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Galil DMC-3425 user manual

Models: DMC-3425

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The DMC-3415 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 controller will 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.

* 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec (default rate).

DMC-3425

Chapter 1 Overview• 3

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Contents

DMC-3425 USER MANUALBy Galil Motion Control, Inc Manual Rev. 1.1bPage Chapter 2 Getting Started ContentsContents Chapter 1 OverviewChapter 4 Communication Chapter 3 Connecting HardwareChapter 5 Command Basics Chapter 6 Programming Motion Chapter 7 Application Programming Chapter 10 Theory of Operation Chapter 9 TroubleshootingChapter 8 Hardware & Software Protection Index AppendicesIntroduction Chapter 1 OverviewBrushless Servo Motor with Sinusoidal Commutation Stepper Motor with Step and Direction SignalsOverview of Motor Types The DMC-3415can control BLMs equipped with Hall sensors as well as without Hall sensors. If hall sensors are available, once the controller has been setup, the controller will 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 Communication DMC-3425Functional ElementsMicrocomputer Section Motor InterfaceAmplifier Driver General I/OSystem Elements MotorDMC-3425 Watch Dog TimerEncoder 6 • Chapter 1 OverviewDMC-3425 Chapter 2 Getting StartedThe DMC-3425Motion Controller Figure 2.1 – Outline of the DMC-3425Elements You Need Installing the DMC-3425ControllerStandard Servo Motor Operation Step 1. Determine Overall Motor ConfigurationStep 2. Configuring Jumpers on the DMC-3425 Master Reset and Upgrade JumperSD MC Setting the Baud Rate on the DMC-3425Selecting MO as default on the DMC-3425 Stepper Motor JumpersA1 A2 A4 A8 Axis Configuration JumpersUsing Windows 3.x 16 bit versions Step 4. Installing the Communications SoftwareUsing Galil Software for DOS Using DOSUsing Galil Software for Windows DMC-3425 14 • Chapter 2 Getting StartedUsing Galil Software for Windows Using Non-GalilCommunication SoftwareSending Test Commands to the Terminal Communicating through the EthernetDMC-3425 ADDRESS16 • Chapter 2 Getting Started Sending Test Commands to the Terminal Step 7. Make connections to amplifier and encoderStep C. Connect the encoders Step 8a. Connect Standard Servo Motor Check the Polarity of the Feedback Loop Inverting the Loop Polarity DMC-3425 Power SupplyMotor 22 • Chapter 2 Getting StartedStep A. Disable the motor amplifier If Hall Sensors are Available If Hall Sensors are Available If Hall Sensors are Not AvailableIf Hall Sensors are Not Available Step 8c. Connect Step Motors Step 9. Tune the Servo System Configuring Operation for Distributed Control Step 10. Configure the Distributed Control SystemManual Slave IP configuration with HC command Interpretation Automatic Configuration ExampleManual Configuration of Distributed Control InstructionManual Configuration Example Example 3 - Position Interrogation Design ExamplesExample 1 - System Set-up Example 2 - Profiled MoveExample 8 - Operation in the Buffer Mode Example 5 - Velocity Control JoggingExample 6 - Operation Under Torque Limit Example 7 - InterrogationExample 11- Motion Programs with Trippoints Example 9 - Motion ProgramsExample 10 - Motion Programs with Loops Example 13 - Control Variables and Offset Example 12 - Control VariablesDMC-3425 36 • Chapter 2 Getting StartedOverview Chapter 3 Connecting HardwareUsing Inputs Limit Switch InputDMC-3425 Home Switch InputAbort Input 38 • Chapter 3 Connecting HardwareUncommitted Digital Inputs Amplifier InterfaceAMPEN TTL InputsAnalog Inputs DMC-3425TTL Outputs DMC-3425 THIS PAGE LEFT BLANK INTENTIONALLY42 • Chapter 3 Connecting Hardware RS232 - Port 1 DATATERM RS-232ConfigurationChapter 4 Communication RS232 PortHandshaking Modes Ethernet ConfigurationCommunication Protocols AddressingGlobal vs. Local Operation Ethernet HandlesDMC-3425 LOCAL OPERATIONGLOBAL OPERATION 46 • Chapter 4 CommunicationOperation of Distributed Control Accessing the I/O of the SlavesDigital Inputs Handling Communication ErrorsMulticasting Digital OutputsIOC-7007Support Unsolicited Message HandlingDefinition Modbus SupportFunction Code User Defined Ethernet Variables Handle SwitchingHandle Restore on Communication Failure Other Communication OptionsWaiting on Handle Responses Data RecordData Record Map Chapter 4 Communication• general output bank 2 DB-14064DMC-3425 DMC-3425 54 Chapter 4 CommunicationGeneral Status Information 1 Byte Axis Switch Information 1 ByteHeader Information - Byte 0, 1 of Header Bytes 2, 3 of HeaderAxis Status Information 2 Byte QZ CommandNotes Regarding Velocity and Torque Information Using Third Party Software DMC-3425 THIS PAGE LEFT BLANK INTENTIONALLY58 • Chapter 4 Communication Introduction Chapter 5 Command BasicsCommand Syntax - ASCII Coordinated Motion with more than 1 axis Command Syntax - BinaryByte Binary Command FormatByte Header FormatExample Binary command tableDatafields Format Controller Response to DATA Interrogating the Controller Interrogation CommandsSummary of Interrogation Commands Interrogating Current Commanded ValuesCommand Summary DMC-3425 66 • Chapter 5 Command BasicsTHIS PAGE LEFT BLANK INTENTIONALLY DMC-3425 Chapter 6 Programming MotionOverview Global vs. Local OperationGlobal CommandsMode of Motion Basic descriptionIndependent Axis Positioning Absolute Position Movement Command Summary - Independent AxisOperand Summary - Independent Axis Examples15000 VELOCITYCOUNTS/SEC 20000Operand Summary - Independent Axis Command Summary - JoggingIndependent Jogging Jog in A and C axesJoystick Jogging Linear Interpolation Mode Local ModeSpecifying Linear Segments Specifying Vector Speed for Each Segment Additional CommandsChanging Feedrate Command Summary - Linear InterpolationOperand Summary - Linear Interpolation VS = VA 2 + VB ExampleExample - Linear Move Linear Interpolation MotionInterpretation Example - Multiple MovesFigure 6.2 - Linear Interpolation InstructionDMC-3425 Specifying Vector Segments78 • Chapter 6 Programming Motion Changing Feedrate Additional commandsSpecifying Vector Speed for Each Segment Trippoints Command Summary - Coordinated Motion SequenceOperand Summary - Coordinated Motion Sequence Example C -4000,3000D 0,3000 R =B -4000,0 A 0,0Example - Gantry Mode Command Summary - Electronic GearingElectronic Gearing Local Mode Example - Electronic GearingEAp where p = A,B p is the selected master axis Electronic Cam Local ModeEM a,b ET0=,0 ET1=,3000 ET2=,2250 ET3=,1500 6000 3000 2250 15002000 4000This is done with the program DMC-3425 88 • Chapter 6 Programming MotionSpecifying Contour Segments Contour Mode Local ModeCOUNTS InstructionDescription POSITIONGenerating an Array - An Example Command Summary - Contour ModeOperand Summary - Contour Mode General Velocity ProfilesContour Mode Example Chapter 6 Programming Motion• Teach Record and Play-BackRecord and Playback Example DMC-3425Virtual Axis usage Virtual Axis Local ModeCommands Mode of MotionSpecifying Stepper Motor Operation Stepper Motor OperationEcam Master Example Sinusoidal Motion ExampleDMC-3425 Monitoring Generated Pulses vs. Commanded PulsesStepper Motor Smoothing 96 • Chapter 6 Programming MotionOperand Summary - Stepper Motor Operation Using an Encoder with Stepper MotorsCommand Summary - Stepper Motor Operation Motion Complete TrippointBacklash Compensation Using the CE CommandAdditional Commands for the Auxiliary Encoder Dual Loop Auxiliary EncoderExample Continuous Dual LoopSampled Dual Loop Example Using the IT and VT CommandsMotion Smoothing SMOOTHING TIME VELOCITY WITH SMOOTHING TIME HomingACCELERATION TIME VELOCITY TIME ACCELERATION WITH DMC-3425 Example102 Chapter 6 Programming Motion Chapter 6 Programming Motion• HOME SWITCHDMC-3425 Operand Summary - Homing Operation Command Summary - Homing OperationHigh Speed Position Capture Latch Chapter 6 Programming Motion• Example#Latch DMC-3425DMC-3425 THIS PAGE LEFT BLANK INTENTIONALLY106 • Chapter 6 Programming Motion Overview Chapter 7 Application ProgrammingGlobal vs. Local Programming Entering Programs Edit Mode CommandsInvalid labels Using Labels in ProgramsProgram Format Valid labelsCommenting Programs NO Command and the Apostrophe ‘Special Labels Executing Programs - Multitasking REM CommandDebugging Programs RAM Memory Interrogation Commands Trace CommandError Code Command Stop Code CommandOperands Breakpoints and single steppingEEPROM Memory Interrogation Operands Error ConditionEvent Triggers & Trippoints Program Flow CommandsDMC-3425 DMC-3425Event TriggersExample- Multiple Move Sequence 116 • Chapter 7 Application ProgrammingExample - Start Motion on Input Example- Set Output after DistanceExample- Repetitive Position Trigger 118 • Chapter 7 Application Programming Example - Set Output when At SpeedExample - Change Speed along Vector Path Example - Multiple Move with WaitConditional Jumps Example- Define Output Waveform Using ATCommand Format - JP and JS Multiple Conditional Statements Example using variables named V1, V2, V3 andLogical operators Conditional StatementsExamples Using the IF and ENDIF CommandsIf, Else, and Endif 122 • Chapter 7 Application Programming Using the ELSE CommandCommand Format - IF, ELSE and ENDIF Nesting IF Conditional StatementsStack Manipulation Auto-Startand Auto Error RoutineSubroutines Automatic Subroutines for Monitoring Conditions Example - Limit SwitchExample - Position Error Example - Input Interrupt Example - Motion Complete TimeoutExample - Command Error Instruction Example - Command Error w/MultitaskingOPERAND FUNCTIONMathematical Operators Example – Ethernet Communication ErrorMathematical and Functional Expressions DMC-3425 Bit-WiseOperators128 • Chapter 7 Application Programming Functions VariablesDisplaying the value of variables at the terminal Programmable VariablesAssigning Values to Variables Special Operands Example - Using Variables for JoystickOperands Examples ArraysDefining Arrays Assignment of Array EntriesAutomatic Data Capture into Arrays Using a Variable to Address Array ElementsExample - Recording into An Array Command Summary - Automatic Data CaptureData Types for Recording Operand Summary - Automatic Data CaptureSpecifying the Port for Messages Outputting Numbers and StringsDeallocating Array Space Sending MessagesExample Using the MG Command to Configure TerminalsFormatting Messages Interrogation Commands Displaying Variables and ArraysSummary of Message Functions Example Local Formatting of Variables Formatting Variables and Array ElementsExample- Set Bit and Clear Bit Hardware I/OConverting to User Units Digital OutputsExample- Output Port Example - Using Inputs to control program flowExample - Start Motion on Switch Digital InputsExample - Input Interrupt Input Interrupt FunctionAnalog Inputs Example - Position Follower Point-to-PointExample - Position Follower Continuous Move Configuring the I/O of the DMC-3425Extended I/O of the DMC-3425Controller Binary Representation Accessing Extended I/O8-BitI/O BlockInterfacing to Grayhill or OPTO-22G4PB24 Wire CutterExample Applications DMC-3425 A-B X-YTable Controller146 Chapter 7 Application Programming 1 inch = 40,000 counts and the speeds of Speed Control by Joystick Position Control by Joystick DMC-3425 THIS PAGE LEFT BLANK INTENTIONALLY150 • Chapter 7 Application Programming Introduction Chapter 8 Hardware & Software ProtectionHardware Protection Output Protection LinesExample Software ProtectionInput Protection Lines Programmable Position LimitsExamples Off-On-ErrorAutomatic Error Routine ExampleLimit Switch Example Limit Switch RoutineOverview Chapter 9 TroubleshootingInstallation 156 • Chapter 9 Troubleshooting CommunicationStability OperationCONTROLLER Chapter 10 Theory of OperationOverview COMPUTERLEVEL Figure 10.3 - Velocity and Position Profiles Operation of Closed-LoopSystemsCONTROLLER System Modeling= RJ Motor-AmplifierVoltage Drive PV = KV Kt SSTm + 1STe +Velocity Loop VELOCITY LOOP VOLTAGE SOURCECURRENT SOURCE Z − B Digital FilterKZ − A 1 − BSystem Analysis Page The Analytical Method System Design and CompensationMs = P/I = Kt/Js2 = 1000/s2 Amp However, since As = Ls Gs Equivalent Filter Form Appendices Electrical SpecificationsPerformance Specifications Power RequirementsJ3 DMC-3425General I/O; 37- PIN D-type Connectors for DMC-3425J3 DMC-3425-StepperGeneral I/O; 37- PIN D-type J5 POWER; 6 PIN MOLEXJ1 RS232 Main port: DB-9Pin Male Pin-OutDescriptionSpecifications ICM-1460Interconnect ModuleFeatures DMC-3425 176 • AppendicesOpto-isolatedinputs Opto-IsolationOption for ICM-1460CONNECTIONS Opto-isolatedoutputsICM-1460 TO CONTROLLER64 Extended I/O of the DMC-3425Controller Configuring the I/O of the DMC-3425with DB-14064Accessing extended I/O Block Connector DescriptionSignal J6 50-PINIDCBit No J8 50-PINIDCBlock Bit @INnDescription DMC-3425 Overview184 • Appendices Digital Inputs Configuring Hardware BanksSinking Input CircuitSinking SourcingFigure A-7 High Power Digital OutputsFigure A-6 Result Standard Digital OutputsOutput Command Digital Inputs Electrical SpecificationsHigh Power Digital Outputs Standard Digital OutputsScrew Terminal Listing Relevant DMC CommandsAppendices• I/O65DMC-3425 DMC-3425 192 • Appendices2000 Coordinated Motion - Mathematical Analysis1000 2000Lk = Rk ΔΘk 2π Velocitytime s Lk = Xk 2 + YkTs = VSD − Ta = 10000035708 - 0.05 = 0.307s 100000= 0.05s 2000000ADVANCED MOTION CONTROL List of Other PublicationsTraining Seminars MOTION CONTROL MADE EASYAppendices Contacting UsGalil Motion Control DMC-3425WARRANTY Index Differential Encoder, 19, 21, Jumper, SDK, 27,