RoboteQ AX3500 Motor Controller Overview, Advanced Safety Features, Data Logging Capabilities

Page 28

Advanced Safety Features

AX3500 Motor Controller Overview

•60A up to 15 seconds (per channel)

•50A up to 30 seconds

•40A extended

•High current operation may be extended with forced cooling

•250A peak Amps per channel

•16kHz Pulse Width Modulation (PWM) output

•Auxiliary output for brake, clutch or armature excitation

•Heat sink on PCB

•Optional Bottom Aluminum place for conduction cooling (BP version)

Advanced Safety Features

•Safe power on mode

•Optical isolation on R/C control inputs

•Automatic Power stage off in case of electrically or software induced program fail- ure

•Overvoltage and Undervoltage protection

•Regeneration current limiting

•Watchdog for automatic motor shutdown in case of command loss (R/C and RS232 modes)

•Large, bright run/failure diagnostics on 7 segment LED display

•Programmable motor acceleration

•Built-in controller overheat sensor

•Emergency Stop input signal and button

Data Logging Capabilities

•13 internal parameters, including battery voltage, captured R/C command, tempera- ture and Amps accessible via RS232 port

•Data may be logged in a PC, PDA or microcomputer

Compact Open Frame PCB Design

•Surface mount PCB design

•Efficient heat sinking. Operates without a fan in most applications.

•6.75” (171.5mm) long x 4.20” (106.7mm) wide

•-20o to +85o C heatsink operating environment

•7.5oz (220g)

28

AX3500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

Image 28

Contents AX3500 Dual Channel High Power Digital Motor ControllerUser’s Manual AX3500 Motor Controller User’s Manual Version 1.9b. June 1Revision History Revision HistoryDate VersionAX3500 Motor Controller User’s Manual Revision History General Operation SECTION SECTIONSECTION SECTION SECTION SECTION Programming using built-in Switches and Display AX3500 Motor Controller User’s Manual Important Safety Avoid Shorts when Mounting Board against ChassisDo not Connect to a RC Radio with a Battery Attached WarningsImportant Safety Warnings Locating the Switches and Connectors AX3500Quick Start What you will needAX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and MotorsConnecting to the 15-pin Connector Important WarningSignal RC ModePowering On the Controller Connecting the R/C RadioConnecting the R/C Radio Prog and Set button status Button OperationFunction Default Controller Configuration Default Controller ConfigurationDefault Values ParameterConnecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision NumberExploring further = Software version 1.9bSECTION 3AX3500 Motor Controller Overview Product DescriptionTechnical features Multiple Command ModesAutomatic Joystick Command Corrections AX3500 Motor Controller OverviewTechnical features Low Power ConsumptionHigh Efficiency Motor Power Outputs Optical Encoder InputsData Logging Capabilities Advanced Safety FeaturesCompact Open Frame PCB Design Power Connections Connecting Power and Motors to the ControllerPower Connections Controller Power Connecting Power and Motors to the ControllerController Power Power Control input isAnd Main Battery mended Off ConfigurationController Powering Schemes Powering the Controller from a single BatteryPowering the Controller Using a Main and Backup Battery Controller Powering SchemesConnecting the Motors Converting the AX3500 to Single Channel Single Channel OperationSingle Channel Operation Power Fuses Wire Length Limits Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Wire Length LimitsOvervoltage Protection Undervoltage ProtectionUsing the Controller with a Power Supply Using the Controller with a Power SupplyAX3500 Motor Controller User’s Manual Input Command Modes General OperationBasic Operation Basic OperationSelecting the Motor Control Modes Open Loop, Separate Speed ControlOpen Loop, Mixed Speed Control General OperationClose Loop Position Control Closed Loop Speed ControlSelecting the Motor Control Modes User Selected Current Limit Settings Temperature-Based Current LimitationPosition Feedback Position Sensor Gear box SettingBattery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio TemperatureRegeneration Current Limiting Motor Current = Battery Current / PWM RatioProgrammable Acceleration Setting UsingSwitches Programmable AccelerationCommand Control Curves 15 Hex17.97% 0.089 secondLeft / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected CurveSpeed Adjustment Parameter ValueEmergency Shut Down Using Controller Switches Emergency Stop using External SwitchActivating Brake Release or Separate Motor Excitation Activating Brake Release or Separate Motor ExcitationSpecial Use of Accessory Digital Inputs Using the Inputs to Activate the Buffered OutputUsing the Inputs to turn Off/On the Power MOSFET transistors Inverted OperationSelf-Test Mode Self-Test ModeEncoder Speed or Position AX3500 Connections Connecting Sensors and Actuators to Input/OutputsAX3500 Connections AX3500’s Inputs and Outputs Connecting Sensors and Actuators to Input/OutputsI/O type AX3500’s Inputs and OutputsActivated Pin1 I/O List and Pin AssignmentSignal depending Input orConnecting devices to Output C Connecting devices to Output CConnecting Switches or Devices to Input F Important warningConnecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert InputConnecting Position Potentiometers to Analog Inputs Analog InputsConnecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsAna2 Operating ModeAna 1 p11 Ana2 p10Ana 3 p12 Ana 4 p8Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhmUsing the Analog Inputs to Monitor External Voltages Connecting User Devices to Analog Inputs Internal Voltage Monitoring SensorsInternal Heatsink Temperature Sensors Connecting User Devices to Analog InputsValue Temperature Conversion C Source CodeAnalog Internal Heatsink Temperature Sensors elseLoTemp = i * 5 HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1AX3500 Motor Controller User’s Manual RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview Connector Location and Pinout Connecting Servos to ControllersServo Connection to RevA Controllers RC Pulses OutputServo Connection to RevB Controllers Connecting to Slave ControllersConnecting to Slave Controllers Pulse Timing Information Command ValuePulse Width 1.00ms 1.50msRC Channel Testing Using the PC Utility RC Channel Testing Using the PC UtilityAX3500 Motor Controller User’s Manual Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview Recommended Encoder Types Connecting and Using the Encoder FunctionConnecting the Encoder Connecting the EncoderPulse Frequency in Hz = RPM / 60 * PPR Cable Length and Noise Considerations Motor - Encoder Polarity MatchingName Cable ColorVoltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit SwitchesWiring Optional Limit Switches Wiring Limit Switches Without Encoders Effect of Limit SwitchesWiring Limit Switches Without Encoders Motor 1 FwdUsing the Encoder Module to Measure Distance Using the Encoder to Measure SpeedMotor 2 Fwd Motor 2 RevImportant Notice Using the Encoder to Track PositionUsing the Encoder to Track Position The actual formula is as follows Distance = Destination - Counter value / DividerRS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC UtilityRS232 Communication with the Encoder Module AX3500 Motor Controller User’s Manual Closed Loop Position Mode Mode DescriptionSelecting the Position Mode Mode DescriptionPosition Sensor Selection Sensor MountingPosition Feedback Position Sensor Gear box Closed Loop Position ModeFeedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringFeedback Potentiometer wiring Feedback Potentiometer wiring in Analog Mode Feedback Wiring in RC or RS232 Mode on Single Channel Controllers Feedback Wiring in Analog Mode on Single Channel ControllersAnalog Feedback on Single Channel Controllers Analog Feedback on Single Channel ControllersUsing Optical Encoders in Position Mode Sensor and Motor PolarityImportant Safety Warning Encoder Error Detection and ProtectionAdding Safety Limit Switches Encoder Error Detection and ProtectionFIGURE 62. Safety limit switches interrupting power to motors Control Loop Description Using Current Limiting as ProtectionUsing Current Limiting as Protection PID tuning in Position Mode PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional GainAX3500 Motor Controller User’s Manual Closed Loop Speed Mode Selecting the Speed ModeUsing Optical Encoder for Speed FeedbackDigital Optical Encod Tachometer wiringTachometer or Encoder Mounting Closed Loop Speed ModeSpeed Sensor and Motor Polarity Speed Sensor and Motor PolarityAdjust Offset and Max Speed PID tuning in Speed Mode PID tuning in Speed ModeIn 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 Direction Status Normal and Fault Condition LED MessagesPossible Display MotorFault Messages No ControlFault Messages Rapidly FlashingPermanent Faults Temporary FaultsSelf-Test Display = Software version 1.9b Self-Test DisplayAX3500 Motor Controller User’s Manual SECTION 12 R/C Operation Connector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin1 R/C OperationSupplied Cable Description R/C Input Circuit DescriptionR/C Input Circuit Description FIGURE 74. RC Cable wiring diagram Powering the Radio from the controllerFIGURE 75. RC connection cable Powering the Radio from the controller Connecting to a Separately Powered Radio Operating the Controller in R/C modeReception Watchdog Reception WatchdogImportant Notice about PCM Radios R/C Transmitter/Receiver Quality ConsiderationsJoystick Deadband Programming Joystick Deadband ProgrammingDeadband Parameter Value Deadband as Percent of full Joystick TravelLeft/Right Tuning Adjustment Joystick CalibrationAutomatic Joystick Calibration Automatic Joystick CalibrationData Logging in R/C Mode On before entering joystick calibrationDB15 Male Data Logging in R/C ModeTo Controller AX3500 Motor Controller User’s Manual Analog Control and Operation Connector I/O Pin Assignment Analog Mode Analog Control and OperationConnecting a Potentiometer Connecting to a Voltage SourceConnecting to a Voltage Source Selecting the Potentiometer Value Analog Deadband Adjustment Power-On Safety Under Voltage SafetyData Logging in Analog Mode Motor Power at 0%Data Logging in Analog Mode AX3500 Motor Controller User’s Manual Use and benefits of RS232 Serial RS-232 Controls and OperationUse and benefits of RS232 Connector I/O Pin Assignment RS232 Mode Serial RS-232 Controls and OperationExtending the RS232 Cable Cable configurationCable configuration 9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Communication SettingsEstablishing Manual Communication with a PC Establishing Manual Communication with a PC RS232 Communication with the Encoder ModuleRoboteq v1.9b 06/01/07 s Entering RS232 from R/C or Analog mode Data Logging String in R/C or Analog modeCommands Acknowledge and Error Messages RS232 Mode if defaultCommand Acknowledgement Command ErrorController Commands and Queries RS-232 WatchdogCommand TypeSet Motor Command Value Set Accessory OutputQuery Power Applied to Motors Controller Commands and QueriesQuery Amps from Battery to each Motor Channel SyntaxQuery Analog Inputs Query Heatsink Temperatures?r or ?R ?m or ?MQuery Battery Voltages Reset ControllerQuery Digital Inputs ExamplesAccessing & Changing Configuration Parameter in Flash Apply Parameter ChangesAccessing & Changing Configuration Parameter in Flash Read parameterLocation Flash Configuration Parameters ListActive after Input Control Mode Motor Control ModeAccess After ResetAcceleration Amps LimitDefinition Input Switches Function Left/Right Adjust RC Joystick or Analog DeadbandExponentiation on Channel 1 and Channel 08 - ChannelDefault Encoder Time Base 1 and Default Encoder Distance Divider0B - Encoder 0C - EncoderDefault PID Gains Joystick Min, Max and Center Values0F - Proportional Gain 10 - Integral GainReading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at RuntimeOperating Modes Registers Read/Change PID ValuesAccess Read/Write Effective Instantly 80 - ChannelPWM Frequency Register Controller Status RegisterAddress Access Read/Write Effective Instantly Fault ConditionController Identification Register Current Amps Limit RegistersModel or Function 8B - ChannelRS232 Encoder Command Set Set/Reset Encoder Counters and Destination RegistersRead Encoder Counter RS232 Encoder Command SetRead Speed q or !Q n7 Set Encoder 1 destination register with value in buffer 8 Set Encoder 2 destination register with value in bufferRead Distance Read Encoder Limit Switch StatusRead Speed/Distance Important Note Read / Modify Encoder Module Registers and ParametersSwitch n ValueParameter Description SizeSwitch Status Register DescriptionEncoder Hardware ID code Address *84Speed or Distance 1 or Counter Read/Write MailboxCounter 1 and Destination Register 1 andDistance 1 and Speed 1 andTime Base 1 and Encoder ThresholdCounter Read Data Format RC Pulse Outputs ActivationDefault Value Counter Read Data Format32-bit Hex DecimalController Output Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeAnalog and R/C Modes Data Logging String Format 00 11 22 33 44 55 66 77 88 99 AA BB CCData Logging Cables Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableAX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Programming using built-in Switches and Display SECTION 15 Configuring the Controller using the SwitchesProgramming Methods Configuring the Controller using the Switches Entering Programming ModeProgram The Special Case of Joystick Calibration Changing parametersProgramming using built-in Switches and Display Restoring factory defaults Exiting the Parameter Setting ModeProgrammable Parameters List This manual is for software version 1.9bPossible Values default For safety reasons, the modes belowcannot be selected using the switches Programmable Parameters ListConfiguring the Controller using the Switches Downloading and Installing the Utility SECTION 16 Using the Roborun Configuration UtilitySystem Requirements Connecting the Controller to the PC Using the Roborun Configuration UtilityRoborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions1- Program Revision Number 2- Controller and Communication Link InformationGetting On-Screen Help 3- Parameter Selection and Setting and Special Functions4- File and Program Management Commands 5- View Controller Connector PinoutControl Settings Loading, Changing Controller ParametersLoading, Changing Controller Parameters 1- Controller InputPower Settings 3- Input Command Adjustment4- Emergency Stop or Invert Switch Select 5- Effect of Digital InputsAnalog or R/C Specific Settings Loading, Changing Controller Parameters 2- Left/Right Adjust3- Acceleration Setting 1- DeadbandEncoder Setting and Testing Closed Loop ParametersEncoder Module Parameters Setting Encoder Setting and TestingExercising the Motors RC Output TestingViewing Encoder Data Running the Motors Running the Motors1- Run/Stop Button 2- Motor Power setting3- Measurement 6- Input Status and Output Setting 4- Real-Time Strip Chart Recorder5- Transmit and Receive Data Logging Data to Disk 7- Data Logging and Timer8- Joystick Enable 4- Reset Timer buttonConnecting a Joystick Parameter HeaderData type/range Measured Parameter2- Command Entry Using the Console1- Terminal Screen Viewing and Logging Data in Analog and R/C Modes Loading and Saving Profiles to Disk4- Send Reset String Viewing and Logging Data in Analog and R/C ModesOperating the AX3500 over a Wired or Wireless LAN Updating the Controller’s Software Updating the Controller’s SoftwareCreating Customized Object Files Updating the Encoder SoftwareCreating Customized Object Files AX3500 Motor Controller User’s Manual Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Thermal Considerations Mounting ConsiderationsMechanical Specifications Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a ChassisPrecautions to observe Weight Wire DimensionsWire Dimensions AX3500 Motor Controller User’s Manual Mechanical SpecificationsVersion 1.9b. June 1

Related manuals

Manual 2 pages 10.03 Kb