Mechanical Specifications, Mechanical Dimensions

Contents

User’s Manual Dual Channel High Power Digital Motor ControllerAX3500 Version 1.9b. June 1 AX3500 Motor Controller User’s Manual Version Revision HistoryRevision History Date Version 1.9b. June 1 Revision History General Operation SECTION SECTIONSECTION SECTION SECTION SECTION Programming using built-in Switches and Display Version 1.9b. June 1 Warnings Important SafetyAvoid Shorts when Mounting Board against Chassis Do not Connect to a RC Radio with a Battery Attached Important Safety Warnings What you will need Locating the Switches and ConnectorsAX3500 Quick Start AX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors RC Mode Connecting to the 15-pin ConnectorImportant Warning Signal Connecting the R/C Radio Connecting the R/C RadioPowering On the Controller Function Button OperationProg and Set button status Parameter Default Controller ConfigurationDefault Controller Configuration Default Values Connecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision Number = Software version 1.9b Exploring further Product Description SECTION 3AX3500 Motor Controller Overview AX3500 Motor Controller Overview Technical featuresMultiple Command Modes Automatic Joystick Command Corrections Optical Encoder Inputs Technical featuresLow Power Consumption High Efficiency Motor Power Outputs Compact Open Frame PCB Design Advanced Safety FeaturesData Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller Power mended Off Configuration Controller PowerPower Control input is And Main Battery Powering the Controller from a single Battery Controller Powering Schemes Controller Powering Schemes Powering the Controller Using a Main and Backup Battery Connecting the Motors Single Channel Operation Single Channel OperationConverting the AX3500 to Single Channel Power Fuses Wire Length Limits Wire Length LimitsPower Regeneration Considerations Electrical Noise Reduction Techniques Undervoltage Protection Overvoltage Protection Using the Controller with a Power Supply Using the Controller with a Power Supply Version 1.9b. June 1 Basic Operation Input Command ModesGeneral Operation Basic Operation General Operation Selecting the Motor Control ModesOpen Loop, Separate Speed Control Open Loop, Mixed Speed Control Selecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control Setting User Selected Current Limit SettingsTemperature-Based Current Limitation Position Feedback Position Sensor Gear box Temperature Battery Current vs. Motor CurrentBattery Current vs. Motor Current Motor Current = Battery Current / PWM ratio Motor Current = Battery Current / PWM Ratio Regeneration Current Limiting Programmable Acceleration Programmable AccelerationSetting Using Switches 0.089 second Command Control Curves15 Hex 17.97% Selected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Exponentiation Parameter Value Parameter Value Speed Adjustment Activating Brake Release or Separate Motor Excitation Emergency Shut Down Using Controller SwitchesEmergency Stop using External Switch Activating Brake Release or Separate Motor Excitation Inverted Operation Special Use of Accessory Digital InputsUsing the Inputs to Activate the Buffered Output Using the Inputs to turn Off/On the Power MOSFET transistors Self-Test Mode Self-Test Mode Encoder Speed or Position AX3500 Connections Connecting Sensors and Actuators to Input/OutputsAX3500 Connections Connecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and Outputs Activated AX3500’s Inputs and OutputsI/O type Input or Pin1I/O List and Pin Assignment Signal depending Connecting devices to Output C Connecting devices to Output C Important warning Connecting Switches or Devices to Input F Connecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert Input Analog Inputs Connecting Position Potentiometers to Analog Inputs Operating Mode Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Ana2 Ana 4 p8 Ana 1 p11Ana2 p10 Ana 3 p12 Resistance kOhm Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Temp oC Using the Analog Inputs to Monitor External Voltages Connecting User Devices to Analog Inputs Connecting User Devices to Analog InputsInternal Voltage Monitoring Sensors Internal Heatsink Temperature Sensors Analog Temperature Conversion C Source CodeValue HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1 Internal Heatsink Temperature Sensorselse LoTemp = i * 5 Version 1.9b. June 1 RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview RC Pulses Output Connector Location and PinoutConnecting Servos to Controllers Servo Connection to RevA Controllers Connecting to Slave Controllers Connecting to Slave ControllersServo Connection to RevB Controllers 1.50ms Pulse Timing InformationCommand Value Pulse Width 1.00ms RC Channel Testing Using the PC Utility RC Channel Testing Using the PC Utility Version 1.9b. June 1 Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview Connecting and Using the Encoder Function Recommended Encoder Types Pulse Frequency in Hz = RPM / 60 * PPR Connecting the EncoderConnecting the Encoder Cable Color Cable Length and Noise ConsiderationsMotor - Encoder Polarity Matching Name Voltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Motor 1 Fwd Wiring Limit Switches Without EncodersEffect of Limit Switches Wiring Limit Switches Without Encoders Motor 2 Rev Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Motor 2 Fwd Using the Encoder to Track Position Using the Encoder to Track PositionImportant Notice Distance = Destination - Counter value / Divider The actual formula is as follows RS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC UtilityRS232 Communication with the Encoder Module Version 1.9b. June 1 Mode Description Closed Loop Position ModeMode Description Selecting the Position Mode Closed Loop Position Mode Position Sensor SelectionSensor Mounting Position Feedback Position Sensor Gear box Feedback Potentiometer wiring Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiring in Analog Mode Analog Feedback on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersFeedback Wiring in Analog Mode on Single Channel Controllers Analog Feedback on Single Channel Controllers Sensor and Motor Polarity Using Optical Encoders in Position Mode Encoder Error Detection and Protection Important Safety WarningEncoder Error Detection and Protection Adding Safety Limit Switches FIGURE 62. Safety limit switches interrupting power to motors Using Current Limiting as Protection Using Current Limiting as ProtectionControl Loop Description PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional Gain PID tuning in Position Mode Version 1.9b. June 1 Selecting the Speed Mode Closed Loop Speed Mode Closed Loop Speed Mode Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer wiring Tachometer or Encoder Mounting Speed Sensor and Motor Polarity Speed Sensor and Motor Polarity Adjust Offset and Max Speed PID tuning in Speed Mode PID tuning in Speed Mode In Speed Mode, the Integral component of the PID is the most important and must be set first. The Proportional and Differential component will help improve the response time and loop stability Use of the LED Display Normal and Fault Condition LED MessagesUse of the LED Display Motor Motor Direction StatusNormal and Fault Condition LED Messages Possible Display Rapidly Flashing Fault MessagesNo Control Fault Messages Self-Test Display Temporary FaultsPermanent Faults Self-Test Display = Software version 1.9b Version 1.9b. June 1 SECTION 12 R/C Operation R/C Operation Connector I/O Pin Assignment R/C ModeSelecting the R/C Input Mode Pin1 R/C Input Circuit Description R/C Input Circuit DescriptionSupplied Cable Description FIGURE 75. RC connection cable Powering the Radio from the controllerFIGURE 74. RC Cable wiring diagram Powering the Radio from the controller Operating the Controller in R/C mode Connecting to a Separately Powered Radio Reception Watchdog Reception Watchdog R/C Transmitter/Receiver Quality Considerations Important Notice about PCM Radios Deadband as Percent of full Joystick Travel Joystick Deadband ProgrammingJoystick Deadband Programming Deadband Parameter Value Joystick Calibration Left/Right Tuning Adjustment Automatic Joystick Calibration Automatic Joystick Calibration On before entering joystick calibration Data Logging in R/C Mode To Controller Data Logging in R/C ModeDB15 Male Version 1.9b. June 1 Analog Control and Operation Analog Control and Operation Connector I/O Pin Assignment Analog Mode Connecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer Selecting the Potentiometer Value Analog Deadband Adjustment Motor Power at 0% Power-On SafetyUnder Voltage Safety Data Logging in Analog Mode Data Logging in Analog Mode Version 1.9b. June 1 Use and benefits of RS232 Serial RS-232 Controls and OperationUse and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 Mode Cable configuration Cable configurationExtending the RS232 Cable Establishing Manual Communication with a PC Communication Settings9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Roboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog mode Command Error Commands Acknowledge and Error MessagesRS232 Mode if default Command Acknowledgement Type Controller Commands and QueriesRS-232 Watchdog Command Controller Commands and Queries Set Motor Command ValueSet Accessory Output Query Power Applied to Motors Syntax Query Amps from Battery to each Motor Channel ?m or ?M Query Analog InputsQuery Heatsink Temperatures ?r or ?R Examples Query Battery VoltagesReset Controller Query Digital Inputs Read parameter Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Accessing & Changing Configuration Parameter in Flash Active after Flash Configuration Parameters ListLocation After Reset Input Control ModeMotor Control Mode Access Definition Amps LimitAcceleration Input Switches Function 08 - Channel Left/Right AdjustRC Joystick or Analog Deadband Exponentiation on Channel 1 and Channel 0C - Encoder Default Encoder Time Base 1 andDefault Encoder Distance Divider 0B - Encoder 10 - Integral Gain Default PID GainsJoystick Min, Max and Center Values 0F - Proportional Gain Reading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime 80 - Channel Operating Modes RegistersRead/Change PID Values Access Read/Write Effective Instantly Fault Condition PWM Frequency RegisterController Status Register Address Access Read/Write Effective Instantly 8B - Channel Controller Identification RegisterCurrent Amps Limit Registers Model or Function RS232 Encoder Command Set RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers Read Encoder Counter 8 Set Encoder 2 destination register with value in buffer Read Speedq or !Q n 7 Set Encoder 1 destination register with value in buffer Read Speed/Distance Read Encoder Limit Switch StatusRead Distance n Value Important NoteRead / Modify Encoder Module Registers and Parameters Switch Size Parameter Description Address *84 Switch StatusRegister Description Encoder Hardware ID code Destination Register 1 and Speed or Distance 1 orCounter Read/Write Mailbox Counter 1 and Encoder Threshold Distance 1 andSpeed 1 and Time Base 1 and Counter Read Data Format Counter Read Data FormatRC Pulse Outputs Activation Default Value Controller Output Decimal32-bit Hex Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode Data Logging Cables 00 11 22 33 44 55 66 77 88 99 AA BB CCAnalog and R/C Modes Data Logging String Format Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table Version 1.9b. June 1 Programming Methods SECTION 15 Configuring the Controller using the SwitchesProgramming using built-in Switches and Display Program Entering Programming ModeConfiguring the Controller using the Switches Programming using built-in Switches and Display Changing parametersThe Special Case of Joystick Calibration This manual is for software version 1.9b Restoring factory defaultsExiting the Parameter Setting Mode Programmable Parameters List Programmable Parameters List Possible Values defaultFor safety reasons, the modes below cannot be selected using the switches Letter System Requirements SECTION 16 Using the Roborun Configuration UtilityDownloading and Installing the Utility Using the Roborun Configuration Utility Connecting the Controller to the PC 2- Controller and Communication Link Information Roborun Frame, Tab and Menu DescriptionsRoborun Frame, Tab and Menu Descriptions 1- Program Revision Number 5- View Controller Connector Pinout Getting On-Screen Help3- Parameter Selection and Setting and Special Functions 4- File and Program Management Commands 1- Controller Input Control SettingsLoading, Changing Controller Parameters Loading, Changing Controller Parameters 5- Effect of Digital Inputs Power Settings3- Input Command Adjustment 4- Emergency Stop or Invert Switch Select 1- Deadband Analog or R/C Specific SettingsLoading, Changing Controller Parameters 2- Left/Right Adjust 3- Acceleration Setting Closed Loop Parameters Encoder Setting and Testing Encoder Setting and Testing Encoder Module Parameters Setting Viewing Encoder Data RC Output TestingExercising the Motors Running the Motors Running the Motors 3- Measurement 2- Motor Power setting1- Run/Stop Button 5- Transmit and Receive Data 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting 4- Reset Timer button Logging Data to Disk7- Data Logging and Timer 8- Joystick Enable Measured Parameter Connecting a JoystickParameter Header Data type/range 1- Terminal Screen Using the Console2- Command Entry Viewing and Logging Data in Analog and R/C Modes Viewing and Logging Data in Analog and R/C ModesLoading and Saving Profiles to Disk 4- Send Reset String Operating the AX3500 over a Wired or Wireless LAN Updating the Controller’s Software Updating the Controller’s Software Updating the Encoder Software Creating Customized Object Files Creating Customized Object Files Version 1.9b. June 1 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mechanical Specifications Mounting ConsiderationsThermal Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions Wire DimensionsWeight Version 1.9b. June 1 Mechanical SpecificationsAX3500 Motor Controller User’s Manual

RoboteQ AX3500 user manual Mechanical Specifications, Mechanical Dimensions

Models: AX3500