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DMC-40x0 User Manual

1. A cates tae aaa Independent Axis Positioning Command Summary Independent Axis 79 Operand Summary Independent AXis eriiic 79 Independent Joggitg vivan ist dic Command Summary Jogging Operand Summary Independent AXIS occcccococoncnnonencnneninancnnenes 82 Position 6s AT pill io lll ne ree 82 Example Motion 2 84 Example Motion 4 Trip Points Command Summary Position Tracking Mode cccccoccocccnncnnss 87 Linear Interpolation Mode Specifyina Linear Segmento 87 Command Summary Linear Interpolation 89 Operand Summary Linear Interpolation 89 Example Linear Move asrasin 290 Example Multiple Moves el Vector Mode Linear and Circular Interpolation MotiON cccocccocnonocencnnonenconacancancanccnos 92 Specifying the Coordm te Plane ais rc 92 Specifying Vector Segments ad Additonal commands Command Summary Coordinated Motion Sequence 95 Operand Summary Coordinated Motion Sequence a ELSA A lea sgt nab oneuresetie 96 Ramped DESTA ld 97 Example Electronic Gearing Over a Specified Interval 98 Command Summary Electronic Gearing 229 Example Simple Master Slave a99 Example Elecitonie Gearing counters iia 99 Example Gantry Mode ssl ia 99 Electronic Cam Command Summary Electronic CAM oocccccononenconecnacanccnccnnas 104 Operand Summary Elect
2. Using If Else and Endif Commands SUDOVE S pps 143 Stack Maniprlat n OOo nen PES Oe renee Peer 144 AOS AR RUNG bs 144 Automatic Subroutines for Monitoring Conditions 144 JS Subroutine Stack Variables Ma b c d e E g h 148 General Program Flow and Timing information Mathematical and Functional Expressing crac asia iio ido crisis 153 Mathematical Operators 153 Bit Wise Operators MES Pinc UoN in N 154 Defining Arrays Assionm nt of Array PMs sp ip nana 158 Automatic Data Capture into Arrays a159 De allocating Array Space Input of Data Numeric and String Input Of Dota poli Operator Data Bitty Mode ji Using Communication Interrupt ia Quiputof Data Numeric arid SUE vin carino iria ii ais E 2 eee eee ee eee DMC 40x0 Contents y Displaying Variables and Arays inicia rr ii 165 Interrogation Commands io 165 Formatting Variables and Array Elements 166 Converting to User Units sisi ico Hardware 10 is Dieta l Caps a DA pa The Auxiliary Encoder Inputs s Input Interrupt Function ua AAA AN Extended I O of the DMC 40x0 Controller Configuring the I O of the DMC 40x0 essere 171 Saving the State of the Outputs in Non Volatile Memory 172 Accessing Extended I O Example Applications Wire Cullen suc ds A
3. A5 CMB 41012 C012 e 255 DMC 40x0 User Manual RS 422 Auxiliary Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option Pin 1 2 3 4 5 6 7 8 9 Ethernet 100 BASE T 10 BASE T Kycon GS NS 88 3 5 Pin Signal 1 TXP 2 TXN 3 RXP 4 NC 5 NC 6 RXN 7 NC 8 NC 10 BASE 2 AMP 227161 7 10 BASE F HP HFBR 1414 TX Transmitter HP HFBR 2416 RX Receiver DMC 40x0 User Manual A5 CMB 41012 C012 e 256 Jumper Description for CMB 41012 Jumper Function If jumpered Communications Reserved When controller is powered on or reset Amplifier Enable lines will be in a Motor Off state A SH will be required to re enable the motors Baud Rate setting see table below Baud Rate setting see table below Used to upgrade controller firmware when resident firmware 1s corrupt Master Reset enable Returns controller to factory default settings and erases EEPROM Requires power on or RESET to be activated Baud Rate Jumper Settings 19 2 BAUD RATE ON 9600 ON 19200 OFF 38400 OFF 115200 LCD Description In the default state the LCD provides the status information for the number of axes available on the controller This automatic LCD status update can also be disabled and text can be written directly to the display with the
4. 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 DMC 40x0 User Manual Chapter 6 Programming Motion e 80 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 cts sec DC 20000 20000 Specify X Z deceleration of 20000 cts sec JG 50000 25000 Specify jog speed and direction for X and Z axis BG X Begin X motion AS X Wait until X is at speed BG Z Begin Z motion EN Example 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 Jo
5. Appendices e 209 DMC 40x0 User Manual 4 RTS 3 TXD 2 RXD 1 CTS 5 GND Controller 5V 8 CTS 2 RXD 3 TXD 7 RTS 5 GND 9 Jumper APWR if required Pin Out Description for DMC 40x0 Outputs Motor Command Amplifier Enable PWM Step PWM Step Sign Direction Error Output 1 Output 8 Output 9 Output 16 DMC 4050 thru 4080 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 Magnitude In the Inverter mode the PWM 64kHz signal is 2 duty cycle for full negative voltage 50 for 0 Voltage and 99 8 for full positive voltage 64kHz Switching Frequency In the Sign Magnitude Mode MT1 5 the PWM 128 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 128kHz Switching Frequency For stepper motors The STEP OUT pin produces a series of pulses for inp
6. DMC 40x0 Contents e vi AMP Internal Amplifier Options essari 207 Power Connectors for the DMCAOx0 susunana rte rain 208 DE E A Tere eer nee Merrie E reer Tree Molex Part Numbers Used ja Cable Connections Tor DIC cocine arto tea ocio aiaia 209 Standard RS 232 Specifications casaria DMC 40x0 Serial Cable Specifications a PisOtt Description for DMC 400 spin ti 211 Configuring the Amplifier Enable Clroult spp sis 213 ICM 42000 and ICM 42100 DMC 4040 Steps 1 and 2 213 DMC 4080 Steps 1 and 2 z215 DMC 4040 and DMC 4080 Step 3 at LE DMC 4040 Steps 4 and 5 224 DMC 4080 Steps 4 and 5 226 Coordinated Motion Mathematical Amalysis cssssssssssessetsesseeseessesesseseeseeneets 228 Example Communicating with OPTO 22 SNAP B3000 ENET 23l DMC 40x0 DMC 2200 CompaliSOM ccecccconoconcnncnenconencnenccnanenanaso 2233 List of Other Publications 234 Training Seminars 234 COMAS asa 235 SERAN TS A A A A thane e A 236 Integrated Components 237 OA A N dada tauasmianSeereraaeeleenanes 237 Al AMP 430x0 D3040 D3020 2 and 4 axis 500W Servo DriV8S ccccococcnocnonencncnnonencnncnanoncccinencnnccnos 237 A2 AMP 43140 D3140 4 axis 20W Linear Servo Drives 237 A3
7. DMC 40x0 User Manual Chapter 2 Getting Started e 14 http www galilmc com products software galiltools html All other Galil software is also available for download at the Galil software downloads page http 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 Step 4 Connect 20 80VDC 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 40x0 Power Connections WARNING Dangerous voltages current temperatures 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 light indicator should go on when power is applied Step 5 Establish Communications with Galil Software Communicating through an Ethernet connection The DMC 40x0 motion controller is equipped with DHCP If the co
8. DMC 40x0 User Manual A6 ICM 42000 1000 e 260 ICM 42000 Encoder 15 pin HD D Sub Connector Female Pin ICM 42000 Analog 15 pin D sub Connector Male Pin o o a a aj u Jo nj AJN Label MI MB MA AB GND s s gt HALA gt gt gt gt ies HALB HALC 5V Description T Index Pulse Input B Main Encoder Input A Main Encoder Input B Aux Encoder Input Digital Ground I Index Pulse Input B Main Encoder Input A Main Encoder Input A Aux Encoder Input A Channel Hall Sensor A Aux Encoder Input B Aux Encoder Input B Channel Hall Sensor C Channel Hall Sensor 5V 1 2 3 4 5 6 7 8 9 ATR ui Label AGND All AB AIS AI7 AGND 12V 5V AGND AD AI4 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 A6 ICM 42000 1000 e 261 DMC 40x0 User Manual Jumper Description for ICM 42000 Function If jumpered Connect AECOM1 or AECOM2 to Digital Ground Connect AECOM1 or AECOM2 to Controller 5V Connect AECOM1 or AECOM2 to Controller 12V Connect AECOM1 to AEC pin on External Driver D Sub Connect AECOM2 to AEC2 pin on External Driver D Sub Jumper Amplifier Enable
9. ED 3 Edit Line 3 003 AMX PR5000 BGX Add After Motion Done lt cntrl gt Q Quit Edit Mode XQ A Execute A Program Flow Commands The DMC 40x0 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 40x0 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 Chapter 7 Application Programming e 135 DMC 40x0 User Manual The DMC 40x0 provides several event triggers that cause the program sequencer to halt until the specified event occurs Normally a program is automatically executed sequentially one line at a time When an event trigger instruction is decoded however the actual program sequence is halted The program sequence does not continue until the event trigger is tripped For example the motion complete trigger can be used to separate two move sequences in a program The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence In this way the controller can make decisions based on its own status or external events w
10. For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 Power Supply Ground 3 VS DC Power 4 VS DC Power Motor Connector 1 Motor Lead A 2 Motor Lead A A2 AMP 43140 D3140 e 245 DMC 40x0 User Manual Operation Using External Amplifiers Use connectors on top of 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 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 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 motor 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 amplif
11. BI 6 or BIC 6 Step 8a Connect Standard Servo Motors The following discussion applies to connecting the DMC 40x0 controller to standard servo motors Chapter 2 Getting Started e 19 DMC 40x0 User Manual 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 signal of 10 volts should run the motor at the maximum required speed For Galil amplifiers see Integrated 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 7 Before connecting the motor amplifiers to the controller read the following discussion on setting Error Limits and Torque Limits Note that this discussion only uses the 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 lt return gt Sets error limit on the A axis to be 2000 encoder counts OE 1 lt return gt Disables A axis amplifier when excess position error exists If the motor runs away and creates a posit
12. AXIS A AXIS A AXIS A 00000000 000000000 123456 5V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn V 12V 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn V AMP ENABLE POWER PIN 20 10K CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn V AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware e 45 DMC 40x0 User Manual AXIS A S 45V o 5V o CPU AEN HIGH AMP ENABLE o be fd pe SOURCING 08 MOn 0V ay PIN 2 10K 123456 8 H12V 12V CPU AEN HIGH AMP ENABLE SHn 5V AEN TO DRIVE SOURCING MOn 0V PIN 2 10K lt 0 AMP ENABLE POWER g 26 PIN 20 T 0 ISOLATED SUPPLY 999 CPU AEN HIGH AMP ENABLE 992 SHn 5V AEN TO DRIVE SOURCING 080 i MOn 0V PIN 2 10K AMP ENABLE RETURN PIN 11 DMC 40x0 User Manual Chapter 3 Connecting Hardware e 46 5V LOW AMP ENABLE SOURCING 12V LOW AMP ENABLE SOURCING ISOLATED SUPPLY LOW AMP ENABLE SOURCING AXIS A AXIS A o AXISA o o 0 0 o 0 0 0 0 0 0 0 0 0 0 0 0 0 0000000 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 SZ AMP ENABLE POWER 45V PIN 20 CPU AEN AEN TO DRIVE PIN 2 SHn 5V MOn 0V 10K AMP ENABLE RETURN PIN 11 Chapter 3 Connecting Hardware e 47 DMC 40x0 User Manual Chapter 4 Software Tools and Communication Introduction The default configuration DMC 40x0 has
13. Note See ICM 42000 and ICM 42100 Amplifier Enable Circuit in Chapter 3 and Configuring the Amplifier Enable Circuit in the Appendix for more information DMC 40x0 User Manual A6 ICM 42000 1000 e 262 A7 1CM 42100 1100 Description The ICM 42100 option resides inside the DMC 40x0 enclosure and accepts sinusoidal encoder signals instead of digital encoder signals as accepted by the ICM 42000 The ICM 42100 provides interpolation of up to four 1 volt differential sinusoidal encoders resulting in a higher position resolution The AFn command selects sinusoidal interpolation where n specifies 2 interpolation counts per encoder cycle n 5 to 12 For example if the encoder cycle is 40 microns AF10 results in 2 1024 counts per cycle or a resolution of 39 nanometers per count With the ICM 42100 the sinusoidal encoder inputs replace the main digital encoder inputs The ICM 42100 provides a 15 pin D sub connector for the encoders on each axis a 15 pin D sub for analog inputs a 44 pin D sub for I O and a 44 pin D sub for the motor command signals Two ICMs are required for 5 thru 8 axis controllers Note Hardware Rev B of the the ICM 42100 supports the use of standard differential quadrature encoders for axes that will not be using the sinusoidal encoders A standard ICM 42100 does not support the use of single ended quadrature encoders Contact Galil if a single ended quadrature encoder is required when using the ICM 421
14. This chapter describes the inputs and outputs and their proper connection Using Optoisolated Inputs Limit Switch Input The forward limit switch FLSx inhibits motion in the forward direction immediately upon activation of the switch The reverse limit switch RLSx inhibits motion in the reverse direction immediately upon activation of the switch If a limit switch is activated during motion the controller will make a decelerated stop using the deceleration rate previously set with the SD command The motor will remain on in a servo state after the limit switch has been activated and will hold motor position When a forward or reverse limit switch is activated the current application program that is running in thread zero will be interrupted and the controller will automatically jump to the 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 This usually involves physically opening the tripped switch Any attempt at further motion before the logic state has been reset will result in the following error 022 Be
15. the notch parameters by the frequency terms The poles and zeros have a frequency in Hz selected by the command NF The real part of the poles is set by NB and the real part of the zeros is set by NZ The most simple procedure for setting the notch filter identify the resonance frequency and set NF to the same value Set NB to about one half of NF and set NZ to a low value between zero and 5 ZOH The ZOH or zero order hold represents the effect of the sampling process where the motor command is updated once per sampling period The effect of the ZOH can be modeled by the transfer function H s 1 1 sT 2 If the sampling period is T 0 001 for example H s becomes H s 2000 s 2000 However in most applications H s may be approximated as one This completes the modeling of the system elements Next we discuss the system analysis System Analysis To analyze the system we start with a block diagram model of the system elements The analysis procedure is illustrated in terms of the following example Consider a position control system with the DMC 40x0 controller and the following parameters K 0 1 Nm A Torque constant J 2 10 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 M
16. 0V p LTV8441 Amp Enable Output to Drive AENn RP6 820 Ohm fe El GND a U AECOM1 JP2 2 2 GND E AEC2 AECOM2 Figure 3 4 Amplifier Enable Circuit Sinking Output Configuration Sinking Configuration pin1 of LTV8441 chip in pin2 of socket U4 Logic State JP1 SV HAEN Default Configuration SV AECOM1 SV LAEN SV AECOM1 12V HAEN 12V AECOM1 12V LAEN 12V AECOM1 Isolated 24V HAEN Isolated 24V LAEN For 24V isolated enable tie 24V of external power supply to AEC1 at the D sub tie common return to AEC2 Replace RP6 with a 4 7 KQ resistor pack For Axes A D AEC1 and AEC2 are located on the EXTERNAL DRIVER A D D Sub connector For Axes E H AEC1 and AEC2 are located on the EXTERNAL DRIVER E H D Sub connector Note AEC1 and AEC2 for axes A D are NOT connected to AEC1 and AEC2 for axes E H AECI AECOM1 AECI AECOM1 JP2 GND AECOM2 GND AECOM2 GND AECOM2 GND AECOM2 AEC2 AECOM2 AEC2 AECOM2 RP2 square pin next to RP2 label is 5V Dot on R pack next to RP2 label Dot on R pack opposite RP2 label Dot on R pack next to RP2 label Dot on R pack opposite RP2 label Dot on R pack next to RP2 label Dot on R pack opposite RP2 label Table 3 2 Sinking Configuration DMC
17. SP 20000 20000 AC 200000 00000 BG X AD 2000 BG Y EN This program corresponds to the velocity profiles shown in Fig 10 3 Note that the profiled positions show where the motors must be at any instant of time Finally it remains up to the servo system to verify that the motor follows the profiled position by closing the servo loop The following section explains the operation of the servo system First 1t is explained qualitatively and then the explanation is repeated using analytical tools for those who are more theoretically inclined DMC 40x0 User Manual Chapter 10 Theory of Operation e 186 X VELOCITY Y VELOCITY X POSITION Le eee ase Y POSITION TIME Figure 10 3 Velocity and Position Profiles Chapter 10 Theory of Operation e 187 DMC 40x0 User Manual 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 a
18. Step A Connect the motor to the amplifier with no connection to the controller Consult the amplifier documentation for instructions regarding proper connections Connect and turn on the amplifier power supply If the amplifiers are operating properly the motor should stand still even when the amplifiers are powered up Step B Connect the amplifier enable signal Before making any connections from the amplifier to the controller you need to verify that the ground level of the amplifier is either floating or at the same potential as earth WARNING When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground serious damage may result to the computer controller and amplifier If you are not sure about the potential of the ground levels connect the two ground signals amplifier ground and earth by a 10 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 When configured with the ICM 42000 or ICM 42100 this signal is labeled AENA for the A axis and is found on the 15 pin Dsub connector associated with the A axis if configured with the ICM 42200 the AENA signal is located on the 26 pin Dsub associated with the A axis Note that many amplifiers designate this signal as the INHIBIT signal Use the command M
19. USER MANUAL DMC 40x0 Manual Rev 1 0i By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Rev 6 10 Using This Manual This user manual provides information for proper operation of the DMC 40x0 controller A separate supplemental manual the Command Reference contains a description of the commands available for use with this controller Your DMC 40x0 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 al El 0 408 Attention Pertains to controllers with more than 4 axes Please note that many examples are written for the DMC 4040 four axes controller or the DMC 4080 eight axes controller Users of the DMC 4030 3 axis controller DMC 4020 2 axes controller or DMC 4010 1 axis controller should note that the DMC 4030 uses the axes denoted as XYZ the DMC 4020 uses the axes denoted
20. 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 Loop1 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 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 Chapter 7 Application Programming e 133 DMC 40x0 User Manual The program above is executed with the instruction XQ TASK2 0 which designates TASK2 as the main thread i e Thread 0 TASK1 is executed within TASK2 Debugging Programs The DMC 40x0 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 w
21. 180 tan 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 40x0 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 Wc with a phase margin PM The system parameters are assumed known The design procedure is best illustrated by a design example Consider a system with the following parameters K Nm A Torque constant J 2 10 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 40x0 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 0 500 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
22. ActiveX Toolkit Includes a terminal control for sending commands and editing programs a polling window for displaying responses from the controller such as position and speed a storage scope control for plotting real time trajectories such as position versus time or X versus Y a send file control for sending contour data or vector DMC files a continuous array capture control for data collection and for teach and playback a graphical display control for monitoring a 2 D motion path a diagnostics control for capturing current configurations a display control for input and output status a vector motion control for tool offsets and corner speed control For more detailed information on the ActiveX Toolkit please refer to the user manual at http www galilmc com support manuals activex pdf DMCWin Programmers Toolkit Galil recommends the GalilTools Communication Library for all new applications DMCWin is a programmer s toolkit for C C and Visual Basic users The toolkit includes header files for the Galil communications API as well as source code and examples for developing Windows programs that communicate to Galil Controllers The Galil communications API includes functions to send commands download programs download upload arrays access the data record etc For a complete list of all the functions refer to the DMCWin user manual at http www galilmc com support manuals dmcwin pdf This software package is free
23. For example when operating with servo motors the trippoint AM After Motion is used to determine when the motion profiler is complete and is prepared to execute a new motion command However when operating in stepper mode the controller may still be generating step pulses when the motion profiler is complete This is caused by the stepper motor smoothing filter KS To understand this consider the steps the controller executes to generate step pulses First the controller generates a motion profile in accordance with the motion commands Second the profiler generates pulses as prescribed by the motion profile The pulses that are 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 there will always be some amount of stepper motor smoothing The default value for KS is 1 313 which corresponds to a time constant of 3 939 sample periods Fourth the output of the stepper smoothing filter is buffered and is available for input to
24. Label Description 1 AGND Analog Ground 2 All Analog Input 1 3 Analog Input 3 4 Analog Input 5 5 AI7 Analog Input 7 6 AGND Analog Ground 8 5V 5V 9 AGND Analog Ground 0 Analog Input 2 1 Analog Input 4 2 AI6 Analog Input 6 3 AI8 Analog Input 8 4 N C No Connect 5 12V 12V Jumper Description for ICM 42200 Jumper Label Function If jumpered Q and P Sink Source Selection Sink Source Selection Sink Source Selection HAEN LAEN Selection 5V 12V External Power Selection 5V 12V External Power Selection 6 Note See ICM 42200 Amplifier Enable Circuit in Chapter 3 for detailed information DMC 40x0 User Manual A8 ICM 42200 1200 e 272 Index A PEASE AAEE ALEN EE ERATES EAS AN 86 92 179 181 210 Absolute Post e ra cado AA 26 78 136 141 Absolute Value ll e er id dl e TEE 100 141 153 180 ACCEle ration E E E E 2 24 138 160 166 228 INUA AT NEO 157 Amplifier Er a a ra 179 Amplifier A a da 3 189 193 195 Analog Inputs ir A A iaa 1 4 32 39 81 154 156 176 198 230 ATM A a ro 140 152 Artin atch NN 128 O 1 4 14 77 90 111 134 140 152 156 200 Automatic SUDOR laa dedo 143 TGPER Ro atole dle 147 Ar e o ad Es e ao 98 Ba ada 77 120 176 Ba a TO e 16 49 Begin Mo eo SS 20 23 137 144 155 159 A 1 53 70 73 171 BRAVAS a da ALS 152 Burn 22 48 Burn EEPROM suce 1 Bypassing Optols ola daa ii 37 Ml A dia BEE 173 Circular Interpolati ar S 91 96 158 1
25. MOLEX 39 31 0060 MOLEX 44476 3112 4 pin Molex Mini Fit Jr MOLEX 39 31 0040 Terminal Pins 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 DMC 40x0 User Manual A3 SDM 44040 D4040 e 248 Operation The AG command sets the current on each axis the LC command configures each axis s behavior when holding position and the YA 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 206x0 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 n 1 n 2 n 3 0 5 A 0 75 A default LOA 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
26. Set speeds on A and B axes Begin motion on A and B axes Label B Report A and B axes positions Wait 1000 milliseconds Jump to B End of program Interrupt subroutine Displays the message Stops motion on A and B axes Loop until Interrupt cleared Specify new speeds Wait 300 milliseconds Begin motion on A and B axes Return from Interrupt subroutine The DMC 40x0 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 of the Analog to Digital conversion is 12 bits 16 bit ADC is available as an option Analog inputs are useful for reading special sensors such as temperature tension or pressure The following examples show programs which cause the motor to follow an analog signal The first example is a point to point move The second example shows a continuous move Example Position Follower Point to Point Objective The motor must follow an analog signal When the analog signal varies by 10V motor must move 10000 counts Method Read the analog input and command A to move to that point Instruction Interpretation POINTS Label SP 7000 Speed AC 80000 DC 80000 Acceleration LOOP VP AN 1 1000 Read and analog input compute position PA VP Command position BGA Start motion AMA After completion JP LOOP Repeat Chapter 7 Application Programming e 169 DMC 40x0 User Manual EN End Example Posi
27. Similar to the command IT this produces a smooth velocity profile The step motor smoothing is specified by the following command KS x y z w where x y z w is an integer from 0 25 to 64 and represents the amount of smoothing The smoothing parameters x y z w and n are numbers between 0 25 and 64 and determine the degree of filtering The minimum value of 0 25 implies no filtering resulting in trapezoidal velocity profiles Larger values of the 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 value must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch The Home HM command can be used to position the motor on the index pulse after the home swi
28. 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 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 2 3 or 4 axis coordinated motion where path is described by Linear Interpolation LM linear segments LI LE VS VR VA VD DMC 40x0 User Manual Chapter 6 Programming Motion e 76 2 D motion path consisting of arc segments and linear segments such as engraving or quilting Third axis must remain tangent to 2 D motion path such as knife cutting Electronic gearing where slave axes are scaled to master axis which can move in both directions Master slave where slave axes must follow a master such as conveyer speed Moving along arbitrary profiles or mathematically prescribed profiles such as sine or cosine trajectories Teaching or Record and P
29. 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 xy lt n gt m CRr 0 6 lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and
30. for example the trajectory shown in Fig 6 18 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 IP Wait CM lt gt 511 Wait until path is done E DMC 40x0 User Manual Chapter 6 Programming Motion e 110 POSITION COUNTS E e a gs epee tcs Bae A 240 192 96 O oe TIME ms E 4 8 12 16 20 24 28 SEGMENT 1 SEGMENT 2 SEGMENT 3 Figure 6 18 The Required Trajectory Additional Commands _CM gives the amount of space available in the contour buffer 511 maximum Zero parameters for DT followed by zero parameters for CD exit the contour mode If no new data record is found and the controller is s
31. j ON ANALOG INPUTS OPTOISOLATED OUTPUTS INPUTS HIGH SPEED LATCH FOR EACH AXIS Figure 1 1 DMC 40x0 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 12 MHz For standard servo operation the controller generates a 10 volt analog signal 16 Bit DAC For sinusoidal commutation operation the controller uses two DACs to generate two 10 volt analog signals For stepper motor operation the controller generates a step and direction signal Communication The communication interface with the DMC 40x0 consists of high speed RS 232 and Ethernet The Ethernet is 10 100Bt and the two RS 232 channels can generate up to 115K General I O The DMC 40x0 provides interface circuitry for 8 bi directional optoisolated inputs 8 high power optoisolated outputs and 8 analog inputs with 12 Bit ADC 16 Bit optional The DMC 40x0 also has an additional 32 I O 3 3V DMC 40x0 User Manual Chapter 1 Overview e 4 logic and unused auxiliary encoder inputs may also be used as additional inpu
32. 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 40x0 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 unsolicited messages Programs Downloading and uploading embedded programs Arrays Downloading and uploading array data Advanced Lesser used calls ad 8 300 Data Record Access to the data record in both synchronous and asynchronous modes 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 Galil1 d11 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 Chapter 4 Software Tools and Communication e 65 DMC 40x0 User Manual COM Windows To further extend the language compatibility on Windows a COM Component
33. 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 Appendices e 233 DMC 40x0 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 galilmc com URL http galilmc com FTP http galilmc com ftp DMC 40x0 User Manual Appendices e 234 WARRANTY All controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship for a period of 18 months after shipment Motors and Power supplies are warranted for 1 year Extended warranties are available In the event of any defects in materials or workmanship Galil Motion Control will at its sole option repair or replace the defective product covered by this warranty without charge To obtain warranty service the defective product must be returned with
34. vibrations The smoothing function is specified by the following commands IT x y z w Independent time constant DMC 40x0 User Manual Chapter 6 Programming Motion e 122 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 Fig 6 15 shows the trapezoidal velocity profile and the modified acceleration and velocity Note that the smoothing process results in longer motion time Example Smoothing PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT ES Filter for smoothing BG X Begin ACCELERATION o ses O e VELOCITY 0 O Z ACCELERATION VELOCITY o lt pra O O 0 K m a lt x Figure 6 20 Trapezoidal velocity and smooth velocity profiles Chapter 6 Programming Motion e 123 DMC 40x0 User Manual 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
35. 1 for high current loop gain 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 For more information on connecting external amplifiers see Connecting to External Amplifiers in Chapter 2 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 A1 AMP 430x0 D3040 D3020 e 241 DMC 40x0 User Manual 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 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 HAMPERR label is included when
36. 15 5V 5V 30 5V 5V DMC 40x0 User Manual A8 ICM 42200 1200 e 270 ICM 42200 DMC 40x0 I O E H 44 pin HD D Sub Connector Female For DMC 4050 thru DMC 4080 controllers only Pin Label Description Pin Label Description Pin Label Description 15 5V 5V 30 5V 5V ICM 42200 Encoder 26 pin HD D Sub Connector Female Pin Label Description Pin Label Description 1 Forward Limit Switch Input 9 Reverse Limit Switch Input 12 Reserved Hall 1 Dir N B Main Encoder Input 13 STP PWM Step 26 MA A Main Encoder Input Notes 1 Negative differential motor command output when DIFF option is ordered on ICM Ex DMC 4040 C012 1200 DIFF Hall Input 2 when ordered with internal amplifier AMP 43040 Ex DMC 4040 C012 1200 D3040 Connected to GND in standard configuration 2 Hall Input 1 when ordered with internal amplifier AMP 43040 Ex DMC 4040 C012 1200 D3040 Negative differential direction output when STEP option is ordered on ICM Ex DMC 4040 C012 1200 STEP Connected to GND in standard configuration 3 Hall Input 0 when ordered with internal amplifier AMP 43040 Ex DMC 4040 C012 1200 D3040 Negative differential step output when STEP option is ordered on ICM Ex DMC 4040 C012 1200 STEP Connected to GND in standard configuration A8 ICM 42200 1200 e 271 DMC 40x0 User Manual ICM 42200 Analog 15 pin D sub Connector Male Pin
37. 192 168 1 100 lt 502 2 Dimension 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 40x0 can provide a block of status information with the use of a single command QR This command 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 Chapter 4 Software Tools and Communication e 55 DMC 40x0 User Manual Note UB Unsigned Byte 1 UW Unsigned Word 2 SW Signed Word 2 SL Signed Long Word 4 UL Unsigned Long Word 4 ADDR TYPE ITEM 00 UB 1 Byte of Header 01 UB 2 Byte of Header 02 UB 3 Byte of Header 03 UB 4 Byte of Header 04 05
38. 40x0 User Manual Chapter 3 Connecting Hardware e 42 TTL level Amp Enable signal from controller SH 5V MO OV RP2 470 Ohm PIN 4 5V or GND Amplifier Enable Circuit Sourcing Output Configuration Pin 1 of LTV8441 in Pin 1 of Socket U4 Socket U4 1 i Pin 1 Pin 1 of socket LTV8441 2 E GND El El 5v El El 12v g 2 Jp2 lol fs AECOM2 Amp Enable Output to Drive AENn Garg 2325 JP4 LO lel aj lol SHeHsHo AECOM1 Figure 3 5 Amplifier Enable Circuit Sourcing Output Configuration Sourcing Configuration pin1 of LTV8441 chip in pin1 of socket U4 Logic State 5V HAEN 5V LAEN 12V HAEN 12V LAEN Isolated 24V HAEN Isolated 24V LAEN For 24V isolated enable tie 24V of external power supply to AEC2 at the D sub tie common return to AEC1 Replace RP6 with a 4 7 KQ resistor pack For Axes A D AEC1 and AEC2 are located on the EXTERNAL DRIVER A D D Sub connector For Axes E H AEC1 and AEC2 are located on the EXTERNAL DRIVER E H D Sub connector AECI and AEC2 for axes A D are NOT connected to AEC1 and AEC2 for axes E H JP1 GND AECOM1 GND AECOM1 GND AECOM1 GND AECOM1 AECI AECOM1 AECI AECOM1 JP2 SV AECOM2 SV AECOM2 12V AECOM2
39. 4A DO_ 16 9 4 VV Ya ma CPU IRP7342 MMBD1204 10K ORET VO E H Figure 3 3 ICM 42x00 General Purpose Digital Output Opto Isolation For controllers with 5 8 axes outputs 9 16 are located on the I O E H D Sub connector The OPWR and ORET for these outputs are also found on the I O E H D Sub connector Connections to the OPWR and ORET on the I O E H as described above are required for operation of outputs 9 16 DMC 40x0 User Manual Chapter 3 Connecting Hardware e 38 Analog Inputs The DMC 40x0 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 4020 16bit C012 1000 The analog inputs are specified as AN x where x is a number 1 thru 8 AQ settings The analog inputs can be set to a range of 10V 5V 0 5V or 0 10V 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 respectivally See the AQ command in the command reference for more information Electrical Specifications Input Impedance 12 and 16 bit Single Ended Unipolar 42kQ Differential Bipolar 31kQ TTL Outputs 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
40. 500000 counts sec Acceleration Z Axis 100 counts Position 5000 counts sec Speed 500000 counts sec Acceleration This example will specify a relative position movement on X Y and Z axes The movement on each axis will be separated by 20 msec Fig 6 0 shows the velocity profiles for the X Y and Z axis FA Begin Program PR 2000 500 100 Specify relative position movement of 1000 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 Chapter 6 Programming Motion e 79 DMC 40x0 User Manual 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 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 decelerati
41. 64 65 66 69 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 UB UB UL new UL new UW new UW UW SL UW new UW UW SL UW new UW UB UB SL SL SL SL SL SL new size SW or UW UB new UB SL new UW UB UB SL SL SL SL SL SL new size SW or UW UB new UB SL new UW UB UB SL SL 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 statu
42. AC DC BG BG 500 1000 600 400 10000 12000 20000 10000 10000 10000 10000 10000 80000 40000 30000 50000 AC BD Example 4 Independent Moves Speed Deceleration Acceleration Start Motion Interpretation Distances of A B C D Slew speeds of A B C D Accelerations Decelerations Start A and C motion Start B and D motion The motion parameters may be specified independently as illustrated below Instruction PR SP DC AC AC 300 600 2000 80000 100000 100000 DC 150000 BG BG C B Interpretation Distances of B and C Slew speed of B Decel Accel Accel eration o eration o eration o Deceleration o Start C motion Start B motion Example 5 Position Interrogation Es B f B EL E The position of the four axes may be interrogated with the instruction TP Instruction TP TP TE TP TP 0 QW YP Interpretation Tell Tell Tell Tell Tell position position position position position all four axis axis axis o Aw YP axis of A B C D of A B C D axes only only only only The position error which is the difference between the commanded position and the actual position can be interrogated with the instruction TE Instruction TE TE TE TE TE 0 QA Ww YP Example 6 Absolute Position Interpretation Tell Tell Tell Tell Tell SETO A 11 axes error A axis only error B error E erro
43. AIl IN enter Length IN len PR len 4000 BGX AMX SB1 WT100 CB1 JP CUT EN LABEL Acceleration Deceleration Speed Initial length in inches Cut routine Wait for start signal Prompt operator for length in inches Specify position in counts Begin motion to move material Wait for motion done Set output to cut Wait 100 msec then turn off cutter Repeat process End program 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 40x0 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 40x0 provides special the following keywords Keyword P2CH P2ST P2NM P2CD Function Contains the last character received Contains the received string Contains the received number Contains the status code 1 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 corre
44. 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 ae a DA for S or T Plane ua oa BITIS 15 BiT14 14 BITI3 13 BIT12 12 BmTu 11 BiT10 10 BIT9 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 40x0 User Manual Chapter 4 Software Tools and Communication e 60 Axis Status 1 Word BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8 Move in Mode of Mode of FE Home 1 Phase 2 Phase Mode of Progress Motion Motion Find HM in of HM of HM Motion PA or PA only Edge in Progress complete complete Coord PR Progress or FI Motion command issued BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 Negative Mode of Motion Motion Motion Latch is 3rd Phase Motor Direction Motion is is is armed of HM in Off Move slewing stopping making Progress due to final Contour ST of decel Limit Axis Switches 1 Byte Latch State of State of State of Stepper Occurred Forward Reverse Home Mode Limit Limit Input 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 a
45. C DELTA C C 1 JP L C lt 500 Compute the difference Store difference in array Increment index Repeat until done Chapter 6 Programming Motion e 113 DMC 40x0 User Manual 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 1I 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 40x0 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 not an external encoder but has to be a controlled variable This can be achieved by defining the N axis as the master with the command EAN and setting the modulo of the master with a command such as EMN 4000 Next the table is constructed To
46. Configuration 1 Change JP1 to 12V RP2 PIN 1 ee U4 PIN 1 E re E fehicv 42000 DALIL REV C 12V Low Amp Enable Sinking Configuration JP1 JP2 SHUNT AT 12V SHUNT AT GND From Default Configuration l Reverse RP2 2 Change JP1 to 12V U4 PIN 1 3 RP2 PIN 1 a SEX FSNCM 42000 GAIL REV C Appendices e 219 DMC 40x0 User Manual 12V High Amp Enable Sourcing Configuration SHUNT AT 12V JP2 JP1 SHUNT AT GND From Default Configuration Move U4 up one pin location on socket Reverse RP2 Change JP1 to GND Change JP2 to 12V 4 Beececceccecces 0000000000000002 ete YY 2 OR 3 12V Low Amp Enable Sourcing Configuration SHUNT AT 12V JP2 JP1 SHUNT AT GND From Default Configuration Move U4 up one pin location on socket Change JP1 to GND 2 Change JP2 to 12V a Pio taa U4 PIN 1 oc0000000 Tooocooococooooo 0009000000000002 20000000000000 0000009 000000 coc0o A0ooooo RP2 PIN 1 o o t N a e Ss Es z a Appendices e 220 DMC 40x0 User Manual Isolated Power High Amp Enable Sinking Configuration JP1 JP2 SHUNT AT AEC1 SHUNT AT AEC2 AEC1 AEC2 V y For 5V to 12V RP6 820 Ohms For 13V to 24V RP6 4 7K Ohms From Default Configuration 1 Change JP1 to AEC1 RP2 PIN 1 RP6 PIN 1 5 2 Change JP2 to AEC2 Es 3 If AECI is 13V to 24V Replace RP6 with 38 4 7K Resistor Pack U4 PIN 1
47. Configuration pg 220 Isolated Power High Amp Enable Sinking Configuration pg 221 Isolated Power Low Amp Enable Sinking Configuration pg 221 Isolated Power High Amp Enable Sourcing Configuration pg 222 Isolated Power Low Amp Enable Sourcing Configuration pg 222 DMC 40x0 User Manual Appendices e 216 5V High Amp Enable Sinking Configuration Default JP1 JP2 SHUNT AT 5V SHUNT AT GND Default Configuration Shipped with controller when no specific setup is ordered RP2 PIN 1 U4 PIN 1 5V Low Amp Enable Sinking Configuration JP1 SHUNT AT 5V JP2 SHUNT AT GND From Default Configuration 1 Reverse RP2 U4 PIN 1 4 RP2 PIN 1 AR Eho 42000 ALIL REV C Appendices e 217 DMC 40x0 User Manual 5V High Amp Enable Sourcing Configuration JP1 JP2 SHUNT AT GND SHUNT AT 5V From Default Configuration l Move U4 up one pin location on socket 2 Reverse RP2 3 Change JP1 to GND 4 Change JP2 to 5V U4 PIN 1 RP2 PIN 1 i 5V Low Amp Enable Sourcing Configuration JP1 JP2 SHUNT AT GND SHUNT AT 5V From Default Configuration 1 Move U4 up one pin location on socket bog E 2 Change JP1 to GND 3 Change JP2 to 5V U4 PIN 1 RP2 PIN 1 o o o o o o o v0000000090090000 ORE DMC 40x0 User Manual Appendices e 218 12V High Amp Enable Sinking Configuration Does not require the removal of Metal JP1 JP2 SHUNT AT 12V SHUNT AT GND From Default
48. Data Record auspicia Explanation Data Record Bit Fields Notes Regarding Velocity and Torque Information 62 QZ Command g Controller Response 16 Co A 62 Unsolicited Messages Generated by Controller conciso icono 63 DMC 40x0 Contents e iii GallTot Windows and Limi A A ayia ipa ccadae se lasdeeeaniand 64 Creating Custom Software IMteia0Gi ssc terres acetals aces anaieesaimescnes 66 HelloGalil Quick Start to PC programming GalilTools Communication Libraries ActiveX Toolkit ee eee 2 DMC Win Programmers Toolkit Galil Communications API with C Chhccoccccoccconoonconcconacncoconoos Galil Communications API with Visual Basic iz DES AUN POO IB a tats aaa s ean teenie ited se ece NS muttlseeaieeteeE 70 Chapter 5 Command Basics 71 A A O 71 Command Synir ASCI a is 71 Coordinated Motion with more than 1 axis e Cominand Syntax Binary advanced moiociconasio rinc n reinado J3 Binary Command Forti ii a Biar command table sii 74 Controller Response to DATA mterropatina the Controller cui ia Intercopation Commands ii Summary of Interrogation Commands da Interrogating Current Commanded ValueS cocococcconncnonincnncaneso 76 o A nou seri pes seasseesemuaiebes 76 Command UIA EY ui 76 Chapter 6 Programming Motion rid
49. Digital Output 10 Digital Output 9 DO12 Digital Output 12 DO15 Digital Output 15 CMP Output Compare E H DO13 Digital Output 13 DO16 Digital Output 16 5V 5V x o E DMC 40x0 User Manual A7 ICM 42100 1100 e 264 ICM 42100 External Driver A D 44 pin HD D Sub Connector Male Pin Label Description Pin Label Description Pin Label Description PUES CPT res renace es reenen 1 2 2 2 1 STPB PWM Step B 1 RES Reserved Step C_N 3 S Digital Ground DIRB Sign Direction B 6 7 8 9 0 Reserved Dir C_N R 1 Amplifier Enable A Reserved Dir D_N Amplifier Enable D 2 2 23 1s 9 ora sign Direct 5 DIRC sign pirectinc 20 res Resred Dimn 35 res a pmp sign DirecionD 36 oND ital Ground RES o y n z lz ls z z 2 2 3 a 2 lt z z u a 11 Motor Command B Reserved MCMDA_N i Res Reserved MCMDB_N 12 Reserved MCMDC_N MCMC Motor Command C MCMD Motor Command D 15 5V 5V 30 N C No Connect Notes 1 Negative differential motor command outputs when DIFF option is ordered on ICM Ex DMC 4040 C012 I100 DIFE These pins may be used for other functions when DIFF option is not ordered 2 Negative differential step and direction outputs when STEP option is ordered on ICM EX DMC 4040 C012 I100 STEP These pins may be used for other functions when STEP option is not ordered AT ICM 42100
50. E qa E fehicv 42000 GALL REV C Isolated Power Low Amp Enable Sinking Configuration JP1 JP2 SHUNT AT AEC1 SHUNT AT AEC2 AEC1 V AEC2 V For 5V to 12V RP6 820 Ohms For 13V to 24V RP6 4 7K Ohms From Default Configuration 1 Reverse RP2 U4 PIN 1 RP6 PIN 1 E 2 Change JP1 to AEC1 3 3 Change JP2 to AEC2 33 4 If AECI is 13V to 24V Replace RP6 with ge 4 7K Resistor Pack RP2 PIN 1 a ata 9 fsticw 42000 GAIL REV C Appendices e 221 DMC 40x0 User Manual Isolated Power High Amp Enable Sourcing Configuration JP1 JP2 SHUNT AT AEC1 SHUNT AT AEC2 AEC1 V AEC2 V For 5V to 12V RP6 820 Ohms For 13V to 24V RP6 4 7K Ohms From Default Configuration U4 PIN 1 1 Move U4 up one pin location on socket RP6 PIN 1 US 2 Reverse RP2 3 3 Change JP1 to AECI 33 4 Change JP2 to AEC2 RP2 PIN 1 BE 5 If AEC2 is 13V to 24V Replace RP6 with 4 7K Resistor Pack Isolated Power Low Amp Enable Sourcing Configuration JP1 JP2 SHUNT AT AEC1 SHUNT AT AEC2 AEC1 V AEC2 V For 5V to 12V RP6 820 Ohms For 13V to 24V RP6 4 7K Ohms From Default Configuration pad 1 Move U4 in 1 1 k RPG PIN 1 l i ove U4 up one pin location on socket Se 2 Change JP1 to AEC1 3 Change JP2 to AEC2 gt ss H 4 If AEC2 is 13V to 24V Replace RP6 with RP2 PIN 1 A 4 7K Resistor Pack 9 fsticw 42000 GAIL REV C DMC 40x0 User Manual Appendices e 222 For Steps 4 and 5 wi
51. FA Begin Program count 0 DM pos 10 Initialize counter and define array LOOP Begin loop WT 10 Wait 10 msec pos count _TPX Record position into array element pos count Report position count count 1 Increment counter JP LOOP count lt 10 Loop until 10 elements have been stored EN End Program The above example records 10 position values at a rate of one value per 10 msec The values are stored in an array named POS The variable COUNT is used to increment the array element counter The above example can also be executed with the automatic data capture feature described below Uploading and Downloading Arrays to On Board Memory Arrays may be uploaded and downloaded using the QU and QD commands QU array start end delim QD array start end where array is an array name such as A start is the first element of array default 0 end is the last element of array default last element delim specifies whether the array data is separated by a comma delim 1 or a carriage return delim 0 Chapter 7 Application Programming e 157 DMC 40x0 User Manual The file is terminated using lt control gt Z lt control gt Q lt control gt D or Automatic Data Capture into Arrays The DMC 40x0 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
52. LSCOM terminal and source current at switch inputs switch inputs Figure 3 2 Connecting a single Limit or Home Switch to an Isolated Supply This diagram only shows the connection for the forward limit switch of the X axis 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 TTL Inputs 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 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 Y of the full voltage range for example connect the input to 6 volts if the signal is a 0 12 volt logic Example A DMC 4010 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
53. Motor M s P I Kt Js 1000 s Amp K 2 Amp V DAC K4 10 32768 0003 Encoder K 4N 2n 636 ZOH H s 2000 s 2000 Chapter 10 Theory of Operation e 195 DMC 40x0 User Manual Compensation Filter G s P sD The next step is to combine all the system elements with the exception of G s into one function L s L s M s K Kg 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 L500 3 17 10 j500 2 500 2000 This function has a magnitude of L j500 0 00625 and a phase Arg L 500 180 tan 1 500 2000 194 G s is selected so that A s has a crossover frequency of 500 rad s and a phase margin of 45 degrees This requires that A j500 1 Arg A j500 135 However since 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 A 500 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 GG500 P G500D 160 and arg G 500 tan 500D P 59 The solution of these equations leads to P 160cos 59 82 4 500D 160sin 59 137 Therefo
54. 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 ActiveX Toolkit Galil recommends the GalilTools Communication Library for all new applications Galil s ActiveX Toolkit is useful for the programmer who wants to easily create a custom operator interface to a Galil controller The ActiveX Toolkit includes a collection of ready made ActiveX COM controls for use with Visual Basic Visual C Delphi LabVIEW and other ActiveX compatible programming tools The most common environment is Visual Basic 6 but Visual Basic NET Visual C Wonderware LabVIEW and HPVEE have all been tested by Galil to work with the OCX controls The ActiveX Toolkit can be purchased from Galil at http www galilmc com buy index html The ActiveX toolkit can save many hours of programming time Built in dialog boxes are provided for quick parameter setup selection of color size location and text The toolkit controls are easy to use and provide context sensitive help making it ideal for even the novice programmer
55. POSERR LIMSWI MCTIME and ININT run without a thread Removed Commands VT WC DMC 40x0 User Manual Appendices e 232 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 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
56. RLSF Reverse Limit Switch F FLSG Forward Limit Switch G 9 HOMG Home Switch G RLSG Reverse Limit Switch G FLSH Forward Limit Switch H 10 HOMH Home Switch H RLSH Reverse Limit Switch H Digital Ground 12 DOI Digital Output 11 DO10 Digital Output 10 DO12 Digital Output 12 13 DO14 Digital Output 14 DO13 Digital Output 13 DOIS Digital Output 15 15 5V 5V 30 5V 5V ICM 42000 External Driver A D 44 pin HD D Sub Connector Male Pin Label Description Pin Label Description Pin Label Description 1 Reserved Step A_N 2 STPA PWM Step A STPB PWM Step B 2 STPC PWM Step C Reserved Step B_N 2 Reserved Step C_N 3 Reserved Step D_N 2 STPD PWM Step D Digital Ground 4 Reserved Dir A_N A Sign Direction A DIRB Sign Direction B 5 DIRC Sign Direction C Reserved Dir B_N A Reserved Dir C_N 4 6 Reserved Dir D_N Sign Direction D Digital Ground 7 AENA Amplifier Enable A AECI Amp Enable Common 1 AENB Amplifier Enable B 8 AEND Amplifier Enable D AENC Amplifier Enable C AEC2 Amp Enable Common 2 11 MCMB Motor Command B Reserved MCMDA_N Reserved MCMDB_N 12 Reserved MCMDC_N MCMC Motor Command C MCMD Motor Command D 15 5V 5V 30 N C No Connect Notes Negative differential motor command outputs when DIFF option is ordered on ICM Ex DMC 4040 C012 I000 DIFE These pins may be used for other functions when DIFF option is not ordered Negative differential step and direction outputs when STEP option is ordered
57. Started e 13 DMC 40x0 User Manual Stepper Motor Operation To configure the DMC 40x0 for stepper motor operation the controller requires that the command MT must be given Further instruction for stepper motor connections are discussed in Step 8c Step 2 Install Jumpers on the DMC 40x0 Master Reset and Upgrade Jumpers JP1 on the main board contains two jumpers MRST and UPGRD 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 variables and motion control parameters stored in EEPROM will be ERASED The UPGRD jumper enables the user to unconditionally update the controller s firmware This jumper is not necessary for firmware updates when the controller is operating normally but may be necessary in cases of corrupted EEPROM EEPROM corruption should never occur however it is possible if there is a power fault during a firmware update If EEPROM corruption occurs your controller may not operate properly In this case install the UPGRD Jumper and use the update firmware function on the Galil Terminal to re load the system firmware Motor Off Jumpers The state of the motor upon power up may be selected with the placement of a hardware jumper on the controller With a jumper installed at the MO location the controller will be powered up in the motor off
58. The lt cntrl gt Q quits the editor mode In response the DMC 40x0 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 LSS Begin listing at line 5 ES 5 9 List lines 5 thru 9 LS A 9 List line label A thru line 9 LS A A 5 List line label A and additional 5 lines Program Format A DMC 40x0 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 40x0 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 40x0 programs must beg
59. 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 Nm A Chapter 10 Theory of Operation e 189 DMC 40x0 User Manual R 20 J 0 0283 oz in s 2 10 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 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 Fig 10 5 Note that the t
60. Y Table Caller us is Speed Control By Joystick ancoan Position Control by Joystick ds Backlash Compensation by Sampled Dual L00P ccccccocconccnnos 177 Chapter 8 Hardware amp Software Protection 180 Ti ner nee ene Tere ener mre ee errr ae 180 TAS SA 180 Output Protection Lines Input Protection Lines Software Protection Programmable Position Limits rica 182 Off On Error Automate Eror ROME usara 182 Lon Ce 001 IN ers 183 Chapter 9 Troubleshooting 184 LASS Gl A Titer 184 Installation 184 Stability 185 D ae a ee eae 185 Chapter 10 Theory of Operation 186 OLS Rd A Operation of Closed Loop Systems sti A eo Dasa cameo GEO A MINN nunaa a Encoder is Sa A is 194 System Design and Compensation 196 The Analytical Method Appendices 199 Electrical Spectator sisi isis 199 Servo Control Stepper Control Input Output y Power Requirements oops rn eii Sodus sus ea 200 5 12V Power Output Specifications vicio sis cies ease 200 Ordering Options fot he DMCADO op ii iii 203 Onil ARA 203 DMC 40x0 Controller Board Options 203 CMB Communication Board OptiONS ccccccocococccncnncanconacanenass 204 ICM Interconnect Board Options ninia 205
61. 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 The next page provides the results captured by the WSDK program This shows how the motion will be seen during the ECAM cycles The first graph is for the X axis the second graph shows the cycle on the Y axis and the third graph shows the cycle of the Z axis Three Storage Scopes Ey plural os vr actual Postion z Zeon J foma E loa Pion _ Figure 6 13 Three Storage Scopes DMC 40x0 User Manual Chapter 6 Programming Motion e 104 PVT Mode The DMC 40x0 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 en
62. 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 1 000 000 counts sec and the gear ratio is 1 1 but the gearing is slowly engaged over 30 000 cts of the master axis greatly diminishing the initial shock to the slave axis Figure 6 10 below shows the velocity vs time profile for instantaneous gearing Figure 6 11 shows the velocity vs time profile for the gradual gearing engagement p 4 i L i i 1 Se Figure 6 10 Velocity cts sec vs Time msec Instantaneous Gearing Engagement DMC 40x0 User Manual Chapter 6 Programming Motion e 96 AS AS 1 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 i ecsedcocea la Figure 6 11 Velocity cts sec vs Time msec Ramped Gearing The slave axis for each figure is shown on the bottom portion of the figure the master axis is shown on the top portion The shock to the slave axis will be significantly less in Figure 6 11 than in Figure 6 10 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 pos
63. as PR PA or JG When the master axis is driven by the controller in the jog mode or an independent motion mode it is possible to define the master as the command position of that axis rather than the actual position The designation of the commanded position master is by the letter C For example GACX indicates that the gearing is the commanded position of X Chapter 6 Programming Motion e 95 DMC 40x0 User Manual An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS For example if the X and Y motor form a circular motion the Z axis may move in proportion to the vector move Similarly if X Y and Z perform a linear interpolation move W can be geared to the vector move Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing For example when a geared motor follows a master at a ratio of 1 1 it may be advanced an additional distance with PR or JG commands or VP or LI Ramped Gearing In some applications especially when the master is traveling at high speeds it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing is engaged For example if the master axis is already traveling at 1 000 000 cts sec and the slave will be geared at a ratio of 1 1 when the gearing is engaged the slave will instantly develop following error
64. be divided into three levels as illustrated in Fig 10 2 The levels are 1 Closing the Loop 2 Motion Profiling 3 Motion Programming The first level the closing of the loop assures that the motor follows the commanded position This is done by closing the position loop using a sensor The operation at the basic level of closing the loop involves the subjects of modeling analysis and design These subjects will be covered in the following discussions The motion profiling is the generation of the desired position function This function R t describes where the motor should be at every sampling period Note that the profiling and the closing of the loop are independent functions The profiling function determines where the motor should be and the closing of the loop forces the motor to follow the commanded position The highest level of control is the motion program This can be stored in the host computer or in the controller This program describes the tasks in terms of the motors that need to be controlled the distances and the speed Chapter 10 Theory of Operation e 185 DMC 40x0 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
65. begin the setup of the brushless motor and amplifier it is first necessary to have communications with the motion controller Refer to the user manual supplied with your controller for questions regarding controller communications 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 Review the command reference and controller user manual for further details There are 3 settings for the amplifier gain 0 4 A V 0 7 A V and 1 0 A V corresponding to AG amplifier gain 0 1 and 2 If the gain is set to 0 7 A V a torque limit of 3 TLn 3 will allow the amplifier to output no more than 2 1 amps of current on the specified axis The controller has been programmed to test whether the Hall commutation order is correct To test the commutation for the X axis issue the BS command BSX n m The controller will attempt to move the motor through one revolution If the motor is unable to move the controller will return unknown Hall transition check wiring and execute BS again It may be necessary to issue more voltage to create motion The default for the BS command is BSn 0 25 1000 which will send 0 25 volts to
66. 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 CR 1500 90 180 DMC 40x0 User Manual Chapter 7 Application Programming e 132 HALF CIRCLE MOTION VE END VECTOR SEQUENCE BGS BEGIN SEQUENCE MOTION EN END OF PROGRAM Note The NO command is an actual controller command Therefore inclusion of the NO commands will require process time by the controller Executing Programs Multitasking The DMC 40x0 can run up to 8 independent programs simultaneously These programs are called threads and are numbered 0 through 7 where 0 is the main thread Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion The main thread differs from the others in the following ways 1 Only the main thread thread 0 may use the input command IN 2 When input interrupts are implemented for limit switches position errors or command errors the subroutines are executed as thread 0 To begin execution of the various programs use the following instruction XQ A n Where n indicates the thread number To halt the execution of any thread use the instruction HX n
67. comment takes time to process i i 1 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 4020 the output from the above program returned a 116 which indicates that it took 116 samples TM 1000 to process the commands from t TIME 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 4020 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 DMC 40x0 User Manual Chapter 7 Application Programming e 150 ta i 0 initialize a counter t TIME set an initial time reference loop REM this comment is removed upon download REM this comment is removed upon download i i 1 REM this comment is removed upon download JP loop i lt 1000 G TIME t display number of samples from EN WT vs AT and coding deterministic loops and takes no and takes no and takes no initial time time to process time to process time to process reference The main difference between WT and AT is that WT will hold up execution of the next command for the specifie
68. configuration causes the controller to reconfigure the number of available control axes Each sinusoidally commutated motor requires two DACs In standard servo operation the DMC 40x0 has one DAC per axis In order to have the additional DAC for sinusoidal commutation the controller must be designated as having one additional axis for each sinusoidal commutation axis For example to control two standard servo axes and one axis of sinusoidal commutation the controller will require a total of four DACs and the controller must be a DMC 4040 Sinusoidal commutation is configured with the command BA For example BAA sets the A axis to be sinusoidally commutated The second DAC for the sinusoidal signal will be the highest available DAC on the controller For example Using a DMC 4040 the command BAA will configure the A axis to be the main sinusoidal signal and the D axis to be the second sinusoidal signal The BA command also reconfigures the controller to indicate that the controller has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAA is given to a DMC 4040 controller the controller will be re configured to a DMC 4030 controller By definition a DMC 4030 controls 3 axes A B and C The D axis is no longer available since the output DAC is being used for sinusoidal commutation Further instruction for sinusoidal commutation connections are discussed in Step 6 Chapter 2 Getting
69. counts since 5 counts out of the 20 would be corrected by the X axis Accordingly the motion correction should be Correction Load Position Error Rotary Position Error The correction can be performed a few times until the error drops below 2 counts Often this is performed in one correction cycle Example 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 JP C ABS ERR lt 2 PR ERR BGX JP B C EN Find the correction Exit if error is small Command correction Repeat the process Chapter 7 Application Programming e 177 DMC 40x0 User Manual THIS PAGE LEFT BLANK INTENTIONALLY DMC 40x0 User Manual Chapter 7 Application Programming e 178 Chapter 8 Hardware amp Software Protection Introduction The DMC 40x0 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 40x0 is an integral part of the machine the engineer should design his overall system with protection against a possible component failure on the DMC 40x0
70. 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 Ey ly de activates the dual loop for the four axes and DV 0 0 0 0 disables the dual loop Chapter 6 Programming Motion e 121 DMC 40x0 User Manual Note that the dual loop compensation depends on the backlash magnitude and in extreme cases will not stabilize the loop The proposed compensation procedure is to start with KP 0 KI 0 and to maximize the value of KD under the condition DV1 Once KD is found increase KP gradually to a maximum value and finally increase KI if necessary Sampled Dual Loop Example In this example we consider a linear slide which is run by a rotary motor via a lead screw Since the lead screw has a backlash it is necessary to use a linear encoder to monitor the position of the slide For stability reasons it is best to use a rotary encoder on the motor Connect the rotary encoder to the X axis and connect the linear encoder to the auxiliary encoder of X Assume that the required motion distance is one inch and that this corresponds to 40 000 counts of the rotary encoder and 10 00
71. exact position synchronization is required the IP command is used to adjust for the difference Chapter 6 Programming Motion e 97 DMC 40x0 User Manual 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 full effect _GPn This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately and the distance traveled since gearing changes take effect over a specified interval GR a b c d e f g h Sets gear ratio for slave axes 0 disables electronic gearing for specified axis GM a b c d e f g h X 1 sets gantry mode 0 disables gantry mode 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 GAY Y Y Specify master axes as Y CRDi DO Set gear ratio
72. 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 KP10 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 KP 20 Set B axis gain only Instruction Interpretation OE 1 1 1 1 1 1 1 1 Enable automatic Off on Error function for all axes ER 1000 Set error limit for all axes to 1000 counts KP10 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 stops Instruction Interpretation PR1000 Distance Chapter 2 Getting Started e 25 DMC 40x0 User Manual SP20000 DC AC 100000 100000 BG A Example 3 Multiple Axes Objective Move the four axes independently Instruction PR SP
73. flexibility Standard Servo Motor with 10 Volt Command Signal The DMC 40x0 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 Brushless Servo Motor with Sinusoidal Commutation The DMC 40x0 can provide sinusoidal commutation for brushless motors BLM In this configuration the controller generates two sinusoidal signals for connection with amplifiers specifically designed for this purpose Note The task of generating sinusoidal commutation may be accomplished in the brushless motor amplifier If the amplifier generates the sinusoidal commutation signals only a single command signal is required and the controller should be configured for a standard servo motor described above Sinusoidal commutation in the controller can be used with linear and rotary BLMs However the motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds with a standard update rate of 1 millisecond For faster motors please contact the factory To simplify the wiring the controller provides a one time automatic set up procedure When the control
74. for download and is available at http www galilmc com support download html DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 66 Galil Communications API with C C Galil recommends the GalilTools Communication Library for all new applications When programming in C C the communications API can be used as included functions or through a class library All Galil communications programs written in C must include the DMCCOM H file and access the API functions through the declared routine calls C programs can use the DMCCOM H routines or use the class library defined in DMCWIN H After installing DMCWin into the default directory the DMCCOM H header file is located in C Program Files Galil DMCWIN INCLUDE C programs that use the class library need the files DMCWIN H and DMCWIN CPP which contain the class definitions and implementations respectively These can be found in the C ProgramFiles Galil DMCWIN CPP directory To link the application with the DLL s the DMC32 lib file must be included in the project and is located at C Program Files Galil DMCWIN LIB Example A simple console application that sends commands to the controller To initiate communication declare a variable of type HANDLEDMC a long integer and pass the address of that variable in the DMCOpen function If the DMCOpen function is successful the variable will contain the handle to the Galil controller which is required for all s
75. 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 40x0 registers The axis designation is required following the command Examples of Internal Variables POSX _TPX Assigns value from Tell Position X to the variable POSX GAIN _GNZ 2 GAIN JP LOOP TEX gt 5 Assigns value from GNZ multiplied by two to variable Jump to LOOP if the position error of X is greater than 5 Chapter 7 Application Programming e 155 DMC 40x0 User Manual JP ERROR TC 1 Jump to ERROR if the error code equals 1 Operands can be used in an expression and assigned to a programmable variable but they cannot be assigned a value For example GNX 2 is invalid Special Operands Keywords The DMC 40x0 provides a few additional operands which give access to internal variables that are not accessible by standard DMC 40x0 commands Keyword Function _BGn Returns a 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 num
76. limit switch occurs on the Notes regarding the LIMSWI Routine Edit Mode Dummy Program Jump to Loop Limit Switch Label Print Message Return to main program Quit Edit Mode Execute Dummy Program Jog Begin Motion X axis the LIMSWI subroutine will be executed 1 The RE command is used to return from the LIMSWI subroutine 2 The LIMSWI subroutine will be re executed if the limit switch remains active The LIMSWI routine is only executed when the motor is being commanded to move Example Position Error ED 000 001 002 003 004 LOOP JP LOOP EN POSERR Vl _TEX MG EXCESS POSITION ERROR 005 006 lt control gt Q XQ LOOP JG 100000 gt BGX MG ERROR V1 RE Edit Mode Dummy Program Loop Position Error Routine Read Position Error E Print Message Print Error Return from Error Quit Edit Mode Execute Dummy Program Jog at High Speed Begin Motion DMC 40x0 User Manual Chapter 7 Application Programming e 144 Example Input Interrupt A Label ELL 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
77. lt return gt BGX lt return gt 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 forward motion The motor will then decelerate to a stop The acceleration rate deceleration rate and slew speed are specified by the user prior to the movement using the commands AC DC and SP When using the FE command it is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch The Find Index routine is initiated by the command sequence FIX lt return gt BGX lt return gt Find Index will cause the motor to accelerate to the user defined slew speed SP at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high The motor then decelerates to a stop at the rate previously specified by the user with the DC command and then moves back to the index pulse and speed HV Although Find Index is an option for homing it is not dependent upon a transition in the logic state of the Home input but instead is dependent upon a transition in the level of the index pulse signal The Standard Homing routine is initiated by the sequence of commands HMX lt return gt BGX lt return gt Standard Homing is a combination of Find Edge an
78. 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 40x0 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode These two sets are identified by the letters S and T To specify vector commands the coordinate plane must first be identified This is done by issuing the command CAS to identify the S plane or CAT to identify the T plane All vector commands will be applied to the active coordinate system until changed with the CA command Specifying Vector Segments The motion segments are described by two commands VP for linear segments and CR for circular segments Once a set of linear segments and or circular segments have been specified the sequence is ended with the command VE This defines a sequence of commands for coordinated motion Immediately prior to the execution of the first coordinated movement the controller defines the current position to be zero for all movements in a sequence Note Chapter 6 Programming Motion e 91 DMC 40x0 User Manual This local definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences The command VP x y specifies the coordinates of the end points of the vector movement with r
79. o o 185 THEO teeenGssh hehe ech ae eee cece et ask xe ee A eA Ree ca ee ee RS Damping ect on 24 Digital Filter siaaa ira di 70 PID rnana rie a AR te HW Oe 2 21 24 25 TIME rii E RR ET R A A RVG ER 156 Time Ita a sh eww dhs ees ee eee ects Re estes ie adie en es ee eS 110 113 158 TO di A A a AA Cav eda sas Wage ide 16 132 136 143 145 Torg e BS 0 eOPPOPOOOAOON n TO 20 27 Vina 130 135 137 187 210 VPO diia 29 78 87 93 136 142 143 TOU DLE SO OL td e ho dr R Coates o lane NAA re dona eat ata 183 TTL 4 32 37 39 41 179 198 210 AUIS 3 234 a oe eldoctor ohn o dr die MO HS o tak 2 1 12 21 25 A a e o Mice sect tees ee o aM ace e al tac o a ie lech asal WD did ds oda col tis 16 A A cats sah cheated gc 28 Usan nt e e Me e a a cd staat eos alo ea ad 166 Vanablern tt o ee anal e leds ento Mes ear etnia 14 29 75 130 162 163 164 166 DMC 40x0 User Manual Index e 276 AS E Internal Variable coat ct 30 ON AAA SEUSS eats nce co eSB oan San Se IR hava ERs 30 88 94 174 Vector D celerations Sec E EE ERE 30 88 94 Necter MOJE raen E Oe E SDAN Circular Interpolation cecesceeceeseeeseeseeeseeeeeees 30 Linear Interpolation ccesceeseseeeeceeeeteeeesneeeeenees 30 Nec PCO 2 sexe sete teesce dai A O BOE ease A Re ae 30 86 94 138 174 Wire Cullera dd E Whe i Tas PLEAS SSeS RII AR ia ONG 172 LO SLACK rere a AY ee Rate Sal a ak MN Ns ee oa et to te ales AO 145 169 Index e 277 DMC 40x0
80. of 1 Vp p sinusoidal encoders This interconnect module is the ICM 42100 See A7 ICM 42100 1100 in the Appendix for more information Watch Dog Timer The DMC 40x0 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 of a serious DMC 40x0 failure 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 40x0 to normal operation Consult the factory for a Return Materials Authorization RMA Number if your DMC 40x0 is damaged DMC 40x0 User Manual Chapter 1 Overview e 6 Chapter 2 Getting Started DMC 4040 Layout The following layouts assume either an ICM 42000 1000 or ICM 42100 1100 interconnect modules are installed For layouts of systems with ICM 42200 s 1200 installed please contact Galil Overall dimensions and footprint are identical the only differences are in connector type and location E _ _ _ _ _ _ _ _ _ _J 2 gt PA NS E H O k A B C D POWER O D ENCODER STEPPER SERVO POWER DMC 4040 15 8V sona
81. position G axis motor position G axis position error G axis auxiliary position G axis velocity G axis torque G axis analog input G Hall Input Status Reserved G User defined variable ZA H axis status see bit field map below H axis switches see bit field map below H axis stop code H axis reference position H axis motor position H axis position error H axis auxiliary position H axis velocity H axis torque H axis analog input H Hall Input Status Reserved 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 59 DMC 40x0 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 ET G are 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 Thread Status 1 Byte BIT 7 BIT 6 BIT 5 BIT 4
82. provide information which may be useful in debugging an application program Below is a list of operands which are particularly valuable for program debugging To display the value of an operand the message command may be used For example since the operand ED contains the last line of program execution the command MG _ED will display this line number _ED contains the last line of program execution Useful to determine where program stopped _DL contains the number of available labels _UL contains the number of available variables _DA contains the number of available arrays _DM contains the number of available array elements _AB contains the state of the Abort Input _LFx contains the state of the forward limit switch for the x axis _LRx contains the state of the reverse limit switch for the x axis Debugging Example The following program has an error It attempts to specify a relative movement while the X axis is already in motion When the program is executed the controller stops at line 003 The user can then query the controller using the command TC1 The controller responds with the corresponding explanation ED Edit Mode 000 A Program Label 001 PR1000 Position Relative 1000 002 BGX Begin 003 PR5000 Position Relative 5000 004 EN End lt cntrl gt Q Quit Edit Mode XQ A Execute A 2003 PR5000 Error on Line 3 PCL Tell Error Code 27 Command not valid Command not valid while running while running
83. reconfigured as a DMC 4050 controller The A and C axes are configured for sinusoidal commutation The first phase of the A axis will be the motor command A signal The second phase Chapter 2 Getting Started e 17 DMC 40x0 User Manual of the A axis will be F signal The first phase of the C axis will be the motor command C signal The second phase of the C axis will be the motor command G signal Step 7 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 40x0 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 40x0 There can also be a combination of axes running from Galil integrated amplifiers and drivers and external amplifiers or drivers If sinusoidal commutation is to be used special attention must be paid to the reconfiguration of axes see above section for more information Connecting to External Amplifiers Here are the first steps for connecting a motion control system
84. reversed direction Stepper Motor Smoothing The command KS provides stepper motor smoothing The effect of the smoothing can be thought of as a simple Resistor Capacitor single pole filter The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor Use of KS is most applicable when operating in full step or half step operation KS will cause the step pulses to be delayed in accordance with the time constant specified When operating with stepper motors you will always have some amount of stepper motor smoothing KS Since this filtering effect occurs after the profiler the profiler may be ready for additional moves before all of the step pulses have gone through the filter It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed See the discussion below Monitoring Generated Pulses vs Commanded Pulses The general motion smoothing command IT can also be used The purpose of the command IT is to smooth out the motion profile and decrease jerk due to acceleration Monitoring Generated Pulses vs Commanded Pulses 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
85. 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 0 Normal quadrature Normal quadrature Pulse amp direction Pulse amp direction DMC 40x0 User Manual Chapter 6 Programming Motion e 120 Reverse quadrature EN 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 pulse and direction n 4 the total is 6 and the command for the X axis is CE 6 Additional Commands for the Auxiliary Encoder The command DE x y z w can be used to define the position of the auxiliary enc
86. signals to warn the host system of the error condition These signals include Signal or Function State if Error Occurs POSERR Jumps to automatic excess position error subroutine Error Light Turns on OE Function Shuts motor off if OE1 AEN Output Line Goes low DMC 40x0 User Manual Chapter 8 Hardware amp Software Protection e 180 The Jump on Condition statement is useful for branching on a given error within a program The position error of X Y Z and W can be monitored during execution using the TE command Programmable Position Limits The DMC 40x0 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 40x0 will not accept position commands beyond the limit Motion beyond the limit is also prevented Example DP0 0 0 Define Position BL 2000 4000 8000 Set Reverse position limit FL 2000 4000 8000 Set Forward position limit JG 2000 2000 2000 Jog BG XYZ Begin motion stops at forward limits Off On Error The DMC 40x0 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 for X Y Z and W axis To disable this function specify 0 for the axes When this function is enabled the specified motor will be disabled under the following 3 conditions 1 The position error for the specified axis ex
87. statements following to be automatically executed if any limit switch is activated and that axis motor is moving in that direction The RE command ends the subroutine The state of the forward and reverse limit switches may also be tested during the jump on condition statement The _ER 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 RA JP A EN Dummy Program LIMSWI Limit Switch Utility V1 _LFX Check if forward limit V2 _LRX Check if reverse limit JP LF V1 0 Jump to LF if forward JPF LR V2 0 Jump to LR if reverse JP END Jump to end LF LF MG FORWARD LIMIT Send message STX AMX Stop motion PR 1000 BGX AMX Move in reverse JP END End LR LR MG REVERSE LIMIT Send message STX AMX Stop motion PR1000 BGX AMX Move forward END End RE Return to main program DMC 40x0 User Manual Chapter 8 Hardware amp Software Protection e 182 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 The various symptoms along with the cause and the remedy are described in the following tables Installation SYMPTOM DIAGNOSIS CAUSE REMEDY Motor runs away with no Adj
88. 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 INSTRUCTION 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 40 20 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 4 280 140 5 point in the ECAM table ET 5 280 140 6 point in the ECAM table ET 6 280 140 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 Chapter 6 Programming Motion e 103 DMC 40x0 User Manual ET 9 40 20 10 point in the ECAM table ET 10 0 0 Starting point for next cycle EB 1 Enable ECAM mode JGZ 4000 Set Z to jog at 4000 EG 0 0 Engage both X and Y when Master 0 BGZ Begin jog on
89. the input prompt the controller will respond with the following T Response from command MG len6 S4 E Response from command MG len5 S4 S Response from command MG len4 S4 T Response from command MG len3 5S4 M Response from command MG len2 5S4 E Response from command MG lenl 54 Functions FUNCTION DESCRIPTION ASIN n Sine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution COS n Cosine of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution TAN n Tangent of n n in degrees with range of 32768 to 32767 and 16 bit fractional resolution ASIN n Arc Sine of n between 90 and 90 Angle resolution in 1 64000 degrees YACOS 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 Chapter 7 Application Programming e 153 DMC 40x0 User Manual IE convert fraction Flen to integer AN n Return analog input at general analog in n where n starts
90. the stepper motor driver The pulses which are generated by the smoothing filter can be monitored by the command TD Tell Dual TD gives the absolute value of the position as determined by actual output of the buffer The command DP sets the value of the step count register as well as the value of the reference position For example DP 0 defines the reference position of the X axis to be zero Chapter 6 Programming Motion e 115 DMC 40x0 User Manual Stepper Smoothing Filter Output Buffer 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 the main encoder input Note The auxiliary encoder is not available while operating with stepper motors The position of the encoder can be interrogated b
91. through the Galil software under the File menu in WSDK or under the Tools menu in the Galil Smart Terminal Use the New Controller button to add a new entry to the Registry You will need to supply the Galil Controller model eg DMC 40x0 Pressing the down arrow to the right of this field will reveal a menu of valid controller types You then need to choose serial or Ethernet connection The registry information will show a default Comm Port of 1 and a default Comm Speed of 115200 appears This information can be changed as necessary to reflect the computers Comm Port and the baud rate set by the jumpers found on the communications board The registry entry also displays timeout and delay information These are advanced parameters which should only be modified by advanced users see software documentation for more information Once you have set the appropriate Registry information for your controller Select OK and close the registry window You will now be able to communicate with the controller To establish communication to the controller open up the Terminal and hit the Enter key You should receive a colon prompt Communicating with the controller is described in later sections DMC 40x0 User Manual Chapter 2 Getting Started e 16 If you are not properly communicating with the controller the program will pause for 3 15 seconds and an error message will be displayed In this case there is most likely an incorrec
92. to the coordinated motion path To handle these applications the DMC 40x0 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 as tangent TN 2000 360 500 2000 360 counts degree posit
93. to your Galil amplifier or driver refer to the specific amplifier driver in the Integrated Components section Molex Part Numbers Used There are 3 different Molex connectors used with the DMC 40x0 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 Note These part number list the connectors that are found on the controller For more information see the Molex Website Molex Part Number Crimp Part Number Type 39 31 0060 44476 3112 6 Position 39 31 0040 44476 3112 4 Position 39 31 0020 44476 3112 2 Position Galil Amplifier Driver Molex Part Number Type None 39 31 0020 2 Position 39 31 0060 6 Position AMP 43040 39 31 0040 4 Position 39 31 0040 4 Position AMP 43140 39 31 0020 2 Position 39 31 0060 6 Position SDM 44040 39 31 0040 4 Position 39 31 0060 6 Position SMD 44140 Motor 39 31 0040 4 Position Appendices e 207 DMC 40x0 User Manual Cable Connections for DMC 40x0 The DMC 40x0 requires the transmit receive and ground for slow communication rates i e 9600 baud For faster rates the handshake lines are required The connection tables below contain the handshake lines Standard RS 232 Specification
94. two RS232 ports and 1 Ethernet port The main RS 232 port is the data set and can be configured through the jumpers on the top of the controller The auxiliary RS 232 port is the data term and can be configured with the software command CC The auxiliary RS 232 port can be configured either for daisy chain operation or as a general port This configuration can be saved using the Burn BN instruction The RS232 ports also have a clock synchronizing line that allows synchronization of motion on more than one controller Galil software is available for PC computers running Microsoft Windows to communicate with the DMC 40x0 controller Standard Galil communications software utilities are available for Windows operating systems which includes GalilTools This software package has been developed to operate under Windows and Linix 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 app
95. values of the main output port of the controller Outputs 1 8 block 0 The additional parameters set the value of the extended I O as outlined OP m a b where m is the decimal representation of the bits 1 8 values from 0 to 255 and a b c d represent the extended I O in consecutive groups of 16 bits values from 0 to 65535 Arguments which are given for I O points which are configured as inputs will be ignored The following table describes the arguments used to set the state of outputs Argument Blocks Bits Description m 0 1 8 General Outputs 2 3 17 32 Extended I O b 4 5 33 48 Extended I O Chapter 7 Application Programming e 171 DMC 40x0 User Manual For example if block 8 is configured as an output the following command may be issued OP 7 7 This command will set bits 1 2 3 block 0 and bits 33 34 35 block 4 to 1 Bits 4 through 8 and bits 36 through 48 will be set to 0 All other bits are unaffected When accessing I O blocks configured as inputs use the TIn command The argument n refers to the block to be read n 0 2 3 or 4 The value returned will be a decimal representation of the corresponding bits Individual bits can be queried using the IN n function where n 1 through 8 or 17 through 48 If the following command is issued Individual bits can be queried using the IN n function where n 1 through 48 MG IN 17 the controller will return the state of the least significant bit of block 2 assuming b
96. velocity and position will be accurate The t value is 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 Chapter 6 Programming Motion e 105 DMC 40x0 User Manual 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 14 v t 1000 1 1000 Desired Velocity Profile 1200 1000 800 600 m Velocity 400 Velocity counts second 200 Time Seconds Figure 6 14 Pa
97. 0 250us update rate MOVE Label PRX 1000 Position Relative Move BGX Begin Motion MCX Wait for motion to complete WE 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 40x0 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 40x0 can decide between two motion profiles based on the state of an input line Command Format JP and JS FORMAT DESCRIPTION Chapter 7 Application Programming e 139 DMC 40x0 User Manual 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 s
98. 0 counts of the linear encoder The design approach is to drive the motor a distance which corresponds to 40 000 rotary counts Once the motion is complete the controller monitors the position of the linear encoder and performs position corrections This is done by the following program INSTRUCTION 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 V1 10000 _ DEX V2 _TEX 4 V1 JP END ABS V2 lt 2 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 40x0 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 accomplished with the IT command This command filters the acceleration and deceleration functions to produce a smooth velocity profile The resulting velocity profile has continuous acceleration and results in reduced mechanical
99. 0 User Manual This command causes the controller to be reconfigured as a DMC 4050 controller The A and C axes are configured for sinusoidal commutation The first phase of the A axis will be the motor command A signal The second phase of the A axis will be the motor command F signal The first phase of the C axis will be the motor command C signal The second phase of the C axis will be the motor command G signal Step C Specify the Size of the Magnetic Cycle Use the command BM to specify the size of the brushless motors magnetic cycle in encoder counts For example if the X axis is a linear motor where the magnetic cycle length is 62 mm and the encoder resolution is 1 micron the cycle equals 62 000 counts This can be commanded with the command BM 62000 On the other hand if the C axis is a rotary motor with 4000 counts per revolution and 3 magnetic cycles per revolution three pole pairs the command is BM 1333 333 Step D part 1 Systems with or without Hall Sensors Test the Polarity of the DACs Use the brushless motor setup command BS to test the polarity of the output DACs This command applies a certain voltage V to each phase for some time T and checks to see if the motion is in the correct direction The user must specify the value for V and T For example the command BSA 2 700 will test the A axis with a voltage of 2 volts applying it for 700 millisecond for each phase In response this tes
100. 00 or if you require encoder inputs with a Rev A ICM 42100 The ID command will indicate the hardware Rev of the ICM 42100 where Rev B will return Rev 1 and Rev A will return Rev 0 A typical response from ID with a ICM 42100 Rev B is shown below DMC4000 Connector J3 Communications Board CMB 41012 5 0 volt i o rev 0 Connector Jl 42100 Sine rev 1 Connector Pl Servo Amplifier Board AMP 43040 500 watt rev 1 Connector P2 Servo Amplifier Board AMP 43040 500 watt rev 1 AT ICM 42100 1100 e 263 DMC 40x0 User Manual Connectors for ICM 42100 Interconnect Board ICM 42100 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 ICM 42100 I O E H 44 pin HD D Sub Connector Female For DMC 4050 thru DMC 4080 controllers only Pin Label Description Pin Label Description Label Description GN DILO DI13 Digital Ground Digital Input 10 F latch Pin c 30 Digital Input 13 DI16 Digital Input 16 Digital Ground FLSE Forward Limit Switch E G FLSF Forward Limit Switch F G FLSG Forward Limit Switch G FLSH Forward Limit Switch H NO o0 N an nN A w N D ND 10 HOMH Home Switch H RLSH Reverse Limit Switch H D in opw 12 DO11 Digital Output 11 13 DO14 Digital Output 14 15 5V 5V N Digital Ground N HOMG Home Switch G RLSG Reverse Limit Switch G Ni E rca DO10
101. 00002020 Error 00001156 Torque 2 1309 Axis Position 00000700 Error 00001300 Torque 2 3963 Axis Position 00000156 Error 00000792 Torque 1 4599 G Axis Position 00002212 Error 00001732 Torque 3 1926 H Axis Position 00002665 Error 00001721 Torque 3 1723 Recursed through 8 stacks AoA Ww Pp 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 instances 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 Note Actual processing time will vary dependent upon number of axes communication activity number of threads currently executing etc ta i 0 initialize a counter t TIME set an initial time reference loop NO this comment takes time to process this
102. 008 oq ey Halse NOSE 9000 SOO jog ey SIE gaisg SNe m POLE eres SNOEE 1340 bl ae be dO vb say 2b ac a 1380 bb a E dINO tt L eo k S38 ZL HiS a 2 aa z 0zOl Lt 50 if l As SI 3d1s 9 AS SI vals 94 m l gyorg 401 l H 3 ON H 3 Y3AI8O TWNYALXS a v Ol 0 V 83AISO TWNHSLX4 0 1 030N31X3 m m El a Aste 5 5 S RESI ale Z 2 AVE ON PL 5 E e awe gl E 2 By z 5 aly Zt 3 2 2 2 z z svp a m 2 5 S 2 aye vv Z m S D 5 D a i myz Ivo m 3 E gt 2 2 N Nove En 7 7 5 7 F i pu ES i z 8 E i b gt gt ANDY I i 3 i BR RR i DOWNY S amp oo S El Ss E y 4 y zov REN zoay 103v nal mie nal MH umdy N AS N Nt Wely l ano an9 No No We H3 aY l 4 m m L L L 2 l By Be i 2 p4 l fa 6 S 6 6 le o jo o je jo o o jo Q is o fo gt a m 5 m m 5 m m D D lo D D D D D I D 5 m o o gt l l bh hh vane wane ah Oy l N9 INL an TWEE YSN NI SQVW ONG wg A TOHLNO9 NOLLOW VO Tivo OOO AND o olo a aL olo Y WWE aye EME E o E any vamos HRS o8s0rv OWd Lt Lt a YIMOd ONIS H3dd31S 3000Na wv YaMOd H 9 d 3 YaMOd d 9 a y HE as ra 7 2 22 oe 9 sau ie 2 gt l Se Rast EO es e Oe EN Nem 4 J Figure 2 2 Outline of the of the DMC 4080 Chapter 2 Getting Started e 8 DMC 40x0 User Manual DMC 40x0 Power Connections Power Connector for Controller without Galil A
103. 040 connected as a Modbus master to a 3rd party PLC The DMC 4040 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 2 Dimension an array to store the results DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 54 DM myanalog 4 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 4040 connected as a Modbus master to a hydraulic pump The DMC 4040 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
104. 0x0 instruction set is BASIC like and easy to use Instructions consist of two uppercase letters that correspond phonetically with the appropriate function For example the instruction BG begins motion and ST stops the motion In binary commands are represented by a binary code ranging from 80 to FF ASCII commands can be sent live over the communications port for immediate execution by the DMC 40x0 or an entire group of commands can be downloaded into the DMC 40x0 memory for execution at a later time Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter Binary commands cannot be used in Applications programming This section describes the DMC 40x0 instruction set and syntax A summary of commands as well as a complete listing of all DMC 40x0 instructions is included in the Command Reference Command Syntax ASCII DMC 40x0 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 40x0 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 and not begin execution until the user gives the lt return gt command IMPO
105. 1 to go low and then starts motion Note The AI command actually halts execution of the program until the input occurs If you do not want to halt the program sequences you can use the Input Interrupt function II or use a conditional jump on an input such as JP GO IN 1 1 INPUT Program Label AI 1 Wait for input 1 low PR 10000 Position command BGX Begin motion EN End program Event Trigger Set output when At speed ATSPEED Program Label JG 50000 Specify jog speed AC 10000 Acceleration rate BGX Begin motion ASX Wait for at slew speed 50000 SB1 Set output 1 EN End program Event Trigger Change Speed along Vector Path The following program changes the feed rate or vector speed at the specified distance along the vector The vector distance is measured from the start of the move or from the last AV command VECTOR Label VMXY VS 5000 Coordinated path VP 10000 20000 Vector position VP 20000 30000 Vector position VE End vector BGS Begin sequence AV 5000 After vector distance vs 1000 Reduce speed EN 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 Label PR 12000 Distance SP 20000 Speed AC 100000 Acceleration BGX Start Motion AD 10000 Wait a distance of 10 000 counts SP 5000 New Speed AMX Wait until motion is completed W
106. 1100 e 265 DMC 40x0 User Manual ICM 42100 External Driver E H 44 pin HD D Sub Connector Male For DMC 4050 thru DMC 4080 controllers only These pins may be used for other functions when STEP option is not ordered Pin Label Description Pin Label Description Pin Label Description 1 Reserved Step E_N STPE PWM Step E STPF PWM Step F 2 STPG PWM Step G Reserved Step F_N 4 Reserved Step G_N 2 3 Reserved Step H_N 2 STPH PWM Step H Digital Ground 4 Reserved Dir E_N 3 Sign Direction E DIRF Sign Direction F 5 Sign Direction F Reserved Dir F_N 5 Reserved Dir G_N j 6 Reserved Dir H_N E Sign Direction H Digital Ground 7 AENE Amplifier Enable E AECI Amp Enable Common 1 AENF Amplifier Enable F 8 AENH Amplifier Enable H AENG Amplifier Enable G AEC2 Amp Enable Common 2 11 MCMF Motor Command F Reserved MCMDE_N Reserved MCMDF_N j 12 Reserved MCMDG_N MCMG Motor Command G MCMH Motor Command H 15 5V 5V 30 N C No Connec Notes 1 Negative differential motor command outputs when DIFF option is ordered on ICM Ex DMC 4080 C012 1100 1100 DIFF These pins may be used for other functions when DIFF option is not ordered 2 Negative differential step and direction outputs when STEP option is ordered on ICM EX DMC 4080 C012 1100 1100 STEP DMC 40x0 User Manual A7 ICM 42100 1100 e 266 ICM 42100 Encoder 15 pin HD D Sub Connector Female S gt w Au
107. 12V AECOM2 AEC2 AECOM2 AEC2 AECOM2 RP2 square pin next to RP2 label is 5V Dot on R pack opposite RP2 label Dot on R pack next to RP2 label Dot on R pack opposite RP2 label Dot on R pack next to RP2 label Dot on R pack opposite RP2 label Dot on R pack next to RP2 label Note Table3 3 Sourcing Configuration Chapter 3 Connecting Hardware e 43 DMC 40x0 User Manual ICM 42200 Amplifier Enable Circuit This section describes how to configure the ICM 42200 for different Amplifier Enable outputs The ICM 42200 is designed to be used with external amplifiers 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 Every different configuration is described below with jumper settings and a schematic of the circuit 45V 5V i a di HIGH AMP ENABLE AEN TO DRIVE SINKING dE PIN 2 SHn 5V MOn 0V a 23456 12V 2 12V A d HIGH AMP ENABLE AEN TO DRIVE SINKING S PIN 2 SHn 5V MOn 0V AMP ENABLE POWER PIN 20 ISOLATED SUPPLY A ii HIGH AMP ENABLE AEN TO DRIVE SINKING CEREN PIN 2 SHn 5V ia AMP Suites DMC 40x0 User Manual Chapter 3 Connecting Hardware e 44 5V LOW AMP ENABLE SINKING 12V LOW AMP ENABLE SINKING ISOLATED SUPPLY LOW AMP ENABLE SINKING
108. 2 32 64 ATO set initial time reference loop REM calculate filtered output and then way 2 samples from last REM time reference last AT 2 1 or ATO anl k1 AN 1 k2 anl1 AT 2 1 JP loop Extended I O of the DMC 40x0 Controller The DMC 40x0 controller offers 32 extended I O points which can be configured as inputs or outputs in 8 bit increments through software The I O points are accessed through 1 44 pin high density connector Configuring the I O of the DMC 40x0 The 32 extended I O points of the DMC 40x0 series controller can be configured in blocks of 8 The extended I O is denoted as blocks 2 5 or bits 17 48 The command CO is used to configure the extended I O as inputs or outputs The CO command has one field DMC 40x0 User Manual Chapter 7 Application Programming e 170 COn where n is a decimal value which represents a binary number Each bit of the binary number represents one block of extended I O When set to 1 the corresponding block is configured as an output The least significant bit represents block 2 and the most significant bit represents block 5 The decimal value can be calculated by the following formula n n2 2 n3 4 n4 5 n5 where nx represents the block If the nx value is a one then the block of 8 I O points is to be configured as an output If the nx value is a zero then the block of 8 1 O points will be configured as an input For example if block 4 and 5 is to be configured as an ou
109. 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 3 Connecting Hardware e 37 DMC 40x0 User Manual High Power Opto Isolated Outputs The DMC 40x0 has different interconnect module options this section will describe the 500mA optically isolated outputs that are used on the ICM 42x00 Electrical Specifications Output Common Max Voltage 30 VDC Output Common Min Voltage 12 VDC Max Drive Current per Output 0 5 A not to exceed 3A for all 8 outputs Wiring the Opto Isolated Outputs The ICM 42x00 module allows for opto isolation on all of the digital inputs and outputs The digital outputs are optically isolated and are capable of sourcing up to 0 5 A per pin with a 3 A limit for the group of 8 outputs The outputs are configured for hi side drive only The supply voltage must be connected to output supply voltage OPWR and the supply return must be connected to output return ORET Figure 3 3 shows the manner in which the load should be connected The output will be at the voltage that is supplied to the OPWR pin Up to 30 VDC may be supplied to OPWR 3 3V de OPWR VO A D 4A NW e CPU IRF73I42 MMBD 1204 10K LOAD ORET VO A D 3 3V OPWR VO E H
110. 2 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 E Connect Hall Sensors if available Hall sensors are only used with sinusoidal commutation and are not necessary for proper operation The use of Hall sensors allows the controller to automatically estimate the commutation phase upon reset and also provides the controller the ability to set a more precise commutation phase Without Hall sensors the commutation phase must be determined manually The Hall Effect sensors are connected to the digital inputs of the controller These inputs can be used with the general use inputs bits 1 8 the auxiliary encoder inputs bits 81 96 or the extended I O inputs of the DMC 40x0 controller bits 17 80 NOTE The general use inputs are optoisolated and require a voltage connection at the INCOM point for more information regarding the digital inputs see Chapter 3 Connecting Hardware Each set of sensors must use inputs that are in consecutive order The input lines are specified with the command BI For example if the Hall sensors of the C axis are connected to inputs 6 7 and 8 use the instruction
111. 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 Fig 2 8 Note that the vector motion starts at a local position 0 0 which is defined at the beginning of any vector motion sequence See application programming for further information Instruction Interpretation VM AB 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 VE End vector sequence BGS Start motion DMC 40x0 User Manual Chapter 2 Getting Started e 30 4000 4000 0 4000 R 2000 O 4000 0 0 0 local zero Figure 2 7 Motion Path for Circular Interpolation Example Chapter 2 Getting Started e 31 DMC 40x0 User Manual Chapter 3 Connecting Hardware Overview The DMC 40x0 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 high power opto isolated outputs and 8 analog inputs configured for voltages between 10 volts ontrollers with 5 or more axes have an additional 8 opto 1solated inputs and an additiona 1g 4080 C 11 ith 5 h dditional 8 isolated i d an additional 8 high power opto isolated outputs
112. 34 Reset put ssp in ei ra 34 Uncommitted Digital Inputs y Wirme Me Datos lied Ma tS o E 34 Electrical Specifications BreDirscu nal Capability pcc 34 Using an isolated Power Supply ocoricininie iniciado 36 Bypassing the Opto Isolation s TEL Ut sn re es ae EiS 37 The Auxiliary Encoder Tapu s conspira 37 High Power Opio Tsolated QUEDO cau 38 Electrical Specifications Wiring the Opto Isolated Outputs i Anglos MPS coo E 39 TSE R S Electrical Specifications SS MAL AAA eA a ial aA nace ease 39 A O S Hone PET OTE RE TP 39 Error Output e Extended WO of the DIMC 40x0 Controller siii eiii reir 40 Electrical Specifications 3 3V Standard ccccocococicorannecinncnnes 40 Electrical Specifications 5V Option Amplifier Interface Electrical Specifications Overview ICM 42000 and ICM 42100 Amplifier Enable Circuit 41 ICM 42200 Amplifier Enable Circult occcionccioonecioniacerecnicicaso 44 Chapter 4 Software Tools and Communication 48 ESO geste tice ieee ices Geeta ge ai eens see aes acetates ES232 and RS422 PWG sra RS 232 Configuration RS 422 Configuration Ethernet Configuration sossa Communication Protocol sesioan Addres ini aona E Communicating with Multiple Devices iE II a a iertee tern MeCN Ter eee rery Using Third Party So ar a bai MO OS Modbus Examples
113. 4 CMP 14 ORET l 321022 18 1023 21041 D a2 RES 18 STPD 2 SIP 43 DO7 29008 13 DO6 32 RES 18 STPH eama 43 D015 280018 13 D014 l l 33GND 9 jopg 31024 E 38 GND 3 RES 28 D05 33 GND 3RES 28 D013 E 19 DIRA 42 DO4 12 D03 19 DIRE 42 D012 12 D011 341027 yop 41025 m 34DIRB Speg 4 RES Sool 22002 ORW p DRF speg 4 RES Giver 2221 op 1 351030 51029 35 RES 5 DIRC 26 NIC 35 RES 5 DIRG 26 NIC I 211031 21 DIRD 40 GND 10 HOMD 21 DIRH 40 GND 10 HOMH O 36 GND 61032 36 GND 6 RES 25 RLSD 36 GND 6 RES 25 RLSH 22 NIC 22 AEC1 39 FLSD 9 HOMC 2 AEC1 39 FLSH 9HOMG 37 1034 71033 37 AENB 7 AENA 24 ALSC 37 AENF 7 AENE 24 RLSG J RESET 38 N C 231035 81036 38 AEC2 PO AENG 8 AEND Ba 23 RLSB SHOWS 38 AEC2 GAENG 8 AENH ASS 23 RLSF OE L 24 1037 24 NIC 37 FLSB 7HOMA 4 NIC 37 FLSF 7 HOME l 39GND osc 21038 OPT i 39GND os yay SNC geFisa RISA gi scons 39GND as stay INS gerise ALSE giscom 401039 Soso TONO MO GH LINK ACT 40NCMA de zo 10 121 voo ZINC so 40MCME Se meo 10 121 co ZINC sE 1 I 41 1042 27 1043 11 1041 38 4K h 41 RES 27 MCMC 11 MCMB 34 DIB 20 ABRT 4DI7 41 RES 27 MCMG 11 MCMF 34 DIt6 20 ABRT 4015 I 42 1045 12 1044 19 2K D ERROR 42 MCMD 12 RES 19 DI6 42 MCMH 12 RES 19 DI14 43 GND 281046 131047 gt 43 GND 28 FES 13N C El 18 DIS DA 43 GND ER 13 NIC aons 18 D111 aniz l UPGD h l anc RIO tne MAST Power anc Somo TNC o INCOM Ono anc NG TNC BEDNO 17INCOM En l i HOY 45 RES R 15 5V 16 RST j 1545V 16 RST LI d VDC 20 201 DC GROUND p Figure 2 4 Power Conn
114. 45 40 temp IN 1 amp IN 2 The variable speed is equal to 7 5 multiplied by V1 and divided by 2 The variable count is equal to the current value plus 2 Puts the position of X 28 28 in result 40 cosine of 45 is 28 28 temp is equal to 1 only if Input 1 and Input 2 are high Bit Wise Operators The mathematical operators amp and are bit wise operators The operator amp is a Logical And The operator is a Logical Or These operators all ow for bit wise operations on any valid DMC 40x0 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 represente as one byte 8 bits therefore th placed in the top byte of the var fraction The characters can be example TEST d as 32 bits of integer and 16 bits of fraction Each ASCII character is represented e input variable can hold up to six characters The first character of the string will be iable and the last character will be placed in the lowest significant byte of the individually separated by using bit wise operations as illustrated in the following Begin main program DMC 40x0 User Manual Chapter 7 Application Programmin
115. 5 counts 937 counts sec move of 214 counts 750 counts sec move of 151 counts 437 counts sec in in in in in in 256 sam sam sam sam sam 256 sam pies pies pies pies pies pies with a final with a final with a final with a final with a final with a final move of 57 counts in 256 samples with a final 0 counts sec of PVT buffer Chapter 6 Programming Motion e 107 DMC 40x0 User Manual Velocity counts second Actual Velocity and Position vs Time 1400 Velocity e Position Position counts Time Samples Figure 6 15 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 Y Axis Counts 6000 5000 4000 3000 2000 1000 Required XY Points 4 4 0 1000 2000 3000 4000 5000 6000 7000 8000 X Axis Counts Figure 6 16 Required XY Points DMC 40x0 User Manual C
116. 50 Step Drive Resolution Setting YA command 250 ELO it dd 251 A4 SDM 44140 D4140 252 Desorption see oe st erties S 252 lr a a ao a aaa a E 253 Mating Connectors fy MN A ete 254 Current Level Setup AG Command Low Current Setting LC Command a PEGS TD nr tee rere Ten treet 254 A5 CMB 41012 C012 255 MES CR AO SA aes abil gee stas ie eadvannds 255 Connectors for CMB 41012 Interconnect Boat cion ssn esrsiteccrenes 255 CMB 41012 Extended I O 44 pin HD D Sub Connector Male ccccococonconocinonconenencnnnnanoncnnanenonccnoncnccanannos 255 RS 232 Main Port Malo scrasa R5 232 Auxiliary Port Female j ninos sitas RS 422 Main Port Non Standard Option m RS 422 Auxiliary Port Non Standard Option 257 EME iii Jumper Description for CMB 41012 se LED Depa a a es coor ese Ss sacar A6 ICM 42000 1000 259 DES eae Rene cere ee ree eT eer E Connectors for ICM 42000 Interconnect Board coi 259 ICM 42000 I O A D 44 pin HD D Sub Connector Female 259 ICM 42000 I O E H 44 pin HD D Sub Connector Female 260 ICM 42000 External Driver A D 44 pin HD D Sub Connector Male ccoccoccoconcoccocicncncocanocncaccnccnccconoss 260 ICM 42000 External Driver E H 44 pin HD D Sub Connector Male cccccccicoconiccnncncnonconanconacancanccncnnos 262 ICM 42000 Encoder 15 pin HD D Sub Connector Fema
117. 6 120 166 172 180 191 198 Quit aN OI t AEE hess aceseiks dias 1 198 211 Record A NN 77 111 156 159 A A eases ied el bea ube eae octet eds ae ea ens sea vase tetas das eae saad ald eae MT eos 15 16 155 RESGE Aen Be da osteo eo oak eh eR 2 14 19 22 23 32 39 52 62 139 179 181 211 257 ne AE A 1A AE A NN 87 123 SDK 130 Serial Pom ae A EA BOLE 16 17 146 147 161 163 208 209 Set Biter a A A A A WS RNA BR E e a ER 167 210 Sine 77 102 153 Sifigle Ended neire era a ad 6 19 21 198 Slew 24 25 78 98 136 138 172 SmoOothin gasirea n a E delve cater ESEE E aee ASAE AE a a EIEE a EE 1 24 77 87 88 92 94 122 Special Label ee blended estes 132 182 SPCCIHICAtL OM 2 Avie s covers OS 87 92 E O 121 176 183 188 194 DS LACK A O AO 142 145 147 A E EIN ll a E Ne a8 158 SLEP LIOI Sr cess ah OT 2 3 5 13 24 124 Step MOOR NS KS Smoothing cceceeceeseesceeeeseeeseeseeeeeseeeneeensaees 24 Stepper Position Maint nanice e PA 117 Stop 84 00 700 POPECCNE OL O aa 75 158 SON O 86 92 145 182 SUDTOU IM ra tt data tc 32 91 130 132 139 161 168 180 A E lsa vested se weave bate EE EEREN nueat eTEN aes 1 6 48 99 Mt a dd Ana ni 70 71 Laietana a a de E TS 77 91 93 Va di aio 113 TM nt A dt cas o heii e id ae ce ER 5 19 Tell Error o SP A AVE A 74 75 Tell P sitiomnes rarene Re a E E o E IEEE ESB BD REID STs Sos Boas 26 62 75 165 Ts 21 75 e dl 14 15 16 17 20 28 32 70 155 MA A ee
118. 6 95 Halt 87 138 NE LEIRO Aig REEERE AAS ETAS ee a rr en a E Se eS os ota ene 32 10167 Hardware Handshake cu baii 49 62 Home pu di riot cateo ico daa Lada 33 156 NA E EN NO 124 DMC 40x0 User Manual Index e 274 Amplifier Enables Demn iaiia 19 Digital putita ets 1 168 Home Input encina a dis 198 Limit Switche 3 ee eee rie tice elie ae a 211 Index Pull Secs ise See ck ais ose eae Bes Dek as EE A eR 19 33 A 132 143 Input Inti AA AA Nt AAA Teas Sari 132 144 168 169 Inputiof Data A A A A AA DAA A R 159 Install e tt de 183 Tnbe Sratry a a AI A A AA Aira 24 25 188 Internal Variable A a EE ER 140 154 155 Interrogation icici eee ease ER E A dias 24 26 27 74 75 89 95 164 165 Tnterr pt iene cake vk cas hPa eae ake ate E ween He ln cs Dba wade dat awed das age eo AC aA ko LOL Na LAOS Ce aaa ON eae 138 143 A O 20 120 Jog 1 80 95 104 128 137 144 155 161 176 181 Joystick r Ge ieee eh TA ies eters oo AO 81 155 175 A Ri ede tee Mech a Beal he ses Bi Bie dal he te Nol aaa ert Ae Res 13 14 184 257 262 272 Keyword eehne Att te AT eh se te BNA Ms Boh Dd Aula AN T 140 152 154 156 A O OA 24 81 91 102 113 122 128 136 155 160 174 176 181 NN OR se Ne AE AN Be lek Oe tet dae iceman Sey seta at E N 143 156 180 LIMIS Wil ats eit ar ea take eth ee Aa a hotles ee Nenad SNM aN athe otal tanks oh Atl ahi tha 32 132 143 180 Teinear Interpolation 42s tx tate eee Ri ON 76 86 96 110 T
119. 73 Cleat Bd A ERI EEE ERNE AR 167 210 Clear Sequence iii 86 88 92 94 NT 156 CMDERR ii sde 132 143 145 Code144 158 172 175 Soma A E 78 80 88 94 158 Commanded Position ccccccccccessscceesscceesseccessceceesceccssseccesseecesseeccesseccssseeceeeeeesseeesssseeeseeeeensssseeeeeees 79 95 145 158 185 Gomaditiorial O o 34 135 138 SAA ies A TR O 76 110 Coordinated MOON BEI SS A Rabe AS i E Ao 76 91 CSO SIS eas see cata steers ON eae aot tees O 77 152 157 DAC188 191 195 Daim pin gai cceest seapesdeadeesth cvvacrnnes idolo 188 Dala Caplio ssl 157 Data Records is td Meal pu sires a 55 60 61 DU ti laa 134 Index e 273 DMC 40x0 User Manual Decele rations x ce Seki cease Lge A IRE at an Eo 0 160 Digital Filter scecscctees O LAG eee bad sa thos Bees cuba Sa eb Sac edd cect gweld ah sense eed ita 192 195 Digital Mp a A A A A eae E a eee e ie 34 153 Digital OPUS dada beato Jets a 153 Dia A a EE aida BR 121 158 A Opis icczieses t Beas Sacte eck Bee T A MA RE ee OR AR 77 114 115 120 176 CATV Es hac AA E lee oo ua ca A A EE ae EE EE AE BE ACT 100 103 Echo49 62 Edit Modena A A Bases Cath sa AA A CSI BCE 28 144 EII AAA AA A A E E a dre 28 EEPROM eiieeii at r A A dde 4 14 171 257 Electronic CA LA A E PS I BCE E E E E 76 99 Ellipse Scalene nna a a RE AKE EE o E E ORRE A A eis 94 E coder eee pS eS SC Tag E E a a A A a nE INEA 1 5 19 24 37 168 199 211 Differential aaa iaa 6 19 21 37 168 19
120. 8 199 Dual Encoder ooocooccnoccnocnnonnconnnonnnocononoconononoconnnnnnnoos 75 A A A E AED ROA 53 74 156 Error A O a E ee tid a al a AA aiii ii a 0 get E16 10 EAEE rah Nene EAE A AE O AE AE CEE ORESTEEN N A 144 179 Errored NS OfFOn ErTOfT coooccccnnncccnonnnnonnncconnnaconnnaconnnonoranancnonononons 18 41 A A O Communication IntertUpt oooooncninninniocnnnnnncnonnnnnncnnns 146 161 Design Example ineine nen ai 25 Ethernet Communication Error ccccccccsccesseeesseeees 147 Input Intermuptcescci ecsstesnede nea a helt Setecrtteeshecess 169 A E 230 Output Bit csn era Dat eee 167 Output Portu os 167 Printing a Variable oooonooncnnnnncnicnnncnocnooncnnncnnnnnnnnnnno 164 Set Bit and Clear Bit ooooocnooccnoccconcconncnonanccnonnnanonnnnno 167 Sinusoidal ComMuUtatiOM ooooocnncccnnoncnononcnononcnononanononos 17 21 Start Motion on SWitCh oooocooccnocnconncoonccononncnononnno 168 Turn on output after MOVe ooooooonncicnionononccononnconnnnnnns 167 Using Input ade 168 NN 88 92 94 138 173 O O eee 62 134 IS A NEON AM A A a a 25 Proportional coco opticas 24 25 Find EO a6 comio ica 33 EM ii dd 163 165 166 Frequency ii A as 24 124 194 198 Func dai ista 86 111 121 138 140 144 174 176 UOC iaa ArHthmetiC sita tddi 130 166 Gain 3 5 20 24 25 28 155 ct BAT h TOPE EEEE A Se ee ta dorar NO 95 Geanina Apis a a sce dete Mths hens a a a a bet cdevee nhaagoetastncase terete hace 1 7
121. A The ICM 42000 is user configurable for a broad range of amplifier enable options including High amp enable Low amp enable 5 V logic 12 V logic external voltage supplies up to 24 V and sinking or sourcing Two ICMs are required for 5 thru 8 axis controllers For more information regarding the Amplifier Enable Operation see Chapter 3 and Configuring the Amplifier Enable Circuit in the Appendix For electrical specifications on the I O see Chapter 3 Connectors for ICM 42000 Interconnect Board ICM 42000 I O A D 44 pin HD D Sub Connector Female Pin Label Description Pin Label Description Pin Label Description 10 HOMD Home Switch D RLSD Reverse Limit Switch D GN Digital Ground Alun Q S J 15 5V 5V 30 5V 5V DMC 40x0 User Manual A6 ICM 42000 1000 e 258 ICM 42000 I O E H 44 pin HD D Sub Connector Female For DMC 4050 thru DMC 4080 controllers only Pin Label Description Pin Label Description Pin Label Description 2 o Distt input 97 atch INCOM DO Digital input 10 F latch 3 DI12 Digital Input 12 H latch Dill Digital Input 11 G latch DI13 Digital Input 13 4 DI15 Digital Input 15 DI14 Digital Input 14 DI16 Digital Input 16 5 Electronic Lock Out ABRT Abort Input Digital Ground 6 uscom Limit Switch Common FLSE Forward Limit Switch E 7 HOME Home Switch E RLSE Reverse Limit Switch E FLSF Forward Limit Switch F 8 HOMF Home Switch F
122. A B C D values PR Request B value only The controller can also be interrogated with operands Operands Most DMC 40x0 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 Used as an Operand Also see description of operands in Chapter 7 Command Summary For a complete command summary see Command Reference manual Chapter 5 Command Basics e 75 DMC 40x0 User Manual Chapter 6 Programming Motion Overview The DMC 40x0 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 4010 are single axis controllers and use X axis motion only Likewise the DMC 4020 use X and Y the DMC 4030 use X Y and Z and the DMC 4040 use X Y Z and W The DMC 4050 use A B C D and E The DMC 4060 use A B C D E and F The DMC 4070 use A B C D E F and G The DMC 4080 use the axes A B C D E F G
123. All Galil controllers belong to a default multicast address of 239 255 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 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 DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 52 The DMC 40x0 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 byte slave address The DMC 40x0 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 ca
124. C if the value of V1 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 motor to absolute position 1000 counts and back to zero ten times Wait 100 msec between moves BEGIN Begin Program COUNT 10 Initialize loop counter LOOP Begin loop PA 1000 Position absolute 1000 BGX Begin move AMX Wait for motion complete WT 100 Wait 100 msec 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 40x0 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 sin
125. C012 1000 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 40x0 Power Connections section in Chapter 2 This option is not valid when Galil amplifies are not ordered with the DMC 40x0 Part number ordering example DMC 4010 ISCNTL C012 1000 ETL ETL Certified DMC 40x0 The DMC 40x0 can be ordered in a configuration that is ETL listed CAMARA RAN SEIS Figure 22 ETL Mark with ETL Option Part number ordering example DMC 4010 ETL C012 1000 CMB Communication Board Options 5V Configure Extended I O for 5V logic The 5V option for the CMB 41012 configures the 32 configurable extended I O for 5V logic The standard configuration for the extended I O is 3 3V For more information see the Extended I O of the DMC 40x0 Controller section in Chapter 3 Part number ordering example DMC 4010 C012 5V 1000 Appendices e 203 DMC 40x0 User Manual RS 232 RS 422 Serial Port Serial Communication The default serial configuration for the DMC 40x0 is to have RS 232 communication on both the Main P1 and Aux P2 serial ports The controller can be ordered to have RS 422 on the Main Aux or both serial ports Part number ordering example DMC 4010 C012 P422 1000 ICM Interconnect Board Options SSI S
126. CI 1 Check for enter NMLP Routine to check input from terminal JP NMLP P2CD lt 2 Jump to error if string JP ERROR P2CD 2 Read value val P2NM EN End subroutine ERROR CI 1 Error Routine MG INVALID TRY AGAIN Error message JP NMLP EN End Inputting String Variables String variables with up to six characters may be input using the specifier Sn where n represents the number of string characters to be input If n is not specified six characters will be accepted For example IN Enter A B or C V S specifies a string variable to be input The DMC 40x0 stores all variables as 6 bytes of information When a variable is specified as a number the value of the variable is represented as 4 bytes of integer and 2 bytes of fraction When a variable is specified as a string the variable can hold up to 6 characters each ASCII character is 1 byte When using the IN command for string input the first input character 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 see section Bit wise Operators 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 othe
127. Communication e 50 TCP IP is a connection protocol The master must be connected to the slave in order to begin communicating Each packet sent is acknowledged when received If no acknowledgement is received the information is assumed lost and is resent Unlike TCP IP UDP IP does not require a connection This protocol is similar to communicating via RS232 If information is lost the controller does not return a colon or question mark Because the protocol does not provide for lost information the sender must re send the packet Although UDP IP is more efficient and simple Galil recommends using the TCP IP protocol TCP IP insures that if a packet is lost or destroyed while in transit it will be resent Ethernet communication transfers information in packets The 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 Galil recommends that the user wait for an acknowledgement of receipt of a packet 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 40x0 MAC address is set by the factory and the last two bytes of the address are the serial number of the board To find the Ethernet MAC address
128. Configuration is accomplished with command CO see Extended I O of the DMC 40x0 Controller The I O points are accessed through the 44 pin D Sub connector labeled EXTENDED I O See the A5 CMB 41012 C012 section in the Appendix for a complete pin out of the Extended I O Electrical Specifications 3 3V Standard Inputs Max Input Voltage 3 4 VDC Guarantee High Voltage 2 0 VDC Guarantee Low Voltage 0 8 VDC Inputs are internally pulled up to 3 3V through a 4 7kQ resistor Outputs Sink Source 4mA per output Electrical Specifications 5V Option Inputs Max Input Voltage 5 25 VDC Guarantee High Voltage 2 0 VDC Guarantee Low Voltage 0 8 VDC Inputs are internally pulled up to 5V through a 4 7kQ resistor Outputs Sink Source 20mA DMC 40x0 User Manual Chapter 3 Connecting Hardware e 40 Amplifier Interface Electrical Specifications Max Amplifier Enable Voltage 24V Max Amplifier Enable Current 24V sink source 25 mA Motor Command Output Impedance 500 Q Overview The DMC 40x0 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 requ
129. Connect 9 No Connect Can be connected to 5V with APWR jumper 5 Ground Configuration Configure your PC for 8 bit data one start bit one stop bit full duplex and no parity The baud rate for the RS232 communication can be selected by setting the proper switch configuration on the front panel according to the table below Baud Rate Selection SWITCH SETTINGS 19 2 BAUD RATE ON 9600 ON 19200 OFF 38400 OFF OFF 115200 Handshaking The RS232 main port is set for hardware handshaking Hardware Handshaking uses the RTS and CTS lines The CTS line will go high whenever the DMC 40x0 is not ready to receive additional characters The RTS line will inhibit the DMC 40x0 from sending additional characters Note the RTS line goes high for inhibit The auxiliary port of the DMC 40x0 can be configured either as a general port or for the daisy chain When configured as a general port the port can be commanded to send ASCII messages to another DMC 40x0 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 38400 115200 n Handshake 0 N0 1 Yes r Mode 0 Disabled 1 enabled
130. 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 position 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 40x0 User Manual Chapter 4 Software Tools and Communication e 58 292 UB new 293 UB 294 297 SL new 298 299 UW 300 UB 301 UB 302 305 SL 306 309 SL 310 313 SL 314 317 SL 318 321 SL 322 325 SL new size 326 327 SW or UW 328 UB new 329 UB 330 333 SL new 334 335 UW 336 UB 337 UB 338 341 SL 342 345 SL 346 349 SL 350 353 SL 354 357 SL 358 361 SL new size 362 363 SW or UW 364 UB new 365 UB 366 369 SL new F Hall Input Status Reserved F User defined variable ZA G axis status see bit field map below G axis switches see bit field map below G axis stop code G axis reference
131. Galil shall not be liable or responsible for any incidental or consequential damages Hardware Protection The DMC 40x0 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 Amplifier 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 one of the following error conditions 1 At least one axis has a position error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal Chapter 8 Hardware amp So
132. IN 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 DMC 40x0 User Manual Chapter 7 Application Programming e 130 Edit Mode Commands lt RETURN gt Typing the return key causes the current line of entered instructions to be saved The editor will automatically advance to the next line Thus hitting a series of lt RETURN gt will cause the editor to advance a series of lines Note changes on a program line will not be saved unless a lt return gt is given lt cntrl gt P The lt cntrl gt P command moves the editor to the previous line lt 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 cntrl gt D The lt cntrl gt D command deletes the line currently being edited For example if the editor is at line number 2 and lt cntrl gt D is applied line 2 will be deleted The previous line number 3 is now renumbered as line number 2 lt cntrl gt Q
133. INCOM 2 RH Wee 45 RES 15 5V 16 RST Figure 2 1 Outline of the of the DMC 4040 Chapter 2 Getting Started e 7 DMC 40x0 User Manual DMC 4080 Layout 1589 18491 AS SL SSL on l as NOONIZE Gna ze Hias NOoNIzi hose OND SNe ONY smod gt isu ON yl me gt ON by eld 8 one ONS No ep aan ZOI t ONO Ta WOE ggg S10 ee say 2b S34 2 now zp voua e s toizi POLE cro zy SHar uavoz SHAE AQ yay og OTE anon OZ y ip Aves watt POLLE apo yy l 0136 ONO Se omg pl OND SE oe 34 92 ON OPO 92 woosis ON zoo WOW Oy woosts ANI yon op KOL gja gg WON OF Lovan Onor omge 8801 OF 3914 zz y NO 6 vs Tu zz ING ON9 6 140 801 6 AND 6 JWOH 3914 LE ON ve VINOH 2 8SH Z ON ve 2 0l bz 4 3518 Z 203 8e asw ez aNave 203 8e 9801 8 ON 88 13938 dINOH 8 9S1d 8 amp NAY amp AWOH 8 981 8E ONY Z Seol ez WOH 6 DST pe HS14 68 LOSV zz ANY ONOH 6 OSW Pe OSH 68 UNIV 103 22 NV e 01L IN zz tEOI LE HSH Sz OND 9 asw se s3u9 NO Se 2601 9 OND 9 HINOH OL 4 GND OF HYIG be WOH OL OND OP dela tz LEOI be ON 92 s34 SE IN 92 Ould Ss S34 SE 62015 DEOI SE l BMdO LL 600 lb S34 02 Mao HI 100 Ly 34 02 8201 02 Mao Le ONO ees oO a ITA zoa zz st aula ye m 9201 ZOH Ia 6b 00 2b Od zp vald 61 Szol 6 ploger S
134. Lx k 1 The velocity profile may be specified independently in terms of the vector velocity and acceleration For example the velocity profile corresponding to the path of Fig A 2 may be specified in terms of the vector speed and acceleration VS 100000 VA 2000000 The resulting vector velocity is shown in Fig A 2 Velocity 10000 time s T 0 05 T 0 357 Ta 0 407 a s Figure A 2 Vector Velocity Profile The acceleration time Ta is given by _ VS 100000 VA 2000000 The slew time Ts is given by 0 05s DMC 40x0 User Manual Appendices e 228 gs Do gy 5 35708 a 0 05 0 3075 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 Fig A 1 are given in Fig A 3 Fig A 3a shows the vector velocity It also indicates the position point along the path starting at A and ending at D Between the points A and B the motion is along the Y axis Therefore Vy Vs Between the points B and C the velocities vary gradually and finally between the points C and D the motion is in the X direction B C time Figure A 3 Vector and Axes Velocities Appendices e 229 DMC 40x0 User Manual Example Commun
135. MC 4080 Position Accuracy Velocity Accuracy Long Term Short Term Position Range Velocity Range Velocity Resolution Motor Command Resolution Variable Range Variable Resolution Array Size Program Size Normal Fast Firmware 62 5 usec 31 25 usec 62 5 usec 31 25 usec 125 usec 62 5 usec 125 usec 62 5 usec 156 25 usec 93 75 usec 156 25 usec 93 75 usec 187 5 usec 125 usec 187 5 usec 125 usec 1 quadrature count Phase locked better than 0 005 System dependent 2147483647 counts per move Up to 22 000 000 counts sec servo 6 000 000 pulses sec stepper 2 counts sec 16 bit or 0 0003 V 2 billion 1 10 4 16000 elements 30 arrays 2000 lines x 80 characters DMC 40x0 User Manual Appendices e 200 Fast Update Rate Mode The DMC 40x0 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 4010 31 25 usec DMC 4020 31 25 usec DMC 4030 62 5 usec DMC 4040 62 5 usec DMC 4050 93 75 usec DMC 4060 93 75 usec DMC 4070 125 usec DMC 4080 125 usec In order to run the DMC 40x0 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 40x0 utilities In order to set the desired update rates use the command TM When t
136. MC 40x0 User Manual Chapter 6 Programming Motion e 82 Figure 6 2 Position vs Time msec Motion 1 Example Motion 2 The previous step showed the plot if the motion continued all the way to 5000 however partway through the motion the object that was being tracked changed direction so the host program determined that the actual target position should be 2000 cts at that time Figure 6 2 shows what the position profile would look like if the move was allowed to complete to 5000 cts The position was modified when the robot was at a position of 4200 cts Note that the robot actually travels to a distance of almost 5000 cts before it turns around This is a function of the deceleration rate set by the DC command When a direction change is commanded the controller decelerates at the rate specified by the DC command The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position In Figure 6 3 the velocity profile is triangular because the controller doesn t have sufficient time to reach the set speed of 50000 cts sec before it is commanded to change direction Figure 6 3 Position vs Time msec Motion 2 Chapter 6 Programming Motion e 83 DMC 40x0 User Manual Figure 6 4 Velocity vs Time msec Motion 2 Example Motion 4 In this motion the host program commands the controller to begin motion towards position 5000 changes the targe
137. MG command The LU command is used to enable and disable the LCD update The contrast can also be set with LB command For more information see the LU LB and MG commands in the DMC 40x0 Command Reference The following table describes the information shown when the LCD update is enabled LU1 Axis Status Description Idle Low power Idle Motor Off Motion Axis Running in independent mode Error Positions Error exceeded TEn gt ERn Stop Stopped from ST command Limit Decelerating or stopped by a limit switch Abort Stopped by abort Vector Running in Vector or Linear Interpolation Mode Contour Running in Contour Mode PVT Runnning in PVT mode Homing Running in a Homing Routine ECAM Running in ECAM mode Fault Amplifier Fault Stall Stepper Position Maintenance Mode Stall Detected 310 3 30 lt gt Hua ZO A5 CMB 41012 C012 e 257 DMC 40x0 User Manual A6 ICM 42000 1000 Description The ICM 42000 resides inside the DMC 40x0 enclosure and breaks out the internal CPU board connector into convenient D sub connectors for interface to external amplifiers and I O devices The ICM 42000 provides a 15 pin HD D sub connector for the encoders on each axis a 15 pin D sub for analog inputs a 44 pin HD D sub for I O and a 44 pin D sub for the motor command signals Eight 500 mA highside drive outputs are available total current not to exceed 3
138. 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 lt 750 LE AMS MG DONE EN C BGS EN Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full wait Begin motion on 500 segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Motion Subroutine Vector Mode Linear and Circular Interpolation Motion The DMC 40x0 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 40x0 performs all the complex computations of linear and circular interpolation freeing the host PC from this time intensive task The coordinated motion mode is similar to the linear interpolation mode Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments In addition a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes Note that only one pair of axes can be specified for coordinated motion at any given time The command VM
139. NGES DIRECTION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD INDEX E y O L POSITION Figure 6 21 Homing Sequence for Normally Closed Switch and CN 1 INDEX PULSES POSITION DMC 40x0 User Manual Chapter 6 Programming Motion e 126 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 40x0 provides a position latch feature This feature allows the position of the main or auxiliary encoders of X Y Z or W to be captured within 25 microseconds of an external low input signal or index pulse The general inputs 1 th
140. O 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 AMPEN can be used to disable the amplifier for these conditions The AMPEN signal from the DMC 40x0 is shipped as a default of 5V active high or high amp enable In other words the AMPEN signal will be high when the controller expects the amplifier to be enabled If your amplifier requires a different configuration it is highly recommended that the DMC 40x0 is ordered with the desired configuration See the DMC 40x0 ordering information in the catalog http www galilmc com catalog cat40x0 pdf or contact Galil for more information on ordering different configurations If the amplifier enable needs to be changed see the ICM 42000 and ICM 42100 Amplifier Enable Circuit section in Chapter 3 Connecting Hardware DMC 40x0 User Manual Chapter 2 Getting Started e 18 When ordered with ICM 42000 s or ICM 42100 s the AEN signal is configurable for axes 1 4 and axes 5 8 Ex axes 1 4 could be ordered as 5V high amp enable and axes 5 8 could be ordered as 12V low amp enable When ordered with ICM 42200 s each axis is individually configurable Step C Connect the encoders For s
141. P PAA 10000 BGA Interpretation Label for beginning of program Setup communication configuration for auxiliary serial port Setup communication interrupt for auxiliary serial port Message out of auxiliary port Message out of auxiliary port Message out of auxiliary port Variable to remember speed Set speed of A axis motion Label for Loop Move to absolute position 10000 Begin Motion on A axis DMC 40x0 User Manual Chapter 7 Application Programming e 146 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 JP PAUSE P2CH 1 JP RESUME P2CH 2 Check for S stop motion Check for P pause motion 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 e
142. P Label EAX Select X as master EM 2000 1000 Cam cycles EP 20 0 Master position increments N 0 Index LOOP Loop to construct table from equation P N 3 6 Note 3 6 0 18 20 S SIN P 100 Define sine position Y N 10 S Define slave position ET N Y Define table N N 1 JP LOOP N lt 100 EN 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 driven to that point to avoid a jump This is done with the program INSTRUCTION INTERPRETATION RUN Label EBL Enable cam PA 500 starting position SP 5000 Y speed BGY Move Y motor AM After Y moved AT1 Wait for start signal EG 1000 Engage slave AI 1 Wait for stop signal EQ 1000 Disengage slave EN End DMC 40x0 User Manual Chapter 6 Programming Motion e 102 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 EBn 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
143. Q X Y Z W where x y z w are the master positions at which the corresponding slave axes are disengaged DMC 40x0 User Manual Chapter 6 Programming Motion e 100 3000 A E a OO as dias adas 0 2000 4000 6000 Master X Figure 6 12 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 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 Chapter 6 Programming Motion e 101 DMC 40x0 User Manual INSTRUCTION INTERPRETATION SETU
144. RTANT All DMC 40x0 commands are sent in upper case For example the command PR 4000 lt return gt Position relative PR is the two character instruction for position relative 4000 is the argument which represents the required position value in counts The lt return gt terminates the instruction The space between PR and 4000 is optional 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 is specified for an axis the previous value is maintained To view the current values for each command type the command followed by a for each axis requested DMC 40x0 User Manual Chapter 5 Command Basics e 70 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 2 2 Request A B C D values PR Request B value only The DMC 40x0 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 Specify acceleration for the B axis as 200000 Instead of data some commands request action to occur on an axis or group
145. S EN SUM a b c d e f g h global EN a Executed program from program2 dmc 36 0000 36 0000 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 bt 1 JP zeroAry b lt a 1 EN Example Abstracting Axes Axes JS runMove 0 10000 1000 100000 100000 MG Position JS EN trunMove DMC 40x0 User Manual Chapter 7 Application Programming e 148 a a PR a b sP a tc AC a d DCra e BG a MC a Example Local Scope Local JS POWER 2 2 MG JS JS POWER 2 16 MG_JS JS POWER 2 8 MG JS POWER cel F b 0 EN 1 ENDIF ELSE d 0 ENDIF PWRHLPR c c a b b 1 JP PWRHLPR b gt 0 TF d 1 c 1 c ENDIF EN C Executed program from programl dmc 4 0000 65536 0000 0 0039 Example Recursion JS AxsInfo 0 MG Z2 0 Recursed through JS stacks EN HAxsInfo h a b a 41 1000000 Chapter 7 Application Programming e 149 DMC 40x0 User Manual MG b S1 Axis N ME FS 0 Position TP h Error TE h Torquez TT A F1 4 IF a 7 EN 1 ENDIF JS AxsInfo a 1 EN JS 1 Executed program from programl dmc Axis Position 00029319 Error 00001312 Torque 9 9982 Axis Position 00001612 Error 00000936 Torque 1 7253 Axis Position 00001696 Error 00001076 Torque 1 9834 Axis Position
146. SDM 44040 D4040 4 axis Stepper Drives 237 A4 SDM 44140 D4140 4 axis Microstep Drives 237 AS CMB 41012 C012 Communications Board 237 A6 ICM 42000 1000 Interconnect Module 237 A7 1ICM 42100 1100 Sinusoidal Encoder Interpolation Module occcocccicononccnnnonenonncnanonccnanencnnanecanecnos 238 A8 ICM 42200 1200 Interconnect Modul8 cccccocconiccncconas 238 A1 AMP 430x0 D3040 D3020 239 DSC A a weer Electrical Specifications Nata CON a Ue 240 ODO susi i n 241 Brushless Motor Setup ES Brushless Amplifier Software Setup sii nssserssasiisncs 241 Chopper Mode AAA Brush Amplifier Operation si Using External Ai cap siii Error Monitoring and Protection avinsinina sisi ori 242 Hall Error Protection a Under Voltage PESO sins a 243 Over Voltage Protec osca 243 Over Current Protection da Over Temperature Protection voca iii cd 244 A A 244 A2 AMP 43140 D3140 245 DESC A A sen 245 Elsetrical SDE A sade aaa usassaaout 246 Mating Connectors 246 MCS NOM ices a A asda uae 247 Using External Amplifiers 247 ELO input eee 247 SOR ENON ecient csr a 247 A3 SDM 44040 D4040 248 Desoniptioi asic cadets a es A emacs 248 A A 249 Matino COMES ss S 249 PEA de A Ceca aa eles 250 DMC 40x0 Contents e vii Current Level Setup AG Command ririri 250 Low Current Setting LC Command cin princi 2
147. SI encoder Option The SSI option configures the ICM interconnect module for SSI encoder inputs For more information on the SSI implementation see Application Note 2438 Galil SSI Encoder Interface Note This option is not valid with the ICM 42100 1100 Consult Galil if the Sinusoidal encoder and SSI encoder interfaces are required on the same set of 4 axes Part number ordering example DMC 4010 C012 1000 SSD DIFF Differential analog motor command outputs The DIFF option configures the ICM interconnect module with differential analog motor command outputs Single ended motor command outputs are standard See the individual ICM sections in Integrated Components for pinout information Part number ordering example DMC 4010 C012 I000 DIFF STEP Differential step and direction outputs The STEP option configures the ICM interconnect module with differential step and direction outputs Single ended step and direction outputs are standard See the individual ICM sections in Integrated Components for pinout information Part number ordering example DMC 4010 C012 I000 STEP Amplifier Enable Configurations The default amplifier enable configuration for the ICM interconnect modules is 5V HAEN SINK This is 5V logic high amplifier enable and sinking The amplifier enable configuration can be configured at the factory or in the field It is recommended that the correct amplifier enable configuration be ordered from the fac
148. SP 2000 Speed 003 BGA Start A motion 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 If the ED command is issued from the Galil Windows terminal software such as SmartTERM the software will open a Windows based editor From this editor a program can be entered edited downloaded and uploaded to the controller Example 12 Motion Programs with Loops Motion programs may include conditional jumps as shown below Instruction Interpretation A Label DP 0 Define current position as zero v1 1000 Set initial value of V1 LOOP Label for loop PA V1 Move A motor V1 counts BG A Start A motion AM A After A motion is complete DMC 40x0 User Manual Chapter 2 Getting Started e 28 WT 500 TP A v1 V1 1000 JP LOOP V1 lt 10001 EN Wait 500 ms Tell position A Increase the value of V1 Repeat if V1 lt 10001 End After the above program is entered quit the Editor Mode lt cntrl gt Q To start the motion command XQ A Execute Program A Example 13 Motion Programs with Trippoints The motion programs may include trippoints as shown below Instruction B DP 0 0 PR 30000 60000 SP 5000 5000 BGA AD 4000 BGB AP 6000 SP 2000 50000 AP 50000 SP 10000 EN To start the program command XQ B Interpretation Label Define initial positions Set targets Set speeds Start A motion ait until A move
149. Sub Connectors INCOM I O E H D Sub Connectors LSCOM I O E H D Sub Connectors Table 3 1 INCOM and LSCOM information Chapter 3 Connecting Hardware e 35 DMC 40x0 User Manual sto 5555 que gt 2 2kQ Additional Limit RPACK 2 Switches Dependent on Number of Axes X X xX o o xX x xX x N N N N N XN X X MA b b b b b b FLSX RLSX HOMEX FLSY RLSY HOMY INCOM 2 2kQ RPACK ve 5 Y RS 5 5 5 ws Sas L T yo ys Se So DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 ABRT XLATCH YLATCH ZLATCH WLATCH Figure 3 1 The Optoisolated Inputs Using an Isolated Power Supply To take full advantage of opto isolation an isolated power supply should be used to provide the voltage at the input common 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 2 For voltages greater than 28 Volts a resistor R is needed in series with the input such that 1 mA lt V supply R 2 2KQ lt 11 mA DMC 40x0 User Manual Chapter 3 Connecting Hardware e 36 External Resistor Needed for External Resistor Needed for Voltages gt 28V LSCOM Voltages gt 28V LSCOM 2 2K 2 2K XN g FLSX A FLSX Configuration to source current at the Configuration to sink current at the LSCOM terminal and sink current at
150. T 200 Wait 200 ms PR 10000 New Position SP 30000 New Speed AC 150000 New Acceleration BGX Start Motion DMC 40x0 User Manual Chapter 7 Application Programming e 138 EN End Define Output Waveform Using AT The following program causes Output 1 to be high for 10 msec and low for 40 msec The cycle repeats every 50 msec OUTPUT Program label ATO Initialize time reference SB1 Set Output 1 LOOP Loop AL LO After 10 msec from reference CB1 Clear Output 1 AT 40 Wait 40 msec from reference and reset reference SB1 Set Output 1 JP LOOP Loop EN End Program 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 l is minimal The difference comes when the servo update rate is changed With a low servo update rate it is 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 25
151. 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 new Reserved 28 29 SW new Reserved 30 31 SW new Reserved 32 33 SW new Reserved 34 35 SW new Reserved 36 37 SW new Reserved 38 39 SW new Reserved 40 41 SW new 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 40x0 User Manual Chapter 4 Software Tools and Communication e 56 50 51 52 55 56 59 60 61 62 63
152. User Manual
153. X 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 DMC 40x0 User Manual A4 SDM 44140 D4140 e 252 Operation 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 1 A default n 2 2A n 3 30A 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 sample
154. 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 40x0 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 DMC 40x0 User Manual Chapter 6 Programming Motion e 78 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 Example 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
155. a complete operational DMC 40x0 system consists of 9 steps Step 1 Determine overall motor configuration Step 2 Install Jumpers on the DMC 40x0 Step 3 Install the communications software Step 4 Connect DC power to controller Step 5 Establish communications with the Galil Communication Software Step 6 Determine the Axes to be used for sinusoidal commutation Step 7 Make connections to amplifier and encoder Step 8a Connect standard servo motors Step 8b Connect sinusoidal commutation motors Step 8c Connect step motors Step 9 Tune the servo system Step 1 Determine Overall Motor Configuration Before setting up the motion control system the user must determine the desired motor configuration The DMC 40x0 can control any combination of standard servo motors sinusoidally commutated brushless motors and stepper motors Other types of actuators such as hydraulics can also be controlled please consult Galil The following configuration information 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 40x0 has been setup by the factory for standard servo motor operation providing an analog command signal of 10V No hardware or software configuration is required for standard servo motor operation Sinusoidal Commutation Sinusoidal commutation is configured through a single software command BA This
156. abel IN ENTER OF REVOLUTIONS n1 Prompt for revs PR n1 2000 Convert to counts IN ENTER SPEED IN RPM s1 Prompt for RPMs SP s1 2000 60 Convert to counts sec IN ENTER ACCEL IN RAD SEC2 al Prompt for ACCEL AC al 2000 2 3 14 Convert to counts sec2 BG Begin motion EN End program DMC 40x0 User Manual Chapter 7 Application Programming e 166 Hardware I O Digital Outputs The DMC 40x0 has an 8 bit uncommitted output port and an additional 32 I O which may be configured as inputs or outputs with the CO command for controlling external events The DMC 4050 through DMC 4080 has an additional 8 outputs Each bit on the output port may be set and cleared with the software instructions SB Set Bit and CB Clear Bit or OB define output bit 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 CIN 1 Set Output 2 if Input 1 is high If Input 1 is low clear Output 2 OB 3 QIN 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
157. aces Galil provides programming tools so that users can develop their own custom software interfaces to a Galil controller These tools include the GalilTools Communication Library ActiveX Toolkit NET API and DMCWin For new applications Galil recommends the GalilTools Communication Libraries 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 serial numbers to the screen m Form SEE Connected to DMC1842 Rev 1 00 Serial number 2039 0000 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 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
158. 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 for each axis If the Off On Error function is enabled for any given axis the motor for that axis will be turned off when the abort signal is generated This could cause the motor to coast to a stop since it is no longer under servo control If the Off On Error function is disabled the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state All motion programs that are currently running 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 Chapter 3 Connecting Hardware e 33 DMC 40x0 User Manual 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 When this input is triggered the controller will reset This is the same as pressing the RESET button on the controller Uncommitted Digital Inputs The DMC 40x0 has 8 opto isolated inputs These inputs can be read individually using the functi
159. al 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 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 ended 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 5 12V Power Output Specifications Output Voltage Tolerance 5V 5 12V 5 12V 5 Max Current Output 1 14 40mA 40mA Appendices e 199 DMC 40x0 User Manual Performance Specifications Minimum Servo Loop Update Time Minimum Servo Loop Update Time MC 4010 MC 4020 MC 4030 MC 4040 MC 4050 MC 4060 MC 4070 D D D D D D D D
160. amplifier The over temperature condition will trigger the AMPERR routine if included in the program on the controller The amplifier will re enable when the temperature drops below 100 C Rev C and newer amplifiers 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 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 Rev C Amplifiers began shipping in December 2008 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 A1 AMP 430x0 D3040 D3020 e 243 DMC 40x0 User Manual A2 AMP 43140 D3140 Description The AMP 43140 resides inside the DMC 40x0 enclosure and contains four linear driv
161. an 2 360 V a The overall position can be determined using Position Coarse_cycles 2 Fine Where n is the number of bits of resolution that were used in the conversion Coarse_cycles is the whole number of cycles counted Fine is the interpolated position within one cycle Vb and Va are the two signals as indicated in Figure A7 24 Sinusoidal Encoder Signals For example if the encoder cycle is 40 microns AF10 results in 2 1024 counts per cycle or a resolution of 39 nanometers per count AT ICM 42100 1100 e 269 DMC 40x0 User Manual AS ICM 42200 1200 Description The ICM 42200 interconnect option resides inside the DMC 40x0 enclosure and provides a pin out that is optimized for easy connection to external drives The ICM 42200 uses 26 pin HD D sub connectors for each axis that includes encoder limit home and motor command signals Other connectors include a 44 pin HD D sub for digital I O and a 15 pin LD D sub for analog I O The ICM 42200 is configurable on each individual axis for high or low amplifier enable 5 V 12 V or isolated input power up to 24 V sinking or sourcing The DMC 40x0 cover does not have to be removed to install these options Two ICMs are required for 5 through 8 axis controllers Connectors for ICM 42200 Interconnect Board ICM 42200 I O A D 44 pin HD D Sub Connector Female Pin Label Description Pin Label Description Pin Label Description
162. 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 AMPERR subroutine if it is included in a running program 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 Over Voltage Protecti
163. ance stand alone controller The controller series offers many enhanced features including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 40x0 provides two communication channels high speed RS 232 2 channels up to 115K Baud and 10BaseT Ethernet The controllers allow for high speed servo control up to 22 million encoder counts sec and step motor control up to 6 million steps per second Sample rates as low as 31 25 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 40x0 is available with up to eight axes in a single stand alone unit The DMC 4010 4020 4030 4040 are one thru four axes controllers and the DMC 4050 4060 4070 4080 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 40x0 can be used for applications involving jogging point to point positioning vector positioning electronic gearing multiple move sequences and contouring The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing For smooth following of complex contours the DMC 40x0 provides continuous vector feed of an infinite number of l
164. and Command to end IF conditional statement Program must have an ENDIF command for every IF command Example using IF ELSE and ENDIF TEST irra 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 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 27 IF conditional statement executed if 1 IF conditional true Message to be executed if 2 IF conditional is true ELSE command for 2 IF conditional statement Message to be executed if 2 IF conditional is false End of 2 conditional statement ELSE command for 1 IF conditional statement Message to be executed if 1 IF conditional statement is false End of 1 conditional statement Label to be used for a loop Loop until both input 1 and input 2 are not active End Input Interrupt Routine without restoring trippoints A subroutine is a group of instructions beginning with a label and ending with an end command EN Subroutines are called from the main program with the jump subroutine instruction JS followed by a label or line number and condi
165. and X motion BG X Start motion on X axis You may also perform profiled position corrections in the electronic gearing mode Suppose for example that you need to advance the slave 10 counts Simply command IP 10 Specify an incremental position movement of 10 on Y axis Under these conditions this IP command is equivalent to PR 10 Specify position relative movement of 10 on Y axis BGY Begin motion on Y axis Often the correction is quite large Such requirements are common when synchronizing cutting knives or conveyor belts Example Synchronize two conveyor belts with trapezoidal velocity correction GA X Define X as the master axis for Y GR 2 Set gear ratio 2 1 for Y PR 300 Specify correction distance SP 5000 Specify correction speed AC 100000 Specify correction acceleration DC 100000 Specify correction deceleration BGY Start correction 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 4080 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
166. ands 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 vl vl Return vl 0000000010 0000 Default Format vl F4 2 Specify local format 04 LO 00 New format vl 4 2 Specify hex format S000A 00 Hex value vl ALPHA Assign string ALPHA to vl v1l S4 Specify string format first 4 characters ALPH The local format is also used with the MG command Converting to User Units Variables and arithmetic operations make it easy to input data in desired user units such as inches or RPM The DMC 40x0 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 L
167. ant for coordinated moves Return number of available spaces for linear and circular segments in DMC 40x0 sequence buffer Zero means buffer is full 511 means buffer is empty Specifies which coordinate system is to be active S or T Operand Summary Coordinated Motion Sequence OPERAND _VPM _AV _LM CS _VE DESCRIPTION The absolute coordinate of the axes at the last intersection along the sequence Distance traveled Number of available spaces for linear and circular segments in DMC 40x0 sequence buffer Zero means buffer is full 511 means buffer is empty Segment counter Number of the segment in the sequence starting at zero 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 Fig 6 8 Feed rate is 20000 counts sec Plane of motion is XY VM XY Specify motion plane vs 20000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration VP 4000 0 Segment AB CR 1500 270 180 Segment BC DMC 40x0 User Manual Chapter 6 Programming Motion e 94 VP 0 3000 Segment CD CR 1500 90 180 Segment DA VE End of sequence BGS Begin Sequence The resulting motion starts at the point A and moves toward points B C D A Supp
168. 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 RA nf m o 1 p RD typel type2 type3 type4 RC n m RC Description Selects up to eight arrays for data capture The arrays must be defined with the DM command Selects the type of data to be recorded where typel type2 type3 and type 4 represent the various types of data see table below The order of data type is important and corresponds with the order of n m o p arrays in the RA command The RC command begins data collection Sets data capture time interval where 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 misa negative number the recording is done continuously in a circular manner _RD is the recording pointer and indicates the address of the next array element n 0 stops recording Returns a 0 or 1 where 0 denotes not recording 1 specifies recording in progress Data Types for Recording 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 posit
169. as XY and the DMC 4010 uses the X axis only Examples for the DMC 4080 denote the axes as A B C D E F G H Users of the DMC 4050 5 axes controller DMC 4060 6 axes controller or DMC 4070 7 axes controller should note that the DMC 4050 denotes the axes as A B C D E the DMC 4060 denotes the axes as A B C D E F and the DMC 4070 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 40x0 Contents e i Contents Contents iii Chapter 1 Overview 1 MMR eNO chara cas OR 1 Overview of Motor Types Standard Servo Motor with 10 Volt Command Signal Brushless Servo Motor with Sinusoidal Commutation 2 Stepper Motor with Step and Direction Signals Overview of External Amplifiers Amplifiers in Current Mode Amplifiers in Velocity Mode Stepper Motor Amplifiers Overview of Galil Amplifiers amd Dyer vs criar titi iii 3 Al AMP 430x0 D3040 D3020 A3 SDM 44040 D4040 AR Ad SDM 44140 D4140 ococooccoocooncoonconconcconconnacoconconcaconoccnnos DMC 40x0 Functional Elements Microcomputer Section 4 Motor Interface 4 Communic
170. aster 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 4010 31 25 usec DMC 4020 31 25 usec DMC 4030 62 5 usec DMC 4040 62 5 usec DMC 4050 93 75 usec DMC 4060 93 75 usec DMC 4070 125 usec DMC 4080 125 usec In order to run the DMC 40x0 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 40x0 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 e 129 DMC 40x0 User Manual Chapter 7 Application Programming Overview The DMC 40x0 provides a powerful programming language that allows users to customize the controller for their particular application Programs can be downloaded into the DMC 40x0 memory freeing the host computer for other tasks However the host computer can send commands to the controller at any time even while a program is being executed Only ASCII commands can be used for application programming In addition to standard motion commands the DMC 40x0 provides commands that allow the DMC 40x0 to make its own decisions These commands include conditional jumps event triggers and subroutines For example the
171. 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 v1l ABS V7 The variable vl is equal to the absolute value of variable v7 v2 5 SIN pos The variable v2 is equal to five times the sine of the variable pos v3 IN 1 The variable v3 is equal to the digital value of input 1 v4 2 5 AN 5 The variable v4 is equal to the value of analog input 5 plus 5 then multiplied by 2 Variables For applications that require a parameter that is variable the DMC 40x0 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 remY 70 Assigns variable rpmY multiplied by 70 to JG command Programmable Variables The DMC 40x0 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 howev
172. 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 40x0 has a set of commands that directly interrogate the controller When the command is entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF Variable Format VF and Leading Zeros LZ command See Chapter 7 and the Command Reference DMC 40x0 User Manual Chapter 5 Command Basics e 74 Summary of Interrogation Commands RP Report Command Position RL Report Latch R V Firmware Revision Information SC Stop Code 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 Velocity For example the following example illustrates how to display the current position of the X axis TP A lt return gt Tell position A 0 Controllers Response TP AB lt return gt 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 Pp ep Request
173. ates all the arrays Input of Data Numeric and String Input of Data The command IN is used to prompt the user to input numeric or string data Using the IN command the user may specify a message prompt by placing a message in quotations When the controller executes an IN command the controller will wait for the input of data The input data is assigned to the specified variable or array element An Example for Inputting Numeric Data A IN Enter Length lenX EN In this example the message Enter Length is displayed on the computer screen The controller waits for the operator to enter a value The operator enters the numeric value which is assigned to the variable lenX Cut to Length Example In this example a length of material is to be advanced a specified distance When the motion is complete a cutting head is activated to cut the material The length is variable and the operator is prompted to input it in inches Motion starts with a start button which is connected to input 1 The load is coupled with a 2 pitch lead screw A 2000 count rev encoder is on the motor resulting in a resolution of 4000 counts inch The program below uses the variable len to length The IN command is used to prompt the operator to enter the length and the entered value is assigned to the variable len Chapter 7 Application Programming e 159 DMC 40x0 User Manual BEGIN AC 800000 DC 800000 SP 5000 len 3 4 CUT
174. ation 4 Amplifier Driver Encoder Watch Dog Timer Chapter 2 Getting Started 7 UO Bee OI Uc Meer eeeeenre er ere meer er pensar ee et ngs trnme seer Peers mcnn eee eee ere ree F DMC 4080 Layout DMC 40x0 Power Connections DMC 4040 Dimensions DMC 4080 Dimension Step 2 Install Jumpers on the DMC 40X0 occoccococoncnonanincnncnanos Step 3 Install the Communications Software Step 4 Connect 20 80VDC Power to the Controller Fe DMC 40x0 Contents e ii Example 3 Multiple AS armbar csicssnsersie Example 4 Independent Moves conspira rios Example 5 Position Interrogation Example 6 Absolute Position Example 7 Velocity Control e Example 8 Operation Under Torque Limit Exaile 9 Eto RON ss rr Example 10 Operation in the Buffer Mode sd Example 11 Using the On Board Editor sss tees Example 12 Motion Programs with LOOPS ccccococccconcnancnnaness Example 13 Motion Programs with Trippoints ES Example 14 Control Variables cccssosscrssresreressesesoees Example 15 Linear Interpol usina Example 16 Circular Interpolation vapor Chapter 3 Connecting Hardware 32 A O O Using Optoisolated Inputs Limit Switoli UO is 32 Home Switch pul siii iii 33 Abort Input de ELO Electrons Lack Out input cnn sabi
175. axis Y when the master is X Such a graphic relationship is shown in Figure 6 12 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 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 Chapter 6 Programming Motion e 99 DMC 40x0 User Manual where x y z w specify the cycle of the master and the total change of the slaves over one cycle The cycle of the master is limited to 8 388 607 whereas the slave change per cycle is limited to 2 147 483 647 If the change is a negative number the absolute value is specified For the given example the cycle of the master is 6000 counts and the change in the slave is 1500 Therefore we use the instruction EM 6000 1500 Step 3 Specify the master interval and starting point Ne
176. ber 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 231 DMC 40x0 User Manual DMC 40x0 DMC 2200 Comparison BENEFIT DMC 40x0 DMC 2200 Higher servo bandwidth Up to 32kHz update rate Up to 8kHz update rate Faster Processing power 10X faster than DMC 20x0 Increased Program Storage 2000lines x 80 Characters 1000 lines x 80 characters Increased Array Storage 16000 array elements in 30 arrays 8000 array elements in 30 arrays Increased Variable Storage 510 Variables 254 labels Faster servo operation good for very 22 MHz encoder speed for servos 12 MHz high resolution sensors Faster stepper operation 6 MHz stepper rate 3 MHz Improved EMI Connections broken out through D Sub 100 pin high density connector connectors and high power amps run and cable away from control lines Contour Buffer 511 elements 1 element New commands features ALAK PW OV OT OA ALTX TR1 1 HV LD M axis EY ZA OE2 TM scaling NO LC1000 MT1 5
177. ber of available variables TIME Free Running Real Time Clock off by 2 4 Resets with power on Note TIME does not use an underscore character _ as other keywords These keywords have corresponding commands while the keywords LF LR and TIME do not have any associated commands All keywords are listed in the Command Reference Examples of Keywords V1 _LFX Assign V1 the logical state of the Forward Limit Switch on the X axis V3 TIME Assign V3 the current value of the time clock V4 _HMW Assign V4 the logical state of the Home input on the W axis Arrays For storing and collecting numerical data the DMC 40x0 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 wi
178. bit 1 WT 80 Wait 80 ms JP A Repeat the process DMC 40x0 User Manual Chapter 7 Application Programming e 172 START PULSE 11 Me o IP MOTOR VELOCITY OUTPUT PULSE E e MSS output TIME INTERVALS move wait ready move Figure 7 1 Motor Velocity and the Associated Input Output signals X Y Table Controller An X Y Z system must cut the pattern shown in Fig 7 2 The X Y table moves the plate while the Z axis raises and lowers the cutting tool The solid curves in Fig 7 2 indicate sections where cutting takes place Those must be performed at a feed rate of 1 inch per second The dashed line corresponds to non cutting moves and should be performed at 5 inch per second The acceleration rate 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 travers
179. 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 1 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 2 2 6 OPO Clears all bits of output port to zero OP 255 Sets all bits of output port to one 22 21 2 23 244 29 26 27 The output port is useful for setting relays or controlling external switches and events during a motion sequence Example Turn on output after move Instruction Interpretation OUTPUT Label PR 2000 Position Command BG Begin AM After move SB1 Set Output 1 WT 1000 Wait 1000 msec CB1 Clear Output 1 EN End Chapter 7 Application Programming e 167 DMC 40x0 User Manual 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 through 48 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 s
180. ce this causes re direction of command execution In this case the command interpreter may not execute an ENDIF command Using the ELSE Command The ELSE command is an optional part of an IF conditional statement and allows for the execution of command only when the argument of the IF command evaluates False The ELSE command must occur after an IF command and has no arguments If the argument of the IF command evaluates false the controller will skip commands until Chapter 7 Application Programming e 141 DMC 40x0 User Manual 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 40x0 allows for IF conditional statements to be included within other IF conditional statements This technique is known as nesting and the DMC 40x0 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 comm
181. ceeds the limit set with the command ER 2 The abort command is given 3 The abort input is activated with a low signal Note If the motors are disabled while they are moving they may coast to a stop because they are no longer under servo control To re enable the system use the Reset RS or Servo Here SH command Examples OE L T T T Enable off on error for X Y Z and W OE 0 1 0 1 Enable off on error for Y and W axes and disable off on error for W and Z axes Automatic Error Routine The POSERR label causes the statements following to be automatically executed if error on any axis exceeds the error limit specified by ER The error routine must be closed with the RE command The RE command returns from the error subroutine to the main program NOTE The Error Subroutine will be entered again unless the error condition is gone Example RA 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 Chapter 8 Hardware amp Software Protection e 181 DMC 40x0 User Manual Limit Switch Routine The DMC 40x0 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 the limit switch subroutine This label causes the
182. cess ends up in the motor off MO state A negative number causes the process to end in the Servo Here SH state WARNING This command must move the motor to find the zero commutation phase This movement is instantaneous and will cause the system to jerk Larger applied voltages will cause more severe motor jerk The applied voltage will typically be sufficient for proper operation of the BZ command For systems with significant friction this voltage may need to be increased and for systems with very small motors this value should be decreased For example BZ 2 0 1 will drive both A and C axes to zero will apply 2V and 1V respectively to A and C and will end up with A in SH and C in MO Step F part 2 Systems with Hall Sensors Only Set Zero Commutation Phase With Hall sensors the estimated value of the commutation phase is good to within 30 This estimate can be used to drive the motor but a more accurate estimate is needed for efficient motor operation There are 3 possible methods for commutation phase initialization Method 1 Use the BZ command as described above Method 2 Drive the motor close to commutation phase of zero and then use BZ command This method decreases the amount of system jerk by moving the motor close to zero commutation phase before executing the BZ command The controller makes an estimate for the number of encoder counts between the current position and the position of zero com
183. cified 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 Example Instruction Interpretation DP21 Define position TPA Tell position 0000000021 Default format PF4 Change format to 4 places DMC 40x0 User Manual Chapter 7 Application Programming 164 TPA Tell position 0021 New format PF 4 Change to hexadecimal format TPA Tell Position 0015 Hexadecimal value PEF2 Format 2 places TPA Tell Position 99 Returns 99 if position greater than 99 Removing Leading Zeros from Response to Interrogation Commands The leading zeros on data returned as a response to interrogation commands can be removed by the use of the command LZ 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 97 5 Response Without Leading Zeros Local Formatting of Response of Interrogation Commands The response of interrogation commands
184. 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 lt return gt 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 adjust the PID filter parameters KP KD and KI It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section Step 8b Connect Sinusoidal Commutation Motors When using sinusoidal commutation the parameters for the commutation must be determined and saved in the controller s non volatile memory The setup for sinusoidal commutation is different when using Hall Sensors Each step which is affec
185. 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 40x0 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 Using the DMC 40x0 Editor to Enter Programs The GalilTools software package provides an editor and utilities that allow the upload and download of DMC programs to the motion controller Application programs for the DMC 40x0 may also be created and edited locally using the DMC 40x0 The DMC 40x0 provides a line Editor for entering and modifying programs The Edit mode is entered with the ED instruction Note The ED command can only be given when the controller is in the non edit mode which is signified by a colon prompt In the Edit Mode each program line is automatically numbered sequentially starting with 000 If no parameter follows the ED command the editor prompter will default to the last line of the last program in memory If desired the user can edit a specific line number or label by specifying a line number or label following ED ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED BEGIN Puts Editor at label BEG
186. command will also exit PVT mode Motion will come to a controlled 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
187. ction which raises the water temperature until the temperature error is reduced sufficiently The closing of the servo loop is very similar Suppose that we want the motor position to be at 90 degrees The motor position is measured by a position sensor often an encoder and the position feedback is sent to the controller Like the brain the controller determines the position error which is the difference between the commanded position of 90 degrees and the position feedback The controller then outputs a signal that is proportional to the position error This signal produces a proportional current in the motor which causes a motion until the error is reduced Once the error becomes small the resulting current will be too small to overcome the friction causing the motor to stop The analogy between adjusting the water temperature and closing the position loop carries further We have all learned the hard way that the hot water faucet should be turned at the right rate If you turn it too slowly the temperature response will be slow causing discomfort Such a slow reaction is called 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
188. d 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 execution from the time reference of ATO REM since the WT 1000 1 took 1000 samples REM of the 4000 samples for AT 4000 1 MG t t2 this should output 1000 3000 EN End program there was only 3000 samples left Where the functionality of the operation of the AT command is very useful is when it is 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 r
189. d 4000 tart B motion hange speeds wW S Wait until position A 6000 Wait until position B 50000 hange speed of B End program Execute Program B Example 14 Control Variables Objective To show how control variables may be utilized Instruction FA DPO PR 4000 SP 2000 BGA r Wyss Pp WT 500 V1 JP C V1 0 JP B C Interpretation Label Define current position as zero Initial position Set speed Move A Wait until move is complete Wait 500 ms Determine distance to zero Command A move 1 2 the distance Start A motion After A moved Wait 500 ms Report the value of V1 Exit if position 0 Repeat otherwise Label C Chapter 2 Getting Started e 29 DMC 40x0 User Manual 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 Internal variables may be created by preceding a DMC 40x0 instruction with an underscore _ 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 LM ABC Specify linear interpolation axes LI 7000 3000 6000 Relative distances for linear interpolation LE Linear End VS 6000 Vector speed VA
190. d Find Index homing Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input The motor will accelerate at the rate specified by the command AC up to the slew speed After detecting the transition in the logic state on the Home Input the motor will decelerate to a stop at the rate specified by the command DC After the motor has decelerated to a stop it switches direction and approaches the transition point at the speed of 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 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
191. d 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 Chapter 6 Programming Motion e 87 DMC 40x0 User Manual 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 lt lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 5 results in the specification VS 2000 to be divided in half Command Summary Linear Interpolation COMMAND DESCRIPTION LM xyzw Specify axes for linear interpolation LM abcdefgh same controllers with 5 or more axes LM Returns number of available spaces for linear segments in DMC 40x0 sequence buffer Zero means buffer full 511 means buffer empty LI x y z w lt n Specify incremental
192. distances relative to current position and assign vector speed n LI a b c d e f g h lt n VSn Specify vector speed VAn Specify vector acceleration VDn Specify vector deceleration VRn Specify the vector speed ratio BGS Begin Linear Sequence CS Clear sequence LE Linear End Required at end of LI command sequence LE Returns the length of the vector resets after 2147483647 AMS Trippoint for After Sequence complete AVn Trippoint for After Relative Vector distance n IT S curve smoothing constant for vector moves Operand Summary Linear Interpolation OPERAND DESCRIPTION _AV Return distance traveled _CS Segment counter returns number of the segment in the sequence starting at zero _LE Returns length of vector resets after 2147483647 _LM Returns number of available spaces for linear segments in DMC 40x0 sequence buffer Zero means buffer full 511 means buffer empty _VPm 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 DMC 40x0 User Manual Chapter 6 Programming Motion e 88 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 The value of CS VPX and VPY will be zero Now suppose that the
193. 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 SDM 44040 D4040 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 A4 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 e 3 DMC 40x0 User Manual DMC 40x0 Functional Elements The DMC 40x0 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 ETHERNET RISC BASED HIGH SPEED MAIN ENCODERS MICROCOMPUTER MOTOR ENCODER AUXILIARY ENCODERS INTERFACE FOR A B C D p 10 VOLT OUTPUT FOR SERVO MOTORS PULSE DIRECTION OUTPUT FOR STEP MOTORS RS 232 RS 422 HIGH SPEED ENCODER 32 Configurable I O I O INTERFACE COMPARE OUTPUT v AUNCOMM TED 8 PROGRAMMABLE
194. 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 Note Do not hot swap the motor power 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 gt 18 a a 2 DMC 4040 mae OTON o 3 UN E o A oJ g 7 Figure A1 1 DMC 4040 C012 1000 D4140 DMC 4040 with SDM 44140 A4 SDM 44140 D4140 e 251 DMC 40x0 User Manual Electrical 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 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 MOLE
195. e The ZS0 command resets the stack to its initial value For example if a limit occurs and the LIMSWI routine is executed it is often desirable to restart the program sequence instead of returning to the location where the limit occurred To do this give a ZS command at the end of the LIMSWI routine Auto Start Routine The DMC 40x0 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 40x0 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 LIMSWI ININT POSERR MCTIME CMDERR AUTO DESCRIPTION Limit switch on any axis goes low Input specified by II goes low Position error exceeds limit specified by ER Motion Complete timeout occurred Timeout period set by TW command Bad command given Automatically executes on pow
196. e controller In addition the DMC 40x0 executes operations from left to right See Mathematical and Functional Expressions for more information For example using variables named V1 V2 V3 and V4 JP TEST V1 lt V2 amp V3 lt V4 In this example this statement will cause the program to jump to the label TEST if V1 is less than V2 and V3 is less than V4 To illustrate this further consider this same example with an additional condition JP TEST V1 lt V2 amp V3 lt V4 V5 lt 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 VS is less than V6 DMC 40x0 User Manual Chapter 7 Application Programming e 140 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 V1L V7 lt V8 V2 Jump to
197. e 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 change OE Profiler Off On Error YA Step Drive Resolution pulses full motor step YB Step Motor Resolution full motor steps revolution YC Encoder Resolution counts revolution YR Error Correction pulses YS Stepper Position Maintenance enable status A pulse is defined by the resolution of the step drive being used Therefore one pulse could be a full step a half step or a microstep When a Galil controller is configured for step motor operation the step pulse output by the controller is internally fed back to the auxilia
198. e 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 40x0 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 SDM 44040 D4040 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 A4 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 A5 CMB 41012 C012 Communications Board The CMB 41012 provides the connections for the Ethernet and serial communication It also breaks out the Extended I O into a convenient D sub connector for interface to external devices A6 ICM 42000 1000 Intercon
199. ector 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 9 DMC 40x0 User Manual DMC 4040 Dimensions DMC 4040 GALIL MOTION CONTROL MADE IN USA Figure 2 5 Dimensions of DMC 4040 DMC 40x0 User Manual Chapter 2 Getting Started e 10 imensions DMC 4080 D Figure 2 6 Dimensions of DMC 4080 DMC 40x0 User Manual Chapter 2 Getting Started e 11 Elements You Need For a complete system Galil recommends the following elements 1 or DMC 4010 4020 4030 or DMC 4040 Motion Controller DMC 4050 4060 4070 or DMC 4080 2 3 4 De 6 Motor Amplifiers Integrated when using Galil amplifiers and drivers Power Supply for Amplifiers and controller Brush or Brushless Servo motors with Optical Encoders or stepper motors a Cables for connecting to the DMC 40x0 s integrated ICM s PC Personal Computer RS232 or Ethernet for DMC 40x0 GalilTools or GalilTools Lite Software package GalilTools is highly recommended for first time users of the DMC 40x0 It provides step by step instructions for system connection tuning and analysis DMC 40x0 User Manual Chapter 2 Getting Started e 12 Installing the DMC 40x0 Installation of
200. ed the burn command BN should be given NOTE Without Hall sensors the controller will not be able to estimate the commutation phase of the brushless motor In this case the controller could become unstable until the commutation phase has been set using the BZ command see next step It is highly recommended that the motor off command be given before executing the BN command In this case the motor will be disabled upon power up or reset and the commutation phase can be set before enabling the motor Step F part 1 Systems with or without Hall Sensors Set Zero Commutation Phase When an axis has been defined as sinusoidally commutated the controller must have an estimate for commutation phase When Hall sensors are used the controller automatically estimates this value upon DMC 40x0 User Manual Chapter 2 Getting Started e 22 reset of the controller If no Hall sensors are used the controller will not be able to make this estimate and the commutation phase must be set before enabling the motor To initialize the commutation without Hall effect sensor use the command BZ This function drives the motor to a position where the commutation phase is zero and sets the phase to zero The BZ command is followed by real numbers in the fields corresponding to the driven axes The number represents the voltage to be applied to the amplifier during the initialization When the voltage is specified by a positive number the initialization pro
201. ed to some terminals This function can be disabled by issuing the command CW2 For more information see the CW command in the Command Reference When handshaking is used hardware and or software handshaking characters which are generated by the controller are placed in a FIFO buffer before they are sent out of the controller The size of the RS 232 buffer is 512 bytes When this buffer becomes full the controller must either stop executing commands or ignore additional characters generated for output The command CW 1 causes the controller to ignore all output from the controller while the FIFO is full The command CW 0 causes the controller to stop executing new commands until more room is made available in the FIFO This command can be very useful when hardware handshaking is being used and the communication line between controller and terminal will be disconnected In this case characters will continue to build up in the controller until the FIFO is full For more information see the CW command in the Command Reference DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 62 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 utilitie
202. eed 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 MTS 2 2 52 p 23 Motor type set to stepper YA64 Step resolution of the microstepping drive YB200 Motor resolution full steps per revolution Chapter 6 Programming Motion e 119 DMC 40x0 User Manual YC4000 Encoder resolution counts per revolution SHX Enable axis WT50 Allow slight settle time YSL Enable SPM mode MOTION Perform motion SP16384 Set the speed PR10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction MOTION2 SP16384 Set the speed PR 10000 Prepare mode of motion BGX Begin motion MCX JS CORRECT Move to correction JP MOTION CORRECT Correction code spx _SPX LOOP Save speed value SP2048 Set a new slow correction speed WT100 Stabilize JP END ABS _QSX lt 10 End correction if error is within defined tolerance YRX _QSX Correction move MCX WT100 Stabilize JP LOOP Keep correcting until error is within tolerance END End CORRECT subroutine returning to code SPX spx EN Dual Loop Auxiliary Encoder The DMC 40x0 provides an interface for a
203. egardless of REM states of inputs 1 2 or 3 plcscan ATO 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 the REM if input 4 is high set bit 1 and clear bit 3 REM ti 8 gets 4th bit if 4th bit is high result 8 Chapter 7 Application Programming e 151 DMC 40x0 User Manual F ti 8 8 b1 1 EM ti87 get lo F tig 7 3 b3 1 EM set output B1 b1 0B3 b3 EM wait 500ms I R I R REM set outputs O R R EM the wil AT 500 JP scan ELSE wer 3 bits if 011 then result 3 ENDIF ENDIF bits 1 and 3 accordingly at the end for a PLC scan for 500 samples use AT 500 1 1 reset the time reference Mathematical and Functional Expressions Mathematical Operators For manipulation of data the DMC 40x0 provides the use of the following mathematical operators Operator amp 0 Function Addition Subtraction Multiplication Division Modulus Logical And Bit wise Logical Or On some computers a solid vertical line appears as a broken line Parenthesis The numeric range for addition for division is 1 65 000 subtraction and multiplication operations is 2 147 483 647 9999 The precision Mathematical operations are executed from left to right Calculations within parentheses have precedence Examples speed 7 5 V1 2 count count 2 result _TPX COS
204. elapsed For m 1 Same functionality except that n is number of samples rather than msec The AM trippoint is used to separate the two PR moves If AM is not used the controller returns a for the second PR command because a new PR cannot be given until motion is complete TWOMOVE PR 2000 BGX AMX PR 4000 BGX EN Label Position Command Begin Motion Wait for Motion Complete ext Position Move Begin 2 move End program Event Trigger Set Output after Distance Set output bit 1 after a distance of 1000 counts from the start of the move The accuracy of the trippoint is the speed multiplied by the sample period SETBIT SP 10000 PA 20000 BGX AD 1000 SBI Y EN Label Speed is 10000 Specify Absolute position Begin motion Wait until 1000 counts Set output bit 1 End program Event Trigger Repetitive Position Trigger To set the output bit every 10000 counts during a move the AR trippoint is used as shown in the next example TRIP JG 50000 BGX n 0 REPEAT AR 10000 TPX SBL WT50 BL n n 1 JP REPEAT n lt 5 LX EN Label Specify Jog Speed Begin Motion Repeat Loop Wait 10000 counts Tell Position Set output 1 Wait 50 msec Clear output 1 Increment counter Repeat 5 times Stop End Chapter 7 Application Programming e 137 DMC 40x0 User Manual Event Trigger Start Motion on Input This example waits for input
205. en the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the forward direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Reverse Limit Switch Low input inhibits motion in reverse direction If the motor is moving in the reverse direction when the limit switch is activated the motion will decelerate and stop In addition if the motor is moving in the reverse direction the controller will automatically jump to the limit switch subroutine LIMSWI if such a routine has been written by the user The CN command can be used to change the polarity of the limit switches Software Protection The DMC 40x0 provides a programmable error limit The error limit can be set for any number between 0 and 2147483647 using the ER n command The default value for ER is 16384 Example ER 200 300 400 500 Set X axis error limit for 200 Y axis error limit to 300 Z axis error limit to 400 counts W axis error limit to 500 counts ER 1 10 Set Y axis error limit to 1 count set W axis error limit to 10 counts The units of the error limit are quadrature counts The error is the difference between the command position and actual encoder position If the absolute value of the error exceeds the value specified by ER the controller will generate several
206. ent in terms of A counts in B milliseconds we can describe the motion in the following manner Chapter 6 Programming Motion e 111 DMC 40x0 User Manual 1 cos 2z B 4 4sin 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 50T 6000 27 sin 2m T 120 Note that the velocity in count ms is 50 1 cos 2x T 120 Figure 6 19 Velocity Profile with Sinusoidal Acceleration The DMC 40x0 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 is stored at the array POS Then the difference between the positions is computed and is stored in the array DIF Finally the motors are run in the contour mode Contour Mode Example INSTRUCTION INTERPRETATION POINTS Program defines X points DM POS 16 Allocate memory DM DIF 15 Cc 0 Set initial conditions C is index T 0 T is time in ms A V1 50 T V2 3 T Argument in degrees V3 955 SIN V2 V1 Compute position V4 INT V3 Integer value of V3 POS C v4 Store in array POS T T 8 C C 1 JP A C lt 16 DMC 40x0 User Manual Chapter 6 Programm
207. er numbers are permitted in the rest of the name Spaces are not permitted Variable names should not be the same as DMC 40x0 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 posl speedZ Invalid Variable Names RealLongName Cannot have more than 8 characters 123 Cannot begin variable name with a number speed Z Cannot have spaces in the name Assigning Values to Variables Assigned values can be numbers internal variables and keywords functions controller parameters and strings The range for numeric variable values is 4 bytes of integer 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 40x0 function can be used to assign a value to a variable For example vI ABS v2 or v2 IN 1 Arithmetic operations are also permitted DMC 40x0 User Manual Chapter 7 Application Programming e 154 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 log
208. er up Chapter 7 Application Programming e 143 DMC 40x0 User Manual AUTOERR Automatically executes when a checksum is encountered during AUTO start up Check error condition with RS bit 0 for variable checksum error bit 1 for parameter checksum error bit 2 for program checksum error bit 3 for master reset error there should be no program For example the POSERR subroutine will automatically be executed when any axis exceeds its position error limit The commands in the POSERR subroutine could decode which axis is in error and take the appropriate action In another example the ININT label co uld 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 runnin Example Limit Switch g for CMDERR to function This program prints a message upon the occurrence of a limit switch Note for the LIMSWI routine to function the DMC 40x0 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 L OOP JP LOOP EN Motion commands such as JG 5000 can still be sent from the PC even while the dummy applications program is being executed ED 000 LOOP 001 JP LOOP EN 002 LIMSWI 003 MG LIMIT OCCURRED 004 RE lt control gt Q XQ LOOP JG 5000 BGX Now when a forward
209. 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 The operands are used with the XQ command in the following format XQ _ED2 or _ED3 EDI 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 A JP A EN B N 1 KP N TY EN CMDERR IF _TC 6 N 1 XQ _ED2 ED1 1 ENDIF IF TC 1 XQ _ED3 ED1 1 ENDIF EN w Multitasking 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 4010 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 Instruction BEGIN cc 9600 0 1 0 GE 2 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 LOO
210. es 360 in the CW negative direction Such a path is specified with the instruction CR 80000 270 360 Chapter 7 Application Programming e 173 DMC 40x0 User Manual INSTRUCTION A VM XY VP 160000 160000 VE VS 200000 VA 1544000 BGS AMS PR 80000 SP 80000 BGZ AMZ CR 80000 270 360 VE vs 40000 BGS AMS PR 80000 BGZ AMZ PR 21600 SP 20000 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 40x0 User Manual Chapter 7 Application Programming e 174 0 4 9 3 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 object
211. es 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 Note Do not hot swap the motor power 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 Figure A2 1 DMC 4040 C012 1000 D3140 DMC 4040 with AMP 43140 DMC 40x0 User Manual A2 AMP 43140 D3140 e 244 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
212. espect 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 AB1 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 AB1 must be used to abort the coordinated motion sequence It is the responsibility of the user to keep enough motion segments in the DMC 40x0 sequence buffer to ensure continuous motion If the controller receives no additional motion segments and no VE command the controller will stop motion instantly at the last vector There will be no controlled deceleration LM or LM returns the
213. figurable I O bit 21 1020 Configurable I O bit 20 1022 Configurable I O bit 22 3 1024 Configurable I O bit 24 1023 Configurable I O bit 23 Digital Ground 4 1026 Configurable I O bit 26 1025 Configurable I O bit 25 1027 Configurable I O bit 27 5 1029 Configurable I O bit 29 1028 Configurable I O bit 28 1030 Configurable I O bit 30 6 1032 Configurable I O bit 32 1031 Configurable I O bit 31 Digital Ground 7 1033 Configurable I O bit 33 1034 Configurable I O bit 34 8 1036 Configurable I O bit 36 1035 Configurable I O bit 35 No Connect 9 1038 Configurable I O bit 38 1037 Configurable I O bit 37 Digital Ground 11 1041 Configurable 1 O bit 41 1040 Configurable I O bit 40 1042 Configurable I O bit 42 12 1044 Configurable I O bit 44 1043 Configurable I O bit 43 1045 Configurable I O bit 45 13 1047 Configurable 1 O bit 47 1046 Configurable I O bit 46 Digital Ground 15 RES Reserved 30 3 3V 3 3V7 Notes 1 SV when 5V option is ordered on CMB Ex DMC 4040 C012 5V 1200 2 Reserved when 5V option is ordered on CMB DMC 40x0 User Manual A5 CMB 41012 C012 e 254 RS 232 Main Port Male Standard connector and cable 9Pin Signal NC TXD RXD NC GND NC CTS RTS NC RS 232 Auxiliary Port Female Standard connector and cable 9Pin NC 5V with APWR Jumper RS 422 Main Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option
214. for a DMC 40x0 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 20 04 AF 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 40x0 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 40x0 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 40x0 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 save the IP address to the non volati
215. ftware Protection e 179 DMC 40x0 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 amplifiers will be disabled This could cause the motor to coast to a stop If the Off On Error function is not enabled the motor will instantaneously stop and servo at the current position The Off On Error function is further discussed in this chapter 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 wh
216. g Mode BGX Begin motion B Label for loop Vl AN 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 Imsec 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 applications such as tracking an object the controller must proceed towards a target and have the ability to change Chapter 6 Programming Motion e 81 DMC 40x0 User Manual the target during t
217. g e 152 IN ENTER len S6 Flen FRAC len Flen 10000 Flen Input character string of up to 6 characters into variable len Define variable Flen as fractional part of variable len Shift Flen by 32 bits len1l Flens 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 SO00000FF Let variable len3 bottom byte of len len4 lens 0000FF00 100 Let variable 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 len1 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
218. 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 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 n 2 n 4 n 16 Full Half 1 4 1 16 A3 SDM 44040 D4040 e 249 DMC 40x0 User Manual 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 DMC 40x0 User Manual A3 SDM 44040 D4040 e 250 A4 SDM 44140 D4140 Description The SDM 44140 resides inside the DMC 40x0 enclosure and contains four microstepping drives for operating two phase bipolar stepper motors The
219. gin not possible due to limit switch error The operands LFx and _LRx contain the state of the forward and reverse limit switches respectively x represents the axis X Y Z W etc The value of the operand is either a 0 or 1 corresponding to the logic state of the limit switch Using a terminal program the state of a limit 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 DMC 40x0 User Manual Chapter 3 Connecting Hardware e 32 Home Switch Input Homing inputs are designed to provide mechanical reference points for a motion control application A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system A reference point can be a point in space or an encoder index pulse The Home input detects any transition in the state of the switch and toggles between logic states 0 and at every transition A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user There are three homing routines supported by the DMC 40x0 Find Edge FE Find Index FI and Standard Home HM The Find Edge routine is initiated by the command sequence FEX
220. h must be set to the size of the response string m_sResponse is the string containing the controller response to the command DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 68 DOS and QNX tools Galil offers unsupported code examples that demonstrate communications to the controller using the following operating systems DOS DOS based utilities amp Programming Libraries for Galil controllers which includes a terminal utilities to upload and download programs and source code for BASIC and C programs Download DMCDOS at http www galilmc com support download html dos QNX Galil offers sample drivers for ISA and PCI cards for the QNX 4 24 operating system We also offer drivers and utilities for QNX 6 2 for PCI only Download at http www galilmc com support download html linux Linux Galil now offers full support to Linux users through the GalilTools software package For more information see the previous section on GalilTools or visit the Galil website http www galilmc com products software galiltools html Chapter 4 Software Tools and Communication e 69 DMC 40x0 User Manual Chapter 5 Command Basics Introduction The DMC 40x0 provides over 100 commands for specifying motion and machine parameters Commands are included to initiate action interrogate status and configure the digital filter These commands can be sent in ASCII or binary In ASCII the DMC 4
221. hapter 6 Programming Motion e 108 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 PVT 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 1 point in Figure 27 point in Figure 2 point in Figure 3 point in Figure 3 point in Figure Begin PVT mode for 4 poin 4 poin 5 poir 5 poin in in in in Termination Termination Figure Figure Figure Figure of PVT of PVT 16 A axis 16 B axis 16 16 16 A axis B axis A axis B axis and B axes 16 16 16 Lo buffer buffer 6 6 6 6 6 6 16 A 6 6 6 6 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
222. he 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 201 DMC 40x0 User Manual Ordering Options for the DMC 40x0 Overview The DMC 40x0 can be ordered in many different configurations and with different options This section provides information regarding the different options available on the DMC 40x0 motion controller interconnect modules and internal amplifiers For information on pricing and how to order a controller with these options see our DMC 40x0 part number generator on our website http www galilmc com products dmc 40x0 part number php DMC 40x0 Controller Board Options DIN DIN Rail Mounting The DIN option on the DMC 40x0 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 Part number ordering example DMC 4010 DIN C012 1000 12V Power Controller with 12VDC The 12V option allows the controller to be powered with a regulated 12V supply In most cases this option is only appropriate if no Galil amplifiers are used Part number ordering example DMC 4010 12V C012 1000 TRES Encoder Terminatio
223. he 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 Appendices e 211 DMC 40x0 User Manual Configuring the Amplifier Enable Circuit ICM 42000 and ICM 42100 The following section details the steps needed to change the amplifier enable configuration for the DMC 40x0 controller with an ICM 42000 or ICM 42100 For detailed instruction on changing the amplifier enable configuration on a DMC 40x0 with an ICM 42200 see the section in Chapter 3 labeled ICM 42200 Amplifier Enable Configuration For electrical details about the amplifier enable circuit see the ICM 42000 and ICM 42100 Amplifier Enable Circuit section in Chapter 3 For DMC 4080 refer to DMC 4080 Steps 1 and 2 section below NOTE From the default configuration the configuration for 12V High Amp Enable Sinking Configuration does not require the
224. he move In a tracking application this could occur at any time during the move or at regularly scheduled intervals For example if a robot was designed to follow a moving object at a specified distance and the path of the object wasn t known the robot would be required to constantly monitor the motion of the object that it was following To remain within a specified distance it would also need to constantly update the position target it is moving towards Galil motion controllers support this type of motion with the position tracking mode This mode will allow scheduled or random updates to the current position target on the fly Based on the new target the controller will either continue in the direction it is heading change the direction it is moving or decelerate to a stop The position tracking mode shouldn t be confused with the contour mode The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate In this mode the position can be updated randomly or at a fixed time rate but the velocity profile will always be trapezoidal with the parameters specified by AC DC and SP Updating the position target at a specific rate will not allow the user to create a custom profile The following example will demonstrate the possible different motions that may be commanded by the controller in the position tracking mode In this example there is a host program that will generate the absolute pos
225. ical value of input 2 to variable input v2 v1 v3 v4 Assigns the value of vl plus v3 times v4 to the variable v2 CAT to var CAT var CAT Assign the string MG var S3 Displays the variable var Assigning Variable Values to Controller Parameters Variable values may be assigned to controller parameters such as GN or PR PR v1 SP vS 2000 Assign vl to PR command 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 Variables for Joystick The example below reads the voltage of an X Y joystick and assigns it to variables vX and vY to drive the motors at proportional velocities where 10 Volts 3000 rpm 200000 c sec Speed Analog input 200000 10 20000 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 AT 4 JP LOOP EN Jog at variable vX vY Wait 4ms from last time reference creates a deterministic loop time Repeat End Operands Operands allow motion or status parameters of the DMC 40x0 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 40x0 command The command reference indicates which commands
226. icating 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 THF 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 1 1 A 1 CFGVALUE I 1 1 JP CFGLOOP I lt 2 NUMOFTO 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 variable Jump to subroutine Label Dimension array Set variable Loop subroutine Set array element Increment Set array element Increment Conditional statement DMC 40x0 User Manual Appendices e 230 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 num
227. ied as a collection of segments For the purpose of specifying the path define a special X Y coordinate system whose origin is the starting point of the sequence Each linear segment is specified by the X Y coordinate of the final point expressed in units of resolution and each circular arc is defined by the arc radius the starting angle and the angular width of the arc The zero angle corresponds to the positive direction of the X axis and the CCW direction of rotation is positive Angles are expressed in degrees and the resolution is 1 256th of a degree For example the path shown in Fig A l is specified by the instructions VP 0 10000 CR 10000 180 90 VP 20000 20000 20000 10000 10000 20000 Figure A 1 X Y Motion Path Appendices e 227 DMC 40x0 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 segments A B Linear 10000 units Rid 621 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 Lie RilA 0 1127 360 The total travel distance is given by D y
228. ied 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 1 N MG counts sec EN When A is executed the above example will appear on the screen as The speed is 50000 counts sec Using the MG Command to Configure Terminals The MG command can be used to configure a 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 ey 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 n m Formats numeric values in hexadecimal n Sends ASCII character specified by integer n N Su
229. ier 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 DMC 40x0 User Manual A2 AMP 43140 D3140 e 246 A3 SDM 44040 D4040 Description The SDM 44040 resides inside the DMC 40x0 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 Note Do not hot swap the motor power 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 aon ENEN Em ae m ama gt a T DMC 4040 Jd ja ddr a Figure A3 1 DMC 4040 C012 1000 D4040 DMC 4040 with SDM 44040 A3 SDM 44040 D4040 e 247 DMC 40x0 User Manual 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
230. ill default to 1000 The protocol TCP IP or UDP IP to use must also be 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
231. imum 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 lt return gt 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 DMC 40x0 User Manual Chapter 2 Getting Started e 24 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 lt return gt Proportion gain TE A lt return gt Tell error ea 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 lt return gt 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 see Chapter 10 Theory of Operation Design Examples Here are a few
232. in 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 Control Inc Appendices e 235 DMC 40x0 User Manual Integrated Components Overview When ordered the following components will reside inside the box of the DMC 40x0 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 ar
233. in with a label and end with an End EN statement Labels start with the pound sign followed by a maximum of seven characters The first character must be a letter after that numbers are permitted Spaces are not permitted The maximum number of labels which may be defined is 510 Chapter 7 Application Programming e 131 DMC 40x0 User Manual Valid labels BEGIN SQUARE X1 BEGINI 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 40x0 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 ININT Label for Input Interrupt subroutine LIMSWI Label for Limit Switch subroutine POSERR Label for excess Position Error subroutine FMCTIME Label for timeout on Motion Complete trip point FCMDERR Label for incorrect command subroutine Commenting Programs Using the command NO or Apostrophe The DMC 40x0 provides a command NO for commenting programs or single apostrophe This
234. index for synchronization The DMC 40x0 can be ordered with 120 Ohm termination resistors installed on the encoder inputs See the Ordering Options for the DMC 40x0 in the Appendix for more information The DMC 40x0 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 5 500 000 full encoder cycles second 22 000 000 quadrature counts sec For example if the encoder line density is 10 000 cycles per inch the maximum speed is 300 inches second If higher encoder frequency is required please consult the factory The standard encoder voltage level is TTL 0 5v however voltage levels up to 12 Volts are acceptable If using differential signals 12 Volts can be input directly to the DMC 40x0 Single ended 12 Volt signals require a bias voltage input to the complementary inputs The DMC 40x0 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 Sinusoidal Encoders The DMC 40x0 can be ordered with an interconnect module that supports the use
235. ine a program must be running in thread 0 at all times for it to be enabled Example A DMC 40x0 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 AUTO speedA 10000 speedB 10000 Cr 2 JG speedA speedB BGXY PRINT MG P2 TO CHANGE SPEEDS MG P2 TYPE A OR B MG P2 TYPE S TO STOP JOGLOOP JG speedA speedB JP JOGLOOP EN COMINT JP A P2CH A JP B P2CH B JP C P2CH S ZS1 C12 JP JOGLOOP HA JS NUM speedX val ZS1 C12 JP PRINT B JS NUM speedY val ZS1 C12 JP PRINT C ST AMX CI 1 MG 8 THE END ZS EN 1 Interpretation Label for Auto Execute Initial A speed Initial B speed Set Port 2 for Character Interrupt Specify jog mode speed for A and B axis Begin motion Routine to print message to terminal Print message Loop to change Jog speeds Set new jog speed End of main program Interrupt routine Check for A Check for B Check for S Jump if not X Y S New X speed Jump to Print New Y speed Jump to Print Stop motion on S End Re enable interrupt Chapter 7 Application Programming 161 DMC 40x0 User Manual NUM Routine for entering new jog speed MG ENTER P2CH S AXIS Prompt for value SPEED N NUMLOOP
236. inear 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 40x0 provides uncommitted I O including 8 opto isolated digital inputs 16 inputs for DMC 4050 thru DMC 4080 8 high power optically isolated outputs 16 outputs for DMC 4050 thru DMC 4080 and 8 analog inputs for interface to joysticks sensors and pressure transducers The DMC 40x0 also has an additional 32 I O at 3 3V logic Further I O is available if the auxiliary encoders are not being used 2 inputs each axis Dedicated optoisolated inputs are provided for forward and reverse limits abort home and definable input interrupts Commands can be sent in either Binary or ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen CAD translation and program development using many environments such as Visual Basic C C etc Drivers for Windows XP 32 amp 64 bit Chapter 1 Overview e 1 DMC 40x0 User Manual Overview of Motor Types The DMC 40x0 can provide the following types of motor control 1 Standard servo motors with 10 volt command signals 2 Brushless servo motors with sinusoidal commutation 3 Step motors with step and direction signals 4 Other actuators such as hydraulics For more information contact Galil The user can configure each axis for any combination of motor types providing maximum
237. inear 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 should accept step and direction signals Overview of Galil Amplifiers and Drivers With the DMC 40x0 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 Al 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 40x0 The standard amplifier accepts DC supply voltages from 18 80 VDC A2 AMP 43140 D3140 The AMP 43140 contains four linear
238. ing Before sending any commands the DMCOpen function must be called This function establishes communication with the controller and is called only once This example code illustrates the use of DMCOpen and DMCCommand A connection is made to controller 1 in the Galil registry upon launching the application Then the controller is sent the command TPX whenever a command button is pressed The response is then placed in a text box When the application is closed the controller is disconnected To use this example start a new Visual Basic project place a Text Box and a Command Button on a Form add the DMCCOM40 BAS module and type the following code Dim m_nController As Integer Dim m hDmc As Long Dim m_nRetCode As Long Dim m nResponseLength As Long Dim m_sResponse As String 256 Private Sub Commandl Click m_nRetCode DMCCommand m_hDmc TPX m_sResponse m_nResponselLength Textl Text Val m_sResponse End Sub Private Sub Form Load m nResponseLength 256 m_nController 1 m nRetCode DMCOpen m_ nController 0 m hDmc End Sub Private Sub Form Unload Cancel As Integer m_nRetCode DMCClose m_hDmc End Sub Where m_nController is the number for the controller in the Galil registry m_hDmc is the DMC handle used to identify the controller It is returned by DMCOpen m_nRetCode is the return code for the routine m_nResponseLength is the response string length whic
239. ing Motion e 112 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 IP Wait CM lt gt 511 EN 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 40x0 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 Dimension array RA C Specify array for automatic record up to 4 for DMC 4040 RD _TPX Specify data for capturing such as _TPX or TPZ RC n m Specify capture time interval where n is 2 sample periods 1 ms for TM1000 m is number of records to be captured RC or RC Returns a 1 if recording Record and Playback Example RECORD Begin Program DM XPOS 501 Dimension array with 501 elements RA XPOS Specify automatic record RD _TPX Specify X position to be captured MOX Turn X motor off RC2 Begin recording 4 msec interval at TM1000 A JP A RC 1 Continue until done recording COMPUTE Compute DX DM DX 500 Dimension Array for DX c 0 Initialize counter L Label D C 1 DELTA XPOS D XPOS C DX
240. 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 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 NVZ VW The result is shown in Figure 6 8 Linear Interpolation Chapter 6 Programming Motion e 89 DMC 40x0 User Manual 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 8 Linear Interpolation Example Multiple Moves This example makes a coordinated linear move in the XY plane The Arrays VX and VY are used to store 750 incremental distances which are filled by the program LOAD LOAD Load Program DM VX 750 VY 750 Define Array COUNT 0 Initialize Counter DMC 40x0 User Manual Chapter 6 Programming Motion e 90 N 0 LOOP VX COUNT N VY COUNT
241. into current The amplifier should be sized properly to meet the power requirements of the motor For brushless motors an amplifier that provides electronic commutation is required or the controller must be configured to provide sinusoidal commutation The amplifiers may be either pulse width modulated PWM or linear They may also be configured for operation with or without a tachometer For current amplifiers the amplifier gain should be set such that a 10 volt command generates the maximum required current For example if the motor peak current is 10A the amplifier gain should be 1 A V For velocity mode amplifiers 10 volts should run the motor at the maximum speed Galil offers amplifiers that are integrated into the same enclosure as the DMC 40x0 See the Integrated section in the Appendices or http galilmc com products accelera dmc40x0 html for more information Chapter 1 Overview e 5 DMC 40x0 User Manual Encoder An encoder translates motion into electrical pulses which are fed back into the controller The DMC 40x0 accepts feedback from either a rotary or linear encoder Typical encoders provide two channels in quadrature known as CHA and CHB This type of encoder is known as a quadrature encoder Quadrature encoders may be either single ended CHA and CHB or differential CHA CHA and CHB CHB The DMC 40x0 decodes either type into quadrature states or four times the number of cycles Encoders may also have a third channel or
242. ion 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 CBO Disengage knife MG ALL DONE EN End program Chapter 6 Programming Motion e 93 DMC 40x0 User Manual Command Summary Coordinated Motion Sequence COMMAND VM m n VP m n CR 1 0 tA VS s t VA s t VD s t VR s t BGST CSST AV s t AMST TN m n ES m n IT s t LM CAS or CAT DESCRIPTION Specifies the axes for the planar motion where m and n represent the planar axes and p is the tangent axis Return coordinate of last point where m X Y Z or W Specifies arc segment where r is the radius is the starting angle and AO is the travel angle Positive direction is CCW Specify vector speed or feed rate of sequence Specify vector acceleration along the sequence Specify vector deceleration along the sequence Specify vector speed ratio Begin motion sequence S or T Clear sequence S or T Trippoint for After Relative Vector distance Holds execution of next command until Motion Sequence is complete Tangent scale and offset Ellipse scale factor S curve smoothing const
243. ion _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 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 DMC 40x0 User Manual Chapter 7 Application Programming e 158 RECORD DM XPOS 300 YPOS 300 DM XERR 300 YERR 300 RA XPOS XERR YPOS YERR RD TPX TEX TPY TEY PR 10000 20000 RC1 BG XY HA JP HA RC 1 G DONE EN PLAY 0 JP DONE N gt 300 X POS N Y POS N XERR N YERR N N N 1 DONE EN De allocating Array Space Begin program Define X Y position arrays Define X Y error arrays Select arrays for capture Select data types Specify move distance Start recording now at rate of 2 msec Begin motion Loop until done Print message End program Play back Initial Counter Exit if done Print Counter Print X position Print Y position Print X error Print Y error Increment Counter Done End Program Array space may be de allocated using the DA command followed by the array name DA 0 dealloc
244. ion by Sampled Dual Loop The continuous dual loop enabled by the DV1 function is an effective way to compensate for backlash In some cases however when the backlash magnitude is large it may be difficult to stabilize the system In those cases it may be easier to use the sampled dual loop method described below This design example addresses the basic problems of backlash in motion control systems The objective is to control the position of a linear slide precisely The slide is to be controlled by a rotary motor which is coupled 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 40x0 User Manual Chapter 7 Application Programming e 176 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 eliminate
245. ion 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 40x0 controller has a torque limit command TL This command sets the maximum voltage output of the controller and can be used to avoid excessive torque or speed when initially setting up a servo system When operating an amplifier in torque mode the voltage output of the controller will be directly related to the torque output of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the motors output torque When operating an amplifier in velocity or voltage mode the voltage output of the controller will be directly related to the velocity of the motor The user is responsible for determining this relationship using the documentation of the motor and amplifier The torque limit can be set to a value that will limit the speed of the motor For example the following command will limit the output of the controller to 1 volt on the X axis TL 1 lt return gt NOTE Once the correct polarity of the feedback loop has been determined the torque limit should in general be increased to the default value of 9 99 The servo will not operate properly if the torque
246. ired current Note The DMC 40x0 controller has an option for differential motor command outputs For more information contact Galil The DMC 40x0 also provides an amplifier enable signal AENn where n is A H 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 For all versions of the ICM 42x00 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 changed by configuring the Amplifier Enable Circuit on the ICM 42x00 If your amplifier requires a different configuration than the default 5V HAEN sinking it is highly recommended that the DMC 40x0 is ordered with the desired configuration See the DMC 40x0 ordering information in the catalog http www galilmc com catalog cat40x0 pdf or contact Galil for more information on ordering different configurations Notel Many amplifiers designate the enable input as inhibit ICM 42000 and ICM 42100 Amplifier Enable Circuit This section describes how to configure the ICM 42000 and ICM 42100 for different Amplifier Enable configurations It is advised that
247. ith 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 Data which is output from the controller is stored in the output UART The UART buffer can store up to 512 characters of information In normal operation the controller places output into the FIFO buffer When the trace mode is enabled the controller will send information to the UART buffer at a very high rate In general the UART will become full because the hardware handshake line will halt serial data until the correct data is read When the UART becomes full program execution will be delayed until it is cleared If the user wants to avoid this delay the command CW 1 can be given This command causes the controller to throw away the data which can not be placed into the FIFO In this case the controller does not delay program execution Error Code Command When there is a program error the DMC 40x0 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 describe
248. ithout intervention from a host computer DMC 40x0 Event Triggers 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 G or H AP X or Y or Z or W A or B or Cor D or E or F or G or H MF X or Y or Z or W A or B or Cor D or E or F or G or H MR X or Y or Z or W A or B or Cor D or 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 Al n ASXYZWS ABCDEFGH AT n m Command Function AMX YZWorS Halts program execution until motion is complete on ABCDEFGH 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 AD X or Y or Z or W 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
249. ition 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 4030 controller where the Z axis is the master and X and Y are the geared axes We will implement the gearing change over 6000 counts 3 revolutions of the master axis MO Z Turn Z off for external master GA Z Z Specify Z as the master axis for both X and Y GD6000 6000 Specify ramped gearing over 6000 counts of the master axis GR 1 132 045 Specify gear ratios Question What is the effect of the ramped gearing Answer Below in the example titled Electronic Gearing gearing would take effect immediately From the start of gearing if the master traveled 6000 counts the slaves would travel 6792 counts and 270 counts Using the ramped gearing the slave will engage gearing gradually Since the gearing is engaged over the interval of 6000 counts of the master the slave will only travel 3396 counts and 135 counts respectively The difference between these two values is stored in the GPn operand If
250. ition targets The absolute target is determined based on the current information the host program has gathered on the object that it is tracking The position tracking mode does allow for all of the axes on the controller to be in this mode but for the sake of discussion it is assumed that the robot is tracking only in the X dimension The controller must be placed in the position tracking mode to allow on the fly absolute position changes This is performed with the PT command To place the X axis in this mode the host would issue PT1 to the controller if both X and Y axes were desired the command would be PT 1 1 The next step is to begin issuing PA command to the controller The BG command isn t required in this mode the SP AC and DC commands determine the shape of the trapezoidal velocity profile that the controller will use Example Motion 1 The host program determines that the first target for the controller to move to is located at 5000 encoder counts The acceleration and deceleration should be set to 150 000 cts sec2 and the velocity is set to 50 000 cts sec The command sequence to perform this is listed below Command Description PTI Place the X axis in Position tracking mode AC150000 Set the X axis acceleration to 150000 cts sec DC150000 Set the X axis deceleration to 150000 cts sec SP50000 Set the X axis speed to 50000 cts sec PA5000 Command the X axis to absolute position 5000 encoder counts D
251. ive is to drive the motor at a speed proportional to the input voltage Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder resolution of 1000 lines or 4000 count rev This speed equals 3000 rpm 50 rev sec 200000 count sec The program reads the input voltage periodically and assigns its value to the variable VIN To get a speed of 200 000 ct sec for 10 volts we select the speed as Speed 20000 x VIN Chapter 7 Application Programming e 175 DMC 40x0 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 FA 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 Compensat
252. l gradually by instructions such as Instruction Interpretation Tb 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 Chapter 2 Getting Started e 27 DMC 40x0 User Manual KP Return gain of A axis KP 522 Return gain of C axis KP 322 7 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 BG A Start the motion Example 11 Using the On Board Editor Motion programs may be edited and stored in the controller s on board memory When the command ED is given from the Galil DOS terminal such as DMCTERM the controllers editor will be started The instruction ED Edit mode moves the operation to the editor mode where the program may be written and edited The editor provides the line number For example in response to the first ED command the first line is zero Line Instruction Interpretation 000 A Define label 001 PR 700 Distance 002
253. lay Back Backlash Correction Following a trajectory based on a master encoder position Smooth motion while operating in independent axis positioning Smooth motion while operating in vector or linear interpolation positioning Smooth motion while operating with stepper motors Gantry two axes are coupled by gantry VM VP CR VS VR VA VD VE VM VP CR VS VA VD TN VE GA GD _GP GR GM if gantry GA GD _GP GR CM CD DT CM CD DT RA RD RC Dual Loop DV Electronic Cam EA EM EP ET EB EG EQ Independent Motion Smoothing IT Vector Smoothing IT Stepper Motor Smoothing KS Gantry Mode GR GM Coordinated Motion Coordinated motion with tangent axis specified Electronic Gearing Electronic Gearing Contour Mode with Automatic Array Capture Chapter 6 Programming Motion e 77 DMC 40x0 User Manual 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 40x0 profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory The controller determines a new command position along the trajectory every sample period until the specified profile is complete Motio
254. le 263 ICM 42000 Analog 15 pin D sub Connector Male 263 Jumper Description for ICM 42000 ersan 264 A7 1ICM 42100 1100 265 DSC init marae an uate Ape uta abeaiaitts 265 Connectors for ICM 42100 Interconnect Board econo riores 266 ICM 42100 I O A D 44 pin HD D Sub Connector Female 266 ICM 42100 I O E H 44 pin HD D Sub Connector Female 266 ICM 42100 External Driver A D 44 pin HD D Sub Connector Male s sscccsssssssssesserseseesesseeetes 267 ICM 42100 External Driver E H 44 pin HD D Sub Connector Male cccocccccccnoncnccncnonconenconacanionccncnnos 268 ICM 42100 Encoder 15 pin HD D Sub Connector Female 269 ICM 42100 Analog 15 pin D sub Connector Male LESA CREE STNG is seats reacts Soretits erases A 270 A8 ICM 42200 1200 272 Decimo ae a eee PTR ER REE Hee OSCR ERE OES eR PEE eye PEP Tene meee ere 272 Connectors for ICM 42200 Interconnect Board sous israel srianta 272 ICM 42200 I O A D 44 pin HD D Sub Connector Female 272 ICM 42200 DMC 40x0 I O E H 44 pin HD D Sub Connector Female ccssscesssstetsteeseeetteenees 273 ICM 42200 Encoder 26 pin HD D Sub Connector Female 273 ICM 42200 Analog 15 pin D sub Connector Male 274 Jumper Description for ICM 42200 nnana 274 Index 275 DMC 40x0 Contents e viii Chapter 1 Overview Introduction The DMC 40x0 Series are Galil s highest perform
255. le 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 40x0 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 RS 232 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 40x0 non volatile memory 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 Chapter 4 Software Tools and Communication e 51 DMC 40x0 User Manual 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 40x0 board Typical port numbers for applications are Port 23 Telnet Port 502 Modbu
256. ler has been properly configured the brushless motor parameters may be saved in non volatile memory The DMC 40x0 can control BLMs equipped with Hall sensors as well as without Hall sensors If Hall sensors are available once the controller has been setup the brushless motor parameters may be saved in non volatile memory In this case the controller will automatically estimate the commutation phase upon reset This allows the motor to function immediately upon power up The Hall effect sensors also provide a method for setting the precise commutation phase Chapter 2 describes the proper connection and procedure for using sinusoidal commutation of brushless motors Stepper Motor with Step and Direction Signals The DMC 40x0 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 DMC 40x0 User Manual Chapter 1 Overview e 2 Overview of External Amplifiers The amplifiers should be suitable for the motor and may be l
257. lication code DMC 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 RS232 and RS422 Ports The RS232 pin out description for the main and auxiliary port is given below Note that the auxiliary port is essentially the same as the main port except inputs and outputs are reversed The DMC 40x0 may also be configured by the factory for RS422 These pin outs are also listed below RS 232 Configuration NOTE If you are connecting the RS232 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 DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 48 RS232 Main Port P1 DATATERM 1 No Connect 6 No Connect 2 Transmit Data output 7 Clear To Send input 3 Receive Data input 8 Request To Send output 4 No Connect 9 No connect 5 Ground RS232 Auxiliary Port P2 DATASET 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
258. 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 lt CR gt Position relative 1000 counts BGA lt CR gt 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 DMC 40x0 User Manual Chapter 2 Getting Started e 20 Inverting the Loop Polarity When the polarity of the feedback is incorrect the user must invert the loop polarity and this may be accomplished by several methods If you are driving a brush type DC motor the simplest way is to invert the two motor wires typically red and black For example switch the M1 and M2 connections going from your amplifier to the motor When driving a brushless motor the polarity reversal may be done with the encoder If you are using a single ended encoder interchange the signal 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
259. lled function codes The DMC 40x0 supports the 10 major function codes 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 os PrestSinleRegister WriteOneWord Preset Multiple Registers Write Words Report Slave ID The DMC 40x0 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 6 F Module is the position of the module in the rack from 1 to 16 BitNum is the I O
260. lock 2 is configured as an input Example Applications Wire Cutter An operator activates a start switch This causes a motor to advance the wire a distance of 10 When the motion stops the controller generates an output signal which activates the cutter Allowing 100 ms for the cutting completes the cycle Suppose that the motor drives the wire by a roller with a 2 diameter Also assume that the encoder resolution is 1000 lines per revolution Since the circumference of the roller equals 27 inches and it corresponds to 4000 quadrature one inch of travel equals 4000 27 637 count inch This implies that a distance of 10 inches equals 6370 counts and a slew speed of 5 inches per second for example equals 3185 count sec The input signal may be applied to I1 for example and the output signal is chosen as output 1 The motor velocity profile and the related input and output signals are shown in Fig 7 1 The program starts at a state that we define as A Here the controller waits for the input pulse on I1 As soon as the pulse is given the controller starts the forward motion Upon completion of the forward move the controller outputs a pulse for 20 ms and then waits an additional 80 ms before returning to A for a new cycle INSTRUCTION FUNCTION A Label AIl 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
261. lowed 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 i e SH or BG 01 One byte per field 02 One word 2 bytes per field 04 One long word 4 bytes per field 06 Galil real format 4 bytes integer and 2 bytes fraction Byte 3 specifies whether the command applies to 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 where A7 is the command number for PR 02 specifies 2 bytes for each data field DMC 40x0 User Manual Chapter 5 Command Basics e 72 00 S is not active for PR 05 specifies bit 0 is acti
262. 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 057000 05 0 0 00 0 0 07 00 Response from Interrogation Command TP 4 2 Tell Position in hexadecimal format 4 2 FFFB 00 0005 00 0000 00 0007 00 Response from Interrogation Command Formatting Variables and Array Elements The Variable Format VF command is used to format variables and array elements The VF command is specified by VF 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 vl Return vl 0000000010 0000 Response Default format VEZ 2 Change format vl Return vl 710 00 Response New format VF 2 2 Specify hex format vl Return vl SOA 00 Response Hex value Chapter 7 Application Programming e 165 DMC 40x0 User Manual VEL Change format vl Return vl 79 Response Overflow Local Formatting of Variables PF and VF comm
263. 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 DMC 40x0 User Manual Chapter 6 Programming Motion e 124 The DMC 40x0 defines the home position as the position at which the index was detected and sets the encoder reading at this point to zero The 4 different motion possibilities for the home sequence are shown in the following table Normally Open Switch Type Inital_HMX state Stage 3 Normally Open 070 a a SA Forward FS Forward fous efron re Forward Normally Closed CN 1 Normally Closed CN 1 Direction of Motion Reverse a Forward Reverse Forward Forward Example Homing Instruction HOME CN 1 AC 1000000 DC 1000000 SP 5000 HM BG AM MG AT HOME EN Interpretation Label Configure the polarity of the home input Acceleration Rate Deceleration Rate Speed for Home Search Home Begin Motion After Complete Send Message End Figure 6 21 shows the velocity profile from the homing sequence of the example program above For this profile the switch is normally closed and CN 1 Chapter 6 Programming Motion e 125 DMC 40x0 User Manual HOME SWITGH _HMX 0 _HMX 1 POSITION VELOCITY MOTION BEGINS IN FORWARD DIRECTION 2 POSITION VELOCITY MOTION CHA
264. move the constrained axes simply command the N axis in the jog mode or with the PR and PA commands For example PAN 2000 BGN will cause the XY axes to move to the corresponding points on the motion cycle Sinusoidal Motion Example The x axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a frequency of 20 Hz This can be performed by commanding the X and N axes to perform circular motion Note that the value of VS must be VS 2r R F where R is the radius or amplitude and F is the frequency in Hz Set VA and VD to maximum values for the fastest acceleration INSTRUCTION INTERPRETATION VMXN Select Axes VA 68000000 Maximum Acceleration VD 68000000 Maximum Deceleration VS 125664 VS for 20 Hz CR 1000 90 3600 Ten Cycles VE BGS DMC 40x0 User Manual Chapter 6 Programming Motion e 114 Stepper Motor Operation When configured for stepper motor operation several commands are interpreted differently than from servo mode The following describes operation with stepper motors Specifying Stepper Motor Operation Stepper motor operation is specified by the command MT The argument for MT is as follows 2 specifies a stepper motor with active low step output pulses 2 specifies a stepper motor with active high step output pulses 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
265. mplifiers or when ISCNTL option is ordered Power Connectors for Galil integrated Amplifiers SS Se eae ame 3 D 3 l I I l ee ee gS H I A B C D POWER k E F G H POWER l I P ENCODER STEPPER SERVO POWER l DMC 4080 1545V agia SOO Fees lolol a l 14 HALO 4ABe A lololg a Lolo ue wWs ooo i IA A ojoje B ojoje GND OOO i i GALIL GALIL MOTION CONTROL pap OMA og i MADE IN USA mae a 1 Mle l l l l l l ye ye I I l lt ao o a w i o Eo I Pa E T E E fed cc T 5 5 5 5 amp 5 5 5 8 8 8 8 8 3 3 3 I 3 8 S S 3 S 8 S a DE 1 16 1 i 1 t 16 1 l l l AD EH MTAM GND GND GND GND I ATRM 5V 5V 45V 45V 1 APWR 12V 12V 12V REN i AECI AEC2 AEC AEC2 i ss 0 si 38 38 ANALOG i lt lt 1 i lt lt vol g a a 8 F 2 I la SANO 3 AGN T E3 lt 2 1 be z y 10 Al2 Y Y o ES ES o D 2 nag 3 Ae Z ES pu gt wi a a 4Al5 2 3 z E ik AS SAU 5 a l ing 13A8 SAGAD S S MESE I AOS fd 5 1 85V E E l ing i a ad EXTENDED VO EXTERNAL DRIVER A D VO A D EXTERNAL DRIVER E H VO E H l stio19 18107 1018 ny aistea ISTA y Res 1 sory BAN sister 16STE y pes 1 asy 158V FA 17 RES 44 CMP 14 ORET 17 RES 4
266. mutation phase This value is stored in the operand BZn Using this operand the controller can be commanded to move the motor The BZ command is then issued as described above For example to initialize the A axis motor upon power or reset the following commands may be given SHA Enable A axis motor PRA 1 _ BZA Move A motor close to zero commutation phase BGA Begin motion on A axis AMA Wait for motion to complete on A axis BZA 1 Drive motor to commutation phase zero and leave motor on Method 3 Use the command BC This command uses the Hall transitions to determine the commutation phase Ideally the Hall sensor transitions will be separated by exactly 60 and any deviation from 60 will affect the accuracy of this method If the Hall sensors are accurate this method is recommended The BC command monitors the Hall sensors during a move and monitors the Hall sensors for a transition point When that occurs the controller computes the commutation phase and sets 1t For example to initialize the A axis motor upon power or reset the following commands may be given SHA Enable A axis motor BCA Enable the brushless calibration command PRA 50000 Command a relative position movement on A axis BGA Begin motion on A axis When the Hall sensors detect a phase transition the commutation phase is reset Chapter 2 Getting Started e 23 DMC 40x0 User Manual Step 8c Connect Step Motors In Steppe
267. n Resistors The TRES option provides termination resistors on all of the main and auxiliary encoder inputs on the DMC 40x0 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 shown below 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 interconnect module contact Galil directly installed whenTRES option is ordered Part number ordering example DMC 4010 TRES C012 1000 DMC 40x0 User Manual Appendices e 202 16 bit 16 bit Analog Inputs The 16 bit option provides 16 bit analog inputs on the DMC 40x0 motion controller The standard resolution of the analog inputs is 12 bits Part number ordering example DMC 4010 16bit C012 1000 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 4759 precision resistors 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 RIO Part number ordering example DMC 4010 4 20mA
268. n is complete when the last position command is sent by the DMC 40x0 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 moving 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
269. nect Module The ICM 42000 breaks out the internal CPU connector into convenient D sub connectors for interface to external amplifiers and I O devices DMC 40x0 User Manual Integrated Components e 236 A7 ICM 42100 1100 Sinusoidal Encoder Interpolation Module The ICM 42100 accepts sinusoidal encoder signals instead of digital encoder signals as accepted by the ICM 42000 and the ICM 42200 A8 ICM 42200 1200 Interconnect Module The ICM 42200 provides a pin out that is optimized for easy connection to external drives Integrated Components e 237 DMC 40x0 User Manual Al AMP 430x0 D3040 D3020 Description The AMP 43040 resides inside the DMC 40x0 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 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 v
270. nection gt Properties gt TCP IP and choose use the following IP address If a Dynamic IP address is used make sure there is a DHCP Server on your network or you will encounter an error Chapter 2 Getting Started e 15 DMC 40x0 User Manual Use the New Controller button to add a new entry in the registry or alternatively click on the Find Ethernet Controller to have the software search for controllers connected to the network When adding a new controller choose DMC 40x0 as the controller type Enter the IP address obtained from your system administrator Select the button corresponding to the UDP or TCP protocol in which you wish to communicate with the controller If the IP address has not been already assigned to the controller click on ASSIGN IP ADDRESS ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do not have an IP address The program will then ask you whether you would like to assign the IP address you entered to the controller with the specified serial number Click on YES to assign it NO to move to next controller or CANCEL to not save the changes If there are no controllers on the network that do not have an IP address assigned the program will state this When done registering click on OK If you do not wish to save the changes click on CANCEL Once the controller has been registered select the correct controller from the list and click on OK If the soft
271. ntroller 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 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 Using DMC SmartTerminal or WSDK Software for Windows NOTE For new applications Galil recommends using the GalilTools software package The controller must be registered in the Windows registry for the host computer to communicate with it The registry may be accessed via Galil software such as WSDK or GALIL Smart Terminal A dedicated network card with a static IP address is recommended To set your NIC card to a static IP go to the Control Panel gt Network Connections gt Local Area Con
272. o CHA and direction into Channel B and using the CE command to configure this mode Once Per Revolution encoder pulse Used in Homing sequence or Find Index command to define home on an encoder index Differential inputs from encoder May be input along with CHA CHB for noise immunity of encoder signals The CHA and CHB inputs are optional Inputs for additional encoder Used when an encoder on both the motor and the load is required Not available on axes configured for step motors A low input stops commanded motion instantly without a controlled deceleration 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 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 t
273. o 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 available the Galil 5V or 12V and GND may be used It is recommended to use an isolated supply for the optoisolated inputs The optoisolated inputs are configured into groups For example the general inputs DI1 DI8 inputs 1 8 the ABRT abort input and RST reset and ELO electronic lock out inputs are one group Figure 3 1 illustrates the internal circuitry The INCOM signal is a common connection for all of the inputs in each group DMC 40x0 User Manual Chapter 3 Connecting Hardware e 34 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 I e There is only one ELO ABRT and RST input for an 8 axis controller The common is the INCOM found on the I O A D D Sub connector The optoisolated inputs are connected in the following groups Group Controllers with 1 4 Axes DII DIS ABRT RST ELO FLSA RLSA HOMA FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD Group Controllers with 5 8 Axes DI DI8 ABRT RST ELO FLSA RLSA HOMA FLSB RLSB HOMB FLSC RLSC HOMC FLSD RLSD HOMD DI9 DI16 FLSE RLSE HOME FLSF RLSF HOMF FLSG RLSG HOMG FLSH RLSH HOMH Common Signal INCOM I O A D D Sub Connectors LSCOM I O A D D Sub Connectors INCOM I O A D D Sub Connectors LSCOM I O A D D
274. oders 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 DET 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 1 Continuous dual loop 2 Sampled dual loop To illustrate the problem consider a situation in which the coupling between the motor and the load has a backlash To compensate for the backlash position encoders are mounted on both the motor and the load The continuous dual loop combines the two feedback signals to achieve stability This method requires careful system tuning and depends on the magnitude of the backlash However once successful this method compensates for the backlash continuously The second method the sampled dual loop reads the load encoder only at the end point and performs a correction This method is independent of the size of the backlash However it is effective only in point to point motion systems which require position accuracy only at the endpoint Continuous Dual Loop Example Connect the load encoder to the main
275. of any of the main encoders on the controller The output can be programmed to produce an active low pulse 250 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 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 At least one axis has a position error greater than the error limit The error limit is set by using the command ER 2 The reset line on the controller is held low or is being affected by noise 3 There is a failure on the controller and the processor is resetting itself 4 There is a failure with the output IC which drives the error signal 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 40x0 User Manual Extended I O of the DMC 40x0 Controller The DMC 40x0 controller offers 32 extended TTL I O points which can be configured as inputs or outputs in 8 bit increments
276. 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 TW Begin coordinated sequence T and D axis Chapter 5 Command Basics e 71 DMC 40x0 User Manual Command Syntax Binary advanced Some commands have an equivalent binary value Binary communication mode can be executed about 20 faster than ASCII commands Binary format can only be used when commands are sent from the PC and cannot be embedded in an application program Binary Command Format All binary commands have a 4 byte header and is fol
277. of delayed reaction and high gain In the case of the temperature control the delay is due to the water flowing in the pipes When the human reaction is too strong the response becomes unstable Servo systems also become unstable if their gain is too high The delay in servo systems is between the application of the current and its effect on the position Note that the current must be applied long enough to cause a significant effect on the velocity and the velocity change must last long enough to cause a position change This delay when coupled with high gain causes instability This motion controller includes a special filter which is designed to help the stability and accuracy Typically such a filter produces in addition to the proportional gain damping and integrator The combination of the three functions is referred to as a PID filter The filter parameters are represented by the three constants KP KI and KD which correspond to the proportional integral and derivative term respectively The damping element of the filter acts as a predictor thereby reducing the delay associated with the motor response The integrator function represented 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 i
278. og Inputs DO thru DO8 Outputs DO9 thru DO16 Outputs DMC 4050 through DMC 4080 only Quadrature phase on CHA CHB Can accept single ended A B only or differential A A B B Maximum A B edge rate 22 MHz Minimum IDX pulse width 45 nsec TTL 0 5 volts level at 50 duty cycle 6 000 000 pulses sec maximum frequency TTL 0 5 volts 2 2K ohm in series with opto isolator Active high or low requires at least 1mA 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 21mA 0ON lt 0 5 mA OFF Standard configuration is 10 volts 12 Bit Analog to Digital converter 16 bit optional High power Opto Isolated 500mA souring High power Opto Isolated 500mA sourcing DMC 40x0 User Manual Appendices e 198 1017 thru 1048 DI81 DI82 DI83 DI84 DMC 4020 through DMC 4080 only DI85 DI86 DMC 4030 through DMC 4080 only DI87 DI88 DMC 4040 through DMC 4080 only DI89 DI90 DMC 4050 through DMC 4080 only DI91 DI92 DMC 4060 through DMC 4080 only DI93 DI94 DMC 4070 through DMC 4080 only DI95 DI96 DMC 4080 only Power Requirements 20 80 VDC 12 16W at 25C Extended configurable I O Standard 3 3V logic with 5V option Auxiliary Encoder Inputs for A X axis Line Receiver Inputs accepts differenti
279. oltages are required please contact Galil 4 Figure Al 1 DMC 4040 C012 1000 D3040 DMC 4040 with AMP 43040 DMC 40x0 User Manual A1 AMP 430x0 D3040 D3020 e 238 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 Chopper Mode 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 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 239 DMC 40x0 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
280. on If the voltage supply to the amplifier rises above 92 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 AMPERR 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 usually due to a short across the motor leads or a short from a motor lead to ground DMC 40x0 User Manual A1 AMP 430x0 D3040 D3020 e 242 Over Temperature Protection The controller is also equipped with over temperature protection Rev A and Rev B amplifiers If the average heat sink temperature rises above 100 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
281. on IN x where x specifies the input number 1 thru 8 These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller For example the user may wish to have the x axis motor move 1000 counts in the positive direction when the logic state of DI goes high This can be accomplished by connecting a voltage in the range of 5V to 28V into INCOM of the input circuitry from a separate power supply Controllers with more than 4 axes have an additional 8 general opto isolated inputs inputs 9 16 The INCOM for these inputs is found on the I O E H D Sub connector An additional 32 I O are provided at 3 3V 5V option through the extended I O These are not opto isolated NOTE INCOM and LSCOM 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 INCOM and LSCOM for axes 1 4 DI9 DI16 INCOM I O E H D Sub connectors FLSE RLSE HOME LSCOM I O E H D Sub connector FLSF RLSF HOMF FLSG RLSG HOMG FLSH RLSH HOMH Wiring the Optoisolated Inputs Electrical Specifications Input Common INCOM Max Voltage 28 VDC Limit Common LSCOM Max Voltage 28 VDC Minimum Current to turn on Inputs 1 mA Bi Directional Capability 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 t
282. on IN 81 and IN 82 NOTE The auxiliary encoder inputs are not available for any axis that is configured for stepper motor Input Interrupt Function The DMC 40x0 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 II 5 enables inputs 1 and 3 A low input on any of the specified inputs will cause automatic execution of the ININT subroutine The Return from Interrupt RI command is used to return from this subroutine to the place in the program where the interrupt DMC 40x0 User Manual Chapter 7 Application Programming e 168 had occurred If it is desired to return to somewhere else in the program after the execution of the ININT subroutine the Zero Stack ZS command is used followed by unconditional jump statements Important Use the RI command not EN to return from the ININT subroutine Example Input Interrupt Instruction A PRSI JG 30000 20000 BG AB B TP AB 000 JP B EN ININT WT H MG Interrupt has occurred ST AB LOOP JP LOOP IN 1 0 JG 15000 10000 WT 300 BG AB RI Analog Inputs Interpretation Label A Enable input 1 for interrupt function
283. on ICM EX DMC 4040 C012 I000 STEP These pins may be used for other functions when STEP option is not ordered A6 ICM 42000 1000 e 259 DMC 40x0 User Manual ICM 42000 External Driver E H 44 pin HD D Sub Connector Male For DMC 4050 thru DMC 4080 controllers only These pins may be used for other functions when STEP option is not ordered Pin Label Description Pin Label Description Pin Label Description 1 Reserved Step E_N STPE PWM Step E STPF PWM Step F 2 STPG PWM Step G Reserved Step F_N 4 Reserved Step G_N 2 3 Reserved Step H_N 7 STPH PWM Step H Digital Ground 4 Reserved Dir EN a Sign Direction E DIRF Sign Direction F 5 Sign Direction F Reserved Dir F_N 3 Reserved Dir G_N i 6 Reserved Dir H_N 2 Sign Direction H Digital Ground 7 AENE Amplifier Enable E AECI Amp Enable Common 1 AENF Amplifier Enable F 8 AENH Amplifier Enable H AENG Amplifier Enable G AEC2 Amp Enable Common 2 11 MCMF Motor Command F Reserved MCMDE_N Reserved MCMDF_N j 12 Reserved MCMDG_N i MCMG Motor Command G MCMH Motor Command H 15 5V 5V 30 N C No Connec Notes 1 Negative differential motor command outputs when DIFF option is ordered on ICM Ex DMC 4080 C012 1000 I000 DIFF These pins may be used for other functions when DIFF option is not ordered 2 Negative differential step and direction outputs when STEP option is ordered on ICM EX DMC 4080 C012 1000 I000 STEP
284. on 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 40x0 converts the velocity profile into a position trajectory and a new position target is generated every sample period This method of control results in precise speed regulation with phase lock accuracy Command Summary Jogging
285. oor Connections Review all connections and intermittent cable connector contacts Encoder Position Drifts Significant noise can be 1 Noise Shield encoder cables seen on MA 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 Servo motor runs away Motor oscillates when the loop is closed Reversed Motor Type 1 Wrong feedback polarity corrects situation MT 1 2 Too high gain or too little damping Reverse Motor or Encoder Wiring remember to set Motor Type back to default value MT 1 Decrease KI and KP Increase KD Operation SYMPTOM DIAGNOSIS CAUSE REMEDY Controller rejects Response of controller 1 Anything Correct problem reported by TC1 commands from TC1 diagnoses error Motor Doesn t Move Response of controller from 2 TC1 diagnoses error Anything Correct problem reported by SC DMC 40x0 User Manual Chapter 9 Troubleshooting 184 Chapter 10 Theory of Operation Overview The following discussion covers the operation of motion control systems A typical motion control system consists of the elements shown in Fig 10 1 COMPUTER CONTROLLER Figure 10 1 Elements of Servo Systems DRIVER The operation of such a system can
286. opical Opt edita 140 160 SA NN Bite Wisin ias deta 162 Mathematica Express etica 152 154 METIME dea 132 136 143 145 Mem Vitel ri rd dede iia 1 2 21 22 28 70 112 130 134 140 144 156 157 171 EA a O O 49 52 62 91 134 144 153 159 162 163 181 A O O O NA 52 53 54 55 231 Modelling coi otis one o o 185 188 193 Motion Smoothitige 4 2502 techy o cease 124 Motor Command ss ache ectee core 5 Secs a ch ee eae Set dci 22 193 Multitasking 2 2 lt 22c8s a cds Bed in eee ok ne et et 133 OPPO mn Bator vi sheets sole e e O A 33 179 181 DM a dioss Amplifier Enable oonconocnocnoncnonnonccrnnornnnncornnononn nooo 6 18 41 Digital Output Aine eceec a erences 1 167 Error OUtpUtuiaiini ro iia 39 Motor Command coooccnnoccnonnnccononcconnnnnnnnnacononononannnnnnnnos 2 17 20 21 22 210 Step and Direction ccccecesceeseeseeeceeseeeeeseeneesrenes 2 PID 188 197 Play Back nia 77 159 POSERR oia a ada 132 143 180 Position Capi idea eed 127 Position PO ist 121 132 143 155 158 177 179 187 Position Limit li id dad SG e edo den A a accio cell e 181 A O E 131 135 168 A sed cesta tomate Mises eee teed ans 1 146 147 161 168 Programmable A O RA 154 176 180 Prol o dro ed nao os dsd Sect da rs hove de le teo ad 4 70 76 A AA 24 188 O A O O E Error Citit 3 23 2 2 ccscvseches eect sts i 18 20 25 39 41 Index e 275 DMC 40x0 User Manual QUA A e ad ia S de adh dad tari ote 4
287. ose that we interrogate the controller when the motion is halfway between the points A and B The value of _AV is 2000 The value of CS is 0 _VPX and _ VPY contain the absolute coordinate of the point A Suppose that the interrogation is repeated at a point halfway between the points C and D The value of _AV is 4000 150077 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 9 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 commands such
288. otor M s P I K Js 500 s rad A Amp K 4 Amp V DAC K 0 0003 V count Encoder K 4N 2n 318 count rad ZOH 2000 s 2000 Digital Filter KP 12 5 KD 245 T 0 001 Therefore Chapter 10 Theory of Operation e 193 DMC 40x0 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 Fig 10 7 FILTER ZOH DAC AMP MOTOR Me ls NN 50 0 980s 2009 0 0003 4 990 Re E f S 2000 f S ENCODER 318 Figure 10 7 Mathematical model of the control system The open loop transfer function A s is the product of all the elements in the loop A s 390 000 s 51 s2 s 2000 To analyze the system stability determine the crossover frequency at which A j 0 equals one This can be done by the Bode plot of AG as shown in Fig 10 8 Magnitude 50 200 2000 W rad s 0 1 Figure 10 8 Bode plot of the open loop transfer function DMC 40x0 User Manual Chapter 10 Theory of Operation e 194 For the given example the crossover frequency was computed numerically resulting in 200 rad s Next we determine the phase of A s at the crossover frequency A j200 390 000 j200 5 1 G200 2 200 2000 a Arg A 200 tan 200 5 1
289. ove 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 AB 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 AB1 must be used to abort the motion sequence It is the responsibility of the user to keep enough LI segments in the DMC 40x0 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 and no additional segments can be sent As long as the buffer is not full additional LI segments can be sent at PC bus s
290. ownloaded 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 Chapter 4 Software Tools and Communication e 63 DMC 40x0 User Manual GalilTools 192 168 1 2 DMC4080 Rev 1 0 1 IHC HardStopHoming dmc SEE Fie Edit Window Controller Tools Help a x D P te cet A N B New Open Save Connect Upload Watch Tuner Scope Terminal r VII Axis a y KD 3 OA Tat kT iis LV fe thot FU Step Ampltudo 100 counts up Ag Lrrrrrrrararaa Step Time 100m j hard stop JA Stone 192 168 1 2 DMC4 8 Rev 5 1 6 1 IHC DCR 6 71074 DR2 MG Lookir _ JGX 1008 Y i gt all Source Value Units 1 OAMI 2578 Y bAa A a N Hl OD Source Scale div Offset div _RPA Axis 4 reference position 20 counts 2 1 _TPA Axis 4 encoder position 20 counts J 1 _TEA Axis 4 position error 100 counts pp _TTA Axis A torque DAC 10 1 4 gt 4 gt 4 gt le 491149 149 4 gt lt gt Time 3 Trigger Channel FE w Edge Rising Y Mode Repeat v READY Figure 4 1 GalilTools DMC 40x0 User Manual Chapter 4 Software Tools and Communication e 64 Creating Custom Software Interf
291. p Echo 0 Off 1 On Valid only if r 0 NOTE for the handshake of the auxiliary port the roles for the RTS and CTS lines are reversed Chapter 4 Software Tools and Communication e 49 DMC 40x0 User Manual 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 40x0 can be ordered with the main and or 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 RS 422 Main Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option RS 422 Auxiliary Port Non Standard Option Standard connector and cable when DMC 40x0 is ordered with RS 422 Option Pin Signal CTS RXD TXD RTS GND CTS RXD TXD RTS 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 40x0 supports two industry standard protocols TCP IP and UDP IP The controller will automatically respond in the format in which it is contacted DMC 40x0 User Manual Chapter 4 Software Tools and
292. pecified condition is satisfied Note that the line number of the first line of program memory is 0 The comma designates IF The logical condition tests two operands with logical operators Logical operators OPERATOR DESCRIPTION lt 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 1f 1t evaluates to any value other than zero The conditional statement can be any valid DMC 40x0 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 V1 V7 6 ABS V1 gt 10 Array Element V1 lt Count 2 Variable vV1 lt V2 Internal Variable _TPX 0 _TVX gt 500 Vo V1 gt AN 2 IN 1 0 Multiple Conditional Statements The DMC 40x0 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 th
293. peeds 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 DMC 40x0 User Manual Chapter 6 Programming Motion e 86 Additional Commands The commands VS n VA n and VD n are used to specify the vector speed acceleration and deceleration The DMC 40x0 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 Y82 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 LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence AV 4000 Set trippoint to wait until vector distance of 4000 is reached Vs 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 i
294. point in the module from to 4 If an explicit slave address is to be used the equation becomes T O Number SlaveAddress 10000 HandleNum 1000 Module 1 4 Bitnum 1 Chapter 4 Software Tools and Communication e 53 DMC 40x0 User Manual Modbus Examples Example 1 DMC 4040 connected as a Modbus master to a RIO 47120 via Modbus The DMC 4040 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 Issued to DMC 4040 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 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 10 12 13 14 15 Example 2 DMC 4
295. position Only one axis may be specified If position is already past the point then MR will trip immediately Will function on geared axis or aux inputs Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position TW x y z w sets timeout to declare an error if not in position If timeout occurs then the trippoint will clear and the stop code will be set to 99 An application program will jump to label 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 4010 4020 4030 4040 n 1 through 16 for DMC 4050 4060 4070 4080 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 DMC 40x0 User Manual Chapter 7 Application Programming e 136 AVn WT n m Event Trigger Examples Event Trigger Multiple Move Sequence Halts program execution until specified distance along a coordinated path has occurred For m omitted or 0 halts program execution until specified time in msec has
296. ppresses carriage return line feed Sn Sends the first n characters of a string variable where n is 1 thru 6 Chapter 7 Application Programming e 163 DMC 40x0 User Manual 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 v1 posA 1 _TPA Assign the first entry vl Print vl Interrogation Commands The DMC 40x0 has a set of commands that directly interrogate the controller When these command are entered the requested data is returned in decimal format on the next line followed by a carriage return and line feed The format of the returned data can be changed using the Position Format PF and Leading Zeros LZ command For a complete description of interrogation commands see Chapter 5 Using the PF Command to Format Response from Interrogation Commands The command PF can change format of the values returned by theses interrogation commands BL LE DE PA DP PR EM TN FL VE IP TE TP The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to the right and left of the decimal point using the PF command Position Format is spe
297. put from the controller to the amplifier The continuous current will set what the maximum average current is over a one second interval The following figure captured with WSDK 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 Chopper Mode The AMP 43040 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 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 500WH inductance DMC 40x0 User Manual A1 AMP 430x0 D3040 D3020 e 240 storage Scope Zoom 078 016 005 797 145 3 Figure Al 2 Peak Current Operation 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 u
298. r D Objective Command motion by specifying the absolute position Instruction Interpretation axis only axis only axis only DMC 40x0 User Manual Chapter 2 Getting Started e 26 DP 0 2000 Define the current positions of A B as 0 and 2000 PA 7000 4000 Sets the desired absolute positions BG A Start A motion BG B 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 BG AB 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 BG AB Start motion after a few seconds command JG 40000 New A speed and Direction TV A Returns A speed and then JG 20000 New B speed TV B 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 Instruction Interpretation TL 02 Set output limit of A axis to 0 2 volts JG 10000 Set A speed BG A 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 touch of a finger Increase the torque leve
299. r 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 40x0 profiler commands the step motor amplifier All DMC 40x0 motion commands apply such as PR PA VP CR and JG The acceleration deceleration slew speed and smoothing are also used Since step motors run open loop the PID filter does not function and the position error is not generated To connect step motors with the DMC 40x0 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 dri
300. r information using the interrogation commands the interrogation commands are described in chapter 5 Sending Messages Messages may be sent to the bus using the message command MG This command sends specified text and numerical or string data from variables or arrays to the screen Text strings are specified in quotes and variable or array data is designated by the name of the variable or array For example MG The Final Value is result In addition to variables functions and commands responses can be used in the message command For example MG Analog input is AN 1 MG The Position of A is TPA Specifying the Port for Messages The port can be specified with the specifier P1 for the main serial port P2 for auxiliary serial port or En for the Ethernet port MG P2 Hello World Sends message to Auxiliary Port DMC 40x0 User Manual Chapter 7 Application Programming e 162 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 specif
301. rabolic Velocity Profile To accomplish this we need to calculate the desired velocities and change in positions In this example we will assume a delta time of 1 4 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 10000 1 1000 ar DMC 40x0 User Manual Chapter 6 Programming Motion e 106 v 25 4375 p 0 to 25 57 v 5 750 p 25 to 5 151 V 75 937 5 p 5 to 75 214 V 1 4000 p 75 to 1 245 v 1 25 937 5 p 1 to 1 25 245 v 1 5 750 p 1 25 to 1 5 214 v 1 75 437 5 p 1 5 to 1 75 151 v 2 0 p 1 75 to 2 57 The DMC program is shown below and the results can be seen in Figure 6 15 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 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 24
302. ransfer function between the input voltage V and the velocity is o V K K Js 1 K K K Js I K sT 1 where the velocity time constant T equals T J K K Ky This leads to the transfer function P V I Kg s sT 1 V a z K kws P Figure 10 5 Elements of velocity loops DMC 40x0 User Manual Chapter 10 Theory of Operation e 190 The resulting functions derived above are illustrated by the block diagram of Fig 10 6 VOLTAGE SOURCE V E W P pa a M ao E NOS K ST 11ST 1 S CURRENT SOURCE V l W P VELOCITY LOOP v 1 di 1 K ST 1 S Figure 10 6 Mathematical model of the motor and amplifier in three operational modes Encoder The encoder generates N pulses per revolution It outputs two signals Channel A and B which are in quadrature Due to the quadrature relationship between the encoder channels the position resolution is increased to 4N quadrature counts rev The model of the encoder can be represented by a gain of K 4N 27 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 Chap
303. re D 0 274 and G 82 4 0 2744s The function G is equivalent to a digital filter of the form D z KP KD 1 z DMC 40x0 User Manual Chapter 10 Theory of Operation e 196 where P KP D KD T and KD D T Assuming a sampling period of T 1 ms the parameters of the digital filter are KP 82 4 KD 247 4 The DMC 40x0 can be programmed with the instruction KP 82 4 KD 68 6 In a similar manner other filters can be programmed The procedure is simplified by the following table which summarizes the relationship between the various filters Equivalent Filter Form DMC 40x0 Digital D z K z A z Cz z 1 1 B Z B Digital D z KP KD 1 21 K1 2 1 2 1 B Z B KP KD KI PL K KP KD A KD KP KD C KI B PL Continuous G s P Ds I s a s a PID T P KP D T KD I KI T a 1 T In 1 PL Chapter 10 Theory of Operation e 197 DMC 40x0 User Manual Appendices Electrical Specifications Servo Control MCMn Amplifier Command 10 volt analog signal Resolution 16 bit DAC or 0 0003 volts 3 mA maximum Output impedance 5000 MA MA MB MB MI MI Encoder andTTL compatible but can accept up to 12 volts Auxiliary Stepper Control STPn Step DIRn Direction Input Output Limit Switch Inputs Home Inputs DII thru DIS Uncommitted Inputs and Abort Input DI9 thru DI16 Uncommitted Inputs DMC 4050 through DMC 4080 only AII thru AI8 Anal
304. remove of the metal cover This can be achieved by simply changing the jumpers DMC 4040 Steps 1 and 2 Step 1 Remove Cover Notes l Cover Removal A Remove Jack Screws 20 Places B Remove 6 32x3 16 Button Head Cover Screws 4 Places 2 Lift Cover Straight Up and Away from Unit REMOVE JACK SCREWS 20 PLCS REMOVE COVER SCREWS 4 PLCS DMC 40x0 User Manual Appendices e 212 Step 2 Remove ICM For DMC 4040 Proceed to Step 3 Configure Circuit DMC 40x0 User Manual Appendices e 213 DMC 4080 Steps 1 and 2 Step 1 Remove Cover Notes 1 Cover Removal A Remove Jack Screws 34 Places B Remove 6 32x3 16 Button Head Cover Screws 4 Places 2 Lift Cover Straight Up and Away from Unit REMOVE COVER SCREWS 4 PLCS DMC 40x0 User Manual Appendices e 214 Step 2 Remove ICM s DMC 40x0 User Manual Appendices e 215 DMC 4040 and DMC 4080 Step 3 Step 3 Configure Circuit Reference the instructions below for the desired configuration and then proceed to Step 4 5V High Amp Enable Sinking Configuration Default pg 217 5V Low Amp Enable Sinking Configuration pg 217 5V High Amp Enable Sourcing Configuration pg 218 5V Low Amp Enable Sourcing Configuration pg 218 12V High Amp Enable Sinking Configuration pg 219 12V Low Amp Enable Sinking Configuration pg 219 12V High Amp Enable Sourcing Configuration pg 220 12V Low Amp Enable Sourcing
305. ronic CAM ssrin 104 Example Electronic CAM 104 PVE Mok ocan 106 Specifying PVT Segments 106 Exitos FYT Mode isc sil iba 106 Error Conditions and Stop Codes scoasa 106 Additional PVT Information Command Summary PVT sanun EXE ESMP S E DMC 40x0 Contents e iv Multi AXis Coordinated Move et aretiranih 109 CA A eer Teo TEES 111 Specifying Contour Segments Additional Commands ati Command Summary Contour Mode 112 Stepper Motor A Raul 116 Specifying Stepper Motor Operation essuie Using an Encoder with Stepper Motors ES Command Summary Stepper Motor Operation 117 Operand Summary Stepper Motor Operation 117 Stepper Position Maintenance Mode SPM Dual Loop Auxiliary Encoder Backlash Ovni an cda Motion A osansa a Command Summary Homing Operation sees 128 Operand Summary Homing Operation sss High Speed Position Capture The Latch Function Fast Update Rate Mode siii a Chapter 7 Application Programming 131 OVON EN y Geet re Eo 131 Using the DMC 40x0 Editor to Enter Prograris escicn 131 Edit Mode Commanida 5 a132 Porm konis AA ce aa ss see a a 132 Using Labels in Prom ur ii 132 Special Tablon Commenting Programs a Executing Programs Multitasking ii ii 134 Debuta Pr A a Program Flow Commands
306. rough 4 and 9 thru 12 correspond to each axis 1 through 4 9 through 12 IN1 X axis latch IN9 E axis latch IN2 Y axis latch IN10 F axis latch IN3 Z axis latch IN11 G axis latch IN4 W axis latch IN12 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 40x0 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 Chapter 6 Programming Motion e 127 DMC 40x0 User Manual 1 Give the AL XYZW command or ABCDEFGH for DMC 4080 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 Latch program JG 5000 Jog Y BG Y Begin motion on Y axis AL Y Arm Latch for Y axis Wait Wait label for loop JP Wait ALY 1 Jump to Wait label if latch has not occurred Result _RLY Set value of variable Result equal to the report position of y axis Result Print result EN End DMC 40x0 User Manual Chapter 6 Programming Motion e 128 Fast Update Rate Mode The DMC 40x0 can operate with much f
307. ry 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 ROSERR to be executed Correction A correction move can be commanded by assigning the value of QS to the YR correction move command The correction move is issued only after the axis has been stopped After an error correction move has completed and Chapter 6 Programming Motion e 117 DMC 40x0 User Manual QS is less than three full motor steps the YS error status bit is au
308. s 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 parameters 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 d
309. s 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 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 57 DMC 40x0 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 new size SW or UW UB new UB SL new UW UB UB SL SL SL SL SL SL new size SW or UW UB new UB SL new UW UB UB SL SL SL SL SL SL new size SW or UW UB new UB SL new UW UB UB SL SL SL SL SL SL new size 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
310. s 25 pin Serial Connector Male D type This table describes the pinout for standard serial ports found on most computers Pin Function 1 NC 2 TXD 3 RXD 4 RTS 5 CTS 6 DSR el GND 8 DCD 9 NC 10 NC 11 NC 12 NC 13 NC 14 NC 15 NC 16 NC 17 NC 18 NC 19 NC 20 DTR 21 NC 22 RI 23 NC 24 NC 25 NC DMC 40x0 User Manual Appendices e 208 9 Pin Serial Connector Male D type Standard serial port connections found on most computers Pin SIl uinn AISAN Function DCD RXD TXD RTS GND DSR RTS CTS RI DMC 40x0 Serial Cable Specifications Cable to Connect Computer 25 pin to Main Serial Port Cable Cable Cable 25 Pin Male computer 5 CTS 3 RXD 2 TXD 4 RTS 7 GND 9 Pin female controller 8 RTS 2 TXD 3 RXD 7 CTS 5 GND to Connect Computer 9 pin to Main Serial Port Cable 9 pin 9 Pin FEMALE Computer 2 RXD 3 TXD 5 GND 7 RTS 8 CTS 9 Pin FEMALE Controller 2 TXD 3 RXD 5 GND 7 CTS 8 RTS to Connect Computer 25 pin to Auxiliary Serial Port Cable 9 pin 25 Pin Male terminal 4 RTS 2 TXD 3 RXD 5 CTS 7 GND Computer 5V 9 Pin male controller 8 CTS 2 RXD 3 TXD 7 RTS 5 GND 9 Jumper APWR if required to Connect Computer 9 pin to Auxiliary Serial Port Cable 9 pin 9 Pin FEMALE terminal 9 Pin MALE Controller
311. s Communicating with Multiple Devices The DMC 40x0 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 40x0 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 RS232 by entering RS The only reset that will not cause the controller to disconnect is a software reset via the Ethernet 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 w
312. s 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 4030 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 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 40x0 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 is the follower To synchronize Y with the commanded position of X use the instructions GA CX Specify the commanded position of X as master for Y DMC 40x0 User Manual Chapter 6 Programming Motion e 98 GR 1 Set gear ratio for Y as 1 1 GM 1 Set gantry mode PR 3000 Comm
313. s 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 present 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 Controller Response to Commands Most DMC 40x0 instructions are represented by two characters followed by the appropriate parameters Each instruction must be terminated by a carriage return or semicolon Chapter 4 Software Tools and Communication e 61 DMC 40x0 User Manual Instructions are sent in ASCII and the DMC 40x0 decodes each ASCII character one byte one at a time It takes approximately 0 05 msec for the controller to decode each command After the instruction is decoded the DMC 40x0 returns a response to the port from which the command was generated If the instruction was valid the controller returns a colon or a question mark if the instruction was not valid For example the controller will respond to commands which are sent via the main RS 232 port back through the RS 232 port and to commands which are sent via the Ethernet port back through the Ethernet port For ins
314. s reached VS 4000 Change vector speed EN Program end In this example the XY system is required to perform a 90 turn In order to slow the speed around the corner we use the AV 4000 trippoint which slows the speed to 1000 count s Once the motors reach the corner the speed is increased back to 4000 cts s Specifying Vector Speed for Each Segment The instruction VS has an immediate effect and therefore must be given at the required time In some applications such as CNC it is necessary to attach various speeds to different motion segments This can be done by two functions lt n and gt m For example LI x y z w lt n gt m The first command lt n is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds subjects to the other constraints The second function gt m requires the vector speed to reach the value m at the end of the segment Note that the function gt m may start the deceleration within the given segment or during previous segments as needed to meet the final speed requirement under the given values of VA and VD Note however that the controller works with one gt m command at a time As a consequence one function may be masked by another For example if the function gt 100000 is followed by gt 5000 and the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the spee
315. s 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 40x0 User Manual Chapter 10 Theory of Operation e 188 System Modeling The elements of a servo system include the motor driver encoder and the controller These elements are shown in Fig 10 4 The mathematical model of the various components is given below CONTROLLER DIGITAL Y FILTER oh 70H 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 1 ST 1 where T RJ K s and T LPR s and the motor parameters and units are Ki
316. s the error condition The command TCO or TC will 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 40x0 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 14010 will have a maximum of 16000 array elements in up to 30 arrays Ifan 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 DMC 40x0 User Manual Chapter 7 Application Programming e 134 Operands In general all operands
317. s the position error Since the required accuracy is 0 5 micron the resolution of the linear sensor should preferably be twice finer A linear sensor with a resolution of 0 25 micron allows a position error of 2 counts The dual loop approach requires the resolution of the rotary sensor to be equal or better than that of the linear system Assuming that the pitch of the lead screw is 2 5mm approximately 10 turns per inch a rotary encoder of 2500 lines per turn or 10 000 count per revolution results in a rotary resolution of 0 25 micron This 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
318. s 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 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 A4 SDM 44140 D4140 e 253 DMC 40x0 User Manual A5 CMB 41012 C012 Description The CMB 41012 provides the connections for the Ethernet and Serial communication as well as the D Sub connector for the Extended I O The CMB 41012 also contains the 8x2 character LCD See Chapter 3 for Electrical Specifications of Extended I O Connectors for CMB 41012 Interconnect Board CMB 41012 Extended I O 44 pin HD D Sub Connector Male Pin Label Description Pin Label Description Pin Label Description 1 1018 Configurable 1 O bit 18 1017 Configurable I O bit 17 1019 Configurable I O bit 19 2 1021 Con
319. sed to calculate the bandwidth of the amplifier using the basic amplifier parameters To calculate the bandwidth for the X axis issue AWX v l 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 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 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 BRO 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 The gain settings for the amplifier are identical for the brush and brushless operation The gain settings can be set to 0 4 0 7 or 1 0 A V represented by gain values of 0 1 and 2 e g AG 0 0 2 1 The current loop gain AU can also be set to either 0 for normal or
320. shown in Figure 6 17 with the specified PVT points enlarged Y Axis Counts 6000 X vs Y Commanded Positions 5000 4000 3000 2000 1000 2000 3000 4000 5000 6000 X Axis Counts Figure 6 17 X vs Y Commanded Positions for Multi Axis Coordinated Move Chapter 6 Programming Motion e 109 DMC 40x0 User Manual Contour Mode The DMC 40x0 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 2n sample period 1 ms for TM1000 where n is a number between 1 and 8 The controller performs linear interpolation between the specified increments where one point is generated for each sample If the time interval changes for each segment use CD x y z w n where n is the new DT value Consider
321. sponding 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 JP LOOP P2CD lt gt 3 JP P P1CH v PR P2NM Interpretation Checks to see if status code is 3 number received Checks if last character received was a V Assigns received number to position DMC 40x0 User Manual Chapter 7 Application Programming e 160 JS XAXIS P1ST X Using Communication Interrupt Checks to see if received string is X The DMC 40x0 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 1 Interrupt on lt enter gt Port 2 n 2 Interrupt on any character Port 2 n 1 Clear any characters in buffer The COMINT label is used for the communication interrupt For example the DMC 40x0 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 the 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 subrout
322. 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 and Upgrade jumpers Communications Jumpers for DMC 40x0 The baud rate for RS232 communication can be set with jumpers found on JP1 of the communication board same set of jumpers where MO MRST and UPGD can be found To set the baud rate to the desired value see below 19 2 BAUD RATE ON 9600 ON 19200 OFF 38400 OFF 115200 Table 2 1 Baud Rate Jumper Settings Other serial communication protocols such as RS 485 can be implemented as a special consult Galil 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 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 and click Install Follow the installation procedure as outlined The most recent copy of the GalilTools software can be downloaded from the Galil website
323. t to 2000 and then changes it again to 8000 Figure 6 5 shows the plot of position vs time Figure 6 6 plots velocity vs time and Figure 6 7 demonstrates the use of motion smoothing IT on the velocity profile in this mode The jerk in the system is also affected by the values set for AC and DC Figure 6 5 Position vs Time msec Motion 4 DMC 40x0 User Manual Chapter 6 Programming Motion e 84 Figure 6 6 Velocity vs Time Motion 4 l Figure 6 7 Velocity cts sec vs Time msec with IT Note the controller treats the point where the velocity passes through zero as the end of one move and the beginning of another move IT is allowed however it will introduce some time delay Trip Points Most trip points are valid for use while in the position tracking mode There are a few exceptions to this the AM and MC commands may not be used while in this mode It is recommended that MF MR or AP be used as they involve motion in a specified direction or the passing of a specific absolute position Chapter 6 Programming Motion e 85 DMC 40x0 User Manual Command Summary Position Tracking Mode COMMAND DESCRIPTION AC n n n n n n n n Acceleration settings for the specified axes AP n n n n n n n n 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 specified axes MF n n n n n n n n Trip point to hold up program e
324. t indicates whether the DAC wiring is correct and will indicate an approximate value of BM If the wiring is correct the approximate value for BM will agree with the value used in the previous step NOTE In order to properly conduct the brushless setup the motor must be allowed to move a minimum of one magnetic cycle in both directions NOTE When using Galil Windows software the timeout must be set to a minimum of 10 seconds time out 10000 when executing the BS command This allows the software to retrieve all messages returned from the controller Step D part 2 Systems with Hall Sensors Only Test the Hall Sensor Configuration Since the Hall sensors are connected randomly it is very likely that they are wired in the incorrect order The brushless setup command indicates the correct wiring of the Hall sensors The Hall sensor wires should be re configured to reflect the results of this test The setup command also reports the position offset of the Hall transition point and the zero phase of the motor commutation The zero transition of the Hall sensors typically occur at 0 30 or 90 of the phase commutation It is necessary to inform the controller about the offset of the Hall sensor and this is done with the instruction BB Step E Save Brushless Motor Configuration It is very important to save the brushless motor configuration in non volatile memory After the motor wiring and setup parameters have been properly configur
325. t setting of the serial communications port or the serial cable is not connected properly The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software The user must also insure that a straight through serial cable is being used NOT a Null Modem cable see appendix for pin out of serial cable Using Non Galil Communication Software The DMC 40x0 main serial port is configured as DATASET Your computer or terminal must be configured as a DATATERM for full duplex no parity 8 data bits one start bit and one stop bit Check to insure that the baud rate jumpers have been set to the desired baud rate as described above Your computer needs to be configured as a dumb terminal which sends ASCII characters as they are typed to the DMC 40x0 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 respond with a number such as 0 Step 6 Determine the Axes to be Used for Sinusoidal Commutation This step is only required when the controller
326. t settle time Enable SPM mode DMC 40x0 User Manual Chapter 6 Programming Motion e 118 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 MI 27 2272 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 REM POSERR query the status YS and the error QS correct EM and return to the main code Ww 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 for correction MCX Wait for motion to complete MG CORRECTED ERROR NOW QSX WT100 Wait helps user see the correction RETURN SPX spsave Return the sp
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328. tch 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 _HMX 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 Stage 1 until the home switch toggles again If Stage 3 is in the opposite direction of Stage 2 the motor will stop immediately at this point and change direction If Stage 2 is in the same direction as Stage 3 the
329. ted by Hall Sensor Operation is divided into two parts part 1 and part 2 After connecting sinusoidal commutation motors the servos must be tuned as described in Step 9 Step A Disable the motor amplifier Use the command MO to disable the motor amplifiers For example MOA will turn the A axis motor off Step B Connect the motor amplifier to the controller The sinusoidal commutation amplifier requires 2 signals usually denoted as Phase A amp Phase B These inputs should be connected to the two sinusoidal signals generated by the controller The first signal is the axis specified with the command BA Step 6 The second signal is associated with the highest analog command signal available on the controller note that this axis was made unavailable for standard servo operation by the command BA When more than one axis is configured for sinusoidal commutation the controller will assign the second phase to the command output which has been made available through the axes reconfiguration The 2 phase of the highest sinusoidal commutation axis will be the highest command output and the 2 phase of the lowest sinusoidal commutation axis will be the lowest command output It is not necessary to be concerned with cross wiring the 1 and 2 signals If this wiring is incorrect the setup procedure will alert the user Step D Example Sinusoidal Commutation Configuration using a DMC 4070 BAAC Chapter 2 Getting Started e 21 DMC 40x
330. tepper 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 40x0 accepts single ended or differential encoder feedback with or without an index pulse The encoder signals are wired to that axis associated 15pin 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 CHA and the direction signal is connected to CHB The controller must be configured for pulse and direction with the command CE See the command summary for further information on the command CE Step D Verify proper encoder operation Start with the 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 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 1
331. ter 10 Theory of Operation e 191 DMC 40x0 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 A CZ PID D z Z Z 1 a de l B OW pass VA gt gt j Z B Notch N z Ca 3 Z p Z 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 For example if the filter parameters of the DMC 40x0 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 40x0 User Manual Chapter 10 Theory of Operation e 192
332. tered one axis at a time using the PVn command The PV command 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 is 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
333. th a DMC 4080 refer to DMC 4080 Steps 4 and 5 section below DMC 4040 Steps 4 and 5 Step 4 Replace ICM REPLACE ICM Appendices e 223 DMC 40x0 User Manual Step 5 Replace Cover Notes 1 Cover Installation A Install Jack Screws 20 Places B Install 6 32x3 16 Button Head Cover Screws 4 Places REPLACE JACK SCREWS 20 PLCS PREPLACE COVER SCREWS 4 PLCS DMC 40x0 User Manual Appendices e 224 DMC 4080 Steps 4 and 5 Step 4 Replace ICM s REPLACE ICM S DMC 40x0 User Manual Appendices e 225 Step 5 Replace Cover Notes 1 Cover Installation A Install Jack Screws 34 Places B Install 6 32x3 16 Button Head Cover Screws 4 Places REPLACE JACK SCREWS 34 PLCS REPLACE COVER SCREWS 4 PLCS DMC 40x0 User Manual Appendices e 226 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 Vx Vy The vector distance is the integral of Vs or the total distance traveled along the path To illustrate this further suppose that a string was placed along the 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 specif
334. th seven entries DM speed 100 Defines an array named speed with 100 entries DA posx Frees array space DMC 40x0 User Manual Chapter 7 Application Programming e 156 Assignment of Array Entries Like variables each array element can be assigned a value Assigned values can be numbers or returned values from instructions functions and keywords Array elements are addressed starting at count 0 For example the first element in the posx array defined with the DM command DM posx 7 would be specified as posx 0 Values are assigned to array entries using the equal sign Assignments are made one element at a time by specifying the element number with the associated array name NOTE Arrays must be defined using the command DM before assigning entry values Examples DM speed 10 Dimension speed Array speed 1 7650 2 Assigns the first element of the array speed the value 7650 2 speed 1 Returns array element value posx 10 _TPX Assigns the 10 element of the array posx the returned value from the tell position command con 2 COS pos 2 Assigns the second element of the array con the cosine of the variable POS multiplied by 2 timer 1 TIME Assigns the first element of the array timer the returned value of the TIME keyword Using a Variable to Address Array Elements An array element number can also be a variable This allows array entries to be assigned sequentially using a counter Example
335. the amplifier for 1 second BSX 0 5 300 will issue 0 5 volts from the controller for 300 milliseconds If the controller is able to move the motor and the Hall transitions are not correct the controller will alert the operator and recommend which motor phases to change For example the controller might return Wire A to Terminal B Wire B to Terminal A If the controller finds that the commutation order is correct but the motor would run away due to positive feedback the controller will prompt the user to Wire Phase B to C and C to B Exchange Hall Sensors A and B After making any necessary changes to the motor phase wiring confirm correct operation by reissuing the BS command Once the axis is wired correctly the controller is ready to perform closed loop motion Note Do not hot swap the motor power 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 Brushless Amplifier Software Setup Select the amplifier gain that is appropriate for the motor 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 out
336. the distance for deceleration is not sufficient the second condition will not be met The controller will attempt to lower the speed to 5000 but will reach that at a different point Changing Feed Rate The command VR n allows the feed rate VS to be scaled between 0 and 10 with a resolution of 0001 This command takes effect immediately and causes VS scaled VR also applies when the vector speed is specified with the lt operator This is a useful feature for feed rate override VR does not ratio the accelerations For example VR 0 5 results in the specification VS 2000 to be divided by two DMC 40x0 User Manual Chapter 6 Programming Motion e 92 Compensating for Differences in Encoder Resolution By default the DMC 40x0 uses a scale factor of 1 1 for the encoder resolution when used in vector mode If this is not the case the command ES can be used to scale the encoder counts The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion The smaller ratio of the two numbers will be multiplied by the higher resolution encoder For more information see ES command in the Command Reference Trippoints The AV n command is the After Vector trippoint which waits for the vector relative distance of n to occur before executing the next command in a program Tangent Motion Several applications such as cutting require a third axis i e a knife blade to remain tangent
337. the user order the DMC 40x0 with the proper Amplifier enable configuration The ICM 42000 and ICM 42100 gives the user a broad range of options with regards to the voltage levels present on the enable signal 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 Tables 3 2 and 3 3 found below illustrate the settings for jumpers resistor packs and the socketed optocoupler IC Refer to Figures 3 4 and 3 5 for precise physical locations of all components Note that the resistor pack located at RP2 may be reversed to change the active state of the amplifier enable output However the polarity of RP6 must not be changed a different resistor value may be needed to limit the current to 6 mA The default value for RP6 is 820 ohms which works at 5V When using 24 V RP6 should be replaced with a 4 7 kQ resistor pack NOTE For detailed step by step instructions on changing the Amplifier Enable configuration on the ICM 42000 or ICM 42100 see the Configuring the Amplifier Enable Circuit section in the Appendices Chapter 3 Connecting Hardware e 41 DMC 40x0 User Manual RP2 470 Ohm PIN 1 Amplifier Enable Circuit Sinking Output Configuration Pin 1 of LTV8441 in Pin 2 of Socket U4 Socket U4 Pin 1 of socket ae pol E Pin 1 TTL level Amp Enable signal from controller 19 SH 5V MO
338. till in the contour mode the controller waits for new data No new motion commands are generated while waiting If bad data is received the controller responds with a Command Summary Contour Mode COMMAND DESCRIPTION CM XYZW Specifies which axes for contouring mode Any non contouring axes may be operated in other modes CM ABCDEFGH Contour axes for DMC 4080 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 4080 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 Generating an Array An Example Consider the velocity and position profiles shown in Fig 6 14 The objective is to rotate a motor a distance of 6000 counts in 120 ms The velocity profile is sinusoidal to reduce the jerk and the system vibration If we describe the position displacem
339. tion Follower Continuous Move Method Read the analog input compute the commanded position and the position error Command the motor to run at a speed in proportions to the position error Instruction Interpretation CONT Label AC 80000 DC 80000 Acceleration rate 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 Because 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 filtered output 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 less filtering REM increase k2 more filtering k1 32 64 k
340. tional statement Up to 8 subroutines can be nested After the subroutine is executed the program sequencer returns to the program location where the subroutine was called unless the subroutine stack is manipulated as described in the following section Example An example of a subroutine to draw a square 500 counts per side is given below The square is drawn at vector position 1000 1000 DMC 40x0 User Manual Chapter 7 Application Programming e 142 B1 P 1000 1000 LE BGS S B1 S Square CB1 Han FP sas Square v1 500 JS HL Vl V1 JS L EN L PR V1 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 lin
341. 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 short if the X axis does not reach the commanded position within second of the end of the profiled move Example Command Error BEGI Begin main program IN ENTER SPEED SPEED Prompt for speed JG SPEED BGX Begin motion JP BEGIN Repeat EN End main program CMDERR Command error utility JP DONE ED lt gt 2 Check if error on line 2 JP DONE TC lt gt 6 Check if out of range MG SPEED TOO HIGH Send message MG TRY AGAIN Send message ZS1 Adjust stack JP BEGIN Return to main program DONE End program if other error ZSO Zero stack EN End program The above program prompts the operator to enter a jog speed If the operator enters a number out of range greater than 8 million the CMDERR routine will be executed prompting the operator to enter a new number In multitasking applications there is an alternate method for handling command errors from different threads Using the XQ command along with the special operands described below allows the controller to either skip or retry invalid commands Chapter 7 Application Programming e 145 DMC 40x0 User Manual OPERAND FUNCTION _EDI1 Returns the number of the thread that generated an
342. tomatically 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 YSL 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 YSL 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 OET 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 Step resolution of the microstepping drive otor resolution full steps per revolution Encoder resolution counts per revolution Enable axis Allow sligh
343. tory when using the ICM 42000 1000 or the ICM 42100 1100 The Galil internal amplifiers will work with any amplifier enable configurations set on the interconnect module See the Amplifier Interface section in Chapter 3 for more information Part number ordering example DMC 4010 C012 1000 24V HAEN SINK 5V 5V Amplifier Enable Voltage Uses the DMC 40x0 internal 5V for the amplifier enable circuit 12V 12V Amplifier Enable Voltage Uses the DMC 40x0 internal 12V for the amplifier enable circuit 24V 24V Amplifier Enable Voltage ICM is configured to be run from an external power supply of 13 24VDC DMC 40x0 User Manual Appendices e 204 LAEN Low Amplifier Enable The controller sets the amplifier enable signal to logic low to enable the drive HAEN High Amplifier Enable The controller sets the amplifier enable signal to logic high to enable the drive SINK Sinking Amplifier Enable The amplifier will sink to controller ground with 5V and 12V options or to external supply ground when 24V is ordered Source Sourcing Amplifier Enable The amplifier will source the internal 5V 12V or the external 13 24V DC supply Appendices e 205 DMC 40x0 User Manual AMP Internal Amplifier Options ISAMP Isolation of power between each AMP amplifier The ISAMP option separates the power pass through between the Axes 1 4 amplifier and the Axes 5 8 amplifier This allows the 2 internal amplifiers to be po
344. tput CO 12 is issued 8 Bit I O Block Block Binary Representation Decimal Value for 17 24 25 32 2 33 40 4 41 48 5 2 8 The simplest method for determining n Step 1 Determine which 8 bit I O blocks to be configured as outputs Step 2 From the table determine the decimal value for each I O block to be set as an output Step 3 Add up all of the values determined in step 2 This is the value to be used for n For example if blocks 2 and 3 are to be outputs then n is 3 and the command CO3 should be issued NOTE This calculation is identical to the formula n n2 2 n3 4 n4 5 n5 where nx represents the block Saving the State of the Outputs in Non Volatile Memory The configuration of the extended I O and the state of the outputs can be stored in the non volatile flash memory with the BN command If no value has been set the default of CO 0 is used all blocks are inputs Accessing Extended I O When configured as an output each I O point may be defined with the SBn and CBn commands where n 1 through 8 and 17 through 48 Outputs may also be defined with the conditional command OBn where n 1 through 8 and 17 through 48 4080 For 5 8 axis controllers each I O point may be defined with the SBn and CBn commands where n 1 through 48 The command OP may also be used to set output bits specified as blocks of data The OP command accepts 3 parameters The first parameter sets the
345. tructions that return data such as Tell Position TP the DMC 40x0 will return the data followed by a carriage return line feed and It is good practice to check for after each command is sent to prevent errors An echo function is provided to enable associating the DMC 40x0 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 main RS 232 port or Ethernet ports 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 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 characters to appear garbl
346. ts 2 inputs each axis The general inputs can also be used as high speed latches for each axis A high speed encoder compare output is also provided The DMC 4050 through DMC 4080 controller provides an additional 8 optoisolated inputs and 8 high power optoisolated outputs System Elements As shown in Fig 1 2 the DMC 40x0 is part of a motion control system which includes amplifiers motors and encoders These elements are described below Power Supply Amplifier Driver Computer DMC 40x0 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 40x0 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
347. ubsequent function calls The following simple example program written as a Visual C console application tells the controller to move the X axis 1000 encoder counts Remember to add DMC32 LIB to your project prior to compiling include lt windows h gt include lt dmccom h gt long lRetCode HANDLEDMC hDmc HWND hWnd int main void Connect to controller number 1 lRetCode DMCOpen 1 hWnd hDmc if rc DMCNOERROR char szBuffer 64 Move the X axis 1000 counts lRetCode DMCCommand hDmc PR1000 BGX szBuffer sizeof szBuffer Disconnect from controller number 1 as the last action lRetCode DMCClose hDmc return 0 Galil Communications API with Visual Basic Declare Functions Galil recommends the GalilTools Communication Library for all new applications To use the Galil communications API functions add the module file included in the C ProgramFiles Galil DMCWIN VB directory named DMCCOM40 BAS This module declares the routines making them available for the VB project To add this file select Add Module from the Project menu in VB5 6 Chapter 4 Software Tools and Communication e 67 DMC 40x0 User Manual Sending Commands in VB Most commands are sent to the controller with the DMCCommand function This function allows any Galil command to be sent from VB to the controller The DMCCommand function will return the response from the controller as a str
348. uch that one leads the other by one quarter of a complete cycle as shown in Figure 3 below These signals are commonly referred to as the Channels A and B The direction of rotation of the encoder can be inferred by which of the A and B signals leads the other Each rising or falling edge indicates one quadrature count Thus for a complete cycle of the square wave there are a total of four encoder counts Channel A Channel B Figure A7 23 Quadrature Encoder Signals A sinusoidal encoder is similar to a quadrature encoder in that it produces two signals that are read from two sets of lines inscribed on an optical disk The difference is that the two signals are output as analog sinusoidal waves as shown in Figure A7 23 Quadrature Encoder Signals Figure A7 24 Sinusoidal Encoder Signals When the DMC 40x0 is ordered with the ICM 42100 the position is tracked on two levels First the number of coarse cycles is counted much like is done with a quadrature encoder On the fine level the precise position inside the cycle is determined from the two sinusoidal signals using bit wise interpolation This interpolation can be set by DMC 40x0 User Manual A7 ICM 42100 1100 e 268 the user in the range of 2 through 2 points per sinusoidal cycle via AF command See the AF command in the command reference for more informaiton The unique position within one cycle can be read using the following equation n Fine t
349. usting offset causes the 1 Amplifier has an Adjust amplifier offset Amplifier connections from controller motor to change speed internal offset offset may also be compensated by use of the offset configuration on the controller see the OF command to amplifier input 2 Damaged amplifier Replace amplifier Motor is enabled even The SH command disables 1 The amplifier requires Refer to Chapter 3 or contact Galil when MO command is the motor the a different Amplifier given Enable setting on the Interconnect Module Unable to read main or The encoder does not work 1 Wrong encoder Check encoder wiring For single auxiliary encoder input when swapped with another connections ended encoders CHA and CHB encoder input only do not make any connections to the CHA and CHB inputs 2 Encoder is damaged Replace encoder 3 Encoder configuration incorrect Check CE command Chapter 9 Troubleshooting 183 DMC 40x0 User Manual Unable to read main or auxiliary encoder input Encoder Position Drifts The encoder works correctly when swapped with another encoder input 1 Wrong encoder connections 2 Encoder configuration incorrect 3 Encoder input or controller is damaged Swapping cables fixes the problem 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 1 P
350. ut 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 high power optically isolated outputs are uncommitted and may be designated by the user to toggle relays and trigger external events The output lines are toggled by Set Bit SB and Clear Bit CB instructions The OP instruction is used to define the state of all the bits of the Output port DMC 40x0 User Manual Appendices e 210 Inputs Encoder MA MB Encoder Index MI 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 Position feedback from incremental encoder with two channels in quadrature CHA and CHB The encoder may be analog or TTL Any resolution encoder may be used as long as the maximum frequency does not exceed 22 000 000 quadrature states sec The controller performs quadrature decoding of the encoder signals resulting in a resolution of quadrature counts 4 x encoder cycles Note Encoders that produce outputs in the format of pulses and direction may also be used by inputting the pulses int
351. ve for A axis and bit 2 is active for C axis 2 2 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 O data fields 01 specifies stop the coordinated axes S 07 specifies stop X bit 0 Y bit 1 and Z bit 2 2 2 2 7 Binary command table Command No Command No KP AC e e fe ooo e Command No o KD reses gt 5 E IE Mi CI IC a DC for reserved e7 EE SP e8 DP 97 EP ed M o PN Piz OR S re po FA A A ca pc pu peo PAL eo DE pe ec fe ee Chapter 5 Command Basics e 73 DMC 40x0 User Manual Sp s e i gt eee a E SH aa reserved d5 Controller Response to DATA The DMC 40x0 returns a for valid commands and a for invalid commands For example if the command BG is sent in lower case the DMC 40x0 will return a bg lt return gt invalid command lower case DMC 40x0 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 TC1 lt return gt Tell Code command 1 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
352. ver 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 40x0 for motor type using MT command You can configure the DMC 40x0 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 Step 9 Tune the Servo System Adjusting the tuning parameters is required when using servo motors standard or sinusoidal commutation The system compensation provides fast and accurate response and the following 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 integrator to zero with the instruction KI 0 lt return gt Integrator gain and set the proportional gain to a low value such as KP 1 lt return gt Proportional gain KD 100 lt return gt Derivative gain For more damping you can increase KD max
353. ware successfully established communications with the controller the registry entry will be displayed at the bottom of the screen in the Status window NOTE The controller must be registered via an Ethernet connection Communicating through the Main Serial Communications Port Connect the DMC 40x0 MAIN serial port to your computer via the Galil CABLE 9PIN D RS 232 Cable This is a straight through serial cable NOT a NULL modem 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 COM1 115200 The default serial communication speed on the DMC 40x0 is 115200Bps For more information on establishing communication to the controller via the Galil Tools software see the GalilTools user manual http www galilmc com support manuals galiltools index html Using DMC SmartTerminal or WSDK Software for Windows NOTE For new applications Galil recommends using the GalilTools software package In order for the windows software to communicate with a Galil controller the controller must be registered in the Windows Registry To register a controller you must specify the model of the controller the communication parameters and other information The registry is accessed
354. wered at separate voltages If the ISCNTL option is NOT ordered on the DMC 40x0 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 4080 C012 1000 1000 D3040 D3040 ISAMP 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 is only valid with the AMP 43140 Part number ordering example DMC 4040 C012 1000 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 4040 C012 1000 D3140 SSR DMC 40x0 User Manual Appendices e 206 Power Connectors for the DMC 40x0 Overview The DMC 40x0 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
355. will be used to control a brushless motor s with sinusoidal commutation The command BA is used to select the axes of sinusoidal commutation For example BAAC sets A and C as axes with sinusoidal commutation Notes on Configuring Sinusoidal Commutation The command BA reconfigures the controller such that it has one less axis of standard control for each axis of sinusoidal commutation For example if the command BAA is given to a DMC 4040 controller the controller will be re configured to be a DMC 4030 controller In this case the highest axis is no longer available except to be used for the 2 phase of the sinusoidal commutation Note that the highest axis on a controller can never be configured for sinusoidal commutation The DAC associated with the selected axis represents the first phase The second phase uses the highest available DAC When more than one axis is configured for sinusoidal commutation the controller will assign the second phases to the DACs which have been made available through the axes reconfiguration The highest sinusoidal commutation axis will be assigned to the highest available DAC and the lowest sinusoidal commutation axis will be assigned to the lowest available DAC Note that the lowest axis is the A axis and the highest axis is the highest available axis for which the controller has been configured Example Sinusoidal Commutation Configuration using a DMC 4070 BAAC This command causes the controller to be
356. witch to on When panel switch is turned to off position motor A must stop turning Solution Connect panel switch to input 1 of DMC 40x0 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 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 Y of the full voltage range for example connect the input to 6 volts if the signal is a 0 12 volt logic Example A DMC 4010 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 functi
357. x Encoder Input B Digital 13 HALB B Channel Hall Sensor 14 HALC C Channel Hall Sensor 15 5V 5V Pin Label Description 1 MI Index Pulse Input Vo Sin Cos or I Digital 2 MB Main Encoder Input V gt Sin Cos or B Digital 3 MA Main Encoder Input V Sin Cos or A Digital 4 AB Aux Encoder Input B Digital 5 GND Digital Ground 6 MI Index Pulse Input Vo Sin Cos or I Digital 7 Main Encoder Input V2 Sin Cos or B Digital 8 Main Encoder Input V Sin Cos or A Digital 9 Aux Encoder Input A Digital 10 A Channel Hall Sensor 11 Aux Encoder Input A Digital HALB HALC ICM 42100 Analog 15 pin D sub Connector Male Pin Label Description AGND Analog Ground 2 All Analog Input 1 3 AIB Analog Input 3 4 AI5 Analog Input 5 5 AI7 Analog Input 7 6 Analog Ground 7 12V 8 5V 5V 9 Analog Ground 0 AI2 Analog Input 2 1 AI4 Analog Input 4 2 AI6 Analog Input 6 3 AI8 Analog Input 8 4 N C No Connect 5 12V 12V AT ICM 42100 1100 e 267 DMC 40x0 User Manual Theory of Operation Traditional quadrature rotary encoders work by having two sets of lines inscribed radially around the circumference of an optical disk A light is passed through each of these two sets of lines On the other side of the gratings photo sensors detect the presence or absence of these lines These two sets of lines are offset from each other s
358. xecutes in the DMC 40x0 and indicates via the serial port when a communication handle fails By monitoring the serial port the user can re establish communication if needed Instruction Interpretation LOOP Simple program loop JP LOOP EN TCPERR Ethernet communication error auto routine MG Pl _IA4 Send message to serial port indicating which handle did not receive proper acknowledgment 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 is advanced DMC programming and is recommended for experienced DMC programmers familiar with the concept of passing arguments by value and by reference Notes 1 Passing parameters has no type checking so it is Important to exercise good programming style when passing parameters See examples below for recommended syntax 2 Do not use spaces in expressions containing 3 Global variables MUST be assigned prior to any use in subroutines where variables are passed by reference Chapter 7 Application Programming e 147 DMC 40x0 User Manual Example A Simple Adding Function Add JS SUM 1 2 3 4 5 6 7 8 MG_JS EN SUM EN 4at b c d e f g h Executed program from programl dmc 36 0000 Example Variable and an Important Note about Creating Global Variables Var value 5 global 8 JS SUM amp value 1 2 3 4 5 6 7 MG value MG J
359. xecution 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 Linear Interpolation Mode The DMC 40x0 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 interpolation change Specifying Linear Segments The command LI x y z w or LI a b c d e f g h specifies the incremental m
360. xt 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 order of the point The value n starts at zero and may go up to 256 The parameters x y z w indicate the corresponding slave position For this example the table may be specified by ET 0 0 ET 1 3000 ET 2 2250 3 1500 Em 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 E
361. y 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 _RPx Contains the commanded position generated by the profiler for the x axis _TDx Contains the value of the step count register for the x axis _TPx Contains the value of the main encoder for the x axis DMC 40x0 User Manual Chapter 6 Programming Motion e 116 Stepper Position Maintenance Mode SPM The Galil controller can be set into the Stepper Position Maintenance SPM mode to handle th

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