Battery Current vs. Motor Current, Temperature | RoboteQ AX3500

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RoboteQ AX3500 Battery Current vs. Motor Current, Temperature, Max Amps, Motor Current = Battery Current / PWM ratio

Contents

Dual Channel High Power Digital Motor Controller AX3500User’s Manual Version 1.9b. June 1 AX3500 Motor Controller User’s Manual Revision History Revision HistoryDate Version 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 Avoid Shorts when Mounting Board against Chassis Important SafetyDo not Connect to a RC Radio with a Battery Attached Warnings Important Safety Warnings AX3500 Locating the Switches and ConnectorsQuick Start What you will need AX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Important Warning Connecting to the 15-pin ConnectorSignal RC Mode Connecting the R/C Radio Powering On the ControllerConnecting the R/C Radio Button Operation Prog and Set button statusFunction Default Controller Configuration Default Controller ConfigurationDefault Values Parameter 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 Multiple Command Modes Technical featuresAutomatic Joystick Command Corrections AX3500 Motor Controller Overview Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Optical Encoder Inputs Advanced Safety Features Data Logging CapabilitiesCompact Open Frame PCB Design Connecting Power and Motors to the Controller Power ConnectionsPower Connections Connecting Power and Motors to the Controller Controller Power Power Control input is Controller PowerAnd Main Battery mended Off Configuration 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 Converting the AX3500 to Single ChannelSingle Channel Operation Power Fuses Power Regeneration Considerations Wire Length LimitsElectrical Noise Reduction Techniques Wire Length Limits Undervoltage Protection Overvoltage Protection Using the Controller with a Power Supply Using the Controller with a Power Supply Connecting Power and Motors to the Controller General Operation Input Command ModesBasic Operation Basic Operation Open Loop, Separate Speed Control Selecting the Motor Control ModesOpen Loop, Mixed Speed Control General Operation Closed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes Temperature-Based Current Limitation User Selected Current Limit SettingsPosition Feedback Position Sensor Gear box Setting Battery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio Temperature Motor Current = Battery Current / PWM Ratio Regeneration Current Limiting Setting Using Programmable AccelerationSwitches Programmable Acceleration 15 Hex Command Control Curves17.97% 0.089 second Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Emergency Stop using External Switch Emergency Shut Down Using Controller SwitchesActivating Brake Release or Separate Motor Excitation Activating Brake Release or Separate Motor Excitation Using the Inputs to Activate the Buffered Output Special Use of Accessory Digital InputsUsing the Inputs to turn Off/On the Power MOSFET transistors Inverted Operation Self-Test Mode Self-Test Mode Encoder Speed or Position Connecting Sensors and Actuators to Input/Outputs AX3500 ConnectionsAX3500 Connections Connecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and Outputs AX3500’s Inputs and Outputs I/O typeActivated I/O List and Pin Assignment Pin1Signal depending Input or 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 Connecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsAna2 Operating Mode Ana2 p10 Ana 1 p11Ana 3 p12 Ana 4 p8 Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhm Using the Analog Inputs to Monitor External Voltages Internal Voltage Monitoring Sensors Connecting User Devices to Analog InputsInternal Heatsink Temperature Sensors Connecting User Devices to Analog Inputs Temperature Conversion C Source Code ValueAnalog else Internal Heatsink Temperature SensorsLoTemp = i * 5 HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1 Connecting Sensors and Actuators to Input/Outputs RC Pulses Output RC Pulse Output OverviewRC Pulse Output Overview Connecting Servos to Controllers Connector Location and PinoutServo Connection to RevA Controllers RC Pulses Output Connecting to Slave Controllers Servo Connection to RevB ControllersConnecting to Slave Controllers Command Value Pulse Timing InformationPulse Width 1.00ms 1.50ms RC Channel Testing Using the PC Utility RC Channel Testing Using the PC Utility RC Pulses Output Connecting and Using the Encoder Function Optical Incremental Encoders OverviewOptical Incremental Encoders Overview Connecting and Using the Encoder Function Recommended Encoder Types Connecting the Encoder Connecting the EncoderPulse Frequency in Hz = RPM / 60 * PPR Motor - Encoder Polarity Matching Cable Length and Noise ConsiderationsName Cable Color Voltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Effect of Limit Switches Wiring Limit Switches Without EncodersWiring Limit Switches Without Encoders Motor 1 Fwd Using the Encoder to Measure Speed Using the Encoder Module to Measure DistanceMotor 2 Fwd Motor 2 Rev Using the Encoder to Track Position Important NoticeUsing the Encoder to Track Position Distance = Destination - Counter value / Divider The actual formula is as follows Encoder Testing and Setting Using the PC Utility RS232 Communication with the Encoder ModuleRS232 Communication with the Encoder Module Connecting and Using the Encoder Function Mode Description Closed Loop Position ModeSelecting the Position Mode Mode Description Sensor Mounting Position Sensor SelectionPosition Feedback Position Sensor Gear box Closed Loop Position Mode Feedback Potentiometer wiring Feedback Potentiometer wiring in RC or RS232 ModeFeedback Potentiometer wiring Feedback Potentiometer wiring in Analog Mode Feedback Wiring in Analog Mode on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersAnalog Feedback 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 WarningAdding Safety Limit Switches Encoder Error Detection and Protection FIGURE 62. Safety limit switches interrupting power to motors Using Current Limiting as Protection Control Loop DescriptionUsing Current Limiting as Protection PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional Gain PID tuning in Position Mode Closed Loop Position Mode Selecting the Speed Mode Closed Loop Speed Mode Tachometer wiring Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer or Encoder Mounting Closed Loop Speed Mode 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 Normal and Fault Condition LED Messages Use of the LED DisplayUse of the LED Display Normal and Fault Condition LED Messages Motor Direction StatusPossible Display Motor No Control Fault MessagesFault Messages Rapidly Flashing Temporary Faults Permanent FaultsSelf-Test Display Self-Test Display = Software version 1.9b Normal and Fault Condition LED Messages SECTION 12 R/C Operation Selecting the R/C Input Mode Connector I/O Pin Assignment R/C ModePin1 R/C Operation R/C Input Circuit Description Supplied Cable DescriptionR/C Input Circuit Description Powering the Radio from the controller FIGURE 74. RC Cable wiring diagramFIGURE 75. RC connection cable 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 Joystick Deadband Programming Joystick Deadband ProgrammingDeadband Parameter Value Deadband as Percent of full Joystick Travel Joystick Calibration Left/Right Tuning Adjustment Automatic Joystick Calibration Automatic Joystick Calibration On before entering joystick calibration Data Logging in R/C Mode Data Logging in R/C Mode DB15 MaleTo Controller R/C Operation Analog Control and Operation Analog Control and Operation Connector I/O Pin Assignment Analog Mode Connecting to a Voltage Source Connecting a PotentiometerConnecting to a Voltage Source Selecting the Potentiometer Value Analog Deadband Adjustment Under Voltage Safety Power-On SafetyData Logging in Analog Mode Motor Power at 0% Data Logging in Analog Mode Analog Control and Operation Serial RS-232 Controls and Operation Use and benefits of RS232Use and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 Mode Cable configuration Extending the RS232 CableCable configuration Communication Settings 9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even ParityEstablishing Manual Communication with a PC RS232 Communication with the Encoder Module Establishing Manual Communication with a PCRoboteq v1.9b 06/01/07 s Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog mode RS232 Mode if default Commands Acknowledge and Error MessagesCommand Acknowledgement Command Error RS-232 Watchdog Controller Commands and QueriesCommand Type Set Accessory Output Set Motor Command ValueQuery Power Applied to Motors Controller Commands and Queries Syntax Query Amps from Battery to each Motor Channel Query Heatsink Temperatures Query Analog Inputs?r or ?R ?m or ?M Reset Controller Query Battery VoltagesQuery Digital Inputs Examples Apply Parameter Changes Accessing & Changing Configuration Parameter in FlashAccessing & Changing Configuration Parameter in Flash Read parameter Flash Configuration Parameters List LocationActive after Motor Control Mode Input Control ModeAccess After Reset Amps Limit AccelerationDefinition Input Switches Function RC Joystick or Analog Deadband Left/Right AdjustExponentiation on Channel 1 and Channel 08 - Channel Default Encoder Distance Divider Default Encoder Time Base 1 and0B - Encoder 0C - Encoder Joystick Min, Max and Center Values Default PID Gains0F - Proportional Gain 10 - Integral Gain Reading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime Read/Change PID Values Operating Modes RegistersAccess Read/Write Effective Instantly 80 - Channel Controller Status Register PWM Frequency RegisterAddress Access Read/Write Effective Instantly Fault Condition Current Amps Limit Registers Controller Identification RegisterModel or Function 8B - Channel Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Encoder Counter RS232 Encoder Command Set q or !Q n Read Speed7 Set Encoder 1 destination register with value in buffer 8 Set Encoder 2 destination register with value in buffer Read Encoder Limit Switch Status Read DistanceRead Speed/Distance Read / Modify Encoder Module Registers and Parameters Important NoteSwitch n Value Size Parameter Description Register Description Switch StatusEncoder Hardware ID code Address *84 Counter Read/Write Mailbox Speed or Distance 1 orCounter 1 and Destination Register 1 and Speed 1 and Distance 1 andTime Base 1 and Encoder Threshold RC Pulse Outputs Activation Counter Read Data FormatDefault Value Counter Read Data Format Decimal 32-bit HexController Output Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode 00 11 22 33 44 55 66 77 88 99 AA BB CC Analog and R/C Modes Data Logging String FormatData Logging Cables 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 SECTION 15 Configuring the Controller using the Switches Programming using built-in Switches and DisplayProgramming Methods Entering Programming Mode Configuring the Controller using the SwitchesProgram Changing parameters The Special Case of Joystick CalibrationProgramming using built-in Switches and Display Exiting the Parameter Setting Mode Restoring factory defaultsProgrammable Parameters List This manual is for software version 1.9b For safety reasons, the modes below Possible Values defaultcannot be selected using the switches Programmable Parameters List Possible Values default SECTION 16 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements Using the Roborun Configuration Utility Connecting the Controller to the PC Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions1- Program Revision Number 2- Controller and Communication Link Information 3- Parameter Selection and Setting and Special Functions Getting On-Screen Help4- File and Program Management Commands 5- View Controller Connector Pinout Loading, Changing Controller Parameters Control SettingsLoading, Changing Controller Parameters 1- Controller Input 3- Input Command Adjustment Power Settings4- Emergency Stop or Invert Switch Select 5- Effect of Digital Inputs Loading, Changing Controller Parameters 2- Left/Right Adjust Analog or R/C Specific Settings3- Acceleration Setting 1- Deadband Closed Loop Parameters Encoder Setting and Testing Encoder Setting and Testing Encoder Module Parameters Setting RC Output Testing Exercising the MotorsViewing Encoder Data Running the Motors Running the Motors 2- Motor Power setting 1- Run/Stop Button3- Measurement 4- Real-Time Strip Chart Recorder 6- Input Status and Output Setting5- Transmit and Receive Data 7- Data Logging and Timer Logging Data to Disk8- Joystick Enable 4- Reset Timer button Parameter Header Connecting a JoystickData type/range Measured Parameter Using the Console 2- Command Entry1- Terminal Screen Loading and Saving Profiles to Disk Viewing and Logging Data in Analog and R/C Modes4- Send Reset String Viewing and Logging Data in Analog and R/C Modes 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 Using the Roborun Configuration Utility Mechanical Specifications Mechanical DimensionsMechanical Dimensions Mounting Considerations Thermal ConsiderationsMechanical Specifications Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions WeightWire Dimensions Mechanical Specifications AX3500 Motor Controller User’s ManualVersion 1.9b. June 1