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MAXnet - Pro-Dex

1. 3 3 3 5 DYNAMIC LINK 3 3 3 6 MAXnet COMMUNICATION ARCHITECTURE 3 4 3 7 REAL TIME POSITION 3 5 4 CONTROL SIGNAL 1 4 1 4 1 28 4 1 42 a r 4 3 4 3 e PETERE 4 3 4 4 GENERAL PURPOSE DIGITAL l O essen 4 3 4 5 ANAIEGOG IO oii rise ent metn en usi eden e Er 4 3 4 6 MOTOR CONTROL 4 4 ENCODER 4 6 4 8 HOME 4 6 4 9 ABSOLUTE ENCODERS WITH 51 4 8 4 10 IOMAXnet ADAPTER 4 10 5 HOST SOFTWARE Ue ett scu tas ner ies Er ME E D EE 5 1 5 1 INTRODUCTION TO MAXnet SUPPORT SOFTWARE 5 1 6 STAND ALONE COMMANDS steterit 6 1 7 SERVICE 7 1 7 1 USER SERVICE tette 7 1 7 2 THEORY OF OPERATION ert nde 7 1 8 FIRMWARE UPGRADE incedentes tel tdm aud e ae edd 8 1 8 1 MAXnet ETHERNET MODE FIRMWARE 8 1 8 2 MAXnet SERIAL MOD
2. Accelerating Possibilities i j OREGON MICRO SYSTEMS USER S MANUAL INTELLIGENT MOTION CONTROLLER FOR ETHERNET MAXnet PRO DEX INC OREGON MICRO SYSTEMS 15201 NW GREENBRIER PARKWAY B 1 RIDGEVIEW BEAVERTON OR 97006 PHONE 503 629 8081 FAX 503 629 0688 mailto support pro dex com http www pro dexOMS com COPYRIGHT NOTICE 2013 Pro Dex Inc Oregon Micro Systems ALL RIGHTS RESERVED This document is copyrighted by Pro Dex Inc Oregon Micro Systems You may not reproduce transmit transcribe store in a retrieval system or translate into any language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise any part of this publication without the express written permission of Pro Dex Inc Oregon Micro Systems TRADEMARKS IBM IBM PC IBM PC XT IBM PC AT IBM PS 2 and IBM PC DOS are registered trademarks of International Business Machines Corporation CompactPCl PICMG PCI PICMG are registered trademarks of the PCI Special Interest Group LabView is a registered trademark of National Instruments Windows 7 Vista XP 2000 amp Win NT are registered trademarks of Microsoft Corporation DISCLAIMER Pro Dex Inc Oregon Micro Systems makes no representations or warranties regarding the contents of this document We reserve the right to revise this document or make changes to the specifications of the product described wit
3. Byte Offset Byte Offset Hex Byte length Description 3476 OxD94 1 Controller insert index 3477 OxD95 1 Host removal index 3478 0 096 550 Table entries 10 bytes per entry and 55 entries The number of entries can be greater than one for each axis if capture events occur on back to back motor update cycles and if the host does not collect the data fast enough The format of each table entry is defined in table 3 2 below TABLE 3 2 Real Time Position Capture Table Entry Byte Offset Byte Offset Hex Byte length Description Encoder position offset 0x00 contains MSBs offset 0x03 0x00 4 contains LSBs 4 0x04 1 Axis X 0 Y 1 etc Home event bits 0x01 Positive edge home switch 298 0x02 Encoder home event 0x04 Negative edge home switch 6 0x06 2 Positive edge bits offset 0x06 contains MSBs and offset 0x07 contains LSBs 8 0x08 2 Negative edge I O bits offset 0x08 contains MSBs and Offset 0x09 contains LSBs MAXnet User s Manual 3 5 COMMUNICATION INTERFACE REAL TIME POSITION CAPTURE A value of 1 for a given bit indicates that it triggered the capture event A value of 0 for a given bit means it did not trigger the capture event The motion controller contains a PowerPC processor which writes the data in the shared memory in big endian format If the host processor is not a big endian processor then appropriate byte
4. DIAGRAM 0 05 overhang 0 05 overhang 2 Ethernet Serial 048 J5 J6 um 0 50 Tyco Amp 5788797 2 Molex 43045 0600 Bel Stewart Connector 08 0 1 1 36 5787169 9 49 Expansion Connection 0 34 0 05 All dimensions in inches 1 unless otherwise specified 0 06 overhang FIGURE 2 3 CONNECTOR LOCATIONS 2 4 MAXnet User s Manual CONFIGURING THE CARD FOR USE WITH ENCODERS GETTING STARTED All hole diameters are 0 1 FIGURE 2 4 MAXNET EXPANSION BOARD DIAGRAM All dimensions are in inches 1 unless 0 05 overhang Molex 4305 0600 Tyco Amp 5787169 9 0 05 J4 Expansion Connection 0 05 overhang FIGURE 2 5 MAXNET EXPANSION BOARD CONNECTOR LOCATIONS MAXnet User s Manual 2 5 GETTING STARTED CONNECT TO STEPPER MOTOR SYSTEM 2 4 SOFTWARE INSTALLATION OMS provides Windows DLL s For other operating systems please contact Pro Dex Inc Oregon Micro Systems refer to Appendix B For Windows NT XP amp 2000 After applying power and communication connections to the MAXnet controller apply power to the host PC and insert the software support disk or CD ROM supplied by OMS or download the software from the OMS website http www pro dexOMS com Follow the installation inst
5. 2 1 SERVO UPDATE RATE intret ee ie ete irte eee nine te enean ee eee eint ee doe 2 11 STAND ALONE COMMANDS nte iere dette rp eere tede te e nee eve D dq dae deca 6 1 STATUS WORD 1 FLAG REGISTER WORD ACCESS OFFSET OXxfcQ eint tieniti rechner ttr ri rana decer e antena scade eec 3 5 V VOLTAGE MODE i Anei M 2 12 W WIRING DIAGRAMS S oat EAE 4 4 WORD ACCESS OFFSET Oxfc0 STATUS WORD 1 FLAG 3 5 MAXnet User s Manual
6. CMD ERR FLAG 0x01000000 3 2 MAXnet User s Manual ASCII COMMAND RING BUFFER COMMUNICATION INTERFACE 3 3 ASCII COMMAND RING BUFFER PREVIOUSLY OUTPUT SIDE OF DATA REGISTER Command characters strings from the host are transferred to the controller by placing it in the ASCII Command Ring Buffer and updating the buffer insert pointer 3 4 ASCII RESPONSE RING BUFFER PREVIOUSLY INPUT SIDE OF DATA REGISTER This ring buffer is resident in the Common Memory area region and the Message Unit s Outbound Message Register 0 OMR Data is sent from the controller to the host by placing data into the ring buffer and then sending data over the communications channel Ethernet or RS 232 being used 3 5 DYNAMIC LINK LIBRARY The OmsMAXnet dll is the Motion Control Dynamic Link Library DLL that provides the means to create C C MFC or Visual Basic applications running under Windows NT 2000 or XP The DLL supports communicating to MAXnet via Ethernet or Serial port and supplies set of wrapper APIs round the more commonly used motion controller commands From the basic Send and Query to issuing multiple axes moves can be achieved using the DLL with minimal lines of code The API manual MAXnet API Manual doc describes each function calling parameters return types and function description The software and documentation are available on the support software CD ROM or on our web site www pro dexOMS com MAXnet User s Manual 3 3
7. 24 X V Home 58 GROUND GROUND 25 Y R 59 T W Phase A ADC 1 ADC 3 26 715 60 T W Phase 94 GROUND 27 ROUND 61 T W Phase B 95 Y R Servo 28 T W Home 62 T W Phase B 96 GROUND 29 U K 63 T W Index 97 T W Servo 30 64 T W Index 98 GROUND 31 X V Aux 65 U K Index 99 DAC 0 DAC 1 32 Y R Aux 66 U K Index GROUND 33 218 Aux 67 34 5 Volts 68 X V Negative Limit Legend X V axis U K axis Y R axis Z S axis Voltage T W axis For a black and white version of this table click here MAXnet User s Manual INTRODUCTION TO MAXnet SUPPORT SOFTWARE HOST SOFTWARE 5 HOST SOFTWARE 5 1 INTRODUCTION TO MAXnet SUPPORT SOFTWARE A disk containing 0115 libraries application software and example code for Pro Dex Oregon Micro Systems MAXnet family controllers is supplied with the purchase of a MAXnet controller Refer to the text files on the disk for installation instructions and other information Some programs on the demo disk that include source code may be adapted for use in application programs that use OMS motion controls No license is required The software is also available on the Pro Dex Oregon Micro Systems web page http www pro dexOMS com MAXnet User s Manual 5 1 HOST SOFTWARE INTRODUCTION TO MAXnet SUPPORT SOFTWARE This page intentionally left blank 5 2 MAXnet User s Manual STAND ALONE COMMANDS 6 STAND ALONE COMMANDS The stand alone mode allo
8. Adjust the signal command gain of the amplifier until the pulse rate of Phase A is approximately 10 of your desired peak operational velocity If the pulse rate is already greater than 1096 of peak your amplifier is not designed for low velocity motion and you will likely have some difficulty tuning your motors Send the KO 3277 command to the MAXnet and recheck the velocity You may need to readjust your amplifier If so do not reduce the signal command gain only increase the setting as needed Increasing the gain will not impair the forward peak velocity but reduction will Send the KO command with the zero value to the MAXnet 5 Verify the direction of your servo encoder a b c d Send the KO2000 command to the MAXnet Send the RE command to the MAXnet and observe the response If the response is positive no further action need be taken go to step 6 i If the response is negative your encoder or analog output must be reversed use one of the methods below ii Use EDI EDN to invert normalize encoder direction or iii Use SVP SVP to invert normalize PID analog output inverts values of KO and KOD or iv if your incremental encoder produces a differential signal swap Phase B with Phase B and repeat from step a above v If your incremental encoder produces a single ended or TTL signal swap Phase A with Phase B and repeat from step a above If the RE response is st
9. The KV variable is used when tuning velocity controlled servos voltage mode servo amplifiers This is the velocity feedforward coefficient KV determines how closely the system follows the desired constant velocity portion of the motion profile By increasing this term the Following Error of the system s response can be minimized However too large of a value may result in unstable behavior after command velocity changes The values for KV range from 0 to 249 99 2 14 MAXnet User s Manual TUNE THE SYSTEM GETTING STARTED Desired Step Response Actual Step Response Velocity Following Error FIGURE 2 12 The KA variable is used when tuning torque controlled servos current mode servo amplifiers This is the acceleration feedforward coefficient Systems with high inertial loads may require additional torque during acceleration or deceleration to achieve optimum performance KA determines how closely the system follows the desired acceleration and deceleration portions of the motion profile Increasing this term reduces the following error occurring during acceleration and deceleration of the system Although if KA is too large instability may occur The values for KA range from 0 to 249 99 Desired Step Response Actual Step Response Acceleration Deceleration Following Error FIGURE 2 13 The block diagram below describes the feedback loop that is taking place in the servo system PID Algorithm Motor and Encode
10. COMMUNICATION INTERFACE REAL TIME POSITION CAPTURE 3 6 MAXnet COMMUNICATION ARCHITECTURE As shown in the simplified diagram below Figure 3 1 communication between the MAXnet controller and the host application is via the Ethernet and the DLL Application Software Requested Data DLL Function call Ethernet Connection Stored Memory Status Data Flags Text Event Responses Notification Text Direct Commands Commands i MAXnet Motion Controller FIGURE 3 1 FUNCTIONAL COMMUNICATIONS FLOW 3 4 MAXnet User s Manual REAL TIME POSITION CAPTURE COMMUNICATION INTERFACE 3 7 REAL TIME POSITION CAPTURE The position capture commands control the real time recording of axis position data and the management of the captured position data The captured position data includes the axis the positive edge I O bits the negative edge I O bits the home and encoder home events and the encoder position of the axis The position data is captured when the conditions specified for the input bit are met The capture conditions for the home switch and general purpose input bits can be a rising positive edge a falling negative edge or the event can be both the rising positive and the falling negative edge so data is captured on any transition of the input bit The real time position capture feature is only available on an axis with incremental encoders See the MAX family command reference manual for more details on the real time position cap
11. 1 X V Phase A 35 T W Aux 69 Y R Negative Limit 2 X V Phase A 36 U K Aux 70 21 5 Negative Limit 3 X V Phase 37 71 T W Negative Limit 4 X V Phase B 38 100 108 72 U Negative Limit 5 X V Index 39 102 1010 73 GROUND 6 X V Index 40 104 1012 74 X V Direction 7 Z S Phase A 41 106 1014 75 Y R Direction 8 Z S Phase A 42 GROUND 76 71 S Direction 9 Z S Phase B 43 ADC 0 ADC 2 GROUND 10 Z S Phase B 44 GROUND W Direction 11 215 Index 45 X V Servo 79 U Direction 12 Z S Index 46 GROUND GROUND 13 U K Phase A 47 215 Servo XIV Step 14 U K Phase A 48 82 Y R Step 15 U K Phase B 49 U K Servo 83 Z S Step 16 U K Phase B 50 GROUND GROUND 17 GROUND 51 Y R Phase A T W Step 18 X V Positive Limit 52 Y R Phase A 86 U K Step 19 Y R Positive Limit 53 Y R Phase B 87 GROUND 20 Z S Positive Limit 54 Y R Phase B 88 101 109 21 T W Positive Limit 55 Y RIndex 89 103 1011 22 U K Positive Limit 56 Y R Index 90 105 1013 23 GROUND GROUND 91 107 1015 24 X V Home 58 GROUND GROUND 25 Y R Home 59 T W Phase A ADC 1 ADC 3 26 Z S Home 60 T W Phase 94 GROUND 27 61 T W Phase B 95 Y Servo 28 T W Home 62 T W Phase B 96 GROUND 29 U V Home 63 T W Index 97 T W Servo 30 64 T W Index 98 GROUND 31 X V Aux 65 U K Index 99 DAC 0 DAC 1 32 Y R Aux 66 U K Index GROUND 33 Z S Aux 67 GROUND 34 5 Volts 68 X V Negative Limit MAXnet User s Manual S
12. LED D1 next to the J5 power connector is lit when power is applied 2 2 MAXnet User s Manual CONFIGURING THE CARD FOR USE WITH ENCODERS GETTING STARTED Using your communication terminal send the characters WY to the MAXnet Windows Hyperterminal program can be used If communication and power are configured properly the MAXnet will respond in ASCII with its model version and serial number The default IP address of the MAXnet is 10 40 30 60 and the port is 23 To configure the MAXnet IP address for use in your network the IP and port addresses must be set with the appropriate commands and the settings should be archived to flash Use the NI command to set the IP address and the NP command to set the network port number Use the APP command to archive the settings to flash so that these settings will be the default after each power up See Command Reference Manual MAX Family for further details on these commands Set J2 for Ethernet communication and cycle the power on the MAXnet You may now connect an Ethernet capable terminal to the IP address previously programmed into the MAXnet If the communication interface is properly configured sending the characters WY to the MAXnet will produce the same model version and serial number as it did in the prior RS 232 test However when using Ethernet communications for each packet sent to the MAXnet controller the controller responds with an acknowledgement packet that contains data consistin
13. etc on the computer or terminal to be used Set the baud rate and other communication parameters on the PC to match the default settings of the MAXnet Connect a straight through 9 pin RS 232 cable between the host terminal and the MAXnet To prevent motors switches or other devices from unexpected activation do not connect the cable to output connector J1 at this time MAXnet User s Manual 2 1 GETTING STARTED CONFIGURING COMMUNICATION FIGURE 2 1 LED AND COMMUNICATION JUMPER SETTINGS 100 pin connector ETHERNET 5 e 6 1 1 1 a E e 8 2 2 8 4 2 Default setting RS232 setting Ethernet setting Ensure that J2 is set for RS 232 communication mode Connect a 5VDC 1 Amp power source to the power connector at J5 NOTE 12VDC is required only for servo operation Caution If the red LED labeled D101 located by the J5 power connector is ON this indicates a power problem Check power supply and all power connections When power is applied to the MAXnet and the firmware has booted there should be two solid green LEDs lit The LED labeled D100 located by the J5 power connector indicates the FPGA successfully configured The LED labeled D3 on the opposite edge of the card from the J1 connector indicates a successful boot of the firmware If both of these LEDs are on solid and all other LEDs are off the MAXnet is ready to communicate With the MAXnet expansion board for 6 10 axes of motion the green
14. 100 pin connector J1 Each digital I O bit can be set as an input or output and is controlled by firmware commands so there are no jumpers to set Aside from extending MAXnet for 6 through 10 axes of motion the optional expansion board is available for extending I O capabilites and for custom solutions Data communication is performed by sending and receiving strings of data ASCII characters via standard Ethernet communication protocol or RS 232 While not strictly required DLLs are provided to allow applications written in high level languages to communicate with the controller Software provided by Pro Dex Inc Oregon Micro Systems directly supports the use of Microsoft C C or Visual Basic In addition any language that has a mechanism for utilizing a standard Microsoft DLL Library can be used for application development The MAXnet I O Breakout Module the IOMAXnet provides an efficient means of connecting the MAXnet signals to external devices More details on the functionality of the controller are included in the following chapter 1 2 MAXnet User s Manual INSTALLATION GETTING STARTED 2 GETTING STARTED 21 INSTALLATION For installation of the MAXnet you will need a computer with either an Ethernet or RS 232 connection or both Read through the following two sections before beginning the installation Do not turn on the power to the MAXnet until you have properly configured the controller per the following instruc
15. Appendix C The MAXnet command set employs two or three ASCII character commands which can be combined into character strings Using virtually any programming language these ASCII command strings can be sent to the MAXnet Motion Controller over the Ethernet or RS 232 Refer to the Command Reference Manual MAX Family for the complete command reference 1 2 SYSTEM OVERVIEW The MAXnet motion controller can manage up to 10 axes of motion For 1 through 5 axes the MAXnet is a single board motion controller and measures 6 5 x 4 x 0 75 For 6 to 10 axes of motion the MAXnet utilizes stackable expansion board and when combined measures 6 5 x 4 x 1 78 The communication interface is accessed through either the Ethernet or RS 232 The MAXnet receives power 5V 12VDC from an external power supply and can be applied to either the MAXnet board 1 5 axes or the MAXnet expansion board 6 10 axes The MAXnet utilizes an optimally configured PowerPC RISC based 32 bit micro controller and FPGA technology for extensive logic integration and flexibility The firmware which resides in flash memory 2MB can be upgraded through the communication interface without having to remove the controller from the system 32MB of system RAM is used for firmware and data storage MAXnet User s Manual 1 1 GENERAL DESCRIPTION SYSTEM OVERVIEW All general purpose digital and analog I O and all motor control signals are available on the
16. INTRODUCTION The MAXnet can be considered a motion co processor to the host computer where it can execute the motion process independent of the host CPU The application software issues DLL function calls and receives requested data from the support DLL All communication is done between the motion controller and the host PC via the DLL and the communication interface Ethernet or RS 232 See also Functional and Data Flow Info Diagrams Figure 3 1 Simplified Data Dictionary of Figure 3 1 Event Notification New status flag data available Query command text response available Direct Commands Kill all motion Text Commands ASCII controller command strings Status Flags Axis done flags X Y Z T U V R S W Axis over travel limit flags X Y Z T U V R S W K Axis encoder slip flags X Y Z T U V R S W K Command error flag Text Responses Query command RP RE ASCII response strings Shared Memory Data Axis motor position data axis encoder position data velocity profile data and servo tuning data Requested Data Null terminated ASCII text response string velocity profile data servo tuning data axis done flags axis over travel limit flags axis encoder slip flags command error status MAXnet User s Manual 3 1 COMMUNICATION INTERFACE 3 2 PROTOCOL To permit flag notification while in TCP IP and RS 232 modes MAXnet will asynchronously send text strin
17. If current limiting is required it should be done externally to the board Contact Pro Dex Inc Oregon Micro Systems technical support for assistance The MAXnet home switch input can be used to physically home a mechanical stage When this functionality is used the axis position counter will be reset to a selected value when the switch is activated At this point the MAXnet can either ramp the axis to a stop or stop the axis immediately The control of the direction of travel the logic active state and the response to the active switch are controlled through commands The other homing method on the MAXnet uses the home switch and the encoder signals to home a motor When using the Home Encoder Index HI mode the homing logic is used with these input signals The home position consists of the logical AND of the encoder index pulse the home switch input and a single quadrant from the encoder logic The home switch and encoder should be positioned relative to each other in such a way that there is only a single location in the entire travel of the axis that creates a true condition for the defined home logic The HT and EH commands can be used to create different patterns for the home logic including the option to ignore an encoder phase signal The default home logic expressed in Boolean terms is Home Phase A Phase B Index Home Switch Default It is necessary that the above quadrant occur within the index pulse as provided by t
18. a valid firmware signature has been successfully sent to the controller flash memory Upgrading flash with filename Maxnsupg has determined that the controller is ready to start the upgrade 8 8 MAXnet User s Manual APPENDIX A LIMITED WARRANTY APPENDIX A LIMITED WARRANTY The Seller warrants that the articles furnished are free from defect in material and workmanship and perform to applicable published Pro Dex Inc Oregon Micro Systems specifications for one year from date of shipment This warranty is in lieu of any other warranty express or implied In no event will Seller be liable for incidental or consequential damages as a result of an alleged breach of the warranty The liability of Seller hereunder shall be limited to replacing or repairing at its option any defective units which are returned f o b Seller s plant Equipment or parts which have been subject to abuse misuse accident alteration neglect or unauthorized repair are not covered by warranty Seller shall have the right of final determination as to the existence and cause of defect As to items repaired or replaced the warranty shall continue in effect for the remainder of the warranty period or for 90 days following date of shipment by Seller of the repaired or replaced part whichever period is longer No liability is assumed for expendable items such as lamps and fuses No warranty is made with respect to custom equipment or products produced to Buyer s speci
19. a velocity override input See Command Reference Manual MAX Family www pro dexOMS com Al AO and VOA commands The MAXnet controller has 8 GPIO and 2 GP analog inputs With the MAXnet expansion board used for 6 10 axes of motion MAXnet has 16 GPIO and 4 GP analog inputs MAXnet can also be customized for other solutions with the MAXnet expansion board MAXnet User s Manual 4 3 CONTROL SIGNAL INTERFACE MOTOR CONTROL OUTPUT 4 5 2 ANALOG OUTPUTS Up to 12 analog outputs provide 10V outputs via the 16 bit digital to analog converters DAC Each servo axis requires a dedicated DAC There are six DACs and a maximum of five axes on the MAXnet controller and another six DACs and up to five axes on the MAXnet expansion board So there is always at least one general purpose analog output available For every available axis that is not being used as a servo motor there is a general purpose analog output available Each DAC has a 15mA maximum output current 4 6 MOTOR CONTROL OUTPUT The MAXnet is configured at the factory to control open loop stepper motors Upon installation axes can be configured for servo motors open loop steppers stepper motors with encoder feedback or a combination thereof The servo output may be either unipolar analog 0 10V or bipolar analog 10 10 V Each axis configured as a servo motor uses one analog output Step pulse and direction outputs are active drive TTL level ouput signals whi
20. com 2 8 3 MANUAL TUNING In most motion control applications the optimum tuning of the servo system is achieved through a manual tuning process Auto tuning algorithms typically can only get the system parameters close and require manual steps to fine tune the parameters An empirical trial and error approach will be discussed first There are some system parameters that need to be determined before attempting to tune a motor The encoder resolution counts per revolution is one element to be determined Another is the system s maximum velocity Note that a motor should never exceed 90 of the motor s maximum rate rpm If the system requirement is for a velocity higher than 9096 of the motors top rpm then another motor with higher rpm capability should be used The system s maximum acceleration is determined several different ways The best method is to determine the system time constant which includes hitting or bumping the motor under system load and measuring the time from 0 rpm to maximum rpm and divide this value by 5 The maximum acceleration is either 2 5 times this value or is based on the system requirements for handling the load as defined in the operating specifications of the system This value is always lower than the calculated value and if this acceleration value is not high enough then a different motor amplifier with more power or bandwidth should be utilized The MAXnet can control either current mode or voltage mo
21. read serial number An error occurred trying to read the serial number from the upgrade file 8 2 MAXnet User s Manual MAXnet ETHERNET MODE FIRMWARE UPGRADE FIRMWARE UPGRADE CRC failure on packet ppp The controller did not accept the upgrade packet number ppp due to a failure to pass the crc checksum test The controller does not attempt to write to flash until the crc checksum is successful for the packet Flash upgrade failed Some failure occurred during the erasing of the flash or the writing of the upgrade file to the flash Flash verify failure on packet ppp The controller did not accept the upgrade packet number ppp due to a flash verify failure Flash write failure on packet ppp The controller did not accept the upgrade packet number ppp due to a flash write failure Invalid command line option The character following a character on the command line was not one of the valid command line options Valid options are B P F Invalid upgrade file for MAXnet serial number nnnnnn An upgrade file with a serial number lock installed did not match the MAXnet controller found Invalid upgrade file signature The upgrade file did not have the required signature of a valid upgrade file Unknown failure on packet ppp The controller did not accept the upgrade packet number ppp due to some unknown failure Upgrade File Seek Error An error occurred trying to access the upgrade file WAIT message NOT
22. swapping to correct for endian differences must be performed by the host processor when accessing the shared memory data 3 6 MAXnet User s Manual INTRODUCTION CONTROL SIGNAL INTERFACE 4 CONTROL SIGNAL INTERFACE 4 1 INTRODUCTION The MAXnet family of motion controllers is available in configurations from one to ten axes to manage combinations of servo and step motor systems The 100 pin MAXnet connector incorporates all of the signals of the MAXnet The MAXnet default configuration is as an open loop stepper controller for the number of axes ordered MAXnet User s Manual 4 1 CONTROL SIGNAL INTERFACE INTRODUCTION TABLE 4 1 OUTPUT CONNECTOR PIN LIST J1 MAXNET AND EXPANSION BOARD in Signal Pin V Phase A X V Phase A X V Phase B Phase B 6 X Vindex 56 Rindex GROUND 8 Z SPhase A 58 GROUND 2 Z SPhase B 59 T WPhase A 10 Z SPhase B 60 lt lt T WPhase A 14 T W Index 15 U K Index U K Phase B U K Index GROUND GROUND X V Positive Limit X V Negative Limit Y R Positive Limit Y R Negative Limit 218 Positive Limit 215 Negative Limit TU o oo NIN NIN olo E o o i o o 5 o m 3 N 14 15 18 19 2 21 18 19 20 21 2 T W Positive Limit T W Negative Limit U K Positive Limit U K Negative Limit G
23. to connect a stepper motor driver to the controller board Begin this procedure with a MAXnet controller board connected to your system Be sure that communication to the board has been established This can be checked by issuing a WY command to the board and verifying that the board responds with its model type and revision levels i e MAXnet 4000 ver 1 00 S N 0000 NOTE Reference section 2 4 SOFTWARE INSTALLATION Once communication has been established with the controller shut down the system and turn power off to the controller board NOTE It is not recommended to continue with the hardware connection if communication has not been established 2 6 MAXnet User s Manual CONNECT TO STEPPER MOTOR SYSTEM GETTING STARTED Connect the motor phase signals from the motor to the stepper driver output signals Use the motor and stepper driver manufacturer s manuals for instructions Now connect the controller signals from J1 of the MAXnet or from IOMAXnet if it is used to the stepper driver Short cable lengths and shielded cables are recommended for improved signal integrity and reduction in signal noise NOTE Using the IOMAXnet interface module is strongly recommended as it provides an easy way to connect to the 100 pin connector J1 on the MAXnet If you are using the IOMAXnet connect the IOMAXnet to the MAXnet using a shielded 100 pin cable From the terminal block on the IOMAXnet connect the appropriate wires to your motor driv
24. you can fine tune your PID filter according to the earlier steps 2 16 MAXnet User s Manual SETTING THE USER DEFAULT CONFIGURATION GETTING STARTED 2 9 SETTING THE USER DEFAULT CONFIGURATION There are many parameters that can be defined by the user as default These parameter values can supersede the factory default values and be stored in flash memory for power up configuration Most of these parameters consist of axis specific values i e velocity acceleration limit switch logic sense etc The MAXnet comes from the factory with default values for all parameters For instance the default value for the velocity of all axes is 200 000 counts per second A count is equivalent to a step pulse or one count of an encoder In a typical application when the system is powered up the main host computer would initialize all of the peripherals such as the MAXnet sending each of the axes the peak velocity When the User Definable Default Parameter value is defined then the velocities of the defined axes will be set accordingly This feature can greatly simplify the software and initialization process Once the values for all of the associated parameters are defined i e velocity acceleration PID values etc then the APP command is executed to place the values into flash memory From this point forward these defined values will be used after reset or power up The individual parameters can be over written at anytime by using the associated co
25. 25 000 2 one axis at 24 bits resolution with a clock frequency of 500 000Hz and two axes at 32 bits resolution at 250000Hz This example also shows the use of clock sharing with other absolute encoders with the same clock frequency and bits resolution AX PSE ECA16 125000 AY PSE ECA16 125000 AZ PSE ECA24 500000 AT PSE ECA32 250000 AU PSE ECA32 250000 Shares clocks with T axis I O 6 7 4 8 MAXnet User s Manual ABSOLUTE ENCODERS WITH SSI CONTROL SIGNAL INTERFACE Below is an example of how the absolute encoder can be connected to the MAXnet This utilizes the IOMAXnet breakout board for easier connectivity to the absolute encoder environment If the MAXnet expansion board was being used an additional IOMAXnet breakout board would be needed for connectivity to the absolute encoder environment CBL10000 we a a IOMAXnet hona 0000 Absolute Encoder FIGURE 4 7 CONNECTION OF AN ABSOLUTE ENCODER TO THE MAXNET VIA THE IOMAXNET BREAKOUT BOARD MAXnet User s Manual CONTROL SIGNAL INTERFACE 4 10 The optional IOMAXnet is an adapter module designed to provide easy connection for each signal of the MAXnet It incorporates two row terminal block It is used with a 10 foot shielded cable to connect to the MAXnet via the 100 pin connector The 5VDC on the IOMAX is supplied IOMAXnet ADAPTER MODULE IOMAXnet ADAPTER MODULE by the MAXnet This supply vol
26. E messages proceeded with WAIT will be displayed continuously until the condition indicated is met Waiting for Controller to enter Upgrade Mode This message indicates that MAXnEupg has requested that the controller enter upgrade mode but the controller has not yet indicated that is in upgrade mode MAXnet User s Manual 8 3 FIRMWARE UPGRADE MAXnet ETHERNET MODE FIRMWARE UPGRADE INFO messages Application Running MAXnSupg has determined that an application is running on the MAXnet controller Erasing flash success This message indicates that flash code area has successfully been erased Invalid upgrade file for MAXnet serial number This message indicates that the upgrade file s serial number entry did not match the controller s serial number or a CRC error was detected MAXnEupg Version n nn Displays the current version of the MAXnet firmware upgrade utility RESTARTING with new firmware This message indicates that the firmware upgrade was successful and MAXnEupg has sent a command to the controller to restart This will start the controller running with the new upgraded firmware Sending nnn packets This message indicates how many packets are going to be sent to the controller flash when sending the new firmware to the controller Serial Number verified This message indicates that the upgrade file had a Serial Number lock installed and it was successfully verified that the specified upgrade file was val
27. E FIRMWARE 8 5 A LIMITED WARRANTY B TECHNICAL INFORMATION RETURN FOR REPAIR PROCEDURES C SPECIFICATIONS INDEX MAXnet User s Manual i TABLE OF CONTENTS This page is intentionally left blank INTRODUCTION GENERAL DESCRIPTION 1 GENERAL DESCRIPTION 1 1 INTRODUCTION The Pro Dex Inc Oregon Micro Systems MAXnet family of motion controllers are high performance Ethernet products The MAXnet motion controller can manage up to 10 axes of open loop stepper closed loop stepper or servo systems in any combination The OMS MAXnet controller synchronizes all independent or coordinated motion of up to 10 axes while incorporating other critical signals such as hard or soft limits home and other digital and or analog I O signals to provide the motion solutions to perform virtually any task With high level functionality such as circular and linear interpolation multi tasking custom profiling etc the MAXnet can satisfy the needs of most any motion control application See Appendix C Ordering Information for specific MAXnet family models The MAXnet communicates as a slave only device and functions as a motion co processor to the Ethernet host It utilizes patented and proprietary technology to control the trajectory profile acceleration velocity deceleration and direction of selected axes In response to commands from the host computer the MAXnet controller will calculate the
28. PECIFICATIONS APPENDIX C ORDERING INFORMATION Model Computer Interface Servo Stepper Digital Encoder Channel Auxiliary General Purpose MAXnet 1000 MAXnet 2000 MAXnet 3000 MAXnet 4000 User Definable 1 User Definable User Definable User Definable MAXnet 5000 Ethernet MAXnet 6000 RS 232 MAXnet 7000 User Definable User Definable User Definable MAXnet 8000 User Definable MAXnet 9000 User Definable MAXnet A000 10 User Definable CBL58 3M 100 Pin 12 ft cable Terminal block Breakout Module can be stacked on MAXnet IOMAXnet 100 Pin Connector Breakout Module i dM BR gt gt MAXnet User s Manual INDEX INDEX A ABSOLUTE ENGODER 1 ee eet aee bei MEER eb Edere 4 8 B BAUD RATE FACTORY DEFAULT setts tide decet aei cadi tette re rbd 2 1 C eiaiiz amor 2 12 H E 4 3 4 10 MOTOR WIRING DIAGRAMS 2 7 QUADRATURE ENCODER WITH TTL LEVEL 2 3 S SERIAL COMMUNICATION
29. REGON MICRO SYSTEMS 15201 NW Greenbrier Parkway B 1 Ridgeview Beaverton OR 97006 RETURN FOR REPAIRS APPENDIX B This page intentionally left blank MAXnet User s Manual APPENDIX C DESCRIPTION The MAXnet is Ethernet RS 232 controller that is capable of up 10 axes of control Each axis can be configured as an open loop stepper a closed loop stepper or a servo axis The MAXnet is available in several different models that support a different number of axes The MAXnet is powered by a PowerPC processor This high performance processor provides a 64 bit Floating Point processor and is clocked at 266MHz This provides the MAX with the pure processing power to update every signal of the controller i e bits direction limits etc at rates up to 122us Every axis includes dedicated over travel limit inputs a home input and an auxiliary output The home over travel limit inputs are TTL level inputs The MAXnet supports 8 general purpose digital signals on the MAXnet controller and 8 general purpose digital I O signals on the MAXnet expansion controller In addition it has up to 4 general purpose analog inputs 2 on the MAxnet controller and 2 on the MAXnet expansion controller that can be used to sense Pressure Transducers Dial Switches etc Analog inputs can also be used to control velocity override These analog inputs have 16 bit of resolution with 10 VDC input There is one general pur
30. ROUND GROUND X V Home X V Direction Y R Home Y R Direction 715 Direction GROUND GROUND 28 T W Direction 29 U K Direction GROUND GROUND X V Aux X V Step Y R Aux Y R Step 215 Step GROUND T W Step U K Step GROUND GROUND 101 109 103 1011 105 1013 107 1015 GROUND GROUND 3 ADC 0 ADC 2 ADC 1 ADC 3 GROUND Y R Servo GROUND GROUND Z S Servo T W Servo GROUND U K Servo DAC 0 DAC 1 GROUND 2 o N 45 24 25 26 N 31 32 33 34 35 36 38 39 40 1 4 ALARA AR ays N AR A AR a o axis Y Raxis Ground Z S axis Voltage T W axis 4 2 MAXnet User s Manual LIMIT INPUTS CONTROL SIGNAL INTERFACE 4 2 LIMIT INPUTS To facilitate system safety TTL inputs for limit conditions are provided for each axis Limits may be activated by mechanical switches using contact closures or other suitable active switches such as a Hall Effect switch or opto isolator that connects to ground If the motor travels beyond its allowable limits and trips the switch the limit condition removes any further excitation in the limit direction from the affected axis Servo Motor systems should be designed for safety i e to have electrical braking to stop them The limit switch active signal state can be selected with the LT command on an axis by axis basis The behavior of the limit functio
31. The commands are executed sequentially allowing the host to send a complex command sequence and attend to other tasks while the MAXnet manages the motion process These command queues store 2559 command values and include a command loop counter which allows multiple executions of any queued commands All commands are sent to the controller as two or three character ASCII strings Some of these commands expect one or more numerical operands to follow These commands are identified with a after the command The indicates a signed integer input parameter or a signed fixed point number of the format when user units are enabled User Units define distances velocity and acceleration parameters and may be inputted in inches millimeters revolutions etc Synchronized moves may be made by entering the AA or AM command mode This form of the command performs a context switch that allows entering commands of the format MR 4 4 4 The order of axes is always X Y Z T U V R S W and K SPECIFICATIONS Numbers are entered for each axis commanded to move An axis may be skipped by entering the comma with no parameter The command be prematurely terminated with i e a move requiring only the X and Y axes would use the command MR followed by the GO command Each axis programmed to move will start together upon executing the GO command The MAXnet can be switched back to the single axis mode by ente
32. ault 0 0 0 Servo axis unipolar bipolar output Factory Default bipolar Servo PID values KP KD KI KO KV KA Factory Default KP 10 KD 160 KI 1 00 KO 0 KV 0 KAO Servo zero value KO Factory Default 0 RS 232 baud rate Factory Default 115200 IP address Factory Default 10 40 30 60 Network port address Factory Default 23 MAXnet User s Manual 2 17 GETTING STARTED POWER SUPPLY REQUIREMENTS 2 10 POWER SUPPLY REQUIREMENTS Minimum Recommended Max Power Requirements 20 Watt 25 Watt 30 Watt Volts Minimum Typical Recommended Current requirements 5 V 596 1 0 Amp 1 4 Amp 3 Amp 12 V 10 50 100 250 12 V 10 50 100 250 CAUTION Maximum 5VDC power supply is 5 5 Volts If power supply is higher than 5 5 Volts the MAXnet controller could be damaged TABLE 2 4 POWER CONNECTOR J5 6 Pin Power Connector Signal Pin Signal Pin Signal 6 5 Volts 4 5 Volts 5 12 Volts 3 12 Volts FIGURE 2 15 J5 POWER CONNECTOR ON MAXNET 2 18 MAXnet User s Manual POWER SUPPLY REQUIREMENTS GETTING STARTED FIGURE 2 16 J5 POWER CONNECTOR ON MAXNET EXPANSION BOARD MAXnet User s Manual 2 19 GETTING STARTED POWER SUPPLY REQUIREMENTS This page is intentionally left blank 2 20 MAXnet User s Manual INTRODUCTION COMMUNICATION INTERFACE 3 COMMUNICATION INTERFACE 3 1
33. ccurs In the case of a continuous error that does not clear the user can abort by entering Control C holding down the Ctrl key and pressing Unless specified via a command line option The default upgrade file name is maxn bin The default baud rate is 115200 baud The default comm port selection is 1 Examples Description MAXnSupg upgrades flash of the controller using file maxn bin upgrades flash of the controller at 19200 baud using the file MAXnSupg b 19200 Hen bin MAXnSupg f newmaxn bin upgrades flash using the file newmaxn bin MAXnSupg p 3 upgrades flash using comm port 3 with file maxn bin MAXnSupg h will display a help message Error messages Cannot open upgrade file file A problem occurred trying to open the upgrade file Controller ID query failed The controller did not respond to a WY query The upgrade will be aborted Controller is not responding The controller did not respond to a WY query The upgrade will be aborted Could not read serial number An error occurred trying to read the serial number from the upgrade file CRC failure on packet ppp The controller did not accept the upgrade packet number ppp due to a failure to pass the crc checksum test The controller does not attempt to write to flash until the crc checksum is successful for the packet Flash upgrade failed Some failure occurred during the erasing of the flash or the writing
34. ch will wire directly into most driver inputs Auxiliary outputs are active drive TTL outputs Each step direction and auxiliary output has a 20mA maximum output current MAXnet Step Clock Direction Opto 5V Supply Ground Opto FIGURE 4 1 CONNECTION TO STEP DRIVES WITH OR WITHOUT INTERNAL PULL UP RESISTORS The MAXnet controller has 6 analog outputs With the MAXnet expansion board used for 6 10 axes of motion MAXnet has 6 additional analog outputs MAXnet can also be customized for other I O solutions with the expansion board 4 4 MAXnet User s Manual MOTOR CONTROL OUTPUT CONTROL SIGNAL INTERFACE Enable Step Step Clock Direction Direction 5V Opto 5VDC Supply Direction Step Clock Ground Opto Ground FIGURE 4 2 CONNECTION TO STEP DRIVES WITH DIFFERENTIAL Home Limit Limit Switch Input FIGURE 4 3 HOME LIMIT INPUT WIRING DIAGRAM TTL output Digital Input Output TTL input FIGURE 4 4 DIGITAL I O WIRING DIAGRAM MAXnet User s Manual 4 5 CONTROL SIGNAL INTERFACE HOME PROCEDURES 4 7 ENCODER FEEDBACK Incremental encoder feedback is provided for all axes Encoder feedback is required for each servo axis Its use is optional for stepper axes The MAXnet encoder feedback accepts quadrature pulse inputs from high resolution encoders at rates up to 16 MHz after quadrature detection When used with stepper motors the encoder monitors the actual position through the enco
35. currently executing on the MAXnet controller If firmware is currently executing then MAXnSupg proceeds to the next step of the upgrade process Otherwise MAXnSupg will upload the maxn_uldr hex file to the controller ram and attempt to execute the uploaded code If a valid response is returned from the maxn uldr application then MAXnSupg proceeds to the next step otherwise MAXnSupg exits flash code blocks are erased If a failure occurs erasing flash the program is aborted firmware file is sent to the controller and the controller programs the flash to the flash code blocks Firmware is sent in packets If any single packet has a transmission error it will be resent until the transmission is successful or the user aborts the upgrade program The first code block is re written with a valid MAXnet signature so that the boot block will recognize that valid firmware is loaded in the flash A restart command is sent to the controller causing the controller to re boot with the new firmware MAXnet User s Manual 8 5 FIRMWARE UPGRADE MAXnet SERIAL MODE FIRMWARE UPGRADE Verify that the controller is running the new firmware by running the MAXnScom utility and sending a WY command to the controller The WY response should indicate the version number of the upgraded firmware If MAXnSupg encounters an error that will not allow it continue it will either abort the program or continuously retry until the error no longer o
36. de amplifiers The servo update rate of the MAXnet is user selectable 976 6us 488 3us 244 1us 122 1us High Following Error can be MAXnet User s Manual 2 11 GETTING STARTED TUNE THE SYSTEM compensated for using the feedforward coefficients explained later in this section There are some general formulas that have been developed to determine acceptable Following Error for both current and velocity mode systems Current mode Following Error for KP 3 360 x counts per revolution Voltage mode Following Error for KP 90 360 x counts per revolution It is obvious that the voltage mode allows for much greater Following Errors than the current mode This value is the Following Error when the motor is at peak velocity and will be used when determining the proportional gain KP The Following Error for the integral term KI or long term gain value will follow the guidelines below Current Mode Following Error for KI 0 counts Voltage Mode Following Error for KI 80 of 360 expressed in motor counts While still in open loop mode CLO use the KO command to zero the motor This variable is used to provide a constant output that will compensate for torque offset from the load So when the system should be stationary the necessary voltage will be sent to the amplifier to cause the motor to maintain position With the correct KO value the motor should successfully maintain a ze
37. der pulse train On servo axes it continuously provides input to calculate the position error adjust for it through the PID filter and change the output accordingly The stepper axes can monitor the error and correct and maintain the position after the move is finished The encoder input can also be used as an independent feedback source or in the encoder tracking mode to mimic an activity All modes are capable of slip or stall detection and encoder tracking with electronic gearing These options are selectable by the user through software commands The MAXnet is compatible with virtually any incremental encoder which provides quadrature outputs Times four quadrature detection is used to increase resolution This means that an encoder rated for 1000 counts or lines per revolution will result in 4000 counts of quadrature encoded input for each encoder shaft revolution The inputs are compatible with encoders that have single ended or differential TTL outputs The MAXnet has differential line receivers to accommodate encoders with differential outputs Encoders with single ended outputs can wire the signals to the plus side of the differential line receiver and ground the minus side see Figure 4 6 4 8 HOME PROCEDURES Two logical input functionalities are provided to synchronize the physical hardware with the MAXnet controller i e put the controlled motor the home position The home switch input is a TTL level input signal
38. ed The three primary gain values used in servo systems are P proportional I integral and D derivative The P term is used as a straight gain factor to get the system response in the ballpark The I term defines how quickly the system will respond to change The D term is a dampening term This term defines how quickly the system settles at its desired position without oscillating The effects of these parameters can be seen when looking at the system s response to a step change at the input The shape of the step response falls into one of three categories under damped critically damped or over damped Over damped systems are slow to reach their final value and produce little or no oscillation Critically damped systems reach final value quickly without overshoot Under damped systems reach final value quickly but have various degrees of ringing or oscillation that decay to zero over time Ideally a system should be critically damped allowing for the fastest response time with the least amount of oscillation 2 8 2 TUNING ASSISTANT is a tuning assistant utility that is provided to assist the user in finding the right combination of parameters This utility plots the motor s response The user can analyze this data to arrive at the right servo parameters for their servo system The application and documentation can be found on the CD ROM supplied with the MAXnet and on OMS web site found at www pro dexOMS
39. ers and system Attach the STEP outputs from the controller to the STEP inputs on the stepper driver Do the same for DIR signals Next connect an external power supply which is OFF to the stepper driver Again refer to the manufacturer s manual for instructions Note that power supply requirements differ from driver to driver Once all wire connections have been made power can be restored to your system It is recommended that you bring the controller board up first so it is in a known state and then apply power to the stepper driver Refer to Figure 2 6 for an example wiring diagram of OMS MAXnet connected to a stepper driver on the X axis Using your communication terminal connected to the MAXnet to send a JG100 command The X axis motor should step at a rate of 100 steps per second 24 Vdc DRIVER Vi 5V GROUND DIRECTION DIRECTION AUXILIARY AUXILIARY INPUT Figure 2 6 Example of Wiring Diagram of MAXnet Controller Connected to a Stepper Driver Motor MAXnet User s Manual 2 7 GETTING STARTED CONNECT AND CHECKOUT THE SERVO SYSTEM 24 Vdc IOMAXnet DRIVER Vi GROUND DIRECTION DIRECTION AUXILIARY AUXILIARY INPUT Figure 2 7 Example of Wiring Diagram of MAXnet Controller via the IOMAXnet Interface Module Analog Input IOMAXnet Analog Ground SERVO MOTOR Han rov3nNviNW 33S ENCODER Figure 2 8 Example of Wiring Diagram of MAXnet Controller v
40. fications except as specifically stated in writing by Seller and contained in the contract MAXnet User s Manual LIMITED WARRANTY APPENDIX A This page intentionally left blank MAXnet User s Manual APPENDIX B TECHNICAL SUPPORT Pro Dex Inc Oregon Micro Systems can be reached for technical support by any of the following methods 1 Internet E Mail mailto support pro dex com 2 World Wide Web http www pro dexOMS com 3 Telephone 8 00 a m 5 00 p m Pacific Standard Time 503 629 8081 or 800 707 8111 4 Facsimile 24 Hours 503 629 0688 5 USPS Pro Dex Inc Oregon Micro Systems 15201 NW Greenbrier Parkway B 1 Ridgeview Beaverton OR 97006 RETURN FOR REPAIRS Call Pro Dex Inc Oregon Micro Systems Customer Service at 503 629 8081 or 800 707 8111 or E Mail to mailto salesor pro dex com Explain the problem and we may be able to solve it on the phone If not we will give you a Return Materials Authorization RMA number Mark the RMA number on the shipping label packing slip and other paper work accompanying the return We cannot accept returns without an RMA number Please be sure to enclose a packing slip with the RMA number serial number of the equipment reason for return and the name and telephone number of the person we should contact if we have further questions Pack the equipment in a solid cardboard box secured with packing material Ship prepaid and insured to PRO DEX INC O
41. g of a single ACK character TABLE 2 2 ETHERNET CONNECTOR J8 Pin out Pin Signal Function 1 BI Bi directional pair A 2 BI DA Bi directional pair A 3 Bi directional pair 4 BI DC Bi directional pair C 5 BI DC Bi directional pair C 6 BI DB Bi directional pair B 7 BI DD Bi directional pair D 8 BI DD Bi directional pair D TABLE 2 3 RS232 CONNECTOR J6 Pin out Pin Signal Function 1 No Connect 2 RXD Receive Data 3 TXD Transmit Data 4 No Connect 5 Ground Ground 6 No Connect 7 RTS Request to Send 8 CTS Clear to Send 9 No Connect 2 3 CONFIGURING THE CARD FOR USE WITH ENCODERS Quadrature encoder with TTL level outputs can be connected directly to the appropriate axis via the J2 connector on IOMAXnet The MAXnet has biasing to allow single ended encoders for each axis board This biasing is automatic Single ended encoders should be wired to the positive connections of each signal The negative side of the differential signal should be connected to ground MAXnet User s Manual 2 3 GETTING STARTED CONFIGURING THE CARD FOR USE WITH ENCODERS All dimensions are in inches 1 unless otherwise specified 0 1255 6 50 0 1255 7 0 1255 0 1255 0 140 Dan s 0 120 0 140 FIGURE 2 2
42. gs to notify the host when status flags are set The flag notification string will consist of an ASCII string of the form 96000 55555555 Where RS 232 AND TCP IP FLAG NOTIFICATION PROTOCOL RS 232 AND TCP IP FLAG NOTIFICATION character indicates that numeric data follows The 000 code indicates that the following numeric data contains status flag information The SSSSSSSS represents 8 ASCII characters that present the contents of the MAXnet style status flag word as hexadecimal digits Status flag information is bit encoded as follows Axis done notification flags X DONE FLAG 0x00000001 Y DONE FLAG 0x00000002 Z DONE FLAG 0x00000004 T DONE FLAG 0x00000008 U DONE FLAG 0x00000010 V DONE FLAG 0x00000020 R DONE FLAG 0x00000040 S DONE FLAG 0x00000080 W DONE FLAG 0x02000000 K DONE FLAG 0x04000000 Axis over travel limit notification flags X LIMIT FLAG 0x00000100 Y LIMIT FLAG 0x00000200 Z LIMIT FLAG 0x00000400 T LIMIT FLAG 0x00000800 U LIMIT FLAG 0x00001000 V LIMIT FLAG 0x00002000 R LIMIT FLAG 0x00004000 LIMIT FLAG 0x00008000 W LIMIT FLAG 0x08000000 K LIMIT FLAG 0x10000000 Axis encoder slip notification flags X SLIP FLAG 0x00010000 Y SLIP FLAG 0x00020000 Z SLIP FLAG 0x00040000 T SLIP FLAG 0x00080000 U SLIP FLAG 0x00100000 V SLIP FLAG 0x00200000 R SLIP FLAG 0x00400000 S SLIP FLAG 0x00800000 W SLIP FLAG 0x20000000 K SLIP FLAG 0x40000000 Command error flag
43. he encoder for this logic to function properly It may be necessary with some encoders to shift the phase of this quadrant by inverting one or both of the phases Inverting one phase or swapping Phase A for Phase B will also reverse the direction The encoder counter read by a RE PE commands must increase for positive moves or the system will oscillate due to positive feedback For other options please contact OMS Technical Support 4 6 MAXnet User s Manual HOME PROCEDURES CONTROL SIGNAL INTERFACE Home Switch Phase A Phase B Index FIGURE 4 5 ENCODER HOMING STATE DETECTION Ground FIGURE 4 6 ENCODER WIRING DIAGRAM FOR SINGLE ENDED INPUT SIGNALS MAXnet User s Manual CONTROL SIGNAL INTERFACE ABSOLUTE ENCODERS WITH SSI 4 9 ABSOLUTE ENCODERS WITH SSI The MAXnet comes with two axes of configurable absolute encoders with SSI Synchronous Serial Interface technology By default the X and Y axes will have up to 12 bits of resolution of absolute encoding The MAXnet can have up to 10 axes of absolute encoders and up to 32 bits of resolution per axis The MAXnet provides a differential clock output through the 1 0 port on the MAXnet board to deliver clocking to an absolute encoder With the MAXnet expansion board for 6 10 axes of absolute encoding the differential clocking is provided out of the index signal outputs The clocking can be configured for the following freque
44. hin it at any time without notice and without obligation to notify any person of such revision or change 3301 1800000 Rev E TABLE OF CONTENTS TABLE OF CONTENTS 1 GENERAUDESCRIPTIONI o Da theta 1 1 1 1 INTRODUGTION i Ree no i 1 1 1 2 SYSTEM OVERVY IEW a t eret Pe Fase 1 1 2 3SETTING STARTED RU UA EON dE 2 1 2 1 INSTALLATION ct pert edere e 2 1 2 CONFIGURING COMMUNICATION eeeeeenern 2 1 2 3 CONFIGURING THE CARD FOR USE WITH ENCODERS 2 3 2 4 SOFTWARE 2 6 2 5 CONNECT TO STEPPER MOTOR 5 2 6 2 6 CONNECT AND CHECKOUT THE SERVO SYSTEM 2 9 2 7 CONNECT AND CONFIGURE THE MOTOR AMPLIFIER 2 9 2 8 TUNESTHE SYSTEMSs eed ett e ee ene 2 11 2 9 SETTING THE USER DEFAULT CONFIGURATION 2 17 2 10 POWER SUPPLY 2 18 3 COMMUNICATION INTERFACE eerte 3 1 3 1 INTRODUCTION tia eaten e tee oves et Lisa 3 1 3 2 RS 232 AND TCP IP FLAG NOTIFICATION PROTOCOL 3 2 3 3 ASCII COMMAND RING 3 3 3 4 ASCII RESPONSE RING
45. ia the IOMAXnet Interface Module to Servo Motor 2 8 MAXnet User s Manual CONNECT AND CHECKOUT THE SERVO SYSTEM GETTING STARTED 2 6 CONNECT AND CHECKOUT THE SERVO SYSTEM Servo systems tend not to respond gracefully to connection errors You can reduce the chance of making connection errors by following a step by step procedure Caution The servo motor may jump or spin at a very high velocity during connection and configuration The motor should be restrained by some means before beginning this procedure Keep hands and clothing clear of the motor and any mechanical assemblies while performing this procedure It is recommended that the motor shaft not be connected to the physical system until you are sure you have control over the motor 2 7 CONNECT AND CONFIGURE THE MOTOR AMPLIFIER 1 Connect and configure your amplifier per the manufacturer s instructions for Torque or Open Loop mode 2 With the motor and amplifier power turned off connect the MAXnet to the amplifier 3 Balance your motor a Configure the axis as a servo axis by sending the PSM command b Using a voltage meter verify that the command signal from the MAXnet is less than 500mV If it is not send the command to the MAXnet and recheck the voltage If the voltage is still too high contact Pro Dex Oregon Micro Systems Technical Support department for guidance Turn on power to the amplifier and then to the moto
46. id for the MAXnet controller specified Signature packet re sent successfully This message indicates the last packet with a valid firmware signature has been successfully sent to the controller flash memory Upgrading flash with filename MAXnSupg has determined that the controller is ready to start the upgrade MAXnet User s Manual MAXnet SERIAL MODE FIRMWARE UPGRADE FIRMWARE UPGRADE 8 2 MAXnet SERIAL MODE FIRMWARE UPGRADE Files Required MAXnSupg EXE Host executable that does the firmware upgrade via RS232 MAXn BIN The default new controller firmware file maxn uldr hex Controller firmware for assisting MAXnSupg This file is only required if no firmware is running on controller when maxnsupg is executed This can occur when an attempt to do a firmware upgrade has failed or has been interrupted before completion MAXnSupg command line parameters b n n specifies the RS232 baud rate default is 115200 valid is 9600 19200 38400 57600 or 115200 p n n specifies the number of the RS232 Comm port the controller is connected to default is 1 valid is 1 32 f n n specifies controller firmware filename default is maxn bin h for help display a usage line no default Description of operation MAXnSupg will verify the existence and the validity of the firmware upgrade file prior to sending any commands to the controller to erase or program flash MAXnSupg determines whether there is firmware
47. ill negative contact OMS Technical Support for assistance 6 Repeat from step 1 for the other servo axes 7 Remember to set KO for each axis at every power up unless you store the values in Flash NOTE Most encoder problems are caused by lack of power or incorrect connections If the encoder position changes by only 1 count this is an indication that one of the phases is not connected Do not proceed until you perform all the steps in this procedure ensure that the outputs of the MAXnet are as described and ensure that the encoder is operating correctly Do not proceed until you perform all the steps in this procedure ensure that the outputs of the MAXnet are as described and ensure that the encoder is operating correctly 2 10 MAXnet User s Manual TUNE THE SYSTEM GETTING STARTED 2 8 TUNE THE SYSTEM 2 8 1 INTRODUCTION The following is an introduction to the basics of tuning a servo motor Tuning a servo system is the process of balancing three primary gain values Proportional Integral and Derivative in order to achieve optimum system performance In a closed loop system an error signal is derived from the command position and actual position amplified and then supplied to the motor to correct any error If a system is to compensate for infinitely small errors the gain of the amplifier needs to be infinite Real world amplifiers do not possess infinite gain therefore there is some minimal error which cannot be correct
48. ler to enter Upgrade Mode This message indicates that MAXnSupg has requested that the controller enter upgrade mode but the controller has not yet indicated that is in upgrade mode MAXnet User s Manual 8 7 FIRMWARE UPGRADE MAXnet SERIAL MODE FIRMWARE UPGRADE INFO messages Application Running Maxnsupg has determined that an application is running on the MAXnet controller Erasing n flash bytes success This message indicates that n flash bytes has successfully been erased Invalid upgrade file for MAXnet serial number This message indicates that the upgrade file s serial number entry did not match the controller s serial number or a CRC error was detected MAXnSupg Version n nn Displays the current version of the MAXnet firmware upgrade utility RESTARTING with new firmware This message indicates that the firmware upgrade was successful and MAXnSupg has sent a command to the controller to restart This will start the controller running with the new upgraded firmware Sending nnn packets This message indicates how many packets are going to be sent to the controller flash when sending the new firmware to the controller Serial Number verified This message indicates that the upgrade file had a Serial Number lock installed and it was successfully verified that the specified upgrade file was valid for the MAXnet controller specified Signature packet re sent successfully This message indicates the last packet with
49. ling Home switch inputs TTL input levels Input sense low or high true selectable by command input for each axis Accuracy to 1 encoder count User definable I O Up to 16 bits of user definable digital I O The 16 bits are user configurable and are configured as 4 inputs and 4 outputs on Analog inputs Two independent analog inputs 16 bit resolution 10V Analog outputs servo 10V and 0 to 10v max One per axis plus two general purpose all are 16 bit resolution Step pulse output Pulse width 50 duty cycle Open collector TTL level signal Direction output Open collector level signal TTL MAXnet User s Manual SPECIFICATIONS Encoder Feedback Maximum 16 MHz after 4x quadrature detection Differential or single ended signals Two channels of 12 bit Absolute SSI encoder channels by default optional 32 bit absolute encoders available for each axis Ethernet TCP IP Standard RJ45 connector RS 232 Baud rate 9600 155 2K Standard 9 pin D Sub connector SPECIFICATIONS APPENDIX C FEATURES Ethernet or RS232 Communications TCP IP Standard RJ45 connector Baud rate range 9600 115200 PID update Rate of 122 us on all 10 axes Delivers exceptional servo control on multi axis applications Identical outcomes when utilizing one or all axes of motion Configurable PID filter with feedforward coefficients 266 MHz 32 bit RISC processor Updates all signals and data points pro
50. mmand i e VL AC etc To restore the factory defaults the command RDF is executed The RDF command does not restore communication parameters IP address port number and serial baud rate to factory default To restore the User Defined Default Parameters the command RDP is executed The following is a partial list of parameters that can be defined as part of the User Definable Power Up Default Parameters Over travel limit soft limit or hard limit Factory Default Hard limit Over travel limit enabled or disabled Factory Default Enabled Over travel limit polarity active high or active low Factory Default active low Software based over travel for each axis Factory Default disabled Direction Bit polarity Factory Default non inverted normal Acceleration value for each axis Factory Default 2 000 000 Trajectory profile for each axis linear parabolic S curve custom Factory Default Linear Velocity Peak Factory Default 200 000 Velocity Base Factory Default 0 User Unit values for each axis Factory Default Off Auxiliary output settle time for each axis Factory Default 0 Automatic auxiliary control axis by axis Factory Default Off Encoder Ratio for each axis Factory Default 1 1 Encoder Slip tolerance for each axis Used for stepper motors Factory Default 0 Home Active Factory Default Low Position Maintenance Dead Band Hold Gain and Hold Velocity Used for stepper systems Factory Def
51. nality can be set for the axis to decelerate to a stop or to stop without deceleration when a limit condition occurs See Command Reference Manual MAX Family www pro dexOMS com LM and LT commands 4 3 HOME INPUTS To facilitate positioning of an axis to a known reference position a TTL home input is provided for each axis For axes using an encoder the home input can be used in conjunction with the index signal of the encoder The logic of the encoder signals Phase A Phase B Index that constitute a true home condition is programmable Refer to Figure 4 3 Reference Command Reference Manual MAX Family www pro dexOMS com EH HM HR HT KM and KR commands 4 4 GENERAL PURPOSE DIGITAL I O There are up to 16 general purpose digital lines that can be individually configured as either a TTL input or an active drive TTL output Commands are provided for setting the I O direction of the lines setting the state of the outputs and reading the current state of the I O lines Inputs can be used to control loops qualify motion or signal an event Reference Command Reference Manual MAX Family www pro dexOMS com BD BH BL BW BX IOK and SW commands 4 5 ANALOG I O 4 5 1 ANALOG INPUTS Up to 4 general purpose analog inputs are available to read 10V values via 16 bit analog to digital converters These can be used to provide input from analog sensors to application software Analog inputs can also be configured to provide
52. ncies 31 250Hz 62 500Hz 125 000Hz 250 000HGz 500 000Hz 1MHz 2MHz and 4MHz On the MAXnet board with I O 0 7 available typical use of absolute encoders require that clock and clock be configured from the X Axis through I O 0 1 Y Axis through I O 2 3 Z Axis through 4 5 and T Axis through I O 6 7 For the U axis clocking would also be configured from a clock signal set through I O 0 7 This requires that the clocking be shared between the U axis and another axis if more than four axes of absolute encoding are needed Absolute encoders sharing the same I O output clocks have the requirement that the clock frequency is the same and the bits resolution is the same On the MAXnet expansion board the clock and clock signals are provided via the index and index signals for each axis not the I O ports Thus there is no sharing of clocks needed or a same frequency requirement between absolute encoders 4 9 1 CONFIGURATION EXAMPLES The following are two examples on how to configure the MAXnet for absolute encoding The first case is the standard MAXnet with two absolute encoders with up to 12 bits resolution For this example the X axis is 12 bits resolution with a clock frequency at 125 000Hz and the Y axis is 9 bits resolution with a clock frequency of 250 000Hz AX PSE ECA12 125000 AY PSE ECA9 250000 The second example calls for five absolute encoders two axes at 16 bits resolution with a clock frequency of 1
53. of the upgrade file to the flash 8 6 MAXnet User s Manual MAXnet SERIAL MODE FIRMWARE UPGRADE FIRMWARE UPGRADE Flash verify failure on packet ppp The controller did not accept the upgrade packet number ppp due to a flash verify failure Flash write failure on packet ppp The controller did not accept the upgrade packet number ppp due to a flash write failure Invalid baud rate selection The parameter supplied with the B command line option was not valid The valid baud rates are 9600 19200 38400 57600 or 115200 Invalid command line option The character following a character on the command line was not one of the valid command line options Valid options are B E F H or P Invalid serial comm port selection The parameter supplied with the P command line option was not valid The valid range is 1 32 Invalid upgrade file for MAXnet serial number nnnnnn An upgrade file with a serial number lock installed did not match the MAXnet controller found Invalid upgrade file signature The upgrade file did not have the required signature of a valid upgrade file Unknown failure on packet ppp The controller did not accept the upgrade packet number ppp due to some unknown failure Upgrade File Seek Error An error occurred trying to access the upgrade file WAIT message NOTE messages preceded with WAIT will be displayed continuously until the condition indicated is met Waiting for Control
54. optimum velocity profile to reach the desired destination in the minimum time while conforming to the programmed acceleration and velocity parameters In addition the MAXnet can provide motion control information such as axis and encoder position as well as the state of over travel limits home switch inputs and done notification flags The MAXnet motion controllers utilize a PowerPC processor configured to operate as an efficient and powerful co processor with the PC host via the Ethernet or RS 232 The stepper control of the MAXnet produces a 50 duty cycle square wave step pulse at velocities of 0 to 4 194 176 pulses per second and an acceleration of 0 to 8 000 000 pulses per second per second The servo control utilizes a 16 bit DAC and outputs either 10V or 0 to 10V The encoder feedback control can be used as feedback for the servo PID position maintenance for the stepper axes or as strictly a position feedback of any axis The incremental encoder input supports differential or single ended quadrature TTL signals at a rate of up to 16 MHz The absolute encoder using SSI Synchronous Serial Interface technology also supports differential or single ended inputs at a rate up to 4MHz The MAXnet motion controller has 2 general purpose analog inputs that utilize a 16 bit ADC with DC range of 10 to 10 VDC There are six analog outputs that utilize a 16 bit DAC with a range of 10 to 10 VDC Complete specifications for MAXnet can be found in
55. pose analog output that uses a 16 bit resolution DAC with 10 VDC output Each axis has servo output signal capability configured as a 10V or 0 10V signal and is driven by a 16 bit DAC The servo control loop is a PID filter with feedforward coefficients and an update rate up to 122us The servo output of axes not configured as a servo axis is available as a general purpose analog output The step pulse is a TTL level 5096 duty cycle square wave that supports velocities of O through 4 194 176 pulses per second Encoder feedback functionality supports quadrature encoders up to 16 MHz and is used as the servo feedback as feedback for the stepper axes MAXnet User s Manual SPECIFICATIONS APPENDIX C SPECIFICATIONS or as independent position feedback Encoder feedback is also used to provide slip and or stall detection The MAXnet has many user definable parameters that customize the controller s behavior These parameters can be conveniently stored in Flash so that the user defined behavior will be automatically preset at each power up PROGRAMMING MAXnet motion controllers easily programmed with ASCII character commands through an extensive command structure These commands are combined into character strings to create sophisticated motion profiles with features of I O and other functionality A separate FIFO command queue for each axis is used to store the commands once they are parsed by the MAXnet
56. r d Adjust the balance setting of your amplifier if equipped until the motor stops moving e Ifthe motor continues to revolve or your amplifier has no balance adjustment i Send the command KO100 to the MAXnet ii If the motor spins faster reduce the command parameter and resend the command e g KO50 iii If the motor spins slower but does not stop increase the command parameter and resend the command e g KO150 iv Continue adjusting and resending the KO command until the motor comes to rest Write down the final KO value for later reference as your zero setting 4 Maximize your system s usage of the MAXnet s DAC this method works only with incremental encoders skip it if you use absolute encoder only on that axis MAXnet User s Manual 2 9 GETTING STARTED TUNE THE SYSTEM h Connect the servo encoder to the MAXnet See section 4 4 on incremental encoder feedback Set the signal command gain of your amplifier to its minimum setting Send the KO3277 command to MAXnet and observe the velocity of the motor The output of MAXnet will be near 1VDC If the motor does not move at all your amplifier does not work well at a low velocity In this case adjust the signal command gain of the amplifier to approximately 20 of maximum or until the motor begins to move Using a frequency meter measure the pulse rate of Phase A of the encoder The frequency measured is of the actual pulse rate
57. r Amplifier Error i e Position FIGURE 2 14 FEEDBACK LOOP MAXnet User s Manual 2 15 GETTING STARTED SETTING THE USER DEFAULT CONFIGURATION You may want to save the values for KP Kl KD etc for future reference These values can be saved in the board s flash memory so they can be accessed easily on reset or power up This can be done by using the APP command These saved parameters will then be used as the power up default set of values To verify that your motor is tuned properly after you have completed the first 10 steps perform the following test to test the holding torque Send the commands LP0 CL1 and check the shaft of the motor to make sure it is stiff If there is play in the motor shaft when you turn it then you may have to re adjust your PID filter Once you are satisfied with the static holding torque you could check for position error Send the command AC100000 VL5000 MR64000 GO With a 2000 line encoder this move would be equivalent to 8 revolutions of the motor After the move is complete check the position error by sending the RE and RP commands for the specific axis you are moving Compare the difference in the two responses If they are the same then you are on the right track if the error is greater than 32768 the controller will disable the PID so that you don t have a runaway motor In this case major changes to the PID parameters may be required For minor differences in the encoder and the position reading
58. r laser starting the cut at the center of the circle half circle is cut from the center to the outside of the hole positioning the cutting tool at the start of the hole The hole is then cut the torch turned off the stage stopped and the contour definition completed The following would be input from the host computer AA VOAO 5 VV1000 1000 VP0 0 VIO0100 0100 VC0 5000 180 VC0 0 360 VIOO 0100 VV1000 0 VP 1000 0 VE During this sequence the VO command or an analog input may be used to vary the vector velocity from 0 200 of the program vector velocity SPECIFICATIONS Velocity 0 to 4 194 176 pulses per second Acceleration 0 to 8 000 000 pulses per second Position range 4 294 967 295 pulses 2 147 487 647 MAXnet User s Manual APPENDIX C Accuracy Position accuracy and repeatability 0 counts for point to point moves Environmental Operating temperature range 0 to 50 C Storage temperature range 20 to 85 C Humidity O to 9096 non condensing Power 5VDC 5 at 1 amp typical 12VDC at 0 1 amp typical 5 12VDC at 0 1 amp typical 5 Dimensions 6 5 x 4 x 0 75 Limit switch inputs TTL input levels Active low or high true selectable by command input for each axis active low is default Connector One shielded 100 Pin SCSI type connector for all control signals motor control I O Lmits etc Breakout board available for ease of cab
59. r would be put in the stand alone mode SXM1 and the execution of the macros is then controlled by the defined input bits There are no queue requirements for these commands MAXnet User s Manual 6 1 STAND ALONE COMMANDS This page intentionally left blank 6 2 MAXnet User s Manual SERVICE 7 SERVICE 7 1 USER SERVICE The MAXnet family of controllers contain no user serviceable parts 7 2 THEORY OF OPERATION The MAXnet controller uses a PowerPC microprocessor for the core of its design The highest priority process calculates the desired velocity at the selected update rate with a proprietary algorithm patent number 4 734 847 This frequency is written to logic on board which generates the pulses for stepper motor control and or the appropriate voltage levels for Servo Control The velocity profile and synchronization of each axis is also handled by the PowerPC The commands from the host computer are temporarily stored in a character buffer until the MAXnet can parse them The command is then executed immediately or routed to separate command queues for each axis The command queue contains a list of addresses to execute The argument queue stores the parameters as applicable supplied with each command for the axis A command from the host may be expanded into several commands to the appropriate axis The GO command for example will expand into start ramp up constant velocity and ramp down commands The LS command will
60. ring the desired single axis command such as AX PROGRAMMING EXAMPLES In a typical move requirement where it is desired to home the stage then move to a specified position the following will demonstrate the programming for a single axis e Initialize the velocity and acceleration parameters to a suitable value Set a PID filter gain values Enable the PID hold mode Perform the home operation initializing the position counter to zero Perform a motion to an absolute position of 10 000 and set the done flag for that axis when the move is finished The following would be input from the host computer AX VL5000 AC50000 KP20 45 HMO MA10000 GO ID In a move requiring a three axis coordinated move to a select position the following commands could be used AM VL5000 5000 5000 AC50000 50000 50000 MT1000 2000 3000 GO ID The controller would calculate the relative velocities required to perform a straight line APPENDIX C move from the current position to the desired absolute position so that all axes arrive at their destinations at the same time The following demonstrates cutting a hole with a 10 000 count radius using variable velocity contouring with circular interpolation e The vector velocity is set to 1000 counts per second A contour is defined beginning at coordinates 0 0 on the X and Y axes e General purpose l O7 is turned on which could turn on the cutting torch o
61. ro position KO is the offset coefficient used while in closed loop or open loop mode hold on HN You should have determined the correct value the KO variable before beginning to tune the PID filter The values for KO range from 32640 to 32640 Set the known values for velocity acceleration and the move distance for a trapezoidal profile with at least a 20 flat spot at peak velocity Formula Profile distance peak velocity 2 2xacceleration x2 4 Example 50 000 2 2x500 000 x2 4 6 000 Execute the move by sending the move commands to the MAXnet Example MR6000 GO Adjust the KP term while repeating step 3 until the Following Error at the flat spot of the profile is acceptable If the motor becomes unstable prior to obtaining the optimum KP term then increase the KD term until the motor stabilizes Example LPO 2 12 MAXnet User s Manual TUNE THE SYSTEM GETTING STARTED CL1 MR6000 GO LPO KP25 HN MR6000 GO LPO KD100 CL1 LPO KP35 CL1 MR6000 GO LPO KD125 CL1 The values in the above example are totally arbitrary and may vary drastically with different systems The LPO command is used to set the position error to 0 The values for KP range from 10 500 Once the KP term has been obtained continue executing the motion while rising the KI term until the long term Following Error is acceptable This error can be measured at the two knees of the motion profile Increa
62. ructions found in README TXT or README DOC The instructions will show you how to properly install the appropriate DLL To begin communicating with the MAXnet systems that require console application can run the MAXnEcom exe Ethernet or MAXnScom exe RS 232 utility Systems that prefer GUI applications can run OMSuite exe You can begin interactively sending commands and receiving responses immediately if all has been properly installed If the board has been configured with something other than the default communication parameters then the appropriate command line switches need to be entered along with the command For example MAXnEcom I IP Address P port number or MAXnScom b baud rate P comm port or OMSuite exe Select the communication parameters from the Boards drop down menu Type WY and observe the response from the MAXnet If you are communicating to the MAXnet it would return its version number number of axes FPGA version number etc You should receive a reply similar to MAXn 5000 Ver x xx S N 000001 FPGA 20 from the MAXnet If you receive nothing double check that the MAXnet communication and power cables are firmly seated and that communications have been properly configured see Section 2 2 For technical support refer to Appendix B for contact information 2 5 CONNECT TO STEPPER MOTOR SYSTEM The MAXnet control signals are located on the J1 connector This section will explain how
63. save its parameter in the argument queue the loop count on a loop stack along with the address of the LS command to be used by the next LE command as a target for a jump command are stored in the command queue The LE command will decrement the loop count and jump to the most recent LS command providing the loop count has not reached zero If the loop count has reached zero and it is not nested inside another loop the queue space will be flagged as available and the next instruction in the queue will be executed The communication interface is performed by the MAXnet microprocessor MAXnet User s Manual 7 1 SERVICE This page intentionally left blank 7 2 MAXnet User s Manual MAXnet ETHERNET MODE FIRMWARE UPGRADE FIRMWARE UPGRADE 8 FIRMWARE UPGRADE CAUTION The firmware upgrade utility erases the flash memory of the controller during the upgrade process While every precaution has been taken to recover from any failures the customer should also take every precaution to provide a stable environment for the upgrade process in order to minimize the chance of an irrecoverable error that would require the board to be sent back to the factory 8 1 MAXnet ETHERNET MODE FIRMWARE UPGRADE Files Required MAXnEupg EXE Host executable that does the firmware upgrade via Ethernet MAXn BIN The default new controller firmware file MAXnEupg command line parameters i n n n n n n n n specifies the controller s IP address defa
64. sing the KI term increases the response time of your system The motion profile should also have a steeper slope as Kl increases See Figure 2 9 and 2 10 below However as KI increases the system can also become unstable When the instability becomes unacceptable increase the KD parameter This will increase the dampening on the system s motion profile therefore reducing oscillation or ringing Continue adjusting the KD terms until the proper response time is obtained The values for KI range from 0 1 to 20 FIGURE 2 09 If you are getting too much ringing in the motion profile then increase KD to help dampen the system s response f instead the system is over damped and is reaching the final velocity too MAXnet User s Manual 2 13 GETTING STARTED TUNE THE SYSTEM slowly then reduce the KD parameter Optimally the system s motion profile should show the motor reaching the desired velocity as quickly as possible without overshoot and oscillation ringing The values for KD range from 10 100 Desired Step Response Too Much KD FIGURE 2 10 Desired Step Response Too Little KD FIGURE 2 11 KP Kl and KD are the primary parameters of concern when tuning a servo system Once the optimum values for these variables have been determined you can adjust some of the secondary parameters that will help fine tune your system s performance These other variables are described in the subsequent steps
65. tage is intended to be utilized with accessories used in conjunction with the MAXnet such as sensors motor driver modules etc and supports a maximum current of 0 5 amps for these purposes 4 10 TABLE 4 2 IOMAXnet Terminal Block Pin Out Pin Signal Pin Signal Pin Signal 1 X V Phase A 35 T W Aux 69 Y Negative Limit 2 X V Phase A 36 U K Aux 70 215 Negative Limit 3 X1 V Phase B 71 T W Negative Limit 4 X V Phase B 100 108 72 U Negative Limit 5 X V Index 39 102 1010 73 GROUND 6 X V Index 40 104 1012 74 X V Direction 7 218 Phase A 41 106 1014 75 Y R Direction 8 218 Phase A GROUND Z 15 Direction 9 Z S Phase B ADC 0 ADC 2 GROUND 10 218 Phase B GROUND T W Direction 11 218 Index X V Servo U K Direction 12 218 Index GROUND GROUND 13 U K Phase A Z S Servo X V Step 14 U K Phase A Y R Step 15 U K Phase U K Servo 215 Step 16 U K Phase B GROUND GROUND 17 ROUND Y RPhase A T W Step 18 X V Positive Limit 52 Y R Phase A 86 U KStep 19 Y R Positive Limit 53 Y R Phase B 87 GROUND 20 Z S Positive Limit 54 Y LR Phase B 88 101 109 21 T W Positive Limit 55 Y Index 89 103 1011 U K Positive Limit Y R Index 90 105 1013 GROUND 91 107 1015
66. tions Note that the header at location J2 is used to choose the mode of communication Ethernet or RS 232 The MAXnet is set for RS 232 communication mode from the factory Though the MAXnet is a low power device there should be ventilation including forced air around the circuit board 2 2 CONFIGURING COMMUNICATION The first requirement for communication through the RS 232 interface is to ensure that the MAXnet is securely and safely mounted where damage is unlikely This includes the exposure to possible static discharge moisture debris etc Special mounting efforts may be required to protect the extended pins on the bottom of the MAXnet CAUTION The MAXnet is a static sensitive device and standard Electro Static Discharge ESD techniques are required when handling and installing the MAXnet The RS 232 communication port is a DTE com device so that straight connection can be used for communication RxD to TxD TxD to RxD Two handshake signals are supported CTS and RTS that can also be connected straight through baud rates of 9600 19200 38400 57600 and 115200 are supported Any terminal device that supports these signals and baud rates be it a computer dumb terminal etc can be used to communicate to the MAXnet TABLE 2 1 MAXNET DEFAULT SERIAL COMMUNICATION PARAMETERS Default Baud Rate 115200 Data Length 8 Stop Bits 1 Parity Bit None Select an unused COM Port COM1 COM2
67. ture feature The MAXnet controller has a ring buffer in VME shared memory which is used to transfer the real time position capture data to the host When a capture event is recorded by the motor update cycle routine it transfers the capture table entry to the shared VME memory The host is signaled that the data is available via bit number 8 or hexadecimal value 0x00000100 in the controller status word 2 register at offset address Ox00000FC8 data available bit is also available at byte offset 0 00000 and bit number 0 or 0x01 The shared memory for the capture data is implemented as a ring buffer with an insert index that the controller uses to insert data into the shared memory region and a removal index that the host uses to remove data from shared memory region The controller places the capture data into the ring buffer at the location specified by the insert index and advances the insert index If after being advanced the insert index equals the removal index then the controller also advances the removal index If the controller has to advance the removal index this means that the host is not removing data fast enough and capture data was lost by the host The capture data is available in the shared VME memory at offset addresses 0xD94 through OxFBB The format of the capture table data in shared VME memory is defined in table 1 5 below TABLE 3 1 Real Time Position Capture VME Shared Memory Word Access Offset 0xD94
68. ty and sending a WY command to the controller The WY response should indicate the version number of the upgraded firmware If MAXnEupg encounters an error that will not allow it continue it will either abort the program or continuously retry until the error no longer occurs In the case of a continuous error that does not clear the user can abort by entering Control C holding down the Ctrl key and pressing C Unless specified via a command line option The default upgrade file name is maxn bin The default IP address is 10 40 30 61 The default TCP IP port selection number is 23 Examples Description MAXnEupg upgrades flash of the controller using maxn bin MAXnEupg 1 10 40 30 62 upgrades flash of the controller using an IP address of 10 40 30 62 MAXnEupg f newmaxn bin upgrades using newmaxn bin file MAXnEupg p 22 upgrades flash using port 22 MAXnEupg h will display a help message Error messages A connection could not be established with IP address nn and port number pp The specified IP address or port number would not allow a connection to the controller Cannot get file handle filename A problem occurred trying to open the upgrade file named filename Controller ID query failed The controller did not respond to a WY query The upgrade will be aborted Controller is not responding The controller did not respond to a WY query The upgrade will be aborted Could not
69. ult is 10 40 30 61 p n n specifies the controller s TCP IP port number default is 23 valid is 1 65535 f n n specifies controller firmware filename default is maxn bin h for help display an usage line no default Description of operation MAXnEupg will verify the existence and the validity of the firmware upgrade file prior to sending any commands to the controller to erase or program flash MAXnEupg determines whether there is firmware currently executing on the MAXnet controller If firmware is currently executing then MAXnEupg proceeds to the next step of the upgrade process Otherwise MAXnEupg will report the error and exit flash code blocks are erased If a failure occurs erasing flash the program is aborted The firmware file is sent to the controller and the controller programs the flash to the flash code blocks Firmware is sent in packets If any single packet has a transmission error it will be resent until the transmission is successful or the user aborts the upgrade program MAXnet User s Manual 8 1 FIRMWARE UPGRADE MAXnet ETHERNET MODE FIRMWARE UPGRADE The first code block is re written with a valid MAXnet signature so that the boot block will recognize that valid firmware is loaded in the flash A restart command is sent to the controller causing the controller to re boot with the new firmware Verify that the controller is running the new firmware by running the MAXnEcom utili
70. viding superior application control Controller I O Capabilities Each axis has Limit Limit Home Auxiliary out and axis control out 16 General purpose bi directional TTL I O 2 General purpose analog output with 16 bit 10 VDC input in addition to axes output 4 Channels of general purpose analog input with 16 bit 10 VDC Motion Feedback Each axis had an incremental encoder input Quadrature Encoder Feedback up to 16 MHz on all encoder inputs Two 12 bit Absolute SSI encoders by default optional 32 bit Absolute encoders available on each axis Sophisticated Control Functionality 16 bit DAC analog resolution Step pulses from 0 to 4 194 303 steps per second 0 steps Backlash compensation Custom parabolic S Curve amp Linear trajectory profiles Real time encoder position capture S Curve with 4 quadrant jerk parameters Control Signals Two 100 pin SCSI type connectors for high density signal connection 16 user definable digital I O Analog out per each axis can be used as general purpose when axis is configured for Step control MAXnet User s Manual APPENDIX C TABLE 8 1 SPECIFICATIONS 100 PIN CONNECTOR MAXNET AND TERMINAL BLOCK Pin Out IOMAXnet Pin Signal Pin Signal Pin Signal
71. ws a MAXnet Motion Controller to run in a completely independent operation mode when powered by a separate 5 VDC power supply and 12 VDC for servos This mode has several commands that can establish links to macros When set up properly in this mode the MAXnet can scan for a predefined Input bit until it changes to the specified state Upon sensing that this condition has been met it will execute the permanent Macro from Non volatile flash memory that had been previously associated or linked with this I O bit and its state See Command Reference Manual MAX Family for details about macro programming A common application the stand alone mode is to incorporate the KILL KL function Reference the SXK command This will allow the user to stop motion of the device All of these selections are temporary They can be made permanent by executing the APP command which assigns the current parameter values as the Power Up defaults Note The APP command should be used sparingly as it causes a write to the on board Flash Memory and there is a finite amount of times that it can be re written to i e less than 1 000 000 times typical Application Overview The setup of the stand alone mode is performed through the communication interface by the use of the commands The user would define the required motion and or processes and store them in a macro Once all of the setup is completed the macro has been defined and stored in flash the controlle

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