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Aximate Plus Manual - Microcon Technologies Inc.

1. ee tere cridi 5 16 5 6 2 Underdamped response e 5 18 56 9 Overdamped respornse sisiran cheer eererm cheer aad reed 5 19 5 6 4 Critically damped response 0 5 20 5 7 Servo axis eliminating steady state errors 5 21 5 8 Servo axis tuning for velocity control 5 22 5 8 1 Calculating KVELFF sek ose aa greed 5 22 5 8 2 Adjusting KPROP 0220 00 tenneri renina dome el rapa E REN 5 25 5 9 Digital input output configuration o 5 27 5 9 Digital input configuration s iis rnt Rer RR 5 27 5 9 2 Digital output configuration errem rem en ente 5 28 5 10 Saving setup information 000 eee eee eee 5 29 5 10 Loading Saved information oir te enir api 5 30 6 Troubleshooting e eee eee 6 1 6 1 Introd ction ocio teen codo 6 1 611 Problem diagnosis coser are iu tos aeta cua d area Prae dean ulace Pe uda 6 1 6 4 2 SupportMe feature 2 sess ei a 6 1 6 2 Aximate Plus indicators 0 00 cece eee eee 6 2 6 21 Status display 2 2 cccec cece rut E REESE EE ERES ERE ees 6 2 6 2 2 COMMUNICATION arcieri 6 3 6 2 3 Motor Contfol cilea 6 4 ii Contents CMC 6 24 MorkBencli Vb isis tests dh dte entere edita etes 6 5 6 25 OANODOn isses heces rhe tado dos Spa eua Ag 6 6 7 Specifications 2xsxessnedx xeshreSseresErad eed iique d 7 1 l dd trod cliori vicaria ene TES 7 1 TAA InputpOW
2. Demand position Sia oeeo 2000 eee Measured position 3 1 D D D 1 D 1 D D D D 4 1 D 1 1 D j 500 1000 1500 Time ms Figure 25 Correct value of KPROP The two traces will probably appear with a small offset from each other which represents the following error Adjust KPROP by small amounts until the two traces appear on top of each other approximately as shown in Figure 25 Note lt may be useful to use the zoom function to magnify the end point of the move In the graph area click and drag a rectangle around the end point of the traces To zoom out right click in the graph area and choose Undo Zoom 5 26 Operation CMC 5 9 Digital input output configuration The Digital I O window can be used to setup other digital inputs and outputs 5 9 1 Digital input configuration The Digital Inputs tab allows you to define how each digital input will be triggered and if it should be assigned to a special purpose function such as a Home or Limit input In the following example digital input 1 will be set to trigger on an active low input and allocated to the forward limit input of axis 0 1 Inthe Toolbox click the Digital I O icon 2 At the bottom of the Digital I O screen click Irasn Can IN IN 15 the Digital Inputs tab The left of the screen shows a column of yellow icons High Low Rising Falling and Rise Fall These describe how the input w
3. 1 For bus lengths greater than about 1000m 50Kbit s 1000m bridge or repeater devices may be needed 20Kbit s 2500m 1 10Kbit s 5000m The compromise between bus length and CAN baud rate must be determined for each application The CAN baud rate can be set using the BUSBAUD keyword It is essential that all nodes on the network are configured to run at the same baud rate The wiring topology of a CAN network should be as close as possible to a single line bus structure However stub lines are allowed provided they are kept to a minimum 0 3m at 1Mbit s The OV connection of all of the nodes on the network must be tied together through the CAN cabling This ensures that the CAN signal levels transmitted by Aximate Plus or CAN peripheral devices are within the common mode range of the receiver circuitry of other nodes on the network Opto isolation On the Aximate Plus the CAN channel is opto isolated A voltage in the range 12 24V must be applied to pin 5 of the CAN connector From this supply an internal voltage regulator provides the 5V at 100mA required for the isolated CAN circuit A typical Category 5 cable may have a maximum current rating of 1A so the maximum number of Aximate Plus units that could be used on one network would be limited to ten Practical operation of the CAN channel is limited to 500Kbit s owing to the propagation delay of the opto isolators CMC Input Output 4 17 4 5 3 CANopen The Axi
4. ere ere Project Exit orkBench 5 4 Operation CMC 3 In the Select Controller dialog go to the drop down box near the top and select the PC serial port to which the Aximate Plus is connected If you are unsure which PC serial port is connected to the drive select Scan all serial ports If the Aximate Plus is connected using USB it will be scanned automatically Click Scan to search for the Aximate Plus When the search is complete click Aximate Plus in the list to select it and then click Select Select Controller BE Only scan COMI fel Mode 30 E Note If the Aximate Plus is not listed check the serial or USB cable between the Aximate Plus and the PC Check that the Aximate Plus is powered correctly Click Scan to re scan the ports 4 A dialog box may be displayed to tell you that WorkBench v5 has detected new firmware Click OK to continue WorkBench v5 reads back data from the Aximate Plus When this is complete Edit amp Debug mode is displayed This completes the software installation CMC Operation 5 5 5 3 5 3 1 Configuring an axis The Aximate Plus is capable of controlling 4 stepper and 3 servo axes This section describes the basic setup for both types of axis Commands typed in the Command window have immediate effect they do not need to be separately downloaded to the Aximate Plus Selecting a scale MintMT defines all positional and speed
5. 20MHz maximum determines the speed and the direction input determines the direction of motion Both the rising and falling edges of the signal on DIN17 cause an internal counter to be changed If 5V is applied to DIN18 or it is left unconnected the counter will increment If DIN18 is grounded the counter will be decremented Typically one channel of an encoder signal either A or B would be used to provide the step signal on DIN17 allowing the input to be used as an auxiliary master encoder input The input can be used as a master position reference for cam fly and follow move types For this the MASTERSOURCE keyword must be used to configure the step input as a master auxiliary encoder input The master position reference can then be read using the AUXENCODER keyword Since a secondary encoder channel is not used DIN18 allows the direction of motion to be determined The Z signal on DIN19 can be supplied from the encoder s index signal and may be read using the AUXENCODERZLATCH keyword See the MintMT help file for details of each keyword 4 3 1 5 Typical digital input wiring Aximate Plus User o supply 24V User supply GND Figure 10 Digital input typical active high input connection using a switch xg Aximate Plus User supply 24V DIN4 x CREF1 TLP280 User supply GND Figure 11 Digital input typical activ
6. Axis enabled Torque mode The Aximate Plus is in Torque mode See the TORQUE keyword and related commands Hold to Analog The axis is in Hold To Analog mode See the HTA keyword and related commands Follow and offset When an axis is following a demand signal it may be necessary to advance or retard the slave in relation to the master To do this an offset move is performed in parallel with the follow See the FOLLOW and OFFSET keywords Circle A circle move is being performed See the CIRCLEA or CIRCLER keywords Cam A Cam profile is being profiled See the CAM keyword General error See the AXISERROR keyword The motion toolbar displays the status of AXISERROR which is a bit pattern of all latched errors See also the Error Log topics in the help file Error input The ERRORINPUT has been activated and generated an error Flying shear A flying shear is being profiled See the FLY keyword Position following error A following error has occurred See the AXISERROR keyword and associated keywords Following errors could be caused by a badly tuned drive motor At higher acceleration and deceleration rates the following error will typically be greater Ensure that the drive motor is adequately tuned to cope with these acceleration rates The following error limit can be adjusted to suit your application see the FOLERRORFATAL and VELFATAL keywords Following error could also be the cause of enc
7. can be used to gather information which can then be e mailed saved as a text file or copied to another application The PC must have e mail facilities to use the e mail feature If you prefer to contact technical support by telephone or fax contact details are provided on the back of this manual Please have the following information ready The serial number of your Aximate Plus if known Use the Help SupportMe menu item in WorkBench v5 to view details about your system The type of servo amplifier and motor that you are using A clear description of what you are trying to do for example performing fine tuning A clear description of the symptoms that you can observe for example error messages displayed in WorkBench v5 or the current value of any of the Mint error keywords AXISERROR AXISSTATUS INITERROR and MISCERROR The type of motion generated in the motor shaft m Give alist of any parameters that you have setup for example the gain settings you have entered CMC Troubleshooting 6 1 6 2 Aximate Plus indicators 6 2 1 Status display The Status LED normally displays the unit s node number To display information about a specific axis use the LED keyword see the MintMT help file When a specific axis is selected the following symbols may be displayed by the Status LED Some characters will flash to indicate an error Spline A spline move is being performed See the SPLINE keyword and related commands
8. condensing according to DIN40 040 IEC144 Maximum installation altitude above m s l See also section 3 1 1 2000 6560 CMC Specifications 7 3 7 1 12 Weights and dimensions Description Value Weight Approximately 700g 1 5 Ib Nominal overall dimensions 245mm x 135mm x 43mm 9 65in x 5 32in x 1 69in 7 A Specifications CMC A 1 General A Axis renumbering The factory preset axis numbering assigns axes 0 3 as stepper axes and axes 4 6 as servo axes However it is possible to alter the axis numbering scheme For example you might wish axes 0 and 1 to refer to the servo axes and axes 2 to 5 to refer to the stepper axes There are certain hardware limitations that must be considered when altering the axis numbering scheme A maximum of 3 servo axes and 4 stepper axes may be assigned Axes 0 and 4 share an internal hardware channel This means they cannot both be servo or stepper axes If one is servo the other must be stepper The servo demand output for axis 0 or 4 is always the DEMANDO output with Encoder0 as the feedback channel The stepper output is always STEPO Axes 1 and 5 share an internal hardware channel This means they cannot both be servo or stepper axes If one is servo the other must be stepper The servo demand output for axis 1 or 5 is always the DEMAND1 output with Encoder1 as the feedback channel The stepper output is always STEP1 Axes 2 an
9. connection Do not connect Table 2 Connector details for minimum system wiring shown in Figure 18 4 20 Input Output CMC Operation 5 5 1 Introduction The software provided includes a number of applications and utilities to allow you to configure tune and program the Aximate Plus The Motion Toolkit CD containing the software can be found separately within the packaging 5 1 1 Connecting the Aximate Plus to the PC The Aximate Plus can be connected to the PC using either RS232 or USB To use RS232 connect an appropriate serial cable between a PC serial port often labeled as COM and the Aximate Plus Serial connector WorkBench v5 can scan all the PC s COM ports So you can use any port The serial cable must be wired in accordance with Figure 17 in section 4 4 5 To use USB connect a USB cable between a PC USB port and the Aximate Plus USB connector Your PC must be using Windows 2000 or Windows XP 5 1 2 Installing WorkBench v5 You will need to install WorkBench v5 to configure and tune the Aximate Plus 1 Insert the CD into the drive 2 After a few seconds the setup wizard should start automatically If the setup wizard does not appear select Run from the Windows Start menu and type d start where d represents the drive letter of the CD device Follow the on screen instructions to install WorkBench v5 The setup Wizard will copy the files to the Program Files folder although the destination folder can
10. loading saved information 5 30 saving setup information 5 29 starting 5 4 Index CMC
11. menu choose File Save File Locate a folder enter a filename and click Save workbench m workBench i lo 7 5 10 1 Loading saved information 1 In the Toolbox click the Edit amp Debug icon pA k HE Edit amp Debug 2 On the main menu choose File Open File Locate the file and click Open E WorkBench MyconFigd mnt cen A Startup block should be included in every Mint program so that whenever a program is loaded and run the Aximate Plus will be correctly configured Remember that every drive motor combination has a different response If the same program is used on a different Aximate Plus installation the Startup block will need to be changed 5 30 Operation CMC 6 1 6 1 1 6 1 2 Troubleshooting 6 Introduction This section explains common problems and their solutions If you want to know the meaning of the LED indicators see section 6 2 Problem diagnosis If you have followed all the instructions in this manual in sequence you should have few problems installing the Aximate Plus If you do have a problem read this section first In WorkBench v5 use the Error Log tool to view recent errors and then check the help file If you cannot solve the problem or the problem persists the SupportMe feature can be used SupportMe feature The SupportMe feature is available from the Help menu or by clicking the WF button on the motion toolbar SupportMe
12. of the motor shaft and driven equipment Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment Peak torque of several times the rated motor torque can occur during control failure The safe integration of this equipment into a machine system is the responsibility of the machine designer Be sure to comply with the local safety requirements at the place where the machine is to be used In Europe these are the Machinery Directive the Electromagnetic Compatibility Directive and the Low Voltage Directive In the United States this is the National Electrical code and local codes Electrical components can be damaged by static electricity Use ESD electrostatic discharge procedures when handling this drive 1 2 General Information CMC Introduction 2 2 1 Aximate Plus features Aximate Plus is a high performance multi axis intelligent controller for servo and stepper motors E X6 Enc 1 X5 Enc 0 Aximate Plus motion controller amp 7 p Cleveland Motion Controls Aximate Plus features the MintMT motion control language MintMT is a structured form of Basic custom designed for stepper or servo motion control applications It allows you to get started very quickly with simple motion control programs In addition MintMT includes a wide range of powerful commands for complex applications Standard features include Control of 4 stepper and 3 servo axes Point to poi
13. should be decreased to reduce the damping of the move If the overdamping is excessive it may be necessary to increase the value of KPROP En i amo Demand position Siti Gece ceeececes ances a a a scc E Time ms Figure 22 Overdamped response 10 Click in the KDERIV and or KPROP boxes and make the required changes The ideal response is shown in section 5 6 4 Bis 4 Fine tuning CMC Operation 5 19 5 6 4 Critically damped response If the graph shows that the response reaches the demand quickly and only overshoots the demand by a small amount this can be considered an ideal response for most systems See Figure 23 BIO gt Demand position 5000 a e Lola 1000 Time ms Figure 23 Critically damped ideal response 100 150 200 2 5 20 Operation CMC 5 7 Servo axis eliminating steady state errors In systems where precise positioning accuracy is required it is often necessary to position within one encoder count Proportional gain KPROP is not normally able to achieve this because a very small following error will only produce a small demand for the drive which may not be enough to overcome mechanical friction this is particularly true in current controlled Systems This error can be overcome by applying integral gain The integral gain KINT works by accumulating following error over time to produce a demand sufficient to move the
14. show a positive value If the value is negative check that the DEMANDO output and the Encoder0 A and B channels have been wired correctly If necessary the ENCODERMODE keyword can be used to swap the encoder A and B channels thus reversing the encoder count see the MintMT help file By default axis 4 uses demand output 0 and encoder 0 axis 5 uses demand output 1 and encoder 1 and axis 6 uses demand output 2 and encoder 2 See section 4 2 2 for details of the demand outputs CMC Operation 5 11 5 Torepeat the tests for negative reverse demands type TORQUE 4 5 This should cause a demand of 5 of maximum output 0 5V to be produced at the DEMANDO output Correspondingly the Spy window s Velocity display should show a negative value 6 Toremove the demand and stop the test type STOP 4 This should cause the demand produced at the DEMANDO output to become OV If itis necessary for the motor to turn in the opposite direction for a positive demand then the DACMODE and ENCODERMODE keywords should be used The DACMODE keyword is used to invert the demand output voltage The ENCODERMODE keyword must then also be used to reverse the incoming feedback signal to correspond with the inverted demand output Note that if ENCODERMODE had already been used to compensate for a reversed encoder count as described in step 4 above it will be necessary to change it back to its original setting to correspond with the inverted demand o
15. source per output all outputs on Maximum total output current DOUTO 7 DOUT8 10 350 350 62 5 166 500 500 Update interval 7 1 6 Relay output 7 1 7 All models Immediate AII models Contact rating resistive 1A 24VDC or 0 25A 30VAC Operating time max Encoder inputs Description 5 Value Encoder input RS422 A B Differential Z index Maximum input frequency quadrature encoder inputs 0 and 1 quadrature encoder input 2 20 8 Output power supply to encoders 5V 500mA maximum total for all axes Maximum allowable cable length 30 5m 100ft 7 2 Specifications CMC 7 1 8 Stepper control outputs Description Value Output type RS422 step pulse and direction Maximum output frequency 500 Output current maximum per output pair 7 1 9 Serial RS232 port 20 AII models Signal RS232 non isolated CTS RTS Bit rates 7 1 10 CAN interface Description Signal 9600 19200 38400 57600 default 115200 2 wire isolated Channels 1 Protocol CANopen Bit rates 7 1 11 Environmental Description Kbit s 10 20 50 100 125 250 500 1000 Operating temperature range Max 0 45 32 113 Maximum humidity 80 for temperatures up to 31 C 87 F decreasingly linearly to 50 relative humidity at 45 C 113 F non
16. the calculated value of KVELFF If the trace for Measured velocity appears above the trace for Demand velocity reduce the value of KVELFF If the trace for Measured velocity appears below the trace for Demand velocity increase the value of KVELFF Repeat the test after each change When the two traces appear on top of each other approximately the correct value for KVELFF has been found as shown in Figure 24 5 24 Operation CMC 5 8 2 Adjusting KPROP The KPROP term can be used to reduce following error Its value will usually be much smaller than the value used for an equivalent current controlled system A fractional value for example 0 1 will probably be a good starting figure which can then be increased slowly 1 Click in the KPROP box and enter a starting value of 0 1 Fine tuning Anis 4 uod NNNM MEM The Aximate Plus will perform the move and the motor will turn As the soon as the move is completed WorkBench v5 will upload captured data from the Aximate Plus The data will then be displayed in the Capture window as a graph Note The graph that you see will not look exactly the same as the graph shown here Remember that each motor has a different response 3 Using the check boxes below the graph select the Measured position and Demand position traces CMC Operation 5 25 BILD ere 40000 A osoren oaeee e
17. the date purchased the task performed by the control and the problem encountered No liability is assumed for expendable items such as fuses Goods may be returned only with written notification including a CMC Return Authorization Number and any return shipments must be prepaid CMC General Information 1 1 Safety Notice Only qualified personnel should attempt to start up program or troubleshoot this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper use can cause serious or fatal injury AN WARNING Z WARNING AN WARNING AN WARNING AN CAUTION AN CAUTION Precautions Do not touch any circuit board power device or electrical connection before you first ensure that no high voltage is present at this equipment or other equipment to which it is connected Electrical shock can cause serious or fatal injury Be sure that you are completely familiar with the safe operation and programming of this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper use can cause serious or fatal injury The stop input to this equipment should not be used as the single means of achieving a safety critical stop Drive disable motor disconnect motor brake and other means should be used as appropriate Improper operation or programming may cause violent motion
18. the latest firmware and WorkBench v5 releases by visiting the website www cmccontrols com 2 2 Introduction CMC 2 2 2 2 1 Receiving and inspection When you receive your Aximate Plus there are several things you should do immediately I 2 Check the condition of the packaging and report any damage immediately to the carrier that delivered your Aximate Plus Remove the Aximate Plus from the shipping container and remove all packing material The container and packing materials may be retained for future shipment Verify that the catalog number of the Aximate Plus you received is the same as the catalog number listed on your purchase order The catalog part number is described in the next section Inspect the Aximate Plus for external damage during shipment and report any damage to the carrier that delivered it If the Aximate Plus is to be stored for several weeks before use be sure that it is stored in a location that conforms to the storage humidity and temperature specifications shown in section 3 1 1 Identifying the catalog number As a reminder of the product that has been installed it is a good idea to write the catalog number in the space provided below Catalog number AMP7000 Installed ins X Date CMC Introduction 2 3 2 3 Units and abbreviations The following units and abbreviations may appear in this manual n E tea Volt also VAC and VDC ME PPP P
19. value will cause the controller to have a following error ahead of the desired position Using values less than the calculated value will cause the controller to have following error behind the desired position 6 Inthe Move Type drop down box check that the move type is set to Trapezoid Trapezoid B8 10 N 7 Click in the Distance box and enter a distance for the step move It is recommended to set a value that will cause the motor to make a few revolutions for example 10 Note The distance depends on the scale set in section 5 3 1 If you set a scale so that units could be expressed in revolutions or other unit of your choice then those are the units that will be used here If you did not set a scale the amount you enter will be in encoder counts n ke The Aximate Plus will perform the move and the motor will turn As the soon as the move is completed WorkBench v5 will upload captured data from the Aximate Plus The data will then be displayed in the Capture window as a graph Note The graph that you see will not look exactly the same as the graph shown here Remember that each motor has a different response CMC Operation 5 23 9 Using the check boxes below the graph select the Measured velocity and Demand velocity traces DA 40000 300004 20000 T 10000 j 500 1000 1500 Timeims Figure 24 Correct value of KVELFF It may be necessary to make changes to
20. 1 Closed loop control an introduction 5 13 Command outputs See Demand outputs Configuration axis 5 6 axis renumbering A 1 digital inputs 5 27 digital outputs 5 28 Selecting a scale 5 6 setting the drive enable output 5 7 testing a stepper axis 5 10 testing and tuning a servo axis 5 11 testing the drive enable output 5 9 Connectors CAN 4 16 locations 4 2 serial 4 14 USB 4 13 Index Critically damped response 5 20 D Demand outputs 4 5 5 11 Digital I O 4 6 auxiliary encoder inputs 4 8 configuration 5 27 digital inputs 4 6 digital outputs 4 10 Drive enable output setting 5 7 testing 5 9 E Encoder inputs 4 12 Environmental 3 1 7 3 F Features 2 1 Feedback 4 12 7 2 H Hardware requirements 3 3 Help file 5 3 Indicators 6 2 status display 6 2 Input Output 4 1 analog inputs 4 3 7 1 analog outputs 4 5 7 1 CAN connection 4 16 connection summary 4 19 connector locations 4 2 digital inputs 4 6 7 2 digital outputs 4 6 4 10 7 2 encoder inputs 4 12 7 2 serial port 4 14 using RS232 4 14 stepper control outputs 4 11 7 3 USB port 4 13 Installation 3 1 CMC Index Introduction to closed loop control 5 13 L LED indicators status display 6 2 Loading saved information 5 30 O Operation 5 1 connecting to the PC 5 1 installing the USB driver 5 2 installing WorkBench v5 5 1 power on checks 5 2 preliminary checks 5 2 starting
21. 5 1 Overdamped response 5 19 P Power sources 3 3 7 1 Precautions 1 2 R Receiving and Inspection 2 3 RS232 4 14 specification 7 3 S Safety Notice 1 2 Saving setup information 5 29 Scale selecting 5 6 Serial port 4 14 Servo axis 5 11 adjusting KPROP 5 25 eliminating steady state errors 5 21 testing the demand output 5 11 tuning for current control 5 16 tuning for velocity control 5 22 Specifications 7 1 analog inputs 7 1 analog outputs demands 7 1 CAN interface 7 3 digital inputs 7 2 digital outputs 7 2 encoder inputs 7 2 environmental 7 3 power 7 1 relay 7 2 serial port 7 3 Stepper outputs 7 3 weights and dimensions 7 4 Status display 6 2 Stepper axis 5 10 control outputs 4 11 testing the output 5 10 1 Testing Servo axis 5 11 stepper axis 5 10 Troubleshooting 6 1 CANopen 6 6 communication 6 3 help file 5 3 motor control 6 4 problem diagnosis 6 1 status display 6 2 SupportMe 6 1 WorkBench v5 6 5 Tuning adjusting KPROP 5 25 axis for velocity control 5 22 calculating KVELFF 5 22 critically damped response 5 20 eliminating steady state errors 5 21 overdamped response 5 19 selecting servo loop gains 5 16 underdamped response 5 18 U Underdamped response 5 18 Units and abbreviations 2 4 USB installing the driver 5 2 port 4 13 W Weights and dimensions 7 4 WorkBench v5 5 3 digital input output configuration 5 27 help file 5 3
22. 73AM psemiojpae4 uoneJe eoov 7T1399VM uoneJs eooy pueuieq Figure 20 The Aximate Plus servo loop Operation 5 15 CMC 5 6 5 6 1 Selecting servo loop gains Servo axis tuning for current control All servo loop parameters default to zero meaning that the demand output will be zero at power up Most servo amplifiers can be set to current torque control mode or velocity control mode check that the servo amplifier will operate in the correct mode The procedure for Setting system gains differs slightly for each To tune an axis for velocity control go straight to Section 5 8 It is recommended that the system is initially tested and tuned with the motor shaft disconnected from other machinery Confirm that the encoder feedback signals from the motor or servo amplifier have been connected and that a positive demand causes a positive feedback signal Note The method explained in this section should allow you to gain good control of the motor but will not necessarily provide the optimum response without further fine tuning Unavoidably this requires a good understanding of the effect of the gain terms In the Toolbox click the Fine tuning icon The Fine tuning window is displayed at the right of the screen The main area of the WorkBench v5 window displays the Capture window When tuning tests are performed this will display a graph representing the response In the Fine tuning window click in the Axis S
23. Cleveland e CII Motion Controls An EPEC Company Aximate Plus Motion Controller Installation Manual 8 04 Contents 1 General Information cia E hn 1 1 Zi OON DII erariali 2 1 2 4 Aximate Plus features eese 2 1 2 2 Receiving and inspection e eee eee 2 3 2 2 4 Identifying the catalog number ers ro care cand eee 2 8 2 3 Units and abbreviations 0c eee eee eee 24 3 Basicinsialiationi i rao rear ds rd n Ramon E dn 3 1 3i IrtroducliOHi ira tcr iem dc on di tr 3 1 3 1 14 Location requirements acidic eren nene em emen 3 1 3 1 2 Mounting the Aximate Plus esses 3 2 3 1 3 Other requirements for installation 3 3 4 Input Output soir 4 1 4 1 Introduction 225r zm tee kim dco ton d nd ni tr 4 1 43 4 Connector locations ness reper RUPEE per EY ED bearers 4 2 42 Analogl O cicli veh rs 4 3 42 1 Analog Inputs eene b hte ether bert hebt i 4 3 4 2 2 Analog Outputs csse e e ce pei 4 5 439 Bigtall Q cse peto P aa Re ted 4 6 43 1 BDigitalinp ls ci EE ER OSER RENE CDET EE EE YR E 4 6 43 2 Digital oHtpuls sro e hb bes oa uds edo Rn vede etate 4 10 4 4 Other VO osse eR Ra RR t a o e Re TR 4 11 4 4 44 Stepper control outputs l i 4 11 44 2 Encoder inputs 0 2 0 cccortnr nse pla RpUeRUEUEERWRERRIG D pA 4 12 443 WWSB DON usurae eb senties rt er atl lea tate acs omic 4 13 444 Serial portieri paia a 4 14 445 Using RS232 coc em RR PR c X EU
24. Description VBUS USB 5V D Data D Data Ground 34 The USB connector can be used as an alternative method for connecting the Aximate Plus to a PC running WorkBench v5 The Aximate Plus is a self powered USB 1 1 12Mbps compatible device If it is connected to a slower USB1 0 host PC or hub communication speed will be limited to the USB1 0 specification 1 5Mbps If itis connected to a faster USB2 0 480Mbps host PC or hub communication speed will remain at the USB1 1 specification of the Aximate Plus Ideally the Aximate Plus should be connected directly to a USB port on the host PC If it is connected to a hub shared by other USB devices communication could be affected by the activity of the other devices A 2m 6 5 ft standard USB cable is supplied The maximum recommended cable length is 5m 16 4 ft CMC Input Output 4 13 4 4 4 Serial port Location Serial Mating connector 9 pin female D type Name Shield RXD TXD NC DGND NC RTS CTS 2 3 4 5 6 7 8 9 DGND Aximate Plus has an RS232 serial port The port is fully ESD protected to IEC 1000 4 2 15kV When the Aximate Plus is connected to WorkBench v5 the Tools Options menu item can be used to configure the serial port The configuration can also be changed using the Mint keyword SERIALBAUD see the Mint help file for details It is stored in EEPROM and restored a
25. EN Watt rr Ampere Qi cade aea Ohm MO orione milliohm Fia microfarad pEr aes picofarad ME ciare millihenry Doriana phase MS iii millisecond lS isa microsecond NS sini nanosecond MAM ssaa millimeter Mira meter zizi inch Tli doi msan i feet Ibf in pound force inch torque Nin cessum retata Newton meter torque ADCO spes Analog to Digital Converter ASGII spiga American Standard Code for Information Interchange BG Ls oco American Wire Gauge CAL csrsiorensrs CAN Application Layer CAN exer Controller Area Network CDROM Compact Disc Read Only Memory GIA sisi CAN in Automation International Users and Manufacturers Group e V CTRL E on the PC keyboard press Ctrl then E at the same time DAC cernis Digital to Analog Converter DS301 it CiA CANopen Application Layer and Communication Profile DS4041 siii CIA Device Profile for Generic I O Devices EDS ise S Electronic Data Sheet EMG siii Electromagnetic Compatibility HMI i auarus Human Machine Interface ISO s goes been ore International Standards Organization Kbaud ici kilobaud the same as Kbit s in most applications LOD posano Liquid Crystal Display MB scio megabytes Mbps siii megabits s NC ere Not Connected HE eteri laine Radio Frequency 2 4 Introduction CMC Basic Installation 3 3 1 Introduction You should read all the sections in Basic Installation It is important that the correct steps are followed when installing the Aximate Plus This sec
26. H RUN Ud s 4 14 4 5 CAN Em 4 16 45 1 CANICONNECION iii r 4 16 45 22 CANWIO ue ap tir e idet ol cha Lato varieta ha ato 4 17 4539 AGANOPEf siii ei 4 18 4 6 Connection summary minimum system wiring 4 19 CMC Contents i 5 Operation MT 5 1 ST d ttoduclloni sepas i cee e s ei E ES 5 1 5 1 1 Connecting the Aximate Plus to the PC cee eee 5 1 5 1 2 Installing WorkBench v5 000 cee eee 5 1 5 1 8 Starting the Aximate Plus 0 cece eee 5 1 54 4 Preliminary Checks ss icaro slo fem sad e ates Did 5 2 5 1 5 Power Om CheCcKS uude mt ro Prae irt nta Ce bet neret en 5 2 52 WOrKBENCH VO ceste aer etarc tee eon manera iare aurons 5 3 5 2 Telp file oce heben dee mdp tbt 5 3 5 2 2 Starting WorkBench v5 06 cette eens 5 4 5 3 QConfig ring am axis iced is ied edere tees thee toe a 5 6 53 1 Selectitig a SCal6 ssl ere pA Y RIPRID iaia 5 6 5 3 2 Setting the drive enable output 5 7 5 3 3 Testing the drive enable output ee eee eee 5 9 5 4 Stepper axis testing 0 00 cece eee eee 5 10 5 4 4 Testing ihe Output ior Rr Re EI nee Rr Rn 5 10 5 5 Servo axis testing and tuning eee eee 5 11 5 5 1 Testing the demand output esr eme e eee n Re 5 11 5 5 2 An introduction to closed loop control LL 5 13 5 6 Servo axis tuning for current control 5 16 5 6 1 Selecting servo loop gains
27. Input Output CMC 4 2 Analog I O The Aximate Plus provides wm Two 12 bit resolution analog inputs m Four 12 bit resolution analog outputs 4 2 1 Analog inputs The analog inputs are available on connector X12 pins 1 amp 2 AINO and 4 amp 5 AIN1 Differential inputs Voltage range 10V Resolution 12 bit with sign accuracy 4 9mV 10V input Input impedance 120kQ Sampling frequency 4kHz maximum 2kHz if both inputs are enabled The analog inputs pass through a differential buffer and second order low pass filter with a cut off frequency of approximately 1kHz Both inputs are normally sampled at 2kHz However an input can be disabled by setting ADCMODE to 4 _acOFF With one input disabled the remaining input will be sampled at 4kHz In MintMT analog inputs can be read using the ADC keyword See the MintMT help file for full details of ADC ADCMODE and other related ADC keywords Figure 2 Analog input AINO shown For differential inputs connect input lines to AIN and AIN Leave AGND unconnected CMC Input Output 4 3 AINO ADC 0 Differential connection Single ended connection Figure 3 AINO analog input wiring 24VDC o 1 5kO 0 25W 1kQ 0 25W potentiometer ov Figure 4 Typical input circuit to provide 0 10V approx input from a 24V sou
28. NNECT fails then it may be because the node being connected to does not support an object which needs to be accessed in order to setup the connection CMC Troubleshooting 6 7 6 8 Troubleshooting CMC Specifications 7 7 1 Introduction This section provides technical specifications of the Aximate Plus 7 1 1 Input power Description Value Input power Nominal input voltage 24V 20 Power consumption 50W 2A 24V 7 1 2 Analog inputs Description Value Type Differential Common mode voltage range 10 Input impedance 120 Input ADC resolution 12 includes sign bit Equivalent resolution 10V input 4 9 Sampling interval 500 both inputs enabled 250 one input disabled 7 1 3 Analog outputs Description Value Type Bipolar Output voltage range 10 Output current maximum 10 Output DAC resolution 12 Equivalent resolution 4 9 Update interval 100 2000 same as LOOPTIME default 1000 CMC Specifications 7 1 7 1 4 Digital inputs 7 1 5 Digital outputs general purpose Description Value Type Opto isolated USR V supply voltage Nominal Minimum Maximum Input voltage Active Inactive Input current maximum per input USR V 24V Description Value USR V supply voltage Nominal Minimum Maximum 24V 12V 30V Output current Max source per output one output on Max
29. NT This sums the error over time so that the motor torque is gradually increased until the positional error is reduced to zero like a person gradually pushing harder and harder on your car until they ve pushed it level with Demang However if there is large load on the motor it is supporting a heavy suspended weight for example it is possible for the output to increase to 100 demand This effect can be limited using the KINTLIMIT keyword which limits the effect of KINT to a given percentage of the demand output Another keyword called KINTMODE can even turn off integral action when it s not needed The 1ms sampling interval can be changed using the LOOPTIME keyword to either 2ms 500us 200us or 100us CMC Operation 5 13 The remaining gain terms are Velocity Feed forward KVELFF and Acceleration Feed forward KACCEL described below In summary the following rules can be used as a guide KPROP Increasing KPROP will speed up the response and reduce the effect of disturbances and load variations The side effect of increasing KPROP is that it also increases the overshoot and if set too high it will cause the system to become unstable The aim is to set the Proportional gain as high as possible without getting overshoot instability or hunting on an encoder edge when stationary the motor will buzz KVEL This gain has a damping effect on the whole response and can be increased to reduce any overshoot If KVEL become
30. OL occitana rst 7 1 PAG Analog ips teret pd ii NA EE Li 7 1 TALS Analog OUlpuls rccte ee rk he yes et ace e doc O 74 TAA Digital inputs 2222s Rhe hn ee ia 7 2 7 1 5 Digital outputs general purpose 0 eee 7 2 7 6 Relay OU puts ei siepe uibem bs UO aa 7 2 TAA Encoderinpuls xctl e RR ERE ERE ELE ee ER ERE 7 2 7 18 Stepper control outpuls scere eee rette e perm 7 8 tA Serial RS232 POM aac cada enced RR ODHPREU PICS AERE AER 7 8 7110 CANE ACS 32 2 entm rara 7 3 Tii Environmental 3 norte E De erc bano e 7 8 7 1 12 Weights and dimensions LL 7 4 Appendices DuWIC o c TCR TT A 1 A 1 Axis renumbering esee A 1 B CE Guidelines elles B 1 Bal SOUTH ili RE ira B 1 B 1 4 EMC Conformity and CE marking 0 B 1 B 1 2 Aximate Plus compliance eere B 1 B 1 3 Use of CE compliant components esee B 2 B 1 4 EMC installation suggestions B 2 B 1 5 Wiring of shielded screened encoder cables B 2 CMC Contents iii iv Contents CMC General Information 1 Copyright c 2004 All rights reserved This manual is copyrighted and all rights are reserved This document or attached software may not in whole or in part be copied or reproduced in any form without the prior written consent of CMC CMC makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of f
31. USBMotion sys Both files must be present for installation 1 Follow the on screen instructions to select and install the driver The driver files are available on the supplied Motion Toolkit CD If you are using a copy of the driver located on the hard disk a floppy disk or another CD the two driver files must be in the same folder During installation Windows XP may report that the driver is unsigned This is normal for the Aximate Plus driver so click the Continue Anyway button to continue with the installation When installation is complete a new USB Motion Controller device will be listed in the Universal Serial Bus controllers section of Windows Device Manager Ed Universal Serial Bus controllers iS USB Motion Controller Intel 8237 1 4B EB PCI to USE Universal Host Controller i USB Root Hub The Aximate Plus is now ready to be configured using WorkBench v5 Note If the Aximate Plus is later connected to a different USB port on the host computer Windows may report that it has found new hardware Either install the driver files again for the new USB port or connect the Aximate Plus to the original USB port where it will be recognized in the usual way 5 2 Operation CMC 5 2 WorkBench v5 WorkBench v5 is a fully featured application for programming and controlling the Aximate Plus The main WorkBench window contains a menu system the Tool
32. ate hardware channel available or the axis is already in use will result in a Hardware channel required is in use or Hardware not available error message See the MintMT help file for details of the CONFIG and AXISCHANNEL keywords A 2 General CMC B 1 B 1 1 CE Guidelines R Outline This section provides general information regarding recommended methods of installation for CE compliance It is not intended as an exhaustive guide to good practice and wiring techniques It is assumed that the installer of the Aximate Plus is sufficiently qualified to perform the task and is aware of local regulations and requirements Products that meet the EMC directive requirements are indicated with a CE mark A duly signed CE declaration of conformity is available from the manufacturer EMC Conformity and CE marking The information contained herein is for your guidance only and does not guarantee that the installation will meet the requirements of the council directive 89 336 EEC The purpose of the EEC directives is to state a minimum technical requirement common to all the member states within the European Union In turn these minimum technical requirements are intended to enhance the levels of safety both directly and indirectly Council directive 89 336 EEC relating to Electro Magnetic Compliance EMC indicates that it is the responsibility of the system integrator to ensure that the entire system complies with all relative
33. be changed during setup 5 1 3 Starting the Aximate Plus If you have followed the instructions in the previous sections you should have now connected the power sources your choice of inputs and outputs and a serial or USB cable linking the PC with the Aximate Plus CMC Operation 5 1 5 1 4 Preliminary checks 5 1 5 1 Before you apply power for the first time it is very important to verify the following Disconnect the load from the motor until instructed to apply a load Inspect all power connections for accuracy workmanship and tightness Verify that all wiring conforms to applicable codes Verify that the Aximate Plus is properly earthed grounded Check all signal wiring for accuracy Power on checks If the status display shows one of the digits 0 7 with a flashing decimal point during startup this indicates that the Aximate Plus has detected a fault see section 6 Turn on the 24V control supply After a brief test sequence 8 followed by the Status display should show the node number for example e the factory default If the display is not lit then re check the power supply connections Installing the USB driver If you have connected the Aximate Plus to the PC using the USB connection it will be necessary to install the USB driver When the Aximate Plus is powered Windows 2000 or XP only will automatically detect the controller and request the driver The driver consists of two files USBMotion inf and
34. box and other toolbars Many functions can be accessed from the menu or by clicking a button use whichever you prefer Most buttons include a tool tip hold the mouse pointer over the button don t click and its description will appear 5 2 1 Help file WorkBench v5 includes a comprehensive help file that contains information about every MintMT keyword how to use WorkBench and background information on motion control topics The help file can be displayed at any time by pressing F1 On the left of the help window the Contents tab shows the tree structure of the help file each book amp contains a number of topics 2 The Index tab provides an alphabetic list of all topics in the file and allows you to search for them by name The Search tab allows you to search for words or phrases appearing anywhere in the help file Many words and phrases are underlined and highlighted with a color normally blue to show that they are links Just click on the link to go to an associated keyword Most keyword topics begin with a list of relevant See Also links lt e gt 8 B fF Hide Locate Back Forward Print Options SupportMe Update Help Contents Index Search Favorites CHA CAPTUREEVENT CPE 7 CAMPHASE ae See Also CAPTURE CAPTUREEVENTDELAY CAPTUREEVENTAXIS 7 CAMTABLE Durn ore pose B EE E imf Configures capturing to stop on an event a CAPTURE CP Wl Format CAPTURECHANNELUPLOAC x 2 CAPTUREDURATION CPR CAPTUREEVENT
35. can be used to change encoder input direction The DACMODE keyword can be used to reverse DAC output polarity Check that the maximum following error is set to a reasonable value For setting up purposes following error detection may be disabled by setting FOLERRORMODE 0 Motor is under control but vibrates or overshoots during a move Servo outputs only Servo loop gains may be set incorrectly See sections 5 5 2 to 5 7 6 4 Troubleshooting CMC Symptom Check Motor is under control but when moved to a position and then back to the start it does not return to the same position 6 2 4 WorkBench v5 Symptom Verify that the Aximate Plus and drive are correctly grounded to a common earth point Servo outputs only Check all encoder channels are free from electrical noise m they are correctly wired to the controller wm when the motor turns the two square wave signals are 90 degrees out of phase Also check the complement signals Ensure that the encoder cable uses shielded twisted pair cable with the outer shield connected at both ends and the inner shields connected only at the Aximate Plus end Stepper outputs only The motor is not maintaining synchronization with the Aximate Plus drive output signals due to excessive acceleration speed or load demands on the motor Check that the acceleration speed and load are within the capabilities of the motor Check The Sp
36. d 6 share an internal hardware channel This means they cannot both be servo or stepper axes If one is servo the other must be stepper The servo demand output for axis 2 or 6 is always the DEMAND output with Encoder2 as the feedback channel The stepper output is always STEP2 Axis 3 is always a stepper axis it cannot be reassigned as a servo axis Its output is always STEP3 Before axes can be reassigned they must be turned off This removes their existing servo stepper assignments and inhibits their electrical outputs In the following example axis 4 will be reassigned as a stepper axis and axis 0 as a servo axis In the Toolbox click Application then click the Edit amp Debug icon CMC General A 1 2 Click in the Command window 3 Type the command CONFIG 0 1 2 3 4 5 6 cfOFF This will turn off all axes There will now E be no electrical output for any of the E axes 5 E 4 Now type CONFIG 4 cfSTEPPER where 4 is the axis to be configured Press Enter to enter the value This immediately configures axis 4 to be a stepper axis 5 To configure axis 0 as a servo axis type CONFIG 0 cfSERVO ue m E m Other axes can be assigned as required subject to the limitations described above It is recommended that unused axes are always turned off This provides more processing time for the axes that are in use Attempting to assign an axis when there is not an appropri
37. directives at the time of installing into service Motors and controls are used as components of a system per the EMC directive Hence all components installation of the components interconnection between components and shielding and grounding of the system as a whole determines EMC compliance The CE mark informs the purchaser that the equipment has been tested and complies with the appropriate standards It rests upon the manufacturer or his authorized representative to ensure the item in question complies fully with all the relative directives in force at the time of installing into service in the same way as the system integrator previously mentioned Remember that it is the instructions of installation and the product that should comply with the directive B 1 2 Aximate Plus compliance When installed as directed in this manual Aximate Plus units meet the emission limits for an industrial environment as defined by the EMC directives EN50081 2 1994 To meet the more stringent emission limits of the residential commercial and light industrial environment EN50081 1 1992 the Aximate Plus must be mounted in a suitable metal cabinet incorporating 360 screened cable glands CMC CE Guidelines B 1 B 1 3 Use of CE compliant components The following points should be considered m Using CE approved components will not guarantee a CE compliant system m The components used in the controller installation methods us
38. e low input connection using a switch 4 8 Input Output CMC Note The circuits shown in Figures 10 and 11 are not suitable for use with fast inputs DINO to DIN3 Using a mechanical switch relay contacts or other source liable to signal bounce could cause unwanted multiple triggering Equipment output User Opto isolated output device supply xg Aximate Plus 24V DIN4 x CREF1 h TLP280 User supply GND Figure 12 Digital input typical connections from external equipment CMC Input Output 4 9 4 3 2 Digital outputs The digital outputs are available on connectors X4 and X11 as shown in section 4 1 1 A digital output can be configured in MintMT as a general purpose output a drive enable output or a global error output Outputs can be shared between axes and can be configured using WorkBench v5 or the OUTPUTACTIVELEVEL keyword to determine their active level 4 3 2 1 DOUTO DOUT7 An external supply typically 24VDC is used to power the UDN2982 output devices as shown in Figure 13 When an output is activated current is sourced from the user supply through a UDN2982 output driver m A total of 500mA may be sourced by DOUTO DOUTZ providing an average 62 5mA per output when all outputs are on 100 duty cycle 24V supply m Amaximum continuous current of 350mA may be sourced on any single output m The maximum allowab
39. ears to be no step or direction output check the electrical connections to connector X2 pins 2 and 3 for axis 0 5 To repeat the tests for reverse moves type JOG 0 2 6 To remove the demand and stop the test type STOP 0 5 10 Operation CMC 5 5 Servo axis testing and tuning This section describes the method for testing and tuning a servo axis The amplifier must already have been tuned for basic current or velocity control of the motor 5 5 1 Testing the demand output This section tests the operation and direction of the demand output for axis 4 By default axis 4 is a servo axis although it can be reassigned as a stepper see section A 1 It is recommended that the motor is disconnected from the load for this test 1 Check that the Drive enable button is E pressed down WorkBench v5 New Projed 2 In the Toolbox click Application then click the Edit amp Debug icon 3 Click in the Command window 4 Type TORQUE 4 5 where 4 is the axis to be tested In this example this should cause a demand of 5 of maximum output 0 5V to be produced at the DEMANDO output connector X13 pin 1 In WorkBench v5 look at the Spy window located on the right of the screen In the Axis selection box at the top select Axis 4 The Spy window s Command display should show 5 percent approximately If there seems to be no command output check the electrical connections to X13 The Spy window s Velocity display should
40. ed materials selected for interconnection of components are important m The installation methods interconnection materials shielding filtering and earthing grounding of the system as a whole will determine CE compliance m The responsibility of CE mark compliance rests entirely with the party who offers the end System for sale such as an OEM or system integrator B 1 4 EMC installation suggestions To ensure electromagnetic compatibility EMC the following installation points should be considered to help reduce interference m Earthing grounding of all system elements to a central earth ground point star point m Shielding of all cables and signal wires B 1 5 Wiring of shielded screened encoder cables Aximate Plus Encoder Connector X5 X6 X7 Cable Housing CHA 1 Twisted pairs CHA CHB CHB CHZ CHZ 5V GND OQ oo0o0 mo NC Connect overall shield Connect overall shield to connector backshell to connector backshell Figure 26 Encoder signal cable grounding B 2 CE Guidelines CMC A Abbreviations 2 4 Analog I O 4 3 analog inputs 4 3 analog outputs 4 5 Auxiliary encoder inputs 4 8 B Basic Installation 3 1 location requirements 3 1 mounting 3 2 C Calculating KVELFF 5 22 CAN interface CANopen 4 18 connector 4 16 introduction 4 16 opto isolation 4 17 specifications 7 3 terminator 4 17 wiring 4 17 Catalog number identifying 2 3 CE Guidelines B
41. election box at the top and select Axis 4 By default axis 4 is a servo axis although it can be reassigned as a stepper see section A 1 Click in the KDERIV box and enter a starting value of 1 Click Apply and then turn the motor shaft by hand Repeatthis process slowly increasing the value of KDERIV until you begin to feel some resistance in the motor shaft The exact value of KDERIV is not critical at this stage Fine tuning Fine tuning Axis 4 5 16 Operation CMC Click in the KPROP box and enter a value thatis approximately one quarter of the value of KDERIV If the motor begins to vibrate Axis 4 decrease the value of KPROP or increase the value of KDERIV until the vibration stops Small changes may be all that is necessary Fine tuning In the Move Type drop down box check that the move type is set to Step Click inthe Distance box and enter a distance for the step move It is recommended to set a value that will cause the motor to turn a short distance for example one revolution Note The distance depends on the scale set in section 5 3 1 If you set a scale so that units could be expressed in revolutions or other unit of your choice then those are the units that will be used here If you did not seta scale the amount you enter will be in encoder counts Click inthe Duration box and enter a duration for the move in seconds This should be a short duration for example 0 15 seconds C
42. ential outputs It is recommended to use separate shielded cables for the step outputs The shield should be connected at one end only The FREQ keyword can be used to directly control the output frequency between 60Hz and 500kHz see the MintMT help file PAN CAUTION The DS26LS31 drivers are static sensitive devices Take appropriate ESD precautions when handling the Aximate Plus Stepper drive Aximate Plus DS26LS31 STEPO Q STEPO Step Step pulse input Step ESS Connect overall shield at one end only Figure 14 Stepper output typical connection to a differential input stepper drive Aximate Plus Stepper drive Step n Output STEPO GND DGND DGND Step pulse input Step CTD Shield Connect overall shield at one end only Figure 15 Stepper output typical connection to a single ended input stepper drive CMC Input Output 4 11 4 4 2 Encoder inputs 0 2 Location X5 X6 X7 Mating connectors 9 pin male D type Name Description CHA Channel A signal CHB Channel B signal CHZ Index channel signal Shield Shield connection GND Digital ground CHA Channel A signal complement CHB Channel B signal complement CHZ Index channel signal complement o CO N om BR oj Po 5V out Power supply to encoder Three incremental encoders may be connected to Aximate Plus each wit
43. errors should not normally occur When a node number between 1 and 15 is displayed it is shown in hexadecimal format 1 F For node numbers greater than 15 three horizontal bars are displayed User defined symbols can be made to appear using the keywords LED and LEDDISPLAY See the MintMT help file for details of each keyword If the status display shows one of the digits 0 7 with a flashing decimal point during startup this indicates that the Aximate Plus has detected a fault and cannot be started In this unlikely event please contact technical support 6 2 2 Communication If the problem is not listed below please contact technical support Symptom Check Cannot detect Aximate Plus Check that the Aximate Plus is powered For serial connections check that the serial cable is wired correctly and properly connected Check that no other application on the PC is attempting to use the same serial port For USB connections check that the cable is properly connected Check that the USB device driver has been installed Cannot communicate with the Verify that WorkBench v5 is loaded and that Aximate Plus controller is the currently selected controller CMC Troubleshooting 6 3 6 2 3 Motor control Symptom Check Controller appears to be working but will not cause motor to turn Check that the connections between motor and drive are correct Use WorkBench v5 to perform the basic system t
44. ests see section 5 5 or 5 4 Confirm that the drive enable output has been configured see section 5 3 2 Ensure that while the Aximate Plus is not in error the drive is enabled and working When the Aximate Plus is first powered up the drive should be disabled if there is no program running there is often an LED on the front of the drive to indicate status Servo outputs only Check that the servo loop gains are setup correctly check the Fine tuning window See sections 5 5 2 to 5 7 Motor runs uncontrollably when controller is switched on Verify that the Aximate Plus and drive are correctly grounded to a common ground Servo outputs only Check that the correct encoder feedback signal is connected to the encoder input the encoder has power if required see sections 4 4 2 and 7 1 7 and is functioning correctly Check that the drive is connected correctly to the Aximate Plus and that with zero demand there is OV at the drive s demand input See section 5 5 1 Motor runs uncontrollably when controller is switched on and servo loop gains are applied or when a move is set in progress Motor then stops after a short time Servo outputs only Check that the encoder feedback signal s are connected to the correct encoder input s Check the demand to the drive is connected with the correct polarity Check that for a positive demand signal a positive increase in axis position is seen The ENCODERMODE keyword
45. h complementary A B and Z channel inputs Each input channel uses a MAX3095 differential line receiver with pull up resistors and terminators Encoders must provide RS422 differential signals The use of individually shielded twisted pair cable is recommended See section 7 1 7 for details of the encoder power supply Aximate Plus Servo amplifier encoder output X5 9 to CPU 120R MAX3095 CHA U Twisted pair DGND Connect internal shield to DGND Do not connect other end Shield mu P d Connect overall shield to connector backshells shield connections Figure 16 Encoder channel input typical connection from a servo amplifier 4 12 Input Output CMC 4 4 2 1 Encoder input frequency The maximum encoder input frequency is affected by the length of the encoder cables The theoretical maximum frequency is 20 million quadrature counts per second This is equivalent to a maximum frequency for the A and B signals of 5MHz However the effect of cable length is shown in Table 1 Maximum cable length A and B signal frequency meters 1 3MHz 2 500kHz 10 250kHz 20 100kHz 50 50kHz 20kHz 10kHz 7kHz Table 1 Effect of cable length on maximum encoder frequency The maximum recommended cable length is 30 5m 100ft 4 4 3 USB port Location USB Mating connector USB Type B downstream plug Name
46. ility of an undetected error is 4 7x10 11 It is optimized for the transmission of small data packets and therefore offers fast update of I O devices peripheral devices connected to the bus The CAN protocol only defines the physical attributes of the network i e the electrical mechanical functional and procedural parameters of the physical connection between devices The higher level network functionality is defined by a number of standards and proprietary protocols CANopen is one of the most used standards for machine control within industries such as printing and packaging machines 4 5 1 CAN connector The CAN connection is made using the RJ45 connector on the Aximate Plus Location Aximate Plus Pin Name Description CAN CANopen channel positive CAN CANopen channel negative 3 NC CANOV Ground earth reference for CAN signals CAN V CANopen power V 12 24V NC NC NC Description Opto isolated CANopen interface using a RJ45 connector The maximum default transmission rate on Aximate Plus is 500Kbit s 4 16 Input Output CMC 4 5 2 CAN wiring A very low error bit rate over CAN can only be achieved with a suitable wiring scheme so the following points should be observed 4 5 2 1 The two wire data bus line may be routed parallel twisted and or shielded depending on EMC requirements It is recommend to use a twisted pair cable w
47. ill be triggered ase 0 7 e Rise Fall CMC Operation 5 27 4 Now drag the IN1 icon Bj onto the Fwd Limit icon Fag init INL x This will setup IN1 as the Forward Limit input of axis 0 Rising Falling 5 Click Apply to send the changes to the Aximate Plus Note If required multiple inputs can be configured before clicking Apply 5 9 2 Digital output configuration The Digital Outputs tab allows you to define how each digital output will operate and if it is to be configured as a drive enable output see section 5 3 2 Remember to click Apply to send the changes to the Aximate Plus 5 28 Operation CMC 5 10 Saving setup information When power is removed from the Aximate Plus all data including configuration and tuning parameters is lost You should therefore save this information in a file which can be loaded when the unit is next used 1 In the Toolbox click the Edit amp Debug icon FR E is Edit amp Debug 2 Onthe main menu choose File New File A new program editing window will appear New File h CkrH M 3 On the main menu choose Tools Upload Configuration Parameters WorkBench v5 will read all the configuration information from the Down ced FESE Firmware Aximate Plus and place it in a Startup block For details of the Startup block see the MintMT help file BUS Enable Upload Configuration Par I CMC Operation 5 29 4 Onthe main
48. ith the shield screen connected to the connector backshell in order to reduce RF emissions and provide immunity to conducted interference The bus must be terminated at both ends only not at intermediate JP1 points with resistors of a nominal value of 1200 This is to reduce reflections of the electrical signals on the bus which helps a node to interpret the bus voltage levels correctly If the Aximate Plus is at the end of the network then ensure that jumper JP1 located just behind the status display is in position This will connect an internal terminating resistor To access the jumper it will be necessary to remove the top cover from the Aximate Plus Before removing the top cover be sure to discharge static electricity from your body and clothing by touching a grounded metal surface Alternatively wear an earth strap while handling the unit All cables and connectors should have a nominal impedance of 1200 Cables should have a length related resistance of 70mQ m and a nominal line delay of 5ns m The maximum bus length depends on the bit timing CAN Maximum configuration baud rate The table opposite shows Baud Rate Bus Length the approximate maximum bus length worst case assuming 5ns m propagation delay and a total 1Mbit s 25m effective device internal in out delay of 210ns at 500Kbit s 100m 1Mbit s 300ns at 500 250Kbit s 450ns at 125Kbit s 250Kbit s 250m and 1 5ms at 50 10Kbit s 125Kbit s 500m 100Kbit s 600m
49. itness for any particular purpose The information in this document is subject to change without notice CMC assumes no responsibility for any errors that may appear in this document Mint is a registered trademark of BEC Windows 95 Windows 98 Windows ME Windows NT Windows 2000 and Windows XP are registered trademarks of the Microsoft Corporation Limited Warranty For a period of two 2 years from the date of original purchase CMC will repair or replace without charge controls and accessories which our examination proves to be defective in material or workmanship This warranty is valid if the unit has not been tampered with by unauthorized persons misused abused or improperly installed and has been used in accordance with the instructions and or ratings supplied This warranty is in lieu of any other warranty or guarantee expressed or implied CMC shall not be held responsible for any expense including installation and removal inconvenience or consequential damage including injury to any person or property caused by items of our manufacture or sale Some countries and U S states do not allow exclusion or limitation of incidental or consequential damages so the above exclusion may not apply In any event CMC s total liability under all circumstances shall not exceed the full purchase price of the control Claims for purchase price refunds repairs or replacements must be referred to CMC with all pertinent data as to the defect
50. le power dissipation for the UDN2982 driver is 1 5W If an output is used to drive an inductive load such as a relay a suitably rated diode must be fitted across the relay coil observing the correct polarity The use of shielded cable is recommended Aximate Plus Voltage sta 470R x UDN2982 User supply USR V 24y De DOUTO Output Load User supply o GND Figure 13 Digital outputs DOUTO 7 DOUTO shown 4 3 2 2 DOUT8 DOUT10 DOUT8 DOUT10 use the same type of output circuitry as DOUTO DOUTT with their own UDN2982 output driver Because only three of the UDN2982 s eight outputs are being used the average current available on DOUT8 DOUT10 is increased m A total of 500mA may be sourced by DOUT8 DOUT10 providing an average 166mA per output when all outputs are on 10096 duty cycle 24V supply m Amaximum continuous current of 350mA may be sourced on any single output The maximum allowable power dissipation for the UDN2982 driver is 1 5W 4 10 Input Output CMC 4 4 Other I O 4 4 1 Stepper control outputs The stepper control outputs are available on connectors X2 and X8 as shown in section 4 1 1 There are four sets of stepper motor control outputs operating in the range OHz to 500kHz Each of the step pulse and direction signals from the Aximate Plus is driven by DS26L S31 line drivers providing RS422 differ
51. lick Go The Aximate Plus will perform the move and the motor will turn As the soon as the move is completed WorkBench v5 will upload captured data from the Aximate Plus The data will then be displayed in the Capture window as a graph Note The graphs that you see will not look exactly the same as the graphs shown here Remember that each motor has a different response Using the check boxes below the graph v Select the traces you require for example Demand position and Measured position 7H CMC Operation 5 17 5 6 2 Underdamped response If the graph shows that the response is underdamped it overshoots the demand as shown in Figure 21 then the value for KDERIV should be increased to add extra damping to the move If the overshoot is excessive or oscillation has occurred it may be necessary to reduce the value of KPROP iiir es HUI RE EDD GO LEE EIS a ED E cS E Hip e auk ue BC H Measured position i Eti asses V illa ai i SS EIA ce Demandjpositio nia sese cece ane eae 200H E EE o 9 Gol 10 19 200 250 Time ms Figure 21 Underdamped response 9 Click in the KDERIV and or KPROP boxes TET and make the required changes The ideal Giro response is shown in section 5 6 4 Avis 4 5 18 Operation CMC 5 6 3 Overdamped response If the graph shows that the response is overdamped it reaches the demand too slowly as shown in Figure 22 then the value for KDERIV
52. ll be required to drive them see section 4 3 2 m APC that fulfills the following specification Minimum specification Recommended specification Processor Intel Pentium 133MHz Intel PentiumII 400MHz or faster RAM 32MB 128MB Hard disk space 40MB 60MB CD ROM A CD ROM drive Serial port US RS232 B port or serial port Screen 800 x 600 256 colors 1024 x 768 16 bit color Mouse A mouse or sim ilar pointing device Operating system Windows 95 Windows NT Windows 98 Windows ME Windows NT Windows 2000 or Windows XP For USB support Windows 2000 or Windows XP is required Software installation will be described later in section 5 A serial cable connected as shown in section 4 4 4 or USB cable Your PC operating system user manual might be useful if you are not familiar with Windows CMC Basic Installation 3 3 3 4 Basic Installation CMC Input Output 4 4 1 Introduction This section describes the input and output capabilities of the Aximate Plus The following conventions will be used to refer to the inputs and outputs VO em Input Output DIN oraria Digital Input DOUT rr Digital Output BIN arose Analog Input ROUT inem Analog Output CMC Input Output 4 1 4 1 1 Connector loca
53. lt expression gt Ia CAPTUREEVENT CPE WER oa Lats 2 CAPTUREEVENTAXIS CPX IH potP 2 CAPTUREEVENTDELAY CPL CHGCI ICED E 2 CAPTUREINTERVAL CPI ifi None 2 CAPTUREMODE CPM m E CAPTUREMODEPARAMETEI Attributes B CAPTURENUMPOINTS Read Write Multi Scaled Default Range 2 CAPTUREPERIOD CPP Axis 2 CAPTUREPOINT l i 7 CHANNELTYPE CHT d di I o Usxs2 2 Chr 2 CIRCLEA CA Description J CIRCLER CR zi A capture is set up using the CAPTURE keyword CAPTUREEVENT is gi ez Je typically used to stop a continuous capWRAP capture but may also be zl Figure 19 The WorkBench help file For help on using WorkBench v5 click the Contents tab then click the small plus sign beside the WorkBench v5 book icon Double click a 2 topic name to display it CMC Operation 5 3 5 2 2 Starting WorkBench v5 1 Onthe Windows Start menu select Programs WorkBench v5 WorkBench v5 WorkBench v5 will start and the Tip of the Day dialog will be displayed You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup Click Close to continue DPETEEGER FEIER Red Acplicalon For Help press FL I r I Me TZ 2 Inthe opening dialog box click Start New Project WorkBench v5 WorkBeneh4 amp 6e Recent Projects Start New Project x Browse for Project Demo Mode Help
54. m damping For this reason KDERIV and KVEL can often be set to zero Correct setting of the velocity feed forward gain KVELFF is important to get the optimum response from the system The velocity feed forward term takes the instantaneous velocity demand from the profile generator and adds this to the output block see Figure 20 KVELFF is outside the closed loop and therefore does not have an effect on system stability This means that the term can be increased to maximum without causing the motor to oscillate provided that other terms are setup correctly When setup correctly KVELFF will cause the motor to move at the speed demanded by the profile generator This is true without the other terms in the closed loop doing anything except compensating for small errors in the position of the motor This gives faster response to changes in demand speed with reduced following error Before proceeding confirm that the encoder feedback signals from the motor or servo amplifier have been connected and that a positive demand causes a positive feedback signal Calculating KVELFF To calculate the correct value for KVELFF you will need to know m The speed in revolutions per minute produced by the motor when a maximum demand 10V is applied to the drive m The setting for LOOPTIME The factory preset setting is 1ms m The resolution of the encoder input The servo loop formula uses speed values expressed in quadrature counts per servo loo
55. mate Plus must have the CANopen firmware loaded to use this protocol A CANopen protocol has been implemented in MintMT based on the Communication Profile CiA DS 301 which supports both direct access to device parameters and time critical process data communication The Aximate Plus design does not comply with a specific CANopen device profile DS4xx although it is able to support and communicate with the following devices m Any third party digital and analog I O device that is compliant with the Device Profile for Generic I O Modules CiA DS 401 m Other controllers with CANopen support for peer to peer access using extensions to the CIA specifications DS301 and DS302 The functionality and characteristics of all CANopen devices are typically defined in individual standardized ASCII format Electronic Data Sheets EDS which can be found on the Motion Toolkit CD supplied with your product or downloaded from www cmccontrols com The configuration and management of a CANopen network must be carried out by a single node acting as the network master This role can be performed by the Aximate Plus when it is configured to be the Network Manager node node ID 1 or by a third party CANopen master device Up to 126 CANopen nodes node IDs 2 to 127 can be added to the network by a Aximate Plus Manager node using the MintMT NODESCAN keyword If successful the nodes can then be connected to using the MintMT CONNECT keyword An
56. motor into the required position with zero following error KINT can therefore overcome errors caused by gravitational effects such as vertically moving linear axes With current controlled drives a non zero demand output is required to hold the load in the correct position to achieve zero following error Care is required when setting KINT since a high value will cause instability during moves A typical value for KINT would be 0 1 The effect of KINT should also be limited by setting the integration limit KINTLIMIT to the smallest possible value that is sufficient to overcome friction or static loads for example 5 This will limit the contribution of the integral term to 5 of the full demand output range 1 Click in the KINT box and enter a small starting value for example 0 1 Fine tuning Anis 4 2 Click in the KINTLIMIT box and enter a value of 5 With Aximate Plus the action of KINT and KINTLIMIT can be set to operate in various modes Never the KINT term is never applied Always the KINT term is always applied Smart the KINT term is only applied when the demand speed is zero or constant Steady State the KINT term is only applied when the demand speed is zero This function can be selected using the KINTMODE drop down box CMC Operation 5 21 5 8 5 8 1 Servo axis tuning for velocity control Drives designed for velocity control incorporate their own velocity feedback term to provide Syste
57. nds not at intermediate nodes m All nodes on the network are running at the same baud rate m All nodes have been assigned a unique node ID m The integrity of the CAN cables To recover from the off state the bus must be reset This can be done using the MintMT BUSRESET keyword or by resetting the Aximate Plus 6 6 Troubleshooting CMC Symptom Check The Manager node cannot scan recognize a node on the network using the MintMT NODESCAN keyword Assuming that the network is working correctly see previous symptoms and the bus is in an Operational state check the following m Only nodes that conform to DS401 are supported by the MintMT NODESCAN keyword m Checkthat the node in question has been assigned a unique node ID m The node must support the node guarding process Aximate Plus does not support the Heartbeat process m Try power cycling the node in question If the node in question does not conform to DS401 communication is still possible using a set of general purpose MintMT keywords See the MintMT help file for further details The node has been successfully scanned recognized by the Manager node but communication is still not possible For communication to be allowed a connection must be made to a node after it has been scanned wm Nodes that conform to DS401 must have the connections made manually using the MintMT CONNECT keyword If a connection attempt using CO
58. nt moves software cams and gearing 20 general purpose digital inputs software configurable as level or edge triggered 11 general purpose digital outputs 2 differential analog inputs with 12 bit resolution 4 single ended analog outputs with 12 bit resolution USB serial port RS232 serial port CANopen or proprietary CAN protocol for communication with MintMT controllers and other third party devices Programmable in MintMT CMC Introduction 2 1 Included with Aximate Plus is the Motion Toolkit CD This contains a number of utilities and useful resources to get the most from your MintMT controller These include m Mint WorkBench v5 This is the user interface for communicating with the Aximate Plus Installing Mint WorkBench v5 will also install firmware for Aximate Plus m PC Developer Libraries Installing Mint WorkBench v5 will install ActiveX interfaces that allow PC applications to be written that communicate with the Aximate Plus This manual is intended to guide you through the installation of Aximate Plus The chapters should be read in sequence The Basic Installation section describes the mechanical installation of the Aximate Plus The following sections require knowledge of the low level input output requirements of the installation and an understanding of computer software installation If you are not qualified in these areas you should seek assistance before proceeding Note You can check that you have
59. oder resolver loss see also the FEEDBACKFAULTENABLE keyword Follow mode The axis is in Follow mode See the FOLLOW keyword Homing The axis is currently homing See the HOME keyword Incremental move An incremental move is being profiled See the INCA and INCR keywords Jog The axis is jogging In the Mint help file see the topics JOG JOGCOMMAND and Jog mode 6 2 Troubleshooting CMC Offset move The axis is performing an offset move Positional Move The axis is performing a linear move See the MOVEA and MOVER keywords Stop A STOP command has been issued or the stop input is active Axis disabled The axis drive must be enabled before operation can continue See section 5 3 3 Click the Drive enable button in WorkBench v5 Suspend The SUSPEND command has been issued and is active Motion will be ramped to zero demand whilst active Reverse software or hardware limit A reverse software limit has been activated See AXISERROR and or AXISSTATUS to determine which applies Forward software or hardware limit A forward software limit has been activated See AXISERROR and or AXISSTATUS to determine which applies Firmware being updated horizontal bars appear sequentially New firmware is being downloaded to the Aximate Plus Initialization error An initialization error has occurred at power on See the Error Log or INITERROR topics in the help file Initialization
60. p To calculate this figure 1 First divide the speed of the motor in revolutions per minute by 60 to give the number of revolutions per second For example if the motor speed is 3000rpm when a maximum demand 10V is applied to the drive 3000 60 50 2 Next calculate how many revolutions will occur during one servo loop The factory preset Servo loop time is 1ms 0 001 seconds so Revolutions per second 50 x 0 001 seconds 0 05 3 Now calculate how many quadrature encoder counts there are per revolution The Aximate Plus counts both edges of both pulse trains CHA and CHB coming from the encoder so for every encoder line there are 4 quadrature counts With a 1000 line encoder Revolutions per servo loop 1000 x 4 4000 4 Finally calculate how many quadrature counts there are per servo loop Quadrature counts per revolution 4000 x 0 05 200 Quadrature counts per servo loop 5 22 Operation CMC The analog demand output is controlled by a 12 bit DAC which can create output voltages in the range 10V to 10V This means a maximum output of 10V corresponds to a DAC value of 2048 The value of KVELFF is calculated by dividing 2048 by the number of quadrature counts per servo loop so KVELFF 2048 200 10 24 5 Click in the KVELFF box and enter the value Fine tuning The calculated value should give zero Anis 4 following error at constant velocity Using values greater than the calculated
61. rce CMC 4 4 Input Output 4 2 2 Analog outputs The four analog outputs are available on connector X13 as shown in section 4 1 1 Four independent bipolar analog outputs Output range 10VDC 0 195 Resolution 12 bit accuracy 4 9mV Output current 10mA maximum Update frequency 10kHz maximum adjustable using the LOOPTIME keyword factory default 1kHz MintMT and the Mint Motion Library use analog outputs DemandO to Demand to control servo axes 0 to 2 respectively The Demand3 output may be used as general purpose analog output See the DAC keyword in the MintMT help file The analog outputs may be used to drive loads of 1kQ or greater Shielded twisted pair cable should be used The shield connection should be made at one end only Aximate Plus X43 Demand0 AGND Aximate Plus X13 Servo amplifier Demand0 N f Servo amplifier 10VDC demand input RS Connect overall shield at one end only Figure 6 Analog output typical connection to a servo amplifier CMC Input Output 4 5 4 3 4 3 1 4 3 1 1 Digital 1 0 The Aximate Plus provides m 20 general purpose digital inputs m 11 general purpose digital outputs Digital inputs Digital inputs are available on connectors X8 X9 and X10 as shown in section 4 1 1 The digital inputs are arranged in three groups each
62. related motion keywords in terms of encoder quadrature counts for servo motors or steps for stepper motors The number of quadrature counts or steps is divided by the SCALEFACTOR allowing you to use units more suitable for your application The unit defined by setting a value for scale is called the user unit uu Consider a servo motor with a 1000 line encoder This provides 4000 quadrature counts for each revolution If SCALEFACTOR is not set a MintMT command that involves distance Speed or acceleration may need to use a large number to specify a significant move For example MOVER 16000 Move Relative would rotate the motor by 16000 quadrature counts only four revolutions By setting a SCALEFACTOR of 4000 the user unit becomes revolutions The more understandable command MOVER 4 could now be used to move the motor four revolutions The same concept applies to stepper motors where the scale can be set according to the number of steps per revolution Typically this would be 200 for a motor with a 1 8 step angle or 400 if driven in half step mode By setting a SCALEFACTOR of 200 or 400 if driven in half step mode the user unit becomes revolutions In applications involving linear motion a suitable value for SCALEFACTOR would allow commands to express values in linear distance for example inches feet or millimeters 1 Inthe Toolbox click Setup then click the Parameters icon l A arare 2 Click the Scale tab x
63. s too large it will amplify any noise on the velocity measurement and introduce oscillations KINT This gain has a de stabilizing effect but a small amount can be used to reduce any steady state errors By default KINTMODE is always on mode 1 KINTLIMIT The integration limit determines the maximum value of the effect of integral action This is specified as a percentage of the full scale demand KDERIV This gain has a damping effect dependent on the rate of change of error and so is particularly useful for removing overshoot KVELFF This is a feed forward term and as such has a different effect on the servo System than the previous gains KVELFF is outside the closed loop and therefore does not have an effect on system stability This gain allows a faster response to demand speed changes with lower following errors for example you would increase KVELFF to reduce the following error during the slew section of a trapezoidal move The trapezoidal test move can be used to fine tune this gain This term is especially useful with velocity controlled servos KACCEL This term is designed to reduce velocity overshoots on high acceleration moves 5 14 Operation CMC ules eaneAueq AMIOM Ay90 9A i poinseoyy i yoeqp 4 ANDORA ules jesBequ ANIM uonisog EA peunseej uogisod ueg puewsq jeuoodold Ajto0 9A pueweq JojeJeuec BYU pJEMJOJp99 4 10 0 N OMS indino ova dio Aj90J8A dwy j6 od XWNLINITOVO 44
64. st use shielded twisted pair cable Do not connect mechanical switches relay contacts or other Sources liable to signal bounce directly to the fast inputs This could cause unwanted multiple triggering 4 6 Input Output CMC 4 3 1 2 DIN4 DIN11 Digital inputs DIN4 to DIN11 have a common specification Opto isolated digital inputs Sampling frequency 1kHz Digital inputs DIN4 to DIN11 use CREF 1 as their common connection Aximate Plus X9 DIN11 CREF1 Shield Figure 8 General purpose digital input DIN11 shown If an input is configured as edge triggered the triggering pulse must have a duration of at least 1ms one software scan to guarantee acceptance by MintMT The use of shielded cable for inputs is recommended 4 3 1 3 DIN12 DIN19 Digital inputs DIN12 to DIN19 have the same electrical specification as DIN4 11 except that they use CREF2 as their common connection Aximate Plus Figure 9 General purpose digital input DIN19 shown CMC Input Output 4 7 4 3 1 4 Auxiliary encoder inputs DIN17 STEP DIN18 DIR DIN19 Z DIN17 DIN19 may also be used as an auxiliary encoder input DIN17 accepts step pulse signals and DIN18 accepts direction signals allowing an external source to provide the reference for the speed and direction of an axis The step frequency
65. stallation 3 1 3 1 2 Mounting the Aximate Plus N CAUTION Before touching the unit be sure to discharge static electricity from your body and clothing by touching a grounded metal surface Alternatively wear an earth strap while handling the unit Ensure you have read and understood the location requirements in section 3 1 1 Mount the Aximate Plus using the supplied M4 screws For effective cooling the Aximate Plus must be mounted on a smooth non flammable vertical surface Orientation must be as shown in Figure 1 with the two slots in the metal carrier heat sink assembly at the bottom 245 9 65 170 6 7 All dimensions shown as mm inches 135 5 3 124 4 9 Drawings not to scale 43 1 7 Mounting keyhole and slot detail Es A 4 5mm nada B 10mm pP T D C iimm A gt Figure 1 Package dimensions There must be at least 20mm 0 8 in clearance between the Aximate Plus and neighboring equipment to allow sufficient cooling by natural convection Remember to allow additional Space around the edges to accommodate the mating connectors and associated wiring For example 70mm 2 8 in clearance will be required for connection of the serial port cable 3 2 Basic Installation CMC 3 1 3 Other requirements for installation m The Aximate Plus requires 24V power supply capable of supplying 2A continuously If digital outputs are to be used a supply wi
66. sult to the motor the further Demand gets ahead or behind you the more you press or release the gas pedal If the Proportional gain is set too high overshoot will occur resulting in the motor vibrating back and forth around the desired position before it settles you press the gas pedal so hard you go right past Demand To try and stay level you ease off the gas but end up falling behind a little You keep repeating this and after a few tries you end up level with Demand traveling at a steady speed This is what you wanted to do but it has taken you a long time If the Proportional gain is increased still further the system becomes unstable you keep pressing and then letting off the gas pedal so hard you never travel at a steady speed To reduce the onset of instability a term called Velocity Feedback gain KVEL is used This resists rapid movement of the motor and allows the Proportional gain to be set higher before vibration starts Another term called Derivative gain KDERIV can also be used to give a similar effect With Proportional gain and Velocity Feedback gain or Derivative gain it is possible for a motor to come to a stop with a small following error Demand stopped so you stopped too but not quite level The Aximate Plus tries to correct the error but because the error is so small the amount of torque demanded might not be enough to overcome friction This problem is overcome by using a term called Integral gain KI
67. t power up The port is capable of operation at up to 115 2 Kbaud on RS232 4 4 5 Using RS232 The Aximate Plus full duplex RS232 serial port has the following preset configuration m 57 6 Kbaud m 1 start bit m 8 data bits m 1 stop bit No parity m Hardware handshaking lines RTS and CTS must be connected Serial COM RXD 2 n f 2 RXD TXD3 H H 3 TXD amp pin Aximate Plus GND 5 H 5GND Computer DTE COM Port RTS 7 H 7 RTS DTE CTS8 8 CTS _ T T yo N Connect overall shield A to connector backshell Figure 17 RS232 serial port connections 4 14 Input Output CMC The RS232 port is configured as a DCE Data Communications Equipment unit so it is possible to operate the controller with any DCE or DTE Data Terminal Equipment Full duplex transmission with hardware handshaking is supported Only the TXD RXD and 0V GND connections are required for communication Pins 4 and 6 are linked on the Aximate Plus The maximum recommended cable length is 3m 10ft at 57 6 Kbaud the factory preset rate When using lower baud rates longer cable lengths may be used up to maximum of 15m 49ft at 9600 baud CMC Input Output 4 15 4 5 CAN The CAN bus is a serial based network originally developed for automotive applications but now used for a wide range of industrial applications It offers low cost serial communications with very high reliability in an industrial environment the probab
68. the electrical connections between the Aximate Plus and amplifier If you are using the relay check that you are using the correct normally open REL NO or normally closed REL NC connections If you are using a digital output check that it is using the correct high or low triggering method expected by the amplifier CMC Operation 5 9 5 4 Stepper axis testing This section describes the method for testing a stepper axis The stepper control is an open loop system so no tuning is necessary 5 4 1 Testing the output This section tests the operation and direction of the output It is recommended that the system is initially tested with the motor shaft disconnected from other machinery 1 Check that the Drive enable button is pressed down WorkBench 5 New Projeq 2 Inthe Toolbox click the Edit amp Debug icon 3 Click in the Command window 4 Type JOG 0 2 where 0 is the axis Stepper output to be tested and 2 is the speed The JOG command specifies the speed in user units per second so the speed is affected by SCALEFACTOR section 5 3 1 If you have notselected a scale the command JOG 0 2 will cause rotation at only 2 half steps per second so it may be necessary to increase this figure significantly to 200 for example If you have selected a scale that provides user units of revolutions as described in section 5 3 1 JOG 0 2 will cause rotation at 2 revolutions per second If there app
69. tion describes the mechanical installation of the Aximate Plus 3 1 1 Location requirements You must read and understand this section before beginning the installation AN CAUTION To prevent equipment damage be certain that input and output signals are powered and referenced correctly CAUTION To ensure reliable performance of this equipment be certain that all signals to from the Aximate Plus are shielded correctly generating equipment or directly below water steam pipes A CAUTION Avoid locating the Aximate Plus immediately above or beside heat CAUTION Avoid locating the Aximate Plus in the vicinity of corrosive substances or vapors metal particles and dust The safe operation of this equipment depends upon its use in the appropriate environment The following points must be considered m The Aximate Plus is designed to be mounted indoors permanently fixed and located m The Aximate Plus must be secured by the slots in the metal case m The Aximate Plus must be installed in an ambient temperature of 0 C to 45 C 32 F to 113 F m The Aximate Plus must be installed in relative humidity levels of less than 80 for temperatures up to 31 C 87 F decreasing linearly to 50 relative humidity at 45 C 113 F non condensing m The Aximate Plus must be installed where the pollution degree according to IEC664 shall not exceed 2 m There shall not be abnormal levels of nuclear radiation or X rays CMC Basic In
70. tions TERM 5 DIN19 fi 7 Seri e erial i v see can DIN16 4 DINIS i X8 DIN 12 19 X7 Encoder2 DIN13 7 DIN12 8 CREF2 9 Shield 10 4 DIN11 1 DIN10 2 INS hi X6 Encoder1 DIN7 5 DING X9 DIN 4 11 DIN5 7 DIN4 8 CREF1 9 4 Shield 10 DIN3 1 Shield 2 X5 Encoder0 CREFO 3 DIN2 4 died 5 X10 DIN 0 3 DINI 7 fast interrupts 710 CREF2 Shield 8 9 GREFI CREFO 9 8 CREFO DNO dO 6 USR GND DOUM B X4 DOUT 8 10 5 USR V 4 USR V DOUT2 3 pou 2 pours J5 X11 DOUT 0 7 1 DOUTS DOUTe 7 2 12 Shield DOUT7 8 11 DIR3 USRV 9 10 DIR3 USR GND 10 SE AINO 1 7 DGND i AINO 2 X3 STEP 2 3 6 Shield ARNO 3 5 DIR2 4 DIR2 Ad E X12 AIN 0 1 3 STEP24 nie 5 RELCOM 7 amp relay sf REEN te z2 Shield RELCOM lt0 11 BILL DEMANDO i 9 STEP1 Shed 8 7 BOND nie DEMANDI l4 X2 STEP 0 1 6 Shield AGND 5 5 DIRO DENARO E X13 AOUT 0 3 4 DIRO 3 STEPO AGND 8 demands 2 STEPO DEMANDS io DoD A 2 24V AGND X1 24Vin 1 ov Shield 12 Required mating connectors 1 Sauro CTF10008 2 Sauro CTF12008 Tightening torque for terminal block 3 Sauro CTF02008 connections is 0 3Nm 2 65 Ibf in 4 9 pin D type plug male 5 9 pin D type socket female 6 RJ45 plug 7 USB type B plug 4 2
71. u counts ta 1 User Position Unit 3 Click in the Axis drop down box to select the axis Each axis can have a different scale if required 4 Click in the Scale box and type a value 5 6 Operation CMC 5 Click Apply This immediately sets the scaling factor for Laen the selected axis which will remain in the Aximate Plus until another scale is defined or power is removed from the Aximate Plus See section 5 10 for details about saving configuration parameters 5 3 2 Setting the drive enable output A drive enable output allows Aximate Plus to enable the external amplifier to allow motion or disable it in the event of an error Each axis can be configured with its own drive enable output or can share an output with other axes If an output is shared an error on any of the axes sharing the output will cause all of them to be disabled The drive enable output can either be the relay or a digital output 1 Inthe Toolbox click the Digital I O icon Digital 1 0 2 Atthe bottom of the Digital I O screen click an 1M F 1M 15 the Digital Outputs tab The left of the screen shows yellow High and Low icons These describe how the output should behave when activated to enable the axis 3 If you are going to use the relay ignore this step and go straight to step 4 If you are going to use a digital output drag the appropriate yellow icon to the grey OUT icon that will be used as the drive enable outp
72. ut In this example OUT1 is being used The icon s color will change to bright blue CMC Operation 5 7 4 Ifyou are going to use i zm m I X relay drag the Relay0 icon to the grey Hsu ERE e o Drive Enable OP icon on the right of the Eg x Screen Low OUT1 To configure multiple axes to use the error output repeat this step for the other axes If you are using a digital output drag the bright blue OUT icon to the grey Drive Enable OP axis icon on the right of the screen High OUTO To configure multiple axes with the same drive enable output repeat this step for the other axes 5 Click Apply at the bottom of the screen This sends the output configuration to the Aximate Plus See section 5 10 for details about saving configuration parameters 5 8 Operation CMC 5 3 3 Testing the drive enable output LE On the main WorkBench v5 toolbar click the Axis 0 7 button In the Select Default Axes dialog select the axes to be controlled Click OK to close the dialog On the main WorkBench v5 toolbar click the Drive enable button Click the button again Each time you click the button the drive enable output s for the selected axes are toggled When the button is in the pressed down position the amplifier should be enabled When the button is in the raised up position the amplifier should be disabled If this is not working or the action of the button is reversed check
73. utput set using DACMODE See the MintMT help file for details of each keyword 5 12 Operation CMC 5 5 2 An introduction to closed loop control This section describes the basic principles of closed loop control If you are familiar with closed loop control go straight to section 5 6 1 When there is a requirement to move an axis the Aximate Plus control software translates this into a demand output voltage This is used to control the drive servo amplifier which powers the motor An encoder or resolver on the motor is used to measure the motor s position Every 1ms adjustable using the LOOPTIME keyword the Aximate Plus compares the demanded and measured positions It then calculates the demand needed to minimize the difference between them known as the following error This system of constant measurement and correction is known as closed loop control For the analogy imagine you are in your car waiting at an intersection You are going to go straight on when the lights change just like the car standing next to you which is called Demand You re not going to race Demand though your job as the controller Aximate Plus is to stay exactly level with Demand looking out of the window to measure your position The main term that the Aximate Plus uses to correct the error is called Proportional gain KPROP A very simple proportional controller would simply multiply the amount of error by the Proportional gain and apply the re
74. with their own common connection This allows each group to be configured independently for active high or active low operation The general purpose digital inputs DINO DIN19 can be shared between axes and are programmable in Mint using a range of keywords beginning with the letters INPUT to determine their active level and if they should be edge triggered The state of individual inputs can be read directly using the INX keyword See the MintMT help file A general purpose digital input can be assigned to a special purpose function such as a home limit stop or error input See the keywords HOMEINPUT LIMITFORWARDINPUT LIMITREVERSEINPUT STOPINPUT and ERRORINPUT in the MintMT help file DINO DIN3 Digital inputs DINO to DIN3 can be assigned as fast interrupts These are used as high speed position latches allowing any combination of axes to be captured by the hardware The latency between input triggering and capture is 1us Special Mint keywords beginning with the letters FAST allow specific functions to be performed as a result of fast position inputs becoming active See the Mint help file for details Aximate Plus X10 DIN3 Shield CREFO Figure 7 Fast interrupt digital input DIN3 shown Digital inputs DINO to DIN3 use CREFO as their common connection Note The fast inputs are particularly sensitive to noise so inputs mu
75. y network and node related events can then be monitored using the MintMT BUS1 event Please refer to the MintMT help file for further details on CANopen and MintMT keywords 4 18 Input Output CMC 4 6 Connection summary minimum system wiring As a guide Figure 18 shows an example of the typical minimum wiring required to allow the Aximate Plus and a single axis servo amplifier to work together Details of the connector pins are shown in Table 2 Host PC Aximate Plus o U Serial or USB connection X5 Servo amplifier axis 0 Demand Demand Enable Gnd Encoder output from X12 drive or motor 9 10 1 2 all 3 X13 24V x1 wv 8 pi 24V control Common SERI earth ground Figure 18 Example minimum system wiring CMC Input Output 4 19 Aximate Plus connector Name of signal Function Connection on amplifier Note connections may be labeled differently X1 oV Control supply ground 24V Control supply 24V input Encoder0 Encoder0 feedback input Encoder output REL NO Normally open relay contact closed to enable drive Enable 24V REL COM Common relay connection Enable GND DemandO Demand output 0 Demand AGND Analog GND Demand Shield Shield
76. y window does not update The system refresh has been disabled Go to the Tools Options menu item select the System tab and then choose a System Refresh Rate 500ms is recommended CMC Troubleshooting 6 5 6 2 5 CANopen Symptom Check The CANopen bus is passive This means that the internal CAN controller in the Aximate Plus is experiencing a number of Tx and or Rx errors greater than the passive threshold of 127 Check m 12 24V is being applied to pin 5 of the RJ45 CAN connector to power the opto isolators m Thereis atleast one other CANopen node in the network m The network is terminated only at the ends not at intermediate nodes m All nodes on the network are running at the same baud rate m All nodes have been assigned a unique node ID m The integrity of the CAN cables The Aximate Plus should recover from the passive state once the problem has been rectified this may take several seconds The CANopen bus is off This means that the internal CAN controller in the Aximate Plus has experiencing a fatal number of Tx and or Rx errors greater than the off threshold of 255 At this point the node will have switched itself to a state whereby it cannot influence the bus Check m 12 24V is being applied to pin 5 of the RJ45 CAN connector to power the opto isolators m Thereis atleast one other CANopen node in the network m The network is terminated only at the e

Aximate Plus Manual - Microcon Technologies Inc.

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