAR2 offset 18H The following PCI information HEX can be used to identity the DMC 1600 controller PCI Device Identification DEVICE ID VENDOR ID SUBSYSTEM ID UBSYSTEM VENDOR ID 9050H 10B5H 1640H 1079H Read Write and Control Registers The DMC 1600 provides four registers used for communication The main communications FIFO register for sending commands and receiving responses occupies address N The control register used to monitor the main communications status occupies address 4 The reset register occupies address N 8 and is used for resetting the controller and or main read write FIFO registers as w
234. sition due to stepper motor smoothing Using an Encoder with Stepper Motors An encoder may be used on a stepper motor to check the actual motor position with the commanded position If an encoder is used it must be connected to the main encoder input Note The auxiliary encoder is not available while operating with stepper motors The position of the encoder can be interrogated by using the command TP The position value can be defined by using the command DE Note Closed loop operation with a stepper motor is not possible Command Summary Stepper Motor Operation COMMAND DESCRIPTION Define Encoder Position When using an encoder pp Define Reference Position and Step Count Register Motion Profile Smoothing Independent Time Constant Stepper Motor Smoothing 102 e Chapter 6 Programming Motion DMC 1600 Low Current Stepper Mode toggles amp enable line when holding position Motor Type 2 2 2 5 or 2 5 for stepper motors Report Commanded Position Report number of step pulses generated by controller Tell Position of Encoder Operand Summary Stepper Motor Operation OPERAND Stepper Position Maintenance Mode SPM DMC 1600 The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle the event of stepper motor position error The mode looks at position feedback from the main encoder and compares it to the commanded step pulses The position information is used to determine
235. sses 1000 or 816 are recommended Note for address 1000 jumper A2 and A4 For address 816 jumper A7 A6 A3 A2 Stability SYMPTOM CAUSE REMEDY Motor runs away when the loop is Wrong feedback polarity Invert the polarity of the loop by closed inverting the motor leads brush type or the encoder Motor oscillates Too high gain or too little Decrease KI and KP Increase KD damping Operation SYMPTOM CAUSE REMEDY Controller rejects command Anything Interrogate the cause with TC or Responded with a TCI Motor does not complete move Noise on limit switches stops the To verify cause check the stop motor code SC If caused by limit switch noise reduce noise During a periodic operation motor Encoder noise Interrogate the position drifts slowly periodically If controller states that the position is the same at different locations it implies encoder noise Reduce noise Use differential encoder inputs Same as above Programming error Avoid resetting position error at end of move with SH command DMC 1600 Chapter 9 Troubleshooting e 163 Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Fig 10 1 COMPUTER CONTROLLER DRIVER Figure 10 1 Elements of Servo Systems The operation of su
236. ssigns logical value of input 2 to variable INPUT V2 V14 V3 V4 Assigns the value of V1 plus V3 times V4 to the variable V2 138 e Chapter 7 Application Programming DMC 1600 Assign the string CAT to VAR Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as SP or PR PR VI Assign V1 to PR command SP VS 2000 Assign VS 2000 to SP command Displaying the Value of Variables at the Terminal Variables may be sent to the screen using the format variable For example V1 returns the value of the variable V1 Example Using Variables for Joystick Control The example below reads the voltage of an X Y joystick and assigns it to variables VX and VY to drive the motors at proportional velocities where 10 Volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 JOYSTIK Label JG 0 0 Set in Jog mode BGXY Begin Motion LOOP Loop VX ANT 1 20000 Read joystick X VY AN 2 20000 Read joystick Y JG VX VY Jog at variable VX VY JPZLOOP Repeat EN End Operands DMC 1600 Operands allow motion or status parameters of the DMC 1600 to be incorporated into programmable variables and expressions Most DMC 1600 commands have an equivalent operand which are designated by adding an underscore prior to the DMC 1600 command The command reference indicates which commands have an associated operand Status commands such as Tell Position return ac
237. ssume that a gantry is driven by two axes X Y on both sides This requires the gantry mode for strong coupling between the motors The X axis is the master and the Y axis is the follower To synchronize Y with the commanded position of X use the instructions GA CX Specify the commanded position of X as master for Y GR 1 Set gear ratio for Y as 1 1 GM 1 Set gantry mode PR 3000 Command X motion BG X Start motion on X axis You may also perform profiled position corrections in the electronic gearing mode Suppose for example that you need to advance the slave 10 counts Simply command IP 10 Specify an incremental position movement of 10 on Y axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on Y axis BGY Begin motion on Y axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity correction GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction Chapter 6 Programming Motion e 89 Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 7 axes can be slaved to one ma
238. ster axis The master axis encoder must be input through a main encoder port The electronic cam is a more general type of electronic gearing which allows a table based relationship between the axes It allows synchronizing all the controller axes For example the DMC 1680 controller may have one master and up to seven slaves To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis Y when the master is X Such a graphic relationship is shown in Figure 6 8 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master axis This is done with the instruction EAp where p X Y Z W p is the selected master axis For the given example since the master 1s x we specify EAX Step 2 Specify the master cycle and the change in the slave axes In the electronic cam mode the position of the master is always expressed modulo one cycle In this example the position of x is always expressed in the range between 0 and 6000 Similarly the slave position is also redefined such that it starts at zero and ends at 1500 At the end ofa cycle when the master 1s 6000 and the slave is 1500 the positions of both x and y are redefined as zero To specify the master cycle and the slave cycle change we use the instruction EM EM x y Zw where x y z w specify the cycle of the master and the total change of the slaves over one cycle The cycle of the master is limited to 8 388
239. t and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit For example Instruction Function SB6 Sets bit 6 of output port CB4 Clears bit 4 of output port The Output Bit OB instruction is useful for setting or clearing outputs depending on the value of a variable array input or expression Any non zero value results in a set bit Instruction Function OB1 POS Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 OB 2 IN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 OB 3 IN 1 amp IN 2 Set Output 3 only if Input 1 and Input 2 are high OB 4 COUNT 1 Set Output 4 if element 1 in the array COUNT is non zero The output port can be set by specifying an 8 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 8 bit output port where 20 is output 1 2l is output 2 and so on A 1 designates that the output 1s on For example Instruction Function Chapter 7 Application Programming e 149 OP6 Sets outputs 2 and 3 of output port to high All other bits are 0 21 22 6 Clears all bits of output port to zero OP 255 Sets all bits of output port to one 20 21 22 23 25 4 25 26 27 The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move ZOUTPUT
240. t IC which drives the error signal Chapter 3 Connecting Hardware e 7 Chapter 4 Software Tools and Communications Introduction Galil software is available for PC computers running Microsoft Windows to communicate with DMC 1600 controllers Standard Galil communications software utilities are available for Windows operating systems which includes Smart TERM and WSDK These software packages operate under Windows 98SE ME NT4 0 2000 and XP and include the necessary drivers In addition Galil offers software development tools DMCWin and ActiveX Toolkit to allow users to create their own application interfaces using programming environments such as C Visual Basic and LabVIEW Galil also offers some basic software drivers and utilities for non Windows environments such as DOS Linux and QNX For users who prefer to develop their own drivers details are provided in this chapter describing the communication registers This chapter is an introduction to the software tools and communication techniques used by Galil Figure 1 illustrates the software hierarchy that Galil communications software employs At the application level SmartTERM and WSDK are the basic programs that the majority of users will need to communicate with the controller to perform basic setup and to develop application code DMC programs that is downloaded to the controller At the Galil API level Galil provides software tools ActiveX and API functions for
241. t command output and the 2 phase of the lowest sinusoidal commutation axis will be the lowest command output It is not necessary to be concerned with cross wiring the 1 and 2 signals If this wiring is incorrect the setup procedure will alert the user Step D Example Sinusoidal Commutation Configuration using a DMC 1640 BAXY This command causes the controller to be reconfigured as a DMC 1620 controller The X and Y axes are configured for sinusoidal commutation The first phase of the X axis will be the motor command X signal The second phase of the X axis will be the motor command Z signal The first phase of the Y axis will be the motor command Y signal The second phase of the Y axis will be the motor command W signal Step C Specify the Size of the Magnetic Cycle Use the command BM to specify the size of the brushless motors magnetic cycle in encoder counts For example if the X axis is a linear motor where the magnetic cycle length is 62 mm and the encoder resolution is 1 micron the cycle equals 62 000 counts This can be commanded with the command BM 62000 On the other hand if the Z axis is a rotary motor with 4000 counts per revolution and 3 magnetic cycles per revolution three pole pairs the command is BM 1333 333 Step D Test the Polarity of the DACs and Hall Sensor Configuration Use the brushless motor setup command BS to test the polarity of the output DACs This command applies a certain v
242. t our expense only to destinations in the United States Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer alteration modification negligence or misuse is not covered by this warranty EXCEPT AS SET FORTH ABOVE GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES COPYRIGHT 3 97 The software code contained in this Galil product is protected by copyright and must not be reproduced or disassembled in any form without prior written consent of Galil Motion Control Inc Appendices e 201 Index A Abort 33 34 60 79 85 159 161 179 182 83 Off On Error 15 35 38 159 161 Stop Motion 79 85 135 162 Absolute Position 74 76 125 26 130 Absolute Value 91 130 138 160 Acceleration 127 28 145 150 153 55 197 98 Accessories 190 Address 142 43 164 191 201 Almost Full Flags 59 AMP 1900 19 Ampflier Gain 4 Amplifier Enable 37 159 Amplifier Gain 170 173 176 Analog Input 4 33 37 78 138 40 141 146 152 53 157 179 Analysis SDK 117 Arithmetic Functions 117 129 137 139 149 Arm Latch 115 Array 3 74 83 98 100 117 123 129 137 141 49 150 180 Automatic Subroutine 133 CMDERR 120 133 135 LIMSWI 33 120 133 160 62 MCTIME 120 125 133 135 POSERR 120 133 34 160 61 Auxiliary Encoder 33 89 102 10 102 10 10
243. t s evaluates true the command interpreter will continue executing commands which follow the IF command If the conditional statement evaluates false the controller will ignore commands until the associated ENDIF command is executed OR an ELSE command occurs in the program see discussion of ELSE command below Note An ENDIF command must always be executed for every IF command that has been executed It is recommended that the user not include jump commands inside IF conditional statements since this causes re direction of command execution In this case the command interpreter may not execute an ENDIF command Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command and has no arguments If the argument of the IF command evaluates false the controller will skip commands until the ELSE command If the argument for the IF command evaluates true the controller will execute the commands between the IF and ELSE command Nesting IF Conditional Statements The DMC 1600 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 1600 allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to specify a variety of different cases for branch
244. te This allows the DMC 1600 to use the next increment only when it 1s finished with the previous one Zero parameters for DT followed by zero parameters for CD exit the contour mode If no new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a Command Summary Contour Mode COMMAND DESCRIPTION CM XYZW Specifies which axes for contouring mode Any non contouring axes may be operated in other modes CM Contour axes for DMC 1680 ABCDEFGH CD x y Z w Specifies position increment over time interval Range is 32 000 Zero ends contour mode D 3 h C Position increment data for DMC 1680 a b c d e f g DTn Specifies time interval 2 msec for position increment where n is an integer between 1 and 8 Zero ends contour mode If n does not change it does not need to be specified with each CD Waits for previous time interval to be complete before next data record is processed General Velocity Profiles The Contour Mode is ideal for generating any arbitrary velocity profiles The velocity profile can be specified as a mathematical function or as a collection of points The design includes two parts Generating an array with data points and running the program Generating an Array An Example Consider the velocity and position profiles shown in Fig 6 7 The objective
245. te velocity JG VEL Change velocity JP Loop Change velocity EN End Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal which activates the cutter Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 27 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Fig 7 1 The program starts at a state that we define as ZA Here the controller waits for the input pulse on As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle Instruction Function 152 e Chapter 7 Application Programming DMC 1600 Label Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AM
246. ter the limit switch has been activated and will hold motor position When a forward or reverse limit switch is activated the current application program that 15 running will be interrupted and the controller will automatically jump to the LIMSWI subroutine if one exists This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch Automatic Subroutines are discussed in chapter 6 After a limit switch has been activated further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to an inactive state This usually involves physically opening the tripped switch Any attempt at further motion before the logic state has been reset will result in the following error 022 Begin not possible due to limit switch error The operands LFx and _LRx contain the state of the forward and reverse limit switches respectively x represents the axis X Y Z W etc The value of the operand is either a 0 or 1 corresponding to the logic state of the limit switch Using a terminal program the state of a limit 32 e Chapter 3 Connecting Hardware DMC 1600 DMC 1600 switch can be printed to the screen with the command MG _LFx or LFx This prints the value of the limit switch operands for the x axis The logic state of the limit switches can also be interrogated with the TS co
247. the BN command If no value has been set the default of CO 0 is used all blocks are inputs Accessing extended I O When configured as an output each I O point may be defined with the SBn and CBn commands where n 9 through 56 OBn can also be used with n 9 through 56 The command OP may be used to set the state of output bits The OP command has 2 parameters The first parameter sets the values of the main output port of the controller The second parameter sets the value of the extended I O configured as outputs The command syntax for the command is the following OP m a b c d e where m is the decimal representation of the bits 1 8 values from 0 to 255 and a b c d e represent the extended I O in consecutive groups of 16 bits values from 0 to 65535 Arguments which are given for I O points which are configured as inputs will be ignored The following table describes the arguments used to set the state of outputs Argument Blocks Bits Description m 0 1 8 General Outputs a 2 3 17 32 Extended I O b 4 5 33 40 Extended I O 6 7 41 48 Extended I O d 8 9 49 56 Extended I O When accessing I O blocks configured as inputs use the TIn command The argument n refers to the block to be read n 1 to 9 Individual bits can be queried using the IN n command where n 9 to 80 If the following command is issued MG IN 17 the controller will return the state of the least significant bit of block 2 assuming block 2 is con
248. ting Started 7 Flash EEPROM EEPROM Master Reset amp UPGRD jumpers Ecos RAM INCOM amp LSCOM jumpers Used for bypassing opto isolation for the limit home and abort switches and the digital inputs INI IN8 See section Bypassing Opto Isolation Chap3 Motorola 68331 microprocessor Jumpers used for configuring stepper motor operation on axes Um _ _ W GL 1800 custom GL 1800customgateamay array EH Part number Amp 2 178238 9 encoder signals Part number Amp 2 178238 9 Elements You Need Before you start you must get all the necessary system elements These include 1 DMC 1610 1620 1630 or DMC 1640 Motion Controller 1 100 pin cable and 1 ICM 1900 interconnect module Servo motors with Optical Encoder one per axis or step motors Power Amplifiers Power Supply for Amplifiers PC Personal Computer ISA bus Utilities Disk for DMC 1600 which contains Plug and Play drivers and communication utilities XA deo 09 7 WSDK 16 or WSDK 32 is optional but recommend for first time users The motors may be servo brush type or brushless or steppers The amplifiers should be suitable for the motor and may be linear or pulse width modulated An amplifier may have current feedback voltage feedback or velocity feedback lt For servo motors in current mode the amplifiers should accept an analog signal in the 10 Volt range
249. tion trajectory and a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging COMMAND DESCRIPTION Specifies acceleration rate paxvaw 76 Chapter 6 Programming Motion DMC 1600 Specifies deceleration rate Increments position instantly Time constant for independent motion smoothing JG x y z w Specifies jog speed and direction Parameters can be set with individual axes specifiers such as 2000 set jog speed for Y axis to 2000 or ACYH 400000 set acceleration for Y and H axes to 400000 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the jog speed for the axis specified by x _TVx Returns the actual velocity of the axis specified by x averaged over 25 sec Example Jog in X only Jog X motor at 50000 count s After X motor is at its jog speed begin jogging Z in reverse direction at 25000 count s HA AC 20000 20000 Specify X Z acceleration of 20000 cts sec DC 20000 20000 Specify X Z deceleration of 20000 cts sec JG 50000 25000 Specify jog speed and direction for X and Z axis BGX Begin X motion AS X Wait until X is at speed BGZ Begin Z motion EN Example Joystick Jogging The jog speed can also be changed usi
250. to download the array The controller s firmware must be recent enough to support the QD command Array values specified in the data file must be comma separated or CRLF deliminated Opens the Upload Array dialog box that allows an array in the controller s RAM to be saved to a file on the hard disk The dialog box uses the DMC32 dll DMCArrayUpload function to upload the array The controller s firmware must be recent enough to support the QU command Opens a dialog box that allows converting a file containing Galil ASCII language commands to Galil binary commands and saves the result to the specified file name Opens a dialog box that allows converting a file containing Galil binary language commands to Galil ASCII commands and saves the result to the specified file name Launches a file open dialog box that selects a file usually a DMC file to be sent to the controller This file can contain binary commands Each line of the file is sent to the controller as a command and executed immediately The Tools menu items described below provide tasks such as updating firmware diagnostics accessing the registry editor and resetting the controller Select Controller DMC 1600 Opens the Select Controller dialog box that displays the currently registered Galil Motion Controllers Selecting a controller from the list and clicking on the OK button or double clicking a controller will cause the application to close
251. to inform the controller about the offset of the Hall sensor and this 15 done with the instruction BB Step E Save Brushless Motor Configuration It is very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configured the burn command BN should be given If Hall Sensors are Not Available Without hall sensors the controller will not be able to estimate the commutation phase of the brushless motor In this case the controller could become unstable until the commutation phase has been set using the BZ command see next step It is highly recommended that the motor off command be given before executing the BN command In this case the motor will be disabled upon power up or reset and the commutation phase can be set before enabling the motor Step F Set Zero Commutation Phase When an axis has been defined as sinusoidally commutated the controller must have an estimate for commutation phase When hall sensors are used the controller automatically estimates this value upon reset of the controller If no hall sensors are used the controller will not be able to make this estimate and the commutation phase must be set before enabling the motor If Hall Sensors are Not Available To initialize the commutation without Hall effect sensor use the command BZ This function drives the motor to a position where the commutation phase is zero and sets t
252. topcode h axis reference position h axis motor position h axis position error Chapter 4 Software Tools and Communications e 61 252 255 256 259 260 261 262 263 SL h axis auxiliary position SL h axis velocity SW h axis torque SW h axis analog input Note UB Unsigned Byte UW Unsigned Word SW Signed Word SL Signed Long Word Explanation of Status Information and Axis Switch Information BIT 7 Program Running BIT 7 Latch Occurred BIT 15 Move in Progress BIT 7 Negative Direction Move BIT 15 Move in Progress BIT 7 N A General Status Information 1 Byte BIT 6 N A BIT 5 N A BIT 4 N A BIT 3 N A Axis Switch Information 1 Byte BIT 6 State of Latch Input BIT 5 N A BIT 4 N A BIT 3 State of Forward Limit Axis Status Information 1 Word BIT 14 Mode of Motion PA or PR BIT 6 Mode of Motion Contour BIT 13 Mode of Motion PA only BIT 5 Motion is slewing BIT 12 FE Find Edge in Progress BIT 4 Motion is stopping due to ST of Limit Switch BIT 11 Home HM in Progress BIT 3 Motion is making final decel BIT 2 N A BIT 2 State of Reverse Limit BIT 10 1 Phase of HM complete BIT 2 Latch is armed BIT 1 Trace on BIT 1 State of Home Input 9 2 Phase of HM complete or FI command issued BIT 1 Off On Error enabled Coordinated Motion Statu
253. tput pulses 2 5 specifies a stepper motor with active low step output pulses and reversed direction 2 5 specifies a stepper motor with active high step output pulse and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought of as a simple Resistor Capacitor single pole filter The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor Use of KS is most applicable when operating in full step or half step operation KS will cause the step pulses to be delayed in accordance with the time constant specified When operating with stepper motors you will always have some amount of stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses In general it is necessary to make sure that the c
254. tual values whereas action commands such as KP or SP return the values in the DMC 1600 registers The axis designation is required following the command Examples of Internal Variables POSX TPX Assigns value from Tell Position X to the variable POSX VARI KPX 2 Assigns value from KPX multiplied by two to variable VARI JP LOOP gt 5 Jump to LOOP if the position error of X is greater than 5 JP ERROR TC 1 Jump to ERROR if the error code equals 1 Operands can be used in an expression and assigned to a programmable variable but they cannot be assigned a value For example KPX 2 is invalid Chapter 7 Application Programming e 139 Arrays Special Operands Keywords The DMC 1600 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 1600 commands KEYWORD ET TIME Free Running Real Time Clock off by 2 4 Resets with power on Note TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords LF LR and TIME do not have any associated commands keywords are listed in the Command Summary Chapter 11 Examples of Keywords V1 _LFX Assign V1 the logical state of the Forward Limit Switch on the X axis V3 TIME Assign V3 the current value of the time clock 4 HMW Assign V4 the logical state of the Home input on the W axis For storing and collecting numerical data the DMC 1600
255. ture 142 43 Position Capture 115 Record 74 98 100 141 144 Teach 100 Limit Torque Limit 17 204 o Limit Switch 33 34 133 141 160 62 164 LIMSWI 33 120 133 160 62 Linear Interpolation 73 78 81 83 89 96 Clear Sequence 79 81 85 87 Logical Operator 129 Masking Bit Wise 129 137 Math Function Absolute Value 91 130 138 160 Bit Wise 129 137 Cosine 74 137 38 142 Logical Operator 129 Sine 74 94 138 Mathematical Expression 129 136 138 MCTIME 120 125 133 135 Memory 65 99 117 123 129 133 141 142 Array 3 74 83 98 100 117 123 129 137 141 49 150 180 Download 65 117 142 Upload 117 Message 84 113 122 133 35 137 14446 152 161 62 Modelling 165 168 69 173 Motion Complete MCTIME 120 125 133 135 Motion Smoothing 74 111 S Curve 79 111 Motor Command 17 173 Moving Acceleration 127 28 145 150 153 55 197 98 Begin Motion 119 22 126 27 134 140 144 45 150 152 Circular 84 87 89 143 154 55 Multitasking 121 Halt 79 121 25 127 28 151 Off On Error 159 161 Off On Error 15 35 38 159 161 Offset Adjustment 163 Operand Internal Variable 129 139 140 Operators Bit Wise 129 137 Optoisolation 33 6 Home Input 34 112 141 Output Amplifier Enable 37 159 ICM 1100 15 37 38 Motor Command 17 173 Output of Data 145 DMC 1600 Clear Bit 150 Set Bit 150 P PID 18 168 178 Play Back 74 144 Plug and Play 1 POSERR 120 133 3
256. ured for a standard servo motor described above Sinusoidal commutation in the controller can be used with linear and rotary BLMs However the motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds For faster motors please contact the factory To simplify the wiring the controller provides a one time automatic set up procedure The parameters determined by this procedure can then be saved in non volatile memory to be used whenever the system is powered on The DMC 1600 can control BLMs equipped with or without Hall sensors If hall sensors are available once the controller has been setup the controller will automatically estimates the commutation phase upon reset This allows the motor to function immediately upon power up The Hall effect sensors also provide a method for setting the precise commutation phase Chapter 2 describes the proper connection and procedure for using sinusoidal commutation of brushless motors 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec default rate Stepper Motor with Step and Direction Signals The DMC 1600 can control stepper motors In this mode the controller provides two signals to connect to the stepper motor Step and Direction For stepper motor operation the controller does not require an encoder and operates the stepper motor in an open loop fashion Chapter 2 describes the proper connection and procedure for using stepper motors 2 e
257. using the command OE 1 If the motor runs away due to positive feedback or another systematic problem the controller will disable the amplifier when the position error exceeds the value set by the command ER Step D Disable motor with the command MO Motor off Step E Connect the Motor and issue SH Once the parameters have been set connect the analog motor command signal ACMD to the amplifier input To test the polarity of the feedback command a move with the instruction PR 1000 lt CR gt Position relative 1000 counts BGX CR Begin motion on X axis When the polarity of the feedback is wrong the motor will attempt to run away The controller should disable the motor when the position error exceeds 2000 counts If the motor runs away the polarity of the loop must be inverted Inverting the Loop Polarity When the polarity of the feedback is incorrect the user must invert the loop polarity and this may be accomplished by several methods If you are driving a brush type DC motor the simplest way is to invert the two motor wires typically red and black For example switch the M1 and M2 connections going from your amplifier to the motor When driving a brushless motor the polarity reversal may be done with the encoder If you are using a single ended encoder interchange the signal CHA and CHB If on the other hand you are using a differential encoder interchange only CHA and CHA The loop polarity and encoder polarity can
258. vertical line appears as a broken line The numeric range for addition subtraction and multiplication operations is 2 147 483 647 9999 The precision for division 15 1 65 000 Mathematical operations are executed from left to right Calculations within a parentheses have precedence Examples SPEED 7 5 V1 2 The variable SPEED is equal to 7 5 multiplied by V1 and divided by 2 COUNT COUNT 2 The variable COUNT is equal to the current value plus 2 RESULT _TPX COS 45 40 Puts the position of X 28 28 in RESULT 40 cosine of 45 is 28 28 TEMP IN 1 J amp IN 2 TEMP is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The operator is a Logical Or These operators allow for bit wise operations on any valid DMC 1600 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be
259. vides impulse step and frequency response tests of actual hardware Four channel storage scope for displaying real time position velocity error and torque Displays X versus Y position for viewing 2 D motion path Terminal editor and program editor for easy communication with the controller 48 e Chapter 4 Software Tools and Communications DMC 1600 et Galil Motion Control Servo Design Kit Ele Terminal Help Select Option RR H Storage Scopes EE System Evaluation e System Information KI Galil Motion Control Inc Set up and Configuration Servo Design kit oh Diagnostics Motion Profile Builder Getting Started O Status Connected with Galil DMC 1840 4 axis controller revision 2 0ndev Figure 4 8 WSDK Main Screen Creating Custom Software Interfaces Galil provides programming tools so that users can develop their own custom software interfaces to a Galil controller These tools include the ActiveX Toolkit and DMCWin ActiveX Toolkit Galil s ActiveX Toolkit is useful for the programmer who wants to easily create a custom operator interface to a Galil controller The ActiveX Toolkit includes a collection of ready made ActiveX COM controls for use with Visual Basic Visual C Delphi LabVIEW and other ActiveX compatible programming tools The most common environment is Visual Basic 6 but Visual Basic NET Visual C Wonderware LabVIEW and HPVEE have all been tested
260. w HX Halt all tasks The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 is executed within TASK2 Debugging Programs DMC 1600 The DMC 1600 provides commands and operands which are useful in debugging application programs These commands include interrogation commands to monitor program execution determine the state of the controller and the contents of the controllers program array and variable space Operands also contain important status information which can help to debug a program Trace Commands The trace command causes the controller to send each line in a program to the host computer immediately prior to execution Tracing is enabled with the command TR1 TRO turns the trace function off Note When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed Data which is output from the controller is stored in an output FIFO buffer The output FIFO buffer can store up to 512 characters of information In normal operation the controller places output into the FIFO buffer The software on the host computer monitors this buffer and reads information as needed When the trace mode is enabled the controller will send information to the FIFO buffer at a very high rate In general the FIFO will become full since the software is unable to read the information fast enough When the FIFO b
261. wed E18 Application program stopped Command done T Inputs uses n for mask TNot used when using new version 7 drivers 43 The argument enables interrupts for the first 8 general inputs To enable interrupts for the desired inputs set bit 15 of the m argument then set the desired inputs using the 8 bit mask for the argument For example to enable interrupt on inputs 1 4 set EI32768 15 Note that the input interrupts must be reset for all inputs after any input has caused an interrupt meme 0 00 du Eolo DMC 1600 Chapter 4 Software Tools and Communications e 55 Input 5 Input 7 Input 8 User Interrupts UI command The DMC 1600 also provides 16 User Interrupts which can be sent by executing the command where n is an integer between 0 and 15 The UI command does not require the EI command UI commands are useful in DMC programs to let the host application know that certain points within the DMC program have occurred Servicing Interrupts Once an interrupt occurs the controller sends a Status Byte to the host computer The Status Byte returned denotes what condition has occurred as described in the table below Status Byte hex Condition 00 No interrupt D9 Watchdog timer activated DA Command done DB Application program done FO thru FF User interrupt UI thru 8 Input interrupt CO Limit switch o
262. xt commands in sequence Conditional Meaning JP ZLoop COUNT 10 Jump to Loop if the variable COUNT is less than 10 JS MOVE2 IN 1 1 Jump to subroutine ZMOVE2 if input 1 is logic level high After the subroutine MOVE2 is executed the program sequencer returns to the main program location where the subroutine was called JP BLUE ABS V2 gt 2 Jump to BLUE if the absolute value of variable V2 is greater than 2 JP 2C VI V7 V8 V2 Jump to C if the value of V1 times V7 is less than or equal to the value of V8 V2 Jump to ZA Example Using JP command Move the X motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves BEGIN Begin Program COUNT 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec PAO Position absolute 0 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec COUNT COUNT 1 Decrement loop counter JP LOOP COUNT gt 0 Test for 10 times thru loop EN End Program Using If Else and Endif Commands The DMC 1600 provides a structured approach to conditional statements using IF ELSE and ENDIF commands DMC 1600 Chapter 7 Application Programming e 129 Using the IF and ENDIF Commands An IF conditional statement is formed by the combination of an IF and ENDIF command The IF command has as its arguments one or more conditional statements If the conditional statemen
263. y to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method described below This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The slide is to be controlled by a rotary motor which is coupled to the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy is for 0 5 micron 156 e Chapter 7 Application Programming DMC 1600 DMC 1600 The basic dilemma is where to mount the sensor If you use a rotary sensor you get a 4 micron backlash error On the other hand if you use a linear encoder the backlash in the feedback loop will cause oscillations due to instability An alternative approach 15 the dual loop where we use two sensors rotary and linear The rotary sensor assures stability because the position loop is closed before the backlash whereas the linear sensor provides accurate load position information The operation principle is to drive the motor to a given rotary position near the final point Once there the load position is read to find the position error and the controller commands the motor to move to a new rotary position which eliminates the position error Since the required accuracy is 0 5 micron the resolution of the linear senso

DMC-1600 User Manual - Galil Motion Control

Contents

Download Pdf Manuals

Related Search

Related Contents