RoboteQ AX3500 Controller Powering Schemes, Powering the Controller from a single Battery, Action

Page 32
Controller Powering Schemes

Connecting Power and Motors to the Controller

TABLE 3. Controller Status depending on Power Control and VMot

Power Control input is

And Main Battery

 

connected to

Voltage is

Action

10.5V to 40V

0V

Controller is On.

 

 

Power Stage is Off

 

 

 

10.5V to 40V

1V to 40V

Controller is On.

 

 

Power Stage is Active

 

 

 

All 3 ground (-) are connected to each other inside the controller. The two main battery wires are also connected to each other internally. However, you must never assume that connecting one wire of a given battery potential will eliminate the need to connect the other.

Controller Powering Schemes

Powering the Controller from a single Battery

The diagram on Figure 12 show how to wire the controller to a single battery circuit and how to turn power On and Off.

Motor2

 

 

+

Power on/off

Fuse

switch

 

-

 

 

-

 

 

+

Optional

Motor1

Emergency

Disconnect

 

VMot

M1+

M1-

VCon GND GND

GND

M2-

M2+

VMot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12V to 24V

 

 

 

Controller

 

 

 

 

 

 

Motor Battery

Notes:

-The Battery Power connection are doubled in order to provide the maximum current to the controller. If only one motor is used, only one set of motor power cables needs to be connected.

-Typically, 1, 2 or 3 x 12V batteries are connected in series to reach 12V, 24V or 36V respectively.

FIGURE 10. Powering the AX3500 from a single battery

Connect two of the three Ground tabs to the minus (-) terminal of the battery that will be used to power the motors. Connect the two VMot tabs to the plus (+) terminal of the bat- tery. The motor battery may be of 12 to 40 Volts.

32

AX3500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

Page 31 Page 33
Image 32
Page 31 Page 33
Contents User’s Manual Dual Channel High Power Digital Motor ControllerAX3500 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 ModeConnecting the R/C Radio Connecting the R/C RadioPowering On the Controller Function Button OperationProg and Set button status 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 InputsCompact Open Frame PCB Design Advanced Safety FeaturesData Logging Capabilities 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 Single Channel Operation Single Channel OperationConverting the AX3500 to Single Channel 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 SupplyVersion 1.9b. June 1 Input Command Modes General OperationBasic Operation Basic OperationSelecting the Motor Control Modes Open Loop, Separate Speed ControlOpen Loop, Mixed Speed Control General OperationSelecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control 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/OutputsActivated AX3500’s Inputs and OutputsI/O type 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 InputsAnalog Temperature Conversion C Source CodeValue Internal Heatsink Temperature Sensors elseLoTemp = i * 5 HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1Version 1.9b. June 1 RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview Connector Location and Pinout Connecting Servos to ControllersServo Connection to RevA Controllers RC Pulses OutputConnecting to Slave Controllers Connecting to Slave ControllersServo Connection to RevB Controllers Pulse Timing Information Command ValuePulse Width 1.00ms 1.50msRC Channel Testing Using the PC Utility RC Channel Testing Using the PC UtilityVersion 1.9b. June 1 Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview Recommended Encoder Types Connecting and Using the Encoder FunctionPulse Frequency in Hz = RPM / 60 * PPR Connecting the EncoderConnecting the Encoder 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 RevUsing the Encoder to Track Position Using the Encoder to Track PositionImportant Notice 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 Version 1.9b. June 1 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 Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode 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 Using Current Limiting as Protection Using Current Limiting as ProtectionControl Loop Description PID tuning in Position Mode PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional GainVersion 1.9b. June 1 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 FlashingSelf-Test Display Temporary FaultsPermanent Faults = Software version 1.9b Self-Test DisplayVersion 1.9b. June 1 SECTION 12 R/C Operation Connector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin1 R/C OperationR/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 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 calibrationTo Controller Data Logging in R/C ModeDB15 Male Version 1.9b. June 1 Analog Control and Operation Connector I/O Pin Assignment Analog Mode Analog Control and OperationConnecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer 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 Version 1.9b. June 1 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 OperationCable 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 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 parameterActive after Flash Configuration Parameters ListLocation Input Control Mode Motor Control ModeAccess After ResetDefinition Amps LimitAcceleration 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 Speed/Distance Read Encoder Limit Switch StatusRead 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 FormatController Output Decimal32-bit Hex Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeData 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 TableAX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual 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 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 System Requirements SECTION 16 Using the Roborun Configuration UtilityDownloading and Installing the Utility 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 TestingViewing Encoder Data RC Output TestingExercising the Motors Running the Motors Running the Motors3- Measurement 2- Motor Power setting1- Run/Stop Button 5- Transmit and Receive Data 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting Logging Data to Disk 7- Data Logging and Timer8- Joystick Enable 4- Reset Timer buttonConnecting a Joystick Parameter HeaderData type/range Measured Parameter1- Terminal Screen Using the Console2- Command Entry 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 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 ChassisPrecautions to observe Wire Dimensions Wire DimensionsWeight Version 1.9b. June 1 Mechanical SpecificationsAX3500 Motor Controller User’s Manual
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