Home

DMC-41x3 User Manual - Ultra Sistemas de Controle

1. o ES Ww oo s 0 93 E a ol ON og o3 o co O N N OOQ o o Oo Oo A oo 0070 I EE 9008 02 E S I 0 00000000 0 LIILIA SO a Lr e at LO eza S 2 e H ZZe O f0000 SOO n A o o Sooooooog Sox oo TOULNOO NOLON INVO ou lolo lo 8xe8 y ON o 0 6 xv FA m 438 i GOS 96 yt lavdi oc 9G loo 1 loo loo 1 618 7 j paz s is DEE 66e ks o S L 22 o 0000000000 43H OF OL LEG Figure 2 2 DMC 4183 Dimensions The dimensions for the DMC 4153 DMC 4163 DMC 4173 and DMC 4183 all CARD are shown in Figure 2 2 Dimensions are subject to change Contact the Galil factory for current dimensions of all products Chapter 2 Getting Started e 8 DMC 41x3 User Manual DMC 4143 BOXA Dimensions
2. po O O D M C 4 1 83 STEPPER SERVO POWER IM EE m A olo e olo vc 4vs ooo GALIL MOTION CONTROL ASSE BOSI enplooo MADE IN USA RESET m O O EN z E 1 lt m o a w u E x tu I 9 2 g g E g a 8 2 E z z E Pi E E E z E ui 2 E z z Link AcT 5 1 2 Enron 1 1 1 1 1 1 1 1 Power lan TA TN TN EN A A TN co 2 a eee EIL ie EE gt tt JOGGGE JORGE sTs sTaToTs 5 TeTeTeTo s sTeTsTeToTo sTsTeTaTeTs sTsTeTeTeTa lalalalalala ERE EEE s o EEE o EEE EEE EEE 123456 123456 123456 123456 123456 123456 123456 123456 I O A D 1 O E H s V N o Je o je 1 1 ANALOG ENCODER xy 1 0 A D 1 O E H OUTPUTS QAGND FATTO 28M ggg BMA ace 95V Ti Pda cup 2025V OPI SINK DO amp H OPOA GND 10 AIZ AI3 25M0 gr Mit 43007 29008 3 pos 430015 220016 13 DOM AmA OPOB 5 24VDC MATA 4AI5 MAN sae Dx 42004 28005 pos 420012 280013 12 pon SINC DOnS3UOPINZOND 12 AIB BAIT 23AB ris SLSCOM Jipor 27002 tiopea 41009 270010 11 OPIA
3. ini 8 05 1 29 p i 1 tA DMC 41 43 1234 56 STEPPER SERVO POWER oaae avi afoloja afololwe ws ooo LAENSNK QQQP 12V P P M GALIL MOTION CONTROL AAEM SNKIQQQE WIP Aoo Boole ennjooo MADE IN USA LAENSRC P PP Q RESET m M pa 5 O EN F E o 54 E o a D 2 2 2 S g E g 2 g a E z z E Link AcT z 1 2 I ERROR O 1 r 9 Power O O D O a sl VEE e ef 6 75 7 25 ajajajaja alele a a a alale a a a ala a ela Q fofofofafofa Q s a sl a s n Q o ojofa ofa l Q ajofo ofa o 123456 123456 123456 123456 I O A D 1 ANALOG ENCODER I O A D 1 ARXD OUTPUTS 9 AGND 14010 BMA ues SNA uar ta OS ACTS SINK DO amp i ORGA GND QAM SAIS Aa MIO QAM 4300 58008 1 b08 APWR 4mA OPOB 5 24VDC HA AAI Seng 1545 Siscom 42004 28008 12003 OPT AI 14 FLS 41001 11 OP0A AIS GAGNO ZARIS msrP 004 segno 26OPOA 10 HOMD MO HIGH POWER OPTION HP0 danc SAGNO armata ISTP g DIR de GND 25 ALSO 1 HOND a 19 2 SOURCE DO amp OPAA 12 24VDC 152V GEN 20ENBL WHALE 3 AEN M so 24RLSC PHOUE UPGD 500mA OP B GND ISMOMD Gup HALC a7 Figg 23RLSB 7
4. Using External Aunpliberg eiii cmieciocsassiieni 243 A6 SDM 44040 D4040 D4020 244 Dieser Ui iis lla oe Le LEM CL p Lo Up eect 244 LS RO PETI SI eT LEUR 245 Mating Connectors ILL RE ERR TE 246 Current Level Setup AG Command iari 246 Low Current Setting LC Command 246 Step Drive Resolution Setting YA command 246 Protec ton CIG societe 247 RI ciii iio os iit co a ae censoch ioi 247 A7 SDM 44140 D4140 248 Current Level Setup AG Command Low Current Setting LC Command Over Current Protection 250 Under Voltage Protectii oases eee tactis 251 ELO Inptib iaciunt cosas 251 DMC 41x3 Contents viii Chapter 1 Overview Introduction The DMC 41x3 Series are Galil s Econo motion controller that is a scaled down version of the DMC 40x0 Acclerra series controller The controller series offers many enhanced features compared to prior generation Econo series controllers including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 41x3 provides two communication channels a high speed 100BaseT Ethernet connection and a USB programming port There is an auxiliary RS 232 port that can be used to communicate to external devices such as HMI s The controllers allow for high speed servo control up to 15 million encoder counts sec and step motor control
5. HOME SWITCH _HMX 0 _HMX 1 POSITION VELOCITY MOTION BEGINS IN FORWARD DIRECTION POSITION VELOCITY MOTION CHANGES DIRECTION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD INDEX saranno Sela i LU POSITION Figure 6 19 Homing Sequence for Normally Closed Switch and CN 1 INDEX PULSES POSITION Chapter 6 Programming Motion e 121 DMC 41x3 User Manual Example Find Edge EDGE Label AC 2000000 Acceleration rate DC 2000000 Deceleration rate SP 8000 Speed FE Find edge command BG Begin motion AM After complete MG FOUND HOME Send message DP 0 Define position as 0 EN End Command Summary Homing Operation command description FE XYZW Find Edge Routine This routine monitors the Home Input FI XYZW Find Index Routine This routine monitors the Index Input HM XYZW Home Routine This routine combines FE and FI as Described Above SC XYZW Stop Code TS XYZW Tell Status of Switches and Inputs Operand Summary Homing Operation operand Description _HMx Contains the value of the state of the Home Input _SCx Contains stop code _TSx Contains status of switches and inputs High Speed Position Capture The Latch Function Often it is desirable to capture the position precisely for registration applications The DMC 41x3 provides a position latch feature This feature allows the
6. DMC 41x3 User Manual Chapter 6 Programming Motion e 80 Scope tj Vertical Horizontal didt Source Scale div Offset div MU RPAAxiAref v 2000cour 0 E v _RPAAxis Aref 10000 co 2 m vl 2 1 BO 0 221383 0 m 4 42765 m 0 442765 COVANHY l lt P ii p i epe b lt b lh lt gt lt gt lt gt 0 x N Channel W RPA Edge w Level Ocounts gt L 0 221383 i 3 m 0 221383 4 t 150 ms 4 F spe N Trigger wa Mode Repeat v READY RPA didt RPA Figure 6 5 Position and Velocity vs Time msec for Motion 3 with IT 0 1 Note the controller treats the point where the velocity passes through zero as the end of one move and the beginning of another move IT is allowed however it will introduce some time delay Trip Points Most trip points are valid for use while in the position tracking mode There are a few exceptions to this the AM and MC commands may not be used while in this mode It is recommended that AR MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position Command Summary Position Tracking Mode COMMAND DESCRIPTION AC n n n n n n n n Acceleration settings for the specified axes APnnnnnnnn Trip point that holds up program execution until an absolute position has been reached DC n n n n n n n n Deceleration settings for the sp
7. NOTE See Configuring the Amplifier Enable Circuit in Chapter 3 for detailed information J1 Ethernet RJ45 The Ethernet connection is Auto MDIX 100bT 10bT J2 USB The USB port on the DMC 41x3 is a Female Type B USB port The standard cable when communicating to a PC will be a Male Type A Male Type B USB cable J3 RS 232 Auxiliary Port Female Standard connector and cable 9Pin NC 5V with APWR Jumper Appendices e 203 DMC 41x3 User Manual J3 RS 422 Auxiliary Port Non Standard Option Standard connector and cable when DMC 41x3 is ordered with RS 422 Option For detailed information on the RS 422 option see RS 422 Auxiliary Serial Port Serial Communication in the Appendices Pin Signal CTS RXD TXD RTS GND CTS RXD TXD RTS JP1 Jumper Description for DMC 41x3 Label Function If jumpered ARXD RS 422 Option Only Connects a 1200hm Termination resistor between the differential Receive inputs on the Aux Serial port Pins 2 and 7 on RS 422 Auxiliary Port ACTS RS 422 Option Only Connects a 1200hm Termination resistor between the differential Clear To Send inputs on the Aux Serial port Pins 1 and 6 on RS 422 Auxiliary Port APWR Connects 5V to pin 9 on the Aux serial port connector J3 OPT Reserved MO When controller is powered on or reset Amplifier Enable li
8. w Description Hall C Amplifier Enable Direction Home Limit Switch Common A Aux Encoder Input I Index Pulse Input A Main Encoder Input T5V Digital Ground Amp Enable Return Hall B PWM Step Pin Label s we s Ew pe s wow En MB 26 MA oO Description Forward Limit Switch Input B Aux Encoder Input I Index Pulse Input B Main Encoder Input Digital Ground Motor Command Amp Enable Power Hall A Reverse Limit Switch Input B Aux Encoder Input A Aux Encoder Input B Main Encoder Input A Main Encoder Input LSCOMn on JAI JB1 JC1 and JDI is common to LSCOMO on J5 LSCOMn on JEI JF1 JG1 and JH1 is common to LSCOMI on J8 J4 Analog 15 pin D sub Connector Male Pin 1 2 3 4 5 6 F 8 9 fJ AJN Label AGND All AI3 AIS Al7 AGND 12V 5V AGND AD AIA AI6 AI8 N C 12V Description Analog Ground Analog Input 1 Analog Input 3 Analog Input 5 Analog Input 7 Analog Ground 12V 5V Analog Ground Analog Input 2 Analog Input 4 Analog Input 6 Analog Input 8 No Connect 12V DMC 41x3 User Manual Appendices e 202 JPn1 Amplifier Enable Jumper Description for DMC 41x3 Jumper Q and P Function If jumpered Sink Source Selection Sink Source Selection Sink Source Selection HAEN LAEN Selection 5V 12V External Power Selection 5V 12V External Power Selection
9. The operands are used with the XQ command in the following format XQ ED2 or _ED3 ED1 1 Where the 1 at the end of the command line indicates a restart therefore the existing program stack will not be removed when the above format executes The following example shows an error correction routine which uses the operands Example Command Error w Multitasking TA JP A EN B Nes KP N TY EN CMDERR IF TC 6 N 1 XQ _ED2 ED1 1 ENDIF IF TC 1 XQ _ED3 ED1 1 ENDIF EN Begin thread 0 continuous loop End of thread 0 Begin thread 1 Create new variable Set KP to value of N an invalid value Issue invalid command End of thread 1 Begin command error subroutine If error is out of range KP 1 Set N to a valid number Retry KP N command If error is invalid command TY Skip invalid command End of command error routine Example Communication Interrupt A DMC 4113 is used to move the A axis back and forth from 0 to 10000 This motion can be paused resumed and stopped via input from an auxiliary port terminal BEGIN cc 9600 0 1 0 CI 2 Label for beginning of program Setup communication configuration for auxiliary serial port Setup communication interrupt for auxiliary serial port MG P2 Type 0 to stop motion MG P2 Type 1 to pause motion MG P2 Type 2 to resume motion rate 2000 SPA rate LOOP Message out of auxiliary port Message ou
10. Description The SDM 44140 resides inside the DMC 41x3 enclosure and contains four microstepping drives for operating two phase bipolar stepper motors The drives produce 64 microsteps per full step or 256 steps per full cycle which results in 12 800 steps rev for a standard 200 step motor The maximum step rate generated by the controller is 6 000 000 microsteps second The SDM 44140 drives motors operating at up to 3 Amps at 12 to 60 VDC available voltage at motor is 10 less There are four softwareselectable current settings 0 5 A 1 A 2 A and 3 A Plus a selectable lowcurrent mode reduces the current by 75 when the motor is not in motion No external heatsink is required The BOX option is required when the SDM 44140 is order with the DMC 41x3 NOTE Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation amne ERROR owen EH us 429486 a mno m TE HIGH POWER OPTIO SOURCE 0016 E Da Figure A7 1 DMC 4143 D4140 DMC 4143 with SDM 44140 DMC 41x3 User Manual A7 SDM 44140 D4140 248 Electrica
11. DMC 41x3 User Manual Appendices 194 Fast Update Rate Mode The DMC 41x3 can operate with much faster servo update rates than the default of every millisecond This mode is known as fast mode and allows the controller to operate with the following update rates DMC 4113 62 5 usec DMC 4123 62 5 usec DMC 4133 125 usec DMC 4143 125 usec DMC 4153 187 5 usec DMC 4163 187 5 usec DMC 4173 250 usec DMC 4183 250 usec In order to run the DMC 41x3 motion controller in fast mode the fast firmware must be uploaded This can be done through the GalilTools communication software The fast firmware is included with the original DMC 41x3 utilities In order to set the desired update rates use the command TM When the controller is operating with the fast firmware the following functions are disabled Gearing mode Ecam mode Pole PL Analog Feedback AF Stepper Motor Operation MT 2 2 2 5 2 5 Trippoints in thread 2 8 Tell Velocity Interrogation Command TV Aux Encoders TD Dual Velocity DV Peak Torque Limit TK Notch Filter NB NF NZ PVT Mode PV BT Appendices e 195 DMC 41x3 User Manual Ordering Options for the DMC 41x3 Overview The DMC 41x3 can be ordered in many different configurations and with different options This section provides information regarding the different options available on the DMC 41x3 motion controller interconnect modules and internal amplifiers For information on pricing an
12. Executing Programs Multitasking The DMC 41x3 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 through 7 where 0 is the main thread Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The main thread differs from the others in the following ways 1 When input interrupts are implemented for limit switches position errors or command errors the subroutines are executed as thread 0 To begin execution of the various programs use the following instruction XQ 4A n Where n indicates the thread number To halt the execution of any thread use the instruction HX n where n is the thread number Note that both the XQ and HX commands can be performed by an executing program The example below produces a waveform on Output 1 independent of a move TASK1 Taskl label ATO Initialize reference time CB1 Clear Output 1 LOOP1 Loopl label AT 10 Wait 10 msec from reference time SB1 Set Output 1 AT 40 Wait 40 msec from reference time then initialize reference CB1 Clear Output 1 JP LOOP1 Repeat Loopl TASK2 Task2 label XQ TASK1 1 Execute Taskl LOOP2 Loop2 label PR 1000 Define relative distance DMC 41x3 User Manual Chapter 7 Application Programming 126 BGX Begin motion AMX After motion done WT 10 Wait 10 msec JP LOOP2 IN 2 1 Repeat motion unless Input 2 is low HX Halt all tasks The
13. 41 Chapter 4 Software Tools and Communication 46 roduc t a aa 46 Controller Response to Comani S sarsana 46 Unsolicited Messages Generated by Controller 47 USB and RSS Boe ini ia OR tg ttm reis 47 USB Programming Port Auxiliary RS 232 Port Configuration sse 48 E5422 Coo TGA EGON giv cocoa inccr orna eode ecd 48 Ethernet Configuration Clommuo nesti m Protocols eei Sad ioca ide 48 PORN SNE cs iioii ind eacus eoi oia tuse 49 Communicating with Multiple Devices 50 Multicastimg NE Using Third Party Software Dos ole RR RERO Modbus Examples ecu butiosi ctp ud ia oeil Data Record Explanation Data Record Bit Fields Notes Regarding Velocity and Torque Information 59 DMC 41x3 Contents e iii DE Conai i o o cid c rs 59 Gali To ols CWindows and LR uei SRI n petis 60 Creating Custom Sofware Inte faeeS uunc tiendas dicite sce ali ian 62 HelloGalil Quick Start to PC programming GalilTools Communication Libraries eeeeees 62 Chapter 5 Command Basics 64 UU I rel mio ee a A 64 Conrinand Syak SIL ae ects rail ae etie tob escis eae dad 64 Implicit Notation Explicit Notation Coordinated Motion with more than 1 ax
14. Operand Summary Automatic Data Capture _RC RD Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Returns address of next array element Example Recording into An Array During a position move store the X and Y positions and position error every 2 msec RECORD Begin program DM XPOS 300 YPOS 300 Define X Y position arrays DM XERR 300 YERR 300 Define X Y error arrays RA XPOS XERR YPOS YERR Select arrays for capture RD TPX TEX TPY TEY Select data types PR 10000 20000 Specify move distance RC1 Start recording now at rate of 2 msec BG XY Begin motion A JP A RC 1 G DONE EN PLAY 0 JP DONE N gt 300 Loop until done Print message End program Play back Initial Counter Exit if done Print Counter DMC 41x3 User Manual Chapter 7 Application Programming e 152 X POS N Print X position Y POS N Print Y position XERR N Print X error YERR N Print Y error N N 1 Increment Counter DONE Done EN End Program De allocating Array Space Array space may be de allocated using the DA command followed by the array name DA 0 deallocates all the arrays Input of Data Numeric and String NOTE The IN command has been removed from the DMC 41x3 firmware Variables should be entered by sending data directly from the host application Sending Data from a Host The DMC 41x3 can accept ASCII strings from a
15. Using External Amplifiers Use connectors on top of controller to access necessary signals to run external amplifiers In order to use the full torque limit make sure the AG setting for the axes using external amplifiers are set to 0 or 1 Set the BR command to 1 for any axis that will be setup to run external amplifiers this will disable the hall error protection For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset A1 AMP 430x0 D3040 D3020 e 221 DMC 41x3 User Manual It is recommended that OE1 be used for all axes when the ELO is used in an application Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will also monitor for illegal Hall states 000 or 111 with 120 phasing The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 1 2 or 3 The command will return an eigh
16. Operands can be used in an expression and assigned to a programmable variable but they cannot be assigned a value For example KDX 2 is invalid Special Operands Keywords The DMC 41x3 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 41x3 commands Keyword Function _BGn Returns a 1 if motion on axis n is complete otherwise returns 0 BN Returns serial of the board _DA Returns the number of arrays available _DL Returns the number of available labels for programming _DM Returns the available array memory _HMn Returns status of Home Switch equals 0 or 1 _LFn Returns status of Forward Limit switch input of axis n equals 0 or 1 _LRX Returns status of Reverse Limit switch input of axis n equals 0 or 1 _UL Returns the number of available variables Chapter 7 Application Programming e 149 DMC 41x3 User Manual TIME Free Running Real Time Clock off by 2 496 Resets with power on Note TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords LF LR and TIME do not have any associated commands All keywords are listed in the Command Reference Examples of Keywords vl LEX Assign vl the logical state of the Forward Limit Switch on the X axis v3 TIME Assign v3 the current value of the time clock v4 HMW Assign v4 the logical state
17. Return Figure 3 8 4mA sinking outputs DO 8 1 3 3V Output Supply CPU Output Supply Return Figure 3 9 4mA sinking outputs DO 16 9 DMC 41x3 User Manual Chapter 3 Connecting Hardware e 34 25mA Sinking Opto Isolated Outputs LSNK Description With the LSNK option on the DMC 41x3 the digital outputs are modified to be capable of sinking up to 25mA per output The ABCD LSNK option configures digital outputs 1 8 for 25mA sinking outputs this is shown in Figure 3 10 The EFGH LSNK option only valid for 5 8 axis controllers configures digital outputs 9 16 for 25mA sinking outputs this is shown in Figure 3 11 These outputs should not be used to drive inductive loads directly Electrical Specifications Output Common OPOB OPIB Max Voltage 24 VDC Min Voltage 5 VDC Max Drive Current per Output 25mA Sinking Wiring the 25mA Sinking Outputs With the 25mA sinking outputs the load is wired in the same fashion as the 4mA sinking outputs The load will be connected from the digital output to the 5 24VDC source and or OPxB as shown in Figure 3 10 and Figure 3 11 The supply voltage must be connected to OPxB and the supply return must be connected to OPxA 3 3V Output Supply CPU Output Supply Return Figure 3 10 25mA sinking outputs for ABCD LSNK option DO 8 1 3 3V Output Supply CPU Output Supply Return Figure 3 11 25mA sinking outputs for EFGH LSNK option DO 16 9 Chapter 3 Conne
18. 1 ej sO Cae es amp sO w S amp t 5ms 23 3 Trigger Channel Wi TTA v Edge mi Level 0 1 V S Mode Repeat v READY d TT 29 03V TTA dt 13 ms 1 dt 74 6 Hz Figure A4 2 Peak Current Operation DMC 41x3 User Manual A4 AMP 435x0 D3540 D3520 e 236 Brushed Motor Operation The AMP 43540 can be setup to run brushed motors by setting the BR command to 1 for a particular axis Wire the motor power leads to phases A and C on the motor power connector Do not set BA BM or use the BX command for any axis that is driving a brushed motor Using External Amplifiers The BR command must be set to a 1 for any axis where an AMP 43540 is installed but the use of an external axis is required This setting will disable the requirement to have the BA BM and BX or BZ commands executed prior to being able to issue the SH command for that axis BR 1 is required for both external servo and stepper drivers Use the connectors on top of the controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH mu
19. Program Flow Commands The DMC 41x3 provides instructions to control program flow The controller program sequencer normally executes program instructions sequentially The program flow can be altered with the use of event triggers trippoints and conditional jump statements Event Triggers amp Trippoints To function independently from the host computer the DMC 41x3 can be programmed to make decisions based on the occurrence of an event Such events include waiting for motion to be complete waiting for a specified amount of time to elapse or waiting for an input to change logic levels The DMC 41x3 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is DMC 41x3 User Manual Chapter 7 Application Programming e 128 complete on the first motion sequence In this way the controller can make decisions based on its own status or external events without intervention from a host computer DMC 41x3 Event Triggers Command Function AMXYZWorS AB
20. The logical condition tests two operands with logical operators Logical operators OPERATOR DESCRIPTION less than gt greater than equal to lt less than or equal to gt greater than or equal to lt gt not equal Conditional Statements The conditional statement is satisfied if it evaluates to any value other than zero The conditional statement can be any valid DMC 41x3 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions If no conditional statement is given the jump will always occur Examples Number v1 6 Numeric Expression vl v7 6 ABS v1 gt 10 Array Element vi lt count 2 Variable vl lt v2 Internal Variable _TPX 0 _TVX gt 500 I O vl gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 41x3 will accept multiple conditions in a single jump statement The conditional statements are combined in pairs using the operands amp and The amp operand between any two conditions requires that both statements must be true for the combined statement to be true The operand between any two conditions requires that only one statement be true for the combined statement to be true NOTE Each condition must be placed in parentheses for proper evaluation by the controller In addition the DMC 41x3 executes operations from left to right See Mathematical and Functional Expressions for more infor
21. USER MANUAL DMC 41x3 Manual Rev 1 0b By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Date 04 12 Using This Manual This user manual provides information for proper operation of the DMC 41x3 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller It is recommended that the user download the latest version of the Command Reference and User Manual from the Galil Website http www galilmc com support manuals php Your DMC 41x3 motion controller has been designed to work with both servo and stepper type motors Installation and system setup will vary depending upon whether the controller will be used with stepper motors or servo motors To make finding the appropriate instructions faster and easier icons will be next to any information that applies exclusively to one type of system Otherwise assume that the instructions apply to all types of systems The icon legend is shown below Attention Pertains to servo motor use Attention Pertains to stepper motor use Attention Pertains to controllers with more than 4 axes E i D Please note that many examples are written for the DMC 4143 four axes controller or the DMC 4183 eight axes controller Users of the DMC 4133
22. move of 151 counts 437 counts sec in 256 sampl in 256 in in in in sampl sampl sampl sampl sampl es es es es es es wit wit wit wit wit wit n a final a final a final a final a final a final move of 57 counts in 256 samples with a final 0 counts sec of PVT buffer DMC 41x3 User Manual Chapter 6 Programming Motion 102 Actual Velocity and Position vs Time 1200 1400 1000 800 600 Velocity e Position 400 Velocity counts second Position counts 200 Time Samples Figure 6 13 Actual Velocity and Position vs Time of Parabolic Velocity Profile Multi Axis Coordinated Move Many applications require moving two or more axes in a coordinated move yet still require smooth motion at the same time These applications are ideal candidates for PVT mode In this example we will have a 2 dimensional stage that needs to follow a specific profile The application requires that the certain points be met however the path between points is not important Smooth motion between points is critical Required XY Points 6000 5000 E 4000 2 c 8 2 3000 n E gt 2000 1000 0 T T T T T T T 0 1000 2000 3000 4000 5000 6000 7000 8000 X Axis Counts Figure 6 14 Required XY Points Chapter 6 Programming Mot
23. 2 The encoder has failed using an oscilloscope observe the encoder signals Verify that both channels A and B have a peak magnitude between 5 and 12 volts Note that if only one encoder channel fails the position reporting varies by one count only If the encoder failed replace the encoder If you cannot observe the encoder signals try a different encoder 3 There is a hardware failure in the controller connect the same encoder to a different axis If the problem disappears you may have a hardware failure Consult the factory for help Step 7a Connect Standard Servo Motors The following discussion applies to connecting the DMC 41x3 controller to standard servo motors The motor and the amplifier may be configured in the torque or the velocity mode In the torque mode the amplifier gain should be such that a 10 volt signal generates the maximum required current In the velocity mode a command Chapter 2 Getting Started e 17 DMC 41x3 User Manual signal of 10 volts should run the motor at the maximum required speed For Galil amplifiers see Integrated Components Step A Check the Polarity of the Feedback Loop It is assumed that the motor and amplifier are connected together and that the encoder is operating correct Step 6 Make Connections to Amplifier and Encoder Before connecting the motor amplifiers to the controller read the following discussion on setting Error Limits and Torque Limits Note that this discussion only u
24. 3 VS DC Power 4 VS DC Power Motor Connector 1 Motor Lead A 2 Motor Lead A A2 AMP 43140 D3140 e 225 DMC 41x3 User Manual Operation ELO Input If the ELO input on the controller is triggered then the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the ZAMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application SSR Option The AMP 43140 linear amplifier require a bipolar power supply It is possible that the plus and minus V and V rise to nominal voltage at different rates during power up and any difference between voltage levels will be seen as an offset in the amplifier This offset may cause a slight jump during power up prior to the controller establishing closed loop control When ordered with the SSR option a solid state relay is added to the amplifier This relay disconnects the amplifier power from the motor power leads when the controller is placed in the motor off state If the MO jumper is installed or the MO command is burned into memory the addition of the SSR option will eliminate any jump due to the power supply Using External Amplifiers Use connectors on top of controller to access necessary signals to run external am
25. Chapter 8 Hardware amp Software Protection 171 OUI achats c p c ra esas co S cnc taste cassia va eS aa ird PES CAE Eee d fe aso ie eo cuerda b cui 71 Output Protection Lines eS Input Protection Lines oos ccelo caa apio sa o eo ii uU ade Protoi aio RT dod a Et 172 Position Error i Encoder Failure deteoliele aos a 173 Programmable Position LMS osni 173 OON ET ON niacara Automatic Error Routine Limit Swieb SACO aii acci ii Chapter 9 Troubleshooting 176 RARO ode id oct pie POR RO EHE DOE EE E POOL ege OTTO 176 indldioii sci esae corio ere Creer re reed 176 Stability Operation Error Lic ORE EEED rione 177 Chapter 10 Theory of Operation 179 DEA Eme 179 Operation of Closed Loop Systeme iu cese ice dac cd ca ira 182 System Modeling Rotor ampli iii riali 183 iD LUCERE OOO 185 System Design and Compensation uisa oisi iii The Analytical Method ceicri iis 189 Appendices 192 Electrical SpeciicWtlote uiu oco suse iioc auda M ci daa ed cp EE iR t Sad 192 Drum Conil aaa Stepper Control i LETT TIC Output oi ii rie eli Power equi Mente coi iaia 193 5 12V Power Output Specifications Pesforimadnc SETA fig uui eset Ld S ape i Ald sda seas Sates e pala bite 194 Minimum Servo Loop Update Time Memory Fast Update Rate NGHE e oiii ceti aaa pts iii ia 195 Ordering Options for the DMC M I
26. D3040 D3020 2 and 4 axis 500W Servo Drives rire ree erre rieenizien 216 A2 AMP 43140 D3140 4 axis 20W Linear Servo Drives 216 A3 AMP 43240 D3240 aiii A4 AMP 435x0 D3540 D3520 AS AMP 43640 D3640 sse A6 SDM 44040 D4040 D4020 4 axis Stepper Drives 217 A7 SDM 44140 D4140 4 axis Microstep Drives 217 A1 AMP 430x0 D3040 D3020 218 Deserti RR ERE iii 218 Elected S Daci CAMS ooa teinte ira 219 Mating Connectors m CO PERMANE cirie AA ARA AAA aal 220 Brushless Motor Setup is Brush Amplifier Operation aee 2220 Setting Amplifier Gain and Current Loop Bandwidth Chopper Male ca see TTT _ gt 9PTTTT 221 Under Voltage Protection di CO ver Voltage Protect en iecit iiit tiec Over Current Protection iu iride Over Temperature PEOTEGUO accoa 223 A2 AMP 43140 D3140 224 MUS iren AC i LL gi 224 Electrical Space catia tie scio csi sierici 225 Mating Connectors Uli cal ERE 226 ELO Input SSR Option 226 Using Extetnal Amplitietg iuis irr dci odia etaed 226 A3 AMP 43240 D3240 227 MSR Pe si x i ri 227 Electrica SPEC CaO ania 228 Mating Connectors n AS iON 2s RO ee Gia n O CO 229 Brushless Motor Setup sciiicet eee re Brushed Motor Operation a Setting Amplifier Gain and Curren
27. DO 16 9 Chapter 3 Connecting Hardware e 37 DMC 41x3 User Manual TTL Inputs and Outputs Main Encoder Inputs The main encoder inputs can be configured for quadrature default or pulse and direction inputs This configuration is set through the CE command The encoder connections are found on the 26 pin HD D sub Encoder connectors and are labeled MA MA MB MB The negative inputs are the differential inputs to the encoder inputs if the encoder is a single ended 5V encoder then the negative input should be left floating If the encoder is a single ended and outputs a 0 12V signal then the negative input should be tied to the 5V line on the DMC 41x3 When the encoders are setup as step and direction inputs the MA channel will be the step or pulse input and the MB channel will be the direction input The encoder inputs can be ordered with 1200hm termination resistors installed See TRES Encoder Termination Resistors in the Appendix for more information Electrical Specifications Maximum Voltage 12 VDC Minimum Voltage 12 VDC Maximum Frequency Quadrature 15 MHz P inputs are internally pulled up to 5V through a 4 7 KQ resistor inputs are internally biased to 1 3V pulled up to 5V through a 7 1 kQ resistor pulled down to GND through a 2 5 kQ resistor The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary e
28. Example 14 Control Variables Objective To show how control variables may be utilized Instruction Interpretation DMC 41x3 User Manual Chapter 2 Getting Started e 24 A DPO Label Define current position as zero PR 4000 Initial position SP 2000 Set speed BGA Move A AMA Wait until move is complete WT 500 Wait 500 ms B vl TPA Determine distance to zero PR v1 2 Command A move 1 2 the distance BGA Start A motion AMA After A moved WT 500 Wait 500 ms MG vl Report the value of v1 JP C v1 0 Exit if position 0 JP B Repeat otherwise C Label C EN End of Program To start the program command XQ A Execute Program A This program moves A to an initial position of 1000 and returns it to zero on increments of half the distance Note _ TPA is an internal variable which returns the value of the A position Example 15 Linear Interpolation Objective Move A B C motors distance of 7000 3000 6000 respectively along linear trajectory Namely motors start and stop together Instruction Interpretation LMABC Specify linear interpolation axes LI 7000 3000 6000 Relative distances for linear interpolation LE Linear End VS 6000 Vector speed VA 20000 Vector acceleration VD 20000 Vector deceleration BGS Start motion Example 16 Circular Interpolation Objective Move the AB axes in circular mode to form the path shown on Figure 2 8 Note that the vector motion starts at a local position 0 0 which is defined at t
29. The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 41x3 position parameters such as PR PA and VP have units of quadrature counts Speed parameters such as SP JG and VS have units of counts sec Acceleration parameters such as AC DC VA and VD have units of counts sec2 The controller interprets time in milliseconds All input parameters must be converted into these units For example an operator can be prompted to input a number in revolutions A program could be used such that the input number is converted into counts by multiplying it by the number of counts revolution Instruction Interpretation RUN Label MG ENTER OF REVOLUTIONS n1 1 Prompt for revs rev JP rev nl 1 Wait until user enters new value for nl PR n1 2000 Convert to counts MG ENTER SPEED IN RPM s1 1 Prompt for RPMs spd JP spd s1 1 Wait for user to enter new value for sl SP s1 2000 60 Convert to counts sec Chapter 7 Application Programming e 159 DMC 41x3 User Manual MG ENTER ACCEL IN RAD SEC2 al 1 Prompt for ACCEL acc JP acc al 1 Wait for user to enter new value for al AC al 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program Hardware I O Digital Outputs The DMC 41x3 has an 8 bit uncommitted output port the DMC 4153 through DMC 4183 has an additional 8 outputs Each bit on t
30. To connect step motors with the DMC 41x3 you must follow this procedure If you have a Galil integrated stepper driver skip Step A the step and direction lines are already connected to the driver Step A Connect step and direction signals from controller to motor amplifier From the controller to respective signals on your step motor amplifier These signals are labeled STPA and DIRA for the A axis on the EXTERNAL DRIVER A D D Sub connector top of the controller Consult the documentation for connecting these signals to your step motor amplifier Step B Configure DMC 41x3 for motor type using MT command You can configure the DMC 41x3 for active high or active low pulses Use the command MT 2 or 2 5 for active low step motor pulses and MT 2 or 2 5 for active high step motor pulses See description of the MT command in the Command Reference Chapter 2 Getting Started e 19 DMC 41x3 User Manual Step 8 Tune the Servo System Adjusting the tuning parameters is required when using servo motors standard or sinusoidal commutation The system compensation provides fast and accurate response and the following section suggests a simple and easy way for compensation More advanced design methods are available with software design tools from Galil such as the GalilTools The filter has three parameters the damping KD the proportional gain KP and the integrator KI The parameters should be selected in this order To start set the
31. Value Units 1 AN 1 2 5781 MG Lookir JGR 1900 v gt DIDO AWN S Source Scale div Offset div _RPA Axis A reference position 20 counts 2 1 lt gt 4 _TPA Axis A encoder position 20 counts 1 4 gt lt b _TEA Axis A position error 100 counts 1 _TTA Axis A torque DAC 4 amp 4 5 4 4 Lam Lam lt b 45 4 gt 14 gt lt gt lt Time i Trigger Channel W 1 v Rising Level 0 counts E Figure 4 1 GalilTools Screen Capture Chapter 4 Software Tools and Communication e 61 DMC 41x3 User Manual Creating Custom Software Interfaces GalilTools provides a programming API so that users can develop their own custom software interfaces to a Galil controller Information on this GalilTools Communication Library can be found in the GalilTools manual http www galilmc com support manuals galiltools library html HelloGalil Quick Start to PC programming For programmers developing Windows applications that communicate with a Galil controller the HelloGalil library of quick start projects immediately gets you communicating with the controller from the programming language of your choice In the Hello World tradition each project contains the bare minimum code to demonstrate communication to the controller and simply prints the controller s model and
32. applications such as tracking an object the controller must proceed towards a target and have the ability to change DMC 41x3 User Manual Chapter 6 Programming Motion e 76 the target during the move In a tracking application this could occur at any time during the move or at regularly scheduled intervals For example if a robot was designed to follow a moving object at a specified distance and the path of the object wasn t known the robot would be required to constantly monitor the motion of the object that it was following To remain within a specified distance it would also need to constantly update the position target it 1s moving towards Galil motion controllers support this type of motion with the position tracking mode This mode will allow scheduled or random updates to the current position target on the fly Based on the new target the controller will either continue in the direction it is heading change the direction it is moving or decelerate to a stop The position tracking mode shouldn t be confused with the contour mode The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate In this mode the position can be updated randomly or at a fixed time rate but the velocity profile will always be trapezoidal with the parameters specified by AC DC and SP Updating the position target at a specific rate will not allow the user to create a custom profile The following exampl
33. axis Stepper Position Maintenance Mode SPM The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle the event of stepper motor position error The mode looks at position feedback from the main encoder and compares it to the commanded step pulses The position information is used to determine if there is any significant difference between the commanded and the actual motor positions If such error is detected it is updated into a command value for operator use In addition the SPM mode can be used as a method to correct for friction at the end of a microstepping move This capability provides closed loop control at the application program level SPM mode can be used with Galil and non Galil step drives SPM mode is configured executed and managed with seven commands This mode also utilizes the POSERR automatic subroutine allowing for automatic user defined handling of an error event Internal Controller Commands user can query QS Error Magnitude pulses User Configurable Commands user can query amp change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status A pulse is defined by the resolution of the step drive being used Therefore one pulse could be a full step a half step or
34. gt 28VDC Bypassing the Opto Isolation If no isolation is needed the internal 5 Volt supply may be used to power the switches This can be done by connecting LSCOM or INCOM to 5V To close the circuit wire the desired input to any ground GND pin on the controller Chapter 3 Connecting Hardware e 33 DMC 41x3 User Manual Opto Isolated Outputs The DMC 41x3 has different options for the uncommitted digital outputs The standard outputs are 4mA sinking outputs these are ideal for interfacing to TTL level devices There are options for 25mA sinking or sourcing and 500mA sourcing outputs Standard 4mA Sinking Opto Isolated Outputs Description The default outputs of the DMC 41x3 are shown in Figure 3 8 and Figure 3 9 and are capable of 4mA and are configured as sinking outputs The voltage range for the outputs is 5 24 VDC These outputs should not be used to drive inductive loads directly Electrical Specifications Output Common OPOB OP1B Max Voltage 24 VDC Min Voltage 5 VDC ON Voltage No Load 5V OPxB 0 1 VDC Max Drive Current per Output 4mA Sinking Wiring the Standard 4mA outputs The standard outputs are sinking outputs With this configuration the load will be connected from the digital output to the 5 24VDC source and or OPxB as shown in Figure 3 8 and Figure 3 9 The supply voltage must be connected to OPxB and the supply return must be connected to OPxA 3 3V Output Supply CPU OPOA Output Supply
35. the slave position is also redefined such that it starts at zero and ends at 1500 At the end of a cycle when the master is 6000 and the slave is 1500 the positions of both x and y are redefined as zero To specify the master cycle and the slave cycle change we use the instruction EM EM X y Z W DMC 41x3 User Manual Chapter 6 Programming Motion e 94 where x y z w specify the cycle of the master and the total change of the slaves over one cycle The cycle of the master is limited to 8 388 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master 1s 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 Step 3 Specify the master interval and starting point Next we need to construct the ECAM table The table is specified at uniform intervals of master positions Up to 256 intervals are allowed The size of the master interval and the starting point are specified by the instruction EP m n where m is the interval width in counts and n is the starting point For the given example we can specify the table by specifying the position at the master points of 0 2000 4000 and 6000 We can specify that by EP 2000 0 Step 4 Specify the slave positions Next we specify the slave positions with the instruction ET n x y Z W where n indicates the orde
36. variables and motion control parameters stored in EEPROM will be ERASED The UPGD jumper enables the user to unconditionally update the controller s firmware This jumper is not necessary for firmware updates when the controller is operating normally but may be necessary in cases of corrupted EEPROM EEPROM corruption should never occur however it is possible if there is a power fault during a firmware update If EEPROM corruption occurs your controller may not operate properly In this case install the UPGD Jumper and use the update firmware function on the Galil Terminal to re load the system firmware Chapter 2 Getting Started e 13 DMC 41x3 User Manual Motor Off Jumper The state of the motor upon power up may be selected with the placement of a hardware jumper on the controller With a jumper installed at the MO location the controller will be powered up in the motor off state The SH command will need to be issued in order for the motor to be enabled With no jumper installed the controller will immediately enable the motor upon power up The MO command will need to be issued to turn the motor off unless an error occurs that will turn the motors off The MO jumper is located on JP1 the same block as the Master Reset MRST and Upgrade UPGD jumpers Communications Jumpers for DMC 41x3 The baud rate for USB communication can be set with jumpers found on JP1 of the communication board same set of jumpers where MO MRST and
37. 000000000 000000000 000000000 o o o o o o o o 000000000 o o o o o o o o o 00000000 o o o o o o o o o 12 3456 5V CPU AEN SHn 5V AEN TO DRIVE MOn 0V PIN 2 10K 412V CPU AEN SHn 5V AEN TO DRIVE MOn 0V PIN 2 10K AMP ENABLE POWER PIN 20 CPU AEN SHn 5V AEN TO DRIVE MOn 0V PIN 2 10K AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware e 43 DMC 41x3 User Manual 45V LOW AMP ENABLE SINKING 12V LOW AMP ENABLE SINKING ISOLATED SUPPLY LOW AMP ENABLE SINKING AXIS A AXISA AXIS A 00000000 000000000 o o o o o o o o 00000000 000000000 000000000 000000000 000000000 000000000 5V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 12V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V AMP ENABLE POWER PIN 20 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V AMP ENABLE RETURN PIN 11 DMC 41x3 User Manual Chapter 3 Connecting Hardware e 44 AXIS A 45V LOW AMP ENABLE SOURCING AXIS A 412V LOW AMP ENABLE SOURCING AXIS A ISOLATED SUPPLY LOW AMP ENABLE SOURCING 00000000 000000000 000000000 o o o o o o o o 000000000 000000000 o o o o o o o o o 00000000 o o o o o o o o o 123456 5V 5V CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K 5V 12V CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K
38. 011 then result 3 IF ti amp 7 3 b3 1 ENDIF ENDIF REM set output bits 1 and 3 accordingly REM set outputs at the end for a PLC scan OB1 b1 0B3 b3 REM wait 500ms for 500 samples use AT 500 1 REM the will reset the time reference AT 500 JP scan Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 41x3 provides the use of the following mathematical operators Operator Function T Addition 5 Subtraction hi Multiplication Division Modulus Chapter 7 Application Programming e 145 DMC 41x3 User Manual Logical And Bit wise EN Logical Or On some computers a solid vertical line appears as a broken line 0 Parenthesis The numeric range for addition subtraction and multiplication operations is 2 147 483 647 9999 The precision for division is 1 65 000 Mathematical operations are executed from left to right Calculations within parentheses have precedence Examples speed 7 5 V1 2 The variable speed is equal to 7 5 multiplied by V1 and divided by 2 count count 2 The variable count is equal to the current value plus 2 result _TPX COS 45 40 puts the position of X 28 28 in result 40 cosine of 45 is 28 28 temp IN 1 amp IN 2 temp is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The op
39. 19 56 The controller s multicast IP address can be changed by using the IA gt u command Using Third Party Software Galil supports DHCP ARP BOOT P and Ping which are utilities for establishing Ethernet connections DHCP is a protocol used by networked devices clients to obtain the parameters necessary for operation in an Internet Protocol network ARP is an application that determines the Ethernet hardware address of a device at a specific IP address BOOT P is an application that determines which devices on the network do not have an IP address and assigns the DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 50 IP address you have chosen to it Ping is used to check the communication between the device at a specific IP address and the host computer The DMC 41x3 can communicate with a host computer through any application that can send TCP IP or UDP IP packets A good example of this is Telnet a utility that comes with most Windows systems Modbus An additional protocol layer is available for speaking to I O devices Modbus is an RS 485 protocol that packages information in binary packets that are sent as part of a TCP IP packet In this protocol each slave has a 1 byte slave address The DMC 41x3 can use a specific slave address or default to the handle number The port number for Modbus is 502 The Modbus protocol has a set of commands called function codes The DMC 41x3 supports the 10 major function co
40. 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ PR 21600 SP 20000 BGX AMX PR 80000 BGZ AMZ CR 80000 270 360 VE VS 40000 BGS AMS PR 80000 BGZ AMZ VP 37600 16000 VE VS 200000 BGS AMS EN Further assume that the Z must move 2 at a linear speed of 2 per second The required motion is performed by the following instructions FUNCTION Label Circular interpolation for XY Positions End Vector Motion Vector Speed Vector Acceleration Start Motion When motion is complete Move Z down Z speed Start Z motion Wait for completion of Z motion Circle Feed rate Start circular move Wait for completion Move Z up Start Z move Wait for Z completion Move X Speed X Start X Wait for X completion Lower Z Z second circle move Raise Z Return XY to start DMC 41x3 User Manual Chapter 7 Application Programming 166 0 4 93 x Figure 7 2 Motor Velocity and the Associated Input Output signals Speed Control by Joystick The speed of a motor is controlled by a joystick The joystick produces a signal in the range between 10V and 10V The objective is to drive the motor at a speed proportional to the input voltage Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec The program reads the input vol
41. 2A To set TL and TK for a particular motor find the continuous current and peak current ratings for that motor and divide that number by the amplifier gain For example a particular motor has a continuous current rating of 0 5A and peak current rating of 1 5A The gain of the AMP 43640 is 0 2A V TL setting 0 5A 0 2A V 2 5V TL n 2 5 TK setting 1 5A 0 2A V 7 5V TK n 7 5 DMC 41x3 User Manual A5 AMP 43640 D3640 e 242 DI Vertical Horizontal didt Source Scale div Offset div MO TTA Axis A torda 2v al 3 ES m ie 1 82 amp m vj i ej T m sj 1 o T m iy 1 eu g sO Cae ej amp sO Ce es amp sO Cae 34 amp t Sms 24 3 Trigger Channel Mi TTA v Edge v Level 0 1 Y S Mode Repeat x READY 4 d TTA 9 08 TTA dt213ms ijdt 274 6H2 Figure A5 3 Peak Current Operation Brushed Motor Operation The AMP 43640 must be configured for brushed motor operation at the factory Contact Galil prior to placing the order Once the amplifier is configured for a brushed motor the controller needs to be set for brushed mode by setting the BR command to a value of 1 The A and C motor phases are used for connecting to the brushed motor B phase is a no connect ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 an
42. 4 x encoder cycles Note Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses into CHA and direction into Channel B and using the CE command to configure this mode Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Appendices e 205 DMC 41x3 User Manual Encoder MA MB MI Auxiliary Encoder AA AB Aux A Aux B Abort Reset Electronic Lock Out Forward Limit Switch Reverse Limit Switch Home Switch Input 1 Input 8 isolated Input 9 Input 16 isolated Latch Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for step motors A low input stops commanded motion instantly without a controlled deceleration Also aborts motion program A low input resets the state of the processor to its power on condition The previously saved state of the controller along with parameter values and saved sequences are restored Input that when triggered will shut down the amplifiers at a hardware level Useful for safety applications where amplifiers must be shut down at a hardware level When active inhibits motion in forward direction Also causes execution
43. 41x3 User Manual Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the ZAMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle DMC 41x3 User Manual A3 AMP 43240 D3240 e 232 A4 AMP 435x0 D3540 D3520 Description The AMP 43540 resides inside the DMC 41x3 enclosure and contains four sinusoidally commutated PWM amplifiers for driving brushless servo motors Each amplifier drives motors operating at up to 8 Amps continuous 15 Amps peak 20 80 VDC The gain settings of the amplifier are user programmable at 0 4 Amp Volt 0 8 Amp Volt and 1 6 Amp Volt The switching frequency is 33 kHz The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43540s can be used for 5 thru 8 axis controllers A shunt regulator option is available A two axis version the AMP 43520 is also available If higher voltages are required please contact Galil If the application has a potential for regenerative energy it is recommended to order the controller with the ISCNTL solate Controller Power option and the
44. AMP ENABLE POWER 5V PIN 20 CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware e 45 DMC 41x3 User Manual Chapter 4 Software Tools and Communication Introduction The default configuration DMC 41x3 has one USB port one RS 232 port and one Ethernet port The auxiliary RS 232 port is the data term and can be configured with the software command CC This configuration can be saved using the Burn BN instruction The Ethernet port is a 10 100BASE T connection that auto negotiates the speed and half or full duplex The GalilTools software package is available for PC computers running Microsoft Windows or Linux to communicate with the DMC 41x3 controller This software package has been developed to operate under Windows and Linux and include all the necessary drivers to communicate to the controller In addition GalilTools includes a software development communication library which allows users to create their own application interfaces using programming environments such as C C Visual Basic and LabVIEW The following sections in this chapter are a description of the communications protocol and a brief introduction to the software tools and communication techniques used by Galil At the application level GalilTools is the basic programs that the majority of users will need to communicate with the controller to perform basic setup and to develop application code dmc
45. B C D E F G and H The example applications described below will help guide you to the appropriate mode of motion For controllers with 5 or more axes the specifiers ABCDEFGH are used XYZ and W may be Motion Path described as incremental position velocity and delta time 2 to 8 axis coordinated motion where path is described by linear segments interchanged with ABCD EXAMPLE APPLICATION MODE OF MOTION COMMANDS Absolute or relative positioning where each axis is Independent Axis Positioning PA PR independent and follows prescribed velocity profile SP AC DC Velocity control where no final endpoint is prescribed Independent Jogging JG Motion stops on Stop command AC DC ST Absolute positioning mode where absolute position targets Position Tracking PA may be sent to the controller while the axis is in motion PT SP AC DC Motion Path described as incremental position points versus Contour Mode CM time CD DT PVT Mode PV BT Linear Interpolation Mode LM LI LE VS VR VA VD Chapter 6 Programming Motion e 71 DMC 41x3 User Manual 2 D motion path consisting of arc segments and linear Vector Mode Linear and Circular Interpolation VM segments such as engraving or quilting Motion VP CR VS VR VA VD VE Third axis must remain tangent to 2 D motion path suchas Vector Mode Linear and Circular Interpolation VM knife cutting Motion with Tangent Motion VP CR VS VA VD TN VE Elect
46. BUODHGE oou ita ero a c cct dr tib ceno eoe Backlash Compensation Motion Smoothing Command Summary Homing Operation Operand Summary Homing Operation High Speed Position Capture The Latch Function Fasc Update Rate Mode ciao a sioe sa doa bai LL cutie ka bd eda Chapter 7 Application Programming 124 DE RA RR RENE Program Format Using Labels in Propra MS ccu on kis cie eie tea cio 124 Special Labels uacua cauce mace 125 Commenting Programs 2125 Executing Programis Mullitaskimpi o ieri a iaia 126 Debugging Programs all 27 Programi Flow CO Fido sirio ario ula cpu ga Ga 128 Event Trispers d THppOolils ia cos c dace 128 Event Trigger Examples is Condironal TOMS ci Using If Else and Endif Commandis 134 Subroutines is Stack Mami pulp oii cess cacao decia ceci es cL codecs 136 PALIO LIA IE MIO ALE I ctii d obese ot b TT TT 136 Automatic Subroutines for Monitoring Conditions 136 JS Subroutine Stack Variables a b c d e f g h 141 General Program Flow and Timing information 143 Mathematical ang Functional Exptresetans coniecit icaro 145 Mathematical OpeRIMGOFI caa ci iac sedora ciiin piera 145 Bit Wise Operators T
47. DMC 41x3 User Manual Chapter 3 Connecting Hardware e 30 5V LSCOMO 2 2K CPU FLS A B C D RLS A B C D HOME A B C D PS2805 Figure 3 3 Limit Switch Inputs for Axes A D 5V LSCOM1 2 2K CPU FLS_ E F G H RLS_ E F G H HOME E F G H PS2805 Figure 3 4 Limit Switch Inputs for Axes E H 5V INCOM 2 2K CPU ELO ABRT RST PS2805 Figure 3 5 ELO Abort and Reset Inputs Wiring the Opto Isolated Digital Inputs All inputs can be used as active high or low If you are using an isolated power supply you can connect the positive voltage of the supply Vs to INCOM or supply the isolated ground to INCOM Connecting Vs to INCOM will configure the inputs for active low Connecting the isolated ground to INCOM will configure the inputs for active high If there is not an isolated supply available the Galil 5V or 12V and GND may be used It is recommended to use an isolated supply for the opto isolated inputs To take full advantage of opto isolation an isolated power supply should be used to provide the voltage at the input common connection When using an isolated power supply do not connect the ground of the isolated power to the ground of the controller A power supply in the voltage range between 5 to 28 Volts may be applied directly see Figure 3 6 Chapter 3 Connecting Hardware e 31 DMC 41x3 User Manual CPU PS2805 5 28VDC RETURN Figure 3 6 Digital Input Wiring for Vs to INCOMO The opto isolated inputs
48. ETERS lp hee m DAC AMP MOTOR ENCODER Figure 10 4 Functional Elements of a Motion Control System Motor Amplifier The motor amplifier may be configured in three modes 1 Voltage Drive 2 Current Drive 3 Velocity Loop The operation and modeling in the three modes is as follows Voltage Drive The amplifier is a voltage source with a gain of K V V The transfer function relating the input voltage V to the motor position P is P V K K S ST ST 1 where T RI K s and T L R s and the motor parameters and units are K Torque constant Nm A R Armature Resistance Q J Combined inertia of motor and load kg m L Armature Inductance H When the motor parameters are given in English units it is necessary to convert the quantities to MKS units For example consider a motor with the parameters K 14 16 oz in A 0 1 N A Chapter 10 Theory of Operation e 183 DMC 41x3 User Manual R 2Q J 0 0283 oz in s 2 1074 kg m L 0 004H Then the corresponding time constants are Tin 0 04 sec and T 0 002 sec Assuming that the amplifier gain is K 4 the resulting transfer function is P V 40 s 0 04s 1 0 002s 1 Current Drive The current drive generates a current I which is proportional to the input voltage V with a gain of K The resulting transfer function in this case is P V K K Js where Kt and J
49. Encoder Position Drifts Significant noise can be 1 Noise Shield encoder cables seen on MAT and or MB Avoid placing power cables near encoder signals encoder cables Avoid Ground Loops Use differential encoders Use 12V encoders Stability SYMPTOM DIAGNOSIS CAUSE REMEDY Reversed Motor Type 1 Wrong feedback polarity Servo motor runs away when the loop is closed corrects situation MT 1 Reverse Motor or Encoder Wiring remember to set Motor Type back to default value MT 1 Motor oscillates 2 Too high gain or Decrease KI and KP Increase KD too little damping Operation SYMPTOM DIAGNOSIS CAUSE REMEDY Controller rejects Response of controller 1 Anything Correct problem reported by TC1 commands from TC1 diagnoses error Response of controller from 2 TC1 diagnoses error Motor Doesn t Move Anything Correct problem reported by SC Error Light Red LED The red error LED has multiple meanings for Galil controllers Here is a list of reasons the error light will come on and possible solutions Under Voltage If the controller is not receiving enough voltage to power up Under Current If the power supply does not have enough current the red LED will cycle on and off along with the green power LED Chapter 9 Troubleshooting e 177 DMC 41x3 User Manual Position Error If any axis that is set up as a servo MT command has a position error value TE that
50. H User defined variable ZA 1 Will be either a Signed Word or Unsigned Word depending upon AQ setting See AQ in the Command Reference for more information Chapter 4 Software Tools and Communication e 57 DMC 41x3 User Manual Explanation Data Record Bit Fields Header Information Byte 0 1 of Header I Block T Block S Block Present Present Present in Data in Data in Data Record Record Record H EUM G ars F Block E Block D Block C Block B Block A Block Present Present Present Present Present Present Present Present in Data in Data in Data in Data in Data in Data in Data in Data Record Record Record Record Record Record Record Record Bytes 2 3 of Header Bytes 2 and 3 make a word which represents the Number of bytes in the data record including the header Byte 2 is the low byte and byte 3 is the high byte NOTE The header information of the data records is formatted in little endian reversed network byte order Thread Status 1 Byte BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Thread 7 Thread 6 Thread 5 Thread 4 Thread 3 Thread 2 Thread 1 Thread 0 Running Running Running Running Running Running Running Running EUN EM CNET for S or T Plane ond oA BITIS O 15 BIT14 14 BITI3 13 BITI2 12 BIT 11 BITIO 10 Bro 9 BITS 8 Move in Progress BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Motion Motion is is slewing stopping due to ST or Limit Switch DMC 41x3 User M
51. HOMA a MRST 36 FLSA SALSA 6 LSCOM 35 GND FINO SELO 34 DIS DI7 33 DIS 19DI6 DIA som WO y api 3IGND IT INCOM 1ERR enp 9 420 60VDC o Y GALIL 7 d Figure 2 3 DMC 4143 BOX4 Dimensions The dimensions for the DMC 4113 DMC 4123 DMC 4133 and DMC 4143 with BOX4 are shown in Figure 2 3 1 Dimensions are subject to change Contact the Galil factory for current dimensions of all products Chapter 2 Getting Started e 9 DMC 41x3 User Manual imensions DMC 4183 BOX8 D Chapter 2 Getting Started e 10 BOX8 Dimensions 4183 Figure 2 4 DMC I I 11v9 i D X oanog oz olo ie Sun aod ASE ones ce ANDY ONYE 90Av2 S GidO vu OW uvs GNE QNO id0 6 91 INIS 140 a SIV tivu DANPT 9 8040 vu uMdv s dive ZIV ol IND YOdO Ligloa NIS SLOV angy E ONOV6 S1ndlno
52. I KI T a 1 T In 1 PL Chapter 10 Theory of Operation e 191 DMC 41x3 User Manual Appendices Electrical Specifications Servo Control MCMn Amplifier Command MA MA MB MB MI MI Encoder and Auxiliary Stepper Control STPn Step DIRn Direction Input Output Limit Switch Inputs Home Inputs DI thru DI8 Uncommitted Inputs and Abort Input DI9 thru DI16 Uncommitted Inputs 4153 through DMC 4183 only DMC All thru AI8 Analog Inputs DO thru DOS Outputs DO thru DO16 Outputs DMC 4153 through DMC 4183 only DI81 DI82 DI83 DI84 DMC 4123 through DMC 4183 only 10 volt analog signal Resolution 16 bit DAC or 0 0003 volts 3 mA maximum Output impedance 5000 TTL compatible but can accept up to 12 volts Quadrature phase on CHA CHB Can accept single ended A B only or differential A A B B Maximum A B edge rate 15 MHz Minimum IDX pulse width 30 nsec TTL 0 5 volts level at 50 duty cycle 3 000 000 pulses sec maximum frequency TTL 0 5 volts 2 2K ohm in series with opto isolator Active high or low requires at least 1 2mA to activate Once activated the input requires the current to go below 0 5ma All Limit Switch and Home inputs use one common voltage LSCOM which can accept up to 24 volts Voltages above 24 volts require an additional resistor 215mA ON lt 0 5 mA OFF Standard configuration is 10 volts 12 Bit Analog to Digital converter
53. Magnitude In the Inverter mode the PWM 31 kHz signal is 2 duty cycle for full negative voltage 50 for 0 Voltage and 99 8 for full positive voltage 31 kHz Switching Frequency In the Sign Magnitude Mode MT1 5 the PWM 62 kHz signal is 0 for 0 Voltage 99 6 for full voltage and the sign of the Motor Command is available at the sign output 62 kHz Switching Frequency For stepper motors The STEP OUT pin produces a series of pulses for input to a step motor driver The pulses may either be low or high The pulse width is 50 Used with PWM signal to give the sign of the motor command for servo amplifiers or direction for step motors The signal goes low when the position error on any axis exceeds the value specified by the error limit command ER The optically isolated outputs are uncommitted and may be designated by the user to trigger external events The output lines are toggled by Set Bit SB and Clear Bit CB instructions The OP instruction is used to define the state of all the bits of the Output port Encoder MA MB Encoder Index MI Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximum frequency does not exceed 15 000 000 quadrature states sec The controller performs quadrature decoding of the encoder signals resulting in a resolution of quadrature counts
54. N VY COUNT N N N 10 COUNT COUNT 1 JP LOOP COUNT lt 750 A LM XY COUNT 0 LOOP2 JP LOOP2 LM 0 JS C COUNT 500 LI VX COUNT VY COUNT COUNT COUNT 1 JP LOOP2 COUNT 750 LE AMS MG DONE EN C BGS EN Load Program Define Array Initialize Counter Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full wait Begin motion on 500 segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Motion Subroutine Vector Mode Linear and Circular Interpolation Motion The DMC 41x3 allows a long 2 D path consisting of linear and arc segments to be prescribed Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments The DMC 41x3 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specif
55. Port 23 Telnet Port 502 Modbus Communicating with Multiple Devices The DMC 41x3 is capable of supporting multiple masters and slaves The masters may be multiple PC s that send commands to the controller The slaves are typically peripheral I O devices that receive commands from the controller NOTE The term Master is equivalent to the internet client The term Slave is equivalent to the internet server An Ethernet handle is a communication resource within a device The DMC 41x3 can have a maximum of 8 Ethernet handles open at any time When using TCP IP each master or slave uses an individual Ethernet handle In UDP IP one handle may be used for all the masters but each slave uses one Pings and ARPs do not occupy handles If all 8 handles are in use and a 9 master tries to connect it will be sent a reset packet that generates the appropriate error in its windows application NOTE There are a number of ways to reset the controller Hardware reset push reset button or power down controller and software resets through Ethernet or USB by entering RS When the Galil controller acts as the master the IH command is used to assign handles and connect to its slaves The IP address may be entered as a 4 byte number separated with commas industry standard uses periods or as a signed 32 bit number A port number may also be specified but if it is not it will default to 1000 The protocol TCP IP or UDP IP to use must also b
56. SINK DO T6 9 OPIA GND wate Ado ganis MES 4HOM dI GND 280P0A MOMO MORO 280PIA iy ROM dma OFIB S H4VOG MNC 7 2v ZIHALA 12HALB SOIR g9FLSD 25RLSD gHomc serisH 25RLSH 9HOMG 1540V gysy AB ENBLY engi 7 AEN gerisc 24 ALSO s Home serisc 24RLSG g HOMF HIGH POWER OPTION HP HP1 J9MOMD seno THALC 37FLSB 23RLS8 7HOMA 37FLSF 23 RLSE 7 HOME SOURCE DO 8 1 OPOA 12 24VDC 36 ELSA ZARLA GLSCOM 36FLSE ARISE 6 LSCOM FM M Dy Ue n EM Ue ilo SOURCE DO 6 9 OPIA 12 24VDC SADIE opis SUE gore ora 008 500mA OP1B GND QD septa SUN Spore worn DI 31GND 7 INCOM 4 ERR 31GND I7 INCOM ERR 16 RST 18R GND 20 60VDC O GALIL Figure 2 5 Power Connector locations for the DMC 41x3 VDC 20 80V DC GROUND Figure 2 6 Power Connector used when controller is ordered without Galil Amplifiers See Power connector information for specific amplifiers in the Integrated section of the Appendices For more information on Connectors mfg PN s and diagrams see the Power Connector Section in the Appendix Chapter 2 Getting Started e 11 DMC 41x3 User Manual DMC 41x3 Mounting Instructions CARD All standoff locations must be used when mounting the CARD version of the DMC 41x3 controllers There are 6 standoff locations for the DMC 4143 controller and 8 standoff locations for the DMC 4183 controller See Figure 2 1 and Figure 2 2 for mounting hole sizing and locations The minimum standoff hei
57. Specify acceleration for the B axis as 200000 Instead of data some commands request action to occur on an axis or group of axes For example ST AB stops motion on both the A and B axes Commas are not required in this case since the particular axis is specified by the appropriate letter A B C or D If no parameters follow the instruction action will take place on all axes Here are some examples of syntax for requesting action BG A Begin A only BG B Begin B only BG ABCD Begin all axes BG BD Begin B and D only BG Begin all axes For controllers with 5 or more axes the axes are referred to as A B C D E F G H The specifiers X Y Z W and A B C D may be used interchangeably BG ABCDEFGH Begin all axes BG D Begin D only Coordinated Motion with more than 1 axis When requesting action for coordinated motion the letter S or T is used to specify the coordinated motion This allows for coordinated motion to be setup for two separate coordinate systems Refer to the CA command in the Command Reference for more information on specifying a coordinate system For example BG S Begin coordinated sequence S BG TD Begin coordinated sequence T and D axis Controller Response to DATA The DMC 41x3 returns a for valid commands and a for invalid commands For example if the command BG is sent in lower case the DMC 41x3 will return a bg invalid command lower case Chapter 5 Command Basics e 65 DMC 41x3 User Manual DMC 4
58. Status Reserved B User defined variable ZA C axis status see bit field map below C axis switches see bit field map below C axis stop code C axis reference position C axis motor position Chapter 4 Software Tools and Communication e 55 DMC 41x3 User Manual 166 169 170 173 174 177 178 181 182 183 184 185 186 189 190 191 192 193 194 197 198 201 202 205 206 209 210 213 214 217 218 219 220 221 222 225 226 227 228 229 230 233 234 237 238 241 242 245 246 249 250 253 254 255 256 257 258 261 262 263 264 265 266 269 270 273 274 277 278 281 282 285 286 289 290 291 SL SL SL SL SW or UW UB UB SL SL SL SW or UW UB SL SL SL SW or UW UB UB SL UW UB UB SL SL SL SL SL SL SW or UW C axis position error C axis auxiliary position C axis velocity C axis torque C axis analog input C Hall Input Status Reserved C User defined variable ZA D axis status see bit field map below D axis switches see bit field map below D axis stop code D axis reference position D axis motor position D axis position error D axis auxiliary position D axis velocity D axis torque D axis analog input D Hall Input Status Reserved D User defined variable ZA E axis status see bit field map below E axis switches see bit field map below E axis stop code E axis reference position E axis motor position E axis posit
59. The design procedure is best illustrated by a design example Consider a system with the following parameters K 0 2 Nm A Torque constant J 2 104 kg m System moment of inertia R 2 Q Motor resistance K 2 Amp Volt Current amplifier gain N 1000 Counts rev Encoder line density The DAC of theDMC 41x3 outputs 10V for a 16 bit command of 32768 counts The design objective is to select the filter parameters in order to close a position loop with a crossover frequency of 500 rad s and a phase margin of 45 degrees The first step is to develop a mathematical model of the system as discussed in the previous system Motor M s P I Kt Js 1000 5 Amp K 2 Amp V DAC K 10 32768 0003 Encoder K 4N 2 636 ZOH H s 2000 s 2000 Compensation Filter G s P sD Chapter 10 Theory of Operation e 189 DMC 41x3 User Manual The next step is to combine all the system elements with the exception of G s into one function L s L s M s K Ka Kp H s 3 17 10 s s 2000 Then the open loop transfer function A s is A s L s G s Now determine the magnitude and phase of L s at the frequency 500 L j500 3 17 10 j500 2 j500 2000 This function has a magnitude of L j500 0 00625 and a phase Arg L j500 180 tan 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that A j
60. The value of CS VPX and VPY will be zero Now suppose that the interrogation is repeated at the second segment when Y 2000 The value of _ AV at this point is 7000 CS equals 1 VPX 5000 and VPY 0 Example Linear Move Make a coordinated linear move in the ZW plane Move to coordinates 40000 30000 counts at a vector speed of 100000 counts sec and vector acceleration of 1000000 counts sec2 LM ZW Specify axes for linear interpolation DMC 41x3 User Manual Chapter 6 Programming Motion e 84 LI 40000 30000 Specify ZW distances LE Specify end move VS 100000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration BGS Begin sequence Note that the above program specifies the vector speed VS and not the actual axis speeds VZ and VW The axis speeds are determined by the controller from VS VVZ VW The result is shown in Figure 6 6 30000 27000 POSITION W 3000 0 4000 36000 40000 POSITION Z FEEDRATE 0 0 1 0 5 0 6 TIME sec VELOCITY Z AXIS TIME sec VELOCITY W AXIS TIME sec Figure 6 6 Linear Interpolation Chapter 6 Programming Motion e 85 DMC 41x3 User Manual Example Multiple Moves This example makes a coordinated linear move in the XY plane The Arrays VX and VY are used to store 750 incremental distances which are filled by the program LOAD LOAD DM VX 750 VY 750 COUNT 0 N 0 LOOP VX COUNT
61. UB 4 Byte of Header 04 05 UW sample number 06 UB general input block 0 inputs 1 8 07 UB general input block 1 inputs 9 16 08 UB general input block 2 inputs 17 24 09 UB general input block 3 inputs 25 32 10 UB general input block 4 inputs 33 40 11 UB general input block 5 inputs 41 48 12 UB general input block 6 inputs 49 56 13 UB general input block 7 inputs 57 64 14 UB general input block 8 inputs 65 72 15 UB general input block 9 inputs 73 80 16 UB general output block 0 outputs 1 8 17 UB general output block 1 outputs 9 16 18 UB general output block 2 outputs 17 24 19 UB general output block 3 outputs 25 32 20 UB general output block 4 outputs 33 40 21 UB general output block 5 outputs 41 48 22 UB general output block 6 outputs 49 56 23 UB general output block 7 outputs 57 64 24 UB general output block 8 outputs 65 72 25 UB general output block 9 outputs 73 80 26 27 SW Reserved 28 29 SW Reserved 30 31 SW Reserved 32 33 SW Reserved 34 35 SW Reserved 36 37 SW Reserved 38 39 SW Reserved 40 41 SW Reserved 42 UB Ethernet Handle A Status 43 UB Ethernet Handle B Status 44 UB Ethernet Handle C Status 45 UB Ethernet Handle D Status 46 UB Ethernet Handle E Status 47 UB Ethernet Handle F Status 48 UB Ethernet Handle G Status 49 UB Ethernet Handle H Status DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 54 50 51 52 55 56 59 60 61 62 63 64 65 66 69
62. a 4 A limit for the group of 8 outputs These outputs are capable of driving inductive loads such as solenoids or relays The outputs are configured for hi side drive only The supply voltage must be connected to OPxA and the supply return must be connected to OPxB The ABCD HRSC option configures digital outputs 1 8 for 500mA sourcing this is shown in Figure 3 14 The EFGH HRSC option only valid for 5 8 axis controllers configures digital outputs 9 16 for 5 00mA sourcing this is shown in Figure 3 15 Electrical Specifications Output Common OPOA OP1A Max Voltage 24 VDC Min Voltage 12 VDC Max Drive Current per Output 0 5 A not to exceed 4A for all 8 outputs Wiring the 500mA Sourcing Opto Isolated Outputs The outputs will be the voltage that is supplied to the OPxA pin Up to 24 VDC may be supplied to OPxA The outputs are configured for hi side drive only The supply voltage must be connected to OPxA and the supply return must be connected to OPxB The load will be connected from the digital output to the Return of the 12 24VDC source and OPxB as shown in Figure 3 14 and Figure 3 15 3 3V Output Supply CPU amp IRF7342 ZN MMBD1204 10K LOAD Output Supply Return Figure 3 14 500mA sourcing outputs for ABCD HRSC option DO 8 1 3 3V Output Supply HA DO 16 9 CPU IRF7342 MMBD1204 40K LOAD Lg OP1B Output Supply Return Figure 3 15 500mA sourcing outputs for EFGH HRSC option
63. also provided The DMC 4153 through DMC 4183 controller provides an additional 8 opto isolated inputs and 8 opto isolated outputs System Elements As shown in Figure 1 2 the DMC 41x3 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Power Supply Amplifier Driver Computer DMC 41x3 Controller Figure 1 2 Elements of Servo Systems Motor A motor converts current into torque which produces motion Each axis of motion requires a motor sized properly to move the load at the required speed and acceleration Galil s MotorSizer Web tool can help you with motor sizing www galilmc com support motorsizer The motor may be a step or servo motor and can be brush type or brushless rotary or linear For step motors the controller can be configured to control full step half step or microstep drives An encoder is not required when step motors are used Other motors and devices such as Ultrasonic Ceramic motors and voice coils can be controlled with the DMC 41x3 Amplifier Driver For each axis the power amplifier converts a 10 volt signal from the controller into current to drive the motor For stepper motors the amplifier converts step and direction signals into current The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides ele
64. and not begin execution until the user gives the lt return gt command IMPORTANT All DMC 41x3 commands are sent in upper case For example the command PR 4000 lt return gt Position relative Implicit Notation PR is the two character instruction for position relative 4000 is the argument which represents the required position value in counts The lt return gt terminates the instruction The space between PR and 4000 is optional DMC 41x3 User Manual Chapter 5 Command Basics e 64 For specifying data for the A B C and D axes commas are used to separate the axes If no data is specified for an axis a comma is still needed as shown in the examples below If no data 1s specified for an axis the previous value is maintained To view the current values for each command type the command followed by a for each axis requested PR 1000 Specify A only as 1000 PR 2000 Specify B only as 2000 PR 3000 Specify C only as 3000 PR 4000 Specify D only as 4000 PR 2000 4000 6000 8000 Specify A B C and D PR 8000 9000 Specify B and D only PR 2 2 7 Request A B C D values PR Request B value only Explicit Notation The DMC 41x3 provides an alternative method for specifying data Here data is specified individually using a single axis specifier such as A B C or D An equals sign is used to assign data to that axis For example PRA 1000 Specify a position relative movement for the A axis of 1000 ACB 200000
65. are as defined previously For example a current amplifier with K 2 A V with the motor described by the previous example will have the transfer function P V 1000 s rad V If the motor is a DC brushless motor it is driven by an amplifier that performs the commutation The combined transfer function of motor amplifier combination is the same as that of a similar brush motor as described by the previous equations Velocity Loop The motor driver system may include a velocity loop where the motor velocity is sensed by a tachometer and is fed back to the amplifier Such a system is illustrated in Figure 10 5 Note that the transfer function between the input voltage V and the velocity is o V K K Js 1 K K K Js 1 K sT 1 where the velocity time constant T equals T J K KK This leads to the transfer function P V V K s sT 1 E E qa NN kK HW kws K Figure 10 5 Elements of velocity loops DMC 41x3 User Manual Chapter 10 Theory of Operation e 184 The resulting functions derived above are illustrated by the block diagram of Figure 10 6 VOLTAGE SOURCE V E m W P L SE x ST 1 ST 1 CURRENT SOURCE V W P VELOCITY LOOP V W P 1 KST 1 S Figure 10 6 Mathematical model of the motor and amplifier in three operational modes Encoder The
66. axis is not profiling The IL command must be set to a value greater than the OV setting The TL command must be set to a value greater than the OV setting Example The A axis is setup with the following settings for encoder failure detection OA 1 OT 500 OV 3 OE 1 ER 1000 The A axis is commanded to move 300 counts but the B channel on the encoder has failed and no longer operates Because the ER setting is greater than the commanded move the error will not be detected by using the OE and ER commands but this condition will be detected as a encoder failure When the axis is commanded to move a 300 counts the position error will cause the motor command voltage to be increased to a value that will be greater than the OV value 3 volts in this case Once the motor command output is greater than the OV threshold for more than than the 500ms defined by the OT command AND there has been less than 4 counts of change on the encoder then the controller will turn off that axis due to an encoder failure The motor will have moved some distance during this operation but it will be shut down before a full runaway condition occurs Using Encoder Failure to detect a hard stop or stalled motor The encoder failure detection can also be used to detect when an axis is up against a hard stop In this scenario the motor command will be commanded above the OV threshold but because the motor is not moving the controller will detect this scenario as an encod
67. better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000 count per revolution results in a rotary resolution of 0 25 micron This results in equal resolution on both linear and rotary sensors To illustrate the control method assume that the rotary encoder is used as a feedback for the X axis and that the linear sensor is read and stored in the variable LINPOS Further assume that at the start both the position of X and the value of LINPOS are equal to zero Now assume that the objective is to move the linear load to the position of 1000 The first step is to command the X motor to move to the rotary position of 1000 Once it arrives we check the position of the load If for example the load position is 980 counts it implies that a correction of 20 counts must be made However when the X axis is commanded to be at the position of 1000 suppose that the actual position is only 995 implying that X has a position error of 5 counts which will be eliminated once the motor settles This implies that the correction needs to be only 15 counts since 5 counts out of the 20 would be corrected by the X axis Accordingly the motion correction should be Correction Load Position Error Rotary Position Error The correction can be performed a few times until the error drops below 2 counts Often this is performed in one correction cy
68. deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point As an example consider the following program ALT Label for alternative program DP 0 0 Define Position of X and Y axis to be 0 LMXY Define linear mode between X and Y axes LI 4000 0 lt 4000 gt 1000 Specify first linear segment with a vector speed of 4000 and end speed 1000 LI 1000 1000 lt 4000 Specify second linear segment with a vector speed of 4000 and end speed gt 1000 1000 LI 0 5000 lt 4000 Specify third linear segment with a vector speed of 4000 and end speed 1000 gt 1000 LE End linear segments BGS Begin motion sequence EN Program end Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS to be scaled VR also applies when the vector speed is specified with the operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided in half Chapter 6 Programming Motion e 83 DMC 41x3 User Manual Command Summary Linear Interpolation COMMAND LM xyzw LM abcdefgh LM LI X Y Z W lt n LI a b c d e f g h lt n VSn VAn VDn VRn BGS CS LE LE AMS AVn IT DESCRIPTION Specify axes for linear interpolation
69. desired output currents of 1 and 5 amps First calculate the minimum power used in the amplifier P i lamp 4 i i 54 1 5 6W P s Samp 4 5 5 54 3 5 125W The power used by the motor will vary by its velocity even though the power lost in the motor is a constant for each value of current The more power sent to the motor the less power will be dissipated by the amplifier as heat Power Dissipated by the Amplifier for a Given Velocity and Current 25 20 a a 1 Amp e 5 Amp zx o Power Watts Velocity KRPM Figure A5 2 Power Dissipation for Velocity and Current A5 AMP 43640 D3640 e 241 DMC 41x3 User Manual Operation Finding Proper Commutation Using the D3640 requires version 1 1d revision firmware or higher be sure this is installed on your controller http www galilmc com support firmware downloads php The 6 commands used for set up are the BA BM BX BZ BC and BI commands Please see the command reference for details For detailed information on setting up commutation on the AMP 43640 can be found here http www galilmc com techtalk drives wiring a brushless motor for galils sine amplifier 1 Issue the BA command to specify which axis you want to use the sinusoidal amplifier on 2 Calculate the number of encoder counts per magnetic cycle For example in a rotary motor that has 2 pole pairs and 10 000 cou
70. distance of 4000 is reached VS 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached VS 4000 Change vector speed EN Program end In this example the XY system is required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trippoint which slows the speed to 1000 count s Once the motors reach the corner the speed is increased back to 4000 counts s Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications such as CNC it is necessary to attach various speeds to different motion segments This can be done by two functions lt n and gt m For example LI x y z w lt n gt m The first command n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function 72100000 is followed by 75000 and the distance for
71. exceeds the error limit ER the error light will come on to signify there is an axis that has exceeded the position error limit Use a DP 0 to set all encoder positions to zero or a SH Servo Here command to eliminate position error Invalid Firmware If the controller is interrupted during a firmware update or an incorrect version of firmware is installed the error light will come on The prompt will show up as a greater than sign gt instead of the standard colon prompt Use GalilTools software to install the correct version of firmware to fix this problem Self Test During the first few seconds of power up it is normal for the red LED to turn on while it is performing a self test If the self test detects a problem such as corrupted memory or damaged hardware the error light will stay on to signal a problem with the board To fix this problem a Master Reset may be required The Master Reset will set the controller back to factory default conditions so it is recommended that all motor and I O cables be removed for safety while performing the Master Reset Cables can be plugged back in after the correct settings have been loaded back to the controller when necessary To perform a Master Reset find the jumper location labeled MR or MRST on the controller and put a jumper across the two pins Power up with the jumper installed The Self Test will take slightly longer up to 5seconds After the error light shuts off it is s
72. function on geared axis or aux inputs Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW x y z w sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stop code will be set to 99 An application program will jump to label MCTIME Halts program execution until after specified input is at specified logic level n specifies input line Positive is high logic level negative is low level n 1 through 8 for DMC 4113 4123 4133 4143 n 1 through 16 for DMC 4153 4163 4173 4183 Also n 17 48 Halts program execution until specified axis has reached its slew speed For m omitted or 0 halts program execution until n msec from reference time AT 0 sets reference AT n waits n msec from reference AT n waits n msec from reference and sets new reference after elapsed time For m 1 Same functionality except that n is number of samples rather than msec Halts program execution until specified distance along a coordinated path has occurred Chapter 7 Application Programming e 129 DMC 41x3 User Manual For m omitted or 0 halts program execution until specified time in msec has elapsed For m 1 Same functionality except that n is number of samples rather than msec Event Trigger Examples Event Trigger Multiple Move Sequence The AM trippoint is used to separate the tw
73. information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connection If information is lost the controller does not return a colon or question mark Because UDP does not provide for lost information the sender must re send the packet It is recommended that the motion control network containing the controller and any other related devices be placed on a closed network If this recommendation is followed UDP IP communication to the controller may be utilized instead of a TCP connection With UDP there is less overhead resulting in higher throughput Also there is no need to reconnect to the controller with a UDP connection Because handshaking is built into the Galil communication protocol through the use of colon or question mark responses to commands sent to the controller the TCP handshaking is not required Packets must be limited to 512 data bytes including UDP TCP IP Header or less Larger packets could cause the controller to lose communication NOTE In order not to lose information in transit the user must wait for the controller s response before sending the next packet Addressing There are three levels of addresses that define Ethernet devices The first is the MAC or hardware address This is a unique and permanent 6 byte number No other device will have the same MAC address The DMC 41x3 MAC address is set by the factory and the last two bytes of the address are the serial number of the boa
74. input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is of the full voltage range for example connect the input to 5 volts if the signal is a 0 12 volt logic Example A DMC 4113 has one auxiliary encoder This encoder has two inputs channel A and channel B Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal will be connected to AA and the second to AB AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Chapter 7 Application Programming e 161 DMC 41x3 User Manual Input Interrupt Function The DMC 41x3 provides an input interrupt function which causes the program to automatically execute the instructions following the ININT label This function is enabled using the II m n o command The m specifies the beginning input and n specifies the final input in the range The parameter o is an interrupt mask If m and n are unused o contains a number with the mask For example IL 5 enables inputs 1 and 3 A low
75. input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RT command is used to return from this subroutine to the place in the program where the interrupt had occurred Important Use the RI command not EN to return from the ZININT subroutine Example Input Interrupt Instruction Interpretation TA Label A II 1 Enable input 1 for interrupt function JG 30000 20000 Set speeds on A and B axes BG AB Begin motion on A and B axes B Label B TP AB Report A and B axes positions WT 1000 Wait 1000 milliseconds JP B Jump to B EN End of program ININT Interrupt subroutine MG Interrupt has occurred Displays the message ST AB Stops motion on A and B axes LOOP JP LOOP IN 1 0 Loop until Interrupt cleared JG 15000 10000 Specify new speeds WT 300 Wait 300 milliseconds BG AB Begin motion on A and B axes RI Return from Interrupt subroutine Jumping back to main program with ININT To jump back to the main program using the JP command the RI command must be issued in a subroutine and then the ZS command must be issued prior to the JP command See Application Note 2418 for more information http www galilmc com support appnotes optima note2418 pdf Analog Inputs The DMC 41x3 provides eight analog inputs The value of these inputs in volts may be read using the AN n function where n is the analog input through 8 The resolution o
76. new data record is found and the controller is still in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a Specifying a 1 for the DT or as the time interval in the CD command will pause the contour buffer Issuing the CM command will clear the contour buffer Command Summary Contour Mode COMMAND DESCRIPTION CM XYZW Specifies which axes for contouring mode Any non contouring axes may be operated in other modes CM ABCDEFGH Contour axes for DMC 4183 CD x y z W Specifies position increment over time interval Range is 32 000 CD 0 0 0 0 ends the contour buffer This is much like the LE or VE commands CD a b c d e f g h Position increment data for DMC 4183 DTn Specifies time interval 2 sample periods 1 ms for TM1000 for position increment where n is an integer between 1 and 8 Zero ends contour mode If n does not change it does not need to be specified with each CD _CM Amount of space left in contour buffer 511 maximum General Velocity Profiles The Contour Mode is ideal for generating any arbitrary velocity profiles The velocity profile can be specified as a mathematical function or as a collection of points The design includes two parts Generating an array with data points and running the program DMC 41x3 User Manual Chapter 6 Programming Motion e 106 Generating an Arra
77. of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command When active inhibits motion in reverse direction Also causes execution of limit switch subroutine LIMSWI The polarity of the limit switch may be set with the CN command Input for Homing HM and Find Edge FE instructions Upon BG following HM or FE the motor accelerates to slew speed A transition on this input will cause the motor to decelerate to a stop The polarity of the Home Switch may be set with the CN command Uncommitted inputs May be defined by the user to trigger events Inputs are checked with the Conditional Jump instruction and After Input instruction or Input Interrupt Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W if the high speed position latch function is enabled High speed position latch to capture axis position on occurrence of latch signal AL command arms latch Input 1 is latch X Input 2 is latch Y Input 3 is latch Z and Input 4 is latch W Input 9 is latch E input 10 is latch F input 11 is latch G input 12 is latch H DMC 41x3 User Manual Appendices 206 Coordinated Motion Mathematical Analysis The terms of coordinated motion are best explained in terms of the vector motion The vector velocity Vs which is also known as the feed rate is the vector sum of the velocities along the X and Y axes Vx and Vy Vs JVx Vy The vecto
78. often desirable to restart the program sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of the LIMSWI routine Auto Start Routine The DMC 41x3 has a special label for automatic program execution A program which has been saved into the controller s non volatile memory can be automatically executed upon power up or reset by beginning the program with the label AUTO The program must be saved into non volatile memory using the command BP Automatic Subroutines for Monitoring Conditions Often it is desirable to monitor certain conditions continuously without tying up the host or DMC 41x3 program sequences The controller can monitor several important conditions in the background These conditions include checking for the occurrence of a limit switch a defined input position error or a command error Automatic monitoring is enabled by inserting a special predefined label in the applications program The pre defined labels are SUBROUTINE DESCRIPTION LIMSWI Limit switch on any axis goes low ININT Input specified by II goes low POSERR Position error exceeds limit specified by ER MCTIME Motion Complete timeout occurred Timeout period set by TW command CMDERR Bad command given AUTO Automatically executes on power up DMC 41x3 User Manual Chapter 7 Application Programming e 136 AUTOERR Automatically executes when a checksum is encountered du
79. position of the main or auxiliary encoders of X Y Z or W to be captured within 25 microseconds of an external low input signal or index pulse The general inputs through 4 and 9 thru 12 correspond to each axis 1 through 4 INI X axis latch IN2 Y axis latch IN3 Z axis latch INA W axis latch 9 through 12 IN9 E axis latch INIO F axis latch INI1 G axis latch INI2 H axis latch NOTE To insure a position capture within 25 microseconds the input signal must be a transition from high to low The DMC 41x3 software commands AL and RL are used to arm the latch and report the latched position The steps to use the latch are as follows DMC 41x3 User Manual Chapter 6 Programming Motion e 122 1 Give the AL XYZW command or ABCDEFGH for DMC 4183 to arm the latch for the main encoder and ALSXSYSZSW for the auxiliary encoders 2 Test to see if the latch has occurred Input goes low by using the AL X or Y or Z or W command Example V1 _ALX returns the state of the X latch into V1 V1 is 1 if the latch has not occurred 3 After the latch has occurred read the captured position with the RL XYZW command or RL XYZW NOTE The latch must be re armed after each latching event Example Latch JG 5000 BG Y AL Y Wait JP Wait ALY 1 Result RLY Result EN Latch program Jog Y Begin motion on Y axis Arm Latch for Y axis Wait label for loop Jump to Wait label if latch has not occurred Set value of variabl
80. programs that is downloaded to the controller At the Galil API level the GalilTools Communication Library is available for users who wish to develop their own custom application programs to communicate to the controller Custom application programs can utilize API function calls directly to our DLL s At the driver level we provide fundamental hardware interface information for users who desire to create their own drivers Controller Response to Commands Most DMC 41x3 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return Multiple commands may be concatenated by inserting a semicolon between each command After the instruction is decoded the DMC 41x3 returns a response to the port from which the command was generated If the instruction was valid the controller returns a colon or the controller will respond with a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the USB port back through the USB port and to commands which are sent via the Ethernet port back through the Ethernet port For instructions that return data such as Tell Position TP the DMC 41x3 will return the data followed by a carriage return line feed and DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 46 It is good practice to check for after each command is sent to prevent
81. short if the X axis does not reach the commanded position within 1 second of the end of the profiled move Example Command Error BEGIN speed 2000 JG speed BGX LOOP JG speed WT100 JP LOOP EN CMDERR JP DONE ED lt gt 2 JP DONE TC lt gt 6 MG SPEED TOO HIGH MG TRY AGAIN ZS1 JP BEGIN DONE Zso EN Begin main program Set variable for speed Begin motion Update Jog speed based upon speed variable End main program Command error utility Check if error on line 2 Check if out of range Send message Send message Adjust stack Return to main program End program if other error Zero stack End program The above program prompts the operator to enter a jog speed If the operator enters a number out of range greater than 8 million the ZCMDERR routine will be executed prompting the operator to enter a new number DMC 41x3 User Manual Chapter 7 Application Programming e 138 In multitasking applications there is an alternate method for handling command errors from different threads Using the XQ command along with the special operands described below allows the controller to either skip or retry invalid commands OPERAND FUNCTION _EDI Returns the number of the thread that generated an error _ED2 Retry failed command operand contains the location of the failed command _ED3 Skip failed command operand contains the location of the command after the failed command
82. the X axis the ZLIMSWI subroutine will be executed Notes regarding the LIMSWI Routine 1 The RE command is used to return from the ZLIMSWI subroutine 2 The LIMSWI subroutine will be re executed if the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error LOOP JP LOOP EN POSERR V1 TEX MG EXCESS POSITION ERROR MG ERROR V1 RE XQ LOOP JG 100000 BGX Dummy Program Loop Position Error Routine Read Position Error Print Message Print Error Return from Error Download program Execute Dummy Program Jog at High Speed Begin Motion Chapter 7 Application Programming e 137 DMC 41x3 User Manual Example Input Interrupt A Label IIL Input Interrupt on 1 JG 30000 60000 Jog BGXW Begin Motion LOOP JP LOOP EN Loop ININT Input Interrupt STXW AM Stop Motion TEST JP TEST IN 1 0 Test for Input 1 still low JG 30000 6000 Restore Velocities BGXW Begin motion RIO Return from interrupt routine to Main Program and do not re enable trippoints Example Motion Complete Timeout BEGIN Begin main program TW 1000 Set the time out to 1000 ms PA 10000 Position Absolute command BGX Begin motion MCX Motion Complete trip point EN End main program MCTIME Motion Complete Subroutine MG X fell short Send out a message EN End subroutine This simple program will issue the message X fell
83. type4 Selects the type of data to be recorded where typel type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command Chapter 7 Application Programming e 151 DMC 41x3 User Manual RC n m The RC command begins data collection Sets data capture time interval where n is an integer between 1 and 8 and designates 2 msec between data m is optional and specifies the number of elements to be captured If m is not defined the number of elements defaults to the smallest array defined by DM When m is a negative number the recording is done continuously in a circular manner _RD is the recording pointer and indicates the address of the next array element n 0 stops recording RC Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Recording Data type Description TIME Controller time as reported by the TIME command _AFn Analog input n X Y Z W E F G H for AN inputs 1 8 _DEX 2 encoder position dual encoder _NOX Status bits _OP Output _RLX Latched position _RPX Commanded position SCX Stop code _TEX Position error TI Inputs _TPX Encoder position _TSX Switches only bit 0 4 valid TTX Torque reports digital value 32544 NOTE X may be replaced by Y Z or W for capturing data on other axes
84. up to 3 million steps per second Sample rates as low as 62 usec per axis are available A Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field The DMC 41x3 is available with up to eight axes in a single stand alone unit The DMC 4113 4123 4133 4143 are one thru four axes controllers and the DMC 4153 4163 4173 4183 are five thru eight axes controllers All eight axes have the ability to use Galil s integrated amplifiers or drivers and connections for integrating external devices Designed to solve complex motion problems the DMC 41x3 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences contouring and a PVT Mode The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 41x3 provides continuous vector feed of an infinite number of linear and arc segments The controller also features electronic gearing with multiple master axes as well as gantry mode operation For synchronization with outside events the DMC 41x3 provides uncommitted I O including 8 opto isolated digital inputs 16 inputs for DMC 4153 thru DMC 4183 8 optically isolated outputs 16 outputs for DMC 4153 thru DMC 4183 and 8 analog inputs for interface to joysticks sensors and pressure
85. usually due to a short across the motor leads or a short from a motor lead to ground DMC 41x3 User Manual A1 AMP 430x0 D3040 D3020 e 222 Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled Bit 2 of TAO will be set when the over temperature occurs on the A D axis amplifier and Bit 6 of TAO will be set when the over temperature occurs on the E H axis amplifier The over temperature condition will trigger the AMPERR routine if included in the program on the controller A1 AMP 430x0 D3040 D3020 e 223 DMC 41x3 User Manual A2 AMP 43140 D3140 Description The AMP 43140 resides inside the DMC 41x3 enclosure and contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 VDC input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 kHz The AMP 43140 can be ordered to have a 100mA maximum current output where the gain of the amplifier is 10mA V Order as D3140 100mA The BOX option is required when the AMP 43140 is ordered with the DMC 41x3 NOTE Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnect
86. where A7 is the command number for PR 02 specifies 2 bytes for each data field DMC 41x3 User Manual Chapter 5 Command Basics e 68 00 S is not active for PR 05 specifies bit 0 is active for A axis and bit 2 is active for C axis 2 22 5 03 E8 represents 1000 FE OC represents 500 Example The command ST XYZS would be Al 00 01 07 where Al is the command number for ST 00 specifies 0 data fields 01 specifies stop the coordinated axes S 07 specifies stop X bit 0 Y bit 1 and Z bit 2 2242142 7 Binary command table Command No Command No pope pec EM KP Em pem pe TT KD pi ee p E i Command No e MI D rem p E a 99 N Chapter 5 Command Basics e 69 DMC 41x3 User Manual EY Ee e pu pem n iM B a S eee o RR RR SH aa reserved d5 DMC 41x3 User Manual Chapter 5 Command Basics e 70 Chapter 6 Programming Motion Overview The DMC 41x3 provides several modes of motion including independent positioning and jogging coordinated motion electronic cam motion and electronic gearing Each one of these modes is discussed in the following sections The DMC 4113 are single axis controllers and use X axis motion only Likewise the DMC 4123 use X and Y the DMC 4133 use X Y and Z and the DMC 4143 use X Y Z and W The DMC 4153 use A B C D and E The DMC 4163 use A B C D E and F The DMC 4173 use A B C D E F and G The DMC 4183 use the axes A
87. with a cycle of 2000 counts The cam table can be constructed manually point by point or automatically by a program The following program includes the set up The instruction EAX defines X as the master axis The cycle of the master is 2000 Over that cycle Y varies by 1000 This leads to the instruction EM 2000 1000 Suppose we want to define a table with 100 segments This implies increments of 20 counts each If the master points are to start at zero the required instruction is EP 20 0 The following routine computes the table points As the phase equals 0 18X and X varies in increments of 20 the phase varies by increments of 3 6 The program then computes the values of Y according to the equation and assigns the values to the table with the instruction ET N Y DMC 41x3 User Manual Chapter 6 Programming Motion e 96 INSTRUCTION SETUP EAX EM 2000 1000 EP 20 0 N 0 LOOP P N 3 6 S SIN P 100 Y N 10 S ET N Y N N41 JP LOOP N lt 100 EN INTERPRETATION Label Select X as master Cam cycles Master position increments Index Loop to construct table from equation Note 3 6 0 18 20 Define sine position Define slave position Define table Repeat the process Now suppose that the slave axis is engaged with a start signal input 1 but that both the engagement and disengagement points must be done at the center of the cycle X 1000 and Y 500 This implies that Y must be driv
88. 0000 Set the X axis acceleration to 150000 counts sec2 DC 1500007 Set the X axis deceleration to 150000 counts sec2 SP 50000 Set the X axis speed to 50000 counts sec PA 5000 Command the X axis to absolute position 5000 encoder counts EN The output from this code can be seen in Figure 6 2 a screen capture from the GalilTools scope Scope ES a vertical Horizontal TE didt Source Scale div Offset div 1 g im _RPA Axis A ref 500 count i 5 a leo w sooo 2 E a 2 s 1 T A BO x 0 221383 0 s m mr w 442765 S 1 m w o4esi j2 S RO x 0 221383 S 3 m a 0 221383 4 E t 50 ms o0 Trigger Channel W RP x Edge iv Level 2500 count Mode Repeat x READY _RPA Figure 6 2 Position vs Time msec Motion 1 DMC 41x3 User Manual Chapter 6 Programming Motion e 78 Example Motion 2 The previous step showed the plot if the motion continued all the way to 5000 however partway through the motion the object that was being tracked changed direction so the host program determined that the actual target position should be 2000 counts at that time Figure 6 2 shows what the position profile would look like if the move was allowed to complete to 5000 counts The position was modified when the robot was at a position of 4200 counts Figure 6 3 Note that the robot actually travels to a distance of almost 5000 counts before it turns
89. 1 0040 MOLEX744476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Phase C Phase B N C for Bushed Motors No Connect Phase A DMC 41x3 User Manual A4 AMP 435x0 D3540 D3520 e 234 Operation Setting up the Brushless Mode and finding proper commutation Using the D3540 requires version 1 1d revision firmware or higher be sure this is installed on your controller http www galilmc com support firmware downloads php The 6 commands used for set up are the BA BM BX BZ BC and BI commands Please see the command reference for details Further information on setting up commutation on the AMP 43540 can also be found here http www galilmc com techtalk drives wiring a brushless motor for galils sine amplifier 1 Issue the BA command to specify which axis you want to use the sinusoidal amplifier on 2 Calculate the number of encoder counts per magnetic cycle For example in a rotary motor that has 2 pole pairs and 10 000 counts per revolution the number of encoder counts per magnetic cycle would be 10 000 2 5000 Assign this value to BM 3 Issue either the BZ or BX command Either the BX or BZ command must be executed on every reset or power up of the controller BZ Command Issue the BZ command to lock the motor into a phas
90. 15 with the specified PVT points enlarged Y Axis Counts 6000 X vs Y Commanded Positions 5000 4000 3000 2000 1000 0 T 0 1000 2000 3000 4000 5000 6000 7000 8000 1000 X Axis Counts Figure 6 15 X vs Y Commanded Positions for Multi Axis Coordinated Move DMC 41x3 User Manual Chapter 6 Programming Motion e 104 Contour Mode The DMC 41x3 also provides a contouring mode This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes This is ideal for following computer generated paths such as parabolic spherical or user defined profiles The path is not limited to straight line and arc segments and the path length may be infinite Specifying Contour Segments The Contour Mode is specified with the command CM For example CMXZ specifies contouring on the X and Z axes Any axes that are not being used in the contouring mode may be operated in other modes A contour is described by position increments which are described with the command CD x y z w over a time interval DT n The parameter n specifies the time interval The time interval is defined as 2 sample period 1 ms for TM1000 where n is a number between 1 and 8 The controller performs linear interpolation between the specified increments where one point is generated for each sample If the time interval changes for each segment use CD x y z w n where n is the ne
91. 16 bit optional Opto Isolated 4mA sinking 25mA and 500mA options Opto Isolated 4mA sinking 25mA and 500mA options Auxiliary Encoder Inputs for A X axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for B Y axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts DMC 41x3 User Manual Appendices e 192 DI85 DI86 DMC 4133 through DMC 4183 only DI87 DI88 DMC 4143 through DMC 4183 only DI89 DI90 DMC 4153 through DMC 4183 only DI91 DI92 DMC 4163 through DMC 4183 only DI93 DI94 DMC 4173 through DMC 4183 only DI95 DI96 DMC 4183 only Power Requirements 20 80 VDC 10W at 25 deg C Auxiliary Encoder Inputs for C Z axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for D W axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for E axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for F axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts Auxiliary Encoder Inputs for G axis Line Receiver Inputs accepts differential or single e
92. 1x3 motion controller The termination resistors are 120 Ohm and are placed between the positive and negative differential inputs on the Main A B Index channels as well as the Auxiliary A and B channels as in Figure A 1 MANB MAAABE MANE MAA AB Installed whenTRES option is ordered Figure A 1 Encoder Inputs with TRES option NOTE Single ended encoders will not operate correctly with the termination resistors installed If a combination of differential encoder inputs with termination resistors and single ended encoders is required on the same controller contact Galil directly Part number ordering example DMC 4113 CARD TRES ISCNTL Isolate Controller Power The ISCNTL option isolates the power input for the controller from the power input of the amplifiers With this option the power is brought in through the 2 pin Molex connector on the side of the controller as shown in the DMC 41x3 Power Connections section in Chapter 2 This option is not valid when Galil amplifies are not ordered with the DMC 41x3 Part number ordering example DMC 4113 BOX4 ISCNTL D3020 Appendices e 197 DMC 41x3 User Manual RS 422 Auxiliary Serial Port Serial Communication The default serial configuration for the DMC 41x3 is to have RS 232 communication on the Aux P2 serial port The controller can be ordered to have RS 422 for this port RS 422 communication is a differentially driven serial communication protocol that should be use
93. 1x3 returns a When the controller receives an invalid command the user can request the error code The error code will specify the reason for the invalid command response To request the error code type the command TC1 For example TCI Tell Code command Unrecognized Returned response There are many reasons for receiving an invalid command response The most common reasons are unrecognized command such as typographical entry or lower case command given at improper time such as during motion or a command out of range such as exceeding maximum speed A complete listing of all codes is listed in the TC command in the Command Reference section Interrogating the Controller Interrogation Commands The DMC 41x3 has a set of commands that directly interrogate the controller When the command is entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and Leading Zeros LZ command See Chapter 7 Application Programming and the Command Reference Summary of Interrogation Commands RP Report Command Position RL Report Latch R V Firmware Revision Information SC Stop Code TA Tell Amplifier Error TB Tell Status TC Tell Error Code TD Tell Dual Encoder TE Tell Error TI Tell Input TP Tell Position TR Trace TS Tell Switches TT Tell Torque TV Tell
94. 3 c aoi eei ecce 196 Overview DMC 41x3 Controller Board Options Jn Encoder 26 pin HD D Sub Connector SSI or BiSS option ernannt 198 Internal Amplifier Options Power Connectors for the DMC A x3 icc cese ect 200 OVET O ica i Moles Parr Un ceu cedi od oe ol a beau 200 Connectors for DMC e413 Pireo Jii ciet b RO 201 DMC 41x3 Contents e vi J5 I O A D 44 pin HD D Sub Connector Female 201 J8 I O E H 44 pin HD D Sub Connector Female 201 Jn1 Encoder 26 pin HD D Sub Connector Female 202 J4 Analog 15 pin D sub Connector Male 202 JPnl Amplifier Enable Jumper Description for DMC 41x3 203 Ji Etiermet RHS h uoi ec a ot eode 203 J2 USB A J3 RS 232 Auxiliary Port F male uitae 203 J3 RS 422 Auxiliary Port Non Standard Option 204 JP1 Jumper Description for DMC 41x3 204 Signal Deseripons Far DMC IXS siiis ceci sates 205 Coordinated Motion Mathematical Analysis 207 Example Communicating with OPTO 22 SNAP B3000 ENET DMC 41x3 DMC 40x0 DMC 21x3 Comparison iin List of Other Publications Training Seminars 213 Contacting Us WARRANTY Integrated Components 216 OVNE aaa A Pet o bem dead 216 Al AMP 430x0
95. 3 axis controller DMC 4123 2 axes controller or DMC 4113 1 axis controller should note that the DMC 4133 uses the axes denoted as XYZ the DMC 4123 uses the axes denoted as XY and the DMC 4113 uses the X axis only Examples for the DMC 4183 denote the axes as A B C D E F G H Users of the DMC 4153 5 axes controller DMC 4163 6 axes controller or DMC 4173 7 axes controller should note that the DMC 4153 denotes the axes as A B C D E the DMC 4163 denotes the axes as A B C D E F and the DMC 4173 denotes the axes as A B C D E F G The axes A B C D may be used interchangeably with A B C D WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machinery Galil shall not be liable or responsible for any incidental or consequential damages DMC 41x3 Contents e i Contents Contents iii Chapter 1 Overview ECLTOR ULIS TRIER TR E 1 Overview of Motor Types Standard Servo Motor with 10 Volt Command Signal Stepper Motor with Step and Direction Signals Overview of External Amplifiers Aimpliiiers m Velocity Mode iui it io critico 2 Stepper Motor Amplifiers aiia Al AMP 430x0 D3040 D3020 A2 AMP 43140 D3140 sse 3 A4 AMP 435x0 D3540 D3520 AS AMP 43640 DO640 ns Microcomputer Se
96. 31 0040 MOLEX 39 01 2045 MOLEX 44476 3112 4 Position MOLEX 39 31 0020 MOLEX 39 01 2025 MOLEX 44476 3112 Type 2 Position The mating connectors listed are not the only mating connectors available from Molex See 366Hhttp www molex com for the full list of available mating connectors Galil Amplifier Driver On Board Connector MOLEX 39 31 0020 MOLEX 39 31 0060 AMP 43040 MOLEX 39 31 0040 MOLEX 39 31 0040 AMP 43140 None MOLEX 39 31 0060 SDM 44040 MOLEX 39 31 0040 MOLEX 39 31 0060 SMD 44140 Motor MOLEX 39 31 0040 MOLEX 39 31 0020 Type 2 Position 6 Position 4 Position 4 Position 2 Position 6 Position 4 Position 6 Position 4 Position DMC 41x3 User Manual Appendices e 200 Connectors for DMC 41x3 Pin outs J5 I O A D 44 pin HD D Sub Connector Female Pin Label Description Pin Label Description Pin Label Description 15 5V 5V 30 5V 5V J8 I O E H 44 pin HD D Sub Connector Female For DMC 4153 thru DMC 4183 controllers only Pin Label Description Pin Label Description Pin Label Description 15 5V 5V 30 5V 5V ABRT RST and ELO use INCOMO Appendices e 201 DMC 41x3 User Manual Jn1 Encoder 26 pin HD D Sub Connector Female Pin Label AEN DIR HOM MI MA 5V GND ENBL HALB STP OPLolrI an rye wopNnyfe JE I o
97. 41x3 User Manual P2CD Contains the status code mode disabled 0 nothing received 1 received character but not lt enter gt 2 received string not a number 3 received number NOTE The value of P2CD returns to zero after the corresponding string or number is read These keywords may be used in an applications program to decode data and they may also be used in conditional statements with logical operators Example Instruction Interpretation JP LOOP P2CD lt gt 3 Checks to see if status code is 3 number received JP P P2CH V Checks if last character received was a V PR P2NM Assigns received number to position JS XAXIS P2ST X Checks to see if received string is X Using Communication Interrupt The DMC 41x3 provides a special interrupt for communication allowing the application program to be interrupted by input from the user The interrupt is enabled using the CI command The syntax for the command is CI n n 0 Don t interrupt Port 2 n l Interrupt on lt enter gt Port 2 n 2 Interrupt on any character Port 2 n l Clear any characters in buffer The COMINT label is used for the communication interrupt For example the DMC 41x3 can be configured to interrupt on any character received on Port 2 The COMINT subroutine is entered when a character is received and the subroutine can decode the characters At the end of the routine the EN command is used EN 1 will re enable the interrupt and return to th
98. 500 1 Arg A j500 135 However since A s L s G s then it follows that G s must have magnitude of GG500 AG500 LG500 160 and a phase arg G j500 arg AG500 arg LG500 135 194 59 In other words we need to select a filter function G s of the form G s P sD so that at the frequency 500 the function would have a magnitude of 160 and a phase lead of 59 degrees These requirements may be expressed as G j500 P j500D 160 and arg G j500 tan 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 Therefore D 0 274 and G 82 4 0 274s The function G is equivalent to a digital filter of the form D z KP KD 1 z7 where P KP DMC 41x3 User Manual Chapter 10 Theory of Operation e 190 D KD T and KD D T Assuming a sampling period of T Ims the parameters of the digital filter are KP 82 4 KD 274 The DMC 41x3 can be programmed with the instruction KP 82 4 KD 274 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters Equivalent Filter Form DMC 41x3 Digital D z K z A z Cz z 1 1 B Z B KP KD KI PL K KP KD A KD KP KD C K B PL Digital D z KP KD 1 z P KI 2 1 21 1 PL Z PL Continuous G s P Ds I s a sta PID T P KP D T KD
99. 70 71 72 73 74 75 76 79 80 81 82 83 84 85 86 89 90 93 94 97 98 101 102 105 106 109 110 111 112 113 114 117 118 119 120 121 122 125 126 129 130 133 134 137 138 141 142 145 146 147 148 149 150 153 154 155 156 157 158 161 162 165 SL SW or UW SL SW or UW error code thread status see bit field map below Amplifier Status Segment Count for Contour Mode Buffer space remaining Contour Mode segment count of coordinated move for S plane coordinated move status for S plane see bit field map below distance traveled in coordinated move for S plane Buffer space remaining S Plane segment count of coordinated move for T plane Coordinated move status for T plane see bit field map below distance traveled in coordinated move for T plane Buffer space remaining T Plane Axis information A axis status see bit field map below A axis switches see bit field map below A axis stop code A axis reference position A axis motor position A axis position error A axis auxiliary position A axis velocity A axis torque A axis analog input A Hall Input Status Reserved A User defined variable ZA B axis status see bit field map below B axis switches see bit field map below B axis stop code B axis reference position B axis motor position B axis position error B axis auxiliary position B axis velocity B axis torque B axis analog input B Hall Input
100. 9 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 12 3 DC Power Supply Ground 4 5 6 VS DC Power Phase C Phase B No Connect Phase A DMC 41x3 User Manual A5 AMP 43640 D3640 e 240 Power Unlike a switching amplifier a linear amplifier does not have a straightforward relationship between the power delivered to the motor and the power lost in the amplifier Therefore determining the available power to the motor is dependent on the supply voltage the characteristics of the load motor and the required velocity and current All of the power delivered by the power supply is either used in the motor or lost in the amplifier Power of Power Supply P ie PE m The power to the motor is both the power used to provide motion and the power lost to heat Power of the motor P Work Power Lost in Motor P K Velocity i i R m Power of amplifier P V i R K Velocity In addition there is a minimum power dissipated by the amplifier when powered regardless of load The minimum power that the amplifier will consume is roughly P A min drop across op amp power stages drop across sense resistor op amp supply 4 i4 i 54 N A min Where N 1 5W for 24V and N 3W for 48V For example assume a 24VDC supply and a motor with R 4ohms and K SV RPM and
101. AGNOSIS Adjusting offset causes the motor to change speed The SH command disables the motor The encoder does not work when swapped with another encoder input CAUSE 1 Amplifier has an internal offset REMEDY Adjust amplifier offset Amplifier offset may also be compensated by use of the offset configuration on the controller see the OF command 2 D d lifier nic LE Replace amplifier 1 The amplifier requires the a different Amplifier Enable setting on the Interconnect Module Refer to Chapter 3 or contact Galil 1 Wrong encoder connections Check encoder wiring For single ended encoders CHA and CHB only do not make any connections to the CHA and CHB inputs Replace encoder 2 Encoder is damaged 3 Encoder configuration incorrect Check CE command DMC 41x3 User Manual Chapter 9 Troubleshooting e 176 The encoder works correctly when swapped with another encoder input 1 Wrong encoder connections Unable to read main or auxiliary encoder input 2 Encoder configuration incorrect 3 Encoder input or controller is damaged Swapping cables fixes the problem Encoder Position Drifts 1 Poor Connections intermittent cable Check encoder wiring For single ended encoders MA and MB only do not make any connections to the MA and MB inputs Check CE command Contact Galil Review all connections and connector contacts
102. Box option limited to specific configurations of integrated drives configurations of integrated drives configurations of controller and drives 511 elements ALAK PW OV OT OA ALTX TR1 1 HV LD M axis _EY ZA OE2 TM scaling NO LC1000 MT1 5 PV BT BW POSERR LIMSWI ZMCTIME and ININT run without a thread 511 elements 1 element L K PW OV OT OA ALTX TR1 1 HV LD M axis _EY ZA OE2 TM scaling NO LC1000 MTI 5 PV BT BW POSERR LIMSWI MCTIME VT WC and ININT run without a thread VT WC IN CO DMC 41x3 User Manual Appendices e 212 List of Other Publications Step by Step Design of Motion Control Systems by Dr Jacob Tal Motion Control Applications by Dr Jacob Tal Motion Control by Microprocessors by Dr Jacob Tal Training Seminars Galil a leader in motion control with over 500 000 controllers working worldwide has a proud reputation for anticipating and setting the trends in motion control Galil understands your need to keep abreast with these trends in order to remain resourceful and competitive Through a series of seminars and workshops held over the past 20 years Galil has actively shared their market insights in a no nonsense way for a world of engineers on the move In fact over 10 000 engineers have attended Galil seminars The tradition continues with three different seminars each designed for your particular skill set
103. CDEFGH AD X or Y or Z or W A or B or Cor D or E or F or G or H AR X or Y or Z or W A or B or Cor D or E or F or Gor H AP X or Y or Z or W A or B or Cor Dor or F or G or H MF X or Y orZor W A or B or Cor Dor or F or Gor H MR X or Y or Z or W A or B or Cor Dor E or F or G or H MC X or Y or Z or W A or B or C or D or E or F or G or H AI n ASXYZWS ABCDEFGH AT n m AVn Halts program execution until motion is complete on the specified axes or motion sequence s AM with no parameter tests for motion complete on all axes This command is useful for separating motion sequences in a program Halts program execution until position command has reached the specified relative distance from the start of the move Only one axis may be specified at a time Halts program execution until after specified distance from the last AR or AD command has elapsed Only one axis may be specified at a time Halts program execution until after absolute position occurs Only one axis may be specified at a time Halt program execution until after forward motion reached absolute position Only one axis may be specified If position is already past the point then MF will trip immediately Will function on geared axis or aux inputs Halt program execution until after reverse motion reached absolute position Only one axis may be specified If position is already past the point then MR will trip immediately Will
104. CODER I O INTERFACE COMPARE OUTPUT T 8 UNCOMMITTED 8 PROGRAMMABLE 8 oa ANALOG INPUTS OPTOISOLATED OUTPUTS INPUTS HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 41x3 Functional Elements Microcomputer Section The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM The RAM provides memory for variables array elements and application programs The flash EEPROM provides non volatile storage of variables programs and arrays The Flash also contains the firmware of the controller which is field upgradeable Motor Interface Galil s GL 1800 custom sub micron gate array performs quadrature decoding of each encoder at up to 15 MHz For standard servo operation the controller generates a 10 volt analog signal 16 Bit DAC For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the DMC 41x3 consists of high speed 100bT Ethernet and a USB programming port General I O The DMC 41x3 provides interface circuitry for 8 bi directional opto isolated inputs 8 opto isolated outputs and 8 analog inputs with 12 Bit ADC 16 Bit optional Unused auxiliary encoder inputs may also be used as additional DMC 41x3 User Manual Chapter 1 Overview e 4 inputs 2 inputs each axis The general inputs as well as the index pulse can also be used as high speed latches for each axis A high speed encoder compare output is
105. CTION INTERPRETATION A V1 0 Label Initialize variable PA 0 0 BGXY AMXY Go to position 0 0 on X and Y axes EA Z Z axis as the Master for ECAM EM 0 0 4000 Change for Z is 4000 zero for X Y EP400 0 ECAM interval is 400 counts with zero start ET 0 0 0 When master is at 0 position 1 point ET 1 0 0 2 point in the ECAM table ET 2 120 60 3 point in the ECAM table ET 3 240 120 4 point in the ECAM table ET 4 360 180 5 point in the ECAM table ET 5 360 180 6 point in the ECAM table ET 6 360 180 7 point in the ECAM table ET 7 240 120 8 point in the ECAM table ET 8 120 60 9 point in the ECAM table DMC 41x3 User Manual Chapter 6 Programming Motion e 98 ET 9 0 0 10 point in the ECAM table ET 10 0 0 Starting point for next cycle EB 1 Enable ECAM mode JGZ 4000 Set Z to jog at 4000 EG 0 0 Engage both X and Y when Master 0 BGZ Begin jog on Z axis LOOP JP LOOP V1 0 Loop until the variable is set EQ2000 2000 Disengage X and Y when Master 2000 MF 2000 Wait until the Master goes to 2000 ST Z Stop the Z axis motion EB 0 Exit the ECAM mode EN End of the program The above example shows how the ECAM program is structured and how the commands can be given to the controller Figure 6 11 shows the GalilTools scope capture of the ECAM profile This shows how the motion will be seen during the ECAM cycles The first trace is for the A axis the second trace shows the cycle on the B axis a
106. D A Suppose that we interrogate the controller when the motion is halfway between the points A and B The value of AV is 2000 The value of CS is 0 _VPX and VPY contain the absolute coordinate of the point A Suppose that the interrogation 1s repeated at a point halfway between the points C and D The value of AV is 4000 15007 2000 10 712 The value of CS is 2 VPX VPY contain the coordinates of the point C C 4000 3000 B 4000 0 A 0 0 Figure 6 7 The Required Path Electronic Gearing This mode allows up to 8 axes to be electronically geared to some master axes The masters may rotate in both directions and the geared axes will follow at the specified gear ratio The gear ratio may be different for each axis and changed during motion The command GAX yzw or GA ABCDEFGH specifies the master axes GR x y z w specifies the gear ratios for the slaves where the ratio may be a number between 127 9999 with a fractional resolution of 0001 There are two modes standard gearing and gantry mode The gantry mode enabled with the command GM allows the gearing to stay enabled even if a limit is hit or an ST command is issued GR 0 0 0 0 turns off gearing in both modes The command GM x y z w select the axes to be controlled under the gantry mode The parameter enables gantry mode and 0 disables it GR causes the specified axes to be geared to the actual position of the master The master axis is commanded with motion comman
107. E to MG TIME t This is about 114ms 2ms Now when the comments inside of the loop routine are changed into REM statements a REM statement must always start on a new line the processing is greatly reduced When executed on the same DMC 4123 the output from the program shown below returned a 62 which indicates that it took 62 samples to process the commands from t TIME to MG TIME t This is about 60ms 2ms and about 50 faster than when the comments where downloaded to the controller fa i 0 initialize a counter t TIME set an initial time reference floop REM this comment is removed upon download and takes no time to process REM this comment is removed upon download and takes no time to process i i 1 REM this comment is removed upon download and takes no time to process JP loop i lt 1000 MG TIME t display number of samples from initial time reference EN WT vs AT and coding deterministic loops The main difference between WT and AT is that WT will hold up execution of the next command for the specified time from the execution of the WT command AT will hold up execution of the next command for the specified time from the last time reference set with the AT command A ATO set initial AT time reference WT 1000 1 wait 1000 samples t1 TIME AT 4000 1 wait 4000 samples from last time reference t2 TIME t1 REM in the above scenario t2 will be 3000 because AT 4000 1 will have REM paused program execut
108. ELSE and TEST ITrr3 MG WAITING FOR INPUT 1 INPUT 2 LOOP JP LOOP EN ININT IF IN 1 0 IF IN 2 0 MG INPUT 1 AND INPUT 2 ARE ACTIVE ELSE MG ONLY INPUT 1 IS ACTIVE ENDIF ELSE MG ONLY INPUT 2 IS ACTIVE ENDIF WAIT JP WAIT IN 1 0 IN 2 0 RIO Subroutines ENDIF Begin Main Program TEST Enable input interrupts on input 1 and input 2 Output message Label to be used for endless loop Endless loop End of main program Input Interrupt Subroutine IF conditional statement based on input 1 2 IF conditional statement executed if 15 IF conditional true Message to be executed if 2 IF conditional is true ELSE command for 2 IF conditional statement Message to be executed if 2 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 15 IF conditional statement is false End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 2 are not active End Input Interrupt Routine without restoring trippoints A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and conditional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program l
109. G INVALID TRY AGAIN JP NMLP EN End of main program Interrupt routine Check for A Check for B Check for S Jump if not X Y S ew X speed Jump to Print ew Y speed Jump to Print Stop motion on S End Re enable interrupt Routine for entering new jog speed Prompt for value Check for enter Routine to check input from terminal Jump to error if string Read value End subroutine Error Routine Error message End Output of Data Numeric and String Numerical and string data can be output from the controller using several methods The message command MG can output string and numerical data Also the controller can be commanded to return the values of variables and arrays as well as other information using the interrogation commands the interrogation commands are described in chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen Text strings are specified in quotes and variable or array data 1s designated by the name of the variable or array For example MG The Final Value is result In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Position of A is TPA Chapter 7 Application Programming e 155 DMC 41x3 User Manual Specifying the Port for Messag
110. IF d c ENDIF EN Execu 4 000 65536 0 003 1 RHLPR b 0 ET Te c ted program from programl dmc 0 0000 9 Example Recursion ISFAX MG Z2 EN Axs b MG b MG F8 IF a EN ENDIF JS Ax EN Execu A Axi B Axi C Axi D Axi E Axi F Axi G Axi H Axi Recur sInfo 0 0 Recursed through JS stacks nfo a 41 1000000 S1 Axis N 0j Position TP h Errori TEch Torque TT h Fl 4 7 sInfo a 1 JS 1 ted program from programl dmc Position 00029319 Error 0000 312 7 S Position 00001612 Error 00000936 S Position 00001696 Error 0000 076 1 S Position 00002020 Error 00001156 S Position 00000700 Error 0000 300 1 S Position 00000156 Error 00000792 7 S Position 00002212 Error 00001732 S Position 00002665 Error 0000 sed through 8 stacks Torque 9 9982 Torque 1 7253 lorque 1 9834 Torque 2 1309 l orque 2 3963 lorque 1 4599 Torque 3 1926 721 7 l orque 3 1723 General Program Flow and Timing information This section will discuss general programming flow and timing information for Galil programming REM vs NO or comments There are 2 ways to add comments to a dmc program REM statements or NO comments The main difference between the 2 is that REM statements are stripped from the program upon download to the controller and NO or comments are left in the program In most ins
111. LE TIE LUDERE TS SERIE Rici RES 147 Programmable Variables 148 OPd E IO NR ENT 149 Special Operands Keywords 149 JV pri Ro i ba cn Lo i YR Uu ke RU utm vasi 150 DCN ARS c c dps udo rion tan Los o Seb EO Ra Assignment of Array Entries is Automatic Data Capture into Arrays sse 151 De allocateng Array Space 153 Input of Data Numeric and String Sending Data froma Host uu cose ilo arl Operator Date Bitty Mode uiii t bo dise Using Communication Interrupt Output of Data Numeric and String Sending Messages T Displaying Variables and Arrays seee T tertogati n Commands cot odii Formatting Variables and Array Elements s Convertitig to User Units eicere Hardware sh nt is Seale RS DMC 41x3 Contents e y Disi CUN uius d dace PRE cuc cio s Cete etie 160 Tis En Dr DURER oc OT prd eid Eon CR ot 161 The Auxiliary Encoder Inputs Input Interrupt Function 162 Analog Inputs Example A Ppa GN uii cocer ettet escis cioe iridis bos ede 164 Wire COMES nc erie adi co So doceo Lala X Y Table Controller s Speed Control by Joystick ucciso cei Paution Control by SONS aetas Backlash Compensation by Sampled Dual Loop T Using the DMC 41x3 Editor to Enter Programs Advanced 169 Edit Mode Commands cosa le epic tton itae ops 170
112. MPERR subroutine if it is included in a running program Under Voltage Protection If the supply to the amplifier drops below 18 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 18V threshold bit 3 of the error status TAO will tell the user whether the supply is in the acceptable range NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V This error is monitored with bit 1 of the TAO command Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 20 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the AMP 43040 is a trans conductance amplifier the amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the ZAMPERR routine Bit 0 of TAO will be set NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is
113. Motion 2 Chapter 6 Programming Motion e 79 DMC 41x3 User Manual Example Motion 3 In this motion the host program commands the controller to begin motion towards position 5000 changes the target to 2000 and then changes it again to 8000 Figure 6 4 shows the plot of position vs time and velocity vs time Below is the code that is used to simulate this scenario EX3 PT 1 Place the X axis in Position tracking mode AC 150000 Set the X axis acceleration to 150000 counts sec2 DC 150000 Set the X axis deceleration to 150000 counts sec2 SP 50000 Set the X axis speed to 50000 counts sec PA 5000 Command the X axis to abs position 5000 encoder counts WT 300 PA 2000 Change end point position to 2000 WT 200 PA 8000 Change end point position to 8000 EN Figure 6 5 demonstrates the use of motion smoothing IT on the velocity profile in this mode The jerk in the system is also affected by the values set for AC and DC Scope tj Vertical Horizontal didt Source Scale div Offset div BL RPAAxiAref v 2000court 0 e _RPA Axis A ref w 10000 cou 2 CAN NH sO sw 2 e mr m 0 221383 S 0 m m 442765 1 mi w 0 442765 t 2 d BO 0 221383 3 m w 0 221383 S 4 t 150ms 4 T Trigger Channel MI RPA Edge w Level Ocounts t Mode Repeat v READY RPA djdt_RPA Figure 6 4 Position and Velocity vs Time msec for Motion 3
114. RP is constant and multiple configurations LC command set to 0 Full Current Mode causes motor to use 100 of peak current AG while at a resting state profiler is not commanding motion This is the default setting LC command set to 1 Low Current Mode causes motor to use 25 of peak current while at a resting state This is the recommended configuration to minimize heat generation and power consumption LC command set to an integer between 2 and 32767 specifying the number of samples to wait between the end of the move and when the amp enable line toggles Percentage of full AG current used while holding position with LC n n n n n n n n The LC command must be entered after the motor type has been selected for stepper motor operation i e MT 2 2 2 2 LC is axis specific thus LC1 will cause only the X axis to operate in Low Current mode Over Current Protection The stepper driver also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 10 A the SDM 44140 will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset The amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the AMPERR routine Bit 0 of TAO will be set NOTE If this fault
115. RRANTY All controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship for a period of 18 months after shipment Motors and Power supplies are warranted for 1 year Extended warranties are available In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control properly packaged and with transportation and insurance prepaid We will reship at our expense only to destinations in the United States and for products within warranty Call Galil to receive a Return Materials Authorization RMA number prior to returning product to Galil Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer alteration modification negligence or misuse is not covered by this warranty EXCEPT AS SET FORTH ABOVE GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES COPYRIGHT 3 97 The software code contained in this Galil product is protected by copyright and must not be reproduced or disassembled in any form without prior written consent of Galil Motion Contr
116. SR90 SR 49000 Shunt Regulator Option The BOX option is required when the AMP 43540 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation qun B 429486 Pone E HPO POWER OPTION gia et mar Figure A4 1 DMC 4143 D3540 BOX4 DMC 4143 with AMP 43540 A4 AMP 435x0 D3540 D3520 e 233 DMC 41x3 User Manual Electrical Specifications The amplifier is a brush brushless transconductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage 18 80 VDC Continuous Current 8 Amps Peak Current 15 Amps Nominal Amplifier Gain 0 8 Amps Volt Switching Frequency 33 kHz Minimum Inductance Vsupply 24VDC 0 75 mH Vsupply 48VDC 1 2 mH Brushless Motor Commutation angle 120 Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr TM MOLEX 39 31 0060 MOLEX744476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr TM Power Connectors MOLEX 39 3
117. TS and CTS lines The RTS line will go high whenever the DMC 41x3 is not ready to receive additional characters The CTS line will inhibit the DMC 41x3 from sending additional characters Note the CTS line goes high for inhibit Example CC 19200 0 1 1 Configure auxiliary communication port for 19200 baud no handshake general port mode and echo turned on RS 422 Configuration The DMC 41x3 can be ordered with the auxiliary port configured for RS 422 communication RS 422 communication is a differentially driven serial communication protocol that should be used when long distance serial communication is required in an application For more information see RS 422 Auxiliary Serial Port Serial Communication in the in Appendix Ethernet Configuration Communication Protocols The Ethernet is a local area network through which information is transferred in units known as packets Communication protocols are necessary to dictate how these packets are sent and received The DMC 41x3 DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 48 supports two industry standard protocols TCP IP and UDP IP The controller will automatically respond in the format in which it is contacted TCP IP is a connection protocol The master or client connects to the slave or server through a series of packet handshakes in order to begin communicating Each packet sent is acknowledged when received If no acknowledgment is received the
118. UPGD can be found There are two options for baud rate 19200 and 115200 19200 should only be used when an external device such as an HMI requires the slower communication speed To set the baud rate to the desired value see Table 2 1 below 19 2 BAUD RATE ON OFF 115200 Table 2 1 Baud Rate settings for USB communication Amplifier Enable Jumper Configuration When using external amplifiers then amplifier enable must be configured to provide the correct polarity and voltage to enable and disable the drive Information on configuring the Amplifier Enable signal can be found in Chapter three in Configuring the Amplifier Enable Circuit section If the Galil internal amplifiers are being utilized for all axes then no configuration of the Amplifier Enable signals is required Step 3 Install the Communications Software After applying power to the computer you should install the Galil software that enables communication between the controller and PC Using Windows XP Vista and 7 32 amp 64 bit Install the Galil Software Products CD ROM into your CD drive A Galil htm page should automatically appear with links to the software products Select the correct version of GalilTools software for your particular operating system 32 or 64 bit and click Install Follow the installation procedure as outlined The most recent copy of the GalilTools software can be downloaded from the Galil website http www galilmc c
119. Velocity For example the following example illustrates how to display the current position of the X axis TP A Tell position A 0 Controllers Response TP AB Tell position A and B 0 0 Controllers Response Interrogating Current Commanded Values Most commands can be interrogated by using a question mark as the axis specifier Type the command followed by a for each axis requested PR Pp ere Request A B C D values DMC 41x3 User Manual Chapter 5 Command Basics e 66 PR Request B value only The controller can also be interrogated with operands Operands Most DMC 41x3 commands have corresponding operands that can be used for interrogation Operands must be used inside of valid DMC expressions For example to display the value of an operand the user could use the command MG operand where operand is a valid DMC operand All of the command operands begin with the underscore character For example the value of the current position on the A axis can be assigned to the variable V with the command V TPA The Command Reference denotes all commands which have an equivalent operand as Operand Usage Also see description of operands in Chapter 7 Application Programming Chapter 5 Command Basics e 67 DMC 41x3 User Manual Command Syntax Binary advanced Some commands have an equivalent binary value Binary communication mode can be executed about 20 faster than ASCII comma
120. WI Label for Limit Switch subroutine MCTIME Label for timeout on Motion Complete trip point POSERR Label for excess Position Error subroutine TCPERR Label for errors over a TCP connection error code 123 Commenting Programs Using the command NO or Apostrophe The DMC 41x3 provides a command NO for commenting programs or single apostrophe This command allows the user to include up to 78 characters on a single line after the NO command and can be used to include comments from the programmer as in the following example PATH 2 D CIRCULAR PATH VMXY VECTOR MOTION ON X AND Y VS 10000 VECTOR SPEED IS 10000 VP 4000 0 BOTTOM LINE CR 1500 270 180 HALF CIRCLE MOTION VP 0 3000 TOP LINE Chapter 7 Application Programming e 125 DMC 41x3 User Manual CR 1500 90 180 HALF CIRCLE MOTION VE END VECTOR SEQUENCE BGS BEGIN SEQUENCE MOTION EN END OF PROGRAM NOTE The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Difference between NO and using the GalilTools software The GalilTools software will treat an apostrophe commend different from an NO when the compression algorithm is activated upon a program download line gt 80 characters or program memory gt 2000 lines In this case the software will remove all comments as part of the compression and it will download all NO comments to the controller
121. X4 DMC 4143 with AMP 43040 DMC 41x3 User Manual A1 AMP 430x0 D3040 D3020 e 218 Electrical Specifications The amplifier is a brush brushless trans conductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage 18 80 VDC Continuous Current 7 Amps Peak Current 10 Amps Nominal Amplifier Gain 0 7 Amps Volt Switching Frequency 60 kHz up to 140 kHz available contact Galil Minimum Load Inductance 0 5 mH Inverter mode 0 2 mH Error Reference source not found Brushless Motor Commutation angle 120 60 option available Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr TM MOLEX 39 31 0060 MOLEX744476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Phase C N C for Bushed Motors Phase B No Connect Phase A A1 AMP 430x0 D3040 D3020 e 219 DMC 41x3 User Manual Operation Brushless Motor Setup NOTE If you purchased a Galil motor with the amplifier it is ready for use No additional setup is necessary To begin the setup of the brushless motor and amplifier it is first necessar
122. a microstep When a Galil controller is configured for step motor operation the step pulse output by the controller is internally fed back to the auxiliary encoder register For SPM the feedback encoder on the stepper will connect to the main encoder port Enabling the SPM mode on a controller with YS 1 executes an internal monitoring of the auxiliary and main encoder registers for that axis or axes Position error is then tracked in step pulses between these two registers QS command TPx YAx YB S TD Q YC Where TD is the auxiliary encoder register step pulses and TP is the main encoder register feedback encoder Additionally YA defines the step drive resolution where YA 1 for full stepping or YA 2 for half stepping The full range of YA is up to YA 9999 for microstepping drives Error Limit The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor steps Once the value of QS exceeds this limit the controller then performs the following actions 1 The motion is maintained or is stopped depending on the setting of the OE command If OE 0 the axis stays in motion if OE 1 the axis is stopped 2 YS is set to 2 which causes the automatic subroutine labeled ZPOSERR to be executed DMC 41x3 User Manual Chapter 6 Programming Motion e 112 Correction A correction move can be commanded by assigning the value of QS to the YR correction move command The correction move is issued o
123. able off on error for Y and W axes and disable off on error for W and Z axes OE 2 3 Enable off on error for limit switch for the X axis and position error or abort input and limit switch for the Y axis Automatic Error Routine The POSERR label causes the statements following to be automatically executed if error on any axis exceeds the error limit specified by ER a encoder failure is detected or the abort input is triggered The error routine must be closed with the RE command The RE command returns from the error subroutine to the main program NOTE The Error Subroutine will be entered again unless the error condition is cleared Example A JP A EN Dummy program POSERR Start error routine on error MG error Send message SB 1 Fire relay STX Stop motor AMX After motor stops SHX Servo motor here to clear error RE Return to main program Limit Switch Routine The DMC 41x3 provides forward and reverse limit switches which inhibit motion in the respective direction There is also a special label for automatic execution of a limit switch subroutine The LIMSWI label specifies the start of DMC 41x3 User Manual Chapter 8 Hardware amp Software Protection e 174 the limit switch subroutine This label causes the statements following to be automatically executed if any limit switch 1s activated and that axis motor is moving in that direction The RE command ends the subroutine The state of the forward and reverse limit
124. achieved by commanding GR 2 Specify gear ratio for X axis to be 2 Example Gantry Mode In applications where both the master and the follower are controlled by the DMC 41x3 controller it may be desired to synchronize the follower with the commanded position of the master rather than the actual position This eliminates the coupling between the axes which may lead to oscillations For example assume that a gantry is driven by two axes X Y on both sides This requires the gantry mode for strong coupling between the motors The X axis is the master and the Y axis 1s the follower To synchronize Y with the commanded position of X use the instructions GA CX Specify the commanded position of X as master for Y Chapter 6 Programming Motion e 93 DMC 41x3 User Manual GR 1 Set gear ratio for Y as 1 1 GM 1 Set gantry mode PR 3000 Command X motion BG X Start motion on X axis You may also perform profiled position corrections in the electronic gearing mode Suppose for example that you need to advance the slave 10 counts Simply command IP 10 Specify an incremental position movement of 10 on Y axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on Y axis BGY Begin motion on Y axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity co
125. afe to power down and remove the Master Reset jumper If performing a Master Reset does not get rid of the error light the controller may need to be sent back to the factory to be repaired Contact Galil for more information DMC 41x3 User Manual Chapter 9 Troubleshooting e 178 Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Figure 10 1 COMPUTER CONTROLLER DRIVER Figure 10 1 Elements of Servo Systems The operation of such a system can be divided into three levels as illustrated in Figure 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming The first level the closing of the loop assures that the motor follows the commanded position This is done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling is the generation of the desired position function This function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the loop forces the motor to follow the co
126. al Amplifiers Use connectors on top of controller to access necessary signals to run external amplifiers In order to use the full torque limit make sure the AG setting for the axes using external amplifiers are set to 0 or 1 Set the BR command to 1 for any axis that will be setup to run external amplifiers this will disable the hall error protection For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 ELO Input If the ELO input on the controller is triggered the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application DMC 41x3 User Manual A3 AMP 43240 D3240 e 230 Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will also monitor for illegal Hall states 000 or 111 with 120 phasing The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 1 2 or 3 The command will return an eight bit number representin
127. als X Y Table Controller An X Y Z system must cut the pattern shown in Figure 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool The solid curves in Figure 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate is 0 1 g The motion starts at point A with the Z axis raised An X Y motion to point B is followed by lowering the Z axis and performing a cut along the circle Once the circular motion is completed the Z axis is raised and the motion continues to point C etc Assume that all of the 3 axes are driven by lead screws with 10 turns per inch pitch Also assume encoder resolution of 1000 lines per revolution This results in the relationship 1 inch 40 000 counts and the speeds of 1 in sec 40 000 count sec 5 in sec 200 000 count sec an acceleration rate of 0 1g equals 0 1g 38 6 in s2 1 544 000 count s Note that the circular path has a radius of 2 or 80000 counts and the motion starts at the angle of 270 and traverses 360 in the CW negative direction Such a path is specified with the instruction CR 80000 270 360 Chapter 7 Application Programming e 165 DMC 41x3 User Manual INSTRUCTION A VM XY VP 160000 160000 VE VS 200000 VA 1544000 BGS AMS PR 80000 SP 80000 BGZ AMZ CR 80000
128. ample Multiple Move Sequence Required Motion Profiles X Axis 500 counts Position 20000 count sec Speed 500000 counts sec Acceleration Y Axis 1000 counts Position 10000 count sec Speed 500000 counts sec2 Acceleration Z Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on X Y and Z axes The movement on each axis will be separated by 20 msec Figure 6 1 shows the velocity profiles for the X Y and Z axis TA Begin Program PR 2000 500 100 Specify relative position movement of 2000 500 and 100 counts for X Y and Z axes SP 20000 10000 5000 Specify speed of 20000 10000 and 5000 counts sec AC 500000 500000 500000 Specify acceleration of 500000 counts sec for all axes DC 500000 500000 500000 Specify deceleration of 500000 counts sec for all axes BG X Begin motion on the X axis WT 20 Wait 20 msec BG Y Begin motion on the Y axis WT 20 Wait 20 msec BG Z Begin motion on Z axis EN End Program DMC 41x3 User Manual Chapter 6 Programming Motion e 74 VELOCITY COUNTS SEC X axis velocity profile 20000 Y axis velocity profile 15000 Z axis velocity profile 10000 5000 TIME ms 0 20 40 60 80 100 Figure 6 1 Velocity Profiles of XYZ Notes on Figure 6 1 The X and Y axis have a trapezoidal velocity profile while the Z axis has a triangular velocity profile The X and Y axes accelerate to the specified speed move
129. ample if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point Chapter 6 Programming Motion e 87 DMC 41x3 User Manual Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed is specified with the operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 0 5 results in the specification VS 2000 to be divided by two Compensating for Differences in Encoder Resolution By default the DMC 41x3 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in the Command Reference Trippoints The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Tangent Motion Several applications such as cutting req
130. and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent at PC bus speeds The instruction CS returns the segment counter As the segments are processed CS increases starting at zero This function allows the host computer to determine which segment is being processed Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 41x3 computes the vector speed based on the axes specified in the LM mode For example LM XYZ designates linear interpolation for the X Y and Z axes The vector speed for this example would be computed using the equation VS2 XS2 YS2 ZS2 where XS YS and ZS are the speed of the X Y and Z axes The controller always uses the axis specifications from LM not LI to compute the speed IT is used to set the S curve smoothing constant for coordinated moves The command AV n is the After Vector trippoint which halts program execution until the vector distance of n has been reached An Example of Linear Interpolation Motion LMOVE label DP 0 0 Define position of X and Y axes to be 0 LMXY Define linear mode between X and Y axes LI 5000 0 Specify first linear segment LI 0 5000 Specify second linear segment DMC 41x3 User Manual Chapter 6 Programming Motion e 82 LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector
131. anual Chapter 4 Software Tools and Communication e 58 Axis Status 1 Word BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Mode of Motion PA or PR Mode of Motion PA only Move in Progress FE Find Edge in Progress 2 Phase of HM complete or FI command issued Phase of HM complete Mode of Motion Coord Motion Home HM in Progress BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Mode of Motion Motion is slewing Negative Direction Move Contour Axis Switches 1 Byte Motion is stopping due to ST of Limit 3rd Phase of HM in Progress Motion is making final decel Latch is Motor armed Off Latch Occurred State of Reverse Limit State of Forward Limit State of Home Input Stepper Mode Notes Regarding Velocity and Torque Information The velocity information that is returned in the data record is 64 times larger than the value returned when using the command TV Tell Velocity See command reference for more information about TV The Torque information is represented as a number in the range of 32767 Maximum negative torque is 32767 Maximum positive torque is 32767 Zero torque is 0 QZ Command The QZ command can be very useful when using the QR command since it provides information about the controller and the data record The QZ command returns the following 4 bytes of information INFORMATION Number of axes prese
132. aracters to appear garbled to some terminals This function can be disabled by issuing the command CW2 For more information see the CW command in the Command Reference USB and RS 232 Ports USB Programming Port The USB port on the DMC 41x3 is a USB to serial converter It should be setup for 115 2kB 8 Data bits No Parity 1 Stop Bit and Flow Control set for Hardware The baud rate can be changed to 19200 baud by installing the 19 2 jumper on JP1 but this configuration is only recommended if a slower baud rate is required from the host communication The USB port on the DMC 41x3 is a Female Type B USB port The standard cable when communicating to a PC will bea Male Type A Male Type B USB cable When connected to a PC the USB connection will be available as a new serial port connection ex with GalilTools COM3 115200 The USB port is not recommended when using the GalilTools Scope In this case the Ethernet connection is advised for higher performance Baud Rate Selection JP1 JUMPER SETTINGS 19 2 BAUD RATE ON 19200 OFF recommended 115200 USB Driver The USB port on the DMC 41x3 utilizes a USB to serial converter The driver for this device is expected to be loaded automatically upon connection of the controller in most OS s If the driver does not load or is not installed automatically it can be downloaded from the mfg website here http www ftdichip com Drivers VCP htm Chapter 4 Softwa
133. are configured into groups For example the general inputs DI 8 1 inputs 1 8 the ABRT abort input and RST reset and ELO electronic lock out inputs are one group The INCOM and LSCOM signals are a common connection for all of the inputs in each group The ELO ABRT and RST pins are found on the I O A D D Sub and are duplicated on the I O E H D Sub Le There is only one ELO ABRT and RST input for an 8 axis controller The common is the INCOMO found on the I O A D D Sub connector The opto isolated inputs are connected in the following groups Group Controllers with 1 4 Axes Common Signal DI1 DI8 ABRT RST ELO INCOMO I O A D D Sub Connectors FLSA RLSA HOMA LSCOMO I O A D D Sub Connectors FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD Group Controllers with 5 8 Axes DI1 DI8 ABRT RST ELO INCOMO I O A D D Sub Connectors FLSA RLSA HOMA LSCOMO I O A D D Sub Connectors FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD DI9 DI16 INCOMI I O E H D Sub Connectors FLSE RLSE HOME LSCOMI V O E H D Sub Connectors FLSF RLSF HOMF FLSG RLSG HOMG FLSH RLSH HOMH Table 3 1 INCOM and LSCOM information DMC 41x3 User Manual Chapter 3 Connecting Hardware e 32 Using Voltages gt 28 VDC For voltages greater than 28 Volts a resistor R is needed in series with the input such that 1 mA lt Vs R 22KQ lt 11 mA PS2805 Vs RETURN Figure 3 7 Wiring inputs for
134. are user programmable at 0 4 Amp Volt 0 7 Amp Volt and 1 Amp Volt The switching frequency is 60 kHz The drive for each axis is software configurable to operate in either a chopper or inverter mode The chopper mode is intended for operating low inductance motors The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43040s are required for 5 thru 8 axis controllers A shunt regulator option is available A two axis version the AMP 43020 is also available If higher voltages are required please contact Galil If the application has a potential for regenerative energy it is recommended to order the controller with the ISCNTL solate Controller Power option and the SR90 SR 49000 Shunt Regulator Option The BOX option is required when the AMP 430x0 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation PUTS QUK poen 984 S nc am TION HPO HIGH POWER OP Tana 2 24V0C SOURCE ool OPER GND Figure Al 1 DMC 4143 D3040 BO
135. around This is a function of the deceleration rate set by the DC command When a direction change is commanded the controller decelerates at the rate specified by the DC command The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position In Figure 6 3 the velocity profile is triangular because the controller doesn t have sufficient time to reach the set speed of 50000 counts sec before it is commanded to change direction The below code is used to simulate this scenario EX2 BH lg Place the X axis in Position tracking mode AC 150000 Set the X axis acceleration to 150000 counts sec2 DC 150000 Set the X axis deceleration to 150000 counts sec2 SP 50000 Set the X axis speed to 50000 counts sec PA 5000 Command the X axis to abs position 5000 encoder counts MF 4200 PA 2000 Change end point position to position 2000 EN Scope 0 a vertical Horizontal i didt Source Scale div Offset div 1 _RPA Axis A ref 1000 couri 0 Pal E v RPAAxisAref w 10000cou t 2 n xj 2 i T e ao x 0 221383 0 s DD a m 4 42765 l 1 T m 0 442765 2 eo x 0 221383 3 gm 0 221383 4 t 101 562 m 3 923 Trigger Channel W RP v Edge w Level Ocounts gt Mode Repeat v READY _RPA didt RPA Figure 6 3 Position and Velocity vs Time msec for
136. at this constant speed and then decelerate such that the final position agrees with the command position PR The Z axis accelerates but before the specified speed is achieved must begin deceleration such that the axis will stop at the commanded position All 3 axes have the same acceleration and deceleration rate hence the slope of the rising and falling edges of all 3 velocity profiles are the same Independent Jogging The jog mode of motion is very flexible because speed direction and acceleration can be changed during motion The user specifies the jog speed JG acceleration AC and the deceleration DC rate for each axis The direction of motion is specified by the sign of the JG parameters When the begin command is given BG the motor accelerates up to speed and continues to jog at that speed until a new speed or stop ST command is issued If the jog speed is changed during motion the controller will make a accelerated or decelerated change to the new speed An instant change to the motor position can be made with the use of the IP command Upon receiving this command the controller commands the motor to a position which is equal to the specified increment plus the current position This command is useful when trying to synchronize the position of two motors while they are moving Note that the controller operates as a closed loop position controller while in the jog mode The DMC 41x3 converts the velocity profile into a po
137. at to 4 places TPA Tell position 0021 New format PF 4 Change to hexadecimal format TPA Tell Position 0015 Hexadecimal value PF2 Format 2 places TPA Tell Position 99 Returns 99 if position greater than 99 Adding Leading Zeros from Response to Interrogation Commands The leading zeros on data returned as a response to interrogation commands can be added by the use of the command LZ The LZ command is set to a default of 1 LZ0 Disables the LZ function TP Tell Position Interrogation Command 0000000009 0000000005 Response With Leading Zeros LZ1 Enables the LZ function TP Tell Position Interrogation Command 9 5 Response Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrogation commands may be formatted locally To format locally use the command Fn m or n m on the same line as the interrogation command The symbol F specifies that the response should be returned in decimal format and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal TP F2 2 Tell Position in decimal format 2 2 05 00 05 00 00 00 07 090 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array eleme
138. ater temperature and closing the position loop carries further We have all learned the hard way that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called over damped response The results may be worse if we turn the faucet too fast The overreaction results in temperature oscillations When the response of the system oscillates we say that the system is unstable Clearly unstable responses are bad when we want a constant level What causes the oscillations The basic cause for the instability is a combination of delayed reaction and high gain In the case of the temperature control the delay is due to the water flowing in the pipes When the human reaction is too strong the response becomes unstable Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which is designed to help the stability and accuracy Typically such a filter produces in addition to the proportional gain damping and integrator The combination of the three functions is r
139. ation of the switch If a limit switch is activated during motion the controller will make a decelerated stop using the deceleration rate previously set with the SD command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position The controller can be configured to disable the axis upon the activation of a limit switch see the OE command in the command reference for further detail When a forward or reverse limit switch is activated the current application program that is running in thread zero will be interrupted and the controller will automatically jump to the LIMSWI subroutine if one exists This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch Automatic Subroutines for Monitoring Conditions are discussed in Chapter 7 Application Programming After a limit switch has been activated further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to an inactive state Any attempt at further motion before the logic state has been reset will result in the following error 22 Begin not possible due to limit switch error The operands LFx and LRx contain the state of the forward and reverse limit switches respectively x represents the axis X Y Z W etc The value of the operand is either a 0 or 1 corresp
140. axuv sn gan i QN9HOO2QAPZ S WOOST Cc S1ndNI Q C 1 9 H 3 O T a v O T 997621 gsrezt gsrezt qerezi gqsrezi qurezi gqerezi 997621 ajajajaja o jejejejejeje o FFF o FFE o PPE o TETTSTSTSTS o FFF PPI 0 TSTSTSTST o n ojo ale ol d a oja m s d fie ms sie al d aja sles d ale sm al d s o ale al d magn d z s e ale s d 3 GL 9 i L8 Sel 9 uawoa i E i i Q uou D El Lovan E gt gt gt gt gt gt gt 2 A 5 A E E 5 E 5 2 D E El a El 5 El a o E mi z o Ed m EI o E gt 4 E E E 2 O O O O O O O O O 3 13938 Odd a ous nav YSN NI 30VIN 000 olo a op v os ddd djousnavu 600 ed an Olo v alolo ly dd i d OD O NSNAYT TOHLNO9 NOLLOW LIV T LI IT DO s OO00pDINSN3YH HIMOd OMNIS H3ddilS gg veci 8 LE OING a HIMOd H 9 j 3 HIMOd AG 9 a V ua LI ni L Lo LI LI o 1 r OS LL The dimensions for the DMC 4153 DMC 4163 DMC 4173 and DMC 4183 with BOXS are shown in Figure 2 4 Dimensions are subject to change Contact the Galil factory for current dimensions of all products DMC 41x3 User Manual DMC 41x3 Power Connections Power Connector for Controller without Galil Amplifiers or when ISCNTL option is ordered Power Connectors for Galil integrated Amplifiers
141. begin variable name with a number Speed Z Cannot have spaces in the name Assigning Values to Variables Assigned values can be numbers internal variables and keywords functions controller parameters and strings The range for numeric variable values is 4 bytes of integer 231 followed by two bytes of fraction 2 147 483 647 9999 Numeric values can be assigned to programmable variables using the equal sign Any valid DMC 41x3 function can be used to assign a value to a variable For example v1 ABS v2 or v2 IN 1 Arithmetic operations are also permitted To assign a string value the string must be in quotations String variables can contain up to six characters which must be in quotation Examples posX TPX Assigns returned value from TPX command to variable posx speed 5 75 Assigns value 5 75 to variable speed input IN 2 Assigns logical value of input 2 to variable input v2 vltv3 v4 Assigns the value of vl plus v3 times v4 to the variable v2 var CAT Assign the string CAT to var MG var S3 Displays the variable var CAT Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as SP or PR PR vl Assign vl to PR command SP vS 2000 Assign vS 2000 to SP command Displaying the value of variables at the terminal Variables may be sent to the screen using the format variable For example vl returns the value of the variable v1 Example Using Var
142. cle Example INSTRUCTION FUNCTION A Label DPO Define starting positions as zero LINPOS 0 PR 1000 Required distance BGX Start motion B AMX Wait for completion WT 50 Wait 50 msec LINPOS DEX Read linear position ERR 1000 LINPOS TEX Find the correction JP C ABS ERR lt 2 Exit if error is small PR ERR Command correction BGX JP B Repeat the process C EN Using the DMC 41x3 Editor to Enter Programs Advanced The GalilTools software package provides an editor and utilities that allow the upload and download of DMC programs to the motion controller In most instances the user will use Galil software or a host application to download programs to the Galil controller rather than using the ED command Application programs for the DMC 41x3 may also be created and edited locally using the DMC 41x3 when using a program such as hyper terminal or telnet Chapter 7 Application Programming e 169 DMC 41x3 User Manual The DMC 41x3 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number o
143. cle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 2x inches and it corresponds to 4000 quadrature one inch of travel equals 4000 27 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Figure 7 1 The program starts at a state that we define as A Here the controller waits for the input pulse on Il As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle INSTRUCTION FUNCTION fA Label AI1 Wait for input 1 PR 6370 Distance SP 3185 Speed BGX Start Motion AMX After motion is complete SB1 Set output bit 1 WT 20 Wait 20 ms CB1 Clear output bit 1 WT 80 Wait 80 ms JP A Repeat the process DMC 41x3 User Manual Chapter 7 Application Programming 164 START PULSE 11 a bai MOTOR VELOCITY OUTPUT PULSE _ AL ____r output TIME INTERVALS move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output sign
144. complete WT 2713 Wait 2 samples 500us SB1 Set bit 1 EN End Program In the above example without using an unscaled WT the output would either need to be set directly after the motion was complete or 2 ms after the motion was complete By using WT n 1 and a lower TM greater delay resolution was achieved Conditional Jumps The DMC 41x3 provides Conditional Jump JP and Conditional Jump to Subroutine JS instructions for branching to a new program location based on a specified condition The conditional jump determines if a condition is satisfied and then branches to a new location or subroutine Unlike event triggers the conditional jump instruction does not halt the program sequence Conditional jumps are useful for testing events in real time They allow the controller to make decisions without a host computer For example the DMC 41x3 can decide between two motion profiles based on the state of an input line Command Format JP and JS FORMAT DESCRIPTION DMC 41x3 User Manual Chapter 7 Application Programming e 132 JS destination logical condition Jump to subroutine if logical condition is satisfied JP destination logical condition Jump to location if logical condition is satisfied The destination is a program line number or label where the program sequencer will jump if the specified condition is satisfied Note that the line number of the first line of program memory is 0 The comma designates IF
145. connections to amplifier and encoder Step 7a Connect standard servo motors Step 7b Connect step motors Step 8 Tune the servo system Step 1 Determine Overall Motor Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 41x3 can control any combination of standard servo motors and stepper motors Other types of actuators such as hydraulics can also be controlled please consult Galil The following configuration information is necessary to determine the proper motor configuration Standard Servo Motor Operation Unless ordered with stepper motor drivers or in a non standard configuration the DMC 41x3 has been setup by the factory for standard servo motor operation providing an analog command signal of 10V No hardware or software configuration is required for standard servo motor operation Stepper Motor Operation To configure the DMC 41x3 for stepper motor operation the controller requires that the command MT must be given Further instruction for stepper motor connections are discussed in Step 7b Step 2 Install Jumpers on the DMC 41x3 Master Reset and Upgrade Jumpers JP1 on the main board contains two jumpers MRST and UPGD The MRST jumper is the Master Reset jumper When MRST is connected the controller will perform a master reset upon PC power up or upon the reset input going low Whenever the controller has a master reset all programs arrays
146. cting Hardware e 35 DMC 41x3 User Manual 25mA Sourcing Opto Isolated Outputs LSRC Description With the LSRC option on the DMC 41x3 the digital outputs are modified to be capable of sourcing up to 25mA per output The ABCD LSRC option configures digital outputs 1 8 for 25mA sourcing outputs this is shown in Figure 3 12 The EFGH LSRC option only valid for 5 8 axis controllers configures digital outputs 9 16 for 25mA sourcing outputs this is shown in Figure 3 13 These outputs should not be used to drive inductive loads directly Electrical Specifications Output Common OPOA OP1A Max Voltage 24 VDC Min Voltage 5 VDC Max Drive Current per Output 25mA Sourcing Wiring the 25mA Sourcing Outputs The load will be connected from the digital output to the 5 24VDC supply return and or OPxB as shown in Figure 3 12 and Figure 3 13 The supply voltage must be connected to OPxA and the supply return must be connected to OPxB 3 3V Output Supply Output Supply Return Figure 3 12 25mA sourcing outputs for ABCD LSRC option DO 8 1 3 3V Output Supply FU ped LOAD Output Supply Return Figure 3 13 25mA sourcing outputs for EFGH LSRC option DO 16 9 10K DMC 41x3 User Manual Chapter 3 Connecting Hardware e 36 500mA Sourcing Opto Isolated Outputs HSRC Description With the HRSC option on the DMC 41x3 the digital outputs are modified to be capable of sourcing up to 0 5 A per pin with
147. ction Motor Interface Communication EXC Gi d con uci o Gad ix teckad Loops E E semana 6 Watch Dod TINE is pecs stasis cen pai 6 Chapter 2 Getting Started DMC 4143 CARD Dimensions DMC 4183 CARD Dimensions DMC 4143 BOX4 Dimensions DMC 4183 BOX8 Dimensions DMC 41x3 Power Connections DMC 41x3 Mounting Instructions Installing the DMC 41x3 Step 1 Determine Overall Motor Configuration Step 3 Install the Communications Software Step 4 Connect 20 80 VDC Power to the Controller Step 5 Establish Communications with Galil Software 15 Step 6 Make Connections to Amplifier and Encoder 16 Step 7a Connect Standard Servo Motors T Step 7b Connect Step Motors Step 8 Tune the Servo System DMC 41x3 Contents ii Deser anp ari 20 Example l Syst m Sepia accesos capio ia og 20 Example 2 Profiled Move Example 3 Multiple Axes Example 4 Independent Moves Example 5 Position Interrogation esee 2i Example 6 Absolute Position nass 22 Example 7 Velocity Control ss Example 8 Operation Under Torque Limit Example 9 Int trogatiQhi niece escis Example 10 Operation in the Buffer Mode is Example 11 Using the On Board Editor Example 12 Motion Program
148. ctronic commutation is required or the controller must be configured to provide sinusoidal commutation The amplifiers may be either pulse width modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 volts should run the motor at the maximum speed Galil offers amplifiers that are integrated into the same enclosure as the DMC 41x3 See the Integrated section in the Appendices or http galilmc com products accelera dmc41x3 html for more information Chapter 1 Overview e 5 DMC 41x3 User Manual Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 41x3 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as MA and MB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended MA and MB or differential MA MA and MB MB The DMC 41x3 decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or index for synchronization The DMC 41x3 can be ordered with 120 Ohm termination resistors installed on the encoder inputs See the Ordering Options f
149. d how to order your controller with these options see our DMC 41x3 part number generator on our website http www galilmc com products dmc 41x3 part number php DMC 41x3 Controller Board Options BOX4 BOX8 The BOX4 or BOXS option on the DMC 41x3 provides a metal enclosure for the controller BOX4 is the box for the 1 4 axis controllers the BOXS is for 5 8 axis controllers The BOXn option is required when using Galil internal amplifiers and is recommended for any application that requires CE certification Part number ordering example DMC 4113 BOX4 DIN DIN Rail Mounting The DIN option on the DMC 41x3 motion controller provides DIN rail mounts on the base of the controller This will allow the controller to be mounted to any standard DIN rail Requires BOX4 or BOX8 option Part number ordering example DMC 4113 BOX4 DIN 12V Power Controller with 12VDC The 12V option allows the controller to be powered with a regulated 12V supply The tolerance of the 12V input must be within 5 Part number ordering example DMC 4113 CARD 12V 16 bit 16 bit Analog Inputs The 16 bit option provides 16 bit analog inputs on the DMC 41x3 motion controller The standard resolution of the analog inputs is 12 bits Part number ordering example DMC 4113 CARD 16bit 4 20mA 4 20mA analog inputs The 4 20mA option converts all 8 analog inputs into 4 20mA analog inputs This is accomplished by installing 475 precision resist
150. d the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application Using External Amplifiers The BR command must be set to a 1 for any axis where an AMP 43640 is installed but the use of an external axis is required This setting will disable the requirement to have the BA BM and BX or BZ commands executed prior to being able to issue the SH command for that axis BR 1 is required for both external servo and stepper drivers Use the connectors on top of the controller to access necessary signals to run external amplifiers For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 A5 AMP 43640 D3640 e 243 DMC 41x3 User Manual A6 SDM 44040 D4040 D4020 Description The SDM 44040 resides inside the DMC 41x3 enclosure and contains four drives for operating two phase bipolar step motors The SDM 44040 requires a single 12 30 VDC input The unit is user configurable for 1 4 A 1 0 A 0 75 A or 0 5 A per phase and for full step half step 1 4 step or 1 16 step A two axis version the SDM 44020 is also available The BOX option is required when the SDM 44040 is order with the DMC 41x3 NOTE Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the mo
151. d when long distance serial communication is required in an application See the JP1 Jumper Description for DMC 41x3 section for termination resistor options for CTS and RXD signals RS 422 Auxiliary Port Standard connector and cable when DMC 41x3 1s ordered with RS 422 Option Pin Signal CTS RXD TXD RTS GND CTS RXD TXD RTS Part number ordering example DMC 4113 CARD P2422 BiSS and SSI BiSS and SSI Absolute Encoder Interface The DMC 41x3 controller can be configured to support BiSS and SSI encoders See the SS and SI commands in the DMC 41x3 Command Reference www galilmc com support manuals com41x3 index html Pinout information is shown below Jn1 Encoder 26 pin HD D Sub Connector SSI or BiSS option Pin Label Description Pin Label Description 1 FLS Forward Limit Switch Input 3 DIR Direction 16 MI I Index Pulse Input 4 HOM MB B Main Encoder Input 9 5V 5V Reverse Limit Switch Input 10 GND AB Data Dn or SLO T AAF Clock Cnt or MA 12 MB B Main Encoder Input 13 STP PWM Step 26 MA A Main Encoder Input LSCOMn on JAI JB1 JC1 and JDI is common to LSCOMO on J5 LSCOMn on JEI JF1 JG1 and JH1 is common to LSCOMI on J8 DMC 41x3 User Manual Appendices e 198 Internal Amplifier Options ISAMP Isolation of power between each AMP amplifier The ISAMP option separates the power pass through bet
152. des Function Code Read Coil Status Read Bits Read Input Status Read Bits Read Holding Registers Read Words Read Input Registers Read Words Force Single Coil Write One Bit Hes Preset Single Register Write One Word Read Exception Status Read Error Code li Force Multiple Coils Write Multiple Bits e Preset Multiple Registers Write Words Report Slave ID The DMC 41x3 provides three levels of Modbus communication The first level allows the user to create a raw packet and receive raw data It uses the MBh command with a function code of 1 The format of the command is MBh 1 len array where len is the number of bytes array is the array with the data The second level incorporates the Modbus structure This is necessary for sending configuration and special commands to an I O device The formats vary depending on the function code that is called For more information refer to the Command Reference The third level of Modbus communication uses standard Galil commands Once the slave has been configured the commands that may be used are IN AN SB CB OB and AO For example AO 2020 8 2 would tell I O number 2020 to output 8 2 volts If a specific slave address is not necessary the I O number to be used can be calculated with the following I O Number HandleNum 1000 Module 1 4 BitNum 1 Where HandleNum is the handle number from 1 A to 8 8 Module is the position of the modul
153. ds such as PR PA or JG DMC 41x3 User Manual Chapter 6 Programming Motion e 90 When the master axis is driven by the controller in the jog mode or an independent motion mode it is possible to define the master as the command position of that axis rather than the actual position The designation of the commanded position master is by the letter C For example GACX indicates that the gearing is the commanded position of X An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the X and Y motor form a circular motion the Z axis may move in proportion to the vector move Similarly 1f X Y and Z perform a linear interpolation move W can be geared to the vector move Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced an additional distance with PR or JG commands or VP or LI Ramped Gearing In some applications especially when the master is traveling at high speeds it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing is engaged For example if the master axis is already traveling at 500 000 counts sec and the slave will be geared at a ratio of 1 1 when the gearing is engaged the slave will instantly develop following
154. e Result equal to the report position of y axis Print result End Fast Update Rate Mode The DMC 41x3 can operate with much faster servo update rates than the default of every millisecond This mode is known as fast mode and allows the controller to operate with the following update rates DMC 4113 DMC 4123 DMC 4133 DMC 4143 DMC 4153 DMC 4163 DMC 4173 DMC 4183 62 5 usec 62 5 usec 125 usec 125 usec 187 5 usec 187 5 usec 250 usec 250 usec In order to run the DMC 41x3 motion controller in fast mode the fast firmware must be uploaded This can be done through the GalilTools communication software The fast firmware is included with the original DMC 41x3 utilities In order to set the desired update rates use the command TM When the controller is operating with the fast firmware some functions are disables For details see Fast Update Rate Mode in the Appendix Chapter 6 Programming Motion e 123 DMC 41x3 User Manual Chapter 7 Application Programming Overview The DMC 41x3 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 41x3 memory freeing the host computer for other tasks However the host computer can send commands to the controller at any time even while a program is being executed Only ASCII commands can be used for application programming In addition to standard motion c
155. e Note that this will cause up to a magnetic cycle of motion Be sure to use a high enough value with BZ to ensure the motor is locked into phase properly BX Command Issue the BX command The BX command utilizes a minimal movement algorithm in order to determine the correct commutation of the motor As of April 2011 this command was still in the Beta testing phase Setting Amplifier Gain and Current Loop Gain The AG command will set the amplifier gain Amps Volt and the AU command will set the current loop gain for the AMP 43540 The current loop gain will need to be set based upon the bus voltage and inductance of the motor and is critical in providing the best possible performance of the system AG command The AMP 43540 has 3 amplifier gain settings The gain is set with the AG command as shown in Table A4 1 for AG n m AG setting Gain Value m 0 0 4 A V m 1 0 8 A V m 2 1 6 A V Table A4 1 Amplifier Gain Settings for AMP 43540 The axis must be in a motor off MO state prior to execution of the AG command With an amplifier gain of 2 1 6A V the maximum motor command output is limited to 5V TL of 5 AU command Proper configuration of the AU command is essential to optimum operation of the AMP 43540 This command sets the gain for the current loop on the amplifier The goal is to set the gain as high as possible without causing the current loop to go unstable In most cases AU 0 should not be
156. e 1 until the home switch toggles again If Stage 3 is in the opposite direction of Stage 2 the motor will stop immediately at this point and change direction If Stage 2 is in the same direction as Stage 3 the motor will never stop but will smoothly continue into Stage 3 Stage 3 The motor traverses forward at HV counts sec until the encoder index pulse is detected The motor then decelerates to a stop and goes back to the index The DMC 41x3 defines the home position as the position at which the index was detected and sets the encoder reading at this point to zero Chapter 6 Programming Motion e 119 DMC 41x3 User Manual The 4 different motion possibilities for the home sequence are shown in the following table Direction of Motion Switch Type Stage 3 Normally Open RE fasta Forward Normally Open Lx oi genas 2 Forward Forward Nomally Closed e o lrn rem Forvard Normally Closed CN 1 Reverse Forward Forward Example Homing Instruction Interpretation HOME Label CN 1 Configure the polarity of the home input AC 1000000 Acceleration Rate DC 1000000 Deceleration Rate SP 5000 Speed for Home Search HM Home BG Begin Motion AM After Complete MG AT HOME Send Message EN End Figure 6 19 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 DMC 41x3 User Manual Chapter 6 Programming Motion e 120
157. e Chapter 10 Theory of Operation and our Manual Tuning Application Note 3413 http www galilmc com support appnotes optima note3413 pdf Design Examples Here are a few examples for tuning and using your controller These examples have remarks next to each command these remarks must not be included in the actual program Example 1 System Set up This example assigns the system filter parameters error limits and enables the automatic error shut off Instruction Interpretation KP 10 10 10 10 Set gains for a b c d or A B C D axes KP 10 Alternate method for setting gain on all axes KPA 10 Method for setting only A or X axis gain KPX 10 Method for setting only X or A axis gain DMC 41x3 User Manual Chapter 2 Getting Started e 20 RP 20 Instruction OE ii i i i i i i Set B axis gain only Interpretation Enable automatic Off on Error function for all axes ER 1000 Set error limit for all axes to 1000 counts KP 10 10 10 10 10 10 10 10 Set gains for a b c d e f g and h axes KP 10 Alternate method for setting gain on all axes KPA 10 Alternate method for setting A axis gain KP 10 Set C axis gain only KPD 10 Alternate method for setting D axis gain KPH 10 Alternate method for setting H axis gain Example 2 Profiled Move Rotate the A axis a distance of 10 000 counts at a slew speed of 20 000 counts sec and an acceleration and deceleration rates of 100 000 counts s2 In this example the motor turns and s
158. e coordinates of the end points of the vector movement with respect to the starting point Non sequential axis do not require comma delimitation The command CR r q d define a circular arc with a radius r starting angle of q and a traversed angle d The notation for q is that zero corresponds to the positive horizontal direction and for both q and d the counter clockwise CCW rotation is positive Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE The motion can be initiated with a Begin Sequence BGS command Once motion starts additional segments may be added The Clear Sequence CS command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or ABI ST stops motion at the specified deceleration ABI aborts the motion instantaneously The Vector End VE command must be used to specify the end of the coordinated motion This command requires the controller to decelerate to a stop following the last motion requirement If a VE command is not given an Abort ABI must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 41x3 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and no VE command the controller will stop motion instantly at the last vector Th
159. e designated at this time Otherwise the controller will not connect to the slave Ex IHB 151 25 255 9 lt 179 gt 2 This will open handle 2 and connect to the IP address 151 25 255 9 port 179 using TCP IP Which devices receive what information from the controller depends on a number of things If a device queries the controller it will receive the response unless it explicitly tells the controller to send it to another device If the command that generates a response is part of a downloaded program the response will route to whichever port is specified as the default unless explicitly told to go to another port with the CF command To designate a specific destination for the information add Eh to the end of the command Ex MG EC Hello will send the message Hello to handle 3 TP EF will send the z axis position to handle 6 Multicasting A multicast may only be used in UDP IP and is similar to a broadcast where everyone on the network gets the information but specific to a group In other words all devices within a specified group will receive the information that is sent in a multicast There can be many multicast groups on a network and are differentiated by their multicast IP address To communicate with all the devices in a specific multicast group the information can be sent to the multicast IP address rather than to each individual device IP address All Galil controllers belong to a default multicast address of 239 255
160. e in the rack from 1 to 16 BitNum is the I O point in the module from 1 to 4 Chapter 4 Software Tools and Communication e 51 DMC 41x3 User Manual Modbus Examples Example 1 DMC 4143 connected as a Modbus master to a RIO 47120 via Modbus The DMC 4143 will set or clear all 16 of the RIO s digital outputs 1 Begin by opening a connection to the RIO which in our example has IP address 192 168 1 120 IHB 192 168 1 120 lt 502 gt 2 Issued to DMC 4143 2 Dimension an array to store the commanded values Set array element 0 equal to 170 and array element 1 equal to 85 array element 1 configures digital outputs 15 8 and array element 0 configures digital outputs 7 0 DM myarray 2 myarray 0 170 which is 10101010 in binary myarray 1 85 which is 01010101in binary 3 a Send the appropriate MB command Use function code 15 Start at output 0 and set clear all 16 outputs based on the data in myarray MBB 15 0 16 myarray 3 b Set the outputs using the SB command SB2001 SB2003 SB2005 SB2007 SB2008 SB2010 SB2012 SB2014 Results Both steps 3a and 3b will result in outputs being activated as below The only difference being that step 3a will set and clear all 16 bits where as step 3b will only set the specified bits and will have no affect on the others Bit Number Status Bit Number Status Status Status po o o ei o Or o0 LN Example 2 DMC 4143 connected as a Modbus master to a 3rd pa
161. e line of the program where the interrupt was called EN will just return to the line of the program where it was called without re enabling the interrupt As with any automatic subroutine a program must be running in thread 0 at all times for it to be enabled Example A DMC 41x3 is used to jog the A and B axis This program automatically begins upon power up and allows the user to input values from the main serial port terminal The speed of either axis may be changed during motion by specifying the axis letter followed by the new speed value An S stops motion on both axes Instruction Interpretation AUTO Label for Auto Execute speedA 10000 Initial A speed speedB 10000 Initial B speed CE 2 Set Port 2 for Character Interrupt JG speedA speedB Specify jog mode speed for A and B axis BGXY Begin motion PRINT Routine to print message to terminal MG P2 TO CHANGE SPEEDS Print message MG P2 TYPE A OR B MG P2 TYPE S TO STOP JOGLOOP Loop to change Jog speeds JG speedA speedB Set new jog speed JP JOGLOOP DMC 41x3 User Manual Chapter 7 Application Programming e 154 EN COMINT JP A P2CH A JP B P2CH B JP C P2CH S ZS1 C1I2 JP JOGLOOP TA JS NUM speedX val ZS1 CI2 JP PRINT B JS NUM speedY val ZS1 CI2 JP PRINT C ST AMX CI 1 MG 8 THE END ZS EN 1 NUM MG ENTER P2CH S AXIS SPEED N NUMLOOP CI 1 NMLP JP NMLP P2CD lt 2 JP ERROR P2CD 2 val P2NM EN ERROR CI 1 M
162. e must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch The Home HM command can be used to position the motor on the index pulse after the home switch is detected This allows for finer positioning on initialization The HM command and BG command causes the following sequence of events to occur Stage 1 Upon begin the motor accelerates to the slew speed specified by the JG or SP commands The direction of its motion is determined by the state of the homing input If HMX reads 1 initially the motor will go in the reverse direction first direction of decreasing encoder counts If HMX reads 0 initially the motor will go in the forward direction first CN is the command used to define the polarity of the home input With CN 1 the default value a normally open switch will make HMX read 1 initially and a normally closed switch will make HMxX read zero Furthermore with CN 1 a normally open switch will make HMxX read 0 initially and a normally closed switch will make HMX read 1 Therefore the CN command will need to be configured properly to ensure the correct direction of motion in the home sequence Upon detecting the home switch changing state the motor begins decelerating to a stop NOTE The direction of motion for the FE command also follows these rules for the state of the home input Stage 2 The motor then traverses at HV counts sec in the opposite direction of Stag
163. e will demonstrate the possible different motions that may be commanded by the controller in the position tracking mode In this example there is a host program that will generate the absolute position targets The absolute target is determined based on the current information the host program has gathered on the object that it is tracking The position tracking mode does allow for all of the axes on the controller to be in this mode but for the sake of discussion it is assumed that the robot 1s tracking only in the X dimension The controller must be placed in the position tracking mode to allow on the fly absolute position changes This is performed with the PT command To place the X axis in this mode the host would issue PT1 to the controller if both X and Y axes were desired the command would be PT 1 1 The next step 1s to begin issuing PA command to the controller The BG command isn t required in this mode the SP AC and DC commands determine the shape of the trapezoidal velocity profile that the controller will use Chapter 6 Programming Motion e 77 DMC 41x3 User Manual Example Motion 1 The host program determines that the first target for the controller to move to is located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 countts sec2 and the velocity is set to 50 000 counts sec The command sequence to perform this is listed below EX1 PT Lp Place the X axis in Position tracking mode AC 15
164. each axis the LC command configures each axis s behavior when holding position and the Y A command sets the step driver resolution These commands are detailed below see also the command reference for more information Current Level Setup AG Command AG configures how much current the SDM 44040 delivers to each motor Four options are available 0 5A 0 75A 1 0A and 1 4 Amps Drive Current Selection per Axis AG n n n n n n n n n 0 05A n 1 0 75 A default n 2 10A n 3 14A Low Current Setting LC Command LC configures each motor s behavior when holding position when RP is constant and multiple configurations LC command set to 0 Full Current Mode causes motor to use 100 of peak current AG while at a resting state profiler is not commanding motion This is the default setting LC command set to 1 Low Current Mode causes motor to use 25 of peak current while at a resting state This is the recommended configuration to minimize heat generation and power consumption LC command set to an integer between 2 and 32767 specifying the number of samples to wait between the end of the move and when the amp enable line toggles Percentage of full AG current used while holding position with LC n n n n n n n n 100 The LC command must be entered after the motor type has been selected for stepper motor operation i e MT 2 2 2 2 LC is axis specific thus LC1 will cause only the X axis to operate in Low Cur
165. ecified axes MFnnnnnnnn Trip point to hold up program execution until n number of counts have passed in the forward direction Only one axis at a time may be specified MR n n n n n n n n Trip point to hold up program execution until n number of counts have passed in the reverse direction Only one axis at a time may be specified PT n n n n n n n n Command used to enter and exit the Trajectory Modification Mode PA n n n n n n n n Command Used to specify the absolute position target SP n n n n n n n n Speed settings for the specified axes Chapter 6 Programming Motion e 81 DMC 41x3 User Manual Linear Interpolation Mode The DMC 41x3 provides a linear interpolation mode for 2 or more axes In linear interpolation mode motion between the axes is coordinated to maintain the prescribed vector speed acceleration and deceleration along the specified path The motion path is described in terms of incremental distances for each axis An unlimited number of incremental segments may be given in a continuous move sequence making the linear interpolation mode ideal for following a piece wise linear path There is no limit to the total move length The LM command selects the Linear Interpolation mode and axes for interpolation For example LM YZ selects only the Y and Z axes for linear interpolation When using the linear interpolation mode the LM command only needs to be specified once unless the axes for linear inter
166. ecify automatic record Specify X position to be captured Turn X motor off Begin recording 4 msec interval at TM1000 Continue until done recording Compute DX Dimension Array for DX Initialize counter Label DMC 41x3 User Manual Chapter 6 Programming Motion e 108 D C 1 DELTA XPOS D XPOS C Compute the difference DX C DELTA Store difference in array C C 1 Increment index JP L C lt 500 Repeat until done PLAYBCK Begin Playback CMX Specify contour mode DT2 Specify time increment I 0 Initialize array counter B Loop counter CD DX I I I 1 Specify contour data I I 1 Increment array counter JP B I lt 500 Loop until done CD 0 0 End countour buffer Wait JP Wait CM lt gt 511 Wait until path is done EN End program For additional information about automatic array capture see Chapter 7 Arrays Virtual Axis The DMC 41x3 controller has two additional virtual axes designated as the M and N axes These axes have no encoder and no DAC However they can be commanded by the commands AC DC JG SP PR PA BG IT GA VM VP CR ST DP RP The main use of the virtual axes is to serve as a virtual master in ECAM modes and to perform an unnecessary part of a vector mode These applications are illustrated by the following examples ECAM Master Example Suppose that the motion of the XY axes is constrained along a path that can be described by an electronic cam table Further assume that the ecam master is no
167. ector Segre eine E TT Additional comualele i iii Command Summary Coordinated Motion Sequence gt Operand Summary Coordinated Motion Sequence ERIC ARR A A RS Ramped Gearing a Command Summary Electronic Gearing Examples Simple Master Sli coii Example Electronic Gearing Example Gantry Mode Electram Calc ooo acci iaia Command Summary Electronic CAM rie Operand Summary Electronic CANL aaa iia cud Example Electronic CAM is EVT I ae vad eae ae ath la ahd arenas abu 100 Specifying PVT Segments cics aa eoe acies 100 Exiting PVT Mode Error Conditions and Stop Codes Additional PVT Information Command Summary PVT auia acis cot idiots IA RR S Multi Axis Coordinated Move E Contour Mode iiia cca cione eee e ana 105 Specie Contour SERIE crinali 105 DMC 41x3 Contents iv Additonal Commands ei cn a ois o decia e nto 106 Command Summary gt Contour Mode ee 106 Va AN RR 109 Specifying Stepper Motor Operation Using an Encoder with Stepper Motors Command Summary Stepper Motor Operation 111 Operand Summary Stepper Motor Operation 111 Stepper Position Maintenance Mode SPM Dial Loop dAuxeliary
168. ed damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation DMC 4143 f TS LIMCACT pa hb ns 8 ist rj QUTPUTS SIMK DOIEM OPA GNO p Opee 24v0C HIGH POWER OPTION HP9 12 24V0C SOURCE 003 900A 2 24 per Es pu E la Figure A2 1 DMC 4143 D3140 BOX4 DMC 4143 with AMP 43140 DMC 41x3 User Manual A2 AMP 43140 D3140 e 224 Electrical Specifications The amplifier is a brush type trans conductance linear amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input DC Supply Voltage 12 30 VDC bipolar Max Current per axis 1 0 Amps 100mA option Amplifier gain 0 1 A V 10mA V option Power output per channel 20 W Total max power output 60 W Mating Connectors On Board Connector Terminal Pins POWER 4 pin Molex Mini Fit Jr MOLEX 39 01 2045 MOLEX 44476 3112 A B C D 4 pin Motor 2 pin Molex Mini Fit Jr Power Connectors MOLEX 39 01 2025 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 Power Supply Ground
169. een written by the user The CN command can be used to change the polarity of the limit switches The OE command can also be configured so that the axis will be disabled upon the activation of a limit switch Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches The OE command can also be configured so that the axis will be disabled upon the activation of a limit switch Software Protection The DMC 41x3 provides a programmable error limit as well as encoder failure detection It is recommended that both the position error and encoder failure detection be used when running servo motors with the DMC 41x3 Along with position error and encoder failure detection then DMC 41x3 has the ability to have programmable software limit Position Error The error limit can be set for any number between 0 and 2147483647 using the ER n command The default value for ER is 16384 Example ER 200 300 400 500 Set X axis error limit for 200 Y axis error limit to 300 z axis error limit to 400 counts W axis error limit to 500 counts ER 1 10 Set Y axis error limit
170. eferred to as a PID filter The filter parameters are represented by the three constants KP KI and KD which correspond to the proportional integral and derivative term respectively The damping element of the filter acts as a predictor thereby reducing the delay associated with the motor response The integrator function represented by the parameter KI improves the system accuracy With the KI parameter the motor does not stop until it reaches the desired position exactly regardless of the level of friction or opposing torque The integrator also reduces the system stability Therefore it can be used only when the loop is stable and has a high gain The output of the filter is applied to a digital to analog converter DAC The resulting output signal in the range between 10 and 10 Volts is then applied to the amplifier and the motor The motor position whether rotary or linear is measured by a sensor The resulting signal called position feedback is returned to the controller for closing the loop The following section describes the operation in a detailed mathematical form including modeling analysis and design DMC 41x3 User Manual Chapter 10 Theory of Operation e 182 System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Figure 10 4 The mathematical model of the various components is given below CONTROLLER DIGITAL Y
171. ements in the loop A s 390 000 s 51 s s 2000 To analyze the system stability determine the crossover frequency at which A j equals one This can be done by the Bode plot of AG as shown in Figure 10 8 Magnitude 50 200 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function For the given example the crossover frequency was computed numerically resulting in 200 rad s DMC 41x3 User Manual Chapter 10 Theory of Operation e 188 Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 51 G200 j200 2000 a Arg A j200 tan 1 200 5 1 180 tan 1 200 2000 a 76 180 6 110 Finally the phase margin PM equals PM 180 a 70 As long as PM is positive the system is stable However for a well damped system PM should be between 30 and 45 The phase margin of 70 given above indicated over damped response Next we discuss the design of control systems System Design and Compensation The closed loop control system can be stabilized by a digital filter which is preprogrammed in the DMC 41x3 controller The filter parameters can be selected by the user for the best compensation The following discussion presents an analytical design method The Analytical Method The analytical design method is aimed at closing the loop at a crossover frequency c with a phase margin PM The system parameters are assumed known
172. en to that point to avoid a jump This is done with the program INSTRUCTION INTERPRETATION RUN Label EB1 Enable cam PA 500 starting position SP 5000 Y speed BGY Move Y motor AM After Y moved AI1 Wait for start signal EG 1000 Engage slave AI 1 Wait for stop signal EQ 1000 Disengage slave EN End Chapter 6 Programming Motion e 97 DMC 41x3 User Manual Command Summary Electronic CAM Command Description EA p Specifies master axes for electronic cam where p X Y Z or W or A B C D E F G H for main encoder as master or M or N a for virtual axis master EB n Enables the ECAM ECn ECAM counter sets the index into the ECAM table EG x y z w Engages ECAM EM x y z w Specifies the change in position for each axis of the CAM cycle EP m n Defines CAM table entry size and offset EQ m n Disengages ECAM at specified position ET n Defines the ECAM table entries EW Widen Segment see Application Note 2444 EY Set ECAM cycle count Operand Summary Electronic CAM Command Description _EB Contains State of ECAM _EC Contains current ECAM index _EGx Contains ECAM status for each axis _EM Contains size of cycle for each axis _EP Contains value of the ECAM table interval _EQx Contains ECAM status for each axis _EY Set ECAM cycle count Example Electronic CAM The following example illustrates a cam program with a master axis Z and two slaves X and Y INSTRU
173. encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the position resolution is increased to 4N quadrature counts rev The model of the encoder can be represented by a gain of K 4N 21 count rad For example a 1000 lines rev encoder is modeled as K 638 DAC The DAC or D to A converter converts a 16 bit number to an analog voltage The input range of the numbers is 65536 and the output voltage range is 10V or 20V Therefore the effective gain of the DAC is K 20 65536 0 0003 V count Chapter 10 Theory of Operation e 185 DMC 41x3 User Manual Digital Filter The digital filter has three element in series PID low pass and a notch filter The transfer function of the filter The transfer function of the filter elements are K Z 4 CZ PID D z Z Z 1 L L z lag OW pass vA i Z B Notch N z EA a 2 Z pXZ p The filter parameters K A C and B are selected by the instructions KP KD KI and PL respectively The relationship between the filter coefficients and the instructions are K KP KD A KD KP KD C KI B PL The PID and low pass elements are equivalent to the continuous transfer function G s G s P sD I s a s a where P KP D T KD I KIT 1 a 1n L T B where T is the sampling period and B is the pole setting Fo
174. ents Next we discuss the system analysis System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 41x3 controller and the following parameters K 0 1 Nm A Torque constant J 2 104 kg m System moment of inertia R 2 Q Motor resistance K 4 Amp Volt Current amplifier gain KP 12 5 Digital filter gain KD 245 Digital filter zero KI 0 No integrator N 500 Counts rev Encoder line density T 1 ms Sample period The transfer function of the system elements are Motor M s P I KyJs 500 s rad A Amp K 4 Amp V DAC K 0 0003 V count Encoder K 4N 27 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 T 0 001 Therefore Chapter 10 Theory of Operation e 187 DMC 41x3 User Manual D z 1030 z 0 95 Z Accordingly the coefficients of the continuous filter are P 50 D 0 98 The filter equation may be written in the continuous equivalent form G s 50 0 98s 098 s 51 The system elements are shown in Figure 10 7 FILTER ZOH DAC AMP MOTOR EN d A 50 0 980s 2000 0 0003 4 200 e p i S 2000 i g ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s is the product of all the el
175. er failure Programmable Position Limits The DMC 41x3 provides programmable forward and reverse position limits These are set by the BL and FL software commands Once a position limit is specified the DMC 41x3 will not accept position commands beyond the limit Motion beyond the limit is also prevented Chapter 8 Hardware amp Software Protection e 173 DMC 41x3 User Manual Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog BG XYZ Begin motion stops at forward limits Off On Error The DMC 41x3 controller has a built in function which can turn off the motors under certain error conditions This function is known as Off On Error To activate the OE function for each axis specify 1 2 or 3 for that axis To disable this function specify 0 for the axes When this function is enabled the specified motor will be disabled under the following 3 conditions 1 The position error for the specified axis exceeds the limit set with the command ER 2 A hardware limit is reached 3 The abort command is given 4 The abort input is activated with a low signal NOTE If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Examples OE lr Enable off on error for X Y Z and W OE 0 1 0 1 En
176. erator is a Logical Or These operators allow for bit wise operations on any valid DMC 41x3 numeric operand including variables array elements numeric values functions keywords and arithmetic expressions The bit wise operators may also be used with strings This is useful for separating characters from an input string When using the input command for string input the input variable will hold up to 6 characters These characters are combined into a single value which is represented as 32 bits of integer and 16 bits of fraction Each ASCII character is represented as one byte 8 bits therefore the input variable can hold up to six characters The first character of the string will be placed in the top byte of the variable and the last character will be placed in the lowest significant byte of the fraction The characters can be individually separated by using bit wise operations as illustrated in the following example TEST Begin main program len 123456 Set len to a string value Flen FRAC len Define variable Flen as fractional part of variable len Flen 10000 Flen Shift Flen by 32 bits IE convert fraction Flen to integer lenl Flen amp 00FF Mask top byte of Flen and set this value to variable lenl len2 Flen amp FF00 100 Let variable len2 top byte of Flen len3 len amp 000000FF Let variable len3 bottom byte of len len4 len amp 0000FF00 100 Let variable
177. eratures and energy levels exist in this product and the associated amplifiers and servo motor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install set up and operate this equipment Never open the controller box when DC power is applied to it The green power POWER led indicator should go on when proper power is applied Step 5 Establish Communications with Galil Software Communicating through an Ethernet connection The DMC 41x3 motion controller is equipped with DHCP If the controller is connected to a DHCP enabled network an IP address will automatically be assigned to the controller See Ethernet Configuration in Chapter 4 for more information Using GalilTools Software for Windows Registering controllers in the Windows registry is no longer required when using the GalilTools software package A simple connection dialog box appears when the software is opened that shows all available controllers Any available controllers with assigned IP addresses can be found under the Available tab in the Connections Dialog Box If the controller is not connected to a DHCP enabled network or the DH command is set to 0 and the controller has not been assigned an IP address the controller can be found under the No IP Address tab Chapter 2 Getting Started e 15 DMC 41x3 User Manual For more information on establishing communication to the controller
178. ere will always be some amount of stepper motor smoothing Fourth the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver The pulses which are generated by the smoothing filter can be monitored by the command TD Tell Dual TD DMC 41x3 User Manual Chapter 6 Programming Motion e 110 gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Stepper Smoothing Filter Output Buffer EN Output Motion Profiler Adds a Delay To Stepper Driver Reference Position RP Step Count Register TD Motion Complete Trippoint When used in stepper mode the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position The MC trippoint Motion Complete is generally more useful than AM trippoint After Motion since the step pulses can be delayed from the commanded position due to stepper motor smoothing Using an Encoder with Stepper Motors An encoder may be used on a stepper motor to check the actual motor position with the commanded position If an encoder is used it must be connected to t
179. ere will be no controlled deceleration LM or LM returns the available spaces for motion segments that can be sent to the buffer 511 returned means the buffer is empty and 511 segments can be sent A zero means the buffer is full and no additional segments can be sent As long as the buffer is not full additional segments can be sent at PC bus speeds The operand CS can be used to determine the value of the segment counter Additional commands The commands VS n VA n and VD n are used for specifying the vector speed acceleration and deceleration IT is the s curve smoothing constant used with coordinated motion Specifying Vector Speed for Each Segment The vector speed may be specified by the immediate command VS It can also be attached to a motion segment with the instructions VP x y lt n gt m CR r 0 8 lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For ex
180. error and command maximum current to the motor This can be a large shock to the system For many applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame Galil allows the user to specify an interval of the master axis over which the gearing will be engaged For example the same master X axis in this case travels at 500 000 counts sec and the gear ratio is 1 1 but the gearing is slowly engaged over 30 000 counts of the master axis greatly diminishing the initial shock to the slave axis Figure 6 8 below shows the velocity vs time profile for instantaneous gearing Figure 6 9 shows the velocity vs time profile for the gradual gearing engagement Scope t1 a vertical Horizontal FE didt Source Scale div Offset div y MM RPA Axis A refa 100000 cc 1 c e m v RPBAxsBrefw 100000 cc 4 mr v 2 ei T e ao x 0 221383 0 T B s0 vw 4 42765 1 T a ao m 0 442765 S 2 a m 0 221383 3 BO x 0 221383 4 T T 100 ms Trigger Channel MM _RPE Edge Level 1000 count Mode Repeat v READY didt RPA didt RPS Figure 6 8 Velocity counts sec vs Time msec Instantaneous Gearing Engagement Chapter 6 Programming Motion e 91 DMC 41x3 User Manual Scope tj pe Vertical Horizontal didt Source Scale div Offset div 4 MM RPA Axis A
181. errors An echo function is provided to enable associating the DMC 41x3 response with the data sent The echo is enabled by sending the command EO 1 to the controller Unsolicited Messages Generated by Controller When the controller is executing a program it may generate responses which will be sent via the USB port or Ethernet handles This response could be generated as a result of messages using the MG command OR as a result of a command error These responses are known as unsolicited messages since they are not generated as the direct response to a command Messages can be directed to a specific port using the specific Port arguments see the MG and CF commands in the Command Reference If the port is not explicitly given or the default is not changed with the CF command unsolicited messages will be sent to the default port The default port is the main serial port When communicating via an Ethernet connection the unsolicited messages must be sent through a handle that is not the main communication handle from the host The GalilTools software automatically establishes this second communication handle The controller has a special command CW which can affect the format of unsolicited messages This command is used by Galil Software to differentiate response from the command line and unsolicited messages The command CWI causes the controller to set the high bit of ASCII characters to 1 of all unsolicited characters This may cause ch
182. es The port can be specified with the specifier P1 for the main USB P2 for auxiliary serial port or En for the Ethernet port MG P2 Hello World Sends message to Auxiliary Port Formatting Messages String variables can be formatted using the specifier Sn where n is the number of characters 1 thru 6 For example MG STR S3 This statement returns 3 characters of the string variable named STR Numeric data may be formatted using the Fn m expression following the completed MG statement n m formats data in HEX instead of decimal The actual numerical value will be formatted with n characters to the left of the decimal and m characters to the right of the decimal Leading zeros will be used to display specified format For example MG The Final Value is result F5 2 If the value of the variable result is equal to 4 1 this statement returns the following The Final Value is 00004 10 If the value of the variable result is equal to 999999 999 the above message statement returns the following The Final Value is 99999 99 The message command normally sends a carriage return and line feed following the statement The carriage return and the line feed may be suppressed by sending N at the end of the statement This is useful when a text string needs to surround a numeric value Example A JG 50000 BGA ASA MG The Speed is TVA F5 0 N MG counts sec EN When A is executed the above example will appear o
183. es vs Commanded Pulses For proper controller operation it is necessary to make sure that the controller has completed generating all step pulses before making additional moves This is most particularly important if you are moving back and forth For example when operating with servo motors the trippoint AM After Motion is used to determine when the motion profiler is complete and 1s prepared to execute a new motion command However when operating in stepper mode the controller may still be generating step pulses when the motion profiler is complete This 1s caused by the stepper motor smoothing filter KS To understand this consider the steps the controller executes to generate step pulses First the controller generates a motion profile in accordance with the motion commands Second the profiler generates pulses as prescribed by the motion profile The pulses that are generated by the motion profiler can be monitored by the command RP Reference Position RP gives the absolute value of the position as determined by the motion profiler The command DP can be used to set the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Third the output of the motion profiler is filtered by the stepper smoothing filter This filter adds a delay in the output of the stepper motor pulses The amount of delay depends on the parameter which is specified by the command KS As mentioned earlier th
184. f the Analog to Digital conversion is 12 bits 16 bit ADC is available as an option Analog inputs are useful for reading special sensors such as temperature tension or pressure The following examples show programs which cause the motor to follow an analog signal The first example is a point to point move The second example shows a continuous move Example Position Follower Point to Point Objective The motor must follow an analog signal When the analog signal varies by 10V motor must move 10000 counts DMC 41x3 User Manual Chapter 7 Application Programming e 162 Method Read the analog input and command A to move to that point Instruction Interpretation POINTS Label SP 7000 Speed AC 80000 DC 80000 Acceleration LOOP VP QAN 1 1000 Read and analog input compute position PA VP Command position BGA Start motion AMA After completion JP LOOP Repeat EN End Example Position Follower Continuous Move Method Read the analog input compute the commanded position and the position error run at a speed in proportions to the position error Instruction Interpretation CONT Label AC 80000 DC 80000 Acceleration rate JG 0 Start job mode BGX Start motion LOOP vp AN 1 1000 Compute desired position ve vp TPA Find position error vel ve 20 Compute velocity JG vel Change velocity JP LOOP Change velocity EN End Example Low Pass Digital Filter for the Analog inputs Command the motor to Because
185. forward motion The motor will then decelerate to a stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP When using the FE command it is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine is initiated by the command sequence FIX BGX Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command and then moves back to the index pulse and speed HV Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HMX BGX Standard Homing is a combination of Find Edge and Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detecting the transition in the logic state on the Home Input the motor will decelerate to a s
186. four PWM drives for sinusoidally commutating brushless motors It is capable of up to 8 Amps of continuous current and 15Amps of peak current and requires a single DC supply voltage in the range of 18 80 VDC AS AMP 43640 D3640 The AMP 43640 contains four linear drives for sinusoidally commutating brushless motors The AMP 43640 requires a single 18 30VDC input Output power delivered is typically 20 W per amplifier or 80 W total DMC 41x3 User Manual Integrated Components e 216 A6 SDM 44040 D4040 D4020 4 axis Stepper Drives The SDM 44040 is a stepper driver module capable of driving up to four bipolar two phase stepper motors The current is selectable with options of 0 5 0 75 1 0 and 1 4 Amps Phase The step resolution is selectable with options of full half 1 4 and 1 16 A7 SDM 44140 D4140 4 axis Microstep Drives The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution the SDM 44140 drives two The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis Integrated Components e 217 DMC 41x3 User Manual Al AMP 430x0 D3040 D3020 Description The AMP 43040 resides inside the DMC 41x3 enclosure and contains four transconductance PWM amplifiers for driving brushless or brush type servo motors Each amplifier drives motors operating at up to 7 Amps continuous 10 Amps peak 20 80 VDC The gain settings of the amplifier
187. from a motor lead to ground Over Temperature Protection The amplifier is also equipped with over temperature protection If the average heat sink temperature rises above 80 C then the amplifier will be disabled The over temperature condition will trigger the ZAMPERR routine if included in the program on the controller The amplifier will not be re enabled until the temperature drops below 80 C and then either an SH command is sent to the controller or the controller is reset RS command or power cycle DMC 41x3 User Manual A4 AMP 435x0 D3540 D3520 e 238 A5 AMP 43640 D3640 Introduction The AMP 43640 contains four linear drives for sinusoidally commutating brushless motors The AMP 43640 requires a single 15 30VDC input Output power delivered is typically 20 W per amplifier or 80 W total The gain of each transconductance linear amplifier is 0 2 A V Typically a 24VDC supply will deliver 1A continuous and 2A peak while a 30VDC will be able to provide 1 0 A continuous and 2 0 A peak The current loop bandwidth is approximately 4 kHz By default the amplifier will use 12 bit DAC s however there is an option for 16 bit DAC s to increase the current resolution for systems with high feedback gain The BOX option is required when the AMP 43640 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or d
188. from beginner to the most advanced MOTION CONTROL MADE EASY WHO SHOULD ATTEND Those who need a basic introduction or refresher on how to successfully implement servo motion control systems TIME 4 hours 8 30 am 12 30 pm ADVANCED MOTION CONTROL WHO SHOULD ATTEND Those who consider themselves a servo specialist and require an in depth knowledge of motion control systems to ensure outstanding controller performance Also prior completion of Motion Control Made Easy or equivalent is required Analysis and design tools as well as several design examples will be provided TIME 8 hours 8 00 am 5 00 pm PRODUCT WORKSHOP WHO SHOULD ATTEND Current users of Galil motion controllers Conducted at Galil s headquarters in Rocklin CA students will gain detailed understanding about connecting systems elements system tuning and motion programming This is a hands on seminar and students can test their application on actual hardware and review it with Galil specialists Attendees must have a current application and recently purchased a Galil controller to attend this course TIME Two days 8 30 4 30pm http www galilmc com learning training at galil php Appendices e 213 DMC 41x3 User Manual Contacting Us Galil Motion Control 270 Technology Way Rocklin CA 95765 Phone 916 626 0101 Fax 916 626 0102 E Mail Address support galilme com Web 370Hhttp www galilmc com DMC 41x3 User Manual Appendices e 214 WA
189. g specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA1 will return hall errors on the appropriate axes TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label AMPERR in their program to amplifier errors As long as a program is executing in thread zero and the ZAMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition See the TA command for detailed information on bit status during error conditions Hall Error Protection During normal operation the controller should not have any Hall errors Hall errors can be caused by a faulty Hall effect sensor or a noisy environment If at any time the Halls are in an invalid state the appropriate bit of TA1 will be set The state of the Hall inputs can also be monitored through the QH command Hall errors will cause the amplifier to be disabled if OE 1 is set and will cause the controller to enter the ZAMPERR subroutine if it is included in a running program Under Voltage Protection If the supply to the amplifier drops below 18 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised ab
190. geared axes We will implement the gearing change over 6000 counts 3 revolutions of the master axis MO Z Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GD 6000 6000 Specify ramped gearing over 6000 counts of the master axis GR 1 132 045 Specify gear ratios Question What is the effect of the ramped gearing Answer Below in the example titled Electronic Gearing gearing would take effect immediately From the start of gearing if the master traveled 6000 counts the slaves would travel 6792 counts and 270 counts Using the ramped gearing the slave will engage gearing gradually Since the gearing is engaged over the interval of 6000 counts of the master the slave will only travel 3396 counts and 135 counts respectively The difference between these two values is stored in the GPn operand If exact position synchronization is required the IP command is used to adjust for the difference DMC 41x3 User Manual Chapter 6 Programming Motion e 92 Command Summary Electronic Gearing COMMAND DESCRIPTION GAn Specifies master axes for gearing where n X Y Z or W or A B C D E F G H for main encoder as master n CX CY CZ CW or CA CB CC CD CE CF CG CH for commanded position n DX DY DZ or DW or DA DB DC DD DE DF DG DH for auxiliary encoders n S or T for gearing to coordinated motion GD a b c d e f g h Sets the distance the master will travel for the gearing change to take ful
191. gging an application program Below is a list of operands which are particularly valuable for program debugging To display the value of an operand the message command may be used For example since the operand ED contains the last line of program execution the command MG ED will display this line number ED contains the last line of program execution Useful to determine where program stopped DL contains the number of available labels UL contains the number of available variables DA contains the number of available arrays DM contains the number of available array elements AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to specify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation Download Code TA Program Label PR1000 Position Relative 1000 BGX Begin PR5000 Position Relative 5000 EN End From Terminal XQ dA Execute 4A 2003 PR5000 Error on Line 3 FIGI Tell Error Code 7 Command not valid Command not valid while running while running Change the BGX line to BGX AMX and re download the program XQ A Execute A
192. ght that should be used for the DMC 41x3 CARD controllers is 0 656 BOX4 and BOX8 All 4 mounting holes should be used to mount the controller to a secure base See Figure 2 3 and Figure 2 4 for mounting hole locations and sizes If the controller is shipped with internal amplifiers the base of the DMC 41x3 is used as the heat sync for those amplifiers Elements You Need For a complete system Galil recommends the following elements 1 DMC 4113 4123 4133 or DMC 4143 Motion Controller Or DMC 4153 4163 4173 or DMC 4183 2 Motor Amplifiers Integrated when using Galil amplifiers and drivers 3 Power Supply for Amplifiers and controller 4 Brush or Brushless Servo motors with Optical Encoders or stepper motors a Cables for connecting to the DMC 41x3 5 PC Personal Computer USB or Ethernet for DMC 41x3 6 GalilTools or GalilTools Lite Software package GalilTools is highly recommended for first time users of the DMC 41x3 It provides step by step instructions for system connection tuning and analysis DMC 41x3 User Manual Chapter 2 Getting Started e 12 Installing the DMC 41x3 Installation of a complete operational DMC 41x3 system consists of 8 steps Step 1 Determine overall motor configuration Step 2 Install Jumpers on the DMC 41x3 Step 3 Install the communications software Step 4 Connect DC power to controller Step 5 Establish communications with the Galil Communication Software Step 6 Make
193. hat the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 kQ resistor and measure the voltage across the resistor Only if the voltage is zero connect the two ground signals directly The amplifier enable signal is used by the controller to disable the motor Use the command MO to disable the motor amplifiers check to insure that the motor amplifiers have been disabled often this is indicated by an LED on the amplifier This signal changes under the following conditions the watchdog timer activates the motor off command MO is given or the OE3 command Enable Off On Error is given and the position error exceeds the error limit AEN can be used to disable the amplifier for these conditions The AEN signal from the DMC 41x3 is shipped as a default of 5V active high or high amp enable In other words the AEN signal will be high when the controller expects the amplifier to be enabled If your amplifier requires a different configuration see the Configuring the Amplifier Enable Circuit section in Chapter 3 The DMC 41x3 can be configured from the factor
194. he Y axis issue AU 0 1 The command AW is used to calculate the bandwidth of the amplifier using the basic amplifier parameters To calculate the bandwidth for the X axis issue AWX v n where v represents the DC voltage input to the card represents the inductance of the motor in millihenries and n represents 0 or 1 for the AU setting A3 AMP 43240 D3240 e 229 DMC 41x3 User Manual NOTE For most applications unless the motor has more than 5 mH of inductance with a 24V supply or 10 mH of inductance with a 48 volts supply the normal current loop bandwidth option should be chosen AW will return the current loop bandwidth in Hertz tj vertical Horizontal didt Source Scale idiv Offset div MO TTA Axis A tord 2v ei amp sO li 3 2 m iv eu T mi se 1 S o a ist 1 eu xm sO sli Si amp sO sj 1 ez t m vj 1 1 5ms 2 3 Trigger Channel TA vl Edge v Level 0 1V Mode Repeat v READY d TT 2 9 03 V TA dt 13 ms 1 dt 74 6 Hz Figure A3 2 Peak Current Operation Chopper Mode The AMP 43240 runs in what is called a Chopper mode The chopper mode is in contrast to the normal inverter mode AMP 43040 in which the amplifier sends PWM power to the motor of VS In chopper mode the amplifier sends a 0 to VS PWM to the motor when moving in the forward direction and a 0 to VS PWM to the motor when moving in the negative direction Using Extern
195. he beginning of any vector motion sequence See application programming for further information Instruction Interpretation VMAB Select AB axes for circular interpolation VP 4000 0 Linear segment CR 2000 270 180 Circular segment VP 0 4000 Linear segment CR 2000 90 180 Circular segment VS 1000 Vector speed VA 50000 Vector acceleration VD 50000 Vector deceleration Chapter 2 Getting Started e 25 DMC 41x3 User Manual VE End vector sequence BGS Start motion B 4000 4000 0 4000 R 2000 O 4000 0 0 0 local zero Figure 2 8 Motion Path for Circular Interpolation Example DMC 41x3 User Manual Chapter 2 Getting Started e 26 Chapter 3 Connecting Hardware Overview The DMC 41x3 provides opto isolated digital inputs for forward limit reverse limit home and abort signals The controller also has 8 opto isolated uncommitted inputs for general use as well as 8 opto isolated outputs and 8 analog inputs configured for voltages between 10 volts Controllers with 5 or more axes have an additional 8 opto isolated inputs and an additional 8 opto isolated outputs This chapter describes the inputs and outputs and their proper connection Overview of Opto Isolated Inputs Limit Switch Input The forward limit switch FLSx inhibits motion in the forward direction immediately upon activation of the switch The reverse limit switch RLSx inhibits motion in the reverse direction immediately upon activ
196. he main encoder input Note The auxiliary encoder is not available while operating with stepper motors The position of the encoder can be interrogated by using the command TP The position value can be defined by using the command DE Note Closed loop operation with a stepper motor is not possible Command Summary Stepper Motor Operation COMMAND DESCRIPTION DE Define Encoder Position When using an encoder DP Define Reference Position and Step Count Register IT Motion Profile Smoothing Independent Time Constant KS Stepper Motor Smoothing MT Motor Type 2 2 2 5 or 2 5 for stepper motors RP Report Commanded Position TD Report number of step pulses generated by controller TP Tell Position of Encoder Operand Summary Stepper Motor Operation OPERAND DESCRIPTION _DEx Contains the value of the step count register for the x axis _DPx Contains the value of the main encoder for the x axis _ITx Contains the value of the Independent Time constant for the x axis _KSx Contains the value of the Stepper Motor Smoothing Constant for the x axis _MTx Contains the motor type value for the x axis Chapter 6 Programming Motion e 111 DMC 41x3 User Manual Contains the commanded position generated by the profiler for the x axis Contains the value of the step count register for the x axis _TPx Contains the value of the main encoder for the x
197. he output port may be set and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit Example Set Bit and Clear Bit Instruction Interpretation SB6 Sets bit 6 of output port CB4 Clears bit 4 of output port Example Output Bit The Output Bit OB instruction is useful for setting or clearing outputs depending on the value of a variable array input or expression Any non zero value results in a set bit Instruction Interpretation OB1 POS Set Output 1 if the variable POS is non zero Clear Output 1 if POS equals 0 OB 2 GIN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 OB 3 GIN 1 amp IN 2 Set Output 3 only if Input 1 and Input 2 are high OB 4 COUNT 1 Set Output 4 if element 1 in the array COUNT is non zero The output port can be set by specifying an 16 bit word using the instruction OP Output Port This instruction allows a single command to define the state of the entire 16 bit output port where bit 0 is output 1 bitl is output2 and so on A designates that the output is on Example Output Port Instruction Interpretation OP6 Sets outputs 2 and 3 of output port to high All other bits are 0 21 2 6 OPO Clears all bits of output port to zero OP 255 Sets all bits of output port to one 29 21 2 23 244 29 29 27 The output port is useful for setting relays or controlling external switches and events during a motion seque
198. he rotary encoder to the X axis and connect the linear encoder to the auxiliary encoder of X Assume that the required motion distance is one inch and that this corresponds to 40 000 counts of the rotary encoder and 10 000 counts of the linear encoder The design approach is to drive the motor a distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program V1 10000 DEX V2 _TEX 4 V1 JP END ABS V2 lt 2 INSTRUCTION INTERPRETATION DUALOOP Label CE 0 Configure encoder DEO Set initial value PR 40000 Main move BGX Start motion Correct Correction loop AMX Wait for motion completion Find linear encoder error Compensate for motor error Exit if error is small PR V2 4 Correction move BGX Start correction JP CORRECT Repeat END EN Motion Smoothing The DMC 41x3 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value The discontinuous acceleration results in jerk which causes vibration The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration Using the IT Command S When operating with servo motors motion smoothing can be accomplis
199. he velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt on the X axis TL 1 NOTE Once the correct polarity of the feedback loop has been determined the torque limit should in general be increased to the default value of 9 99 The servo will not operate properly if the torque limit is below the normal operating range See description of TL in the command reference Step D Connect the Motor Once the parameters have been set connect the analog motor command signal MCMn where n is A H to the amplifier input To test the polarity of the feedback command a move with the instruction PR 1000 Position relative 1000 counts BGA Begin motion on A axis When the polarity of the feedback is wrong the motor will attempt to run away The controller should disable the motor when the position error exceeds 2000 counts If the motor runs away the polarity of the loop must be inverted Inverting the Loop Polarity When the polarity of the feedback is incorrect the user must invert the loop polarity and this may be accomplished by several methods If you are driving a brush type DC motor the simplest way is to invert the two motor wires typically red and black For example switch the M1 and M2 connections g
200. hed with the IT command This command filters the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile has continuous acceleration and results in reduced mechanical vibrations The smoothing function is specified by the following commands IT x y z w Independent time constant Chapter 6 Programming Motion e 117 DMC 41x3 User Manual The command IT is used for smoothing independent moves of the type JG PR PA and to smooth vector moves of the type VM and LM The smoothing parameters x y z w and n are numbers between 0 and 1 and determine the degree of filtering The maximum value of 1 implies no filtering resulting in trapezoidal velocity profiles Smaller values of the smoothing parameters imply heavier filtering and smoother moves The following example illustrates the effect of smoothing Figure 6 18 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed LT 9 Filter for smoothing BG X Begin ACCELERATION D E x o e VELOCITY o O Z ACCELERATION VELOCITY D cC O O E o 2 d O en il ED d Figure 6 18 Trapezoidal velocity and smooth velocity profiles DMC 41x3 User Manual Chapter 6 Programming Mo
201. host This is the most common way to send data to the controller such as setting variables to numbers or strings Any variable can be stored in a string format up to 6 characters by simply specifying defining that variable to the string value with quotes for example varS STRING Will assign the variable varS to a string value of STRING To assign a variable a numerical value the direct number is used for example varN 123456 Will assign the variable varN to a number of 123 456 All variables on the DMC 41x3 controller are stored with 6 bytes of integer and 4 bytes of fractional data Operator Data Entry Mode The Operator Data Entry Mode provides for un buffered data entry through the auxiliary RS 232 port In this mode the DMC 41x3 provides a buffer for receiving characters This mode may only be used when executing an applications program The Operator Data Entry Mode may be specified for Port 2 only This mode may be exited with the or lt escape gt key NOTE Operator Data Entry Mode cannot be used for high rate data transfer Set the third field of the CC command to one to set the Operator Data Entry Mode To capture and decode characters in the Operator Data Mode the DMC 41x3 provides special the following keywords Keyword Function P2CH Contains the last character received P2ST Contains the received string P2NM Contains the received number Chapter 7 Application Programming e 153 DMC
202. iables for Joystick The example below reads the voltage of an X Y joystick and assigns it to variables vX and vY to drive the motors at proportional velocities where DMC 41x3 User Manual Chapter 7 Application Programming 148 10 Volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 JOYSTIK Label JG 0 0 Set in Jog mode BGXY Begin Motion ATO Set AT time reference LOOP Loop vX AN 1 20000 Read joystick X vY AN 2 20000 Read joystick Y JG vX vY Jog at variable vX vY AT 4 Wait 4ms from last time reference creates a deterministic loop time JP LOOP Repeat EN End Operands Operands allow motion or status parameters of the DMC 41x3 to be incorporated into programmable variables and expressions Most DMC commands have an equivalent operand which are designated by adding an underscore _ prior to the DMC 41x3 command The command reference indicates which commands have an associated operand Status commands such as Tell Position return actual values whereas action commands such as KP or SP return the values in the DMC 41x3 registers The axis designation is required following the command Examples of Internal Variables posX TPX Assigns value from Tell Position X to the variable posX deriv KDZ 2 Assigns value from KDZ multiplied by two to variable deriv JP LOOP TEX gt 5 Jump to LOOP if the position error of X is greater than 5 JP ERROR TC 1 Jump to ERROR if the error code equals 1
203. ibed below This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The slide is to be controlled by a rotary motor which is coupled to the slide by a lead screw Such a lead screw has a backlash of 4 micron and the required position accuracy is for 0 5 micron The basic dilemma is where to mount the sensor If you use a rotary sensor you get a 4 micron backlash error On the other hand if you use a linear encoder the backlash in the feedback loop will cause oscillations due to instability An alternative approach is the dual loop where we use two sensors rotary and linear The rotary sensor assures stability because the position loop is closed before the backlash whereas the linear sensor provides accurate load position information The operation principle is to drive the motor to a given rotary position near the final point DMC 41x3 User Manual Chapter 7 Application Programming e 168 Once there the load position is read to find the position error and the controller commands the motor to move to a new rotary position which eliminates the position error Since the required accuracy is 0 5 micron the resolution of the linear sensor should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or
204. ied for coordinated motion at any given time The command VM m n p where m and n are the coordinated pair and p is the tangent axis Note the commas which separate m n and p are not necessary For example VM XWZ selects the XW axes for coordinated motion and the Z axis as the tangent Specifying the Coordinate Plane The DMC 41x3 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T To specify vector commands the coordinate plane must first be identified This is done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applied to the active coordinate system until changed with the CA command DMC 41x3 User Manual Chapter 6 Programming Motion e 86 Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence Note This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y specifies th
205. ill return the error code without the text message For more information about the command TC see the Command Reference Stop Code Command The status of motion for each axis can be determined by using the stop code command SC This can be useful when motion on an axis has stopped unexpectedly The command SC will return a number representing the motion status See the command reference for further information RAM Memory Interrogation Commands For debugging the status of the program memory array memory or variable memory the DMC 41x3 has several useful commands The command DM will return the number of array elements currently available The command DA will return the number of arrays which can be currently defined For example a standard DMC 14113 will have a maximum of 16000 array elements in up to 30 arrays If an array of 100 elements is defined the command DM will return the value 15900 and the command DA will return 29 To list the contents of the variable space use the interrogation command LV List Variables To list the contents of array space use the interrogation command LA List Arrays To list the contents of the Program space use the interrogation command LS List To list the application program labels only use the interrogation command LL List Labels Chapter 7 Application Programming e 127 DMC 41x3 User Manual Operands In general all operands provide information which may be useful in debu
206. integrator to zero with the instruction KI 0 Integrator gain and set the proportional gain to a low value such as KP 1 Proportional gain KD 100 Derivative gain For more damping you can increase KD maximum is 4095 875 Increase gradually and stop after the motor vibrates A vibration is noticed by audible sound or by interrogation If you send the command TE A Tell error a few times and get varying responses especially with reversing polarity it indicates system vibration When this happens simply reduce KD by about 20 Next you need to increase the value of KP gradually maximum allowed is 1023 875 You can monitor the improvement in the response with the Tell Error instruction KP 10 Proportion gain TE A Tell error As the proportional gain is increased the error decreases Again the system may vibrate if the gain is too high In this case reduce KP by about 20 Typically KP should not be greater than KD 4 only when the amplifier is configured in the current mode Finally to select KI start with zero value and increase it gradually The integrator eliminates the position error resulting in improved accuracy Therefore the response to the instruction TE A becomes zero As KI is increased its effect is amplified and it may lead to vibrations If this occurs simply reduce KI Repeat tuning for the B C and D axes NOTE For a more detailed description of the operation of the PID filter and or servo system theory se
207. ion and fill an array with values that will be written to the PLC DM pump 2 pump 0 16531 0x4093 pump 1 13107 0x3333 3 Send the appropriate MB command Use function code 16 Start at address 30000 and write to 2 registers using the data in the array pump MBB 16 30000 2 pump Results Analog output will be set to 0x40933333 which is 4 6V To view an example procedure for communicating with an OPTO 22 rack refer to Example Communicating with OPTO 22 SNAP B3000 ENET in the Appendices Data Record The DMC 41x3 can provide a binary block of status information with the use of the QR and DR commands These commands along with the QZ command can be very useful for accessing complete controller status The QR command will return 4 bytes of header information and specific blocks of information as specified by the command arguments OR ABCDEFGHST Each argument corresponds to a block of information according to the Data Record Map below If no argument is given the entire data record map will be returned Note that the data record size will depend on the number of axes The following is the byte map for the binary data Chapter 4 Software Tools and Communication e 53 DMC 41x3 User Manual NOTE UB Unsigned Byte 1 UW Unsigned Word 2 SW Signed Word 2 SL Signed Long Record 4 UL Unsigned Long 4 ADDR TYPE ITEM 00 UB 1 Byte of Header 01 UB 2 Byte of Header 02 UB 3 Byte of Header 03
208. ion e 103 DMC 41x3 User Manual The resultant DMC program is shown below The position points are dictated by the application requirements and the velocities and times were chosen to create smooth yet quick motion For example in the second segment the B axis is slowed to 0 at the end of the move in anticipation of reversing direction during the next segment INSTRUCTION TPVT PVA 500 2000 500 PVB 500 5000 500 PVA 1000 4000 1200 PVB 4500 0 1200 PVA 1000 4000 750 PVB 1000 1000 750 BTAB PVA 800 10000 250 PVB 200 1000 250 PVA 4000 0 1000 PVB 900 0 1000 PVA 0 0 0 PVB 0 0 0 EN INTERPRETATION Label 1 point in Figure 15 point in Figure 2 point in Figure 2 point in Figure 35 point in Figure 35 point in Figure Begin PVT mode for 4 point 4 poin 5 poin 5 poin in in in in Termination Termination Figure Figure Figure Figure of PVT of PVT 14 14 14 14 14 A axis B axis A axis B axis A axis B axis and B axes 14 14 14 6 6 6 6 6 6 14 A 6 6 6 6 14 buffer buffer A axis B axis A axis B axis for A axis for B axis NOTE The BT command is issued prior to filling the PVT buffers and additional PV commands are added during motion for demonstration purposes only The BT command could have been issued at the end of all the PVT points in this example The resultant X vs Y position graph is shown in Figure 6
209. ion error E axis auxiliary position E axis velocity E axis torque E axis analog input E Hall Input Status Reserved E User defined variable ZA F axis status see bit field map below F axis switches see bit field map below F axis stop code F axis reference position F axis motor position F axis position error F axis auxiliary position F axis velocity F axis torque F axis analog input DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 56 292 UB F Hall Input Status 293 UB Reserved 294 297 SL F User defined variable ZA 298 299 UW G axis status see bit field map below 300 UB G axis switches see bit field map below 301 UB G axis stop code 302 305 SL G axis reference position 306 309 SL G axis motor position 310 313 SL G axis position error 314 317 SL G axis auxiliary position 318 321 SL G axis velocity 322 325 SL G axis torque 326 327 SW or UW G axis analog input 328 UB G Hall Input Status 329 UB Reserved 330 333 SL G User defined variable ZA 334 335 UW H axis status see bit field map below 336 UB H axis switches see bit field map below 337 UB H axis stop code 338 341 SL H axis reference position 342 345 SL H axis motor position 346 349 SL H axis position error 350 353 SL H axis auxiliary position 354 357 SL H axis velocity 358 361 SL H axis torque 362 363 SW or UW H axis analog input 364 UB H Hall Input Status 365 UB Reserved 366 369 SL
210. ion from the time reference of ATO REM since the WT 1000 1 took 1000 samples there was only 3000 samples left DMC 41x3 User Manual Chapter 7 Application Programming e 144 REM of the 4000 samples for AT 4000 1 MG t t2 this should output 1000 3000 EN End program Where the functionality of the operation of the AT command is very useful is when it 1s required to have a deterministic loop operating on the controller These instances range from writing PLC type scan threads to writing custom control algorithms The key to having a deterministic loop time is to have a trippoint that will wait a specified time independent of the time it took to execute the loop code In this definition the AT command is a perfect fit The below code is an example of a PLC type scan thread that runs at a 500ms loop rate A typical implementation would be to run this code in a separate thread ex XQ plcscan 2 REM this code will set output 3 high if REM inputs 1 and 2 are high and input 3 is low REM else output 3 will be low REM if input 4 is low output 1 will be high REM and ouput 3 will be low regardless of the REM states of inputs 1 2 or 3 fplcscan AT0 set initial time reference scan REM mask inputs 1 4 ti TIO amp F REM variables for bit 1 and bit 3 b1 0 b3 0 REM if input 4 is high set bit 1 and clear bit 3 REM ti amp 8 gets 4th bit if 4th bit is high result 8 IF ti amp 8 8 b1 1 ELSE REM ti amp 7 get lower 3 bits if
211. is 65 Controller Response to DATA 2i i a eint ossia I Lisa eU ieri 65 Interrogating the Controller 66 Interrogation Commands 66 Summary of Interrogation CommandS rr 66 Interrogating Current Commanded Values 66 Operands T Command Syntax Binary advanced intacta ree cien 68 Binary Comit Format ce iii proel tease 68 Binary command table conecta casis 69 Chapter 6 Programming Motion 71 Overview ludependent Axis POOR licia 73 Command Summary Independent Axis i Operand Summary Independent Axis sees 23 Tadepehdert JOpgin ssp tario Command Summary Jogging Operand Summary Independent Axis 76 Position Tracking PExdt pl IVIGEIBR ti ni ea 78 Example Motion 2 Example Motion 3 TE ili Command Summary Position Tracking Mode E Linear lnterpalabon Mode aciei tete cacher aeneo deett ii 82 Specifying Lincar Seems sss ones cau siii Command Summary Linear Interpolation i Operand Summary Linear Interpolation BxunplesLinent Move aiio o a cid i Dres Example Multiple Moves Vector Mode Linear and Circular Interpolation Motion Specifying the Coordinate Plane di TSO vine V
212. isconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation COS QUE e xo GR POWER OPTION MISC pole QPR Wr Figure A5 1 DMC 4143 D3640 BOX4 DMC 4143 with AMP 43640 A5 AMP 43640 D3640 e 239 DMC 41x3 User Manual Electrical Specifications The amplifier is a brushless type trans conductance linear amplifier for sinusoidal commutation The amplifier outputs a motor current proportional to the command signal input DC Supply Voltage 15 30 VDC In order to run the AMP 43640 in the range of 15 20 VDC the ISCNTL Isolate Controller Power option must be ordered Continuous Current 1 0 Amps Peak Current per axis 2 0 Amps Amplifier gain 0 2 A V Power output per channel 20 W see section below Total max power output 80 W assuming proper thermal mounting and heat dissipation The amplifier has built in thermal protection which will cause the amplifier to be disabled until the temperature of the transistors falls below the threshold Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr TM MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr Power Connectors MOLEX 3
213. ith range of 32768 to 32767 and 16 bit fractional resolution TAN n Tangent of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution ASIN n Arc Sine of n between 90 and 90 Angle resolution in 1 64000 degrees ACOS n Arc Cosine of n between 0 and 180 Angle resolution in 1 64000 degrees ATAN n Arc Tangent of n between 90 and 90 Angle resolution in 1 64000 degrees COM n 1 s Complement of n ABS n Absolute value of n FRAC n Fraction portion of n INT n Integer portion of n RND n Round of n Rounds up if the fractional part of n is 5 or greater SQR n Square root of n Accuracy is 004 IN n Return digital input at general input n where n starts at 1 OUT n Return digital output at general output n where n starts at 1 AN n Return analog input at general analog in n where n starts at 1 Note that these functions are multi valued An application program may be used to find the correct band Functions may be combined with mathematical expressions The order of execution of mathematical expressions is from left to right and can be over ridden by using parentheses Examples v1 ABS V7 v2 5 SIN pos The variable vl is equal to the absolute value of variable v7 The variable v2 is equal to five times the sine of the variable pos v3 IN 1 The variable v3 is equal to the digital value of input 1 v4 2 5 AN 5 The variable v4 is equal to
214. l Specifications DC Supply Voltage 12 60 VDC Max Current per axis 3 0 Amps Selectable with AG command Max Step Frequency 6 MHz Motor Type Bipolar 2 Phase Switching Frequency 60 kHz Minimum Load Inductance 0 5 mH Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr TM MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power A SDM 44140 D4140 e 249 DMC 41x3 User Manual Operation The SDM 44140 should be setup for Active High step pulses MT 2 or MT 2 5 The AG command sets the current on each axis and the LC command configures each axis s behavior when holding position These commands are detailed below Current Level Setup AG Command AG configures how much current the SDM 44140 delivers to each motor Four options are available 0 5A 1 0A 2 0A and 3 0Amps NOTE when using the 3 0A setting mounting the unit to a metal or heat dissipating surface is recommended Drive Current Selection per Axis AG n n n n n n n n n 0 05A n 1 14A default n 2 2A n 3 30A Low Current Setting LC Command LC configures each motor s behavior when holding position when
215. l effect _GPn This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately and the distance traveled since gearing changes take effect over a specified interval GR a b c d e f g h Sets gear ratio for slave axes 0 disables electronic gearing for specified axis GM a b c d e f g h X 1 sets gantry mode 0 disables gantry mode MR x y z w Trippoint for reverse motion past specified value Only one field may be used MF x y z w Trippoint for forward motion past specified value Only one field may be used Example Simple Master Slave Master axis moves 10000 counts at slew speed of 100000 counts sec Y is defined as the master X Z W are geared to master at ratios of 5 5 and 10 respectively GA Y Y Y Specify master axes as Y CR Sprm 5410 Set gear ratios PR 10000 Specify Y position SP 100000 Specify Y speed BGY Begin motion Example Electronic Gearing Objective Run two geared motors at speeds of 1 132 and 0 045 times the speed of an external master The master is driven at speeds between 0 and 1800 RPM 2000 counts rev encoder Solution Use a DMC 4133 controller where the Z axis is the master and X and Y are the geared axes MO Z Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GR 1 132 045 Specify gear ratios Now suppose the gear ratio of the X axis is to change on the fly to 2 This can be
216. lculate the desired velocities and change in positions In this example we will assume a delta time of of a second which is 256 samples 1024 samples 1 second with the default TM of 1000 Velocity counts second Position counts v t 1000 1 1000 p t C 1000 1 1000ar Chapter 6 Programming Motion e 101 DMC 41x3 User Manual v 25 7 4375 p 0 to 25 57 v 5 459 p 25 to 5 151 v 75 7 937 5 pC5 to 75 214 v l 1000 p 75 to 1 245 1 25 9375 p l to 1 25 245 v 1 5 450 p 1 25 to 1 5 214 v 1 75 431 5 p 1 5 to 1 75 151 v 2 9 p 1 75 to 2 57 INSTRUCTION PVT PVX 57 437 256 PVX 151 750 256 PVX 214 937 256 PVX 245 1000 256 PVX 245 937 256 PVX 214 750 256 PVX 151 437 256 PVX 57 0 256 PVX 0 0 0 BTX EN The DMC program is shown below and the results can be seen in Figure 6 13 INTERPRETATION Label ncremental velocity of ncremental velocity of ncremental velocity of ncremental velocity of ncremental velocity of ncremental velocity of ncremental velocity of ncremental velocity of Termination Begin PVT move of 57 counts in 256 samples with a final 437 counts sec move of 151 counts 750 counts sec move of 214 counts 937 counts sec move of 245 counts 1000 counts sec move of 245 counts 937 counts sec move of 214 counts 750 counts sec
217. le Joystick Jogging The jog speed can also be changed using an analog input such as a joystick Assume that for a 10 Volt input the speed must be 50000 counts sec JOY Label JGO Set in Jog Mode BGX Begin motion B Label for loop V1 QAN 1 Read analog input VEL V1 50000 10 Compute speed JG VEL Change JG speed JP B Loop Position Tracking The Galil controller may be placed in the position tracking mode to support changing the target of an absolute position move on the fly New targets may be given in the same direction or the opposite direction of the current position target The controller will then calculate a new trajectory based upon the new target and the acceleration deceleration and speed parameters that have been set The motion profile in this mode is trapezoidal There is not a set limit governing the rate at which the end point may be changed however at the standard TM rate the controller updates the position information at the rate of 1msec The controller generates a profiled point every other sample and linearly interpolates one sample between each profiled point Some examples of applications that may use this mode are satellite tracking missile tracking random pattern polishing of mirrors or lenses or any application that requires the ability to change the endpoint without completing the previous move The PA command is typically used to command an axis or multiple axes to a specific absolute position For some
218. len4 second byte of len len5 len amp 00FF0000 10000 Let variable len5 third byte of len len6 len amp FF000000 1000000 Let variable len6 fourth byte of len G len6 S4 Display len6 as string message of up to 4 chars G len5 S4 Display len5 as string message of up to 4 chars G len4 S4 Display len4 as string message of up to 4 chars G len3 S4 Display len3 as string message of up to 4 chars G len2 S4 Display len2 as string message of up to 4 chars G leni S4 Display lenl as string message of up to 4 chars EN This program will accept a string input of up to 6 characters parse each character and then display each character Notice also that the values used for masking are represented in hexadecimal as denoted by the preceding For more information see section Sending Messages To illustrate further if the user types in the string TESTME at the input prompt the controller will respond with the following Response from command MG len6 S4 E Response from command MG len5 S4 DMC 41x3 User Manual Chapter 7 Application Programming 146 E x H oo Response from command MG len4 S4 Response from command MG len3 S4 Response from command MG len2 8S4 Response from command MG lenl S4 Functions FUNCTION DESCRIPTION SIN n Sine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution COS n Cosine of n n in degrees w
219. leted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q The lt cntrl gt Q quits the editor mode In response the DMC 41x3 will return a colon After the Edit session is over the user may list the entered program using the LS command If no operand follows the LS command the entire program will be listed The user can start listing at a specific line or label using the operand n A command and new line number or label following the start listing operand specifies the location at which listing is to stop Example Instruction Interpretation LS List entire program LS 5 Begin listing at line 5 LS 5 9 List lines 5 thru 9 LS A 9 List line label A thru line 9 LS 4A A 5 List line label A and additional 5 lines DMC 41x3 User Manual Chapter 7 Application Programming e 170 Chapter 8 Hardware amp Software Protection Introduction The DMC 41x3 provides several hardware and software features to check for error conditions and to inhibit the motor on error These features help protect the various system components from damage WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machine Since the DMC 41x3 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 41x3 Galil shall not be liable or responsible for an
220. lifiers will be disabled This could cause the motor to coast to a stop If the Off On Error function is not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in this chapter The Abort input by default will also halt program execution this can be changed by changing the 5 field of the CN command See the CN command in the command reference for more information Selective Abort The controller can be configured to provide an individual abort for each axis Activation of the selective abort signal will act the same as the Abort Input but only on the specific axis To configure the controller for selective abort issue the command CN 1 This configures the inputs 5 6 7 8 13 14 15 16 to act as selective aborts for axes A B C D E F G H respectively ELO Electronic Lock Out Used in conjunction with Galil amplifiers this input allows the user the shutdown the amplifier at a hardware level For more detailed information on how specific Galil amplifiers behave when the ELO is triggered see Integrated in the Appendices Forward Limit Switch Low input inhibits motion in forward direction If the motor is moving in the forward direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has b
221. lure The AMPEN output is normally high During power up and if the microprocessor ceases to function properly the AMPEN output will go low The error light will also turn on at this stage A reset is required to restore the DMC 41x3 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 41x3 is damaged DMC 41x3 User Manual Chapter 1 Overview e 6 Chapter 2 Getting Started DMC 4143 CARD Dimensions 4 550 4 290 4 050 3 614 5 529 oF ooooo0 o0000 0000000000 RP46 2 849 25 1 592 gt o ooooooo oo o 2 0 o0 0 o olo ioO00000 pio 9 o ojo O Q9 9o ooo Eolo ojo O 123456 RPABIT 23456 BDM ooooooolj joooooooooooo 55835958351 ooco00000000000 0 000 0 322 0 700 0 200 0 000 Figure 2 1 DM C 3 500 4 488 4 143 Dimesions 6 400 6 650 The dimensions for the DMC 4113 DMC 4123 DMC 4133 and DMC 4143 all CARD are shown in Figure 2 1 1 Dimensions are subject to change Contact the Galil factory for current dimensions of all products Chapter 2 Getting Started e 7 DMC 41x3 User Manual imensions DMC 4183 CARD D
222. mation For example using variables named v1 v2 v3 and v4 JP TEST vl lt v2 amp v3 v4 In this example this statement will cause the program to jump to the label TEST if v1 is less than v2 and v3 is less than v4 To illustrate this further consider this same example with an additional condition JP TEST vl lt v2 amp v3 lt v4 v5 v6 This statement will cause the program to jump to the label TEST under two conditions 1 If v1 is less than v2 and v3 is less than v4 OR 2 If v5 is less than v6 Chapter 7 Application Programming e 133 DMC 41x3 User Manual Using the JP Command If the condition for the JP command is satisfied the controller branches to the specified label or line number and continues executing commands from this point If the condition is not satisfied the controller continues to execute the next commands in sequence Conditional Meaning JP Loop count lt 10 Jump to Loop if the variable count is less than 10 JS MOVE2 IN 1 1 Jump to subroutine MOVE2 if input 1 is logic level high After the subroutine MOVE2 is executed the program sequencer returns to the main program location where the subroutine was called JP BLUE ABS v2 gt 2 Jump to BLUE if the absolute value of variable v2 is greater than 2 JP C vl v7 lt v8 v2 Jump to C if the value of vl times v7 is less than or equal to the value of v8 v2 JP A Jump to A Example Using JP command Move the X mo
223. ments A B Linear 10000 units RA 821 B C Circular 15708 360 C D Linear 10000 Total 35708 counts In general the length of each linear segment is Le V Xk Yk Where Xk and Yk are the changes in X and Y positions along the linear segment The length of the circular arc is Les RilA 0 421 360 The total travel distance is given by D y Lk kel The velocity profile may be specified independently in terms of the vector velocity and acceleration For example the velocity profile corresponding to the path of Figure A 2 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Figure A 3 Velocity 10000 time s T4 0 05 T 0 357 T 0 407 Figure A 3 Vector Velocity Profile The acceleration time Ta is given by VS 100000 _ VA 2000000 The slew time Ts is given by 0 055 DMC 41x3 User Manual Appendices e 208 p D p 357 0 05 0 307s VS 100000 The total motion time Tt is given by D T Ta 0 407s VS The velocities along the X and Y axes are such that the direction of motion follows the specified path yet the vector velocity fits the vector speed and acceleration requirements For example the velocities along the X and Y axes for the path shown in Figure A 2 are given in Figure A 4 Figure A 4 shows the vector velocity It also indicates the position point along the path starting at A and ending a
224. meters in a tabular format and includes units and scale factors for easy viewing The Tuning Tool helps select PID parameters for optimal servo performance The Communication Library provides function calls for communicating to Galil Controllers with C Windows and Linux and COM enabled languages such as VB C and Labview Windows only GalilTools runs on Windows and Linux platforms as standard with other platforms available on request GalilTools Lite is available at no charge and contains the Editor Terminal Watch and Communcition Library tools only The latest version of GalilTools can be downloaded from the Galil website at http www galilmc com products software galiltools html For information on using GalilTools see the help menu in GalilTools or the GalilTools user manual http www galilmc com support manuals galiltools index html DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 60 GalilTools 192 168 1 2 DMC4080 Rev 1 0 1 IHC HardStopHoming dmc DO Fie Edit Window Controller Tools Help d DRD e e 9 A OBA E New Open Save Connect Upload Watch Tuner Scope Terminal LN TROU al Fe E UL D 3 1 la v KD ga Wa pero fnr ter eer bn Step Amplitude 100 counts KP yo o 36 to Step Time iom K jo L 0 0o OO NEM hard stop 14 Terminal thone 192 168 1 2 DMC4080 Rev Jj 1 80 1 IHC DCR 6718 t DR2 Source
225. mmanded position The highest level of control is the motion program This can be stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed Chapter 10 Theory of Operation e 179 DMC 41x3 User Manual LEVEL MOTION 3 PROGRAMMING MOTION 2 PROFILING CLOSED LOOP 1 CONTROL Figure 10 2 Levels of Control Functions The three levels of control may be viewed as different levels of management The top manager the motion program may specify the following instruction for example PR 6000 4000 SP 20000 20000 AC 200000 00000 BG X AD 2000 BG Y EN This program corresponds to the velocity profiles shown in Figure 10 3 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The following section explains the operation of the servo system First it is explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined DMC 41x3 User Manual Chapter 10 Theory of Operation e 180 X VELOCITY Y VELOCITY X POSITION eT Y POSITION M ud TIME Figure 10 3 Velocity and Position Profiles Chapter 10 Theory of Operation e 181 DMC 41x3 User Man
226. must begin with a label and end with an End EN statement Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted in a label The maximum number of labels which may be defined is 510 Valid labels BEGIN SQUARE X1 BEGIN1 DMC 41x3 User Manual Chapter 7 Application Programming e 124 Invalid labels 1Square 123 A Simple Example Program START Beginning of the Program PR 10000 20000 Specify relative distances on X and Y axes BG XY Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP START Jump to label START EN End of Program The above program moves X and Y 10000 and 20000 units After the motion is complete the motors rest for 2 seconds The cycle repeats indefinitely until the stop command is issued Special Labels The DMC 41x3 have some special labels which are used to define input interrupt subroutines limit switch subroutines error handling subroutines and command error subroutines See section on AMPERR Label for Amplifier error routine AUTO Label that will automatically run upon the controller exiting a reset power on AUTOERR Label that will automatically run if there is an EEPROM error out of reset CMDERR Label for incorrect command subroutine COMINT Label for Communications Interrupt See CC Command ININT Label for Input Interrupt subroutine See II Command LIMS
227. n ms A V1 50 T V2 3 T Argument in degrees V3 955 SIN V2 V1 Compute position Chapter 6 Programming Motion e 107 DMC 41x3 User Manual V4 INT V3 POS C V4 T T 8 C C 1 JP A C lt 16 B c 0 C D C 1 DIF C POS D POS C C C 1 JP C C lt 15 RUN CMX DT3 C 0 E CD DIF C C C 1 JP E C lt 15 CD 0 0 Wait JP Wait CM lt gt 511 EN Integer value of V3 Store in array POS Program to find position differences Compute the difference and store Program to run motor Contour Mode 8 millisecond intervals Contour Distance is in DIF End contour buffer Wait until path is done End the program Teach Record and Play Back Several applications require teaching the machine a motion trajectory Teaching can be accomplished using the DMC 41x3 automatic array capture feature to capture position data The captured data may then be played back in the contour mode The following array commands are used DM C n RA C RD TPX RC n m RC or _RC Dimension array Specify array for automatic record up to 4 for DMC 4143 Specify data for capturing such as TPX or TPZ Specify capture time interval where n is 2 sample periods 1 ms for TM1000 m is number of records to be captured Returns a 1 if recording Record and Playback Example RECORD DM XPOS 501 RA XPOS RD TPX MOX RC2 A JP A RC 1 COMPUTE DM DX 500 C20 L Begin Program Dimension array with 501 elements Sp
228. n subsequently be used as general use inputs queried with the QH command Setting Amplifier Gain and Current Loop Bandwidth AG command Select the amplifier gain that 1s appropriate for the motor The gain settings for the amplifier are identical for the brush and brushless operation The gain is set with the AG command as shown in Table A3 1 for AG n m AG setting Gain Value m 0 0 5 A V m 1 1 0 A V m 2 2 0 A V Table A3 1 Amplifer Gain Settings for AMP 43240 In addition to the gain peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A3 2 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts Note The TL command is limited to 5 with the amplifier gain setting of 2 0A V AU and AW commands With the AMP 43240 the user is also given the ability to choose between normal and high current bandwidth AU In addition the user can calculate what the bandwidth of the current loop is for their specific combination AW To select normal current loop gain for the X axis and high current loop gain for t
229. n the screen as The Speed is 50000 counts sec Using the MG Command to Configure Terminals The MG command can be used to configure a terminal Any ASCII character can be sent by using the format n where n is any integer between and 255 Example MG 07 255 sends the ASCII characters represented by 7 and 255 to the bus Summary of Message Functions function description n Surrounds text string Fn m Formats numeric values in decimal n digits to the left of the decimal point and m digits to the right P1 P2 or E Send message to Main Serial Port Auxiliary Serial Port or Ethernet Port DMC 41x3 User Manual Chapter 7 Application Programming e 156 Formats numeric values in hexadecimal Sends ASCII character specified by integer n Suppresses carriage return line feed Sn Sends the first n characters of a string variable where n is 1 thru 6 Displaying Variables and Arrays Variables and arrays may be sent to the screen using the format variable or array x For example v1 returns the value of v1 Example Printing a Variable and an Array element Instruction Interpretation DISPLAY Label DM posA 7 Define Array posA with 7 entries PR 1000 Position Command BGX Begin AMX After Motion vl TPA Assign Variable vl posA 1 TPA Assign the first entry vl Print vl Interrogation Commands The DMC 41x3 has a set of commands that directly interrogate the con
230. nce Example Turn on output after move Instruction Interpretation OUTPUT Label PR 2000 Position Command DMC 41x3 User Manual Chapter 7 Application Programming 160 BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec GBT Clear Output 1 EN End Digital Inputs The general digital inputs for are accessed by using the IN n function or the TI command The IN n function returns the logic level of the specified input n where n is a number 1 through 16 Example Using Inputs to control program flow Instruction Interpretation JP A IN 1 0 Jump to A if input 1 is low JP B IN 2 1 Jump to B if input 2 is high AI 7 Wait until input 7 is high AI 6 Wait until input 6 is low Example Start Motion on Switch Motor A must turn at 4000 counts sec when the user flips a panel switch to on When panel switch is turned to off position motor A must stop turning Solution Connect panel switch to input 1 of DMC 41x3 High on input 1 means switch is in on position Instruction Interpretation S JG 4000 Set speed AI 1 BGA Begin after input 1 goes high AI 1 STA Stop after input 1 goes low AMA JP S After motion repeat EN The Auxiliary Encoder Inputs The auxiliary encoder inputs can be used for general use For each axis the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 Each
231. ncoder consists of two inputs channel A and channel B The auxiliary encoder inputs are mapped to the inputs 81 96 The Aux encoder inputs are not available for any axis that is configured for step and direction outputs stepper Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between 12 volts The inputs have been configured to accept TTL level signals To connect TTL signals simply connect the signal to the input and leave the input disconnected For other signal levels the input should be connected to a voltage that is 4 of the full voltage range for example connect the input to the 5 volts on the Galil if the signal is 0 12V logic Example A DMC 4113 has one auxiliary encoder This encoder has two inputs channel A and channel B Channel A input is mapped to input 81 and Channel B input is mapped to input 82 To use this input for 2 TTL signals the first signal will be connected to AA and the second to AB AA and AB will be left unconnected To access this input use the function IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor DMC 41x3 User Manual Chapter 3 Connecting Hardware e 38 Electrical Specifications Maximum Voltage 12 VDC Minimum Voltage 12 VDC P inputs are internally pulled up to 5V through a 4 7kQ resistor inputs are internally biased to 1 3V pulled up to 5V th
232. nd includes the target distance to be moved and target velocity to be obtained over the specified timeframe Positions are entered as relative moves similar to the standard PR command in units of encoder counts and velocity 1s entered in counts second The controller will interpolate the motion profile between subsequent PV commands using a 3rd order polynomial equation During a PV segment jerk is held constant and accelerations velocities and positions will be calculated every other sample Motion will not begin until a BT command is issued much like the standard BG command This means that the user can fill the PVT buffer for each axis prior to motion beginning The BT command will ensure that all axes begin motion simultaneously It is not required for the t value for each axis to be the same however if they are then the axes will remain coordinated Each axis has a 255 segment buffer This buffer is a FIFO and the available space can be queried with the operand PVn As the buffer empties the user can add more PVT segments Exiting PVT Mode To exit PVT mode the user must send the segment command PVn 0 0 0 This will exit the mode once the segment is reached in the buffer To avoid an abrupt stop the user should slow the motion to a zero velocity prior to executing this command The controller will instantly command a zero velocity once a PVn 0 0 0 is executed In addition a ST command will also exit PVT mode Motion will come to a contr
233. nd the third trace shows the cycle of the C axis Scope E Y A Vertical Horizontal Hu didt Source Scale div Offset div a L RPA Axis A ref w 200 count 2 e x a _RPB Axis B refi 100 count amp 1 n RPC Axis C ref 2000 cour 4 e A n m 0 221383 o D n w 442765 i 1 d n m 0 442765 8 2 S n m 0 221383 3 n m 0 221383 4 t sooms j 0 X J ji N Trigger A X Channel W RPG Edge Level 2D00 count V7 VIZ 7 Mode Repeat v READY sw um di Pa P d p E P d P d s m ban r a P z P x p RPA RPB RPC Figure 6 11 ECAM cycle with Z axis as master Chapter 6 Programming Motion e 99 DMC 41x3 User Manual PVT Mode The DMC 41x3 controllers now supports a mode of motion referred to as PVT This mode allows arbitrary motion profiles to be defined by position velocity and time individually on all 8 axes This motion is designed for systems where the load must traverse a series of coordinates with no discontinuities in velocity By specifying the target position velocity and time to achieve those parameters the user has control over the velocity profile Taking advantage of the built in buffering the user can create virtually any profile including those with infinite path lengths Specifying PVT Segments PVT segments must be entered one axis at a time using the PVn command The PV comma
234. nd with a number such as 0 Step 6 Make Connections to Amplifier and Encoder If the system is run solely by Galil s integrated amplifiers or drivers skip this section the amplifier is already connected to the controller Once you have established communications between the software and the DMC 41x3 you are ready to connect the rest of the motion control system The motion control system typically consists of the controller with interconnect module an amplifier for each axis of motion and a motor to transform the current from the amplifier into torque for motion System connection procedures will depend on system components and motor types Any combination of motor types can be used with the DMC 41x3 There can also be a combination of axes running from Galil integrated amplifiers and drivers and external amplifiers or drivers Connecting to External Amplifiers Here are the first steps for connecting a motion control system Step A Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are operating properly the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal DMC 41x3 User Manual Chapter 2 Getting Started e 16 Before making any connections from the amplifier to the controller you need to verify t
235. nded voltages with voltage range of 12 volts Auxiliary Encoder Inputs for H axis Line Receiver Inputs accepts differential or single ended voltages with voltage range of 12 volts NOTE The DMC 41x3 power should never be plugged in HOT Always power down the power supply before installing or removing the power connector on the controller 5 12V Power Output Specifications Output Voltage Tolerance T5V 5 12V 5 12V 5 Max Current Output LIA 40mA 40mA Appendices e 193 DMC 41x3 User Manual Performance Specifications Minimum Servo Loop Update Time Memory Minimum Servo Loop Update Time DMC 4113 DMC 4123 DMC 4133 DMC 4143 DMC 4153 DMC 4163 DMC 4173 DMC 4183 Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Number of Variables Array Size Program Size Normal Fast Firmware 125 usec 62 5 usec 125 usec 62 5 usec 250 usec 125 usec 250 usec 125 usec 375 usec 187 5 usec 375 usec 187 5 usec 500 usec 250 usec 500 usec 250 usec 1 quadrature count Phase locked better than 0 005 System dependent 2147483647 counts per move Up to 15 000 000 counts sec servo 3 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1 10 4 510 16000 elements 30 arrays 2000 lines x 80 characters
236. nds Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format All binary commands have a 4 byte header and is followed by data fields The 4 bytes are specified in hexadecimal format Header Format Byte 1 specifies the command number between 80 to FF The complete binary command number table is listed below Byte 2 specifies the of bytes in each field as 0 1 2 4 or 6 as follows 00 No data fields 1 e SH or BG 01 One byte per field 02 One word 2 bytes per field 04 One long word 4 bytes per field 06 Galil real format 4 bytes integer and 2 bytes fraction Byte 3 specifies whether the command applies to a coordinated move as follows 00 No coordinated motion movement 01 Coordinated motion movement For example the command STS designates motion to stop on a vector move S coordinate system The third byte for the equivalent binary command would be 01 Byte 4 specifies the axis or data field as follows Bit 7 H axis or 8 data field Bit 6 G axis or 7 data field Bit 5 F axis or 6 data field Bit 4 E axis or 5 data field Bit 3 D axis or 4 data field Bit 2 C axis or 3 data field Bit 1 B axis or 2 data field Bit 0 A axis or 1 data field Data fields Format Data fields must be consistent with the format byte and the axes byte For example the command PR 1000 500 would be A7 02 00 05 03 E8 FE OC
237. nes will be in a Motor Off state A SH will be required to re enable the motors 19 2K Baud Rate setting see table below UPGD Used to upgrade controller firmware when resident firmware is corrupt MRST Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated Note The ARXD and ACTS jumpers should be installed for single drop RS 422 For multi drop the jumpers should be installed on the last device Baud Rate Jumper Settings 19 2 BAUD RATE ON OFF 115200 Recommended DMC 41x3 User Manual Appendices e 204 Signal Descriptions for DMC 41x3 Outputs Inputs Motor Command Amplifier Enable PWM Step PWM Step Sign Direction Error Output 1 Output 8 Output 9 Output 16 DMC 4153 thru 4183 10 Volt range signal for driving amplifier In servo mode motor command output is updated at the controller sample rate In the motor off mode this output is held at the OF command level Signal to disable and enable an amplifier Amp Enable goes low on Abort and OE1 PWM STEP OUT is used for directly driving power bridges for DC servo motors or for driving step motor amplifiers For servo motors If you are using a conventional amplifier that accepts a 10 Volt analog signal this pin is not used and should be left open The PWM output is available in two formats Inverter and Sign
238. net communication error auto routine MG Pl IA4 Send message to serial port indicating which handle did not receive proper acknowledgment RE Example Amplifier Error The program below will execute upon the detection of an error from an internal Galil Amplifier The bits in TAI will be set for all axes that have an invalid hall state even if BR1 is set for those axes this is handled with the mask variable shown in the code below AMPERR REM mask out axes that are in brushed mode for TA1 mask _BRH 128 _BRG 64 _BRF 32 _BRE 16 _BRD 8 _BRC 4 _BRB 2 BRA mask COM mask mask _TA1 amp mask amp 0000FFFF REM amplifier error status MG A ER TAO TAO MG A ER TA1 mask MG A ER TA2 TA2 MG A ER TA3 TA3 WT5000 DMC 41x3 User Manual Chapter 7 Application Programming e 140 REM the sum of the amperr bits should be 0 with no amplifier error er TA0 mask TA2 TA3 JP AMPERR er0 REM Notify user amperr has cleared MG AMPERR RESOLVED WT3000 RE JS Subroutine Stack Variables a b c d e f g h There are 8 variables that may be passed on the subroutine stack when using the JS command Passing values on the stack 1s advanced DMC programming and is recommended for experienced DMC programmers familiar with the concept of passing arguments by value and by reference Notes 1 Passing parameters has no type checking so it is important to exercise good programming style when passing parame
239. ng the IP command is equivalent to the PR and BG command combination Command Summary Independent Axis COMMAND DESCRIPTION PR x y Z W Specifies relative distance PA x y Z W Specifies absolute position SP x y z w Specifies slew speed AC x y Z w Specifies acceleration rate DC x y z w Specifies deceleration rate BG XYZW Starts motion ST XYZW Stops motion before end of move IP x y z w Changes position target IT x y z w Time constant for independent motion smoothing AM XYZW Trippoint for profiler complete MC XYZW Trippoint for in position The lower case specifiers x y z w represent position values for each axis The DMC 41x3 also allows use of single axis specifiers such as PRY 2000 Operand Summary Independent Axis OPERAND DESCRIPTION Return acceleration rate for the axis specified by x Return deceleration rate for the axis specified by x Chapter 6 Programming Motion e 73 DMC 41x3 User Manual Returns the speed for the axis specified by x Returns current destination if x axis is moving otherwise returns the current commanded position if in a move _PRx Returns current incremental distance specified for the x axis Example Absolute Position Movement PA 10000 20000 Specify absolute X Y position AC 1000000 1000000 Acceleration for X Y DC 1000000 1000000 Deceleration for X Y SP 50000 30000 Speeds for X Y BG XY Begin motion Ex
240. nged by configuring the Amplifier Enable Circuit on the DMC 41x3 NOTE Many amplifiers designate the enable input as inhibit Configuring the Amplifier Enable Circuit This section describes how to configure the DMC 41x3 for different Amplifier Enable configurations The DMC 41x3 is designed to be easily interfaced to multiple amplifier manufactures As a result the amplifier enable circuit for each axis is individually configurable through jumper settings The user can choose between High Amp Enable HAEN Low Amp Enable LAEN 5V logic 12V logic external voltage supplies up to 24V sinking or sourcing The different configurations are described below with jumper settings and a basic schematics of the circuit Chapter 3 Connecting Hardware e 41 DMC 41x3 User Manual 5V lt x o9 Z 090 95 V 10K 45V oS 5 HIGH AMP ENABLE 959 AEN TO DRIVE SINKING 090 1 REN PIN 2 SHn 5V MOn QV 12V z 308 000 95 V 10K 12V eee 9 HIGH AMP ENABLE 959 AEN TO DRIVE SINKING o9o SURE PIN 2 SHn 5V MOn 0V AMP ENABLE POWER PIN 20 lt o o Z 090 25 45V 10K ISOLATED SUPPLY 209 HIGH AMP ENABLE 00 AEN TO DRIVE SINKING 090 i PIN 2 SHn 5V AMP ENABLE RETURN MOn 0V PIN 11 DMC 41x3 User Manual Chapter 3 Connecting Hardware e 42 AXIS A 45V HIGH AMP ENABLE SOURCING AXIS A 12V HIGH AMP ENABLE SOURCING AXIS A ISOLATED SUPPLY HIGH AMP ENABLE SOURCING 00000000
241. nly after the axis has been stopped After an error correction move has completed and QS is less than three full motor steps the YS error status bit is automatically reset back to 1 indicating a cleared error Example SPM Mode Setup The following code demonstrates what is necessary to set up SPM mode for a full step drive a half step drive and a 1 64th microstepping drive for an axis with a 1 8 step motor and 4000 count rev encoder Note the necessary difference is with the YA command Full Stepping Drive X axis SETUP OE1 KS16 MT 2 YA1 YB200 YC4000 SHX WT50 YS1 Set the profiler to stop axis upon error Set step smoothing otor type set to stepper Step resolution of the full step drive otor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode Half Stepping Drive X axis SETUP OE1 KS16 MT 2 YA2 YB200 YC4000 SHX WT50 YS1 Set the profiler to stop axis upon error Set step smoothing otor type set to stepper Step resolution of the half step drive otor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode 1 64 Step Microstepping Drive X axis SETUP OE1 KS16 MT 2 YA64 YB200 YC4000 SHX WT50 YS1 Set the profiler to stop axis upon error Set step smoothing otor type set to stepper Ste
242. nsolicited messages Programs Downloading and uploading embedded programs Arrays Downloading and uploading array data Advanced Lesser used calls QN EA EX jS Data Record Access to the data record in both synchronous and asynchronous modes DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 62 C Library Windows and Linux Both Full and Lite versions of GalilTools ship with a native C communication library The Linux version libGalil so is compatible with g and the Windows version Galill dll with Visual C 2008 Contact Galil if another version of the C library is required See the getting started guide and the hello cpp example in lib COM Windows To further extend the language compatibility on Windows a COM Component Object Model class built on top of the C library is also provided with Windows releases This COM wrapper can be used in any language and IDE supporting COM Visual Studio 2005 2008 etc The COM wrapper includes all of the functionality of the base C class See the getting started guide and the hello examples in lib for more info For more information on the GalilTools Communications Library see the online user manual http www galilmc com support manuals galiltools library html Chapter 4 Software Tools and Communication e 63 DMC 41x3 User Manual Chapter 5 Command Basics Introduction The DMC 41x3 provides over 100 commands for specif
243. nt number of bytes in general block of data record number of bytes in coordinate plane block of data record Number of Bytes in each axis block of data record Chapter 4 Software Tools and Communication e 59 DMC 41x3 User Manual GalilTools Windows and Linux GalilTools is Galil s set of software tools for current Galil controllers It is highly recommended for all first time purchases of Galil controllers as it provides easy set up tuning and analysis GalilTools replaces the WSDK Tuning software with an improved user interface real time scopes and communications utilities The Galil Tools set contains the following tools Scope Editor Terminal Watch and Tuner and a Communication Library for development with Galil Controllers The powerful Scope Tool is ideal for system analysis as it captures numerous types of data for each axis in real time Up to eight channels of data can be displayed at once and additional real time data can be viewed by changing the scope settings This allows literally hundreds of parameters to be analyzed during a single data capture sequence A rising or falling edge trigger feature is also included for precise synchronization of data The Program Editor Tool allows for easy writing of application programs and multiple editors to be open simultaneously The Terminal Tool provides a window for sending and receiving Galil commands and responses The Watch Tool displays controller para
244. nt of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port The dual loop method splits the filter function between the two encoders It applies the KP proportional and KI integral terms to the position error based on the load encoder and applies the KD derivative term to the motor encoder This method results in a stable system The dual loop method is activated with the instruction DV Dual Velocity where DV Ty yd ul activates the dual loop for the four axes and DV 0 0 0 0 disables the dual loop DMC 41x3 User Manual Chapter 6 Programming Motion e 116 NOTE that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if necessary Sampled Dual Loop Example In this example we consider a linear slide which is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it 1s best to use a rotary encoder on the motor Connect t
245. nts The VF command is specified by VF m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format The default format for VF is VF 10 4 Hex values are returned preceded by a and in 2 s complement Instruction Interpretation v1 10 Assign vl DMC 41x3 User Manual Chapter 7 Application Programming e 158 vl Return vl 0000000010 0000 Response Default format VF2 2 Change format vi Return vl 10 00 Response New format VF 2 2 Specify hex format vi Return vl 0A 00 Response Hex value VF1 Change format vi Return vl x9 Response Overflow Local Formatting of Variables PF and VF commands are global format commands that affect the format of all relevant returned values and variables Variables may also be formatted locally To format locally use the command Fn m or n m following the variable name and the symbol F specifies decimal and specifies hexadecimal n is the number of digits to the left of the decimal and m is the number of digits to the right of the decimal Instruction Interpretation v1 10 Assign v1 vi Return vl 0000000010 0000 Default Format vl F4 2 Specify local format 0010 00 New format vl 4 2 Specify hex format 000A 00 Hex value vl ALPHA Assign string ALPHA to vl vl S4 Specify string format first 4 characters ALPH
246. nts per revolution the number of encoder counts per magnetic cycle would be 10 000 2 5000 Assign this value to BM 3 Issue either the BZ or BX command Either the BX or BZ command must be executed on every reset or power up of the controller BZ Command Issue the BZ command to lock the motor into a phase Note that this will cause up to a magnetic cycle of motion Be sure to use a high enough value with BZ to ensure the motor is locked into phase properly BX Command Issue the BX command The BX command utilizes a minimal movement algorithm in order to determine the correct commutation of the motor As of April 2011 this command was still in the Beta testing phase Setting Peak and Continuous Current TL and TK The peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A5 1 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts The TL command is limited to 5V for the AMP 43640 This limits to continuous current output of the amplifier to 1A The TK command can be set to 9 998V which provides a peak current output of
247. o PR moves If AM is not used the controller returns a for the second PR command because a new PR cannot be given until motion is complete TWOMOVE Label PR 2000 Position Command BGX Begin Motion AMX Wait for Motion Complete PR 4000 ext Position Move BGX Begin 2 move EN End program Event Trigger Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period SETBIT Label SP 10000 Speed is 10000 PA 20000 Specify Absolute position BGX Begin motion AD 1000 Wait until 1000 counts SB1 Set output bit 1 EN End program Event Trigger Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR trippoint is used as shown in the next example TRIP Label JG 50000 Specify Jog Speed BGX n 0 Begin Motion fREPEAT f Repeat Loop AR 10000 Wait 10000 counts TPX Tell Position SB1 Set output 1 WT50 Wait 50 msec CB1 Clear output 1 n n 1 Increment counter JP REPEAT n lt 5 Repeat 5 times STX Stop EN End DMC 41x3 User Manual Chapter 7 Application Programming e 130 Event Trigger Start Motion on Input This example waits for input 1 to go low and then starts motion Note The AI command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Inp
248. ocation where the subroutine was called unless the subroutine stack is manipulated as described in the following section Example An example of a subroutine to draw a square 500 counts per side is given below The square is drawn at vector position 1000 1000 Chapter 7 Application Programming e 135 DMC 41x3 User Manual Bl P 1000 1000 LE BGS S Bl S Square CB1 Han p X Q s fSquare vl 500 JS L vl v1 JS L EN L PR vl v1 BGX AMX BGY AMY EN Stack Manipulation Begin Main Program Clear Output Bit 1 pick up pen Define vector position move pen Wait for after motion trippoint Set Output Bit 1 put down pen Jump to square subroutine End Main Program Square subroutine Define length of side Switch direction End subroutine Define X Y Begin X After motion on X Begin Y End subroutine It is possible to manipulate the subroutine stack by using the ZS command Every time a JS instruction interrupt or automatic routine such as POSERR or LIMSWI is executed the subroutine stack is incremented by 1 Normally the stack is restored with an EN instruction Occasionally it is desirable not to return back to the program line where the subroutine or interrupt was called The ZS1 command clears 1 level of the stack This allows the program sequencer to continue to the next line The ZS0 command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is
249. occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short from a motor lead to ground DMC 41x3 User Manual A7 SDM 44140 D4140 e 250 Under Voltage Protection If the supply to the amplifier drops below 12 VDC the amplifier will be disabled The amplifier will return to normal operation once the supply is raised above the 12V threshold bit 3 of the error status TAO will tell the user whether the supply is in the acceptable range Note If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered ELO Input If the ELO input on the controller is triggered then the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application A7 SDM 44140 D4140 e 251 DMC 41x3 User Manual
250. of the Home input on the W axis Arrays For storing and collecting numerical data the DMC 41x3 provides array space for 16000 elements The arrays are one dimensional and up to 30 different arrays may be defined Each array element has a numeric range of 4 bytes of integer 2 followed by two bytes of fraction 2 147 483 647 9999 Arrays can be used to capture real time data such as position torque and analog input values In the contouring mode arrays are convenient for holding the points of a position trajectory in a record and playback application Defining Arrays An array is defined with the command DM The user must specify a name and the number of entries to be held in the array An array name can contain up to eight characters starting with an uppercase alphabetic character The number of entries in the defined array is enclosed in Example DM posx 7 Defines an array names posx with seven entries DM speed 100 Defines an array named speed with 100 entries DA posx Frees array space Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the posx array defined with the DM command DM posx 7 would be specified as posx 0 Values are assigned to array entries using the equal sign Assignments are made
251. oing from your amplifier to the motor DMC 41x3 User Manual Chapter 2 Getting Started e 18 When driving a brushless motor the polarity reversal may be done with the encoder If you are using a single ended encoder interchange the signal MA and MB If on the other hand you are using a differential encoder interchange only MA and MA The loop polarity and encoder polarity can also be affected through software with the MT and CE commands For more details on the MT command or the CE command see the Command Reference section To Invert Polarity using Hall Commutated brushless motors invert motor phases B amp C exchange Hall A with Hall B and invert encoder polarity as described above Sometimes the feedback polarity is correct the motor does not attempt to run away but the direction of motion is reversed with respect to the commanded motion If this is the case reverse the motor leads AND the encoder signals If the motor moves in the required direction but stops short of the target it is most likely due to insufficient torque output from the motor command signal MCMn This can be alleviated by reducing system friction on the motors The instruction TTA Tell torque on A reports the level of the output signal It will show a non zero value that is below the friction level Once you have established that you have closed the loop with the correct polarity you can move on to the compensation phase servo system tuning to adju
252. ol Inc Appendices e 215 DMC 41x3 User Manual Integrated Components Overview When ordered the following components will reside inside the box of the DMC 41x3 motion controller The amplifiers and stepper drivers provide power to the motors in the system and the interconnect modules and communication boards provide the connections for the signals and communications Al AMP 430x0 D3040 D3020 2 and 4 axis 500W Servo Drives The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless amplifiers that are capable of handling 500 watts of continuous power per axis The AMP 43040 43020 Brushless drive modules are connected to a DMC 41x3 The standard amplifier accepts DC supply voltages from 18 80 VDC A2 AMP 43140 D3140 4 axis 20W Linear Servo Drives The AMP 43140 contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 DC Volt input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 KHz A3 AMP 43240 D3240 The AMP 43240 is a multi axis brush brushless amplifiers that is capable of handling 750 watts of continuous power per axis The AMP 43240 Brushless drive module is connected to a DMC 40x0 The standard amplifier accepts DC supply voltages from 18 80 VDC A4 AMP 435x0 D3540 D3520 The AMP 43540 contains
253. olled stop using the DC value for deceleration The same controlled stop will occur if a limit switch is activated in the direction of motion As a result the controller will be switched to a jog mode of motion Error Conditions and Stop Codes If the buffer is allowed to empty while in PVT mode then the profiling will be aborted and the motor will come to a controlled stop on that axis with a deceleration specified by the DC command Also PVT mode will be exited and the stop code will be set to 32 During normal operation of PVT mode the stop code will be 30 If PVT mode is exited normally PVn 0 0 0 then the stop code will be set to 31 Additional PVT Information It is the users responsibility to enter PVT data that the system s mechanics and power system can respond to in a reasonable manner Because this mode of motion is not constrained by the AC DC or SP values if a large velocity or position is entered with a short period to achieve it the acceleration can be very high beyond the capabilities of the system resulting in excessive position error The position and velocity at the end of the segment are guaranteed to be accurate but it is important to remember that the required path to obtain the position and velocity in the specified time may be different based on the PVT values Mismatched values for PVT can result in different interpolated profiles than expected but the final velocity and position will be accurate The t value i
254. om products software galiltools html All other Galil software is also available for download at the Galil software downloads page 3 3http www galilmc com support download html Using Linux 32 amp 64 bit The GalilTools software package is fully compatible with a number of Linux distributions See the GalilTools webpage and user manual for downloads and installation instructions http www galilmc com products software galiltools html DMC 41x3 User Manual Chapter 2 Getting Started e 14 Step 4 Connect 20 80 VDC Power to the Controller If the controller was ordered with Galil Amplifiers or Drivers then power to the controller will be supplied through those power connectors Otherwise the power will come through the connector on the side of the controller See DMC 41x3 Power Connections The DMC 41x3 power should never be plugged in HOT Always power down the power supply before installing or removing the power connector to the controller NOTE Any E Stop or Disconnect switches should be installed on the AC input to the DC power supply Relays and or other switches should not be installed on the DC line between the Galil and the Power supply This is shown in Figure 2 7 with a DMC 4183 and 2 AMP 43040 s BREAKER OR RELAY L fL V N N V 1 POWER SUPPLY DMC 41X3 Figure 2 7 Wiring for DMC 4183 with Amplifiers WARNING Dangerous voltages current temp
255. ommand The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command and has no arguments If the argument of the IF command evaluates false the controller will skip commands until DMC 41x3 User Manual Chapter 7 Application Programming e 134 the ELSE command If the argument for the IF command evaluates true the controller will execute the commands between the IF and ELSE command Nesting IF Conditional Statements The DMC 41x3 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 41x3 allows up to 255 IF conditional statements to be nested This is a very powerful technique allowing the user to specify a variety of different cases for branching Command Format IF ELSE and ENDIF Format IF conditional statement s ELSE ENDIF Description Execute commands proceeding IF command up to ELSE command if conditional statement s is true otherwise continue executing at ENDIF command or optional ELSE command Optional command Allows for commands to be executed when argument of IF command evaluates not true Can only be used with IF command Command to end IF conditional statement Program must have an ENDIF command for every IF command Example using IF
256. ommands the DMC 41x3 provides commands that allow the DMC 41x3 to make its own decisions These commands include conditional jumps event triggers and subroutines For example the command JP LOOP n lt 10 causes a jump to the label LOOP if the variable n is less than 10 For greater programming flexibility the DMC 41x3 provides user defined variables arrays and arithmetic functions For example with a cut to length operation the length can be specified as a variable in a program which the operator can change as necessary The following sections in this chapter discuss all aspects of creating applications programs The program memory size is 80 characters x 2000 lines Program Format A DMC 41x3 program consists of DMC instructions combined to solve a machine control application Action instructions such as starting and stopping motion are combined with Program Flow instructions to form the complete program Program Flow instructions evaluate real time conditions such as elapsed time or motion complete and alter program flow accordingly Each DMC 41x3 instruction in a program must be separated by a delimiter Valid delimiters are the semicolon or carriage return The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 80 characters A carriage return enters the final command on a program line Using Labels in Programs All DMC 41x3 programs
257. onding to the logic state of the limit switch Using a terminal program the state of a limit switch can be printed to the screen with the command MG LFx or MG LRx This prints the value of the limit switch operands for the x axis The logic state of the limit switches can also be interrogated with the TS command For more details on TS see the Command Reference Chapter 3 Connecting Hardware e 27 DMC 41x3 User Manual Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user There are three homing routines supported by the DMC 41x3 Find Edge FE Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX BGX The Find Edge routine will cause the motor to accelerate and then slew at constant speed until a transition is detected in the logic state of the Home input The direction of the FE motion is dependent on the state of the home switch High level causes
258. one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples DM speed 10 Dimension speed Array speed 0 7650 2 Assigns the first element of the array speed the value 7650 2 speed 0 Returns array element value posx 9 TPX Assigns the 10 element of the array posx the returned value from the tell position command con 1 COS pos 2 Assigns the second element of the array con the cosine of the variable POS multiplied by 2 timer 0 TIME Assigns the first element of the array timer the returned value of the TIME keyword DMC 41x3 User Manual Chapter 7 Application Programming e 150 Using a Variable to Address Array Elements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter Example TA Begin Program count 0 DM pos 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec pos count TPX Record position into array element pos count Report position count count 1 Increment counter JP LOOP count lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named pos The variable count is used to increment the array element counter The above example can also be executed with the au
259. onstant for coordinated moves LM Return number of available spaces for linear and circular segments in DMC 41x3 sequence buffer Zero means buffer is full 511 means buffer is empty CAS or CAT Specifies which coordinate system is to be active S or T Operand Summary Coordinated Motion Sequence OPERAND DESCRIPTION _VPM The absolute coordinate of the axes at the last intersection along the sequence _AV Distance traveled _LM Number of available spaces for linear and circular segments in DMC 41x3 sequence buffer Zero means buffer is full 511 means buffer is empty _CS Segment counter Number of the segment in the sequence starting at zero _VE Vector length of coordinated move sequence When AV is used as an operand AV returns the distance traveled along the sequence The operands VPX and _ VPY can be used to return the coordinates of the last point specified along the path Example Traverse the path shown in Figure 6 7 Feed rate is 20000 counts sec Plane of motion is XY VM XY Specify motion plane VS 20000 Specify vector speed Chapter 6 Programming Motion e 89 DMC 41x3 User Manual VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration VP 4000 0 Segment AB CR 1500 270 180 Segment BC VP 0 3000 Segment CD CR 1500 90 180 Segment DA VE End of sequence BGS Begin Sequence The resulting motion starts at the point A and moves toward points B C
260. or and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation reus s ON oom great nc Es je TION HPO HIGH POWER SP Orea dvo sees Fas Figure A3 1 DMC 4143 D3240 BOX4 DMC 4143 with AMP 43240 A3 AMP 43240 D3240 e 227 DMC 41x3 User Manual Electrical Specifications The amplifier is a brush brushless trans conductance PWM amplifier The amplifier operates in torque mode and will output a motor current proportional to the command signal input Supply Voltage 18 80 VDC Continuous Current 10 Amps Peak Current 20 Amps Nominal Amplifier Gain 1 0 Amps Volt Switching Frequency 24 kHz Minimum Load Inductance Brushless Motor Commutation angle 120 60 option available Mating Connectors On Board Connector Terminal Pins POWER 6 pin Molex Mini Fit Jr MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin Molex Mini Fit Jr TM Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Phase C N C for Bushed Motors Phase B No Connect Phase A DMC 41x3 User Manual A3 AMP 43240 D3240 e 228 Operation Brushless Mot
261. or Setup NOTE If you purchased a Galil motor with the amplifier it is ready for use No additional setup is necessary To begin the setup of the brushless motor and amplifier it is first necessary to have communications with the motion controller It is also necessary to have the motor hardware connected and the amplifier powered to begin the setup phase After the encoders and motor leads are connected the controller and amplifier need to be configured correctly in software Take all appropriate safety precautions For example set a small error limit ER 1000 a low torque limit TL 3 and set off on Error to 1 for all axes OE 1 The AMP 43240 requires that the hall commutation for a brushless motor be manually configured Details on how to determine the correct commutation for a brushless motor see Application Note 5489 http www galilmc com support appnotes miscellaneous note5489 pdf Brushed Motor Operation The AMP 43240 allows for brush operation To configure an axis for brush type operation connect the 2 motor leads to Phase A and Phase B connections for the axis Connect the encoders homes and limits as required Set the controller into brush axis operation by issuing BR n n n n By setting n 1 the controller will operate in brushed mode on that axis For example BR 0 1 0 0 sets the Y axis as brush type all others as brushless If an axis is set to brush type the amplifier has no need for the Hall inputs These inputs ca
262. or correction MCX Wait for motion to complete MG CORRECTED ERROR NOW QSX WT100 Wait helps user see the correction RETURN SPX spsave Return the speed to previous setting REO Return from POSERR Example Friction Correction The following example illustrates how the SPM mode can be useful in correcting for X axis friction after each move when conducting a reciprocating motion The drive is a 1 64th microstepping drive with a 1 8 step motor and 4000 count rev encoder SETUP Set the profiler to continue upon error KS16 Set step smoothing MT 25 5 25 2y 25 Motor type set to stepper YA64 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution DMC 41x3 User Manual Chapter 6 Programming Motion 114 YC4000 SHX WT50 YS1 MOTION SP16384 PR10000 BGX MCX JS CORRECT MOTION2 SP16384 PR 10000 BGX MCX JS CORRECT JP MOTION CORRECT spx SPX LOOP SP2048 WT100 JP END ABS _QSX lt 10 YRX _QSX MCX WT100 JP LOOP END SPX spx EN Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode Perform motion Set the speed Prepare mode of motion Begin motion Move to correction Set the speed Prepare mode of motion Begin motion Move to correction Correction code Save speed value Set a new slow correction speed Stabilize End correction if error is within defined tolerance C
263. or the DMC in the Appendix for more information The DMC 41x3 can also interface to encoders with pulse and direction signals Refer to the CE command in the command reference for details There is no limit on encoder line density however the input frequency to the controller must not exceed 3 750 000 full encoder cycles second 15 000 000 quadrature counts sec For example 1f the encoder line density is 10 000 cycles per inch the maximum speed is 200 inches second If higher encoder frequency is required please consult the factory The standard encoder voltage level is TTL 0 5v however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 41x3 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 41x3 can accept analog feedback 10v instead of an encoder for any axis For more information see the command AF in the command reference To interface with other types of position sensors such as absolute encoders Galil can customize the controller and command set Please contact Galil to talk to one of our applications engineers about your particular system requirements Watch Dog Timer The DMC 41x3 provides an internal watch dog timer which checks for proper microprocessor operation The timer toggles the Amplifier Enable Output AMPEN which can be used to switch the amplifiers off in the event ofa serious DMC 41x3 fai
264. orrection move Stabilize Keep correcting until error is within tolerance End CORRECT subroutine returning to code Dual Loop Auxiliary Encoder The DMC 41x3 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation and axis used in circular compare When used the second encoder is typically mounted on the motor or the load but may be mounted in any position The most common use for the second encoder is backlash compensation described below The second encoder may be a standard quadrature type or it may provide pulse and direction The controller also offers the provision for inverting the direction of the encoder rotation The main and the auxiliary encoders are configured with the CE command The command form is CE x y z w or a b c d e f g h for controllers with more than 4 axes where the parameters x y z w each equal the sum of two integers m and n m configures the main encoder and n configures the auxiliary encoder Using the CE Command m Main Encoder n Second Encoder 0 Normal quadrature 0 Normal quadrature Pulse amp direction Pulse amp direction Chapter 6 Programming Motion e 115 DMC 41x3 User Manual Reverse quadrature Dea Reversed quadrature 3 Reverse pulse amp direction 12 Reversed pulse amp direction For example to configure the main encoder for reversed quadrature m 2 and a second encoder of pul
265. ors between the analog inputs and ground When using this option the analog inputs should be configured for 0 10V analog inputs using the AQ command AQ n 4 The equation for calculating the current is Ima 2 105 V Where Ima current in mA V Voltage reading from DMC 41x3 Part number ordering example DMC 4113 CARD 4 20mA DMC 41x3 User Manual Appendices e 196 LSNK 25mA Sinking Outputs The LSNK option modifies the digital outputs on the DMC 41x3 to be capable of sinking up to 25mA per output For detailed information see the 25mA Sinking Opto Isolated Outputs LSNK section in Chapter 3 Connecting Hardware Part number ordering example DMC 4113 CARD ABCD LSNK LSRC 25mA Sourcing Outputs The LSRC option modifies the digital outputs on the DMC 41x3 to be capable of sourcing up to 25mA per output For detailed information see the 25mA Sourcing Opto Isolated Outputs LSRC section in Chapter 3 Connecting Hardware Part number ordering example DMC 4113 CARD ABCD LSRC HSRC 500mA Sourcing Outputs The HSRC option modifies the digital outputs on the DMC 41x3 to be capable of sourcing up to 500mA per output For detailed information see the 500mA Sourcing Opto Isolated Outputs HSRC section in Chapter 3 Connecting Hardware Part number ordering example DMC 4113 CARD ABCD HSRC TRES Encoder Termination Resistors The TRES option provides termination resistors on all of the main and auxiliary encoder inputs on the DMC 4
266. otors It is capable of up to 8 Amps of continuous current and 15Amps of peak current and requires a single DC supply voltage in the range of 18 80 VDC AS AMP 43640 D3640 The AMP 43640 contains four linear drives for sinusoidally commutating brushless motors The AMP 43640 requires a single 18 30VDC input Output power delivered is typically 20 W per amplifier or 80 W total A6 SDM 44040 D4040 D4020 The SDM 44040 is a stepper driver module capable of driving up to four bipolar two phase stepper motors The current is selectable with options of 0 5 0 75 1 0 and 1 4 Amps Phase The step resolution is selectable with options of full half 1 4 and 1 16 AT SDM 44140 D4140 The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution the SDM 44140 drives two The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis Chapter 1 Overview 3 DMC 41x3 User Manual DMC 41x3 Functional Elements The DMC 41x3 circuitry can be divided into the following functional groups as shown in Figure 1 1 and discussed below WATCHDOG TIMER ISOLATED LIMITS AND HOME INPUTS MAIN ENCODERS AUXILIARY ENCODERS ETHERNET RISC BASED HIGH SPEED MICROCOMPUTER MOTOR ENCODER INTERFACE FOR A B C D 10 VOLT OUTPUT FOR SERVO MOTORS PULSE DIRECTION OUTPUT FOR STEP MOTORS E HIGH SPEED EN
267. ove the 18V threshold NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 40 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the AMP 43240 is a transconductance amplifier the amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the ZAMPERR routine NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short from a motor lead to ground A3 AMP 43240 D3240 e 231 DMC
268. p resolution of the microstepping drive otor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow slight settle time Enable SPM mode Chapter 6 Programming Motion e 113 DMC 41x3 User Manual Example Error Correction The following code demonstrates what is necessary to set up SPM mode for the X axis detect error stop the motor correct the error and return to the main code The drive is a full step drive with a 1 8 step motor and 4000 count rev encoder SETUP OE1 Set the profiler to stop axis upon error KS16 Set step smoothing MT 25 772 725727 Motor type set to stepper YA2 Step resolution of the drive YB200 Motor resolution full steps per revolution YC4000 Encoder resolution counts per revolution SHX Enable axis WT100 Allow slight settle time MOTION Perform motion SP512 Set the speed PR1000 Prepare mode of motion BGX Begin motion LOOP JP LOOP Keep thread zero alive for POSERR to run in REM When error occurs the axis will stop due to OEl In EM POSERR query the status YS and the error QS correct EM and return to the main code Es Es POSERR Automatic subroutine is called when YS 2 WT100 Wait helps user see the correction spsave SPX Save current speed setting JP RETURN YSX lt gt 2 Return to thread zero if invalid error SP64 Set slow speed setting for correction MG ERROR QSX YRX QSX Else error is valid use QS f
269. pezoidal or triangular velocity profile and position trajectory The controller determines a new command position along the trajectory every sample period until the specified profile is complete Motion is complete when the last position command is sent by the DMC 41x3 profiler Note The actual motor motion may not be complete when the profile has been completed however the next motion command may be specified The Begin BG command can be issued for all axes either simultaneously or independently XYZ or W axis specifiers are required to select the axes for motion When no axes are specified this causes motion to begin on all axes The speed SP and the acceleration AC can be changed at any time during motion however the deceleration DC and position PR or PA cannot be changed until motion is complete Remember motion is complete when the profiler is finished not when the actual motor is in position The Stop command ST can be issued at any time to decelerate the motor to a stop before it reaches its final position An incremental position movement IP may be specified during motion as long as the additional move is in the same direction Here the user specifies the desired position increment n The new target is equal to the old target plus the increment n Upon receiving the IP command a revised profile will be generated for motion towards the new end position The IP command does not require a begin Note If the motor is not movi
270. plifier will return to normal operation once the supply is raised above the 18V threshold NOTE If there is an AMPERR routine and the controller is powered before the amplifier then the AMPERR routine will automatically be triggered Over Voltage Protection If the voltage supply to the amplifier rises above 94 VDC then the amplifier will automatically disable The amplifier will re enable when the supply drops below 90 V The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Over Current Protection The amplifier also has circuitry to protect against over current If the total current from a set of 2 axes ie A and B or C and D exceeds 20 A the amplifier will be disabled The amplifier will not be re enabled until there is no longer an over current draw and then either SH command has been sent or the controller is reset Since the AMP 43540 is a trans conductance amplifier the amplifier will never go into this mode during normal operation The amplifier will be shut down regardless of the setting of OE or the presence of the ZAMPERR routine NOTE If this fault occurs it is indicative of a problem at the system level An over current fault is usually due to a short across the motor leads or a short
271. plifiers For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 DMC 41x3 User Manual A2 AMP 43140 D3140 e 226 A3 AMP 43240 D3240 Description The AMP 43240 resides inside the DMC 41x3 enclosure and contains four transconductance PWM amplifiers for driving brushless or brush type servo motors Each amplifier drives motors operating at up to 10 Amps continuous 20 Amps peak 20 80 VDC The gain settings of the amplifier are user programmable at 0 5 Amp Volt 1 0 Amp Volt and 2 0 Amp Volt The switching frequency is 24 kHz The drive operates in a Chopper Mode The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43240s can be used in 5 thru 8 axis controllers A shunt regulator option is available If higher voltages are required please contact Galil If the application has a potential for regenerative energy it is recommended to order the controller with the ISCNTL solate Controller Power option and the SR90 SR 49000 Shunt Regulator Option The BOX option is required when the AMP 43240 is ordered with the DMC 41x3 Note Do not hot swap the motor power or supply voltage power input connections If the amp is enabled when the motor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connect
272. polation change Specifying Linear Segments The command LI x y z w or LI a b c d e f g h specifies the incremental move distance for each axis This means motion is prescribed with respect to the current axis position Up to 511 incremental move segments may be given prior to the Begin Sequence BGS command Once motion has begun additional LI segments may be sent to the controller The clear sequence CS command can be used to remove LI segments stored in the buffer prior to the start of the motion To stop the motion use the instructions STS or AB The command ST causes a decelerated stop The command AB causes an instantaneous stop and aborts the program and the command ABI aborts the motion only The Linear End LE command must be used to specify the end of a linear move sequence This command tells the controller to decelerate to a stop following the last LI command If an LE command is not given an Abort ABI must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 41x3 sequence buffer to ensure continuous motion If the controller receives no additional LI segments and no LE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or LM returns the available spaces for LI segments that can be sent to the buffer 511 returned means the buffer is empty and 511 LI segments can be sent A zero means the buffer is full
273. pper Motor with Step and Direction Signals The DMC 41x3 can control stepper motors In this mode the controller provides two signals to connect to the stepper motor Step and Direction For stepper motor operation the controller does not require an encoder and operates the stepper motor in an open loop fashion Chapter 2 describes the proper connection and procedure for using stepper motors If encoders are available on the stepper motor Galil s Stepper Position Maintenance Mode may be used for automatic monitoring and correction of the stepper position See Stepper Position Maintenance Mode SPM in Chapter 6 for more information Overview of External Amplifiers The amplifiers should be suitable for the motor and may be linear or pulse width modulated An amplifier may have current feedback voltage feedback or velocity feedback Amplifiers in Current Mode Amplifiers in current mode should accept an analog command signal in the 10 volt range The amplifier gain should be set such that a 10V command will generate the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V Amplifiers in Velocity Mode For velocity mode amplifiers a command signal of 10 volts should run the motor at the maximum required speed The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed Stepper Motor Amplifiers For step motors the amplifiers
274. ppropriate for the motor The gain settings for the amplifier are identical for the brush and brushless operation The amplifier gain command AG can be set to 0 1 or 2 corresponding to 0 4 0 7 and 1 0 A V In addition to the gain peak and continuous torque limits can be set through TK and TL respectively The TK and TL values are entered in volts on an axis by axis basis The peak limit will set the maximum voltage that will be output from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval Figure A1 2 is indicative of the operation of the continuous and peak operation In this figure the continuous limit was configured for 2 volts and the peak limit was configured for 10 volts AU and AW commands With the AMP 43040 and 43020 the user is also given the ability to choose between normal and high current bandwidth AU In addition the user can calculate what the bandwidth of the current loop is for their specific combination AW To select normal current loop gain for the X axis and high current loop gain for the Y axis issue AU 0 1 The command AW is used to calculate the bandwidth of the amplifier using the basic amplifier parameters To calculate the bandwidth for the X axis issue AWX v n where v represents the DC voltage input to the card 1 represents the inductance of the motor in millihenries and n represents 0 or 1 for the AU setting NOTE For most applica
275. program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 41x3 provides commands and operands which are useful in debugging application programs These commands include interrogation commands to monitor program execution determine the state of the controller and the contents of the controllers program array and variable space Operands also contain important status information which can help to debug a program Trace Commands The trace command causes the controller to send each line in a program to the host computer immediately prior to execution Tracing is enabled with the command TR1 TRO turns the trace function off Note When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed NOTE When the trace function is enabled the line numbers as well as the command line will be displayed as each command line is executed Error Code Command When there is a program error the DMC 41x3 halts the program execution at the point where the error occurs To display the last line number of program execution issue the command MG ED The user can obtain information about the type of error condition that occurred by using the command TC1 This command reports back a number and a text message which describes the error condition The command TCO or TC w
276. r distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the path in the X Y plane The length of that string represents the distance traveled by the vector motion The vector velocity is specified independently of the path to allow continuous motion The path is specified as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle corresponds to the positive direction of the X axis and the CCW direction of rotation is positive Angles are expressed in degrees and the resolution is 1 256th of a degree For example the path shown in Figure A 2 is specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 20000 10000 10000 20000 Figure A 2 X Y Motion Path Appendices 207 DMC 41x3 User Manual The first line describes the straight line vector segment between points A and B The next segment is a circular arc which starts at an angle of 180 and traverses 90 Finally the third line describes the linear segment between points C and D Note that the total length of the motion consists of the seg
277. r example if the filter parameters of the DMC 41x3 are KP 16 KD 144 KI 2 PL 0 75 T 0 001 s the digital filter coefficients are K 160 A 0 9 C 2 a 250 rad s and the equivalent continuous filter G s is G s 16 0 144s 2000 s 250 s 250 The notch filter has two complex zeros z and z and two complex poles p and P The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of the resonance poles The notch poles P and p are programmable and are selected to have sufficient damping It is best to select DMC 41x3 User Manual Chapter 10 Theory of Operation e 186 the notch parameters by the frequency terms The poles and zeros have a frequency in Hz selected by the command NF The real part of the poles is set by NB and the real part of the zeros is set by NZ The most simple procedure for setting the notch filter identify the resonance frequency and set NF to the same value Set NB to about one half of NF and set NZ to a low value between zero and 5 ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 sT 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elem
278. r label by specifying a line number or label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEGIN Line numbers appear as 000 001 002 and so on Program commands are entered following the line numbers Multiple commands may be given on a single line as long as the total number of characters doesn t exceed 80 characters per line While in the Edit Mode the programmer has access to special instructions for saving inserting and deleting program lines These special instructions are listed below Edit Mode Commands RETURN Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of lt RETURN gt will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a return is given lt cntrl gt P The lt cntrl gt P command moves the editor to the previous line lt entrl gt I The lt cntrl gt I command inserts a line above the current line For example if the editor is at line number 2 and lt cntrl gt I is applied a new line will be inserted between lines 1 and 2 This new line will be labeled line 2 The old line number 2 is renumbered as line 3 lt entrl gt D The lt cntrl gt D command deletes the line currently being edited For example if the editor is at line number 2 and lt cntrl gt D is applied line 2 will be de
279. r of the point The value n starts at zero and may go up to 256 The parameters x y z w indicate the corresponding slave position For this example the table may be specified by ET 0 0 ET 1 3000 ET 2 2250 3 1500 PM El This specifies the ECAM table Step 5 Enable the ECAM To enable the ECAM mode use the command EB n where n 1 enables ECAM mode and n 0 disables ECAM mode Step 6 Engage the slave motion To engage the slave motion use the instruction EG X Y Z W where x y z w are the master positions at which the corresponding slaves must be engaged If the value of any parameter is outside the range of one cycle the cam engages immediately When the cam is engaged the slave position is redefined modulo one cycle Step 7 Disengage the slave motion To disengage the cam use the command EQ X Y Z W where x y z w are the master positions at which the corresponding slave axes are disengaged Chapter 6 Programming Motion e 95 DMC 41x3 User Manual 3000 e l 2250 ME 1500 ara ie eae botnets E Eds E 0 2000 4000 6000 Master X Figure 6 10 Electronic Cam Example This disengages the slave axis at a specified master position If the parameter is outside the master cycle the stopping is instantaneous To illustrate the complete process consider the cam relationship described by the equation Y 0 5 X 100 sin 0 18 xX where X is the master
280. r that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no longer under servo control If the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running are terminated when a transition in the Abort input is detected This can be configured with the CN command For information see the Command Reference OE and CN DMC 41x3 User Manual Chapter 3 Connecting Hardware e 28 ELO Electronic Lock Out Input Used in conjunction with Galil amplifiers this input allows the user the shutdown the amplifier at a hardware level For more detailed information on how specific Galil amplifiers behave when the ELO is triggered see Integrated in the Appendices Reset Input Reset Button When the Reset line is triggered the controller will be reset The reset line and reset button will not master reset the controller unless the MRST jumper is installed during a controller reset Uncommitted Digital Inputs The DMC 41x3 has 8 opto isolated inputs These inputs can be read individually using the function IN x where x specifies the input number 1 thru 8 These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller For example the user may wish to have the x axis motor move 1000 co
281. rd To find the Ethernet MAC address for a DMC 41x3 unit use the TH command A sample is shown here with a unit that has a serial number of 3 Sample MAC Ethernet Address 00 50 4C 38 00 03 The second level of addressing is the IP address This is a 32 bit or 4 byte number that usually looks like this 192 168 15 1 The IP address is constrained by each local network and must be assigned locally Assigning an IP address to the DMC 41x3 controller can be done in a number of ways The first method for setting the IP address is using a DHCP server The DH command controls whether the DMC 41x3 controller will get an IP address from the DHCP server If the unit is set to DH1 default and there is a DHCP server on the network the controller will be dynamically assigned an IP address from the server Setting the board to DHO will prevent the controller from being assigned an IP address from the server The second method to assign an IP address is to use the BOOT P utility via the Ethernet connection The BOOT P functionality is only enabled when DH is set to 0 Either a BOOT P server on the internal network or the Galil software may be used When opening the Galil Software it will respond with a list of all DMC 41x3 s and other controllers on the network that do not currently have IP addresses The user must select the board and the software will assign the specified IP address to it This address will be burned into the controller BN internally to sa
282. re Tools and Communication e 47 DMC 41x3 User Manual Auxiliary RS 232 Port Configuration NOTE If you are connecting the RS 232 auxiliary port to a terminal or any device which is a DATASET it is necessary to use a connector adapter which changes a dataset to a dataterm This cable is also known as a null modem cable RS232 Auxiliary Port 1 No Connect 6 No Connect 2 Receive Data input 7 Request To Send output 3 Transmit Data output 8 Clear To Send input 4 No Connect 9 No Connect Can be connected to 5V with APWR jumper 5 Ground Handshaking The auxiliary port of the DMC 41x3 can be configured either as a general port output port or setup for communication interrupts CI command When configured as a general port the port can be commanded to send ASCII messages to another DMC 41x3 controller or to a display terminal or panel CC Command Configure Communication at port 2 The command is in the format of See CC in the Command Reference for more information CC m n r p where m sets the baud rate n sets for either handshake or non handshake mode r sets for general port or the auxiliary port and p turns echo on or off m Baud Rate 9600 19200 n Handshake 0 No 1 Yes r Mode 0 Disabled 1 enabled p Echo 0 Off 1 On Valid only if r 0 Hardware Handshaking The RS 232 Aux port can be set for hardware handshaking with the second field of the CC command Hardware Handshaking uses the R
283. refa 100000 ccf 1 E Em v RPB Axis Brefi 100000cc t 4 mi sl 2 21 s A E x 0 221383 S o 5 EC m 4 42765 1 2 80 w 0 442765 2 x sO v 0 221383 3 sO m 0 221383 4 _ amp T T t 100 ms Trigger Channel B RPEv Edge Level 1000 count gt Mode Repeat v READY didt RPAdidt RPE Figure 6 9 Velocity counts sec vs Time msec Ramped Gearing The slave axis for each figure is shown on the bottom portion of the figure the master axis is shown on the top portion The shock to the slave axis will be significantly less in Figure 6 9 than in Figure 6 8 The ramped gearing does have one consequence There isn t a true synchronization of the two axes until the gearing ramp is complete The slave will lag behind the true ratio during the ramp period If exact position synchronization is required from the point gearing is initiated then the position must be commanded in addition to the gearing The controller keeps track of this position phase lag with the GP operand The following example will demonstrate how the command is used Example Electronic Gearing Over a Specified Interval Objective Run two geared motors at speeds of 1 132 and 045 times the speed of an external master Because the master is traveling at high speeds it is desirable for the speeds to change slowly Solution Use a DMC 4133 controller where the Z axis is the master and X and Y are the
284. rent mode Step Drive Resolution Setting YA command When using the SDM 44040 the step drive resolution can be set with the YA command Step Drive Resolution per Axis YA n n n n n n n n n 1 Full n 2 Half n 4 1 4 n 16 1 16 DMC 41x3 User Manual A6 SDM 44040 D4040 D4020 e 246 Protection Circuitry The SDM 44040 has short circuit protection as well as over temperature and under voltage detection The short circuit protection will protect against phase to phase shorts a shorted load and a short to ground or chassis The over current shutdown will occur when any one phase exceeds an output greater than 2Amps The over temperature shutdown will occur when the driver temperature exceeds 165 deg C In the event of any of these faults bit 0 of TAO will be set bit 5 for axes E H and the SDM 44040 will be disabled All 4 axes on the amplifier must be in MO state in order for the error status to be cleared ELO Input If the ELO input on the controller is triggered then the amplifier will be shut down at a hardware level the motors will be essentially in a Motor Off MO state TA3 will return a 3 and the AMPERR routine will run when the ELO input is triggered To recover from an ELO an MO then SH must be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application A6 SDM 44040 D4040 D4020 e 247 DMC 41x3 User Manual A7 SDM 44140 D4140
285. ring ZAUTO start up Check error condition with RS bit 0 for variable checksum error bit 1 for parameter checksum error bit 2 for program checksum error bit 3 for master reset error there should be no program AMPERR Error from internal Galil amplifier For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the ZPOSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label could be used to designate an input interrupt subroutine When the specified input occurs the program will be executed automatically NOTE An application program must be running for CMDERR to function Example Limit Switch This program prints a message upon the occurrence of a limit switch Note for the ZLIMSWI routine to function the DMC 41x3 must be executing an applications program from memory This can be a very simple program that does nothing but loop on a statement such as LOOP JP LOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed LOOP JP LOOP EN LIMSWI MG LIMIT OCCURRED RE XQ LOOP JG 5000 BGX Dummy Program Jump to Loop Limit Switch Label Print Message Return to main program Download Program Execute Dummy Program Jog Begin Motion Now when a forward limit switch occurs on
286. ronic gearing where slave axes are scaled to master axis Electronic Gearing GA which can move in both directions GD _GP GR GM if gantry Master slave where slave axes must follow a master such as Electronic Gearing and Ramped Gearing GA conveyer speed GD _GP GR Moving along arbitrary profiles or mathematically prescribed Contour Mode CM profiles such as sine or cosine trajectories CD DT Teaching or Record and Play Back Contour Mode with Teach Record and Play CM Back CD DT RA RD RC Backlash Correction Dual Loop Auxiliary Encoder DV Following a trajectory based on a master encoder position Electronic Cam EA EM EP ET EB EG EQ Smooth motion while operating in independent axis Motion Smoothing IT positioning Smooth motion while operating in vector or linear Motion Smoothing IT interpolation positioning Smooth motion while operating with stepper motors Stepper Motion Smoothing KS Gantry two axes are coupled by gantry Electronic Gearing Example Gantry Mode GR GM DMC 41x3 User Manual Chapter 6 Programming Motion e 72 Independent Axis Positioning In this mode motion between the specified axes is independent and each axis follows its own profile The user specifies the desired absolute position PA or relative position PR slew speed SP acceleration ramp AC and deceleration ramp DC for each axis On begin BG the DMC 41x3 profiler generates the corresponding tra
287. rough a 7 1kQ resistor pulled down to GND through a 2 5kQ resistor Step Direction Outputs PWM SIGN The controller provides step and direction STPn DIRn outputs for every axis available on the controller These outputs are typically used for interfacing to external stepper drivers but they can be configured for a PWM output See the MT command for more details Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA Sink Source Output Compare The output compare signal is TTL and is available on the I O A D D Sub connector as CMP Output compare is controlled by the position of any of the main encoder inputs on the controller The output can be programmed to produce an active low pulse 510 nsec based on an incremental encoder value or to activate once when an axis position has been passed When setup for a one shot the output will stay low until the OC command is called again For further information see the command OC in the Command Reference For controllers with 5 8 axes a second output compare signal is available on the I O E H D Sub connector Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA Sink Source Error Output The controller provides a TTL signal ERR to indicate a controller error condition When an error condition occurs the ERR signal will go low and the controller LED will go on An error occurs because of one of the following conditions 1 Atleast one axis has a po
288. rrection GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction Electronic Cam The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion Up to 7 axes can be slaved to one master axis The master axis encoder must be input through a main encoder port The electronic cam is a more general type of electronic gearing which allows a table based relationship between the axes It allows synchronizing all the controller axes For example the DMC 4183 controllers may have one master and up to seven slaves To illustrate the procedure of setting the cam mode consider the cam relationship for the slave axis Y when the master is X Such a graphic relationship is shown in Figure 6 10 Step 1 Selecting the master axis The first step in the electronic cam mode is to select the master axis This is done with the instruction EAp where p X Y Z W E F G H p is the selected master axis For the given example since the master is x we specify EAX Step 2 Specify the master cycle and the change in the slave axis or axes In the electronic cam mode the position of the master is always expressed modulo one cycle In this example the position of x is always expressed in the range between 0 and 6000 Similarly
289. rty PLC The DMC 4143 will read the value of analog inputs 3 and 4 on the PLC located at addresses 40006 and 40008 respectively The PLC stores values as 32 bit floating point numbers which is common 1 Begin by opening a connection to the PLC which has an IP address of 192 168 1 10 in our example IHB 192 168 1 10 lt 502 gt 2 2 Dimension an array to store the results DM myanalog 4 DMC 41x3 User Manual Chapter 4 Software Tools and Communication e 52 3 Send the appropriate MB command Use function code 4 as specified per the PLC Start at address 40006 Retrieve 4 modbus registers 2 modbus registers per analog input as specified by the PLC MBB 4 40006 4 myanalog Results Array elements 0 and 1 will make up the 32 bit floating point value for analog input 3 on the PLC and array elements 2 and 3 will combine for the value of analog input 4 myanalog 0 16412 0x401C myanalog 1 52429 0xCCCD myanalog 2 49347 0xC0C3 myanalog 3 13107 0x3333 Analog input 3 0x401CCCCD 2 45V Analog input 4 0xC0C33333 6 1V Example 3 DMC 4143 connected as a Modbus master to a hydraulic pump The DMC 4143 will set the pump pressure by writing to an analog output on the pump located at Modbus address 30000 and consisting of 2 Modbus registers forming a 32 bit floating point value 1 Begin by opening a connection to the pump which has an IP address of 192 168 1 100 in our example IHB 192 168 1 100 lt 502 gt 2 2 Dimens
290. s Input Impedance 12 and 16 bit Single Ended Unipolar 42kQ Differential Bipolar 31kQ DMC 41x3 User Manual Chapter 3 Connecting Hardware e 40 External Amplifier Interface Electrical Specifications Max Amplifier Enable Voltage 24V Max Amplifier Enable Current 24V sink source 25 mA Motor Command Output Range 10 VDC Motor Command Output Impedance 500 Q Overview The DMC 41x3 command voltage ranges between 10V and is output on the motor command line MCMn where n is A H This signal along with GND provides the input to the motor amplifiers The amplifiers must be sized to drive the motors and load For best performance the amplifiers should be configured for a torque current mode of operation with no additional compensation The gain should be set such that a 10 volt input results in the maximum required current The DMC 41x3 also provides an amplifier enable signal AEN This signal changes under the following conditions the motor off command MO is given the watchdog timer activates or the OE command Enable Off On Error is set and the position error exceeds the error limit or a limit switch is reached see OE command in the Command Reference for more information The standard configuration of the amplifier enable signal is 5V active high amp enable HAEN sinking In other words the AEN signal will be high when the controller expects the amplifier to be enabled The polarity and the amplitude can be cha
291. s entered in samples which will depend on the TM setting With the default TM of 1000 one sample is 976us This means that a t value of 1024 will yield one second of motion The velocity value v will always be in units of counts per second regardless of the TM setting PVT mode is not available in the FAST version of the firmware If this is required please consult Galil DMC 41x3 User Manual Chapter 6 Programming Motion e 100 Command Summary PVT COMMAND DESCRIPTION PVa p v t Specifies the segment of axis a for a incremental PVT segment of p counts an end speed of v counts sec in a total time of t samples _PVa Contains the number of PV segments available in the PV buffer for a specified axes BT Begin PVT mode _BTa Contains the number PV segments that have executed PVT Examples Parabolic Velocity Profile In this example we will assume that the user wants to start from zero velocity accelerate to a maximum velocity of 1000 counts second in 1 second and then back down to 0 counts second within an additional second The velocity profile would be described by the following equation and shown in Figure 6 12 v t 1000 1 1000 Desired Velocity Profile 1200 1000 800 600 m Velocity 400 Velocity counts second 200 o Time Seconds Figure 6 12 Parabolic Velocity Profile To accomplish this we need to ca
292. s only valid with the AMP 43140 Part number ordering example DMC 4143 BOX4 D3140 100mA SSR Solid State Relay Option for AMP 43140 The SSR option configures the AMP 43140 D3140 with Solid State Relays on the motor power leads that are engaged and disengaged when the amplifier is enabled and disabled See the SSR Option in the AMP 43140 section of the Appendix for more information This option is only valid with the AMP 43140 Part number ordering example DMC 4143 BOX4 D3140 SSR Appendices e 199 DMC 41x3 User Manual Power Connectors for the DMC 41x3 Overview The DMC 41x3 uses Molex Mini Fit Jr Receptacle Housing connectors for connecting DC Power to the Amplifiers Controller and Motors This section gives the specifications of these connectors For information specific to your Galil amplifier or driver refer to the specific amplifier driver in the Integrated Components section Molex Part Numbers There are 3 different Molex connectors used with the DMC 41x3 The type of connectors on any given controller will be determined be the Amplifiers Drivers that were ordered Below are tables indicating the type of Molex Connectors used and the specific part numbers used on each Amplifier or Driver For more information on the connectors go to http www molex com On Board Connector Common Mating Connectors Crimp Part Number MOLEX 39 31 0060 MOLEX 39 01 2065 MOLEX 44476 3112 6 Position MOLEX 39
293. s tangent TN 2000 360 500 2000 360 counts degree position 500 is 0 degrees in XY plane CR 3000 0 180 3000 count radius start at 0 and go to 180 CCW VE End vector CBO Disengage knife PA 3000 0 TN Move X and Y to starting position move Z to initial tangent position BG XYZ Start the move to get into position AM XYZ When the move is complete SBO Engage knife WT50 Wait 50 msec for the knife to engage BGS Do the circular cut AMS After the coordinated move is complete DMC 41x3 User Manual Chapter 6 Programming Motion e 88 CBO Disengage knife MG ALL DONE EN End program Command Summary Coordinated Motion Sequence COMMAND DESCRIPTION VM m n Specifies the axes for the planar motion where m and n represent the planar axes and p is the tangent axis VP m n Return coordinate of last point where m X Y Z or W CR 1 0 FAO Specifies arc segment where r is the radius is the starting angle and AO is the travel angle Positive direction is CCW VS st Specify vector speed or feed rate of sequence VA s t Specify vector acceleration along the sequence VD st Specify vector deceleration along the sequence VR st Specify vector speed ratio BGST Begin motion sequence S or T CSST Clear sequence S or T AV s t Trippoint for After Relative Vector distance AMST Holds execution of next command until Motion Sequence is complete TN m n Tangent scale and offset ES m n Ellipse scale factor IT s t S curve smoothing c
294. s with Loops Example 13 Motion Programs with Trippoints Example 14 Control Variables Example 15 Linear Interpolation Example 16 Circular Interpolation 25 Chapter 3 Connecting Hardware 27 BCC LIO RR A E E Overview of Opto Isolated Inputs Li ope Inp f eai cette Home S Ipit auia cuc ira Abort Input ELO Electronic Lock Out Input Reset Input Reset Button i Uncommitted Digital ipa caeteri 29 Opto Isolated Input Electrical Information ic eei reiecta 30 Electrical Specifications i Wiring the Opto Isolated Digital Inputs rrrrrrnee 3l OptosTsolat d OUMU aac es oaa e oc eee IA nibii in 34 Standard 4mA Sinking Opto Isolated Outputs 25mA Sinking Opto Isolated Outputs LSNK 25mA Sourcing Opto Isolated Outputs LSRC is 500mA Sourcing Opto Isolated Outputs HSRC 37 TIG TIE LELE RP AR I OT TR a 38 Main Encoder Inputs The Auxiliary Encoder Inputs Step Direction Outputs PWM SIGN rr 39 Output Compare x Pror QUEDUL siii o si usui p co ordo TTT Analog TONG iioii odii ite ci eb re i bi C blico un tcu i L a cd e e ri 40 AO Settings is Electrical Specifications ol ARTT YYZ se 22 41 Electrical Specifica tins iii iero 41 ri A ir 41 Configuring the Amplifier Enable Circuit
295. same controllers with 5 or more axes Returns number of available spaces for linear segments in DMC 41x3 sequence buffer Zero means buffer full 511 means buffer empty Specify incremental distances relative to current position and assign vector speed n Specify vector speed Specify vector acceleration Specify vector deceleration Specify the vector speed ratio Begin Linear Sequence Clear sequence Linear End Required at end of LI command sequence Returns the length of the vector resets after 2147483647 Trippoint for After Sequence complete Trippoint for After Relative Vector distance n S curve smoothing constant for vector moves Operand Summary Linear Interpolation OPERAND _AV _CS LE IM _VPm DESCRIPTION Return distance traveled Segment counter returns number of the segment in the sequence starting at zero Returns length of vector resets after 2147483647 Returns number of available spaces for linear segments in DMC 41x3 sequence buffer Zero means buffer full 511 means buffer empty Return the absolute coordinate of the last data point along the trajectory m X Y Z or W or A B C D E F G or H To illustrate the ability to interrogate the motion status consider the first motion segment of our example LMOVE where the X axis moves toward the point X 5000 Suppose that when X 3000 the controller is interrogated using the command MG AV The returned value will be 3000
296. se and direction n 4 the total is 6 and the command for the X axis is CE 6 Additional Commands for the Auxiliary Encoder The command DE x y z w can be used to define the position of the auxiliary encoders For example DE 0 500 30 300 sets their initial values The positions of the auxiliary encoders may be interrogated with the command DE For example DE 2 42 returns the value of the X and Z auxiliary encoders The auxiliary encoder position may be assigned to variables with the instructions Vl DEX The command TD XYZW returns the current position of the auxiliary encoder The command DV 1 1 1 1 configures the auxiliary encoder to be used for backlash compensation Backlash Compensation There are two methods for backlash compensation using the auxiliary encoders Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independe
297. serial numbers to the screen Figure 4 2 a Form1 GO GalilClass0 dll 0 5 0 0 Galill dll 1 4 4 10 0 5 143 DMC4183 Rev 1 0 2 IHA IHB MG TIME 1963498 Figure 4 2 Sample program output http www galilmc com support hello galil html GalilTools Communication Libraries The GalilTools Communication Library Galil class provides methods for communication with a Galil motion controller over Ethernet USB RS 232 or PCI buses It consists of a native C Library and a similar COM interface which extends compatibility to Windows programming languages e g VB C etc A Galil object usually referred to in sample code as g represents a single connection to a Galil controller For Ethernet controllers which support more than one connection multiple objects may be used to communicate with the controller An example of multiple objects is one Galil object containing a TCP handle to a DMC 41x3 for commands and responses and one Galil object containing a UDP handle for unsolicited messages from the controller If recordsStart is used to begin the automatic data record function the library will open an additional UDP handle to the controller transparent to the user The library is conceptually divided into six categories 1 Connecting and Disconnecting functions to establish and discontinue communication with a controller 2 Basic Communication The most heavily used functions for command and response and u
298. ses the A axis as an examples Step B Set the Error Limit as a Safety Precaution Usually there is uncertainty about the correct polarity of the feedback The wrong polarity causes the motor to run away from the starting position Using a terminal program such as Galil Tools the following parameters can be given to avoid system damage Input the commands ER 2000 Sets error limit on the A axis to be 2000 encoder counts OE 1 Disables A axis amplifier when excess position error exists If the motor runs away and creates a position error of 2000 counts the motor amplifier will be disabled NOTE This function requires the AMPEN signal to be connected from the controller to the amplifier Step C Set Torque Limit as a Safety Precaution To limit the maximum voltage signal to your amplifier the DMC 41x3 controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to t
299. should accept step and direction signals DMC 41x3 User Manual Chapter 1 Overview e 2 Overview of Galil Amplifiers and Drivers With the DMC 41x3 Galil offers a variety of Servo Amplifiers and Stepper Drivers that are integrated into the same enclosure as the controller Using the Galil Amplifiers and Drivers provides a simple straightforward motion control solution in one box A1 AMP 430x0 D3040 D3020 The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless amplifiers that are capable of handling 500 watts of continuous power per axis The AMP 43040 43020 Brushless drive modules are connected to a DMC 41x3 The standard amplifier accepts DC supply voltages from 18 80 VDC A2 AMP 43140 D3140 The AMP 43140 contains four linear drives for operating small brush type servo motors The AMP 43140 requires a 12 30 DC Volt input Output power is 20 W per amplifier or 60 W total The gain of each transconductance linear amplifier is 0 1 A V at 1 A maximum current The typical current loop bandwidth is 4 kHz A3 AMP 43240 D3240 The AMP 43240 is a multi axis brush brushless amplifiers that is capable of handling 750 watts of continuous power per axis The AMP 43240 Brushless drive module is connected to a DMC 40x0 The standard amplifier accepts DC supply voltages from 18 80 VDC A4 AMP 435x0 D3540 D3520 The AMP 43540 contains four PWM drives for sinusoidally commutating brushless m
300. sition error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal The ERR signal is found on the I O A D D Sub connector For controllers with 5 8 axes the ERR signal is duplicated on the I O E H D Sub connector Chapter 3 Connecting Hardware e 39 DMC 41x3 User Manual For additional information see Error Light Red LED in Chapter 9 Troubleshooting Electrical Specifications Output Voltage 0 5 VDC Current Output 20 mA Sink Source Analog Inputs The DMC 41x3 has eight analog inputs configured for the range between 10V and 10V The inputs are decoded by a 12 bit A D decoder giving a voltage resolution of approximately 005V A 16 bit ADC is available as an option Ex DMC 4123 CARD 16bit The analog inputs are specified as AN x where x is a number thru 8 AQ settings The analog inputs can be set to a range of 10V 5V 0 5V or 0 10V this allows for increased resolution when the full 10V is not required The inputs can also be set into a differential mode where analog inputs 2 4 6 and 8 can be set to the negative differential inputs for analog inputs 1 3 5 and 7 respectively See the AQ command in the command reference for more information Electrical Specification
301. sition trajectory and a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging COMMAND DESCRIPTION AC x y Z W Specifies acceleration rate BG XYZW Begins motion DC x y Z W Specifies deceleration rate IP x y z w Increments position instantly IT x y z w Time constant for independent motion smoothing JG x y z w Specifies jog speed and direction ST XYZW Stops motion Parameters can be set with individual axes specifiers such as JGY 2000 set jog speed for Y axis to 2000 Chapter 6 Programming Motion e 75 DMC 41x3 User Manual Operand Summary Independent Axis OPERAND DESCRIPTION _ACx Return acceleration rate for the axis specified by x _DCx Return deceleration rate for the axis specified by x _SPx Returns the jog speed for the axis specified by x _TVx Returns the actual velocity of the axis specified by x averaged over 0 25 sec Example Jog in X only Jog X motor at 50000 count s After X motor is at its jog speed begin jogging Z in reverse direction at 25000 count s A AC 20000 20000 Specify X Z acceleration of 20000 counts sec DC 20000 20000 Specify X Z deceleration of 20000 counts sec JG 50000 25000 Specify jog speed and direction for X and Z axis BG X Begin X motion AS X Wait until X is at speed BG Z Begin Z motion EN Examp
302. st be issued or the controller must be reset It is recommended that OE1 be used for all axes when the ELO is used in an application A4 AMP 435x0 D3540 D3520 e 237 DMC 41x3 User Manual Error Monitoring and Protection The amplifier is protected against over voltage under voltage over temperature and over current for brush and brushless operation The controller will monitor the error conditions and respond as programmed in the application The errors are monitored via the TA command TA n may be used to monitor the errors with n 0 2 or 3 The command will return an eight bit number representing specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label ZAMPERR in their program to handle amplifier errors As long as a program is executing in thread zero and the AMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition See the TA command for detailed information on bit status during error conditions Under Voltage Protection If the supply to the amplifier drops below 18 VDC the amplifier will be disabled The am
303. st the PID filter parameters KP KD and KI It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section Step 7b Connect Step Motors In Stepper Motor operation the pulse output signal has a 50 duty cycle Step motors operate open loop and do not require encoder feedback When a stepper is used the auxiliary encoder for the corresponding axis is unavailable for an external connection If an encoder is used for position feedback connect the encoder to the main encoder input corresponding to that axis The commanded position of the stepper can be interrogated with RP or TD The encoder position can be interrogated with TP If encoders are available on the stepper motor Galil s Stepper Position Maintenance Mode may be used for automatic monitoring and correction of the stepper position See Stepper Position Maintenance Mode SPM in Chapter 6 Programming Motion for more information The frequency of the step motor pulses can be smoothed with the filter parameter KS The KS parameter has a range between 0 25 and 64 where 64 implies the largest amount of smoothing See Command Reference regarding KS The DMC 41x3 profiler commands the step motor amplifier All DMC 41x3 motion commands apply such as PR PA VP CR and JG The acceleration deceleration slew speed and smoothing are also used Since step motors run open loop the PID filter does not function
304. switches may also be tested during the jump on condition statement The LR condition specifies the reverse limit and LF specifies the forward limit X Y Z or W following LR or LF specifies the axis The CN command can be used to configure the polarity of the limit switches Limit Switch Example A JP A EN LIMSWI V1 LFX V2 LRX JP LF V1 0 JP LR V2 0 JP END LF MG FORWARD LIMIT STX AMX PR 1000 BGX AMX JP END LR MG REVERSE LIMIT STX AMX PR1000 BGX AMX END RE Dummy Program Limit Switch Utility Check if forward limit Check if reverse limit Jump Jump Jump LF Send Stop Move End LR Send Stop Move End to LF if forward to LR if reverse to end message motion in reverse message motion forward Return to main program Chapter 8 Hardware amp Software Protection e 175 DMC 41x3 User Manual Chapter 9 Troubleshooting Overview The following discussion may help you get your system to work Potential problems have been divided into groups as follows 1 Installation 2 Stability and Compensation 3 Operation 4 Error Light Red LED The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM Motor runs away with no connections from controller to amplifier input Motor is enabled even when MO command is given Unable to read main or auxiliary encoder input DI
305. t D Between the points A and B the motion is along the Y axis Therefore Vy Vs and Vx 0 Between the points B and C the velocities vary gradually and finally between the points C and D the motion is in the X direction time Figure A 4 Vector and Axes Velocities Appendices e 209 DMC 41x3 User Manual Example Communicating with OPTO 22 SNAP B3000 ENET Controller is connected to OPTO 22 via handle F The OPTO 22 s IP address is 131 29 50 30 The Rack has the following configuration Digital Inputs Module 1 Digital Outputs Module 2 Analog Outputs 10V Module 3 Analog Inputs 10V Module 4 Instruction CONFIG IHF 131 29 50 30 lt 502 gt 2 WT10 JP CFGERR IHF2 0 JS CFGDOUT JS CFGAOUT JS CFGAIN MBF 6 6 1025 1 EN CFGDOUT MODULE 2 CFGVALUE 180 NUMOFIO 4 JP CFGJOIN CFGAOUT MODULE 3 CFGVALUE SA7 NUMOFIO 2 JP CFGJOIN CFGAIN MODULE 5 CFGVALUE 12 NUMOFIO 2 JP CFGJOIN CFGJOIN DM A 8 I 0 CFGLOOP A I 0 I I 1 A I CFGVALUE I I 1 JP CFGLOOP I lt 2 NUMOFIO Interpretation Label Establish connection Wait 10 milliseconds Jump to subroutine Configure digital outputs Configure analog outputs Configure analog inputs Save configuration to OPTO 22 End Label Set variable Set variable Set variable Jump to subroutine Label Set variable Set variable Set variable Jump to subroutine Label Set variable Set variable Set
306. t ED command the first line is zero Line Instruction Interpretation 000 TA Define label 001 PR 700 Distance 002 SP 2000 Speed 003 BGA Start A motion Chapter 2 Getting Started e 23 DMC 41x3 User Manual 004 EN End program To exit the editor mode input lt cntrl gt Q The program may be executed with the command XQ A Start the program running Example 12 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction Interpretation A Label DP 0 Define current position as zero v1 1000 Set initial value of vl LOOP Label for loop PA vl Move A motor vl counts BGA Start A motion AMA After A motion is complete WT 500 Wait 500 ms TPA Tell position A vl v1 1000 Increase the value of vl JP LOOP v1 lt 10001 Repeat if v1 10001 EN End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ A Execute Program A Example 13 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction Interpretation B Label DP 0 0 Define initial positions PR 30000 60000 Set targets SP 5000 5000 Set speeds BGA Start A motion AD 4000 Wait until A moved 4000 BGB Start B motion AP 6000 Wait until position A 6000 SP 2000 50000 Change speeds AP 50000 Wait until position B 50000 SP 10000 Change speed of B EN End program To start the program command XQ 4B Execute Program 4B
307. t Loop Bandwidth 229 Chopp Mode iiu cob odit bii abita reet oc TO 230 Usine External Amplifiers i iecoris 230 DMC 41x3 Contents vii BLO IHDUL iiic ud eodd ceo i oo rein 230 Error Monitoring and PrOlCeUOD scu casa pipe pbi o caesi up ado tiet Ronde Cod 231 Hall Error Protection Under Voltage Protection Over Voltage Protection Over Current Protect ooo a eroe Loans 231 Overs Temperature Protection ori scri 232 A4 AMP 435x0 D3540 D3520 233 Descerpkiofi cou E RO a a dris tds tea ue cou orbc d adr reese 233 Electrical Speer sss episc edo erede iii 234 Boating Comitini aiar 234 Operation Setting Amplifier Gain and Current Loop Gain 235 Setting Peak and Continuous Current TL and TK 236 Brushed Motot Operation a a ciciie s cec xcti Using External Amplifiers PLO Mputa ila Error Monitoring abd Protection sis eicit rete itinebciiticid eiecit 238 Under Voltage Protection Ove Voltage PUOUGCDON o eise stood Overs Current Protecto au aee a id irc eb di Over Temperature Protection lie 238 A5 AMP 43640 D3640 239 Finding Proper Commutation eese caciseee 242 Setting Peak and Continuous Current TL and TK 242 Brushed Motor Operations aa ees 243
308. t an external encoder but has to be a controlled variable This can be achieved by defining the N axis as the master with the command EAN and setting the modulo of the master with a command such as EMN 4000 Next the table is constructed To move the constrained axes simply command the N axis in the jog mode or with the PR and PA commands For example PAN 2000 BGN will cause the XY axes to move to the corresponding points on the motion cycle Sinusoidal Motion Example The x axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a frequency of 20 Hz This can be performed by commanding the X and N axes to perform circular motion Note that the value of VS must be VS 2r R F where R is the radius or amplitude and F is the frequency in Hz Set VA and VD to maximum values for the fastest acceleration INSTRUCTION INTERPRETATION VMXN Select Axes Chapter 6 Programming Motion e 109 DMC 41x3 User Manual VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten Cycles VE BGS Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with acti
309. t bit number representing specific conditions TAO will return errors with regard to under voltage over voltage over current and over temperature TA1 will return hall errors on the appropriate axes TA2 will monitor if the amplifier current exceeds the continuous setting and TA3 will return if the ELO input has been triggered The user also has the option to include the special label AMPERR in their program to handle soft or hard errors As long as a program is executing in thread zero and the ZAMPERR label is included when an error is detected the program will jump to the label and execute the user defined routine Note that the TA command is a monitoring function only and does not generate an error condition The over voltage condition will not permanently shut down the amplifier or trigger the AMPERR routine The amplifier will be momentarily disabled when the condition goes away the amplifier will continue normal operation assuming it did not cause the position error to exceed the error limit Hall Error Protection During normal operation the controller should not have any Hall errors Hall errors can be caused by a faulty Hall effect sensor or a noisy environment If at any time the Halls are in an invalid state the appropriate bit of TA1 will be set The state of the Hall inputs can also be monitored through the QH command Hall errors will cause the amplifier to be disabled if OE 1 is set and will cause the controller to enter the A
310. t of auxiliary port Message out of auxiliary port Variable to remember speed Set speed of A axis motion Label for Loop Chapter 7 Application Programming e 139 DMC 41x3 User Manual PAA 10000 Move to absolute position 10000 BGA Begin Motion on A axis AMA Wait for motion to be complete PAA 0 Move to absolute position 0 BGA Begin Motion on A axis AMA Wait for motion to be complete JP LOOP Continually loop to make back and forth motion EN End main program COMINT Interrupt Routine JP STOP P2CH 0 Check for S stop motion JP PAUSE P2CH 1 Check for P pause motion JP RESUME P2CH 2 Check for R resume motion EN1 1 Do nothing STOP Routine for stopping motion STA ZS EN Stop motion on A axis Zero program stack End Program PAUSE Routine for pausing motion rate SPA Save current speed setting of A axis motion SPA 0 Set speed of A axis to zero allows for pause EN1 1 Re enable trip point and communication interrupt RESUME Routine for resuming motion SPA rate Set speed on A axis to original speed EN1 1 Re enable trip point and communication interrupt For additional information see section on Using Communication Interrupt Example Ethernet Communication Error This simple program executes in the DMC 41x3 and indicates via the serial port when a communication handle fails By monitoring the serial port the user can re establish communication if needed LOOP Simple program loop JP LOOP EN TCPERR Ether
311. tage periodically and assigns its value to the variable VIN To get a speed of 200 000 ct sec for 10 volts we select the speed as Speed 20000 x VIN Chapter 7 Application Programming e 167 DMC 41x3 User Manual The corresponding velocity for the motor is assigned to the VEL variable Instruction fA JGO BGX B VIN AN 1 VEL VIN 20000 JG VEL JP B EN Position Control by Joystick This system requires the position of the motor to be proportional to the joystick angle Furthermore the ratio between the two positions must be programmable For example if the control ratio is 5 1 it implies that when the Joystick voltage is 5 Volts corresponding to 1028 counts the required motor position must be 5120 counts The variable V3 changes the position ratio INSTRUCTION FUNCTION TA Label V3 5 Initial position ratio DPO Define the starting position JGO Set motor in jog mode as zero BGX Start B VIN AN 1 Read analog input V2 V1 V3 Compute the desired position V4 V2 TPX TEX Find the following error V5 V4 20 Compute a proportional speed JG V5 Change the speed JP B Repeat the process EN End Backlash Compensation by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective way to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method descr
312. tances the reason for using REM statements instead of NO or is to save program memory The other benefit to using REM commands comes when command execution of a loop thread or any section of code is critical Although they do not take much time NO and comments still take time to process So when command execution time is critical REM statements should be used The 2 examples below demonstrate the difference in command execution of a loop containing comments Chapter 7 Application Programming e 143 DMC 41x3 User Manual The GalilTools software will treat an apostrophe comment different from an NO when the compression algorithm is activated upon a program download line gt 80 characters or program memory gt 2000 lines In this case the software will remove all comments as part of the compression and it will download all NO comments to the controller Note Actual processing time will vary depending upon number of axes communication activity number of threads currently executing etc fa i 0 initialize a counter t TIME set an initial time reference loop NO this comment takes time to process this comment takes time to process i i l this comment takes time to process JP loop i lt 1000 MG TIME t display number of samples from initial time reference EN When executed on a DMC 4123 the output from the above program returned a 116 which indicates that it took 116 samples TM 1000 to process the commands from t TIM
313. ters See examples below for recommended syntax 2 Do not use spaces in expressions containing 3 Global variables MUST be assigned prior to any use in subroutines where variables are passed by reference 4 Please refer to the JS command in the controller s command reference for further important information Example A Simple Adding Function Add JS SUM 1 2 3 4 5 6 7 8 MG JS EN SUM EN at bt ct dt et ft gt h Executed program from programl dmc 36 0000 Example Variable and an Important Note about Creating Global Variables Var value 5 global 8 JS SUM amp value 1 2 3 4 5 6 7 MG value MG JS EN SUM a b c d e f g h global EN a Executed program from program2 dmc 36 0000 36 0000 Chapter 7 Application Programming e 141 DMC 41x3 User Manual Example Working with Arrays Array DM speeds 8 DM other 256 JS zeroAry speeds 0 JS zeroAry other 0 EN zeroAry a b 0 b b 1 JP zeroAry b lt a 1 EN Example Abstracting Axes Axes JS runMove 0 10000 1000 100000 100000 MG Position JS EN runMove a a PR a b SPeae g AC a d DCva e BG a MC a EN TP a Example Local Scope Local JS POWER 2 2 MG JS JS POWER 2 16 MG JS JS POWER 2 8 MG JS POWER gel F b 0 EN 1 ENDIF F b 0 ELSE d 0 ENDIF PWRHLPR c c a DMC 41x3 User Manual Chapter 7 Application Programming e 142 b b IP PW
314. the analog inputs on the Galil controller can be used to close a position loop they have a very high bandwidth and will therefor read noise that comes in on the analog input Often when an analog input is used in a motion control system but not for closed loop control the higher bandwidth is not required In this case a simple digital filter may be applied to the analog input and the output of the filter can be used for in the motion control application This example shows how to apply a simple single pole low pass digital filter to an analog input This code is commonly run in a separate thread XQ filt 1 example of executing in thread 1 filt REM anl Use this instead of AN 1 anl AN 1 set initial value REM k1 k2 1 this condition must be met REM use division of m 2 n for elimination of round off REM increase kl REM increase k2 k1 32 64 k2 32 64 ATO set initial time reference loop filtered output less filtering more filtering REM time reference last AT 2 1 or ATO anl k1 AN 1 k2 anl1 AT 2 1 JP loop REM calculate filtered output and then way 2 samples from last Chapter 7 Application Programming e 163 DMC 41x3 User Manual Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal which activates the cutter Allowing 100 ms for the cutting completes the cy
315. the value of analog input 5 plus 5 then multiplied by 2 e Variables For applications that require a parameter that is variable the DMC 41x3 provides 510 variables These variables can be numbers or strings A program can be written in which certain parameters such as position or speed are defined as variables The variables can later be assigned by the operator or determined by program calculations For example a cut to length application may require that a cut length be variable Example posx 5000 Assigns the value of 5000 to the variable posx PR posx Assigns variable posx to PR command JG rpmY 70 Assigns variable rpmY multiplied by 70 to JG command Chapter 7 Application Programming e 147 DMC 41x3 User Manual Programmable Variables The DMC 41x3 allows the user to create up to 510 variables Each variable is defined by a name which can be up to eight characters The name must start with an alphabetic character however numbers are permitted in the rest of the name Spaces are not permitted Variable names should not be the same as DMC 41x3 instructions For example PR is not a good choice for a variable name NOTE It is generally a good idea to use lower case variable names so there is no confusion between Galil commands and variable names Examples of valid and invalid variable names are Valid Variable Names posx posi speedZ Invalid Variable Names RealLongName Cannot have more than 8 characters 123 Cannot
316. tion Programming e 131 DMC 41x3 User Manual EN End Define Output Waveform Using AT The following program causes Output 1 to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec fOUTPUT Program label ATO Initialize time reference Bist Set Output 1 LOOP Loop T T0 After 10 msec from reference Clear Output 1 T 40 Wait 40 msec from reference and reset reference Bl Set Output 1 P LOOP Loop End Program Ei C p Aa 5 s YH vs n Using AT WT with non default TM rates By default both WT and AT are defined to hold up program execution for n number of milliseconds WT n or AT n The second field of both AT and WT can be used to have the program execution be held up for n number of samples rather than milliseconds For example WT 400 or WT 400 0 will hold up program execution for 400 msec regardless of what is set for TM By contrast WT 400 1 will hold up program execution for 400 samples For the default TM of 1000 the servo update rate is 976us per sample so the difference between WT n 0 and WT n 1 is minimal The difference comes when the servo update rate is changed With a low servo update rate it 1s often useful to be able to time loops based upon samples rather than msec and this is where the unscaled WT and AT are useful For example MAIN Label TM 250 250us update rate MOVE Label PRX 1000 Position Relative Move BGX Begin Motion MCX Wait for motion to
317. tion e 118 Using the KS Command Step Motor Smoothing When operating with step motors motion smoothing can be accomplished with the command KS The KS command smoothes the frequency of step motor pulses Similar to the command IT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS x y Zw where x y z w is an integer from 0 5 to 128 and represents the amount of smoothing The smoothing parameters x y z w and n are numbers between 0 5and 128 and determine the degree of filtering The minimum value of 0 5 implies the least filtering resulting in trapezoidal velocity profiles Larger values of the smoothing parameters imply heavier filtering and smoother moves Note that KS is valid only for step motors Homing The Find Edge FE and Home HM instructions may be used to home the motor to a mechanical reference This reference is connected to the Home input line The HM command initializes the motor to the encoder index pulse in addition to the Home input The configure command CN is used to define the polarity of the home input The Find Edge FE instruction is useful for initializing the motor to a home switch The home switch is connected to the Homing Input When the Find Edge command and Begin is used the motor will accelerate up to the slew speed and slew until a transition is detected on the Homing line The motor will then decelerate to a stop A high deceleration valu
318. tions unless the motor has more than 5 mH of inductance with a 24V supply or 10 mH of inductance with a 48 volts supply the normal current loop bandwidth option should be chosen AW will return the current loop bandwidth in Hertz DMC 41x3 User Manual A1 AMP 430x0 D3040 D3020 e 220 tj Vertical Horizontal didt Source Scale div Offset div MO TTA Axis A tord 2v ajs E sO Cae Sb amp m iv eu T m MIE j o m ie Tu sO sli Si amp sO v 1 25 amp m xj 4 e 5ms 3 Trigger Channel Ml TA vl Edge v Level 0 1V Mode Repeat v READY d TTA 9 03V TA dt 13 ms 1 dt 74 6 Hz Figure A1 2 Peak Current Operation Chopper Mode The AMP 430x0 can be put into what is called a Chopper mode The chopper mode is in contrast to the normal inverter mode in which the amplifier sends PWM power to the motor of VS In chopper mode the amplifier sends a 0 to VS PWM to the motor when moving in the forward direction and a 0 to VS PWM to the motor when moving in the negative direction This mode is set with the AU command A setting of 0 5 is Chopper mode with normal current bandwidth A setting of 1 5 is Chopper mode with high current bandwidth This mode is useful when using low inductance motors because it reduces the losses due to switching voltages across the motor windings It is recommended to use chopper mode when using motors with 200 500uH inductance
319. to 1 count set W axis error limit to 10 counts DMC 41x3 User Manual Chapter 8 Hardware amp Software Protection e 172 The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position If the absolute value of the error exceeds the value specified by ER the controller will generate several signals to warn the host system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 or OE3 AEN Output Line Switches to Motor Off state The Jump on Condition statement is useful for branching on a given error within a program The position error of X Y Z and W can be monitored during execution using the TE command Encoder Failure detection The encoder failure detection on the controller operates based upon two factors that are user settable a threshold of motor command output OV a time above that threshold OT in which there is no more than 4 counts of change on the encoder input for that axis The encoder failure detection is activated with the OA command When an encoder failure is detected and OA is set to 1 for that axis the same conditions will occur as a position error Conditions for proper operation of Encoder Failure detection The axis must have a non zero KI setting order to detect an encoder failure when the
320. tomatic data capture feature described below Uploading and Downloading Arrays to On Board Memory The GalilTools software is recommended for downloading and uploading array data from the controller The GalilTools Communication library also provides function calls for downloading and uploading array data from the controller to from a buffer or a file Arrays may also be uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A start is the first element of array default 0 end is the last element of array default last element delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 The file is terminated using lt control gt Z lt control gt Q lt control gt D or V Automatic Data Capture into Arrays The DMC 41x3 provides a special feature for automatic capture of data such as position position error inputs or torque This is useful for teaching motion trajectories or observing system performance Up to eight types of data can be captured and stored in eight arrays The capture rate or time interval may be specified Recording can done as a one time event or as a circular continuous recording Command Summary Automatic Data Capture Command Description RA n m o p Selects up to eight arrays for data capture The arrays must be defined with the DM command RD typel type2 type3
321. top at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of HV counts sec When the logic state changes again the motor moves forward in the direction of increasing encoder count at the same speed until the controller senses the index pulse After detection it decelerates to a stop moves back to the index and defines this position as 0 The logic state of the Home input can be interrogated with the command MG HMX This command returns a 0 or 1 if the logic state is low or high respectively The state of the Home input can also be interrogated indirectly with the TS command For examples and further information about Homing see command HM FI FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual Abort Input The function of the Abort input is to immediately stop the controller upon transition of the logic state NOTE The response of the abort input is significantly different from the response of an activated limit switch When the abort input is activated the controller stops generating motion commands immediately whereas the limit switch response causes the controller to make a decelerated stop NOTE The effect of an Abort input is dependent on the state of the off on error function OE Command for each axis If the Off On Error function is enabled for any given axis the motor fo
322. tops Instruction Interpretation PR 1000 Distance SP 20000 Speed DC 100000 Deceleration AC 100000 Acceleration BGA Start Motion Example 3 Multiple Axes Objective Move the four axes independently Instruction Interpretation PR 500 1000 600 400 SP 10000 12000 20000 10000 AC 10000 10000 10000 10000 DC 80000 40000 30000 50000 BGAC BGBD Distances of A B C D Slew speeds of A B C D Accelerations of A B C D Decelerations of A B C D Start A and C motion Start B and D motion Example 4 Independent Moves The motion parameters may be specified independently as illustrated below Instruction Interpretation PR 300 600 Distances of B and C SP 2000 Slew speed of B DC 80000 Deceleration of B AC 100000 Acceleration of B AC 100000 Acceleration of C DC 150000 Deceleration of C BGC Start C motion BGB Start B motion Example 5 Position Interrogation The position of the four axes may be interrogated with the instruction TP Instruction Interpretation Chapter 2 Getting Started e 21 DMC 41x3 User Manual TP Tell position all four axes TPA Tell position A axis only TPB Tell position B axis only TPC Tell position C axis only TPD Tell position D axis only The position error which is the difference between the commanded position and the actual position can be interrogated with the instruction TE Instruction Interpretation TE Tell error all axes TEA Tell error A axis only TEB Tell error B a
323. tor connector is connected or disconnected damage to the amplifier can occur Galil recommends powering the controller and amplifier down before changing the connector and breaking the AC side of the power supply connection in order to power down the amplifier The ELO input may be used to cut power to the motors in an Emergency Stop or Abort situation VIN ACT ERROR POWER outputs a Sm oen GPR TE HIGH POWER OPTIO SOURCE 0018 Er La Figure A6 1 DMC 4143 D4040 BOX4 DMC 4143 with SDM 44040 DMC 41x3 User Manual A6 SDM 44040 D4040 D4020 e 244 Electrical Specifications DC Supply Voltage Max Current per axis Maximum Step Frequency Motor Type Mating Connectors 12 30 VDC 1 4 Amps Phase Amps Selectable with AG command 6 MHz Bipolar 2 Phase POWER A B C D 4 pin Motor Power Connectors On Board Connector 6 pin Molex Mini Fit Jr MOLEX 39 31 0060 4 pin Molex Mini Fit Jr MOLEX 39 31 0040 Terminal Pins MOLEX 44476 3112 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection DC Power Supply Ground VS DC Power A6 SDM 44040 D4040 D4020 e 245 DMC 41x3 User Manual Operation The SDM 44040 should be setup for Active High step pulses MT 2 or MT 2 5 The AG command sets the current on
324. tor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves BEGIN Begin Program count 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec PA 0 Position absolute 0 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec count count 1 Decrement loop counter JP LOOP count gt 0 Test for 10 times thru loop EN End Program Using If Else and Endif Commands The DMC 41x3 provides a structured approach to conditional statements using IF ELSE and ENDIF commands Using the IF and ENDIF Commands An IF conditional statement is formed by the combination of an IF and ENDIF command The IF command has as it s arguments one or more conditional statements If the conditional statement s evaluates true the command interpreter will continue executing commands which follow the IF command If the conditional statement evaluates false the controller will ignore commands until the associated ENDIF command is executed OR an ELSE command occurs in the program see discussion of ELSE command below NOTE An ENDIF command must always be executed for every IF command that has been executed It is recommended that the user not include jump commands inside IF conditional statements since this causes re direction of command execution In this case the command interpreter may not execute an ENDIF command Using the ELSE C
325. touch of a finger Increase the torque level gradually by instructions such as Instruction Interpretation TL 1 0 Increase torque limit to 1 volt TL 9 998 Increase torque limit to maximum 9 998 volts The maximum level of 9 998 volts provides the full output torque Example 9 Interrogation The values of the parameters may be interrogated Some examples Instruction Interpretation KP Return gain of A axis KP Return gain of C axis KP Return gains of all axes Many other parameters such as KI KD FA can also be interrogated The command reference denotes all commands which can be interrogated Example 10 Operation in the Buffer Mode The instructions may be buffered before execution as shown below Instruction Interpretation PR 600000 Distance SP 10000 Speed WT 10000 Wait 10000 milliseconds before reading the next instruction BGA Start the motion Example 11 Using the On Board Editor Motion programs may be edited and stored in the controller s on board memory When the command ED is given from the a terminal such as telnet or hyperterminal the controllers editor will be started It is recommended to use the GalilTools software to download programs to the controller rather than using the ED command The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited The editor provides the line number For example in response to the firs
326. transducers Further I O 1s available if the auxiliary encoders are not being used 2 inputs each axis Dedicated opto isolated inputs are provided for forward and reverse limits abort home and definable input interrupts Commands are sent in ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen and program development using many environments such as Visual Basic C C etc Drivers for Windows XP Vista and 7 32 amp 64 bit as well as Linux are available Chapter 1 Overview e 1 DMC 41x3 User Manual Overview of Motor Types The DMC 41x3 can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Step motors with step and direction signals 3 Other actuators such as hydraulics and ceramic motors For more information contact Galil The user can configure each axis for any combination of motor types providing maximum flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 41x3 achieves superior precision through use of a 16 Bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feed forward an extra pole filter and integration limits The controller is configured by the factory for standard servo motor operation In this configuration the controller provides an analog signal 10 volts to connect to a servo amplifier This connection is described in Chapter 2 Ste
327. troller When these command are entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF and Leading Zeros LZ command For a complete description of interrogation commands see Chapter 5 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by theses interrogation commands BL LE DE PA DP PR EM TN FL VE IP TE TP The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the decimal point using the PF command Position Format is specified by PF m n where m is the number of digits to the left of the decimal point 0 thru 10 and n is the number of digits to the right of the decimal point 0 thru 4 A negative sign for m specifies hexadecimal format Hex values are returned preceded by a and in 2 s complement Hex values should be input as signed 2 s complement where negative numbers have a negative sign The default format is PF 10 0 If the number of decimal places specified by PF is less than the actual value a nine appears in all the decimal places Chapter 7 Application Programming e 157 DMC 41x3 User Manual Example Instruction Interpretation DP21 Define position TPA Tell position 0000000021 Default format PF4 Change form
328. ual Operation of Closed Loop Systems To understand the operation of a servo system we may compare it to a familiar closed loop operation adjusting the water temperature in the shower One control objective is to keep the temperature at a comfortable level say 90 degrees F To achieve that our skin serves as a temperature sensor and reports to the brain controller The brain compares the actual temperature which is called the feedback signal with the desired level of 90 degrees F The difference between the two levels is called the error signal If the feedback temperature is too low the error is positive and it triggers an action which raises the water temperature until the temperature error is reduced sufficiently The closing of the servo loop is very similar Suppose that we want the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the w
329. uire a third axis i e a knife blade to remain tangent to the coordinated motion path To handle these applications the DMC 41x3 allows one axis to be specified as the tangent axis The VM command provides parameter specifications for describing the coordinated axes and the tangent axis VM m n p m n specifies coordinated axes p specifies tangent axis such as X Y Z W p N turns off tangent axis Before the tangent mode can operate it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m n command m defines the scale factor in counts degree and n defines the tangent position that equals zero degrees in the coordinated motion plane The operand TN can be used to return the initial position of the tangent axis Example Assume an XY table with the Z axis controlling a knife The Z axis has a 2000 quad counts rev encoder and has been initialized after power up to point the knife in the Y direction A 180 circular cut is desired with a radius of 3000 center at the origin and a starting point at 3000 0 The motion is CCW ending at 3000 0 Note that the 0 position in the XY plane is in the X direction This corresponds to the position 500 in the Z axis and defines the offset The motion has two parts First X Y and Z are driven to the starting point and later the cut is performed Assume that the knife is engaged with output bit 0 EXAMPLE Example program VM XYZ XY coordinate with Z a
330. unts in the positive direction when the logic state of DI goes high The Digital inputs can be used as high speed position latch inputs see High Speed Position Capture The Latch Function for more information This can be accomplished by connecting a voltage in the range of 5V to 28V into INCOMO of the input circuitry from a separate power supply Controllers with more than 4 axes have an additional 8 general opto isolated inputs inputs 9 16 INCOMI is used for these inputs and is found on the I O E H D Sub connector The grouping is shown in Table 3 1 NOTE INCOMI and LSCOMI for Inputs 9 16 and Limit and Home Switches for axes 5 8 are found on the connectors for the E H axes These are NOT the same INCOMO and LSCOMO for axes 1 4 Chapter 3 Connecting Hardware e 29 DMC 41x3 User Manual Opto Isolated Input Electrical Information Electrical Specifications Input Common INCOM and Digital Input Max Voltage 28 VDC Input Common INCOM and Digital Input Min Voltage 0 VDC Limit Common LSCOM and Limit Home Input Max Voltage 28 VDC Input Command INCOM and Limit Home Input Max Min Voltage 0 VDC Minimum current to turn on Inputs 1 2 mA Minimum current to turn off Inputs once activated hysteresis 0 5 mA Internal Resistance of Inputs xxCOM to Inputs 2 2 KQ 5V INCOMO 2 2K CPU DI 8 1 PS2805 Figure 3 1 Digital Inputs 1 8 DI 8 1 5V INCOM1 CPU DI 16 9 PS2805 Figure 3 2 Digital Inputs 9 16 DI 16 9
331. used Table A4 2 indicates the recommended AUn m settings for 24 and 48 VDC power supplies A4 AMP 435x0 D3540 D3520 e 235 DMC 41x3 User Manual To set the AU command put the axis in a motor off MO state set the preferred AG setting and then set the AU setting To verify that the current loop is stable set the PID s to 0 KP KD and KI and then enable the axis SH An unstable current loop will result in oscillations of the motor or a high frequency buzz from the motor Vsupply VDC Inductance L mH m 24 0 24 L lt 1 1 24 1 lt L lt 2 3 2 24 23 L 42 3 24 42 lt L 4 48 0 48 L lt 24 1 48 24 lt L lt 4 2 2 48 42 lt L lt 7 3 48 7 L 4 Table A4 2 Amplifier Current Loop Gain Settings Setting Peak and Continuous Current TL and TK To set TL and TK for a particular motor find the continuous current and peak current ratings for that motor and divide that number by the amplifier gain For example a particular motor has a continuous current rating of 2 0 A and peak current rating of 5 0 A With an AG setting of 1 the amplifier gain of the AMP 43540 is 0 8A V TL setting 2 0A 0 8A V 2 5V TL n 2 5 TK setting 5 0A 0 8A V 7 5V TK n 6 25 Scope _ NM E Y y serial Horizontal didt Source Scale div Offset div W TTA Axis A torda 2v 2 3 sO im 1 32 gt O sj ej T m sj 0 m IM 1 eu m sO v
332. ut Interrupt function II or use a conditional jump on an input such as JP GO IN 1 1 INPUT AI 1 PR 10000 BGX EN Program Label Wait for input 1 low Position command Begin motion End program Event Trigger Set output when At speed ATSPEED JG 50000 AC 10000 BGX ASX SB1 EN Program Label Specify jog speed Acceleration rate Begin motion Wait for at slew speed 50000 Set output 1 End program Event Trigger Change Speed along Vector Path The following program changes the feed rate or vector speed at the specified distance along the vector The vector distance is measured from the start of the move or from the last AV command VECTOR VMXY VS 5000 VP 10000 20000 VP 20000 30000 VE BGS AV 5000 VS 1000 EN Label Coordinated path Vector position Vector position End vector Begin sequence After vector distance Reduce speed End Event Trigger Multiple Move with Wait This example makes multiple relative distance moves by waiting for each to be complete before executing new moves MOVES PR 12000 SP 20000 AC 100000 BGX AD 10000 SP 5000 AMX WT 200 PR 10000 SP 30000 AC 150000 BGX Label Distance Speed Acceleration Start Motion Wait a distance of 10 000 counts New Speed Wait until motion is completed Wait 200 ms New Position New Speed New Acceleration Start Motion Chapter 7 Applica
333. variable Jump to subroutine Label Dimension array Set variable Loop subroutine Set array element Increment Set array element Increment Conditional statement DMC 41x3 User Manual Appendices e 210 MBF 6 16 632 Configure I O using Modbus function code 16 where MODULE 8 NUMOFIO 2 A the starting register is 632 MODULE 8 number of registers is NUMOFIO 2 and A contains the data EN end CFERR Label MG UNABLE TO ESTABLISH Message CONNECTION EN End Using the equation T O number Handlenum 1000 Module 1 4 Bitnum 1 MG IN 6001 display level of input at handle 6 module 1 bit 2 SB 6006 set bit of output at handle 6 module 2 bit 3 or to one OB 6006 1 AO 608 3 6 set analog output at handle 6 module 53 bit 1 to 3 6 volts MG AN 6017 display voltage value of analog input at handle6 module 5 bit 2 Appendices e 211 DMC 41x3 User Manual DMC 41x3 DMC 40x0 DMC 21x3 Comparison Specification DMC 40x0 DMC 41x3 DMC 21x3 Servo bandwidth Processing power Program Storage Array Storage Variable Storage Number of Labels Encoder Frequency Stepper Frequency Ethernet Connection Box option availability Contour Buffer New commands features Removed Commands Up to 32kHz update rate Up to 16kHz update rate Up to 8kHz update rate 8000 array elements in 30 arrays 2 Wi i Box options available for all Box options available for all
334. ve low step output pulses 2 specifies a stepper motor with active high step output pulses 2 5 specifies a stepper motor with active low step output pulses and reversed direction 2 5 specifies a stepper motor with active high step output pulse and reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought of as a simple Resistor Capacitor single pole filter The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor Use of KS is most applicable when operating in full step or half step operation KS will cause the step pulses to be delayed in accordance with the time constant specified When operating with stepper motors you will always have some amount of stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Puls
335. ve the IP address to the non volatile memory NOTE if multiple boards are on the network use the serial numbers to differentiate them CAUTION Be sure that there is only one BOOT P or DHCP server running If your network has DHCP or BOOT P running it may automatically assign an IP address to the DMC 41x3 controller upon linking it to the network In order to ensure that the IP address is correct please contact your system administrator before connecting the I O board to the Ethernet network The third method for setting an IP address is to send the IA command through the USB port Note The IA command is only valid if DHO is set The IP address may be entered as a 4 byte number delimited by commas industry standard uses periods or a signed 32 bit number e g IA 124 51 29 31 or IA 2083724575 Type in BN to save the IP address to the DMC 41x3 non volatile memory Chapter 4 Software Tools and Communication e 49 DMC 41x3 User Manual NOTE Galil strongly recommends that the IP address selected is not one that can be accessed across the Gateway The Gateway is an application that controls communication between an internal network and the outside world The third level of Ethernet addressing is the UDP or TCP port number The Galil board does not require a specific port number The port number is established by the client or master each time it connects to the DMC 41x3 board Typical port numbers for applications are
336. via the GalilTools software see the GalilTools user manual http www galilmc com support manuals galiltools index html Communicating through the USB Programming Port Connect the DMC 41x3 USB port to your computer via a Male Type A Male Type B USB cable The port will be identified as a new Serial port The USB port is designed for basic communication to the controller Higher speed communication such as scope captures and continuous polling of data should be done through the Ethernet port Using GalilTools Software for Windows Registering controllers in the Windows registry is no longer required when using the GalilTools software package A simple connection dialog box appears when the software is opened that shows all available controllers The serial ports are listed as COMn communication speed ex COM3 115200 The default USB communication speed on the DMC 41x3 is 115200Bps For more information on establishing communication to the controller via the GalilTools software see the GalilTools user manual http www galilmc com support manuals galiltools index html Sending Test Commands to the Terminal After you connect your terminal press lt return gt or the lt enter gt key on your keyboard In response to carriage return lt return gt the controller responds with a colon Now type TPA lt RETURN gt This command directs the controller to return the current position of the A axis The controller should respo
337. w DT value Consider for example the trajectory shown in Figure 6 16 The position X may be described by the points Point 1 X 0 at T 0ms Point 2 X 48 at T 4ms Point 3 X 288 at T 12ms Point 4 X 336 at T 28ms The same trajectory may be represented by the increments Increment 1 DX 48 Time 4 DT 2 Increment 2 DX 240 Time 8 DT 3 Increment 3 DX 48 Time 16 DT 4 When the controller receives the command to generate a trajectory along these points it interpolates linearly between the points The resulting interpolated points include the position 12 at 1 msec position 24 at 2 msec etc The programmed commands to specify the above example are A CMX Specifies X axis for contour mode CD 48 2 Specifies first position increment and time interval 2 ms CD 240 3 Specifies second position increment and time interval 2 ms CD 48 4 Specifies the third position increment and time interval 2 ms CD 0 0 End Contour buffer wait UP Wait CM lt gt 511 Wait until path is done E Chapter 6 Programming Motion e 105 DMC 41x3 User Manual POSITION COUNTS e c reel iti cans epee tc Base 240 192 96 d s iuuenes TIME ms o 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 16 The Required Trajectory Additional Commands _CM gives the amount of space available in the contour buffer 511 maximum Zero parameters for DT followed by zero parameters for CD will exit the contour mode If no
338. ween the Axes 1 4 amplifier and the Axes 5 8 amplifier This allows the 2 internal amplifiers to be powered at separate voltages If the ISCNTL option is NOT ordered on the DMC 41x3 the amplifier with the higher bus voltage will automatically power the controller The amplifier with the higher voltage and the voltage level does not have to be specified during time of purchase as long as the voltage falls within the range of 20 80VDC This option is only valid on the 5 8 Axes amplifier board Part number ordering example DMC 4183 BOX8 D3040 D3040 ISAMP SR90 SR 49000 Shunt Regulator Option The SR 49000 is a shunt regulator for the DMC 41x3 controller and internal amplifiers This option is highly recommended for any application where there is a large inertial load or a gravitational load The SR 49000 is installed inside the box of the DMC 41x3 controller The Shunt Regulator activates when the voltage supplied to the amplifier rises above 90V When activated the power from the power supply is dissipated through a 5Q 20W power resistor The SR 49000 can be ordered to activate at different voltages 33V 66V and 90V are all standard ordering options and can be ordered as SR33 SR66 and SR90 respectively Part number ordering example DMC 4143 BOX8 D3040 SR90 100mA 100mA Maximum Current output for AMP 43140 The 100mA option configures the AMP 43140 D3140 for 10mA V gain with a maximum current output of 100mA This option i
339. xis only TEC Tell error C axis only TED Tell error D axis only Example 6 Absolute Position Objective Command motion by specifying the absolute position Instruction Interpretation DP 0 2000 Define the current positions of A B as 0 and 2000 PA 7000 4000 Sets the desired absolute positions BGA Start A motion BGB Start B motion After both motions are complete the A and B axes can be command back to zero PA 0 0 Move to 0 0 BGAB Start both motions Example 7 Velocity Control Objective Drive the A and B motors at specified speeds Instruction Interpretation JG 10000 20000 Set Jog Speeds and Directions AC 100000 40000 Set accelerations DC 50000 50000 Set decelerations BGAB Start motion after a few seconds command JG 40000 New A speed and Direction TVA Returns A speed and then JG 20000 New B speed TVB Returns B speed These cause velocity changes including direction reversal The motion can be stopped with the instruction ST Stop Example 8 Operation Under Torque Limit The magnitude of the motor command may be limited independently by the instruction TL DMC 41x3 User Manual Chapter 2 Getting Started e 22 Instruction Interpretation TL 0 2 Set output limit of A axis to 0 2 volts JG 10000 Set A speed BGA Start A motion In this example the A motor will probably not move since the output signal will not be sufficient to overcome the friction If the motion starts it can be stopped easily by a
340. y An Example Consider the velocity and position profiles shown in Figure 6 17 The objective is to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe the position displacement in terms of A counts in B milliseconds we can describe the motion in the following manner A 0 1 cos 2z B X 4L Asin 27 B Note is the angular velocity X is the position and T is the variable time in milliseconds In the given example A 6000 and B 120 the position and velocity profiles are X SOT 6000 27 sin 2x T 120 Note that the velocity in count ms is 50 1 cos 2x T 120 Figure 6 17 Velocity Profile with Sinusoidal Acceleration The DMC 41x3 can compute trigonometric functions However the argument must be expressed in degrees Using our example the equation for X is written as X 50T 955 sin 3T A complete program to generate the contour movement in this example is given below To generate an array we compute the position value at intervals of 8 ms This 1s stored at the array POS Then the difference between the positions is computed and is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example INSTRUCTION INTERPRETATION POINTS Program defines X points DM POS 16 Allocate memory DM DIF 15 C 0 Set initial conditions C is index T 0 T is time i
341. y incidental or consequential damages Hardware Protection The DMC 41x3 includes hardware input and output protection lines for various error and mechanical limit conditions These include Output Protection Lines Amp Enable This signal goes low when the motor off command is given when the position error exceeds the value specified by the Error Limit ER command or when off on error condition is enabled OE1 and the abort command is given Each axis amplifier has separate amplifier enable lines This signal also goes low when the watch dog timer is activated or upon reset NOTE The standard configuration of the AEN signal is TTL active low Both the polarity and the amplitude can be changed To make these changes see section entitled Configuring the Amplifier Enable Circuit in Chapter 3 Error Output The error output is a TTL signal which indicates an error condition in the controller This signal is available on the interconnect module as ERR When the error signal is low this indicates an error condition and the Error Light on the controller will be illuminated For details on the reasons why the error output would be active see Error Light Red LED in Chapter 9 Chapter 8 Hardware amp Software Protection e 171 DMC 41x3 User Manual Input Protection Lines General Abort A low input stops commanded motion instantly without a controlled deceleration For any axis in which the Off On Error function is enabled the amp
342. y to have communications with the motion controller It is also necessary to have the motor hardware connected and the amplifier powered to begin the setup phase After the encoders and motor leads are connected the controller and amplifier need to be configured correctly in software Take all appropriate safety precautions For example set a small error limit ER 1000 a low torque limit TL 3 and set off on Error to 1 for all axes OE 1 The AMP 430x0 requires that the hall commutation for a brushless motor be manually configured Details on how to determine the correct commutation for a brushless motor see Application Note 5489 http www galilmc com support appnotes miscellaneous note5489 pdf Brush Amplifier Operation The AMP 43040 and AMP 43020 also allow for brush operation To configure an axis for brush type operation connect the 2 motor leads to Phase A and Phase B connections for the axis Connect the encoders homes and limits as required Set the controller into brush axis operation by issuing BR n n n n By setting n 1 the controller will operate in brushed mode on that axis For example BR 0 1 0 0 sets the Y axis as brush type all others as brushless If an axis is set to brush type the amplifier has no need for the Hall inputs These inputs can subsequently be used as general use inputs queried with the QH command Setting Amplifier Gain and Current Loop Bandwidth AG command Select the amplifier gain that is a
343. y with the required amplifier enable signals for a particular system contact Galil directly for more information Step C Connect the encoders For stepper motor operation an encoder is optional For servo motor operation if you have a preferred definition of the forward and reverse directions make sure that the encoder wiring is consistent with that definition The DMC 41x3 accepts single ended or differential encoder feedback with or without an index pulse The encoder signals are wired to that axis associated 26pin DSub connector found on top of the controller The signal leads are labeled MA channel A MB channel B and MI For differential encoders the complement signals are labeled MA MB and MI For complete pin out information see in the Appendices NOTE When using pulse and direction encoders the pulse signal is connected to MA and the direction signal is connected to MB The controller must be configured for pulse and direction with the command CE See the command summary for further information on the command CE Step D Verify proper encoder operation Start with the A encoder first Once it is connected turn the motor shaft and interrogate the position with the instruction TPA lt return gt The controller response will vary as the motor is turned At this point if TPA does not vary with encoder rotation there are three possibilities 1 The encoder connections are incorrect check the wiring as necessary
344. ying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands are sent in ASCII The DMC 41x3 instruction set is BASIC like and easy to use Instructions consist of two uppercase letters that correspond phonetically with the appropriate function For example the instruction BG begins motion and ST stops the motion Commands can be sent live over the communications port for immediate execution by the DMC 41x3 or an entire group of commands can be downloaded into the DMC 41x3 memory for execution at a later time Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter This section describes the DMC 41x3 instruction set and syntax A summary of commands as well as a complete listing of all DMC 41x3 instructions is included in the Command Reference http www galilmc com support manuals php Command Syntax ASCII DMC 41x3 instructions are represented by two ASCII upper case characters followed by applicable arguments A space may be inserted between the instruction and arguments A semicolon or lt return gt is used to terminate the instruction for processing by the DMC 41x3 command interpreter NOTE If you are using a Galil terminal program commands will not be processed until an lt return gt command is given This allows the user to separate many commands on a single line

DMC-41x3 User Manual - Ultra Sistemas de Controle

Contents

Download Pdf Manuals

Related Search

Related Contents