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DMC-18x6 - Galil Motion Control

1. 23 Example 2 Profiled Move essen a E 23 Example 3 Multiple amp renes 24 Example 4 Independent Moves cccsccessessseeseeeseeesceseceecaecaecsenseesaeenaeeseeeaeeenes 24 Example 5 Position 24 Contents Example 6 Absolute Position 25 Example 7 Velocity Control i3 enne eme enge nete 25 Example 8 Operation Under Torque Limit eee 25 Ex mple 9 IntertOgatiOn a enano e es e ea RE E ORE teta 26 Example 10 Operation in the Buffer Mode eene 26 Example 11 Using the On Board Editor eee 26 Example 12 Motion Programs with Loops eeeeeeeeeneenrnnen en 26 Example 13 Motion Programs with Trippoints eee 27 Example 14 Control Variables essere 27 Example 15 Linear Interpolation essere 28 Example 16 Circular Interpolation esee 28 Chapter 3 Connecting Hardware 31 Ove VIEW oos ette d t PU ed o e dele ned etes 31 Using Optoisolated Inputs essere nennen enne nnne nennen nnne 31 Limit Switch E nnne 31 Home Switch Input sees enne SAT nennen nnne 32 Abort Input P T RU tated intus 32 Uncom
2. N 2s gt lt gt 29 2 2 ee e e st 88 9 gt gt n me 2u0f qria X x gt gt 3 z Filter 3j Chokes A A gt gt gt gt DC Power Supply Encoder Figure 2 6 System Connections with the AMP 1900 Amplifier Note this figure shows a Galil Motor and Encoder which uses a flat ribbon cable for connection to the AMP 1900 unit DMC 18x6 Chapter 2 Getting Started 17 AUX encoder AUX encoder Input connector Input connector Reset Switeh enor LED 100 pin high density connector D625 female 26 pin header part 2 178238 9 Motor Command buffer circuit Amp enable buffer circuit Encoder Wire Connections m Encoder ICM 1900 a 58 ch 1A MAX 3 zZ M E s channel A AD n Channel A MAX o a zi Sas Channel B B X 3 Channel B MBX E Index Channel INX o i3 Index Channel INX o DC Brush Servo Motor Signa Grd 2 PReTin BRUSH TYPE PWM SERVO AMPLIFIER MSA 12 80 hibit 11 Motor Motor Power Gnd Power Gnd High volt BUN DC Power Supply Figure 2 7 System Connections with a separate amplifier MSA 12 80 This diagram shows the connections for a standard DC Servo Motor and encoder 18 Chapter 2 Getting Started DMC 18x6 Step 8b Connect Sinusoidal Commutation Motors When using sinu
3. BGX Begin motion to move material AMX Wait for motion done SBI Set output to cut WT100 CBl Wait 100 msec then turn off cutter JP ZCUT Repeat process 146 Chapter 7 Application Programming DMC 18x6 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 from variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is RESULT In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Gain of X is GNX Formatting Messa
4. DC 91 reserved IZ je bd for o e e ema Te J IGM a EQ c5 f reserved c6 reserved f reserved 9c reserved 07 reserved R reserved 194 AM c8 reserved 08 reserved 9 MC c9 reserved BG a0 MF cb fH AB fa AD cd reserved R k Fre aS Jas dO fb PA jd reserved fe PR AT reserved i JG WT a Mo __ a9__ reserved __ dd_ __reserved _ Ts SH faa reserved pei Chapter 5 Command Basics 65 Controller Response to DATA The DMC 18x6 returns a for valid commands The DMC 18x6 returns a for invalid commands For example if the command BG is sent in lower case the DMC 18x6 will return a bg lt enter gt invalid command lower case DMC 18x6 returns When the controller receives an invalid command the user can request the error code The error code will specify the reason for the invalid command response To request the error code type the command TC1 For example 1 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 du
5. step motor and 4000 count rev encoder SETUP Set the profiler to stop axis upon error DMC 18x6 Chapter 6 Programming Motion 105 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 SHX Enable axis WT100 Allow slight settle time Perform motion SP512 Set the speed PR1000 Prepare mode of motion BGX Begin motion LOOP JP LOOP Keep thread zero alive for POSERR to run in REM When error occurs the axis will stop due to OE1 In REM POSERR query the status YS and the error QS correct REM and return to the main code POSERR Automatic subroutine is called when YS 2 WT100 Wait helps user see the correction spsave _SPX Save current speed setting JP RETURN YSX lt gt 2 Return to thread zero if invalid error SP 64 Set slow speed setting for 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 ZPOSERR Example Friction Correction The following example illustrates how the SPM mode can be useful in correcting for X axis friction after each move when conducting a reciprocating motion The drive is a 1 64 microstepping drive wit
6. DMC 18x6 Event Triggers Command AM XY ZWorS ABCDEFGH AD X or Y or Z or W A or B or Cor Dor E or F or Gor H AR X or Y or Z or W A or B or Cor Dor 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 X or Y orZor W A or B or Cor Dor E or F or Gor 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 Halts program execution until motion is complete on the specified axes or motion sequence s AM with no parameter tests for motion complete on all axes This command is useful for separating motion sequences in a program 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
7. Galil Communications API with Visual Basic Declare Functions To use the Galil communications API functions add the module file included in the C ProgramFiles Galil DMCWIN VB directory named DMCCOM40 BAS This module declares the routines making them available for the VB project To add this file select Add Module from the Project menu in VB5 6 Sending Commands in VB Most commands are 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 string Before sending any commands the DMCOpen 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 Dim m_nController As Integer Dim m hDmc As Long Dim m nRetCode As Long Dim m nResponseLength As Long Dim m sResponse As String 256 Private Sub Command1 Click m
8. JA Label Define current position as zero V1 1000 Set initial value of V1 26 Chapter 2 Getting Started DMC 18x6 Loop Label for loop PA VI Move X motor V1 counts BGX Start X motion AMX After X motion is complete WT 500 Wait 500 ms TPX Tell position X V1 V1 1000 Increase the value of V1 JP Loop V1 lt 10001 Repeat if V1 lt 10001 EN End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ fA Execute Program A Example 13 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction Interpretation B Label DP 0 0 Define initial positions PR 30000 60000 Set targets SP 5000 5000 Set speeds BGX Start X motion AD 4000 Wait until X moved 4000 BGY Start Y motion AP 6000 Wait until position X 6000 SP 2000 50000 Change speeds AP 50000 Wait until position Y 50000 SP 10000 Change speed of Y EN End program To start the program command XQ B Execute Program B Example 14 Control Variables Objective To show how control variables may be utilized Instruction Interpretation ZA DPO Label Define current position as zero PR 4000 Initial position SP 2000 Set speed BGX Move X AMX Wait until move is complete WT 500 Wait 500 ms B V1 _TPX Determine distance to zero PR 1 2 Command X move the distance DMC 18x6 Chapter 2 Getting Started 27 BGX Start X motion AMX After X moved WT 50
9. Quadrature phase on CHA CHB Can accept single ended only or differential A A B B Maximum A B edge rate 22 MHz Minimum IDX pulse width 40 nsec Stepper Control Pulse TTL 0 5 Volts level at 50 duty cycle 6 000 000 pulses sec maximum frequency Direction TTL 0 5 Volts Input Output Uncommitted Inputs Limits Home Abort 2 2K ohm in series with optoisolator Active high or low Inputs requires at least 2mA to activate Can accept up to 24 Volts without additional series resistor Above 24 Volts requires additional resistor AN 1 thru AN 8 Analog Inputs Standard configuration is 10 Volt 12 Bit Analog to Digital converter 16 bit optional OUTT 1 thru OUT 8 Outputs TTL OUT 9 thru OUT 16 TTL for DMC 1856 thru DMC 1886 IN 17 thru IN 24 TTL for DMC 1856 thru DMC 1886 Note The part number for the 100 pin connector is 2 178238 9 from AMP DMC 18x6 Appendices 181 Power 5V 750 mA 12V 40 mA 12V 40mA Performance Specifications Minimum Servo Loop Update Time DMC 1816 DMC 1826 DMC 1836 DMC 1846 DMC 1856 DMC 1866 DMC 1876 DMC 1886 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 182 Appendices Normal Fast Firmware 62 5 usec 31 25 usec 62 5 usec 31 25 usec 125 usec 62 5 usec 125 usec 62
10. Select the communication method that the device driver will use to send commands to the controller icombination of speed and minimum CPU utilization Data Record Cache Depth 50 Data Record s Stall Thread This method is fast but results in 100 CPU utilization if polling continuo Delay Thread This method in mos but is has negligible impact on More Info Figure 4 6 Controller Communications Method Dialog Box 46 Chapter 4 Software Tools and Communications DMC 18x6 Interrupt Communications Method The interrupt method overall is the most efficient of the three methods The interrupt communications method uses a hardware interrupt to notify the driver that a response or unsolicited data is available This allows for greater 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 18x6 controllers the interrupt is configured automatically 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 fu
11. USER MANUAL DMC 18x6 Manual Rev 1 0e By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Rev Date 2 09 Using This Manual This user manual provides information for proper operation of the DMC 18x6 controller The appendix to this manual contains information regarding controller accessories A separate supplemental manual the Command Reference contains a description of the commands available for use with the controller Your 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 E El 0 1X80 Attention Pertains to controllers with more than 4 axes Please note that many examples are written for the DMC 1846 four axes controller or the DMC 1886 eight axes controller Users of the DMC 1836 3 axis controller DMC 1826 2 axes controller or DMC 1816 1 axis controller should note that t
12. 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 Example Multiple Move Sequence Required Motion Profiles X Axis 500 counts 20000 count sec 500000 counts sec2 Y Axis 1000 counts 10000 count sec 500000 counts sec Z Axis 100 counts 5000 counts sec 500000 counts sec Position Speed Acceleration Position Speed Acceleration Position Speed Acceleration This example will specify a relative position movement on X Y and Z axes The movement on each axis will be separated by 20 msec Fig 6 0 shows the velocity profiles for the X Y and Z axis HA PR 2000 500 100 SP 20000 10000 5000 AC 500000 500000 500000 DC 500000 500000 500000 BGX WT 20 BG Y WT 20 BGZ EN DMC 18x6 Begin Program Specify relative position movement of 1000 500 and 100 counts for X Y and Z axes Specify speed of 20000 10000 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 71 VELOCITY COUNTS SEC X axis velocity profile 20000 Y axis velocity profile 15000 Z axis velocity profil
13. 12 Volts ISOLATED GND and ANALOG GND connections added to Rev D J53 provides 4 additional screw terminals for Ground Connection on Revision D 190 Appendices DMC 18x6 ICM 1900 Drawing 13 500 12 560 1 1 620 0 220 6 880 4 940 2 000 Dimensions 13 5 x 2 675 x 6 88 Figure A 1 ICM 1900 Dimensions AMP 19X0 Mating Power Amplifiers The 19 0 series are mating brush type servo amplifiers for the DMC 18x6 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 19 0 requires an external DC supply The AMP 19X0 connects directly to the DMC 18x6 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 18x6 series controllers Screw type terminals for easy connection to motors encoders and switches Steel mounting plate with 4 keyholes Specifications Minimum motor inductance 1 mH PWM frequency 30 kHz Ambient operating temperature 0 to 70 C Mounting Keyholes 4 Gain amp V DMC 18x6 Appendices 191 ICM 2900 FL Interconnect Module The ICM 2900 interconnect module provides easy connections
14. 151 Arm Latch 116 Array 3 69 82 98 100 118 122 129 139 142 50 151 182 Automatic Subroutine 120 132 CMDERR 120 133 134 35 LIMSWI 31 120 132 33 162 63 MCTIME 120 125 133 134 POSERR 120 132 34 162 63 Auxiliary Encoder 31 90 101 9 101 9 101 9 186 188 190 193 194 Dual Encoder 66 108 145 DMC 18x6 Backlash 69 107 9 159 Backlash Compensation Dual Loop 69 101 9 101 9 101 9 159 Begin Motion 120 21 126 27 133 34 142 145 46 151 153 Binary 1 62 65 Bit Wise 129 138 Burn EEPROM 3 Bypassing Optoisolation 35 C Capture Data Record 69 97 100 143 145 Circle 156 Circular Interpolation 83 86 87 144 156 Clear Bit 151 Clear Sequence 78 80 84 86 Clock 142 CMDERR 120 133 134 35 Code 133 142 145 46 154 56 158 60 Command Syntax 62 63 Command Summary 67 70 72 80 85 144 Commanded Position 70 72 87 90 134 145 154 167 69 Communication 3 62 Almost Full Flag 55 FIFO 3 54 55 Compensation Backlash 69 107 9 159 Conditional jump 33 118 123 127 30 153 Index 217 Configuration Jumper 35 166 Contour Mode 68 69 96 100 Control Filter Damping 170 Gain 142 147 Integrator 170 Proportional Gain 170 Coordinated Motion 63 68 83 85 Circular 83 86 87 144 156 Contour Mode 68 69 96 100 Ecam 92 95 Electronic Cam 68 69 91 93 Electronic Gearing 68 69 87 91 Gearing 68 69 87 91 Linear Interpolation 68
15. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 23 26 25 28 27 30 29 32 31 34 33 36 35 38 37 40 39 42 41 44 43 46 45 48 47 50 49 52 51 54 53 56 55 58 57 60 59 62 61 64 63 66 65 68 67 1 064 1 063 1 062 1 061 1 060 I O59 I O58 I O57 OUTC57 64 I OC57 64 I O56 I O55 1 054 1 053 1 052 I O51 I O50 I O49 OUTC49 56 I OC49 56 I O48 I O47 I O46 I O45 I O44 I O43 1 042 1 041 OUTC41 48 I OC41 48 I O40 1 039 1 038 1 037 1 036 1 035 1 034 1 033 OUTC33 40 I OC33 40 1 032 1 031 1 030 1 029 1 028 1 O bit 64 I O bit 63 I O bit 62 I O bit 61 I O bit 60 I O bit 59 I O bit 58 I O bit 57 Out common for I O 57 64 I O common for I O 57 64 I O bit 56 I O bit 55 I O bit 54 I O bit 53 I O bit 52 I O bit 51 I O bit 50 I O bit 49 Out common for I O 49 56 I O common for I O 49 56 I O bit 48 I O bit 47 I O bit 46 I O bit 45 I O bit 44 I O bit 43 I O bit 42 I O bit 41 Out common for I O 41 48 I O common for I O 41 48 I O bit 40 I O bit 39 I O bit 38 I O bit 37 I O bit 36 I O bit 35 I O bit 34 I O bit 33 Out common for I O 33 40 T O common for I O 33 40 I O bit 32 I O bit 31 I O bit 30 I O bit 29 I O bit 28 e N N PRO NY NY WW WWW WW WH HB HR d HP HR HP d HR d d UG t
16. 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 18x6 High on input 1 means switch is in on position 152 Chapter 7 Application Programming DMC 18x6 INSTRUCTION FUNCTION S JG 4000 Set speed AI 1 BGX Begin after input 1 goes high Al 1 STX Stop after input 1 goes low AMX JP S After motion repeat EN Input Interrupt Function The DMC 18x6 provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the II m n o command The m specifies the beginning input and n specifies the final input in the range The parameter o is an interrupt mask If m and n are unused o contains a number with the mask A 1 designates that input to be enabled for an interrupt where 29 is bit 1 2l is bit 2 and so on For example II 5 enables inputs 1 and 3 20 22 5 A low input any of the specified inputs will cause automatic execution of 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 r
17. data field Bit 5 axis or 6 data field Bit 4 E axis or 5 data field Bit 3 D axis or 4 data field Bit 2 C axis or 3 data field Bit 1 B axis or 2 data field Bit 0 A axis or 1 data field Data fields Format Data fields must be consistent with the format byte and the axes byte For example the command PR 1000 500 would be A7 02 00 05 03 E8 FE 0C where 7 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 27 5 03 E8 represents 1000 FE OC represents 500 Example The command ST XYZS would be A1 00 01 07 where Al is the command number for ST 64 Chapter 5 Command Basics DMC 18x6 DMC 18x6 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 COMMAND ee ee CANO reserved 80 reserved ab reserved 146 KI 82 reserved RP d KD 83 reserved 4 DV af TE da AF Js LM DD jd e0 me edit VD b8 resrvd e3 FL VS b9 reserved BL VR Joa je AC 190 reserved CN 4
18. independent and follows prescribed velocity profile SP AC DC Velocity control where no final endpoint is prescribed Independent Jogging JG Motion stops on Stop command AC DC ST Absolute positioning mode where absolute position targets Position Tracking PA may be sent to the controller while the axis is in motion PT SP AC DC Motion Path described as incremental position points versus Contour Mode CM time CD DT LM 2 3 or 4 axis coordinated motion where path is described by Linear Interpolation linear segments 68 Chapter 6 Programming Motion DMC 18x6 2 D motion path consisting of arc segments and linear Coordinated Motion segments such as engraving or quilting Third axis must remain tangent to 2 D motion path 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 GD _GP 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 Dual Loop Following a trajectory based on a master encoder position Electronic Cam EQ Smooth motion while operating in independent axis Indepen
19. the position tracking mode In this example there is a host program that will generate the absolute position targets The absolute target is determined based on the current information the host program has gathered on the object that it is tracking The position tracking mode does allow for all of the axes on the controller to be in this mode but for the sake of discussion it is assumed that the robot is tracking only in the X dimension The controller must be placed in the position tracking mode to allow on the fly absolute position changes This is performed with the PT command To place the X axis in this mode the host would issue PT 1 to the controller if both X and Y axes were desired the command would be PT 1 1 The next step is to begin issuing PA command to the controller The BG command isn t required in this mode the SP AC and DC commands determine the shape of the trapezoidal velocity profile that the controller will use Example Motion 1 The host program determines that the first target for the controller to move to is located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 cts sec and the velocity is set to 50 000 cts sec The command sequence to perform this 1s listed below COMMAND DESCRIPTION PTI Place the X axis in Position tracking mode AC150000 Set the X axis acceleration to 150000 cts sec DC150000 Set the X axis deceleration to 150000 cts sec SP50000 Set the X axis speed to 50000 cts s
20. third byte of LEN Let variable LEN6 fourth byte of LEN Display LEN6 as string message of up to 4 chars Display LENS as string message of up to 4 chars Display LEN4 as string message of up to 4 chars Display LEN3 as string message of up to 4 chars Display LEN2 as string message of up to 4 chars Display LEN1 as string message of up to 4 chars This program will accept a string input of up to 6 characters parse each character and then display each character Notice also 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 DMC 18x6 Response from command MG LEN6 S4 Chapter 7 Application Programming 139 E Response from command MG LENS S4 S Response from command MG LEN4 S4 T Response from command MG LEN3 S4 M Response from command MG LEN2 S4 E Response from command MG LENI S4 Functions FUNCTION TAN QATAN Ta OERACH ant GANT 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
21. 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 ENCODER Figure 10 1 Elements of Servo Systems qm The operation of such a system can be divided into three levels as illustrated in Fig 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming 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 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 DMC 18x6 Chapter 10 Theory of Operati
22. 18x6 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 Vo VI gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 18x6 will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The operand between any two conditions requires that only one statement be true for the combined statement to be true Note Each condition must be placed in parentheses for proper evaluation by the controller In addition the DMC 18x6 executes operations from left to right For further information on Mathematical Expressions and the bit wise operators amp and see pg 7 138 For example using variables named V1 V2 V3 and V4 JP ZTEST 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 DMC 18x6 Chapter 7 Application Programming 129 JP
23. 31 33 34 Home Input 32 143 Output Amplifier Enable 35 161 ICM 1100 13 35 Motor Command 15 175 Output of Data 147 Clear Bit 151 Set Bit 151 P PID 16 170 180 Play Back 69 145 POSERR 120 132 34 162 63 Position Error 15 52 53 120 132 34 142 144 45 154 160 Position Capture 116 Latch 66 116 Teach 100 Position Error 13 15 35 52 53 109 120 132 34 142 144 45 154 160 161 63 169 POSERR 120 132 34 Position Follow 154 220 Index Position Limit 162 Program Flow 119 123 Interrupt 52 120 21 127 132 34 153 Stack 132 135 153 Programmable 141 42 151 159 162 EEPROM 3 Programming Halt 79 121 25 127 28 152 Proportional Gain 170 Protection Error Limit 13 15 35 133 161 63 Torque Limit 15 PWM 4 Q Quadrature 4 107 151 154 162 173 Quit Abort 31 32 56 78 84 161 163 181 185 86 Stop Motion 78 84 134 164 R Record 69 97 100 143 145 Latch 66 116 Position Capture 116 Teach 100 Register 142 Reset 31 36 56 128 161 163 S SB Set Bit 151 Scaling Ellipse Scale 86 S Curve 79 110 Motion Smoothing 69 109 111 SDK 118 Selecting Address 143 45 216 Servo Design Kit SDK 118 Set Bit 151 Sine 69 94 140 Single Ended 4 13 16 Slew 70 90 125 127 155 Smoothing 69 79 80 84 86 109 11 Software SDK 118 Terminal 62 Special Label 120 163 DMC 18x6 Specification 79 80 84 Stability 108 9 159 165 66 17
24. 5 IO 4 38 5 4 37 4 9 T O 4 36 3 11 4 35 2 13 4 34 1 DMC 18x6 Appendices 197 33 32 31 IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO IO 5V 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 41 42 43 44 45 10 12 14 16 18 20 46 47 48 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 GND 46 GND 48 GND 50 DMC 18x6 198 Appendices J8 50 PIN IDC Bit Bit GIN n OUTIn 72 71 Block Signal Pin No IO IO 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 70 69 68 67 66 65 11 13 15 17 19 21 64 63 62 61 23 60 59 58 57 56 55 54 53 52 51 25 27 29 31 33 35 37 39 41 43 50 49 45 47 49 73 74 75 76 77 78 10 12 14 16 18 20 79 80 GND GND GND 22 GND 24 26 GND GND 28 GND 30 Appendices 199 DMC 18x6 IOM 1964 Opto Isolation Module for Extended I O 32 34 36 38 40 42 44 46 48 50 Controll
25. 6 Input 7 Input 8 Abort Input Output 1 Output 2 Output 3 Output 4 Output 5 Appendices 189 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 o c nN OU OU N 5 5 2 2 n UO 2 2 MBX MBX INX INX ANALOG GND VCC MAY MAY MBY MBY INY INY MAZ MAZ MBZ MBZ INZ INZ GND VCC MAW MAW MBW MBW INW INW 12V 12V O O e a n on mM n 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 A Main encoder A Main encoder B Main encoder B X X X X X Main encoder Index X Main encoder Index Analog Ground 5 Volts Main encoder A Main encoder A Main encoder B Main encoder B Main encoder Index Main encoder Index Main encoder A Main encoder A Main encoder B Main encoder B Main encoder Index NNNNNNKKKKKK Main encoder Index Signal Ground 5 Volts W Main encoder A Main encoder A W W Main encoder B W Main encoder B W W Main encoder Index Main encoder Index 12 Volts
26. 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 Ground Ground Ground J5 DMC 1846 A D AXES AUXILIARY ENCODERS 26 PIN IDC 5V 2 Ground 3 A Aux X A Aux X B Aux X B Aux X A Aux Y A Aux Y B Aux Y 10 B Aux Y 11 45V 12 Ground 13 A Aux Z tA a 14 15 16 17 18 19 20 21 22 23 24 25 26 A Aux Z B Aux Z B Aux Z A Aux W A Aux W B Aux W B Aux W Sample Clock NC NC NC NC NC Appendices 183 4l I Z 421 Z 43 A W 45 B W 46 B W 47 1 W 48 I W 49 12V 50 12V Notes X Y Z W are interchangeable designations for A B C D axes J8 DMC 1886 E H AXES MAIN 50 PIN IDC NC Ground 5V Error Output Reset Encoder Compare Output Ground Ground O ON Dn BR WN Motor command H Sign H Dir H PWM Step e ec Motor command 13 Sign G Dir G 14 PWM Step 15 Motor command F 16 Sign F Dir F 17 PWM F Step F 18 Motor command E 19 Sign E Dir E 20 PWM E Step E 21 Amp enable H 22 Amp enable G 23 Amp enable F 24 Amp enable E 25 26 A E 27 B E 28 B E 184 Appendices 91 92 93 94 95 96 97 98 99 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 J6 DMC 1886 E H AXES MAIN 50 PIN IDC 51 52 53 5
27. 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 Additionally the Tools menu items described below provide some advanced tasks such as updating firmware diagnostics accessing the registry editor and resetting the controller Select Controller Disconnect from Controller Controller Registration DMC Program Editor Reset Controller Device Driver Diagnostics 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 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 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 Edi
28. Axis Position 00002212 Error 00001732 Torque 3 1926 Axis Position 00002665 Error 00001721 Torque 3 1723 Recursed through 8 stacks Pp Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 18x6 provides the use of the following mathematical operators 1 tesi Or On some opes a solid veri Tne appear wa eni 138 Chapter 7 Application Programming DMC 18x6 The numeric range for addition subtraction and multiplication operations is 2 147 483 647 9999 The precision for division is 1 65 000 Mathematical operations are executed from left to right Calculations within parentheses have precedence Examples SPEED 7 5 V1 2 COUNT COUNT 2 The variable SPEED is equal to 7 5 multiplied by V1 and divided by 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 I amp IN 2 Bit Wise Operators TEMP is equal to 1 only if Input 1 and Input 2 are high 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 18x6 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings
29. 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 Command Summary Linear Interpolation COMMAND LM abcdefgh same controllers with 5 or more axes Zero means buffer full 511 means buffer empty LI x y z w lt n Specify incremental distances relative to current position and assign vector speed n LI a b c d e f g h lt n Operand Summary Linear Interpolation LAY amiee SSS sequence marem C LE Zero means buffer full 511 means buffer empty 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 80 Chapter 6 Programming Motion DMC 18x6 V S M P 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 t
30. Chapter 2 Getting Started 19 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 to inform the controller about the offset of the Hall sensor and this is done with the instruction BB Step E Save Brushless Motor Configuration It is very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configured the burn command BN should be given If Hall Sensors are Not Available Wi
31. For example a 1000 lines rev encoder is modeled as 638 DMC 18x6 Chapter 10 Theory of Operation 173 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 10 or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count Digital Filter The digital filter has three element in series PID low pass and a notch filter The transfer function of the filter The transfer function of the filter elements are K Z A CZ PID D z Z Z 1 Pul Low pass L z Z B nays 22002 0 Z pXZ p The filter parameters K A C and B are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are K KP KD A KD KP KD C KI2 B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD 1 5 a s a where P KP D T KD I KI 2T where T is the sampling period and B is the pole setting For example if the filter parameters of the DMC 18x6 are KP 16 KD 144 2 PL 0 75 T 0 001 s the digital filter coefficients are K 160 A 0 9 C 1 a 250 rad s and the equivalent continuous filter G s is G s 16 0 1445 1000 s 250 5 250 174 Chapter 10 Theory of Operation DMC 18x6 The notch filter has two complex zeros Z and z
32. Hardware DMC 18x6 TTL Outputs The DMC 18x6 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 be turned On and Off with the commands SB Set Bit CB Clear Bit OB Output Bit and OP Output Port For more information about these commands see the Command Summary The value of the outputs can be checked with the operand and the function QOUT x see Chapter 7 Mathematical Functions and Expressions Controllers with 5 or more axes have an additional eight general use TTL outputs 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 a an isolated power supply 5volts to 24volts and ground For more information consult Galil The output compare signal is TTL and 1s 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 signa
33. I step motors Abort A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program Reset A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored Forward Limit Switch When active inhibits motion in forward direction Also causes execution of limit switch subroutine ZLIMSWI The polarity of the limit switch may be set with the CN command Reverse Limit Switch When active inhibits motion in reverse direction Also causes execution of limit switch subroutine ZLIMSWI The polarity of the limit switch may be set with the CN command I Home Switch Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command 186 Appendices DMC 18x6 Input 1 Input 8 isolated Input 9 Input 16 isolated Input 17 Input 24 TTL 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 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 Latch High sp
34. JP LOOP COUNT gt 0 Test for 10 times thru loop EN End Program Using If Else and Endif Commands The DMC 18x6 provides a structured approach to conditional statements using IF ELSE and ENDIF commands Using the IF and ENDIF Commands An IF conditional statement is formed by the combination of an IF and ENDIF command The IF command has as it s arguments one or more conditional statements If the conditional statement s evaluates true the command interpreter will continue executing commands which follow the IF command If the conditional statement evaluates false the controller will ignore commands until the associated ENDIF command is executed OR an ELSE command occurs in the program see discussion of ELSE command below Note An ENDIF command must always be executed for every IF command that has been executed It is recommended that the user not include jump commands inside IF conditional statements since this causes re direction of command execution In this case the command interpreter may not execute an ENDIF command 130 Chapter 7 Application Programming DMC 18x6 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
35. M axis _EY ZA OE2 TM scaling NO LC1000 MT1 5 POSERR LIMSWI MCTIME and ININT run without a thread 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 214 Appendices DMC 18x6 Training Seminars Galil a leader in motion control with over 500 000 controllers working worldwide has a proud reputation for anticipating and setting the trends in motion control Galil understands your need to keep abreast with these trends in order to remain resourceful and competitive Through a series of seminars and workshops held over the past 20 years Galil has actively shared their market insights in a no nonsense way for a world of engineers on the move In fact over 10 000 engineers have attended Galil seminars The tradition continues with three different seminars each designed for your particular skill set from beginner to the most advanced MOTION CONTROL MADE EASY WHO SHOULD ATTEND Those who need a basic introduction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30pm 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 Contro
36. 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 2lis output 2 and so on A 1 designates that the output is on For example INSTRUCTION FUNCTION OP6 Sets outputs 2 and 3 of output port to high All other bits are 0 Ql 22 6 Clears all bits of output port to zero OP 255 Sets all bits of output port to one 22 21 22 23 424425426427 The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move OUTPUT Label PR 2000 Position Command BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec Clear Output 1 EN End Digital Inputs The DMC 18x6 has eight digital inputs for controlling motion by local switches The IN n function returns the logic level of the specified input through 8 For the DMC 1856 thru DMC 1886 the IN n function is valid for inputs 1 thru 24 For the DMC 18x6 with DB 14064 the IN n function is valid for inputs 1 through 80 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 AJ instruction waits until the specified input has occurred Example
37. 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 18x6 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 18x6 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 configured for a standard servo motor described above Sinusoidal commutation in the controller can be used with linear and rotary BLMs However the motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds For faster motors please contact the fac
38. Potential problems have been divided into groups as follows 1 Installation Communication 2 3 Stability and Compensation 4 Operation The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM DIAGNOSIS CAUSE REMEDY Motor runs away with no connections from controller to amplifier input Motor is enabled even when MO command is given Unable to read the auxiliary encoders Unable to read main or auxiliary encoder input DMC 18x6 Adjusting offset causes the motor to change speed The SH command disables the motor No auxiliary encoder inputs are working The encoder does not work when swapped with another encoder input 1 Amplifier has an internal offset 2 Damaged amplifier 1 The amplifier requires the LAEN option on the Interconnect Module 1 Auxiliary Encoder Cable is not connected 1 Wrong encoder connections 2 Encoder is damaged 3 Encoder configuration incorrect Adjust amplifier offset Amplifier offset may also be compensated by use of the offset configuration on the controller see the OF command Replace amplifier Contact Galil Connect Auxiliary Encoder cable Check encoder wiring For single ended encoders CHA and CHB only do not make any connections to the CHA and CHB inputs Replace encoder Check CE command Chapter 9 Troubleshooting 165 The encoder works correct
39. TEST 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 V1 is less than V2 and V3 is less than V4 OR 2 If V5 is less than V6 Using the JP Command If the condition for the JP command is satisfied the controller branches to the specified label or line number and continues executing commands from this point If the condition is not satisfied the controller continues to execute the next commands in sequence Conditional Meaning JP Loop COUNT lt 10 Jump to Loop if the variable COUNT is less than 10 JS MOVE2 IN 1 1 Jump to subroutine MOVE2 if input 1 is logic level high After the subroutine MOVE2 is executed the program sequencer returns to the main program location where the subroutine was called JP BLUE ABS V2 gt 2 Jump to BLUE if the absolute value of variable V2 is greater than 2 JP 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 A Example Using JP command Move the X motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves BEGIN Begin Program COUNT 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec 0 Position absolute 0 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec COUNT COUNT 1 Decrement loop counter
40. The captured data may then be played back in the contour mode The following array commands are used DM C n Dimension array RA Specify array for automatic record up to 4 for DMC 1846 RD TPX Specify data for capturing such TPZ RC n m Specify capture time interval where n is 2 sample periods 1 ms for TM1000 m is number of records to be captured RC or RC Returns a 1 if recording Record and Playback Example RECORD Begin Program DM XPOS 501 Dimension array with 501 elements RA XPOS Specify automatic record RD TPX Specify X position to be captured MOX Turn X motor off RC2 Begin recording 4 msec interval at TM1000 A JPHA RC 1 Continue until done recording COMPUTE Compute DX DM DX 500 Dimension Array for DX C 0 Initialize counter L Label D C 1 DELTA XPOS D XPOS C DX C DELTA 1 Compute the difference Store difference in array 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 DX I I I 1 Specify contour data I I 1 Increment array counter JP B 1 lt 500 Loop until done CD 0 0 End contour buffer Wait JP Wait CM lt gt 511 EN 100 Chapter 6 Programming Motion Wait until path is done End program For additional information about automatic array capture see Chapter 7 Arrays DMC 18x6 Virtual Axis The DMC 18x6 control
41. US nine E RE E e eE EA RE is 216 WARRANTY E E E A 216 217 Vie pMC i8x Chapter 1 Overview Introduction The DMC 18x6 series motion controllers install directly into a PCI slot This controller series offers many enhanced features including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction The DMC 18x6 provides two channels for high speed communication a high speed main FIFO for sending and receiving commands and Dual Port RAM DPRAM for instant access to controller status and parameters The controllers allow for high speed servo control up to 22 million encoder counts sec and step motor control up to 6 million steps per second Sample rates as low as 31 25 psec per axis are available A Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field without removing the controller from the PC The DMC 18x6 is available from one to eight axes on a single PCI card The DMC 1816 1826 1836 1846 covering from one to four axes are on a single 7 85 x 4 2 card and the DMC 1856 1866 1876 1886 five thru eight axes controllers are on a single 12 28 x 4 2 card Designed to solve complex motion problems the DMC 18x6 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multip
42. W E F G H for AN inputs 1 8 2 encoder position dual encoder Status bits Output Latched position Commanded position Stop code Position error Inputs Encoder position Switches only bit 0 4 valid Torque reports digital value 32544 Note X may be replaced by Y Z or W for capturing data on other axes DMC 18x6 Operand Summary Automatic Data Capture 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 Begin program Define X Y position arrays Define X Y error arrays Select arrays for capture Select data types Specify move distance RC1 Start recording now at rate of 2 msec BG XY Begin motion A JP A RC 1 Loop until done MG DONE Print message EN End program PLAY Play back N 0 Initial Counter JP DONE N gt 300 Exit if done N Print Counter X POS N Print X position Y POS N Print Y position XERR N Print X error Chapter 7 Application Programming 145 YERR N Print Y error N N 1 Increment Counter DONE Done EN End Program Deallocating Array Space 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 n
43. a problem when using active high logic and care should be taken Using active low logic should avoid any problems associated with the outputs floating high 64 Extended I O of the DMC 18x6 with DB 14064 The DMC 18x6 controller offers 64 extended I O points with the addition of the DB 14064 daughterboard which can be interfaced to Grayhill and OPTO 22 I O mounting racks or the Galil IOM 1964 These I O points can be configured as inputs or outputs in 8 bit increments through software The I O points are accessed through two 50 pin IDC connectors each with 32 I O points Configuring the I O of the DMC 18x6 with DB 14064 The 64 extended I O points of the 18x6 w DB 14064 series controller can be configured in blocks of 8 The extended I O is denoted as blocks 2 9 or bits 17 80 The command CO is used to configure the extended I O as inputs or outputs The CO command has one field DMC 18x6 Appendices 195 COn Where n is a decimal value which represents a binary number Each bit of the binary number represents one block of extended I O When set to 1 the corresponding block is configured as an output The least significant bit represents block 2 and the most significant bit represents block 9 The decimal value can be calculated by the following formula n n 2 n 4 n 4 8 n 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
44. 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 controller decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization The DMC 18x6 can also interface to encoders with pulse and direction signals Refer to the CE command in the command reference 4 Chapter 1 Overview for details DMC 18x6 There is no limit on encoder line density however the input frequency to the controller must not exceed 5 500 000 full encoder cycles second 22 000 000 quadrature counts sec For example if the encoder line density is 10 000 cycles per inch the maximum speed is 300 inches second If higher encoder frequency is required please consult the factory The standard encoder voltage level is TTL 0 5v however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 18x6 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 18x6 can accept analog feedback 10v instead of an encoder for any axis For more information see the command AF in the command reference To interface with other types of position sensors such as absolute encoders
45. all DMC 18x6 instructions is included in the Command Reference Command Syntax ASCII DMC 18x6 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 18x6 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 lt enter gt command IMPORTANT All DMC 18x6 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 For specifying data for the X Y Z and W axes commas are used to separate the axes If no data 1s specified for an axis a comma is still needed as shown in the examples below If no data is specified for an axis the previous value is maintained To view the current values for each command type the command followed by a for each axis requested PR 1000 Specify X only as 1000 PR 2000 Specify Y only as 2000 PR 3000 Specify Z only as 3000 DMC 18x6 Chapter 5 Command Basics 62 PR 4000 Specify W only as 4000 PR
46. 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 18x6 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 OElcommand Enable Off On Error is given and the position error exceeds the error limit As shown in Figure 3 3 AEN can be used to disable the amplifier for these 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 1900interface board To change the polarity from active high 5 volts enable zero volts disable to DMC 18x6 Chapter 3 Connecting Hardware 35 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 it so that Pin
47. apostrophe This command allows the user to include up to 78 characters on a single line after the NO command and can be used to include comments from the programmer as in the following example PATH 2 D CIRCULAR PATH VMXY VECTOR MOTION ON X AND Y VS 10000 VECTOR SPEED IS 10000 VP 4000 0 BOTTOM LINE CR 1500 270 180 HALF CIRCLE MOTION 120 Chapter 7 Application Programming DMC 18x6 VP 0 3000 TOP LINE CR 1500 90 180 HALF CIRCLE MOTION VE END VECTOR SEQUENCE BGS BEGIN SEQUENCE MOTION EN END OF PROGRAM Note The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Executing Programs Multitasking The DMC 18x6 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 Only the main thread thread 0 may use the input command IN 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 fA Where n indicates the thread number To halt the execution of any thread use the inst
48. axes power amplifier Interconnect module with 3 axes power amplifier Interconnect module with 4 axes power amplifier Two axis brush brushless amplifier Four axis brush brushless amplifier Utilities for Plug amp Play COMDISK firmware Servo Design Kit for Windows 3 X Servo Design Kit for Windows 98SE NT4 0 2000 or XP Visual Basic Tool Kit includes VBXs and OCXs Set up software for Windows 3 X Set up software for Windows 98SE NT4 0 2000 or XP AutoCAD DXF translator HPGL translator Appendices 187 ICM 1900 Interconnect Module The ICM 1900 interconnect module provides easy connections between the DMC 18x6 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 Two required for DMC 1856 to 1886 The ICM 1900 is contained in a metal enclosure A version of the ICM 1900 is also available with servo amplifiers see AMP 19X0 below The ICM 1900 can be purchased with an option to provide opto isolation see OPTO option below Features e Separate DMC 18x6 cables into individual screw type terminals Clearly identifies all terminals Provides jumper for connecting limit and input supplies to 5 V supply from PC e Available with on board ser
49. cam relationship described by the equation Y 2 0 5 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 The instruction EAX defines X as the master axis The cycle of the master is 2000 Over that cycle Y varies by 1000 This leads to the instruction EM 2000 1000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18X and X varies in increments 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 DMC 18x6 Chapter 6 Programming Motion 93 EM 2000 1000 Cam cycles EP 20 0 Master position increments N 0 Index LOOP Loop to construct table from equation P Note 3 6 0 18420 S SIN P 100 Define sine position Y N xl0 S Define slave position ET Y Define table N N JP LOOP N lt 100 Repeat the process EN Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center
50. comma delimitation The command CR r q d define a circular arc with a radius r starting angle of q and a traversed angle d The notation for q is that zero corresponds to the positive horizontal direction and for both q and d the counter clockwise CCW rotation is positive Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE The motion can be initiated with a Begin Sequence BGS command Once motion starts additional segments may be added The Clear Sequence CS command can be used to remove previous VP and CR commands which 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 coordinated motion This command requires the controller to decelerate to a stop following the last motion requirement If a VE command is not given an Abort ABI must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 18x6 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or LM returns the available spaces for motion segments that can be sent to the b
51. 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 32 Chapter 3 Connecting Hardware DMC 18x6 All motion programs that are currently running are terminated when a transition in the Abort input is detected A This can be configured with the CN command For information on setting the Off On Error function see the Command Reference OE amp CN Uncommitted Digital Inputs The DMC 18x6 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 IN1 goes high 1X80 Controllers with more than 4 axes have 16 optoisolated inputs and 8 TTL inputs which are denoted as Inputs 1 thru 24 For controllers with more than 4 axes the inputs 9 16 and the limit switch inputs for the additional axes are accessed through the second 100 p
52. distance traveled in coordinated move for T plane Buffer space remaining T Plane Axis information A axis status see bit field map below A axis switches see bit field map below A axis stop code A axis reference position A axis motor position A axis position error A axis auxiliary position A axis velocity A axis torque A axis analog input A Reserved for Hall Input Status A User defined variable ZA B axis status see bit field map below B axis switches see bit field map below B axis stop code B axis reference position B axis motor position Chapter 4 Software Tools and Communications 57 126 129 130 133 134 137 138 141 142 143 144 145 146 149 150 151 152 153 154 157 158 161 162 165 166 169 170 173 174 177 178 179 180 181 182 185 186 187 188 189 190 193 194 197 198 201 202 205 206 209 210 213 214 215 216 217 218 221 222 223 224 225 226 229 230 233 234 237 238 241 242 245 246 249 250 251 252 253 254 257 258 259 260 261 262 265 266 269 270 273 274 277 SL SL SL SL new size SW UW new SL new UW UB UB SL SL SL SL SL SL new size SW UW new SL new UW UB UB SL SL SL SL SL SL new size SW UW new SL new UW UB UB SL SL SL SL SL SL new size SW UW new SL new UW UB UB SL SL SL SL B axis position error B axis auxiliary position B axis velocity B axis torq
53. example LI x y Zw lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function 72100000 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 LMXY Define linear mode between X and Y axes DMC 18x6 Chapter 6 Programming Motion 79 LI 4000 0 lt 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 721000 Specify third linear segment with a vector speed of 4000 and end speed 1000 LE End linear segments BGS
54. example the crossover frequency was computed numerically resulting in 200 rad s Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 j200 2 j200 2000 a Arg A j200 tan 1 200 51 180 tan 200 2000 a 76 180 6 110 Finally the phase margin PM equals 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 18x6 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 cx 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 DMC 18x6 Chapter 10 Theory of Operation 177 Kt Nm A Torque constant J 2404 kg m System moment of inertia R 2 Q Motor resistance K 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of theDMC 18x6 outputs 10V for a 16 bit command
55. first parameter sets the values of the main output port of the controller Outputs 1 8 block 0 The additional parameters set the value of the extended I O as outlined OP m a b c d where m is the decimal representation of the bits 1 8 values from 0 to 255 and a b c d represent the extended I O in consecutive groups of 16 bits values from 0 to 65535 Arguments which are given for I O points which are configured as inputs will be ignored The following table describes the arguments used to set the state of outputs 196 Appendices DMC 18x6 Argument Blocks Bits Description m 0 1 8 General Outputs a 2 3 17 32 Extended I O b 4 5 33 48 Extended I O c 6 7 49 64 Extended I O d 8 9 65 80 Extended I O For example if block 8 is configured as an output the following command may be issued OP 7 7 This command will set bits 1 2 3 block 0 and bits 65 66 67 block 8 to 1 Bits 4 through 8 and bits 68 through 80 will be set to 0 All other bits are unaffected When accessing I O blocks configured as inputs use the TIn command The argument n refers to the block to be read n 0 2 3 4 5 6 7 8 or 9 The value returned will be a decimal representation of the corresponding bits Individual bits can be queried using the IN n function where n 1 through 8 or 17 through 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 configured as a
56. for each axis necessary For individual wires simply match the leads from the encoder you are using to 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 DMC 18x6 Chapter 2 Getting Started 13 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 lt return gt 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 c
57. from Galil have an option for opto isolated outputs Standard Opto isolation and High Current Opto isolation The Opto isolation option on the ICM 1900 has 2 forms ICM 1900 OPTO standard and ICM 1900 OPTOHC high current The standard version provides outputs with 4ma drive current output with approximately 2 usec response time The high current version provides 25ma drive current output with approximately 400 usec response time FROM ICM 1900 ICM 2900 CONTROLLER CONNECTIONS 5V ISO OUT POWER ICM 1900 PIN 19 OUT POWER ICM 2900 RP4 on ICM1900 10K OHMS RP3 RP2 on ICM2900 OUT x 66 73 ISO POWER GND ICM 1900 PIN 35 OUT x TTL bd OUT GND ICM 2900 Figure A 2 Opto Output Circuit The ISO OUT POWER OUT POWER ON ICM 2900 and ISO POWER GND OUT GND ON ICM 2900 signals should be connected to an isolated power supply This power supply should be used only to power the outputs in order to obtain isolation from the controller The signal OUT x is one of the isolated digital outputs where X stands for the digital output terminals The default configuration is for active high outputs If active low outputs are desired reverse RP3 in it s socket This will tie RP3 to GND instead of VCC inverting the sense of the outputs NOTE If power is applied to the outputs with an isolated power supply but power is not applied to the controller the outputs will float high unable to sink current This may present
58. functions However the argument must be expressed in degrees Using our example the equation for X is written as X 50T 955 sin 3T A complete program to generate the contour movement in this example is given below To generate an array we compute the position value at intervals of 8 ms This is stored at the array POS Then the difference between the positions is computed and is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example INSTRUCTION INTERPRETATION POINTS Program defines X points DM POS 16 Allocate memory DM DIF 15 C 0 Set initial conditions C is index T 0 T is time in ms HA V1 50 T V2 3 T Argument in degrees V3 955 SIN V2 V1 Compute 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 D C 1 DIF C POS D POS C Compute the difference and store 1 JP lt 15 RUN Program to run motor CMX Contour Mode DT3 8 millisecond intervals C 0 HE CD DIF C Contour Distance is in DIF C C 1 JP E C lt 15 CD 0 0 End contour buffer Wait JP Wait CM lt gt 511 until path is done EN End the program DMC 18x6 Chapter 6 Programming Motion 99 Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 18x6 automatic array capture feature to capture position data
59. held in the array An array name can contain up to eight characters starting with an uppercase alphabetic character The number of entries in the defined array is enclosed in Example DM POSX 7 Defines an array names POSX with seven entries DM SPEED 100 Defines an array named speed with 100 entries DM POSX 0 Frees array space Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the POSX array defined with the DM command DM POSX 7 would be specified as POSX 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples DM SPEED 10 Dimension Speed Array SPEED 1 7650 2 Assigns the first element of the array SPEED the value 7650 2 SPEED 1 Returns array element value POSX 10 TPX Assigns the 10 element of the array POSX the returned value from the tell position command CON 2 QCOS POS 2 Assigns the second element of the array CON the cosine of the variable POS multiplied by 2 TIMER 1 TIME Assigns the first element of the array timer the returned value of the TIME keyword Using a Variable to Address Array E
60. in Fig 4 3 select Display Data Record under the Tools menu of DMC SmartTERM DMC 18x6 Chapter 4 Software Tools and Communications 43 Axis Status Waiting for input from IN command Move in Progressi Mode of Motion PA or PRI Mode of Motion PA only 2504 pm L IS T Fest Output Bank 1 JI L 081 ino Bank 3 08 ino Bank 4 18 0 Configured input Bank 5 L M ino Bank 6 81 contd Input Bank 7 LLLI 1I contd trove Bank Axis Switches ix v z w BB B lt gt of Latch Input IB B of Forward Limit State of Reverse Limit D 0 Of Distance Traveled Figure 4 3 Data Record 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 44 Chapter 4 Software Tools and Communications DMC 18x6 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 appl
61. is backlash compensation described below The second encoder may be a standard quadrature type or it may provide pulse and direction The controller also offers the provision for inverting the direction of the encoder rotation The main and the auxiliary encoders are DMC 18x6 Chapter 6 Programming Motion 107 configured with the CE command The command form is CE x y z w or a b c d e f g h for controllers with more than 4 axes where the parameters x y z w each equal the sum of two integers m and n m configures the main encoder and n configures the auxiliary encoder Using the CE Command Normal quadrature Normal quadrature Reversed quadrature Reverse quadrature Reverse pulse amp direction 2 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 DIN 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 instructions Vl _DEX The command TD XYZW returns the current position of the
62. less axis of standard control for each axis of sinusoidal commutation For example if the command BAX is given to a DMC 1846 controller the controller will be re configured to be a DMC 1836 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 is the X axis Example Sinusoidal Commutation Configuration using a DMC 1876 BAXZ This command causes the controller to be reconfigured as a DMC 1856 controller The X and Z 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 F signal The first phase of the Z axis will be the motor command Z signal The second phase of the Z axis will be the motor command G signal Step 7 Make Connections to Amplifier and Encoder Once you have established communications between the software and the DMC 18x6 you are ready to connect the rest of the motion control system The motion
63. motion towards position 5000 changes the target to 2000 and then changes it again to 8000 Figure 4 shows the plot of position vs time Figure 5 plots velocity vs time and Figure 6 demonstrates the use of motion smoothing IT on the velocity profile in this mode The jerk in the system is also affected by the values set for AC and DC Figure 6 4 Position vs Time msec Motion 4 76 Chapter 6 Programming Motion DMC 18x6 Figure 6 5 Velocity vs Time Motion 4 Figure 6 6 Velocity cts sec vs Time msec with IT Note the controller treats the point where the velocity passes through zero as the end of one move and the beginning of another move IT is allowed however it will introduce some time delay Trip Points Most trip points are valid for use while in the position tracking mode There are a few exceptions to this the AM and MC commands may not be used while in this mode It is recommended that MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position DMC 18x6 Chapter 6 Programming Motion 77 Command Summary Position Tracking Mode MF n n n n n n n n Trip point to hold up program execution until n number of counts have passed in the forward direction Only one axis at a time may be specified reverse direction Only one axis at a time may be specified Linear Interpolation Mode The DMC 18x6 provides a linear interpolation mode for 2 or more a
64. on specifying a coordinate system For example BGS Begin coordinated sequence on S coordinate system BG TW Begin coordinated sequence on T coordinate system and W axis Command Syntax Binary advanced Some commands have an equivalent binary value Binary communication mode can be executed about 20 faster than ASCII commands Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format All binary commands have a 4 byte header and is followed by data fields The 4 bytes are specified in hexadecimal format DMC 18x6 Chapter 5 Command Basics 63 Header Format Byte 1 specifies the command number between 80 to FF The complete binary command number table is listed below Byte 2 specifies the of bytes in each field as 0 1 2 4 or 6 as follows 00 01 02 04 06 No data fields i e SH or BG One byte per field One word 2 bytes per field One long word 4 bytes per field Galil real format 4 bytes integer and 2 bytes fraction Byte 3 specifies whether the command applies to a coordinated move as follows 00 01 No coordinated motion movement Coordinated motion movement For example the command STS designates motion to stop on a vector move S coordinate system The third byte for the equivalent binary command would be 01 Byte 4 specifies the axis or data field as follows Bit 7 H axis or 8 data field Bit 6 axis or 7
65. order to set the desired update rates use the command TM When the controller is operating with the fast firmware the following functions are disabled Gearing mode Ecam mode Pole PL Analog Feedback AF Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in thread 2 8 Data Record Tell Velocity Interrogation Command TV Aux Encoders TD Dual Velocity DV Peak Torque Limit TK Notch Filter NB NF NZ Second field of EI DMC 18x6 Chapter 6 Programming Motion 117 Chapter 7 Application Programming Overview The DMC 18x6 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the controller 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 18x6 provides commands that allow the controller 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 LOOP if the variable n is less than 10 For greater programming flexibility the DMC 18x6 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
66. program which the operator can change as necessary The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 80 characters x 2000 lines Using the DMC 18x6 Editor to Enter Programs Galil s SmartTerminal and WSDK software provide an editor and UPLOAD and DOWNLOAD utilities Application programs for the DMC 18x6 may also be created and edited locally using the DMC 18x6 The DMC 18x6 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number or label by specifying a line number or label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN Line 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 pr
67. ridden by using parentheses Examples V1 ABS V7 The variable V1 is equal to the absolute value of variable V7 V2 5 SIN POS The variable V2 is equal to five times the sine of the variable POS V3 IN 1 The variable V3 is equal to the digital value of input 1 V4 2 5 ANJ5 The variable V4 is equal to the value of analog input 5 plus 5 then multiplied by 2 Variables For applications that require a parameter that is variable the DMC 18x6 provides 510 variables These variables can be numbers or strings A program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by program calculations For example a cut to length application may require that a cut length be variable Example PR POSX Assigns variable POSX to PR command JG RPMY 70 Assigns variable RPMY multiplied by 70 to JG command 140 Chapter 7 Application Programming DMC 18x6 Programmable Variables The DMC 18x6 allows the user to create up to 510 variables Each variable is defined by a name which can be up to eight characters The name must start with an alphabetic character however numbers are permitted in the rest of the name Spaces are not permitted Variable names should not be the same as DMC 18x6 instructions For example PR is not a good choice for a variable name USER LOWER CASE FOR VARIABLE NAMES Examples of valid and invalid variable
68. terminal Any ASCII character can be sent by using the format where n is any integer between 1 and 255 Example MG 07 4255 sends the ASCII characters represented by 7 and 255 to the bus 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 Zn m Same as Fn m but suppress leading zeroes Sn Pal 5 ET 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 1 TPX Assign the first entry VI Print V1 Interrogation Commands The DMC 18x6 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 5 148 Chapter 7 Application Programming DMC 18x6 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by
69. the controller using DMCSmartTERM Note In order for the PC to recognize the plug and play controller as a Galil device the Galil software must be loaded prior to installing the card Select Motion Controller P x Controller 14 7 PCI Address 57332 Interrupt Level 18 Serial 0 Controller2 DMC 1800 PCI Address 57248 Interrupt Level 18 Serialtt21234 DMC 18x0 and DMC 1417 in the Galil Registry Once communication is established click on the menu for terminal and you will receive a colon prompt Communicating with the controller is described in later sections DMC 18x6 Chapter 2 Getting Started 11 Sending Test Commands to the Terminal After you connect your terminal press lt carriage return gt or the lt enter gt key on your keyboard In 66 99 response to carriage return CR the controller responds with a colon Now type TPX CR This command directs the controller to return the current position of the X axis The controller should respond with a number such as 0 Step 6 Determine the Axes to be Used for Sinusoidal Commutation Note 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
70. 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 is specified by PF m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format Hex values are returned preceded by a and in 2 s complement Hex values should be input as signed 2 s complement where negative numbers have a negative sign The default format 1s PF 10 0 If the number of decimal places specified by PF is less than the actual value a nine appears in all the decimal places Examples DP21 Define position TPX Tell position 0000000021 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 Commands 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 Respon
71. to arm the latch for the main encoder and ALSXSYSZSW for the auxiliary encoders 2 Test to see if the latch has occurred Input goes low by using the AL X or Y or Z or W command Example V1 _ALX returns the state of the X latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the RL XYZW command or _RL XYZW Note The latch must be re armed after each latching event Example Latch JG 5000 BGY AL Y 7 Wait JP Wait ALY 1 Result _RLY Result EN 116 Chapter 6 Programming Motion 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 DMC 18x6 Fast Update Rate Mode The DMC 18x6 can operate with much faster servo update rates than the default of every millisecond This mode is known as fast mode and allows the controller to operate with the following update rates DMC 1816 31 25 usec DMC 1826 31 25 usec DMC 1836 62 5 psec DMC 1846 62 5 usec DMC 1856 93 75 usec DMC 1866 93 75 usec DMC 1876 125 usec DMC 1886 125 usec In order to run the DMC 18x6 motion controller in fast mode the fast firmware must be uploaded This can be done through the Galil terminal software such as DMCTERM and WSDK The fast firmware is included with the original DMC 18x6 utilities In
72. useful for teaching motion trajectories or observing system performance Up to eight types of data can be captured and stored in eight arrays The capture rate or time interval may be specified Recording can done as a one time event or as a circular continuous recording Command Summary Automatic Data Capture COMMAND DESCRIPTION RA n m o p Selects up to eight arrays for data capture The arrays must be defined with the DM command RD typel type2 type3 type4 Selects the type of data to be recorded where typel type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command The RC command begins data collection Sets data capture time interval where nis an integer between 1 and 8 and designates 2 msec between data m is optional and specifies the number of elements to be captured If m is not defined the number of elements defaults to the smallest array defined by DM When m is a negative number the recording 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 144 Chapter 7 Application Programming DMC 18x6 Data Types for Recording DATA TYPE DESCRIPTION Controller time as reported by the TIME command Analog input n X Y Z
73. will be engaged For example the same master X axis in this case travels at 1 000 000 counts sec and the gear ratio is 1 1 but the gearing is slowly engaged over 30 000 cts of the master axis greatly diminishing the initial shock to the slave axis Figure 1 below shows the velocity vs time profile for instantaneous gearing Figure 6 9 shows the velocity vs time profile for the gradual gearing engagement p 4 800 1 D 1 D 1 1 1 wenn gene 800 Figure 6 9 Velocity cts sec vs Time msec Instantaneous Gearing Engagement 88 Chapter 6 Programming Motion DMC 18x6 Figure 6 10 Velocity cts sec vs Time msec Ramped Gearing The slave axis for each figure is shown on the bottom portion of the figure the master axis is shown on the top portion The shock to the slave axis will be significantly less in figure 6 10 than in figure 6 9 The ramped gearing does have one consequence There isn t a true synchronization of the two axes until the gearing ramp is complete The slave will lag behind the true ratio during the ramp period If exact position synchronization is required from the point gearing is initiated then the position must be commanded in addition to the gearing The controller keeps track of this position phase lag with the GP operand The following example will demonstrate how the command is used Example Electronic Gearing Over a Specified Interval Objective Run two geared moto
74. 0 176 Stack 132 135 153 Zero Stack 135 153 Status 145 Interrogation 81 87 147 148 Stop Code 66 145 Tell Code 66 Step Motor 111 KS Smoothing 69 79 80 84 86 109 11 Stepper Position Maintenance 103 Stop Abort 31 32 56 78 84 161 163 181 185 86 Stop Code 66 133 142 145 46 145 154 56 158 60 Stop Motion 78 84 134 164 Subroutine 31 83 120 128 34 153 162 63 Automatic Subroutine 120 132 Synchronization 4 91 Syntax 62 63 T Tangent 69 83 85 86 Teach 100 Data Capture 144 45 Latch 66 116 Play Back 69 145 Position Capture 116 Record 69 97 100 143 145 Tell Code 66 Tell Error 66 Position Error 15 52 53 120 132 34 142 144 45 154 160 Tell Position 66 Tell Torque 66 Terminal 32 35 62 118 141 148 Theory 167 Damping 170 Digital Filter 62 174 75 177 79 Modelling 167 170 71 175 PID 16 170 180 Stability 108 9 159 165 66 170 176 DMC 18x6 Time Clock 142 TIME 142 43 Time Interval 96 97 100 144 Timeout 120 125 133 134 MCTIME 120 125 133 134 Torque Limit 15 Trigger 118 123 126 28 169 Trippoint 70 79 80 85 86 125 26 131 132 Troubleshooting 165 TTL 5 31 35 161 Tuning SDK 118 Stability 108 9 159 165 66 170 176 U Upload 118 User Unit 151 V Variable Internal 129 141 142 Vector Acceleration 80 81 86 156 Vector Deceleration 80 81 86 Vector Mode Circle 156 Circular Interpolation 83 86 87 144 156 Cle
75. 0 140 6 point in the ECAM table ET 6 280 140 Tu point in the ECAM table ET 7 240 120 8 point in the ECAM table ET 8 120 60 gh point in the ECAM table ET 9 40 20 10 point in the ECAM table ET 10 0 0 Starting point for next cycle EB 1 Enable ECAM mode JGZ 4000 Set Z to jog at 4000 EG 0 0 Engage both X and Y when Master 0 BGZ Begin jog on Z axis ZLOOP JPZLOOP V1 0 Loop until the variable is set EQ2000 2000 Disengage X and Y when Master 2000 MF 2000 Wait until the Master goes to 2000 STZ Stop the Z axis motion EB 0 Exit the ECAM mode EN End of the program The above example shows how the ECAM program is structured and how the commands can be given to the controller The next page provides the results captured by the WSDK program This shows how the motion will be DMC 18x6 Chapter 6 Programming Motion 95 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 coerce Three Storage Scopes w File Collection Graph First Scope x Actual Position Zoom Normal Second Scope v Position Zoom Normal Third Scope z Position Zoom Normal Command String iStart Collecting Figure 6 12 Three Storage Scopes Contour Mode The DMC 18x6 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 comp
76. 0 LINPOS TEX Find the correction JP C ABS ERR lt 2 Exit if error is small PR ERR Command correction BGX JP 4B Repeat the process HC EN 160 Chapter 7 Application Programming DMC 18x6 Chapter 8 Hardware amp Software Protection Introduction The DMC 18x6 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 18x6 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 18x6 Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 18x6 includes hardware input and output protection lines for various error and mechanical limit conditions These include Output Protection Lines Amp Enable This signal goes low when the motor off command is given when the position error exceeds the value specified by the Error Limit ER command or when off on error condition is enabled OE1 and the abort command is given Each axis amplifier has separate amplifier enable lines This signal also goes low when the watch dog timer is activated or upon reset Note The standard configuration of the AEN s
77. 0 Wait 500 ms 1 Report the value of V1 JP C V1 0 Exit if position 0 JP B Repeat otherwise C Label C EN End of Program To start the program command XQ fA Execute Program A 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 18x6 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 8 Note that the vector motion starts at a local position 0 0 which is defined at the beginning of any vector motion sequence See application programming for further information Instruction Interpretation VM 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 decelera
78. 00 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as G j500 P G500D 160 and arg G j500 tan 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 Therefore D 20274 and G 82 4 0 2744s The function G is equivalent to a digital filter of the form D z KP KD 1 z where P KP D KD T and KD D T Assuming a sampling period of T 1ms the parameters of the digital filter are KP 82 4 KD 247 4 The DMC 18x6 can be programmed with the instruction KP 82 4 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters DMC 18x6 Chapter 10 Theory of Operation 179 Equivalent Filter Form DMC 18x6 Digital D z K z A z Cz z 1 1 B Z B Digital D z KP KD 1 z P KI 2 1 z7 1 B Z B KP KD KI PL K KP KD A KD KP KD C KI2 B PL Continuous G s P Ds I s a sta PID T P KP D T KD I KI 2T 1 T In 1 PL 180 Chapter 10 Theory of Operation DMC 18x6 Appendices Electrical Specifications Servo Control ACMD Amplifier Command 10 Volts analog signal Resolution 16 bit DAC or 0 0003 Volts 3 mA maximum A A B B IDX IDX Encoder and Auxiliary TTL compatible but can accept up to 12 Volts
79. 1 142 43 TIME 142 43 L Label 35 73 79 83 93 95 100 109 116 118 23 125 34 142 146 148 151 54 156 159 60 163 LIMSWI 162 63 POSERR 162 63 Special Label 120 163 Latch 66 116 Arm Latch 116 Data Capture 144 45 Position Capture 116 Record 69 97 100 143 145 Teach 100 Limit Torque Limit 15 Limit Switch 31 32 120 21 132 33 142 162 63 LIMSWI 31 120 132 33 162 63 Linear Interpolation 68 73 80 82 87 96 Clear Sequence 78 80 84 86 Logical Operator 129 Masking Bit Wise 129 138 Math Function Absolute Value 92 130 140 162 Bit Wise 129 138 Cosine 69 139 40 143 Logical Operator 129 Sine 69 94 140 Mathematical Expression 129 138 140 MCTIME 120 125 133 134 Memory 62 99 118 122 129 133 142 144 Array 3 69 82 98 100 118 122 129 139 142 50 151 182 Download 62 118 144 Upload 118 Index 219 Message 83 122 133 34 139 145 47 153 163 Modelling 167 170 71 175 Motion Complete MCTIME 120 125 133 134 Motion Smoothing 69 109 111 S Curve 79 110 Motor Command 15 175 Moving Acceleration 127 28 146 151 154 56 212 13 Begin Motion 120 21 126 27 133 34 142 145 46 151 153 Circular 83 86 87 144 156 Home Inputs 111 Multitasking 121 Halt 79 121 25 127 28 152 Off On Error 161 162 Off On Error 13 32 35 161 162 Operand Internal Variable 129 141 142 Operators Bit Wise 129 138 Optoisolation
80. 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 through a 2kQ resistor For a schematic of how to wire this signal configuration and other AEN options please see Application note 1452 on Galil s web site at http www galilmc com literature technotes html DMC 18X6 DMC 1700 1800 ICM 1900 2900 Connection to 5V or 12V made through Resistor pack RP1 Removing 1 av 5V the resistor pack allows the user to connect their own resistor to the desired voltage level Up to24V Accessed by removing Interconnect cover AMPENX SERVO MOTOF ere Es 100 PIN HIGH DENSITY CABLE 7407 Open Collector Buffer The Enable signal can be inverted by using a 7406 Accessed by removing Interconnect cover Analog Switch Figure 3 3 Connecting AEN to the motor amplifier TTL Inputs As previously mentioned the DMC 18x6 has 8 uncommitted TTL level inputs for controllers with 5 or more axes These are specified as INx where x ranges from 17 thru 24 and are interrogated using the operand IN x These inputs are brought out on the 5 8 axis connection where the analog inputs are located on the 1 4 axes connector The reset input is also a TTL level non isolated signal and is used to locally reset the DMC 18x6 without resetting the PC 36 Chapter 3 Connecting
81. 2 2 VS XS YS 75 where XS YS and ZS are the speed of the X Y and Z axes The controller always uses the axis specifications from LM not LI to compute the speed IT is used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trippoint which halts program execution until the vector distance of n has been reached An Example of Linear Interpolation Motion LMOVE label DP 0 0 Define position of X and Y axes to be 0 LMXY Define linear mode between X and Y axes LI 5000 0 Specify first linear segment LI 0 5000 Specify second linear segment LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector distance of 4000 is reached VS 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached VS 4000 Change vector speed EN Program end In this example the XY system is required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trippoint which slows the speed to 1000 count s Once the motors reach the corner the speed is increased back to 4000 cts s Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications such as CNC it is necessary to attach various speeds to different motion segments This can be done by two functions lt n and gt m For
82. 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 18x6 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 request 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 For controllers with 5 or more axes the axes are referred to as A B C D E F G H The specifiers X Y Z W and A B C D may be used interchangeably BG ABCDEFGH Begin all axes BGD Begin D only Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S or T is used to specify the coordinated motion This allows for coordinated motion to be setup for two separate coordinate systems Refer to the CA command in the Command Reference for more information
83. 256 136 Chapter 7 Application Programming DMC 18x6 DMC 18x6 JS zeroAry speeds 0 JS zeroAry other 0 EN zeroAry a b 0 1 JP zeroAry b a 1 EN Example Abstracting Axes Axes JS runMove 0 10000 1000 100000 100000 MG Position JS EN runMove a a PR a b 5 AC a d DC a e BG a MC a EN IP a Example Local Scope Local JS POWER 2 2 MG JS JS POWER 2 16 G JS JS4 POWER 2 8 GG JS POWER Gel IF b 0 EN 1 ENDIF F lt 0 d 1 b ABS b ELSE d 0 ENDIF PWRHLPR H 3 b b 1 P PWRHLPR b gt 0 IF d 1 1 7 Chapter 7 Application Programming 137 ENDIF EN c Executed program from programl dmc 4 0000 65536 0000 0 0039 Example Recursion JS AxsInfo 0 MG Z2 0 Recursed through JS stacks EN AxsInfo eg b a 41 1000000 MG b S1 Axis N MG F8 0 Position TP h Error TE h Torque TT h F1 4 IF 7 EN 1 ENDIF JStAxsInfo a 1 EN _JS 1 Executed program from programl dmc Axis Position 00029319 Error 00001312 Torque 9 9982 Axis Position 00001612 Error 00000936 Torque 1 7253 Axis Position 00001696 Error 00001076 Torque 1 9834 Axis Position 00002020 Error 00001156 Torque 2 1309 Axis Position 00000700 Error 00001300 Torque 2 3963 Axis Position 00000156 Error 00000792 Torque 1 4599
84. 3 outputs 33 48 extended I O banks 4 amp 5 outputs 49 64 q extended I O banks 6 amp 7 outputs 65 80 Sets the output bit to a logic 1 n is the number of the output from 1 to 80 Clears the output bit to a logic 0 n is the number of the output from 1 to 80 Sets the state of an output as 0 or 1 also able to use logical conditions Returns the state of 8 digital inputs as binary converted to decimal n is the bank number 2 Operand internal variable that holds the same value as that returned by TI n Function that returns state of individual input bit n is number of the input from 1 to 80 Screw Terminal Listing Rev A B boards orange and Rev C boards black have the pinouts listed below 208 Appendices REV A B TERMINAL TERMINAL O DN BW NO NNN NN BR Be Be ee ee Be BR U Ne C Oo Dn FB WN C REV C LABEL DESCRIPTION GND Ground 2 5V 5V DC out 1 GND Ground 4 5V 5V DC out 3 1 080 bit 80 6 1 079 I O bit 79 5 I O78 I O bit 78 8 1077 T O bit 77 7 1 076 I O bit 76 10 I O75 I O bit 75 9 I O74 I O bit 74 12 1 073 I O bit 73 11 OUTC73 80 Out common for I O 73 80 14 I OC73 80 I O common for I O 73 80 13 I O72 I O bit 72 16 I O71 I O bit 71 15 I O70 I O bit 70 18 1 069 bit 69 17 1 068 bit 68 20 1 067 bit 67 19 1 066 bit 66 22 1 065 bit 65 21 OUTC65 72 Out common for I O 65 72 24 I OC65 72 I O common for I O 65 72 DMC 18x6 DMC 18x6 25
85. 32 62 78 98 99 108 10 116 118 121 25 127 129 133 136 43 147 48 151 55 156 159 60 Functions Arithmetic 118 129 139 151 G Gain 142 147 Proportional 170 Gear Ratio 87 90 Gearing 68 69 87 91 H Halt 79 121 25 127 28 152 DMC 18x6 Abort 31 32 56 78 84 161 163 181 185 86 Off On Error 13 32 35 161 162 Stop Motion 78 84 134 164 Hardware 31 52 151 161 Address 143 45 216 Amplifier Enable 35 161 Clear Bit 151 Jumper 35 166 Output of Data 147 Set Bit 151 TTL 5 31 35 161 Home Input 32 143 Home Inputs 111 Homing 32 Find Edge 32 Lo Amplifier Enable 35 161 Analog Input 73 Clear Bit 151 Digital Input 31 33 140 152 Digital Output 140 151 Home Input 32 143 Output of Data 147 Set Bit 151 TTL 5 31 35 161 ICM 1100 13 35 161 Independent Motion Jog 72 73 87 95 116 126 27 133 35 142 159 162 Index Pulse 13 32 ININT 120 133 34 153 Input Analog 73 Input Interrupt 53 120 127 133 34 153 ININT 120 133 34 153 Input of Data 146 Inputs Analog 3 31 35 140 41 143 147 153 54 159 181 Installation 165 Integrator 170 Interconnect Module ICM 1100 13 35 161 Interface Terminal 62 Internal Variable 129 141 142 Interrogation 66 67 81 87 147 148 Interrupt 52 120 21 127 132 34 153 Invert 107 DMC 18x6 J Jog 72 73 87 95 116 126 27 133 35 142 159 162 Joystick 73 141 158 59 Jumper 35 166 K Keyword 129 139 14
86. 4 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 Ground 5V Limit common 2 Home H Reverse limit H Forward limit H Home G Reverse limit G Forward limit G Home F Reverse limit F Forward limit F Home E Reverse limit E Forward limit E Ground 5V Input common 2 Latch E Latch F Latch G Latch H Input 13 Input 14 Input 15 Input 16 Reserved J7 DMC 1886 E H AXES AUXILIARY ENCODER 26 PIN IDC 1 5V 2 Ground A Aux E A Aux E B Aux E B Aux E A Aux F A Aux F B Aux F 10 B Aux F 11 5V 12 Ground 13 A Aux G 14 A AuxG 15 B AuxG 16 B AuxG 17 A AuxH 18 A Aux H 19 B AuxH 20 B Aux H 21 Sample Clock 22 NC 23 NC 24 NC 25 NC 26 NC O Dn A Q DMC 18x6 29 I E 30 I E 31 32 A F 33 34 B F 35 I 36 I F 37 A G 38 A G 39 B G 40 B G 41 I G 42 I G 43 44 45 B 46 47 I 48 I H 49 12V 50 12V 79 80 8 82 83 84 85 86 Output 9 Output 10 Output 11 Output 12 Output 13 Output 14 Output 15 Output 16 87 45V 88 89 90 9 92 93 94 95 96 97 98 99 pa Ground Ground Ground Input 17 Input 18 Input 19 Input 20 Input 21 Input 22 Input 23 Input 24 12V 100 12V Pin Out Description for DMC 18x6 DMC 18x6 Outputs Analog Motor Command 10 Volt range signal for driving amp
87. 5 High Speed Position Capture The Latch Function sese 116 Fast Update Rate Mode sse eene ener rennen 117 Chapter 7 Application Programming 118 uaa 118 Using the DMC 18x6 Editor to Enter 118 Edit M de Cotnimands ee te ttai ttt 119 Prostran Format siete terr ovt E Oleo 119 Using Labels in Programs ccccesscesscesecesecesecnecseecaeecseeeseseeeeeesseenseenseenseenaeenaes 119 oe d eee tecti eese it beet i de e ee 120 Commenting Programs eene ener enne trennen nennen 120 Executing Programs Multitasking eren eren 121 Debugging Programs 2 nne nnne n nnne nr en eren 122 Program Flow Commands esses eere enne eene nennen nennen nnns 123 Event Triggers amp Trippoints ccccccccssesssesscessceesceeeceeceseceaecssecaeecaeeeseeseeeneeserenrens 124 Event Trigger Examples sess 126 Conditional Jumps sess enne nnns 128 Using If Else and Endif Commands sse 130 xlii E 131 Stack Manipulation eiecti tette dieere et Pe 132 Auto Start Routine t eee orta eo e pere rete 132 Automatic Subroutines for Monitoring Conditions sse 132 JS Subroutine Stac
88. 5 usec 156 25 usec 93 75 usec 156 25 usec 93 75 usec 187 5 usec 125 usec 187 5 usec 125 usec 1 quadrature count Phase locked better than 0 005 System dependent 2147483647 counts per move Up to 22 000 000 counts sec Servo 6 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1 104 16000 elements 30 arrays 2000 lines x 80 characters DMC 18x6 Connectors for DMC 18x6 Main Board J1 DMC 1846 A D AXES MAIN 100 PIN HIGH DENSITY 1 O OQ tA d WN _ Oo o tn FP WN 2 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Analog Ground Ground 5V 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 X Step X Amp enable W Amp enable Z Amp enable Y Amp enable X A X DMC 18x6 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 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
89. 59 60 61 62 65 66 67 68 69 70 71 72 75 76 77 78 79 80 81 82 85 86 89 90 93 94 97 98 101 102 105 106 107 108 109 110 113 114 115 116 117 118 121 122 125 DMC 18x6 ecco c B SW new SW new SW new SW new SW new SW new SW new SW new mw L new L new W new W new UW UB UB L L L S S S SL SL SL new size SW UW new SL new UW UB UB SL SL general output block 0 outputs 1 8 general output block 1 outputs 9 16 general output block 2 outputs 17 24 general output block 3 outputs 25 32 general output block 4 outputs 33 40 general output block 5 outputs 41 48 general output block 6 outputs 49 56 general output block 7 outputs 57 64 general output block 8 outputs 65 72 general output block 9 outputs 73 80 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved error code thread status see bit field map below Reserved Segment Count for Contour Mode Buffer space remaining Contour Mode segment count of coordinated move for S plane coordinated move status for S plane see bit field map below distance traveled in coordinated move for S plane Buffer space remaining S Plane segment count of coordinated move for T plane Coordinated move status for T plane see bit field map below
90. 7 Input 8 Input 1 Used for X axis latch input Input 2 Used for Y axis latch input Input 3 Used for Z axis latch input Input 4 Used for W axis latch input 5 Volts 12 Volts 12 Volts Isolated Analog Ground for Use with Analog Inputs Input Common For General Use Inputs Abort Input Reset Input Signal Ground Analog Input 5 Analog Input 6 Analog Input 7 Analog Input 8 Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 5Volts X Main encoder Index X Main encoder Index Signal Ground X Main encoder A X Main encoder A X Main encoder B X Main encoder B 5Volts Y Main encoder Index Y Main encoder Index Appendices 193 194 Appendices 21 22 22 22 22 23 23 23 23 24 24 24 24 25 25 25 25 26 26 26 26 GND MAY MAY MBY MBY INZ GND MAZ MBZ MBZ INW GND MAW MAW MBW MBW nm Signal Ground Y Main encoder Y Main encoder A Y Main encoder B Y Main encoder B 5Volts Z Main encoder Index Z Main encoder Index Signal Ground Z Main encoder Z Main encoder A Z Main encoder B Z Main encoder B 5Volts W Main encoder Index W Main encoder Index Signal Ground Main encoder A Main encoder A Main encoder B z zzz Main encoder B DMC 18x6 Opto Isolated Outputs ICM 1900 ICM 2900 Opto option The ICM AMP 1900 and ICM 2900 modules
91. 73 80 82 87 96 Cosine 69 139 40 143 Cycle Time Clock 142 D DAC 170 174 75 178 Damping 170 Data Capture 144 45 Data Output Set Bit 151 Debugging 122 Deceleration 146 Differential Encoder 13 16 Digital Filter 62 174 75 177 79 Digital Input 31 33 140 152 Digital Output 140 151 Clear Bit 151 Dip Switch Address 143 45 216 DMA 3 Download 62 118 144 Dual Encoder 66 108 145 Backlash 69 107 9 159 Dual Loop 69 101 9 101 9 101 9 159 Dual Loop 69 101 9 101 9 101 9 159 Backlash 69 107 9 159 E Ecam 92 95 Electronic Cam 68 69 91 93 Edit Mode 118 123 133 Editor 118 19 EEPROM 3 218 Index Electronic Cam 68 69 91 93 Electronic Gearing 68 69 87 91 Ellipse Scale 86 Enable Amplifer Enable 35 161 Encoder Auxiliary Encoder 31 90 101 9 101 9 101 9 186 188 190 193 194 Differential 13 16 Dual Encoder 66 108 145 Index Pulse 13 32 Quadrature 4 107 151 154 162 173 Error Code 133 142 145 46 154 56 158 60 Error Handling 31 120 132 33 162 63 Error Limit 13 15 35 133 161 63 Off On Error 13 32 35 161 162 Example Wire Cutter 154 F Feedrate 80 84 86 127 156 FIFO 3 54 55 Filter Parameter Damping 170 Gain 142 147 Integrator 170 PID 16 170 180 Proportional Gain 170 Stability 108 9 159 165 66 170 176 Find Edge 32 Flags Almost full 55 Formatting 147 148 50 Frequency 5 111 176 78 Function
92. 80 CCW 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 WT50 Wait 50 msec for the knife to engage BGS Do the circular cut AMS After the coordinated move is complete CBO Disengage knife MG ALL DONE EN End program Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION DMC 18x6 Chapter 6 Programming Motion 85 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 CR r O tAO Specifies arc segment where r is the radius O is the starting angle and AO is the travel angle Positive direction is CCW Specify vector speed or feed rate of sequence Specify vector acceleration along the sequence Specify vector deceleration along the sequence Specify vector speed ratio Begin motion sequence S or T Clear sequence S or T Trippoint for After Relative Vector distance Holds execution of next command until Motion Sequence is complete Tangent scale and offset Ellipse scale factor S curve smoothing constant for coordinated moves Return number of available spaces for linear and circular segments in DMC 18x6 sequence buffer Zero means buffer is full 511 means buffer is empty CAS or CAT Specifies which coordinate system is to
93. 982 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 18x6 60 Chapter 4 Software Tools and Communications THIS PAGE LEFT BLANK INTENTIONALLY DMC 18x6 Chapter 4 Software Tools and Communications 61 Chapter 5 Command Basics Introduction The DMC 18x6 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands can be sent in ASCII or binary In ASCII the DMC 18x6 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 18x6 or an entire group of commands can be downloaded into the controller s 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 18x6 instruction set and syntax A summary of commands as well as a complete listing of
94. A tA WN Appendices 209 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 70 69 72 71 74 73 76 75 78 77 80 79 82 81 84 83 86 85 88 87 90 89 92 91 94 93 96 95 98 97 100 99 102 101 104 103 1 027 1 026 1 025 OUTC25 32 I OC25 32 OUTC25 32 I OC25 32 PWROUT32 PWROUT31 PWROUT30 PWROUT29 PWROUT28 PWROUT27 PWROUT26 PWROUT25 1 024 1 023 1 022 1 021 1 020 I O19 I O18 I O17 OUTC17 24 I OC17 24 OUTC17 24 I OC17 24 PWROUT24 PWROUT23 PWROUT22 PWROUT21 PWROUT20 PWROUTI9 PWROUT18 PWROUT17 GND I O bit 27 I O bit 26 I O bit 25 Out common for I O 25 32 I O common for I O 25 32 Out common for I O 25 32 I O common for I O 25 32 Power output 32 Power output 31 Power output 30 Power output 29 Power output 28 Power output 27 Power output 26 Power output 25 I O bit 24 I O bit 23 I O bit 22 I O bit 21 I O bit 20 I O bit 19 I O bit 18 I O bit 17 Out common for I O 17 24 I O common for I O 17 24 Out common for I O 17 24 I O common for I O 17 24 Power output 24 Power output 23 Power output 22 Power output 21 Power output 20 Power output 19 Power output 18 Power output 17 Ground Coordinated Motion Mathematical Analysis The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which is also known a
95. BGS Define vector position move pen AMS Wait for after motion trippoint SB1 Set Output Bit 1 put down pen JS Square CB1 Jump to square subroutine EN End Main Program Square Square subroutine V1 500 JS L Define length of side V1 V1 JS L Switch direction EN End subroutine 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 interrupt or automatic routine such as POSERR or LIMSWI is executed the subroutine stack is incremented by 1 Normally the stack is restored with an EN instruction Occasionally it is desirable not to return back to the program line where the subroutine or interrupt was called The ZS1 command clears 1 level of the stack This allows the program sequencer to continue to the next line The ZSO command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is often desirable to restart the program sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of the LIMSWI routine Auto Start Routine The DMC 18x6 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 HAUTO The program must be
96. DOG TIMER ISOLATED LIMITS AND HOME INPUTS DPRAM HIGH SPEED MK ENCODERS MICROCOMPUTER MOTOR ENCODER AUXILIARY ENCODERS ZU INTERFACE A a p 10 VOLT OUTPUT FOR Primary T SERVO MOTORS X Y Z W etc FIFOS AZW PULSE DIRECTION OUTPUT A FOR STEP MOTORS Interrupts Bes HIGH SPEED ENCODER VO INTERFACE COMPARE OUTPUT 8 UNCOMMITTED 8 PROGRAMMABLE 8 PROGRAMMABLE ANALOG INPUTS OPTOISOLATED OUTPUTS INPUTS HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 18x6 Functional Elements Microcomputer Section The main processing unit of the controller is a specialized Microcomputer RAM Flash EEPROM The RAM provides memory for variables array elements and application programs The flash EEPROM provides non volatile storage of variables programs and arrays The Flash also contains the firmware of the controller which is field upgradeable Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 22 MHz For standard servo operation the controller generates a 10 Volt analog signal 16 Bit DAC For sinusoidal commutation operation the controller uses 2 DACs to generate 2 10Volt analog signals For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the host PC contains a primary communication channel for both sending commands e g T
97. EN Label Position Command Begin Motion Wait for Motion Complete Next Position Move Begin 2 move End program Event Trigger Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period SETBIT SP 10000 PA 20000 BGX AD 1000 SBI EN 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 output bit every 10000 counts during a move the AR trippoint 1s used as shown in the next example TRIP JG 50000 BGX n 0 REPEAT AR 10000 TPX SBI WT50 n n 1 JP REPEAT n lt 5 STX EN 126 Chapter 7 Application Programming 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 DMC 18x6 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 Trigge
98. 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 18x6 provides an internal watchdog timer which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AEN which can be used to switch the amplifiers off in the event of a serious controller 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 controller to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 18x6 is damaged DMC 18x6 Chapter 1 Overview 5 THIS PAGE LEFT BLANK INTENTIONALLY 6 Chapter 1 Overview DMC 18x6 Chapter 2 Getting Started The DMC 18x6 Motion Controllers Figure 2 3 Outline of the DMC 1816 through DMC 1846 Figure 2 4 Outline of the DMC 1856 through DMC 1886 DMC 18x6 Chapter 2 Getting Started 7 ERROR puer LED J6 J8 Two 50 pin headers connecting corresponding signals for axes 5 8 100 pin high density connector for axes 1 4 Master Reset amp UPGRD jumpers Part number Amp 2 178238 9 26 pin header connector for the auxiliary encoder cable Axes 5 8 INCOM amp LSCOM jumpers Used for bypassing opto isolation for the limit home a
99. I KD FA can also be interrogated The command reference denotes all commands which can be interrogated Example 10 Operation in the Buffer Mode The instructions may be buffered before execution as shown below Instruction Interpretation PR 600000 Distance SP 10000 Speed 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 controllers on board memory When the command ED is given from the Galil DOS terminal such as DMCTERM the controllers editor will be started The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited The editor provides the line number For example in response to the first ED command the first line 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 cntrl gt Q The program may be executed with the command XQ fA 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
100. 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 is to be configured as an output CO 12 is issued esi Block Block Binary Representation Decima vatue or Block poe wee 1e 23 Lx qe Lem pp E The simplest method for determining n Step 1 Determine which 8 bit I O blocks to be configured as outputs Step 2 From the table determine the decimal value for each I O block to be set as an output Step 3 Add up all of the values determined in step 2 This is the value to be used for n For example if blocks 2 and 3 are to be outputs then n is 3 and the command CO3 should be issued Note This calculation is identical to the formula n n 2 n A n 4 8 ns5 16 ng 32 n 64 ng 128 no where n represents the block Saving the State of the Outputs in Non Volatile Memory The configuration of the extended I O and the state of the outputs can be stored in the EEPROM with 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 1 through 8 and 17 through 80 Outputs may also be defined with the conditional command OBn where n 1 through 8 and 17 through 80 The command OP may also be used to set output bits specified as blocks of data The OP command accepts 5 parameters The
101. 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 SD command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position When a forward or reverse limit switch is activated the current application program that is running in thread zero will be interrupted and the controller will automatically jump to the ZLIMSWI 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 LRx contain the state of the forward and reverse limit switches respectively x represents the axis X
102. Isolated a Power i Supply GND go OUTC Figure A 10 Typical Load Connection DMC 18x6 Appendices 205 The power outputs must be connected in a driving configuration as shown on the previous page Here are the voltage outputs to expect after the Clear Bit and Set Bit commands are given Output Command Result CB Vowr Viso SB Vos GNDigo Standard Digital Outputs The I O banks 2 7 can be configured as optically isolated digital outputs however these banks do not have the high power capacity as in banks 0 1 In order to configure a bank as outputs the optical isolator chips Ux and Ux2 are inserted and the digital input isolator chips Ux3 and Ux4 are removed The resistor packs RPx2 and RPx3 are inserted and the input resistor pack RPx4 is removed Each bank of eight outputs shares one I OC connection which is connected to a DC power supply between 4 and 28 VDC The resistor pack RPx3 is optional used either as a pull up resistor from the output transistor s collector to the external supply connected to I OC or the RPx3 is removed resulting in an open collector output Here is a schematic of the digital output circuit Internal Pullup VOC To DMC 18x65V 7 OE 1 4 NEC2505 1 8 e 10 To DMC 18x6 I O pu ILE pc EI ee aes ase OUTC Figure 11 Output Circuit Diagram The resistor pack RPx3 limits the amount of current available to sou
103. N an invalid value Issue invalid command End of thread 1 Begin command error subroutine If error is out of range KP 1 Set N to a valid number Retry KP N command If error is invalid command TY Skip invalid command Chapter 7 Application Programming 135 EN End of command error routine JS Subroutine Stack Variables a b c d e f g h There are 8 variables that may be passed on the subroutine stack when using the JS command Passing values on the stack is advanced DMC programming and is recommended for experienced DMC programmers familiar with the concept of passing arguments by value and by reference Notes 1 Passing parameters has no type checking so it is important to exercise good programming style when passing parameters See examples below for recommended syntax 2 Do not use spaces in expressions containing 3 Global variables MUST be assigned prior to any use in subroutines where variables are passed by reference Example A Simple Adding Function Add JS SUM 1 2 3 4 5 6 7 8 MG_JS EN SUM EN a b c d e f g h Executed program from programl dmc 36 0000 Example Variable and an Important Note about Creating Global Variables Var value 5 global 8 JS SUM amp value 1 2 3 4 5 6 7 MG value MG _JS EN SUM a bt ct dt et ft gt htglobal EN a Executed program from program2 dmc 36 0000 36 0000 Example Working with Arrays fArray DM speeds 8 DM other
104. OP 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 500 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 Vector Mode Linear and Circular Interpolation Motion The DMC 18x6 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments The DMC 18x6 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specified for coordinated motion at any given time The command VM m n p where m and n are the coord
105. P and receiving responses e g 123 456 as well as a secondary communication channel for receiving axis and I O data in a compact binary form the data record The primary channel uses a bi directional FIFO and includes PC interrupt handling circuitry The secondary channel uses DPRAM where data readable by the PC General I O The controller provides interface circuitry for 8 bi directional optoisolated inputs 8 TTL outputs and 8 analog inputs with 12 Bit ADC 16 bit optional The general inputs can also be used for triggering a high speed positional latch for each axis Each axis on the controller has 2 encoders the main encoder and an auxiliary encoder Each unused auxiliary encoder provides 2 additional inputs available for general use except when configured for stepper motor operation DMC 18x6 Chapter 1 Overview 3 1X80 The DMC 1856 through DMC 1886 controllers provide interface circuitry for 16 optoisolated inputs 8 TTL inputs 16 TTL outputs and 8 analog inputs with 12 bit ADC 16 bit optional System Elements As shown in Fig 1 2 the DMC 18x6 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Computer Power Supply Figure 1 2 Elements of Servo systems Motor A motor converts current into torque which produces motion Each axis of motion requires a motor sized properly to move the load at the requi
106. PRAM IRQ Figure 4 1 Software Communications Hierarchy 40 Chapter 4 Software Tools and Communications DMC 18x6 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 Terminal loj x File Edit Tools View Help za Aa TE AE File Edit 56 3 m Type Commands INT O LOOP MG BEEP WT 100 FE COUNT COUNT 1 Program Editor Window JIP LOOP COUNT lt 10 2 0 1 6 6 Get Responses Here Line 0 Col 4 C XTesting dmc Num 2 Filename Cursor Line and Column Info Display Area Status connected with Galil DMC 18424 axis controller revision 1 Controller Revision Info amp Serial Figure 4 2 Galil SmartTERM The following SmartTERM File menu items briefly describe some 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 fi
107. Plane 2 Byte BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 8 Move in N A N A N A N A N A N A N A Progress BIT7 BIT 6 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 N A N A Motion Motion Motion N A N A N A is is is slewing stopping making due to final ST or decel Limit Switch Axis Status 1 Word BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in Mode of Mode of FE Home 1 Phase 2 Phase Mode of Progress Motion Motion Find HM in of HM of HM Motion PA or PA only Edge in Progress complete complete Coord PR Progress or FI Motion command issued 7 BIT 6 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Negative Mode of Motion Motion Motion Latch is 3rd Phase Motor Direction Motion is is is armed of HM in Off Move slewing stopping making Progress due to final Cont aud ST of decel Limit Switch Axis Switches 1 Byte BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Latch State N A N A State of State of State of Stepper Occurred of Forward Reverse Home Mode Latch Limit Limit Input Input Notes Regarding Velocity Torque and Analog Input Data The velocity information that is returned in the data record is 64 times larger at TM1000 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 9
108. Quit Edit Mode XQ Execute A Program Flow Commands The DMC 18x6 provides instructions to control program flow The controller program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements DMC 18x6 Chapter 7 Application Programming 123 Event Triggers amp Trippoints To function independently from the host computer the DMC 18x6 can be programmed to make decisions based on the occurrence of an event Such events include waiting for motion to be complete waiting for a specified amount of time to elapse or waiting for an input to change logic levels The DMC 18x6 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the controller can make decisions based on its own status or external events without intervention from a host computer 124 Chapter 7 Application Programming DMC 18x6 DMC 18x6
109. Read Only 9 bits starting at N 6 contain the number of N 7 characters currently in the read FIFO 0 to 511 Write FIFO Count N 10 to Read Only 9 bits starting at N 10 contain the number of N 11 characters currently in the write FIFO 0 to 511 Simplified Communication Procedure The simplest approach for communicating with the DMC 18x6 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 18x6 read the control register at address N 4 and check bit 2 If bit 2 is zero the DMC 18x6 has data to be read in the READ register at address N Bit 2 must be checked for every character read Write Procedure To send data to the DMC 18x6 read the control register at address N 4 and check bit 0 If bit 0 is zero the DMC 18x6 FIFO buffer is not full and a character may be written to the WRITE register at address N 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 18x6 as long as the READ WRITE procedure is followed as described above so long as the base address is known FIFO Control Register at N 4 Read Only If 1 DPRAM empty 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 Fre
110. SITION ERROR Print Message 005 MG ERROR V1 Print Error 006 RE Return from Error lt control gt Q Quit Edit Mode XQ LOOP Execute Dummy Program JG 100000 Jog at High Speed BGX Begin Motion Example Input Interrupt JA Label Input Interrupt 1 JG 30000 60000 Jog BGXW Begin Motion T LOOP JPZLOOP EN Loop ININT Input Interrupt STXW AM Stop Motion TEST IN 1 0 Test for Input 1 still low JG 30000 6000 Restore Velocities BGXW Begin motion RIO Return from interrupt routine to Main Program and do not re enable trippoints Example Motion Complete Timeout BEGIN Begin main program TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command BGX Begin motion MCX Motion Complete trip point EN End main program ZMCTIME 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 Begin main program IN ENTER SPEED SPEED Prompt for speed JG SPEED BGX Begin motion JP BEGIN Repeat EN End main program CMDERR Command error utility 134 Chapter 7 Application Programming DMC 18x6 JP DONE ED lt gt 2 JP DONE TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN ZS1 JP BEGIN DONE 750 Check if error on line 2 Check if out of ra
111. 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 1 enables ECAM mode and n 0 disables ECAM mode Step 6 Engage the slave motion To engage the slave motion use the instruction 92 Chapter 6 Programming Motion DMC 18x6 EG x y z w 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 z w where x y z w are the master positions at which the corresponding slave axes are disengaged 5580 ee 1500 ee Med 0 2000 4000 6000 Master X Figure 6 11 Electronic Cam Example This disengages the slave axis at a specified master position If the parameter is outside the master cycle the stopping is instantaneous To illustrate the complete process consider the
112. TERPRETATION VMXN Select axes VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten cycles VE BGS Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step output pulses DMC 18x6 Chapter 6 Programming Motion 101 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 occ
113. The maximum value of 1 implies no filtering resulting in trapezoidal velocity profiles Smaller values of the smoothing parameters imply heavier filtering and smoother moves The following example illustrates the effect of smoothing Fig 6 15 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT 5 Filter for smoothing BGX Begin 110 Chapter 6 Programming Motion DMC 18x6 ACCELERATION p Az VELOCITY z o ACCELERATION VELOCITY oQ g o o n o Ts o e 2 qo lt Figure 6 15 Trapezoidal velocity and smooth velocity profiles Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command smoothes the frequency of step motor pulses Similar to the command IT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS x y z w where x y z w is an integer from 0 25 to 64 and represents the amount of smoothing The smoothing parameters x y z w and n are numbers between 0 25 and 64 and determine the degree of filtering The minimum value of 0 25 implies no filtering resulting in trapezoidal velocity profiles Larger values of the s
114. This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last 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 IN ENTER LEN S6 FLEN FRAC LEN FLEN 10000 FLEN LENI FLEN amp SOOFF LEN2 FLEN amp FF00 100 LEN3 LEN amp 000000FF LEN4 LEN amp 0000FF00 100 LENS LEN amp SOOFF0000 10000 LEN6 LEN amp FF000000 1000000 MG LEN6 S4 MG LENS S4 MG LEN4 S4 MG LEN3 S4 MG LEN2 S4 MG LENI S4 EN Begin main program Input character string of up to 6 characters into variable LEN Define variable FLEN as fractional part of variable LEN Shift FLEN by 32 bits IE convert fraction FLEN to integer Mask top byte of FLEN and set this value to variable Let variable LEN2 top byte of FLEN Let variable LEN3 bottom byte of LEN Let variable LEN4 second byte of LEN Let variable LENS
115. WMY MOCMDX SIGNX PWMX ISO OUT INCOM XLATCH YLATCH ZLATCH WLATCH INS IN6 IN7 IN8 ABORT OUTI OUT2 OUT3 OUT4 OUTS e LM _ Z axis sign output for input to stepper motor 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 amp 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 Isolated gnd used with opto isolation 5 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 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 Used for Z axis latch input Input 4 Used for W axis latch input Input 5 Input
116. Y Z W etc The value of the operand is either a 0 or 1 corresponding to the logic state of the limit DMC 18x6 Chapter 3 Connecting Hardware 31 switch Using a terminal program the state of a limit switch can be printed to the screen with the command MG _LFx or MG _LRx This prints the value of the limit switch operands for the x axis The logic state of the limit switches can also be interrogated with the TS command For more details on TS see the Command Reference 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 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 18x6 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 di
117. a 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 N 500 Counts rev Encoder line density T 1 ms Sample period The transfer function of the system elements are Motor M s Kt Js2 500 s2 rad A Amp 4 Amp V DAC 0 0003 V count Encoder Ke 4N 2n 318 count rad DMC 18x6 Chapter 10 Theory of Operation 175 ZOH 2000 s 2000 Digital Filter 12 5 KD 245 0 001 Therefore D z 1030 z 0 95 Z Accordingly the coefficients of the continuous filter are P 50 D 0 98 The filter equation may be written in the continuous equivalent form G s 50 0 985 098 5 51 The system elements are shown in Fig 10 7 FILTER ZOH DAC AMP MOTOR 50 0 980s 220006 0 0003 4 500 5 2000 Sg ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s 1s the product of all the elements in the loop 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency o at which AG o equals one This can be done by the Bode plot of AG o as shown in Fig 10 8 176 Chapter 10 Theory of Operation DMC 18x6 Magnitude 50 200 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given
118. adjusts the PID filter parameters for optimum performance and displays the resulting system step response A four channel storage scope provides a 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 WSDK 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 Provides impulse step and frequency response tests of actual hardware Four channel storage scope for displaying position velocity error and torque Displays X versus Y position for viewing actual 2 D motion path Terminal editor and program editor for easy communication with the controller 48 Chapter 4 Software Tools and Communications DMC 18x6 WP Galil Motion Control Servo Design Kit File Terminal Help Select ER Storage Scopes System Evaluation system Information Galil Motion Control Inc Setup and Configuration Servo Design Kit PA om Oo Status Connected with Galil DMC 1886 8 axis controller revision 1 0 alpha 0705 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 Ac
119. ain move BGX Start motion Correct Correction loop AMX Wait for motion completion V1 10000 DEX V2 _TEX 4 V1 Find linear encoder error Compensate for motor error JP END ABS V2 lt 2 Exit if error is small PR V2 4 Correction move BGX Start correction JP CORRECT Repeat END EN Motion Smoothing The DMC 18x6 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system DMC 18x6 Chapter 6 Programming Motion 109 Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value The discontinuous acceleration results in jerk which causes vibration The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration Using the IT Command S When operating with servo motors motion smoothing can be accomplished with the IT command This command filters the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following commands IT x y z w Independent time constant The command IT is used for smoothing independent moves of the type JG PR PA and to smooth vector moves of the type VM and LM The smoothing parameters x y z w and n are numbers between 0 and 1 and determine the degree of filtering
120. al O siia basal E oh eL nebat cab eei 3 System Elements act dette detis meat art soles 4 dt ep iae o te ques de e aite ite 4 Amplifier DryVet a oe etta auae E qd 4 Eticodep 752 neo Soest c a en ns M UI 4 Watch Dog Titier eese E ette et HEURE EROR 5 Chapter 2 Getting Started 7 The DMC 18x6 Motion Controllers eese eene nennen eene nennen enne nenne 7 Elements nt UN eU EOM ee IR Ore M Entre 8 Installing the DMC 1I8X6 D iu ite 9 Step 1 Determine Overall Motor Configuration c ccecccsseeseeceeeseeeeeeeseeeeceeenseenaes 9 Step 2 Install Jumpers on the DMC 18x6 sss 10 Step 3 Install the Communications Software sse 10 Step 4 Install the DMC 18x6 in the PC 10 Step 5 Establishing Communication between the Galil controller and the host PC 11 Step 6 Determine the Axes to be Used for Sinusoidal Commutation 12 Step 7 Make Connections to Amplifier and Encoder 12 Step 8a Connect Standard Servo Motors sse 14 Step 8b Connect Sinusoidal Commutation Motors sse 19 Step 8C Connect Step Motors entente ens 21 Step 9 Tune the Servo Systemsin nione niei in E E REE 22 Design Examples innin e i ie EEE E RNE AR EE a end 23 Example 1 System Set up
121. alog signal in the 10 Volt range as a command The amplifier gain should be set such that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V 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 Step 8c Connecting Step Motors 8 Chapter 2 Getting Started DMC 18x6 The WSDK software is highly recommended for first time users of the DMC 18x6 It provides step by step instructions for system connection tuning and analysis Installing the DMC 18x6 Installation of a complete operational DMC 18x6 system consists of 9 steps Step 1 Determine overall motor configuration Step 2 Install Jumpers on the DMC 18x6 Step 3 Install the communications software Step 4 Install the DMC 18x6 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 Befo
122. ample would require a higher resistance such as a 10k ohm resistor pack High Power Digital Outputs The first two banks on the IOM 1964 banks 0 and 1 have high current output drive capability The IOM 1964 is shipped with banks 0 and 1 configured as outputs Each output can drive up to 500mA of continuous current Configuring a bank of I O as outputs is done by inserting the optical isolator NEC2505 IC s into the Ux1 and Ux2 sockets The digital input IC s Ux3 and Ux4 are removed The resistor packs RPx2 and RPx3 are inserted and the input resistor pack RPx4 is removed Each bank of eight outputs shares one I OC connection which is connected to a DC power supply between 4 and 28 VDC A 10k ohm resistor pack should be used for RPx3 Here is a circuit diagram e To 18 6 5V 7 1 4 NEC2505 1 8RPxX22 LM IR6210 vec e IN OUT PWROUT Z e To 18 6 e 1 __ Aue 1 8 RPx3 e 10 e OUTC Figure A 9 High Current Output Circuit The load is connected between the power output and output common The I O connection is for test purposes and would not normally be connected An external power supply is connected to the I OC and OUTC terminals which isolates the circuitry of the DB 14064 daughter board from the output circuit OC e Vico PWROUT External
123. and two complex poles P 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 poles and zeros have a frequency in Hz selected by the command NF The real part of the poles is set by NB and the real part of the zeros is set by NZ The most simple procedure for setting the notch filter identify the resonance frequency and set NF to the same value Set NB to about one half of NF and set NZ to a low value between zero and 5 ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 sT 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 18x6 controller and the following parameters K 0 1 Nm A Torque constant J 2 10 4 kg m2 System moment of inerti
124. apter 6 Programming Motion 91 In the electronic cam mode the position of the master is always expressed modulo one cycle In this example the position of x is always expressed in the range between 0 and 6000 Similarly the slave position is also redefined such that it starts at zero and ends at 1500 At the end of a cycle when the master is 6000 and the slave is 1500 the positions of both x and y are redefined as zero To specify the master cycle and the slave cycle change we use the instruction EM EM x y z w where x y z w specify the cycle of the master and the total change of the slaves over one cycle The cycle of the master is limited to 8 388 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 Step 3 Specify the master interval and starting point Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are specified by the instruction EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0
125. apter describing the PCI communication registers used on Galil DMC 18x6 controllers The following sections in this chapter are a brief introduction to the software tools and communication techniques used by Galil Figure 4 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 advanced users who wish to develop their own custom application programs to communicate to the controller Custom application programs can utilize API function calls directly to our DLL s or use our ActiveX COM objects The ActiveX controls can simplify programming and offer additional functionality over using the communication DLL s directly At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers DMC 18x6 Chapter 4 Software Tools and Communications 39 Application SmartTERM Level Galil API Level 1 Galil ActiveX Controls DMCShell ocx DMCReg ocx DMCTerm ocx etc DMC32 dll ae DMCBUS32 dll Driver Level GLWDMPCI sys Hardware Interface DMC 1800 FIFO D
126. ar Sequence 78 80 84 86 Ellipse Scale 86 Feedrate 80 84 86 127 156 Tangent 69 83 85 86 Vector Speed 78 84 86 127 156 W Wire Cutter 154 Z Zero Stack 135 153 Index 221
127. ariable For example V1 returns the value of the variable V1 Example Using Variables for Joystick The example below reads the voltage of an X Y joystick and assigns it to variables VX and VY to drive the motors at proportional velocities where 10 Volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 DMC 18x6 Chapter 7 Application Programming 141 JOYSTIK Label JG 0 0 Set in Jog mode BGXY Begin Motion LOOP Loop VX AN 1 20000 Read joystick X VY AN 2 20000 Read joystick Y JG VX VY Jog at variable VX VY JP LOOP Repeat EN End Operands Operands allow motion or status parameters of the DMC 18x6 to be incorporated into programmable variables and expressions Most DMC commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 18x6 command The command reference indicates which commands have an associated operand Status commands such as Tell Position return actual values whereas action commands such as KP or SP return the values in the DMC 18x6 registers The axis designation is required following the command Examples of Internal Variables POSX TPX Assigns value from Tell Position X to the variable POSX GAIN GNZ 2 Assigns value from GNZ multiplied by two to variable GAIN JP LOOP TEX gt 5 Jump to LOOP if the position error of X is greater than 5 JP ERROR TC 1 Jump to ERROR if the error code equals 1 Operands can be used in an expression an
128. ating system to automatically install the DMC 18x6 PCI controller into both the Windows and Galil registries Using Win98SE ME NT4 0 2000 and XP Install the Galil Software Products CD ROM into your CD drive A Galil htm page should automatically appear with links to the software products Select DMCSmartTerm and click Install Follow the installation procedure as outlined Note Galil software is also available for download at http www galilmc com support download html Step 4 Install the DMC 18x6 in the PC The DMC 18x6 is installed directly into the PCI expansion bus The procedures are outlined below Step A Make sure the PC is in the power off condition 10 Chapter 2 Getting Started DMC 18x6 Step B Remove unit cover Step C Remove the metal plate covering the expansion bus slot where the DMC 18x6 will be inserted Step D Insert DMC 18x6 card in the expansion bus and secure with screw Step E 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 26 pin IDC connector J5 If you are using a controller with more than 4 axes you will need a CB 50 100 converter board which b
129. auxiliary encoder The command DV 1 1 1 1 configures the auxiliary encoder to be used for backlash compensation Backlash Compensation There are two methods for backlash compensation using the auxiliary encoders 1 Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies the KP proportional and KI 108 Chapter 6 Programming Motion DMC 18x6 integral terms to the position error based on the load encoder and applies the KD derivative term to the motor encoder This method results in a stabl
130. be active S or T Operand Summary Coordinated Motion Sequence OPERAND DESCRIPTION The absolute coordinate of the axes at the last intersection along the sequence Pav Distance traveled Number of available spaces for linear and circular segments in DMC 18x6 sequence buffer Zero means buffer is full 511 means buffer is empty ces Segment counter Number of the segment in the sequence starting at zero Vector length of coordinated move sequence _VPM _AV _LM _ _VE 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 8 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 86 Chapter 6 Programming Motion DMC 18x6 The resulting motion starts at the point A and moves toward points B C D A Suppose that we interrogate the controller when the motion is halfway between the points A and B The value of AV is 2000 The value of CS is 0 _VPX and VPY contain the absolute coordinate of the point A Suppose that the interrogation is repeated at a p
131. be changed until motion is complete Remember motion is complete when the profiler is finished not when the actual motor is in position The Stop command ST can be issued at any time to decelerate the motor to a stop before it reaches its final position An incremental position movement IP may be specified during motion as long as the additional move is in the same direction Here the user specifies the desired position increment n The new target is equal to the old target plus the increment n Upon receiving the IP command a revised profile will be generated for motion towards the new end position The IP command does not require a begin Note If the motor is not moving the IP command is equivalent to the PR and BG command combination Command Summary Independent Axis COMMAND BGXYZW STXYZN AMXYZN MCXYZW The lower case specifiers x y z w represent position values for each axis The DMC 18x6 also allows use of single axis specifiers such as PRY 2000 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _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 70 Chapter 6 Programming Motion DMC 18x6 _PRx Returns current incremental distance specified for the
132. between the DMC 18x6 series controllers and other system elements such as amplifiers encoders and external switches The ICM 2900 accepts the 100 pin main cable and provides screw type terminals for connections Each screw terminal is labeled for quick connection of system elements The ICM 2900 provides access to the signals for up to 4 axes Two required for 5 or more axes Block 4 PIN Label MOCMDZ SIGNZ PWMZ GND MOCMDW SIGNW PWMW GND MOCMDX SIGNX PWMX GND MOCMDY SIGNY PWMY GND OUT PWR ERROR MP OUT GND MPENW MPENZ MPENY MPENX OUTS OUT6 OUT7 OUTS8 OUTI OUT2 OUT3 OUT4 5V HOMEZ RLSZ FLSZ LSCOM HOMEW NO NO NO D 000000 120 ON OQ Annan d A d Pw WW WN NY NY HK Q oo 192 Appendices LO OoOoocococococoocoococoococoococo c ococococooooocoocoocooo n Description 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 Signal Ground 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 Signal Ground 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 Y axis motor command to amp input w respect to ground Y axis s
133. by the parameter KI improves the system accuracy With the KI parameter the motor does not stop until it reaches the desired position exactly regardless of the level of friction or opposing torque The integrator also reduces the system stability Therefore it can be used only when the loop is stable and has a high gain The output of the filter is applied to a digital to analog converter DAC The resulting output signal in the range between 10 and 10 Volts is then applied to the amplifier and the motor The motor position whether rotary or linear is measured by a sensor The resulting signal called position feedback is returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Fig 10 4 The mathematical model of the various components is given below CONTROLLER R X DIGITAL Y V E FILTER ZOH DAC MOTOR E P ENCODER Figure 10 4 Functional Elements of a Motion Control System 170 Chapter 10 Theory of Operation DMC 18x6 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 th
134. cing 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 becomes full program execution will be delayed until it is cleared If the user wants to avoid this delay the command CW 1 can be given This command causes the controller to throw away the data which can not be placed into the FIFO In this case the controller does not delay program execution Error Code Command When there is a program error the DMC 18x6 halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG ED The user can obtain information about the type of error condition that occurred by using the command TC1 This command reports back a number and a text message which describes the error condition The command TCO or TC wil
135. cket used for motion I O 100 pin high density connector J1 The extended I O on the DB 14064 is configured using the CO command The banks of buffers on the IOM 1964 are configured to match by inserting the appropriate IC s and resistor packs The layout of each of the I O banks is identical For example here is the layout of bank 0 DMC 18x6 202 Appendices Resistor Pack for outputs OUT Resistor Pack for inputs U03 U04 Input Buffer IC s NI Resistor Pack for outputs Output Buffer IC s U01 U02 x LINO 20dH E OUT Indicator LED s x Resistor Pack for LED s Figure A 5 IOM 1964 Chip Configuration Layout All of the banks have the same configuration pattern as diagrammed above For example all banks have Ux1 and Ux2 output optical isolator IC sockets labeled in bank 0 as U01 and U02 in bank 1 as U11 and U12 and so on Each bank is configured as inputs or outputs by inserting optical isolator IC s and resistor packs in the appropriate sockets A group of eight LED s indicates the status of each I O point The numbers above the Bank 0 label indicate the number of the I O point corresponding to the LED above it Digital Inputs Configuring a bank f
136. commanded position n DX DY DZ or DW or DA DB DC DD DE DF DG DH for auxiliary encoders n S or T for gearing to coordinated motion GD a b c d e f g h Sets the distance the master will travel for the gearing change to take full effect _GPn This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately and the distance traveled since gearing changes take effect over a specified interval GR a b c d e f g h Sets gear ratio for slave axes 0 disables electronic gearing for specified axis GM a b c d e f g h X 1 sets gantry mode 0 disables gantry mode Trippoint for reverse motion past specified value Only one 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 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 1836 controller where the Z axis is the master and X and Y are the geared axes MOZ Turn Z
137. control system typically consists of an ICM 1900 Interface Module an amplifier for 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 18x6 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 1X80 Motion Controllers with more than 4 axes require a second ICM 1900 or AMP 19x0 and second 100 pin cable System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 18x6 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 12 Chapter 2 Getting Started DMC 18x6 Step A Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply 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
138. d 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 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 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 18x6 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
139. d assigned to a programmable variable but they cannot be assigned a value For example GNX 2 is invalid Special Operands Keywords The DMC 18x6 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 18x6 commands KEYWORD ETT Note TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords LF LR and TIME do not have any associated commands All keywords are listed in the Command Reference 142 Chapter 7 Application Programming DMC 18x6 Examples of Keywords V1 _LFX Assign V1 the logical state of the Forward Limit Switch on the X axis V3 TIME Assign V3 the current value of the time clock V4 HMW Assign V4 the logical state of the Home input on the W axis Arrays For storing and collecting numerical data the DMC 18x6 provides array space for 16000 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 followed by two bytes of fraction 2 147 483 647 9999 Arrays can be used to capture real time data such as position torque and analog input values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Defining Arrays An array is defined with the command DM The user must specify a name and the number of entries to be
140. d by the motion profiler can be monitored by the command RP Reference Position RP gives the absolute value of the position as determined by the motion profiler The command DP can be used to set the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Third the output of the motion profiler is filtered by the stepper smoothing filter This filter adds a delay in the output of the stepper motor pulses The amount of delay depends on the parameter which is specified by the command KS As mentioned earlier there will always be some amount of stepper motor smoothing The default value for KS is 1 313 which corresponds to a time constant of 3 939 sample periods Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver The pulses which are generated by the smoothing filter can be monitored by the command TD Tell Dual TD gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Stepper Smoothing Filter Output Motion Profiler Output Buffer Adds a Delay P To Stepper Driver Reference Position RP Step Count Register TD Motion Complete Trippoint When used in s
141. d the files DMCWIN H and DMCWIN CPP which contain the class definitions and implementations respectively These can be found in the C ProgramFiles Galil DMCWIN CPP directory To link the application with the DLL s the DMC32 lib file must be included in the project and is located at C Program Files Galil DMCWIN LIB Example A simple console application that sends commands to the controller To initiate communication declare a variable of type HANDLEDMC a long integer and pass the address of that variable in the DMCOpen function If the DMCOpen function is successful the variable will contain the handle to the Galil controller which is required for all subsequent function calls The following simple example program written as a Visual C console application tells the controller to move the X axis 1000 encoder counts Remember to add DMC32 LIB to your project prior to compiling include lt windows h gt include lt dmccom h gt long lRetCode HANDLEDMC hDmc HWND hWnd int main void 50 Chapter 4 Software Tools and Communications DMC 18x6 Connect to controller number 1 RetCode DMCOpen 1 hWnd amp hDmc f rc DMCNOERROR har szBuffer 64 Move the X axis 1000 counts lRetCode DMCCommand hDmc PR1000 BGX szBuffer sizeof szBuffer Disconnect from controller number 1 as the last action lRetCode DMCClose hDmc return 0
142. dent Motion Smoothing IT positioning Smooth motion while operating in vector or linear Vector Smoothing IT interpolation positioning Smooth motion while operating with stepper motors Stepper Motor Smoothing Gantry two axes are coupled by gantry Gantry Mode GM DMC 18x6 Chapter 6 Programming Motion 69 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 18x6 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 18x6 profiler Note The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified The Begin BG command can be issued for all axes either simultaneously or independently XYZ or W axis specifiers are required to select the axes for motion When no axes are specified this causes motion to begin on all axes The speed SP and the acceleration AC can be changed at any time during motion however the deceleration DC and position PR or PA cannot
143. distance the motor will move from the commanded position enable the Off On Error function 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 lt CR gt 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 Chapter 2 Getting Started 15 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 th
144. e 10000 5000 TIME ms 0 20 40 60 80 100 Figure 6 0 Velocity Profiles of XYZ Notes on fig 6 0 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 this constant speed and then decelerate such that the final position agrees with the command position PR The Z axis accelerates but before the specified speed is achieved must begin deceleration such that the axis will stop at the commanded position All 3 axes have the same acceleration and deceleration rate hence the slope of the rising and falling edges of all 3 velocity profiles are the same Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion The user specifies the jog speed JG acceleration AC and the deceleration DC rate for each axis The direction of motion is specified by the sign of the JG parameters When the begin command is given BG the motor accelerates up to speed and continues to jog at that speed until a new speed or stop ST command 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 is equal to the specified incr
145. e aedes 191 AMP 19X0 Mating Power Amplifiers essssssssssesseeee eene eene 191 ICM 2900 FL Interconnect Module sss 192 Contents v vi Index Opto Isolated Outputs ICM 1900 ICM 2900 Opto option 195 Standard Opto isolation and High Current Opto isolation sess 195 64 Extended I O of the DMC 18x6 with 14064 195 Configuring the I O of the DMC 18x6 with DB 14064 sse 195 Configuring the 64 Extended I O of the 1856 to 1886 using the DB 14064 197 Connector Description sess ener ener 197 IOM 1964 Opto Isolation Module for Extended I O Controllers sss 200 Descriptiohiz eiue I DUO taedis e tus 200 raa RPM 201 Configuring Hardware Banks sse eee 202 Digital Inp ts ins tt Reti ip ep pedir e e o PD Udo 203 High Power Digital Outputs essere 205 Standard Digital Outputs eren enne 206 Electrical Specifications essere 207 Relevant DMC Commands eese enne rennen ener 208 Screw Terminal Listing iecit iet tiere 208 Coordinated Motion Mathematical Analysis essen 210 DMC 18x0 DMC 18x6 Comparison sess nnns 213 List of Other Publications re eee ros 214 Training Seminars 3 cns ee ee ii eee eer rede 215 Gontacting
146. e 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 TD The encoder position can be interrogated with TP DMC 18x6 Chapter 2 Getting Started 21 The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a range between 0 25 and 64 where 64 implies the largest amount of smoothing See Command Reference regarding KS The DMC 18x6 profiler commands the step motor amplifier All DMC 18x6 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 18x6 you must follow this procedure Step A Connect step and direction signals from controller to motor amplifier from the controller to respective signals on your step motor amplifier These signals are labeled PULSX and DIRX for the x axis on the ICM 1900 Consult the documentation for your step motor amplifier Step B Configure DMC 18x6 for motor type using MT command You can configure the DMC 18x6 for active high or active low pulses Use the command MT 2 for active high step mo
147. e other hand you are using a differential encoder interchange only CHA and CHA The loop polarity and encoder polarity can also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section Sometimes the feedback polarity is correct the motor does not attempt to run away but the direction of motion is reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals If the motor moves in the required direction but stops short of the target it is most likely due to insufficient torque output from the motor command signal 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 16 Chapter 2 Getting Started DMC 18x6 AUX encoder AUX encoder input connector input connector Reset Switch Error LED 100 pin high density connector DB25 female 26 pin header AME Pat eee Do TEE
148. e system The dual loop method is activated with the instruction DV Dual Velocity where DV 1 1 1 1 activates the dual loop for the four axes and DV 0 0 0 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 ofthe linear encoder and performs position corrections This is done by the following program INSTRUCTION INTERPRETATION DUALOOP Label CE0 Configure encoder DEO Set initial value PR 40000 M
149. ec 5000 Command the X axis to absolute position 5000 encoder counts 74 Chapter 6 Programming Motion DMC 18x6 Figure 6 1 Position vs Time msec Motion 1 Example Motion 2 The previous step showed the plot if the motion continued all the way to 5000 however partway through the motion the object that was being tracked changed direction so the host program determined that the actual target position should be 2000 cts at that time Figure 2 shows what the position profile would look like if the move was allowed to complete to 2000 cts The position was modified when the robot was at a position of 4200 cts Note that the robot actually travels to a distance of almost 5000 cts before it turns around This is a function of the deceleration rate set by the DC command When a direction change is commanded the controller decelerates at the rate specified by the DC command The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position In Figure 3 the velocity profile is triangular because the controller doesn t have sufficient time to reach the set speed of 50000 cts sec before it is commanded to change direction Figure 6 2 Position vs Time msec Motion 2 DMC 18x6 Chapter 6 Programming Motion 75 Figure 6 3 Velocity vs Time msec Motion 2 Example Motion 4 In this motion the host program commands the controller to begin
150. ecreasing encoder counts If HMX reads 0 initially the motor will go in the forward direction first CN is the command used to define the polarity of the home input With CN 1 the default value a normally open switch will make HMxX read 1 initially and a normally closed switch will make HMX read zero Furthermore with CN 1 a normally open switch will make HMX read 0 initially and a normally closed switch will make HMX read 1 Therefore the CN command will need to be configured properly to ensure the correct direction of motion in the home sequence Upon detecting the home switch changing state the motor begins decelerating to a stop Note The direction of motion for the FE command also follows these rules for the state of the home input Stage 2 The motor then traverses at HV counts sec in the opposite direction of Stage 1 until the home switch toggles again If Stage 3 is in the opposite direction of Stage 2 the motor will stop immediately at this point and change direction If Stage 2 is in the same direction as Stage 3 the motor will never stop but will smoothly continue into Stage 3 Stage 3 The motor traverses forward at HV counts sec until the encoder index pulse is detected The motor then decelerates to a stop and goes back to the index The DMC 18x6 defines the home position as the position at which the index was detected and sets the encoder reading at this point to zero The 4 different motion possibilities for
151. eed position latch to capture axis position on occurrence of latch signal AL command arms latch Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W Input 9 is latch E input 10 is latch F input 11 is latch G input 12 is latch H Accessories and Options DMC 1816 DMC 1826 DMC 1836 DMC 1846 DMC 1856 DMC 1866 DMC 1876 DMC 1886 Cable 100 1M Cable 100 2M Cable 100 4M CB 50 100 1800 16 Bit ADC DB 14064 ICM 1900 HAEN or LAEN ICM 1900 Opto HAEN or LAEN AMP 1910 AMP 1920 AMP 1930 AMP 1940 AMP 19520 AMP 19540 DMC 18x6 Utilities WSDK 16 WSDK 32 VBX Tool Kit Setup 16 Setup 32 CAD to DMC HPGL DMC 18x6 1 axis PCI bus motion controller 2 axes PCI bus motion controller 3 axes PCI bus motion controller 4 axes PCI bus motion controller 5 axes PCI bus motion controller 6 axes PCI bus motion controller 7 axes PCI bus motion controller 8 axes PCI bus motion controller 100 pin high density cable 1 meter 100 pin high density cable 2 meter 100 pin high density cable 4 meter 50 pin to 100 pin converter board includes two 50 pin ribbon cables for DMC 1856 thru DMC 1886 Increased resolution for analog inputs Daughterboard for additional 64 digital I O Interconnect module with either High or Low Amp Enable Interconnect module with Optoisolated digital outputs either High or Low Amp Enable Interconnect module with 1 axis power amplifier Interconnect module with 2
152. el following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation 18 List entire program 15 5 Begin listing at line 5 158 5 9 List lines 5 thru 9 15 A 9 List line label A thru line 9 15 ZA A 5 List line label ZA and additional 5 lines Program Format A DMC 18x6 program consists of DMC instructions combined to solve a machine control application Action instructions such as starting and stopping motion are combined with Program Flow instructions to form the complete program Program Flow instructions evaluate real time conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 18x6 instruction in a program must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 80 characters A carriage return enters the final command on a program line Using Labels in Programs All DMC 18x6 programs must begin with a label and end with an End EN statement Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted The maximum number of labels which may be defined is 510 Valid labels ZBEGIN SQUARE DMC 18x6 Chapter 7 Applicatio
153. ement 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 18x6 converts the velocity profile into a position trajectory and a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging 72 Chapter 6 Programming Motion DMC 18x6 Parameters can be set with individual axes specifiers such as JGY 2000 set jog speed for Y axis to 2000 Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the jog speed for the axis specified by x _TVx Returns the actual velocity of the axis specified by x averaged over 0 25 sec Example Jog in X only Jog X motor at 50000 count s After X motor is at its jog speed begin jogging Z in reverse direction at 25000 count s A AC 20000 20000 DC 20000 20000 JG 50000 25000 Specify X Z acceleration of 20000 cts sec Specify X Z deceleration of 20000 cts sec Specify jog speed and direction for X and Z axis BGX Begin X motion ASX Wait until X is at speed BGZ Begin Z motion EN Example Joystick Jogging The jog speed can also be changed using an analog
154. ent 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 DMC 18x6 Chapter 4 Software Tools and Communications 53 Communication Interrupts Communication interrupts can be used in a device driver to minimize the host PC s burden in communicating with the controller They are enabled with CW 1 disabled with CW 0 and generate 3 status bytes in addition to those generated by El and U1 BA BB and BK see table above Hardware Level Communications for PCI This section of the chapter describes in detail the structures used to communicate with the DMC 18x6 controllers at the register interface level The information in this section is intended for advanced programmers with extensive knowledge of PCI bus operation Communications with the DMC 18x6 For main bi directional communication the DMC 18x6 features a 512 character write FIFO buffer and a 512 character read FIFO buffer This permits sending multiple commands at high speeds ahead of their actual processing by the DMC 18x6 Additionally the DMC 18x6 provides Dual Port RAM DPRAM which allows access to the data record structure 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 drive
155. ers uA Uu dA UA Q 2 Description 200 Appendices Provides 64 optically isolated inputs and outputs each rated for 2mA at up to 28 VDC Configurable as inputs or outputs in groups of eight bits Provides 16 high power outputs capable of up to 500mA each Connects to controller via 80 pin shielded cable All I O points conveniently labeled Each of the 64 I O points has status LED Dimensions 6 8 x 11 4 Works with extended I O controllers DMC 18x6 High Current Buffer chips 16 Screw Terminals 011121345617 IOM 1964 REVA GALIL MOTION CONTROL MADE IN USA FOR INPUTS FOR OUTPUTS UX3 UX1 UX4 0 2 J5 RPX4 RPX2 RPX3 DMC 18x6 Banks 0 and 1 provide high power output capability 80 pin high density connector Banks 2 7 are standard banks Figure A 3 IOM 1964 Layout Overview The IOM 1964 is an input output module that connects to the DB 14064 extended I O daughter board cards from Galil providing optically isolated buffers for the extended inputs and outputs of the controller The IOM 1964 also provides 16 high power outputs capable of 500mA of current per output point The IOM 1964 splits the 64 I O po
156. es for axes 5 8 The jumpers are located on the DMC 18x6 at and JP 13 respectively DMC 18x6 Chapter 3 Connecting Hardware 33 LSCOM Additional Limit Switches Dependent on Number of Axes SI SF Sf Sf FLSX RLSX HOMEX FLSY RLSY HOMEY INCOM IN 1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 ABORT XLATCH YLATCH ZLATCH WLATCH Figure 3 1 The Optoisolated Inputs The DMC 18x6 controllers have a separate INCOM labeled INC for IN9 through IN16 Using an Isolated Power Supply To take full advantage of opto isolation an isolated power supply should be used to provide the voltage at the input common connection When using an isolated power supply do not connect the ground of the isolated power to the ground of the controller A power supply in the voltage range between 5 to 24 Volts may be applied directly see Figure 3 2 For voltages greater than 24 Volts a resistor R is needed in series with the input such that 1 mA lt V supply R 2 2KQ lt 11 mA 34 Chapter 3 Connecting Hardware DMC 18x6 External Resistor Needed for External Resistor Needed for Voltages gt 24V LSCOM Voltages gt 24V LSCOM 2 2K FLSX Configuration to source current at the Configuration to sink current at the LSCOM terminal and sink current at LSCOM terminal and source current at switch inputs switch inputs Figure 3 2 Connecting a single Limi
157. ess 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 2 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 1 IF conditional statement is false End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 2 are not active End Input Interrupt Routine without restoring trippoints A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer DMC 18x6 Chapter 7 Application Programming 131 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 132 Chapter 7 Application Programming M Begin Main Program 1 Clear Output Bit 1 pick up pen VP 1000 1000 LE
158. et too fast The overreaction results in temperature oscillations When the response of the system oscillates we say that the system is unstable Clearly unstable responses are bad when we want a constant level What causes the oscillations The basic cause for the instability is a combination of delayed reaction and high gain In the case of the temperature control the delay is due to the water flowing in the pipes When the human reaction is too strong the response becomes unstable Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which is designed to help the stability and accuracy Typically such a 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
159. eturn 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 Label A Enable input 1 for interrupt function JG 30000 20000 Set speeds on X and Y axes BG XY Begin motion on X and Y axes B Label B TP XY Report X and Y axes positions WT 1000 Wait 1000 milliseconds JP B Jump to B EN End of program ININT Interrupt subroutine MG Interrupt has occurred Displays the message ST XY Stops motion on X and Y axes LOOP JP LOOP IN 1 0 Loop until Interrupt cleared JG 15000 10000 Specify new speeds WT 300 Wait 300 milliseconds BG XY Begin motion on X and Y axes RI Return from Interrupt subroutine Analog Inputs The DMC 18x6 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 DMC 18x6 Chapter 7 Application Programming 153 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 Foll
160. eze Status of DPRAM Write 1 to freeze DPRAM Write 0 to clear freeze of DPRAM Read 1 DPRAM frozen Read Only If 1 DPRAM is busy updating Read Only If 1 DMC to PC Buffer empty No data to be read 1 Read Only 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 DPRAM Immediate access to any or all bytes of the data record is available by reading from the Dual Port RAM registers The starting address for the dual port RAM is stored at BARO of the PCI configuration space The memory map below describes the data record registers and the associated controller information The following procedure for freezing the data record DPRAM should be followed to ensure that all data of the data record is from the same sample period DMC 18x6 Chapter 4 Software Tools and Communications 55 To read the data record from the DPRAM first the freeze bit bit 4 of N 4 of the control register must be set Then wait for the contro
161. fied by the command AC up to the slew speed After detecting the transition in the logic state on the Home Input the motor will decelerate to a stop at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of HV counts sec When the logic state changes again the motor moves forward in the direction of increasing encoder count at the same speed until the controller senses the index pulse After detection it decelerates to a stop moves back to the index and defines this position as 0 The logic state of the Home input can be interrogated with the command MG HMX This command returns a 0 or 1 if the logic state is low or high respectively The state of the Home input can also be interrogated indirectly with the TS command For examples and further information about Homing see command HM FI FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state NOTE The response of the abort input is significantly different from the response of an activated limit switch When the abort input is activated the controller stops generating motion commands immediately whereas the limit switch response causes the controller to make a decelerated stop NOTE The effect of an Abort input is
162. ges String variables can be formatted using the specifier Sn where n is the number of characters thru 6 For example MG STR S3 This statement returns 3 characters of the string variable named STR Numeric data may be formatted using the Fn m expression following the completed MG statement n m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is RESULT F5 2 If the value of the variable RESULT is equal to 4 1 this statement returns the following The Final Value is 00004 10 If the value of the variable RESULT is equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppressed by sending N at the end of the statement This is useful when a text string needs to surround a numeric value Example HA DMC 18x6 Chapter 7 Application Programming 147 JG 50000 BGX ASX MG The Speed is TVX F5 1 N MG counts sec EN When A is executed the above example will appear on the screen as The speed is 50000 counts sec Using the MG Command to Configure Terminals The MG command can be used to configure a
163. gital Inputs sna eae saath het o ea ERE d e ee ets 152 Input Interrupt Function EL de des 153 Analog ee tee Et eed ttp eue Ree e E ede a RR Dd 153 Example Applications se aec e T e en Ul eq ence EI d 154 DMC 18x6 DMC 18x6 Wire Cutler e ed Reh a Hated a BREE REE es 154 X Y Table Gontrolle t s esce e reo rae e n e E anc adh 155 Speed Control by Joystick ee ect e RETE e wasn ns 158 Position Control by Joystick sssri monr generi e a ei i 159 Backlash Compensation by Sampled Dual Loop sees 159 Chapter 8 Hardware amp Software Protection 161 Introductions 161 Hardware Prtotectlon iet eere tut eaae da ge See 161 Output Protection L10658 161 Input Protection ace e dunes a 161 SOftware Protection oet onte ditione tta peteret 162 Programmable Position Limits essere 162 OT OnRsETIOL o Ret t Tt pt nir NETS 162 Automatic Error nennen eren 163 Limit Switch Routine 0 ccceccccecceecessceesceseceeeesceseceseeeecaecsaecseecaeseneeseeeeeeeerenatens 163 Chapter 9 Troubleshooting 165 os conte deeem b nus E In Cus etii d as ttes Ides gol teats 165 IECIT 165 SILET EE 166 Operation ott edic A 166 Chapter 10 Theory of Operation 167 COVER VIC W OR M M 167 Operatio
164. gram 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 _ will display this line number _ED contains the last line of program execution Useful to determine where program stopped _DL contains the number of available labels _UL contains the number of available variables _DA contains the number of available arrays _DM contains the number of available array elements _AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to specify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation 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 XQ A Execute ZA 003 PR5000 Error on Line 3 TCI Tell Error Code 7 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
165. ground and the digital input function IN n returns 0 Note that the external 5V in the circuits above is for example only The inputs optically isolated and can accept a range of input voltages from 4 to 28 VDC Active outputs are connected to the optically isolated inputs in a similar fashion with respect to current An NPN output is connected in a sinking configuration and a PNP output is connected in the sourcing configuration Sinking Sourcing e e 5V e e GND I O e e NPN O e oie output output Ourrent Current Figure A 8 Output Sinking and Sourcing Diagram Whether connected in a sinking or sourcing circuit only two connections are needed in each case When the NPN output is 5 volts then no current flows and the input reads 1 When the NPN output goes to 0 volts then it sinks current and the input reads 0 The PNP output works in a similar fashion but the voltages are reversed i e 5 volts on the PNP output sources current into the digital input and the input reads 0 As before the 5 volt is an example the I OC can accept between 4 28 volts DC 204 Appendices DMC 18x6 Note that the current through the digital input should be kept below 3 mA in order to minimize the power dissipated in the resistor pack This will help prevent circuit failures The resistor pack RPx4 is standard 1 5k ohm which is suitable for power supply voltages up to 5 5 VDC However use of 24 VDC for ex
166. h a 1 8 step motor and 4000 count rev encoder TI 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 106 Chapter 6 Programming Motion DMC 18x6 YB200 YC4000 SHX WT50 YSI MOTION SP16384 PR10000 BGX MCX JS 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 Motor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode 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 18x6 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 or the load but may be mounted in any position The most common use for the second encoder
167. he DMC 1836 uses the axes denoted as XYZ the DMC 1826 uses the axes denoted as XY and the DMC 1816 uses the X axis only Examples for the DMC 1886 denote the axes as A B C D E F G H Users of the DMC 1856 5 axes controller DMC 1866 6 axes controller or DMC 1876 7 axes controller should note that the DMC 1856 denotes the axes as A B C D and E the DMC 1866 denotes the axes as A B C D E and and the DMC 1876 denotes the axes as A B C D E F and G The axes A B C D may be used interchangeably with X Y Z W for any of the DMC 18x6 regardless of the number of axes 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 consequential damages Contents DMC 18x6 Contents i Chapter 1 Overview 1 Introductions 55222 oneslneeoe Bast m be aoa iun ned 1 Overview OF Motor Types icut gr fe s a Ee e e e due a 2 Standard Servo Motor with 10 Volt Command Signal ssssssss 2 Brushless Servo Motor with Sinusoidal Commutation sess 2 Stepper Motor with Step and Direction Signals sse 2 DMG 18x6 Functional El ments cir Ab en ep beide ees 3 Microcomputer estet t e diee 3 MoOtotItitet fae ananas es 3 Communication 3 Genier
168. he drivers and other utilities developed for Linux are available to customers 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 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 Controller Event Interrupts and User Interrupts The DMC 18x6 provides a hardware interrupt line that will when enabled interrupt the PC This allows the controller to notify the host application of particular events occurring on the controller Interrupts free the host from having to poll for the occurrence of certain events such as motion complete or excess position error The DMC 18x6 uses only one of the PC s interrupts however it is 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 18x6 provides an interrupt queue that can hold up to 16 status bytes This allows for multiple interrupt conditions to be stored in sequence of occurrence without loss of data The DMC 18x6 provides two commands related to generating interrupts EI and UI Predefined interrupt conditions can be enabled using the EI command or user defined interrupts can be sent using the UI c
169. he 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 sec2 LM ZW Specify axes for linear interpolation LI 40000 30000 Specify ZW distances LE Specify end move 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 controller from VS JVZ vw The result is shown in Figure 6 7 DMC 18x6 Chapter 6 Programming Motion 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 7 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 LOAD LOAD Load Program DM VX 750 VY 750 Define Array COUNT 0 Initialize Counter 82 Chapter 6 Programming Motion DMC 18x6 N 0 LOOP VX COUNT N VY COUNT N N N 10 COUNT COUNT 1 JP LO
170. ied 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 4 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 DMCReg ocx ActiveX object refer to Fig 4 4 This ActiveX control is used to create maintain and modify the communication parameters which are discussed next Edit Registry Index Description Model Controller Details Controller SN 21527 DMC 1800 Ae rss ee Non PnP Tools Controller2 DMC 18x6 ommunication Interface Controller RS232 DMC 21 TZ Serial Number 18 New Controller Controller SN 11819 DMC 21x3 2 Controlle5 Ethernet DMC 3425 Delete Find Ethernet Controller Edit Controller Properties Plus and Play Device gt WE Non Plug and Play Device Figure 4 4 Galil Registry Editor Setting Communications Parameters and Methods To access the Controller Commu
171. ign output for input to stepper motor amp Y axis pulse output for input to stepper motor amp Signal Ground Isolated Power In for Opto Isolation Option Error output Circular Compare Output Isolated Ground for Opto Isolation Option W axis amplifier enable Z axis amplifier enable Y axis amplifier enable X axis amplifier enable General Output 5 General Output 6 General Output 7 General Output 8 General Output 1 General Output 2 General Output 3 General Output 4 5 Volts Z axis home input Z axis reverse limit switch input Z axis forward limit switch input Limit Switch Common Input W axis home input DMC 18x6 DMC 18x6 10 10 11 11 11 11 12 12 12 12 13 13 13 13 14 14 14 14 15 15 15 15 16 16 16 16 17 17 17 17 18 18 18 18 19 19 19 19 20 20 20 20 21 21 21 RLSW FLSW HOMEX RLSX FLSX GND HOMEY RLSY FLSY GND INS IN6 IN7 IN8 XLATCH YLATCH ZLATCH WLATCH 5V 12V 12V ANA GND INCOM ABORT RESET ND NALOGS5 NALOG6 NALOG7 NALOGS NALOGI NALOG2 NALOG3 NALOG4 5V INX gt gt gt gt gt gt gt 0 gt MBX MBX 5V INY n W axis reverse limit switch input W axis forward limit switch input X axis home input X axis reverse limit switch input X axis forward limit switch input Signal Ground Y axis home input Y axis reverse limit switch input Y axis forward limit switch input Signal Ground Input 5 Input 6 Input
172. ignal 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 in Chapter 3 Error Output The error output is a TTL signal which indicates an error condition in the controller This signal is available on the interconnect module as ERROR When the error signal is low this indicates 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 output IC which drives the error signal Input Protection Lines General Abort A low input stops commanded motion instantly without a controlled deceleration For any axis in which the Off On Error function is enabled the amplifiers will be disabled This could cause the motor to coast to astop Ifthe 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 Selective Abort The controller can be configured to provide an individual abort for each axis Activation of the selective abort signal will act the same as the Abort Input but only on the specific axis To configure the c
173. ignal will be the highest available DAC on the controller For example Using a DMC 1846 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 1846 controller the controller will be re configured to a DMC 1836 controller By definition a DMC 1836 controls 3 axes X Y and Z The W axis is no longer available since the output DAC is being used for sinusoidal commutation DMC 18x6 Chapter 2 Getting Started 9 Further instruction for sinusoidal commutation connections are discussed in Step 6 Stepper Motor Operation To configure the DMC 18x6 for stepper motor operation the controller requires that the command MT must be given Further instruction for stepper motor connections are discussed in Step 8c Step 2 Install Jumpers on the DMC 18x6 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 programs arrays variables and motion control parameters stored in EEPROM will be ERASED The UPGRD jumper enables the user t
174. in connector IN9 IN16 INCOM FLE RLE HOMEE LSCOM FLF RLF HOMEF FLG RLG HOMEG FLH RLH HOMEH 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 Wiring the Optoisolated Inputs Bi Directional Capability All inputs can be used as active high or low If you are using an isolated power supply you can connect 5V 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 INCOM can be located on the DMC 18x6 directly or on the ICM 1900 or AMP 19X0 The jumper is labeled INCOM 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 The optoisolated inputs are connected in the following groups Group Controllers with 1 4 Axes Group Controllers with 5 8 Axes Common Signal IN1 IN8 ABORT IN1 IN16 ABORT INCOM INC FLX RLX HOMEX FLX RLX HOMEX FLY RLY HOMEY LSCOM LSC 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 For the DMC 18x6 there is a separate LSCOM and INCOM for IN1 IN8 home and limit switches for axes 1 4 and for IN9 16 home and limit switch
175. inated 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 18x6 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 Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence Note DMC 18x6 Chapter 6 Programming Motion 83 This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y specifies the coordinates of the end points of the vector movement with respect to the starting point Non sequential axis do not require
176. 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 Position Tracking The Galil controller may be placed in the position tracking mode to support changing the target of an absolute position move on the fly New targets may be given in the same direction or the opposite direction of the current position target The controller will then calculate a new trajectory based upon the new target and the acceleration deceleration and speed parameters that have been set The motion profile in this mode is trapezoidal There is not a set limit governing the rate at which the end point may be changed however at the standard TM rate the controller updates the position information at the rate of 1msec The controller generates a profiled point every other sample and linearly interpolates one sample between each profiled point Some examples of applications that may use this mode are satellite tracking missile tracking random pattern polishing of mirrors or lenses or any application that requires the ability to change the endpoint without completing the previous move DMC 18x6 Chapter 6 Programming Motion 73 The PA command is typically used to command an axis or multiple axes to a specific absolute position For some applications such as tracking a
177. ints into eight banks of eight I O points each corresponding to the eight banks of extended I O on the controller Each bank is individually configured as an input or output bank by inserting the appropriate integrated circuits and resistor packs The hardware configuration of the IOM 1964 must match the software configuration of the controller card All DMC 18x6 series controllers have general purpose I O connections On a DMC 1816 1826 1836 and 1846 the standard uncommitted I O consists of eight optically isolated digital inputs eight TTL digital outputs and eight analog inputs On a DMC 1856 1866 1876 and 1886 the standard uncommitted I O consists of 16 optically isolated digital inputs 16 TTL digital outputs and eight analog inputs The DB 14064 however has an additional 64 digital input output points than the 16 described above for a total of 80 input output points The 64 I O points are attached via two 50 pin ribbon cable header connectors A CB 50 80 adapter card is used to connect the two 50 pin ribbon cables to an 80 pin high density connector An 80 pin shielded cable connects from the 80 pin connector of the CB 50 80 board to the 80 pin high density connector J5 on the IOM 1964 Appendices 201 CB 50 80 End bracket 80 pin high density connector used for extended I O Figure A 4 CB 50 80 and CB 50 100 Bracket Layout Configuring Hardware Banks Error LED DMC 18x6 End bra
178. ircular arc which starts at an angle of 180 and traverses 90 Finally the third line describes the linear segment between points C and D Note that the total length of the motion consists of the segments A B Linear 10000 units R a2z B C Circular 15708 360 C D Linear 10000 DMC 18x6 Appendices 211 Total 35708 counts In general the length of each linear segment is Liz KR YR 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 x 2 2 360 The total travel distance is given by D SL 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 12 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 14 Velocity 10000 time s T4 0 05 T 0 357 T4 0 407 S Figure A 14 Vector Velocity Profile The acceleration time Tg is given by VS 100000 0 055 2000000 The slew time Ts is given by D _ 35708 VS 100000 Ts 0 05 0 3075 The total motion time Tt is given by Ti 0 4075 VS 212 Appendices DMC 18x6 The velocities along the X and Y axes are such that the direction of motion follows the specified path yet the vector velocity fits the vector speed and accelera
179. isters for that axis or axes Position error is then tracked in step pulses between these two registers QS command TPxYAx YB S TD Q YC Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally YA defines the step drive resolution where YA 1 for full stepping or YA 2 for half stepping The full range of YA is up to YA 9999 for microstepping drives Error Limit The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor steps Once the value of QS exceeds this limit the controller then performs the following actions 1 The motion is maintained or is stopped depending on the setting of the OE command If OE 0 the axis stays in motion if OE 1 the axis is stopped 2 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 and a 1 64 microstepping drive for an axis with a 1 8 step motor and 4000 count rev e
180. it 40 msec from reference and reset reference SBI Set Output 1 JP LOOP Loop EN Conditional Jumps The DMC 18x6 provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition The conditional jump determines if a condition is satisfied and then branches to a new location or subroutine Unlike event triggers the conditional jump instruction does not halt the program sequence Conditional jumps are useful for testing events in real time They allow the controller to make decisions without a host computer For example the DMC 18x6 can decide between two motion profiles based on the state of an input line 128 Chapter 7 Application Programming DMC 18x6 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 DESCRIPTION Conditional Statements The conditional statement is satisfied if it evaluates to any value other than zero The conditional statement can be any valid DMC
181. ive 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 few seconds command JG 40000 New X speed and Direction TV X 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 DMC 18x6 Chapter 2 Getting Started 25 Example 9 Interrogation The values of the parameters may be interrogated Some examples Instruction Interpretation KP Return gain of X axis KP Return gain of Z axis KP Return gains of all axes Many other parameters such as K
182. k Variables a b c d e f g 136 Mathematical and Functional Expressions sse 138 Mathematical Operators essent 138 Bit Wise Operators cessent ee ette eite esed 139 Pu nctiotis 5o eee aet t e beta dete D e e aoi ie ad 140 Variables eee em o b Eo ee rr EO Ee es 140 Programmable 141 Operands tecti e i EH et e de eU Ee dettes 142 Special Operands Keywords nnne 142 Lure Dp 143 Detitiig Arrays ic e Ree ee Ug Ad Re e A AL ee 143 Assignment of eie ener 143 Automatic Data Capture into Arrays sssssssseseeeeeeeeeenneen eene 144 Deallocating Atray eee det d aur 146 Input of Data Numeric and String sss eene enne 146 Input otD t i54 nee tee ce e Rte Te e itai hr 146 Output of Data Numeric and String ssssssssssssseseeeee ener 147 Sending Messages edet te as UR A RE RN TRA a eee 147 Displaying Variables and Arrays sss 148 Interrogation Commands esee Ret e er i e ed eod 148 Formatting Variables and Array Elements eee 150 Converting to User Units 3 otitis ese Rei e PRO e i Ree 151 Hardware T 0 deae tete 151 Digital Outputs cs a n ead vete men RO eet e Sate ae e x d qe 151 Di
183. l Made Easy or equivalent is required Analysis and design tools as well as several design examples will be provided TIME 8 hours 8 5pm PRODUCT WORKSHOP WHO SHOULD ATTEND Current users of Galil motion controllers Conducted at Galil s headquarters in Rocklin CA students will gain detailed understanding about connecting systems elements system tuning and motion programming This is a hands on seminar and students can test their application on actual hardware and review it with Galil specialists Attendees must have a current application and recently purchased a Galil controller to attend this course TIME Two days 8 30 4 30pm DMC 18x6 Appendices 215 Contacting Us Galil Motion Control 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail address support galilmc com URL www galilmc com FTP www galilmc com ftp WARRANTY All controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship for a period of 18 months after shipment Motors and Power supplies are warranted for 1 year Extended warranties are available In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable war
184. l is low the LED on the controller will be on indicating 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 reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal DMC 18x6 Chapter 3 Connecting Hardware 37 THIS PAGE LEFT BLANK INTENTIONALLY 38 Chapter 3 Connecting Hardware DMC 18x6 Chapter 4 Software Tools and Communications Introduction Galil software is available for PC computers running Microsoft Windows to communicate with DMC 18x6 controllers through the PCI bus Standard Galil communications software utilities are available for Windows operating systems which includes SmartTERM and WSDK These software packages are developed to operate under Windows 98SE ME NT4 0 2000 and XP and include all the necessary drivers to communicate In addition Galil offers software development tools CToolkit and ActiveX Toolkit to allow users to create their own application interfaces using programming environments such as C C Visual Basic and LabVIEW Galil also offers some basic software drivers and utilities for non Windows environments such as DOS Linux and QNX For users who prefer to develop there own drivers details are provided in this ch
185. l return the error code without the text message For more information about the command TC see the Command Reference Stop Code Command The status of motion for each axis can be determined by using the stop code command SC This can be useful when motion on an axis has stopped unexpectedly The command SC will return a number representing the motion status See the command reference for further information RAM Memory Interrogation Commands For debugging the status of the program memory array memory or variable memory the DMC 18x6 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 1816 will have a maximum of 16000 array elements in up to 30 arrays If an array of 100 elements is defined the command DM will return the value 15900 and the command DA will return 29 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 122 Chapter 7 Application Programming DMC 18x6 Operands In general all operands provide information which may be useful in debugging an application pro
186. le move sequences and contouring The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 18x6 provides continuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with multiple master axes as well as gantry mode operation For synchronization with outside events the DMC 18x6 provide uncommitted I O including 8 digital inputs 24 inputs for DMC 1856 thru DMC 1886 8 digital outputs 16 outputs for DMC 1856 thru DMC 1886 and 8 analog inputs for interface to joysticks sensors and pressure transducers Dedicated optoisolated inputs are provided on all DMC 18x6 controllers for forward and reverse limits abort home and definable input interrupts The DMC 18x6 has plug and play capabilities to ease the setup process 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 WIN98SE ME NT4 0 2000 and XP are available DMC 18x6 Chapter 1 Overview 1 Overview of Motor Types The DMC 18x6 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
187. le 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 DMC 18x6 Chapter 4 Software Tools and Communications 41 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 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 delimited 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 s 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 a file containing Galil ASCII language commands to be converted to Galil binary commands and saves the result to the specified file name Opens a dialog box that allows a file containing Galil binary language commands to be converted to Galil
188. lements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter For example DMC 18x6 Chapter 7 Application Programming 143 A Begin Program COUNT 0 DM POS 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec POS COUNT TPX Record position into array element POS COUNT Report position COUNT 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 uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A Start is the first element of array default 0 End is the last element of array default last element Delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 The file is terminated using lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 18x6 provides a special feature for automatic capture of data such as position position error inputs or torque This is
189. ler has two additional virtual axes designated as the M and N axes These axes have no encoder and no DAC However they can be commanded by the commands AC DC JG SP PR PA BG IT GA VM VP CR ST DP RP The main use of the virtual axes 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 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 IN
190. lifier 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 Amp Enable Signal to disable and enable an amplifier Amp Enable goes low on Abort and OEI IPWM STEP OUT IPWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors Ifl you are using a conventional amplifier that accepts a 10 Volt analog signal this pin is not used and should be left open The PWM output is available in two formats Inverter and Sign Magnitude In the Inverter mode the PWM 25kHz signal is 2 duty cycle for full negative voltage 50 for 0 Voltage and 99 8 for full positive voltage 25kHz Switching Frequency In the Sign Magnitude Mode MT1 5 the PWM 50 kHz signal is 0 for 0 Voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output 50kHz Switching Frequency IPWM STEP OUT For stepper motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Appendices 185 Sign Direction Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors Error The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER Output 1 Outpu
191. ll Input Status 290 293 SL new F User defined variable ZA 294 295 UW G axis status see bit field map below 296 UB G axis switches see bit field map below 297 UB G axis stop code 298 301 SL G axis reference position 302 305 SL G axis motor position 306 309 SL G axis position error 310 313 SL G axis auxiliary position 314 317 SL G axis velocity 318 321 SL new size axis torque 322 323 SW G axis analog input 324 325 UW new G Reserved for Hall Input Status 326 329 SL new G User defined variable ZA 330 331 UW H axis status see bit field map below 332 UB H axis switches see bit field map below 333 UB H axis stop code 334 337 SL H axis reference position 338 341 SL H axis motor position 342 345 SL H axis position error 346 349 SL H axis auxiliary position 350 353 SL H axis velocity 354 357 SL new size axis torque 358 359 SW H axis analog input 360 361 UW new H Reserved for Hall Input Status 362 365 SL new H User defined variable ZA DMC 18x6 Chapter 4 Software Tools and Communications 59 Explanation Data Record Bit Fields Thread Status 1 Byte 7 BIT 6 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Thread 7 Thread 6 Thread 5 Thread 4 Thread 3 Thread 2 Thread 1 Thread 0 Running Running Running Running Running Running Running Running Coordinated Motion Status for S or T
192. ller to be reconfigured as a DMC 1856 controller The X and Z 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 F signal The first phase of the Z axis will be the motor command Z signal The second phase of the Z axis will be the motor command G signal Step C Specify the Size of the Magnetic Cycle Use the command BM to specify the size of the brushless motors magnetic cycle in encoder counts For example if the X axis is a linear motor where the magnetic cycle length 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 voltage V to each phase for some time T and checks to see if the motion is in the correct direction The user must specify the value for V and T For example the command 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 DMC 18x6
193. ller to finish updating the data record by monitoring the busy status bit bit 3 of N 4 When bit 3 is 0 the data record can be read After the data has been read un freeze the DPRAM 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 Enabling and Reading IRQs 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 a device driver s interrupt service routine must verify that the interrupt originated from the DMC 18x6 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 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 set bit 5 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 a
194. ly when swapped with another encoder input Unable to read main or auxiliary encoder input Check encoder wiring For single ended encoders CHA and CHB only do not make any connections 1 Wrong encoder connections to the CHA and CHB inputs Check CE command 2 Encoder configuration incorrect 3 Encoder input or Contact Galil controller is damaged Encoder Position Drifts Swapping cables fixes the 1 Poor Connections Review all terminal connections problem intermittent cable and connector contacts Encoder Position Drifts Significant noise can be 1 Noise Shield encoder cables seen on CHA and or CHB Avoid placing power cables near encoder signals encoder cables Avoid Ground Loops Use differential encoders Use 12V encoders Stability woes cause Servo motor runs away Reversed Motor Type 1 Wrong feedback Reverse Motor or Encoder Wiring when the loop is closed corrects situation MT 1 polarity remember to set Motor Type back to default value MT 1 Motor oscillates 2 Too high gain or Decrease KI and KP Increase KD too little damping Operation SYMPTOM CAUSE REMEDY M C EMI rejects Response m 23888 controller m Correct reported by TC1 commands from TC1 diagnoses error Motor Doesn t Move Response of controller Anything Correct problem reported by SC from TC1 diagnoses error 166 Chapter 9 Troubleshooting DMC 18x6 Chapter
195. m source current and low level voltage applies as in the above circuit The maximum sink current is determined by the NEC2505 and is approximately 2 mA Open Collector To DMC 18x6 5V 1 4 NEC2505 18 RPx2 gt e 10 To DMC 18x6l O amp IP e OUTC Figure A 12 Output Circuit Diagram Open Collector Electrical Specifications e T O points configurable as inputs or outputs in groups of 8 Digital Inputs e Maximum voltage 28 VDC e Minimum input voltage 4 VDC e Maximum input current 3 mA High Power Digital Outputs e Maximum external power supply voltage 28 VDC e Minimum external power supply voltage 4 VDC e Maximum source current per output 500mA e Maximum sink current sinking circuit inoperative Standard Digital Outputs e Maximum external power supply voltage 28 VDC e Minimum external power supply voltage 4 VDC e Maximum source current limited by pull up resistor value e Maximum sink current 2mA DMC 18x6 Appendices 207 Relevant DMC Commands COn OP m n o d SBn CBn OB n m TI n TI n IN n Configures the 64 bits of extended I O in 8 banks of 8 bits each n n 2 n 4 8 16 ng 32 n 64 ng 128 ng where n is a 1 or 0 1 for outputs and 0 for inputs The x is the bank number m 8 standard digital outputs n extended I O banks 0 amp 1 outputs 17 32 extended I O banks 2 amp
196. mbination 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 between the input voltage V and the velocity is V K4 Ky Js 1 K Kt Kg Js 1 Kg sT1 1 where the velocity time constant T1 equals T1 J Ka Kt Kg This leads to the transfer function P V V Kg s sT1 1 K __ Kts Figure 10 5 Elements of velocity loops The resulting functions derived above are illustrated by the block diagram of Fig 10 6 172 Chapter 10 Theory of Operation DMC 18x6 VOLTAGE SOURCE V E W P E etos ST_ 1 ST 1 S CURRENT SOURCE V W VELOCITY LOOP V W P K ST 1 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 4N 2n count rad
197. mitted Digital Inputs 33 Wiring the Optoisolated Inputs sess ener 33 Using an Isolated Power Supply sse 34 Bypassing the Opto Isolation eeeseeeseeeeeeeeereen nennen enne 35 Analoe Inputs AJ 3 2 5 es os te e Ne e Nt ed eb ic dts 35 Amplitier Interface t oet 35 ETE Tnp ts e rere riter eee treten rien re tee ehe en ete PRI pee erede s 36 TTE Outputs sccctten R M 37 Chapter 4 Software Tools and Communications 39 Introduction rect e EO e s eel ete te i E 39 Galil Smart TERM too DUI IN Odor PEINE IM SR RO PRI IR EES 4 Communication 45 Windows Servo Design Kit WSDK sss enne ener 48 Creating Custom Software 49 DOS Linux and ONX tools 5 nein ee eH ER E E Ue P 52 Controller Event Interrupts and User Interrupts 52 Hardware Level Communications for 54 Communication with DMC 16x6 eese ener enne 54 Data Record Memory sssssesessseeseee eene 56 Explanation Data Record Bit Fields esee 60 Chapter 5 Command Basics 62 inside X 62 Command Syntax 62 Coordinated Mo
198. moothing parameters imply heavier filtering and smoother moves Note that KS is valid only for step motors Homing The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference This reference is connected to the Home input line The HM command initializes the motor to the encoder index pulse in addition to the Home input The configure command CN is used to define the polarity of the home input DMC 18x6 Chapter 6 Programming Motion 111 The Find Edge FE instruction is useful for initializing the motor to a home switch The home switch is connected to the Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew speed and slew until a transition is detected on the Homing line The motor will then decelerate to a stop A high deceleration value must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch The Home HM command can be used to position the motor on the index pulse after the home switch is detected This allows for finer positioning on initialization The HM command and BG command causes the following sequence of events to occur Stage 1 Upon begin the motor accelerates to the slew speed specified by the JG or SP commands The direction of its motion is determined by the state of the homing input If HMX reads 1 initially the motor will go in the reverse direction first direction of d
199. n Programming 119 Invalid labels 1 Square 123 A Simple Example Program START Beginning of the Program PR 10000 20000 Specify relative distances on X and Y axes BG XY Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves X and Y 10000 and 20000 units After the motion is complete the motors rest for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 18x6 have some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines See section on Auto Start Routine The DMC 18x6 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 132 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 CMDERR Label for incorrect command subroutine Commenting Programs Using the command NO or Apostrophe The DMC 18x6 provides a command NO for commenting programs or single
200. n input Configuring the 64 Extended I O of the 1856 to 1886 using the DB 14064 The 5 to 8 axis versions of the DMC 18x6 are equipped with 24 inputs and 16 outputs an increase from 8 inputs and 8 outputs on 1 to 4 axis models Since the numbering system for accessing the extended I O ranges from 17 to 80 there will be an overlap of inputs from 17 to 24 When configuring the I O note that the first bank of extended I O 17 24 will only be accessible as outputs Configuring the first block 17 24 as inputs renders them as connection inputs since these inputs are already accessible through the general I O on the main board The procedure for configuring and accessing the extended I O on the 5 8 axis versions is then similarly done as described in the previous section Except when using the OP command the argument is a decimal number from 0 to 65535 which refers to the first 16 general I O Connector Description The DB 14064 has two 50 Pin IDC header connectors The connectors are compatible with I O mounting racks such as Grayhill 70GRCM32 HL and OPTO 22 G4PB24 Note for interfacing to OPTO 22 G4PB24 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 6 50 IDC Signal Block Bit IN n Bit OUT n No 1 4 40 7 3 IO 4 39 6
201. n is increased the error decreases Again the system may vibrate if the gain is too high In this case reduce KP 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 22 Chapter 2 Getting Started DMC 18x6 For a more detailed description of the operation of the PID filter and or servo system theory see Chapter 10 Theory of Operation Design Examples Here are a few examples for tuning and using your controller These examples have remarks next to each command these remarks must not be included in the actual program DMC 18x6 Example 1 System Set up This example assigns the system filter parameters error limits and enables the automatic error shut off Instruction KP10 10 10 10 KP 10 KPX 10 KPA 10 KP 20 Interpretation Set gains for a b c d or X Y Z W axes Alternate method for setting gain on all axes Alternate method for setting X or A axis gain Alternate method for setting A or X axis gain Set Y axis gain only When using controllers with 5 or more axes the X Y Z and W axes can als
202. n object the controller must proceed towards a target and have the ability to change the target during the move In a tracking application this could occur at any time during the move or at regularly scheduled intervals For example if a robot was designed to follow a moving object at a specified distance and the path of the object wasn t known the robot would be required to constantly monitor the motion of the object that it was following To remain within a specified distance it would also need to constantly update the position target it is moving towards Galil motion controllers support this type of motion with the position tracking mode This mode will allow scheduled or random updates to the current position target on the fly Based on the new target the controller will either continue in the direction it is heading change the direction it is moving or decelerate to a stop The position tracking mode shouldn t be confused with the contour mode The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate In this mode the position can be updated randomly or at a fixed time rate but the velocity profile will always be trapezoidal with the parameters specified by AC DC and SP Updating the position target at a specific rate will not allow the user to create a custom profile The following example will demonstrate the possible different motions that may be commanded by the controller in
203. n of Closed Loop Systems cccccesccesscesecesecesecseecseeeseeeseeeseeseeeeeneenseeneeneenseenaes 169 System Modeling sodio edere et ete tutu d ewe eck Er is t ed exten 170 Motor Atipliflet te op e ito eade ated ceo e d era 171 Moltage Drive euet str e demde rec etas 171 Current DIGN er n te etie e eet i eR 171 Velocity LGOp ihc E ices etes ae 172 EfiCOden 4i en c AS seus c e es 173 rented s 174 Digital Filters rore MD eve 174 EE 175 System Analysis 175 System Design and Compensation ener enne nnne nenne 177 The Analytical Method esie deese ire defe teen 177 Appendices 181 Electrical Specifications sssssessseseesee eer eene nennen enne nnne nnne nnns 181 Servo Controls eme ER Pe BUR EGER pen A DR petebat 181 Stepper Gonttol 5 o oe uie RUE S 181 Trnput Output MM 181 eni eaa neget ER TREE e HR E HOO IR WERL 182 Performance Specifications ccccceeccesscessceseceecesecseceecseecseeeseeeaeeeneececeeeeseenseeneeneenaeenaes 182 Connectors for DMC 18x6 Main Board sse eene 183 Pin Out Description for 18 6 185 Accessories and Options sese eee e ee I EGER sede ne dud 187 ICM 1900 Interconnect Module sssssseseseeeeeenenneenene nennen nennen enne 188 ICM 1900 Drawing ett Re eert
204. nRetCode DMCCommand m hDmc TPX m sResponse m nResponseLength Text1 Text Val m_sResponse End Sub Private Sub Form_Load m_nResponseLength 256 m_nController 1 m nRetCode DMCOpen m nController 0 m hDmc End Sub Private Sub Form Unload Cancel As Integer m nRetCode DMCClose m hDmc End Sub DMC 18x6 Chapter 4 Software Tools and Communications 51 Where m_nController is the number for 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 controllers The current version of the software has been tested under Redhat 6 X O S All source code for t
205. 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 18x6 function can be used to assign a value to a variable For example VI ABS V2 or V2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters which must be in quotation Examples POSX TPX Assigns returned value from TPX command to variable POSX SPEED 5 75 Assigns value 5 75 to variable SPEED INPUT IN 2 Assigns logical value of input 2 to variable INPUT V2 V1 V3 V4 Assigns the value of V1 plus V3 times V4 to the variable V2 VAR CAT Assign the string CAT to VAR Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as GN 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 v
206. ncoder Note the necessary difference is with the YA command Full Stepping Drive X axis SETUP 104 Chapter 6 Programming Motion DMC 18x6 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 WTS50 Allow slight settle time YSI Enable SPM mode Half Stepping Drive X axis SETUP 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 SETUP 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 the motor correct the error and return to the main code The drive is a full step drive with a 1 8
207. nction 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 controller 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 two methods are available for both the DMC 18x6 controllers and 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 pe
208. nd 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 18x6 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 A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent at PC bus speeds The instruction CS returns the segment counter As the segments are processed CS increases starting at zero This function allows the host computer to determine which segment is being processed 78 Chapter 6 Programming Motion DMC 18x6 Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 18x6 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 2 2
209. nd abort switches and the digital inputs IN9 IN16 See section Bypassing Opto Isolation Chap3 15 26 pin header connector for the auxiliary INCOM amp LSCOM jumpers Used for bypassing opto encoder cable Axes 1 4 isolation for the limit home and abort switches and the digital inputs IN1 IN8 See section Bypassing Opto Isolation Chap3 DMC 1856 1886 1 thru 4 axis only al Elements You Need Before you start you must get all the necessary system elements These include la DMC 1816 1826 1836 or DMC 1846 Motion Controller 1 100 pin cable and 1 ICM 1900 interconnect module or 1b DMC 1856 1866 1876 or DMC 1886 2 100 pin cables and 2 ICM 1900s CB 50 100 connector board and included two 50 pin ribbon cables which converts the two 50 pin ribbon cables into a single 100 pin connector Servo motors with Optical Encoder one per axis or step motors Power Amplifiers Power Supply for Amplifiers PC Personal Computer with PCI bus Galil SmartTerm from CD ROM or download at www galilmc com QUU ONS UM cmo Ur DD WSDK is optional but recommended 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 S For servo motors in current mode the amplifiers should accept an an
210. nd all other bits are low Resetting the DMC to PC 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 Resetting 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 When the FIFO is reset all FIFO configuration is lost and must be rewritten Reset Register at N 8 Read provides IRQ status byte Data Record Memory Map Note UB Unsigned Byte 1 UW Unsigned Word 2 SW Signed Word 2 SL Signed Long Word 4 UL Unsigned Long Word 4 ADDR TYPE ITEM 00 01 UW sample number 02 UB general input block 0 inputs 1 8 03 UB general input block 1 inputs 9 16 04 UB general input block 2 inputs 17 24 05 UB general input block 3 inputs 25 32 06 UB general input block 4 inputs 33 40 07 UB general input block 5 inputs 41 48 08 UB general input block 6 inputs 49 56 09 UB general input block 7 inputs 57 64 10 UB general input block 8 inputs 65 72 11 UB general input block 9 inputs 73 80 56 Chapter 4 Software Tools and Communications DMC 18x6 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 45 46 47 48 51 52 55 56 57 58
211. nd 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 LIMSWI label specifies the start of the limit switch subroutine This label causes the statements following to be automatically executed if any limit switch is activated and that axis motor is moving in that direction The RE command ends the subroutine The state of the forward and reverse limit switches may also be tested during the jump on condition statement The _LR condition specifies the reverse limit _LF specifies the forward limit X Y Z or W following LR or LF specifies the axis The CN command can be used to configure the polarity of the limit switches Limit Switch Example A EN Dummy Program LIMSWI Limit Switch Utility V1 _LFX Check if forward limit V2 LRX Check if reverse limit JP LF V1 0 Jump to LF if forward JP LR V2 0 Jump to LR if reverse JP END Jump to end LF LF MG FORWARD LIMIT Send message DMC 18x6 Chapter 8 Hardware amp Software Protection 163 STX AMX PR 1000 BGX AMX JP END LR MG REVERSE LIMIT STX AMX PR1000 BGX AMX END RE Stop motion Move in reverse End LR Send message Stop motion Move forward End Return to main program 164 Chapter 8 Hardware amp Software Protection DMC 18x6 Chapter 9 Troubleshooting Overview The following discussion may help you get your system to work
212. nge 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 EDI Returns the number of the thread that generated an error 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 DMC 18x6 Example Command Error w Multitasking HA N 1 KPN TY EN CMDERR IF TC 6 N 1 XQ ED2 EDI I ENDIF IF TC 1 XQ ED3 EDI I ENDIF Begin thread 0 continuous loop End of thread 0 Begin thread 1 Create new variable Set KP to value of
213. nic CAM sse 94 Operand Summary Electronic 95 Example Electronic CAM cesis eren ene er eds 95 Contour Mode n ere i deer ee RR oer lera E TERES 96 Specifying Contour Segment ssssssssssessesee ener 96 Additional Commands iint tense ritenere dore ret P 97 Command Summary Contour Mode sss 98 Stepper Motor Operation seirc seii ete tie e de ee eni erede 101 Specifying Stepper Motor 101 Using an Encoder with Stepper Motors sse 103 Command Summary Stepper Motor Operation sss 103 Operand Summary Stepper Motor Operation 103 Stepper Position Maintenance Mode SPM sse enne 103 CPOE Bui 104 roni 104 D l Loop Auxiliary Encoder uet ER TRAN 107 Backlash Combpetsati ri etes easy e eI 108 Motion Smoothing sss coo ERE RASSE NT 109 Using the EE Command uere e SETS AS T e re e ierra 110 Using the KS Command Step Motor Smoothing sss 111 RE 111 DMC 18x6 Contents iii iv Contents Stage I ee eo e e Ie am Pe ER IRE EN ce CEN Were de etn 112 Nini pM E EL 112 LAGS Sp EE 112 Command Summary Homing Operation ssssssssseeeeeenene 115 Operand Summary Homing 11
214. nication 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 5 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 to a command 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 A time out occurred while waiting for a response from the Galil controller The default setting for the timeout is 5000ms which should be sufficient for most cases DMC 18x6 Chapter 4 Software Tools and Communications 45 Controller Communications Parameters General Parameters PCI Bus Parameters Communication Method Controller 2 DMC 18x6 Timeout milliseconds Description SN 18 optional 15 char max Figure 4 5 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 6 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
215. ntly as illustrated below Instruction PR 300 600 SP 2000 DC 80000 AC 100000 SP 40000 AC 100000 DC 150000 BGZ BG Y Interpretation Distances of Y and Z Slew speed of Y Deceleration of Y Acceleration of Y Slew speed of Z Acceleration of Z Deceleration of Z Start Z motion Start Y motion Example 5 Position Interrogation The position of the four axes may be interrogated with the instruction TP Instruction TP TPX TP Y TPZ TPW Interpretation Tell position all four axes Tell position X axis only Tell position Y axis only Tell position Z axis only 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 TE TEX TE Y TEZ TEW 24 Chapter 2 Getting Started Interpretation Tell error all axes Tell error X axis only Tell error Y axis only Tell error Z axis only Tell error W axis only DMC 18x6 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 BG X 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 Dr
216. nverted 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 1 2000 60 Convert to counts sec IN ENTER ACCEL IN RAD SEC2 A1 Prompt for ACCEL AC A1 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program Hardware I O Digital Outputs The DMC 18x6 has an 8 bit uncommitted output port for controlling external events The DMC 1856 through DMC 1886 have an additional 8 outputs Each bit on the output port may be set and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit 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 DMC 18x6 Chapter 7 Application Programming 151 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
217. o be referred to as the A B C D axes Instruction OE 1 1 1 1 1 1 1 1 ER 1000 KP10 10 10 10 10 10 10 10 KP 10 KPX 10 KPA 10 KP 10 KPZ 10 KPD 10 KPH 10 Interpretation Enable automatic Off on Error function for all axes Set error limit for all axes to 1000 counts Set gains for A B C D E F G and H axes Alternate method for setting gain on all axes Alternate method for setting X or A axis gain Alternate method for setting A or X axis gain Set Z axis gain only Alternate method for setting Z axis gain Alternate method for setting D axis gain Alternate method for setting H axis gain 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 s In this example the motor turns and stops Instruction PR 10000 SP 20000 DC 100000 AC 100000 BGX Interpretation Distance Speed Deceleration Acceleration Start Motion Chapter 2 Getting Started 23 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 BGXZ BG YW 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 Example 4 Independent Moves The motion parameters may be specified independe
218. o the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy is for 0 5 micron The basic dilemma is where to mount the sensor If you use a rotary sensor you get a 4 micron backlash error On the other hand if you use a linear encoder the backlash in the feedback loop will cause oscillations due to instability An alternative approach is the dual loop where we use two sensors rotary and linear The rotary sensor assures stability because the position loop is closed before the backlash whereas the linear sensor provides accurate load position information The operation principle is to drive the motor to a given rotary position near the final point DMC 18x6 Chapter 7 Application Programming 159 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 sensor should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000 count per revolution results in a rotary resolution of 0 25 micron This resul
219. o 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 supply the internal 5 supply from the PC may be used to power the optoisolators This is done by installing jumpers on and or JP 13 Optional Motor Off Jumpers The state of the motor upon power up may be selected with the placement of a hardware jumper on the controller With a jumper installed at the MO location the controller will be powered up in the motor off state The SH command will need to be issued in order for the motor to be enabled With no jumper installed the controller will immediately enable the motor upon power up The MO command will need to be issued to turn the motor off Step 3 Install the Communications Software Before installing the controller in the PC Galil communications software terminal and drivers should be loaded Installing the Galil software prior to installing the card will allow most oper
220. ode the amplifier gain should be such that a 10 Volt signal generates the maximum required current In the velocity mode a command signal of 10 Volts should run the motor at the maximum required speed 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 14 Chapter 2 Getting Started DMC 18x6 DMC 18x6 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 Ste
221. of 32768 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of 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 152 1000 s2 Amp K4 2 Amp V DAC Kd 10 32768 0003 Encoder 4N 2n 636 ZOH H s 2000 s 2000 Compensation Filter G s P sD The next step is to combine all the system elements with the exception of G s into one function L s L s M s Ka Kg Kp H s 3 17 10 s2 s 2000 Then the open loop transfer function A s is A s L s G s Now determine the magnitude and phase of L s at the frequency cy 500 L j500 3 17 106 500 2 j500 2000 This function has a magnitude of LG500 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 AG500 1 Arg A j500 135 However since A s L s G s 178 Chapter 10 Theory of Operation DMC 18x6 then it follows that G s must have magnitude of GG500 AG500 LG500 160 and a phase arg G j500 arg AG500 arg L j500 135 194 59 In other words we need to select a filter function G s of the form G s sD so that at the frequency 0 5
222. of the cycle X 1000 and Y 500 This implies that Y must be driven to that point to avoid a jump This is done with the program INSTRUCTION INTERPRETATION RUN Label EBI Enable cam PA 500 starting position SP 5000 Y speed BGY Move Y motor AM After Y moved AII Wait for start signal EG 1000 Engage slave AI 1 Wait for stop signal EQ 1000 Disengage slave EN End Command Summary Electronic CAM command description Cd Specifies master axes for electronic cam where p X Y Z or W or A B C D E F G H for main encoder as master or M or N a for virtual axis master Enables the ECAM ECAM counter sets the index into the ECAM table EW Widen Segment see Application Note 2444 EY Set ECAM cycle count 94 Chapter 6 Programming Motion DMC 18x6 Operand Summary Electronic CAM command description E Example Electronic CAM The following example illustrates a cam program with a master axis Z and two slaves X and Y INSTRUCTION INTERPRETATION A V1 0 Label Initialize variable PA 0 0 BGXY AMXY Go to position 0 0 on X and Y axes 2 Z axis as the Master for ECAM EM 0 0 4000 Change for Z is 4000 zero for X Y EP400 0 ECAM interval is 400 counts with zero start ET 0 0 0 When master is at 0 position 1 point ET 1 40 20 pnd point in the ECAM table ET 2 120 60 3 point in the ECAM table ET 3 240 120 4 point in the ECAM table ET 4 280 140 5 point in table ET 5 28
223. off for external master GAZ 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 18x6 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 90 Chapter 6 Programming Motion DMC 18x6 For example assume 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 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 cor
224. ogram lines These special instructions are listed below 118 Chapter 7 Application Programming DMC 18x6 Edit Mode Commands lt RETURN gt Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of lt RETURN gt will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a lt return gt is given lt cntrl gt P The lt cntrl gt P command moves the editor to the previous line lt centrl 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 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 entrl 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 18x6 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 lab
225. oint halfway between the points C and D The value of AV is 4000 15002 2000 10 712 The value of CS is 2 _VPX VPY contain the coordinates of the point C C 4000 3000 B 4000 0 A 0 0 Figure 6 8 The Required Path Electronic Gearing This mode allows up to 8 axes to be electronically geared to some master axes The masters may rotate in both directions and the geared axes will follow at the specified gear ratio The gear ratio may be different for each axis and changed during motion The command GAX yzw or GA ABCDEFGH specifies the master axes GR x y z w specifies the gear ratios for the slaves where the ratio may be a number between 127 9999 with a fractional resolution of 0001 There are two modes standard gearing and gantry mode The gantry mode enabled with the command GM allows the gearing to stay enabled even if a limit is hit or an ST command is issued GR 0 0 0 0 turns off gearing in both modes The command GM x y z w select the axes to be controlled under the gantry mode The parameter 1 enables gantry mode and 0 disables it GR causes the specified axes to be geared to the actual position of the master The master axis 1s commanded with motion commands such as PR PA or JG When the master axis is driven by the controller in the jog mode or an independent motion mode it is possible to define the master as the command position of that axis rather than the actual position The designation of the commanded posi
226. ommand Event Interrupts EI To enable interrupting upon predefined conditions use EIm n where the first field represents a 16 bit value of conditions described in the command reference For example to enable interrupts on X and Y motion complete and position error set EI515 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 thereafter except for the limit switch position error and digital input conditions which must be re enabled after every occurrence 52 Chapter 4 Software Tools and Communications DMC 18x6 The argument n enables interrupts for the first 8 general inputs on a low level not edge condition To enable interrupts for the desired inputs set bit 15 of the argument then set the desired inputs using the 8 bit mask for the n 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 User Interrupts UI The DMC 18x6 also provides 16 user defined status bytes which can be sent along with the interrupt programs by executing the command UlIn see command reference where n is an integer between 0 and 15 UI commands are useful in DMC programs to allow the application program communicate with a host application Servicing Interrupts When an interrupt occurs the motion controller provides a
227. on 167 LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000 SP 20000 20000 AC 200000 00000 BG X AD 2000 BG Y EN This program corresponds to the velocity profiles shown in Fig 10 3 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The following section explains the operation of the servo system First it is explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined 168 Chapter 10 Theory of Operation DMC 18x6 X VELOCITY Y VELOCITY X POSITION ee Y POSITION ee 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
228. onnect the same encoder to a different axis If the problem disappears you probably have a hardware failure Consult the factory for help Step E Connect Hall Sensors if available Hall sensors are only used with sinusoidal commutation and are not necessary for proper operation The use of hall sensors allows the controller to automatically estimate the commutation phase upon reset and also provides the controller the ability to set a more precise commutation phase Without hall sensors the commutation phase must be determined manually The hall effect sensors are connected to the digital inputs of the controller These inputs can be used with the general use inputs bits 1 8 the auxiliary encoder inputs bits 81 96 or the extended I O inputs of the DB 14064 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 18x6 controller to standard servo motor amplifiers The motor and the amplifier may be configured in the torque or the velocity mode In the torque m
229. ons 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 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 C C 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 nee
230. ontroller DMC 18x6 Chapter 8 Hardware amp Software Protection 161 for selective abort issue the command CN 1 This configures the inputs 5 6 7 8 13 14 15 16 to act as selective aborts for axes A B C D E F G H respectively Forward Limit Switch Low input inhibits motion in forward direction If the motor is moving in the forward direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Software Protection The DMC 18x6 provides a programmable error limit The error limit can be set for any number between 0 and 2147483647 using the ER n command The default value for ER is 16384 Example ER 200 300 400 500 Set X axis error limit for 200 Y axis error limit to 300 Z axis error limit to 400 counts W axis e
231. operand where operand is a valid DMC operand All of the command operands begin with the underscore character _ For example the value of the current position on the X axis can be assigned to the variable V with the command V2 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 the Command Reference manual DMC 18x6 Chapter 5 Command Basics 67 Chapter 6 Programming Motion Overview The DMC 18x6 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 1816 are single axis controllers and use X axis motion only Likewise the DMC 1826 use X and Y the DMC 1836 use X Y and Z and the DMC 1846 use X Y Z and W The DMC 1856 use A B C D and E The DMC 1866 use A B C D E and F The DMC 1876 use A B C D E F and G The DMC 1886 use the axes A B C D E F G and H The example applications described below will help guide you to the appropriate mode of motion 1X86 For controllers with 5 or more axes the specifiers ABCDEFGH are used XYZ and W may be interchanged with ABCD EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each axis is Independent Axis Positioning PA PR
232. or inputs requires that the Ux3 and Ux4 sockets be populated with NEC2505 optical isolation integrated circuits The IOM 1964 is shipped with a default configuration of banks 2 7 configured as inputs The output IC sockets Ux1 and Ux2 must be empty The input IC s are labeled Ux3 and Ux4 For example in bank 0 the IC s are U03 and U04 bank 1 input IC s are labeled U13 and U14 and so on Also the resistor pack RPx4 must be inserted into the bank to finish the input configuration DMC 18x6 Appendices 203 Input Circuit OC 1 4 NEC2505 1 8 RPx4 To DMC 18x6 I O x bank number 0 7 n input number 17 80 A1 To DMC 18x6 A 1 0 Figure Opto Input Circuit Connections to this optically isolated input circuit are done in a sinking or sourcing configuration referring to the direction of current Some example circuits are shown below Sinking Sourcing e e 5V OC e e GND O GND O e ge e 45V Ourrent Current Figure A 7 Input Sinking and Sourcing Diagram There is one I OC connection for each bank of eight inputs Whether the input is connected as sinking or sourcing when the switch is open no current flows and the digital input function IN n returns 1 This is because of an internal pull up resistor on the DB 14064 When the switch is closed in either circuit current flows This pulls the input on the DB 14064 to
233. ormat VF2 2 Change format le Return V1 10 00 New format VF 2 2 Specify hex format le Return V1 04 00 Hex value VF1 Change format 1 Return V1 9 Overflow Local Formatting of Variables PF and VF commands are global format commands that affect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m or n m following the variable name and the symbol F specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal For example Examples V1 10 Assign V1 1 Return V1 0000000010 0000 Default Format 150 Chapter 7 Application Programming DMC 18x6 V1 F4 2 Specify local format 0010 00 New format V1 4 2 Specify hex format 000A 00 Hex value V1 ALPHA Assign string ALPHA to V1 V1 S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 18x6 position parameters such as PR PA and VP have units of quadrature counts Speed parameters such as SP JG and VS have units of counts sec Acceleration parameters such as AC DC VA and VD have units of counts sec2 The controller interprets time in milliseconds All input parameters must be co
234. osition as 0 EN End Command Summary Homing Operation command deseription FE XYZW Find Edge Routine This routine monitors the Home Input FI XYZW Find Index Routine This routine monitors the Index Input HM XYZW Home Routine This routine combines FE and FI as Described Above SC XYZW Stop Code TS XYZW Tell Status of Switches and Inputs Operand Summary Homing Operation Contains the value of the state of the Home Input Contains stop code Contains status of switches and inputs Chapter 6 Programming Motion 115 High Speed Position Capture The Latch Function Often it is desirable to capture the position precisely for registration applications The DMC 18x6 provides a position latch feature This feature allows the position of the main or auxiliary encoders of X Y Z or W to be captured within 25 microseconds of an external low input signal or index pulse The general inputs through 4 and 9 thru 12 correspond to each axis 1 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 INII G axis 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 18x6 software commands AL and RL are used to arm the latch and report the latched position The steps to use the latch are as follows 1 Give the AL XYZW command or ABCDEFGH for DMC 1886
235. ower 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 INTERPRETATION Points Label SP 7000 Speed AC 80000 DC 80000 Acceleration Loop VAR AN 1 1000 Read and analog input compute position PA VAR 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 Cont AC 80000 DC 80000 JG 0 BGX Loop VAR AN 1 1000 VER VAR _TPX VEL VER 20 JG VEL JP Loop EN Example Applications Wire Cutter INTERPRETATION Label Acceleration rate Start job mode Start motion Compute desired position Find position error Compute velocity Change velocity Change velocity End 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 2x inches and i
236. p B Set Torque Limit as a Safety Precaution To limit the maximum voltage signal to your amplifier the DMC 18x6 controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to the velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt on the X axis TL 1 lt 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
237. polation Mode scssi sinisi eoe e ee OH RP e e EEUU e Pe UTR e e deus 78 Specifying Linear Segmients eee e de oi bese 78 Command Summary Linear Interpolation eese 80 Operand Summary Linear Interpolation eese 80 Example Linear Move eoe at ce eec e Ig CE ER h 81 Example Multiple Moves sisanne sess 82 Vector Mode Linear and Circular Interpolation Motion sese 83 Specifying the Coordinate Plane sssssssseseeeeeeeee nennen 83 Specifying Vector Segment eene 83 Additional commands sese enne nnne 84 Command Summary Coordinated Motion Sequence sss 85 Operand Summary Coordinated Motion Sequence sss 86 Electronic Geannge esie RR ERE Dri 87 Ramped Gearing AE E 88 Example Electronic Gearing Over a Specified 89 Command Summary Electronic Gearing 90 Example Simple Master Slave ccccceccsessceescesseesceeseeeeceeceeceseeesecsaecsaeceeeaeeeseeees 90 Example Electronic Gearing sss ener 90 Example Gantry Mode enne enne 90 Example Synchronize two conveyor belts with trapezoidal velocity correction 91 Electronic Cam rd D DEN EUR Ute Ee HER ER RUD 91 Command Summary Electro
238. ponding velocity for the motor is assigned to the VEL variable Instruction A JGO BGX B VIN AN 1 VEL VIN 20000 JG VEL JP zB 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 JA Label V3 5 Initial position ratio DPO Define the starting position JGO Set motor in jog mode as zero BGX Start JB VIN AN 1 Read analog input V2 V1 V3 Compute the desired position V4 V2 _TPX _TEX Find the following error V5 V4 20 Compute a proportional speed JG V5 Change the speed JP B Repeat the process EN End Backlash Compensation by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective way to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method described below This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The slide is to be controlled by a rotary motor which is coupled t
239. 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 DMC 18x6 Chapter 6 Programming Motion 103 User Configurable Commands user can query amp change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status A pulse is defined by the resolution of the step drive being used Therefore one pulse could be a full step a half step or a microstep When a Galil controller is configured for step motor operation the step pulse output by the controller is internally fed back to the auxiliary encoder register For SPM the feedback encoder on the stepper will connect to the main encoder port Enabling the SPM mode on controller with YS 1 executes an internal monitoring of the auxiliary and main encoder reg
240. r 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 SBI 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 ZVECTOR Label VMXY VS 5000 Coordinated path VP 10000 20000 Vector position VP 20000 30000 Vector position VE End vector BGS Begin sequence AV 5000 After vector distance VS 1000 Reduce speed EN End DMC 18x6 Chapter 7 Application Programming 127 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 1 to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec OUTPUT Program label ATO Initialize time reference SBI Set Output 1 LOOP Loop AT 10 After 10 msec from reference 1 1 1 40 Wa
241. r DMC 1886 a b c d e f g h Specifies time interval 2 sample periods 1 ms for TM1000 for position increment where nis 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 Amount of space left in contour buffer 511 maximum 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 14 The objective is to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe the position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner 1 cos 27 B X amp sin 2z B Note is the angular velocity X is the position and T is the variable time in milliseconds In the given example A 6000 and B 120 the position and velocity profiles are X 50T 6000 27 sin 2x T 120 Note that the velocity in count ms is 50 1 cos 2x T 120 Figure 6 14 Velocity Profile with Sinusoidal Acceleration 98 Chapter 6 Programming Motion DMC 18x6 The DMC 18x6 can compute trigonometric
242. ranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship at our expense only to destinations in the United States and for products within warranty Call Galil to receive a Return Materials Authorization RMA number prior to returning product to Galil Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer alteration modification negligence or misuse is not covered by this warranty EXCEPT AS SET FORTH ABOVE GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES COPYRIGHT 3 97 The software code contained in this Galil product is protected by copyright and must not be reproduced or disassembled in any form without prior written consent of Galil Motion Control Inc 216 Appendices DMC 18x6 Index A Abort 31 32 56 78 84 161 163 181 185 86 Off On Error 13 32 35 161 162 Stop Motion 78 84 134 164 Absolute Position 70 71 125 26 130 Absolute Value 92 130 140 162 Acceleration 127 28 146 151 154 56 212 13 Accessories 187 Address 143 45 216 Almost Full Flags 55 AMP 1100 17 Ampflier Gain 4 Amplifier Enable 35 161 Amplifier Gain 171 175 178 Analog Input 3 31 35 73 140 41 143 147 153 54 159 181 Analysis SDK 118 Arithmetic Functions 118 129 139
243. rce as well as affecting the low level voltage at the I O output The maximum sink current is 2mA regardless of RPx3 or I OC voltage determined by the NEC2505 optical isolator IC The maximum source current is determined by dividing the external power supply voltage by the resistor value of RPx3 The high level voltage at the I O output is equal to the external supply voltage at I OC However when the output transistor is on and conducting current the low level output voltage is determined by three factors The external supply voltage the resistor pack RPx3 value and the current sinking limit of the NEC2505 all determine the low level voltage The sink current available from the NEC2505 is between 0 and 2mA Therefore the maximum voltage drop across RPx3 is calculated by multiplying the 2mA maximum current times the resistor value of RPx3 For example if a 10k ohm resistor pack is used for RPx3 then the maximum voltage drop is 20 volts The digital output will never drop below the voltage at OUTC however Therefore a 10k ohm resistor pack will result in a low level voltage of 7 to 1 0 volts at the I O output for an external supply voltage between 4 and 21 VDC Ifa supply voltage greater than 21 VDC is used a higher value resistor pack will be required 206 Appendices DMC 18x6 Output Command Result CB Vout GNDiso SB Vout Viso The resistor pack RPx3 is removed to provide open collector outputs The same calculations for maximu
244. re setting up the motion control system the user must determine the desired motor configuration The DMC 18x6 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 18x6 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 18x6 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 1846 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 s
245. rection is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity correction GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 7 axes can be slaved to one master axis The master axis encoder must be input through a 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 1886 controllers may have one master and up to seven slaves To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis Y when the master is X Such a graphic relationship is shown in Figure 6 11 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master axis This is done with the instruction EAp where p X Y Z W E F G H p is the selected master axis For the given example since the master is x we specify EAX Step 2 Specify the master cycle and the change in the slave axis or axes DMC 18x6 Ch
246. rection of the FE motion is dependent on the state of the home switch High level causes forward motion The motor will then decelerate to a stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP When using the FE command it is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine is initiated by the command sequence FIX lt return gt BGX lt return gt Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command and then moves back to the index pulse and speed HV Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead 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 lt return gt Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate speci
247. red speed and acceleration Galil s MotorSizer Web tool can help you with motor sizing www galilmc com support motorsizer DMC 18x6 Driver Motor Encoder The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step motors the controller can operate 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 a 10 Volt signal from the controller into current to drive the motor For stepper motors the amplifier converts step and direction signals into current The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation is required or the controller must be configured to provide sinusoidal commutation The amplifiers may be either pulse width modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 Volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 Volts should run the motor at the maximum speed Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 18x6 accepts feedback from either
248. ree 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 L R s and the motor parameters and units are Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m2 L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to MKS units For example consider a motor with the parameters 14 16 oz 0 1 N A R 22 J 0 0283 oz in s2 2 1074 kg m2 L 0 004 Then the corresponding time constants Tm 0 04 sec and Te 0 002 sec Assuming that the amplifier gain is Kv 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of Ka The resulting transfer function in this case is P V Ka Kt Js2 where Kt and J are as defined previously For example a current amplifier with K4 2 A V with the motor described by the previous example will have the transfer function DMC 18x6 Chapter 10 Theory of Operation 171 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 co
249. rforms 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 1s 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 is set The Galil communications DLL will use this value to send the appropriate DR command to the controller when a communications session Is opened DMC 18x6 Chapter 4 Software Tools and Communications 47 Controller Communications Parameters x General Parameters PCI Bus Parameters Communication Method Base lO Port Address Interrupt Vector Data Record Refresh Rate Figure 4 7 DMC 18x6 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
250. ring 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 18x6 has a set of commands that directly interrogate the controller When the command is entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and Leading Zeros LZ command See Chapter 7 and the Command Reference Summary of Interrogation Commands For example the following example illustrates how to display the current position of the X axis TP X lt enter gt Tell position X 0 Controllers Response 66 Chapter 5 Command Basics DMC 18x6 TP XY lt enter gt Tell position X and Y 0 0 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PR Request X Y Z W values PR Request Y value only The controller can also be interrogated with operands Operands Most DMC 18x6 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
251. rings out a second 100 pin cable to be attached to the second ICM 1900 Two 50 pin ribbon cables attach the CB 50 100 to the DMC 1886 DMC 18x6 Install The installation of the DMC 18x6 will vary with operating systems due to how the PCI is handled within that operating system For Win98SE ME NT4 0 2000 and XP the OS will automatically install the drivers With Windows 95 or 98 upon power up your computer should recognize the DMC 18x6 as a new device and will prompt you for an Installation Disk The computer will ask you to point towards the DMC1800 INF file on your PC This file will automatically configure the controller for your computer s available resources The installation will also automatically add this information to the Galil Registry see Step 5 below Step 5 Establishing Communication between the Galil controller and the host PC Using Galil Software for Windows NT 98 SE ME XP and 2000 In order for the Windows software to communicate with a Galil controller the controller must be entered in the Windows Registry In Windows 98 SE 2000 and XP operating systems OS the DMC 18x6 is plug and play This means that on power up the computer will automatically detect the card and install the appropriate device driver A Found New Hardware dialog box may appear during installation of the device driver The controller will be identified by model name and entered into the Galil Registry Now the user can communicate to
252. ro 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 20 Chapter 2 Getting Started DMC 18x6 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 is needed for efficient motor operation There are 3 possible methods for commutation phase initialization Method 1 Use the BZ command as described above Method 2 Drive the motor close to commutation phase of zero and then use BZ command This method decreases the amount of system jerk by moving the motor close to zero commutation phase before executing the BZ command The controller makes an estimate for the number of encoder counts between the current position and the position of zero commutation phase This value i
253. roller The dialog automatically configures itself to display the data record for each type of Galil Motion Controller The Options menu command causes the Options dialog to be displayed The Options 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 memory This window has basic text editing features such as copy cut paste etc Also the editor window File function 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 gt icon or typing CTRL H 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 is available on the DMC 18x6 controllers through a secondary communications channel To display the Data Record shown
254. rror 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 controller will generate several signals to warn the host system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 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 18x6 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 18x6 will not accept position commands beyond the limit Motion beyond the limit is also prevented Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog BG XYZ Begin motion stops at forward limits Off On Error The DMC 18x6 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 activa
255. rs at speeds of 1 132 and 045 times the speed of an external master Because the master is traveling at high speeds it is desirable for the speeds to change slowly Solution Use a DMC 1836 controller where the Z axis is the master and X and Y are the geared axes We will implement the gearing change over 6000 counts 3 revolutions of the master axis Turn Z off for external master GAZ Z Specify Z as the master axis for both X and Y GD6000 6000 Specify ramped gearing over 6000 counts of the master axis GR 1 132 045 Specify gear ratios Question What is the effect of the ramped gearing Answer Below in the example titled Electronic Gearing gearing would take effect immediately From the start of gearing if the master traveled 6000 counts the slaves would travel 6792 counts and 270 counts Using the ramped gearing the slave will engage gearing gradually Since the gearing is engaged over the interval of 6000 counts of the master the slave will only travel 23396 counts and 135 counts respectively The difference DMC 18x6 Chapter 6 Programming Motion 89 between these two values is stored in the GPn operand If exact position synchronization is required the IP command is used to adjust for the difference 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 CW or CA CB CC CD CE CF CG CH for
256. rs 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 and the DPRAM address at BAR 0 The following PCI information HEX can be used to identify the DMC 18x6 controller PCI Device Identification DEVICE ID VENDOR ID SUBSYSTEM ID UBSYSTEM VENDOR ID 9050H 10B5H 1806H 1079H Read Write and Control Registers The DMC 18x6 provides six 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 N 4 The reset register occupies address N 8 and is used for resetting the controller and or main read write FIFO registers as well as retrieving the interrupt status byte The DPRAM address for accessing the data record is available from BAR 0 N 6 to N 7 and N 10 to N 11 contain the read write FIFO byte counts Communication with DMC 18x6 Register Address Read Write Description bytes CONTROL Read Write For FIFO status control 8 IRQ N Read Write For IRQ status byte and controller reset IRESET CLEAR FIFO BAR 0 Read only For binary data record access 54 Chapter 4 Software Tools and Communications DMC 18x6 Read FIFO Count N 6 to
257. ruction 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 DMC 18x6 TASK1 ATO 1 LOOP1 AT 10 SBI AT 40 1 JP LOOP1 TASK2 XQ TASKI 1 LOOP2 PR 1000 BGX Task1 label Initialize reference time Clear Output 1 Loop label Wait 10 msec from reference time Set Output 1 Wait 40 msec from reference time then initialize reference Clear Output 1 Repeat Loopl Task2 label Execute Task1 Loop2 label Define relative distance Begin motion Chapter 7 Application Programming 121 AMX After motion done WT 10 Wait 10 msec JP LOOP2 IN 2 1 Repeat motion unless Input 2 is low HX Halt all tasks The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 18x6 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 Tra
258. rves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate is 0 1 g The motion starts at point A with the Z axis raised An X Y motion to point B is followed by lowering the Z axis and performing a cut along the circle Once the circular motion is completed the Z axis is raised and the motion continues to point C etc Assume that all of the 3 axes are driven by lead screws with 10 turns per inch pitch Also assume encoder resolution of 1000 lines per revolution This results in the relationship and the speeds of 1 in sec 40 000 count sec 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 2 0 1g 38 6 in s2 1 544 000 count s 1 inch 40 000 counts Note that the circular path has a 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 HA VM XY VP 160000 160000 VE VS 200000 VA 1544000 BGS AMS PR 80000 SP 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ PR 21600 SP 20000 156 Chap
259. s 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 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 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 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 requir
260. s the feed rate 1s the vector sum of the velocities along the X and Y axes Vx and Vy 210 Appendices Vs 4Vx Vy me i an 18 6 The vector distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle corresponds to the positive direction of the X axis and the CCW direction of rotation is positive Angles are expressed in degrees and the resolution is 1 256 of a degree For example the path shown in Fig A 13 is specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 20000 10000 10000 20000 Figure A 13 X Y Motion Path The first line describes the straight line vector segment between points A and B The next segment is a c
261. 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 18x6 program sequences The controller can monitor several important conditions in the background These conditions include checking for the occurrence of a limit switch a defined input position error or a command error Automatic monitoring is enabled by inserting a special predefined label in the applications program The pre defined labels are LIMSWI SUBROUTINE DESCRIPTION Limit switch on any axis goes low DMC 18x6 ININT Input specified by II goes low POSERR Position error exceeds limit specified by ER MCTIME Motion Complete timeout occurred Timeout period set by TW command CMDERR Bad command given AUTO Automatically executes on power up AUTOERR Automatically executes when a checksum is encountered during AUTO start up Check error condition with RS bit 0 for variable checksum error bit 1 for parameter checksum error bit 2 for program checksum error bit 3 for master reset error there should be no program For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the ZPOSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt s
262. se from Interrogation Command With Leading Zeros 121 Enables the LZ function TP Tell Position Interrogation Command DMC 18x6 Chapter 7 Application Programming 149 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 F2 2 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 00 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by VF 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 le Return V1 0000000010 0000 Default f
263. soidal commutation the parameters for the commutation must be determined and saved in the controllers 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 highest command output and the 2 phase of the lowest sinusoidal commutation axis will be the lowest command output It is not necessary to be concerned with cross wiring the 1 and 2 signals If this wiring is incorrect the setup procedure will alert the user Step D Example Sinusoidal Commutation Configuration using a DMC 1876 BAXZ This command causes the contro
264. status byte to indicate which condition has occurred Status Byte hex Condition 00 No interrupt D9 EI Watchdog timer activated DA Command done DB El Application program done FO thru FF User interrupt SEI thru E8 El Input interrupt CO El Limit switch occurred C8 El Excess position error D8 E1 All axis motion complete D7 1 axis motion complete D6 El G axis motion complete D5 El F axis motion complete D4 El E axis motion complete D3 W axis motion complete D2 El Zaxis motion complete DI El Y axis motion complete D0 El X axis motion complete BA Controller sent colon response CW 1 BB MG sent from controller program CW 1 BC New record available in DPRAM CW 1 The Galil communication library will service the interrupt and return the Status Byte Any host application that has been properly configured will then be notified For example when using the ActiveX toolkit DMCShell control on Microsoft Windows with Visual Basic 6 the DMCShell1_ DMCInterrupt event procedure shown below will execute and pass the Status Byte in the argument When an interrupt occurs this Status Byte can then be used in a case structure as the key to notify the host application of a specific event or condition In the Visual Basic 6 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 argum
265. t 8 Output 9 Output 16 DMC 1856 thru 1886 These 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 Inputs Encoder B 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 22 000 000 quadrature states sec The controller performs quadrature decoding of the encoder signals resulting in a resolution of quadrature counts 4 x encoder cycles Note Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses into CHA and direction into Channel B and using the CE command to configure this mode Encoder Index I Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Encoder A B I Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Auxiliary Encoder Aux A Aux B Aux I Aux A Aux Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for IB Aux
266. t corresponds to 4000 quadrature one inch of travel equals 154 Chapter 7 Application Programming DMC 18x6 4000 2x 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 2A Here the controller waits for the input pulse on I1 As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle INSTRUCTION FUNCTION Label All Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AMX After motion is complete SBI Set output bit 1 WT 20 Wait 20 ms CBI Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process START PULSE 11 a MOTOR VELOCITY OUTPUT PULSE see output TIME INTERVALS move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals X Y Table Controller An X Y Z system must cut the pattern shown in Fig 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool DMC 18x6 Chapter 7 Application Programming 155 The solid cu
267. t or Home Switch to an Isolated Supply This diagram only shows the connection for the forward limit switch of the X axis NOTE As stated in Chapter 2 the wiring is simplified when using the ICM 1900 or AMP 19XO interface board This board accepts the signals from the ribbon cables of the DMC 18x6 and provides phoenix type screw terminals A picture of the ICM 1900 can be seen in Chapter 2 If an ICM 1900 is not used an equivalent breakout board will be required to connect signals from the DMC 18x6 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 These jumpers can be added on either the ICM 1900 J52 or the DMC 18x6 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 18x6 has eight analog inputs configured for the range between 10V and 10V The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 005V A 16 bit ADC is available as an option The impedance of these inputs is 10 The analog inputs are specified as AN x where x is a number thru 8 Amplifier Interface The DMC 18x6 analog command voltage MOCMD ranges between 10V This signal
268. te 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 162 Chapter 8 Hardware amp Software Protection DMC 18x6 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 Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor AMX After motor stops SHX Servo motor here to clear error RE Return to main program Limit Switch Routine The DMC 18x6 provides forward a
269. tepper mode the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position The MC trippoint Motion Complete is generally more useful than AM trippoint After Motion since the step pulses can be delayed from the commanded position due to stepper motor smoothing 102 Chapter 6 Programming Motion DMC 18x6 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 DE Operand Summary Stepper Motor Operation OPERAND Stepper Position Maintenance Mode SPM The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle the event of stepper motor position error The mode looks at position feedback from the main encoder and compares it to the commanded step pulses The position information is used to determine if there is any significant difference between the commanded and the actual motor
270. ter 7 Application Programming FUNCTION Label Circular interpolation for XY Positions End Vector Motion Vector Speed Vector Acceleration Start Motion When motion is complete Move Z down Z speed Start Z motion Wait for completion of Z motion Circle Feed rate Start circular move Wait for completion Move Z up Start Z move Wait for Z completion Move X Speed X DMC 18x6 DMC 18x6 BGX AMX PR 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ VP 37600 16000 VE VS 200000 BGS AMS EN Start X Wait for X completion Lower Z Z second circle move Raise Z Return XY to start Chapter 7 Application Programming 157 Figure 7 2 Motor Velocity and the Associated Input Output signals Speed Control by Joystick The speed of a motor is controlled by a joystick The joystick produces a signal in the range between 10V and 10V The objective is to drive the motor at a speed proportional to the input voltage Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec The program reads the input voltage periodically and assigns its value to the variable VIN To get a speed of 200 000 ct sec for 10 volts we select the speed as Speed 20000 x VIN 158 Chapter 7 Application Programming DMC 18x6 The corres
271. the actual temperature which is called the feedback signal with the desired level of 90 degrees F The difference between the two levels is called the error signal If the feedback temperature is too low the error is positive and it triggers an action which raises the water temperature until the temperature error is reduced sufficiently The closing of the servo loop is very similar Suppose that we want the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called overdamped response DMC 18x6 Chapter 10 Theory of Operation 169 The results may be worse if we turn the fauc
272. 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 18x6 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 18x6 allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to specify a variety of different cases for branching Command Format IF ELSE and ENDIF FORMAT IF conditional statement s DESCRIPTION Execute commands proceeding IF command up to ELSE command if conditional statement s is true otherwise continue executing at ENDIF command or optional ELSE command ELSE Optional command Allows for commands to be executed when argument of IF command evaluates not true Can only be used with IF command ENDIF Command to end IF conditional statement Program must have an ENDIF command for every IF command Example using IF ELSE and ENDIF TEST IL 3 MG WAITING FOR INPUT 1 INPUT 2 LOOP JP LOOP EN ININT IF 1 0 IF N 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 JP WAIT IN 1 0 QIN 2 0 RIO Subroutines Begin Main Program TEST Enable input interrupts on input 1 and input 2 Output message Label to be used for endl
273. the home sequence are shown in the following table Direction of Motion Switch Type Stage 3 Normally Open ma 1 Forward e CONUM GENE ee Normally Closed eem e Forward Normally Closed Reverse Forward Forward 112 Chapter 6 Programming Motion DMC 18x6 Example Homing Instruction ZHOME CN 1 AC 1000000 DC 1000000 SP 5000 HM BG AM MG AT HOME EN Interpretation Label Configure the polarity of the home input Acceleration Rate Deceleration Rate Speed for Home Search Home Begin Motion After Complete Send Message End Figure 6 16 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 DMC 18x6 Chapter 6 Programming Motion 113 HOME SWITCH HMX 0 HMX 1 VELOCITY MOTION BEGINS IN FORWARD DIRECTION POSITION VELOCITY MOTION CHANGES DIRECTION us POSITION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD INDEX INDEX PULSES POSITION POSITION Figure 6 16 Homing Sequence for Normally Closed Switch and CN 1 Example Find Edge EDGE Label AC 2000000 Acceleration rate 114 Chapter 6 Programming Motion DMC 18x6 DMC 18x6 DC 2000000 Deceleration rate SP 8000 Speed FE Find edge command BG Begin motion AM After complete MG FOUND HOME Send message Define p
274. thout 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 the 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 ends up in the motor off MO state A negative number causes the process to end in the Servo Here SH state Warning This command must move the motor to find the ze
275. tion VE End vector sequence BGS Start motion 28 Chapter 2 Getting Started DMC 18x6 4000 4000 0 4000 R 2000 QO 4000 0 0 0 local zero Figure 2 8 Motion Path for Example 16 DMC 18x6 Chapter 2 Getting Started 29 THIS PAGE LEFT BLANK INTENTIONALLY 30 Chapter 2 Getting Started DMC 18x6 Chapter 3 Connecting Hardware Overview The DMC 18x6 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 1X80 Controllers with 5 or more axes have 16 optoisolated uncommitted inputs 8 TTL inputs and 16 TTL outputs This chapter describes the inputs and outputs and their proper connection If you plan to use the auxiliary encoder feature of the DMC 18x6 you must also connect a cable 26 25 from the 26 pin J5 Auxiliary encoder connector on the DMC 18x6 to the 25 pin DSUB connector on the AMP 19X0 or ICM 1900 This cable is not shipped unless requested when ordering For controllers with 5 or more axes two cable 26 25 cables are necessary for connection to two separate interconnect modules A complete description of how to wire all IO to a Galil ICM 1900 or ICM 2900 can be found on Application Note 1452 at Galil s web site a http www galilmc com literature technotes html Using Optoisolated Inputs Limit Switch
276. tion 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are HA CMX Specifies X axis for contour mode CD 48 2 Specifies first position increment and time interval 2 ms CD 240 3 Specifies second position increment and time interval 2 ms CD 48 4 Specifies the third position increment and time interval 2 ms CD 0 0 End of contour buffer Wait JP HWait CM lt gt 511 Wait until path is done EN POSITION COUNTS Uude 258 240 192 96 48 Lea TIME ms 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 13 The Required Trajectory Additional Commands CM gives the amount of space available in the contour buffer 511 maximum Zero parameters for DT followed by zero parameters for CD exit the contour mode If no new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data 1s received the controller responds with a DMC 18x6 Chapter 6 Programming Motion 97 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 1886 ABCDEFGH CD x y z w Specifies position increment over time interval Range is 32 000 CD 0 0 0 ends contour buffer CD Position increment data fo
277. tion master is 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 DMC 18x6 Chapter 6 Programming Motion 87 Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced an additional distance with PR or JG commands or VP or LI Ramped Gearing In some applications especially when the master is traveling at high speeds it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing is engaged For example if the master axis is already traveling at 1 000 000 cts sec and the slave will be geared at a ratio of 1 1 when the gearing is engaged the slave will instantly develop following error and command maximum current to the motor This can be a large shock to the system For many applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame Galil allows the user to specify an interval of the master axis over which the gearing
278. tion requirements For example the velocities along the X and Y axes for the path shown in Fig A 13 are given in Fig A 15 Fig A 15a 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 velocities vary gradually and finally between the points C and D the motion is in the X direction B C a A D time Figure A 15 Vector and Axes Velocities DMC 18x0 DMC 18x6 Comparison Faster servo operation good for very 12 MHz encoder speed for servos 22 MHz high resolution encoders Faster stepper operation 3 MHz stepper rate Higher servo bandwidth 125 usec minimum sample time 31 25 usec minimum sample time DMC 1810 or DMC 1820 with fast DMC 1816 or DMC 1826 with firmware fast firmware DMC 18x6 Appendices 213 Faster Command Execution 400 usec command 40 usec command Expanded memory lets you store more 1000 lines X 80 character program 2000 lines X 80 characters programs memory Expanded program labels DL 254 labels 510 labels Expanded variables UL 254 variables 510 variables Expanded arrays for more storage 8000 array elements in 30 arrays 16000 array elements in 30 arrays great for data capture DM DA Contour Buffer CM 511 elements New commands features L K PW 96 OV OT OA ALTX TR1 1 HV LD
279. tion will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 0 5 results in the specification VS 2000 to be divided by two 84 Chapter 6 Programming Motion DMC 18x6 Compensating for Differences in Encoder Resolution By default the DMC 18x6 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in the Command Reference Trippoints The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Tangent Motion Several applications such as cutting require a third axis i e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 18x6 allows one a
280. tion with more than 1 axis seen 63 Command Syntax Binary advanced sse 63 Binary Command FotmMataaci seice dininin iiien 63 Binary command table a ee eiae ee edi 65 Controller Response to DATA sss enne enne ener enne 66 Interrogating the Controller rot e reae recede 66 Interrogation Commands enne nennen nennen enne rene 66 Summary of Interrogation Commands sse 66 Interrogating Current Commanded Values eerte 67 Operands tee seit re d eee E tin iuo eie de es 67 Command Summary secret tee e bee pe aude Ere e dva 67 ii e Contents DMC 18x6 Chapter 6 Programming Motion 68 OVet VIEW 2 nece Ahh eee ae ee OL eee naa i a ie eek 68 Independent Axis Positioning eet te D RT Re eee 70 Command Summary Independent Axis sse 70 Operand Summary Independent Axis sse 70 Independent ette aset ee aee t oe e e IEEE tt 72 Command Summary Jogging ener 72 Operand Summary Independent Axis 73 Position TFracking i Oed eade aet eaa etie eter 73 Example Motion 2 3 ee ded ae ee Re Re ie ETE uus 75 Example Moti td cick Sieve Se SR a RR RENI e 76 Trip Points es RR eto e o de egest iei qu ead e die T Command Summary Position Tracking Mode sse 78 Linear Inter
281. tiveX Toolkit is useful for the programmer who wants to easily create a custom operator interface to a Galil controller The ActiveX Toolkit includes a collection of ready made ActiveX COM controls for use with Visual Basic Visual C Delphi LabVIEW and other ActiveX compatible programming tools The most common environment is Visual Basic 6 but Visual Basic NET Visual C Wonderware LabVIEW and HPVEE have all been tested by Galil to work with the OCX controls The ActiveX Toolkit can be purchased from Galil at http 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 18x6 Chapter 4 Software Tools and Communications 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 configurati
282. tor 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 any saved variables programs or parameters Master Reset performs a master reset on the controller A Master Reset does clear any 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 started 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 42 Chapter 4 Software Tools and Communications DMC 18x6 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 Update Firmware Causes the Data Record dialog box to be displayed for the currently connected Display Data Record cont
283. tor 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 parameter 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 Windows Servo Design Kit WSDK software The filter has three parameters the damping KD the proportional gain KP and the integrator KI The parameters should be selected in this order To start set the integrator to zero with the instruction 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 damping 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 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 gai
284. tory 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 18x6 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 provides 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 18x6 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 Chapter 1 Overview DMC 18x6 DMC 18x6 Functional Elements The DMC 18x6 circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed below WATCH
285. ts 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 correction should be Correction Load Position Error Rotary Position Error The correction can be performed a few times until the error drops below 2 counts Often this is performed in one correction cycle Example motion program INSTRUCTION FUNCTION A Label DPO Define starting positions as zero LINPOS 0 PR 1000 Required distance BGX Start motion B AMX Wait for completion WT 50 Wait 50 msec LINPOS DEX Read linear position ERR 100
286. ubroutine When the specified input occurs the program will be executed automatically NOTE An application program must be running for ZCMDERR 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 18x6 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 LOOP 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 LOOP Dummy Program 001 JP ZLOOP EN Jump to Loop 002 LIMSWI Limit Switch Label 003 MG LIMIT OCCURRED Print Message 004 RE Return to main program lt control gt Q Quit Edit Mode XQ LOOP Execute Dummy Program JG 5000 Jog BGX Begin Motion Now when a forward limit switch occurs on the X axis the 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 3 The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error ED Edit Mode 000 LOOP Dummy Program 001 JP LOOP EN Loop 002 POSERR Position Error Routine 003 Vi TEX Read Position Error DMC 18x6 Chapter 7 Application Programming 133 004 MG EXCESS PO
287. ue B axis analog input B Reserved for Hall Input Status B User defined variable ZA C axis status see bit field map below C axis switches see bit field map below C axis stop code C axis reference position C axis motor position C axis position error C axis auxiliary position C axis velocity C axis torque C axis analog input C Reserved for Hall Input Status C User defined variable ZA D axis status see bit field map below D axis switches see bit field map below D axis stop code D axis reference position D axis motor position D axis position error D axis auxiliary position D axis velocity D axis torque D axis analog input D Reserved for Hall Input Status D User defined variable ZA E axis status see bit field map below E axis switches see bit field map below E axis stop code E axis reference position E axis motor position E axis position error E axis auxiliary position E axis velocity E axis torque E axis analog input E Reserved for Hall Input Status E User defined variable ZA F axis status see bit field map below F axis switches see bit field map below F axis stop code F axis reference position F axis motor position F axis position error F axis auxiliary position 58 Chapter 4 Software Tools and Communications DMC 18x6 278 281 SL F axis velocity 282 285 SL new size axis torque 286 287 SW F axis analog input 288 289 UW new F Reserved for Ha
288. uffer 511 returned means the buffer is empty and 511 segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional segments can be sent at PC bus speeds The operand CS can be used to determine the value of the segment counter Additional commands The commands VS n VA n and VD n are used for specifying the vector speed acceleration and deceleration IT is the s curve smoothing constant used with coordinated motion Specifying Vector Speed for Each Segment The vector speed may be specified by the immediate command VS It can also be attached to a motion segment with the instructions VP xy lt n gt m CR 10 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 commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condi
289. umeric 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 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 is 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 A 2000 count rev encoder is on the motor resulting in a resolution of 4000 counts inch The program below uses the variable LEN to length The IN command is used to prompt the operator to enter the length and the entered value 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
290. urs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving 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 Second the profiler generates pulses as prescribed by the motion profile The pulses that are generate
291. uter generated paths such as parabolic spherical or user defined profiles The path is not limited to straight line and arc segments and the path length may be infinite Specifying Contour Segments The Contour Mode is specified with the command CM For example CMXZ specifies contouring on the X and Z axes Any axes that are not being used in the 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 sample period 1 ms for TM1000 where n is a number between 1 and 8 The controller performs linear interpolation between the specified increments where one point is generated for each sample If the time interval changes for each segment use CD x y z w n where n is the new DT value Consider for example the trajectory shown in Fig 6 13 The position X may be described by the points Point 1 X 0 at T 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 96 Chapter 6 Programming Motion DMC 18x6 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 posi
292. vo amplifiers see AMP 19X0 e Can be configured for High or Low amplifier enable Note The part number for the 100 pin connector is 2 178238 9 from AMP Terminal Label y o Description 1 X Auxiliary encoder 2 AAX I X Auxiliary encoder A 3 ABX I X Auxiliary encoder B 4 ABX I X Auxiliary encoder B 5 AAY I Y Auxiliary encoder 6 AAY I Y Auxiliary encoder A 7 Y Auxiliary encoder 8 ABY I Y Auxiliary encoder B 9 AAZ I Z Auxiliary encoder A 10 AAZ I Z Auxiliary encoder A 11 ABZ I Z Auxiliary encoder B 12 ABZ I Z Auxiliary encoder B 13 AAW I W Auxiliary encoder A 14 AAW I W Auxiliary encoder A 15 ABW I W Auxiliary encoder B 16 ABW I W Auxiliary encoder B 17 GND Signal Ground 18 VCC 5 Volts 19 ISO OUT Output Common for use with the opto isolated output option POWER 20 ERROR Error signal 21 RESET I Reset 22 CMP O Circular Compare output 23 MOCMDW O W axis motor command to amp input w respect to ground 24 SIGNW W axis sign output for input to stepper motor amp 25 PWMW W axis pulse output for input to stepper motor amp 26 MOCMDZ O Z axis motor command to amp input w respect to ground 188 Appendices DMC 18x6 DMC 18x6 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 SIGNZ PWMZ MOCMDY SIGNY P
293. will trip immediately Will function on geared axis or 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 is high logic level negative is low level n 1 through 8 for DMC 1816 1826 1836 1846 n 1 through 24 for DMC 1856 1866 1876 1886 n 1 through 80 with DB 14064 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 Chapter 7 Application Programming 125 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
294. xes In linear interpolation mode motion between the axes is coordinated to maintain the prescribed vector speed acceleration and deceleration along the specified path The motion path is described in terms of incremental distances for each axis An unlimited number of incremental segments may be given in a continuous move sequence making the linear interpolation mode ideal for following a piece wise linear path There is no limit to the total move length The LM command selects the Linear Interpolation mode and axes for interpolation For example LM YZ selects only the Y and Z axes for linear interpolation When using the linear interpolation mode the LM command only needs to be specified once unless the axes for linear interpolation change Specifying Linear Segments The command LI x y z w or LI a b c d e f g h specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis position Up to 511 incremental move segments may be given prior to the Begin Sequence BGS command Once motion has begun additional LI segments may be sent to the 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 E
295. xis to be specified as the tangent axis The VM command provides parameter specifications for describing the coordinated axes and the tangent axis VM m n p m n specifies coordinated axes p specifies tangent axis such as X Y Z W p N turns off tangent axis Before the tangent mode can operate it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m n command m defines the scale factor in counts degree and n defines the tangent position that equals zero degrees in the coordinated motion plane The operand 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 Y direction A 180 circular cut is desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion is CCW ending at 3000 0 Note that the 0 position in the XY plane is in the X direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First X Y and Z are driven to the starting point and later the cut is performed Assume that the knife is engaged with output bit 0 EXAMPLE Example program VM XYZ XY coordinate with Z as tangent TN 2000 360 500 2000 360 counts degree position 500 is 0 degrees in XY plane CR 3000 0 180 3000 count radius start at 0 and go to 1
296. you need to verify that the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 resistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal is used by the controller to disable the motor 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 AEN can be used to disable the amplifier for these 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 enable

DMC-18x6 - Galil Motion Control

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