Dual Channel Digital Motor Controller | RoboteQ AX1500 instruction

AX1500

Dual Channel

Digital Motor

Controller

User’s Manual

v1.9b, June 1, 2007

visit www.roboteq.com to download the latest revision of this manual

©Copyright 2003-2007 Roboteq, Inc.

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RoboteQ AX1500, AX2550 user manual Dual Channel Digital Motor Controller

Contents

Dual Channel Digital Motor Controller AX1500 AX1500 Motor Controller User’s Manual Revision History Revision HistoryDate Version Changes AX1500 Motor Controller User’s Manual Section Section Section 100 122 144 173 AX1500 Motor Controller User’s Manual Do not Connect to a RC Radio with a Battery Attached Important SafetyBeware of Motor Runaway in Improperly Closed Loop Important Safety Warnings AX1500 Locating the ConnectorsQuick Start What you will need AX1500 Controller Rear View AX1500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Signal Pin RC Mode RS232 Mode Analog Mode Connecting to the 15-pin Connector Connecting the R/C Radio Connecting the R/C Radio Default Controller Configuration Powering On the ControllerParameter Default Values Letter Connecting the controller to your PC using Roborun Connecting the controller to your PC using Roborun Exploring further Obtaining the Controller’s Software Revision Number Product Description AX1500 Motor Controller Overview Technical features Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Optical Encoder Inputs optional Data Logging Capabilities Advanced Safety FeaturesCompact Open Frame PCB Design Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller Power Mended Off Configuration Controller Power Powering the Controller from a single Battery Controller Powering Schemes Controller Powering Schemes Powering the Controller Using a Main and Backup Battery Powering the AX1500 with a Main and Backup Supply Connecting the Motors Converting the AX1500 to Single Channel Single Channel Operation Wire Length Limits Power Fuses Electrical Noise Reduction Techniques Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Overvoltage Protection Using the Controller with a Power SupplyUndervoltage Protection 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 Close Loop Position Control Closed Loop Speed ControlSelecting the Motor Control Modes Temperature-Based Current Limitation User Selected Current Limit SettingsTemperature Max Amps Battery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio Off Regeneration Current Limiting Programmable Acceleration Programmable Acceleration Command Control Curves Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Activating Brake Release or Separate Motor Excitation Emergency Stop using External SwitchInverted Operation Activating Brake Release or Separate Motor Excitation Using the Inputs to Activate the Buffered Output Special Use of Accessory Digital Inputs AX1500 Connections Connecting Sensors and Actuators to Input/OutputsAX1500 Connections AX1500’s Inputs and Outputs Connecting Sensors and Actuators to Input/Outputs AX1500’s Inputs and Outputs Signal Type Use Activated List and Pin Assignment Pin1 Connecting devices to Output C Connecting devices to Output C Connecting Switches or Devices to Input F Connecting Switches or Devices to Input E 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 InputsAna Ana2 Operating Mode Pin Operating Mode Ana 1 p11 Ana2 p10 Ana 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 Heatsink Temperature Sensors Connecting User Devices to Analog InputsInternal Voltage Monitoring Sensors Temperature Conversion C Source Code Internal Heatsink Temperature Sensors Connecting Sensors and Actuators to Input/Outputs Optical Incremental Encoders Overview Installing Connecting Using Encoder ModuleOptical Incremental Encoders Overview Recommended Encoder Types Installing, Connecting and Using the Encoder Mod Installing the Encoder Module Installing the Encoder ModulePulse Frequency in Hz = RPM / 60 * PPR Connecting the Encoder Cable Length and Noise Considerations Cable Length and Noise ConsiderationsPin Name Cable Color Motor Encoder Polarity Matching Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Wiring Optional Limit Switches SW1 SW2 GND Effect of Limit Switches Wiring Limit Switches Without EncodersWiring Limit Switches Without Encoders Motor 1 Fwd Motor 1 Rev Using the Encoder to Measure Speed Using the Encoder Module to Measure DistanceMotor Fwd Motor Rev Using the Encoder to Track Position Using the Encoder to Track Position Distance = Destination Counter value / Divider RS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC Utility Encoder Testing and Setting Using the PC Utility Installing, Connecting and Using the Encoder Mod Mode Description Closed Loop Position ModeSelecting the Position Mode Mode Description Position Sensor Selection Closed Loop Position ModeSensor Mounting Feedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringFeedback Potentiometer wiring Pot wiring for RS232 or RC Command and Analog Feedback Feedback Potentiometer wiring in Analog Mode Analog Feedback on Single Channel Controllers Analog Feedback on Single Channel Controllers Sensor and Motor Polarity Using Optical Encoders in Position Mode Adding Safety Limit Switches Encoder Error Detection and ProtectionEncoder Error Detection and Protection SW1 SW2 Using Current Limiting as Protection Using Current Limiting as ProtectionControl Loop Description PID tuning in Position Mode PID tuning in Position Mode Closed Loop Position Mode Selecting the Speed Mode Closed Loop Speed Mode Closed Loop Speed Mode Tachometer wiringTachometer 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 Closed Loop Speed Mode Power On LED Normal Fault Condition LED MessagesDiagnostic LED Power On LED Normal and Fault Condition LED Messages Output Off / Fault Condition C Operation C radio control mode Connector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin Input or Number Output Signal Description Operation Supplied Cable Description Input Circuit DescriptionInput Circuit Description RC Cable wiring diagram Powering the Radio from the controller Wiring for powering R/C radio from controller Powering the Radio from the controller Operating the Controller in R/C mode Connecting to a Separately Powered Radio Reception Watchdog Reception Watchdog Joystick Deadband Programming Transmitter/Receiver Quality Considerations Effect of deadband on joystick position vs. motor speed Command Control Curves Activating the Accessory Outputs Left/Right Tuning AdjustmentJoystick Calibration Data Logging in R/C Mode Data Logging in R/C Mode 112 Analog Control and Operation Pin Input or Number Signal Output Description Connector I/O Pin Assignment Analog ModeAnalog Control and Operation Connecting a Potentiometer Connecting to a Voltage SourceConnecting to a Voltage Source = U/R = 5V / 1000 Ohms = 0.005A = 5mA Selecting the Potentiometer Value Analog Deadband Adjustment Analog Deadband Adjustment Under Voltage Safety Power-On SafetyData Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC Data Logging in Analog Mode 120 Use and benefits of RS232 Serial RS-232 Controls 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 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 Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog mode Commands Acknowledge and Error Messages Command Type Description Controller Commands and QueriesRS-232 Watchdog Set Accessory Output Set Motor Command ValueController Commands and Queries Query Amps from Battery to each Motor Channel Query Power Applied to MotorsSyntax Query Battery Voltages Query Heatsink TemperaturesQuery Analog Inputs ?r or ?R Query Digital Inputs Reset Controller Accessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameter Location Description Active after Flash Configuration Parameters List Motor Control Mode Input Control ModeAddress Access Read/Write Effective After Reset Value Mode See pages Bit Definition See pages Amps Limit Acceleration Input Switches Function RC Joystick or Analog Deadband Address Channel Access Read/Write Effective InstantlyExponentiation on Channel 1 and Channel Default Encoder Time Base 1 Left/Right Adjust Default PID Gains Default Encoder Distance DividerJoystick Min, Max and Center Values Location Function Reading & Changing Operating Parameters at Runtime Read/Change PID Values Operating Modes RegistersBit Function Address 82 P1 83 I1 84 D1 85 P2 Controller Status Register PWM Frequency Register Current Amps Limit Registers Controller Identification RegisterBit Model or Function Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Encoder Counter Or !Q n Read Speed Read Distance Read Encoder Limit Switch StatusRead Speed/Distance Read / Modify Encoder Module Registers and Parameters Switch ValueDD= parameter value Address Parameter Description Size Access Register Description Switch StatusEncoder Hardware ID code Speed or Distance 1 or Counter 1 Counter Read/Write MailboxDestination Register 1 Register Description Speed 1 Distance 1Time Base 1 Encoder Threshold Counter Read Data Format Counter Read Data FormatDecimal Bit Hex Controller Output 154 Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode Data Logging Cables Analog and R/C Modes Data Logging String Format Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableDec Hex UDec Hex AX1500 Motor Controller User’s Manual 159 160 Downloading and Installing the Utility Using the Roborun Configuration UtilitySystem Requirements Using the Roborun Configuration Utility Connecting the Controller to the PC Roborun Frame, Tab and Menu Descriptions Parameter Selection and Setting and Special FunctionsRoborun Frame, Tab and Menu Descriptions View Controller Connector Pinout File and Program Management CommandsGetting On-Screen Help Loading, Changing Controller Parameters Motor Control Mode Control SettingsInput Command Adjustment Loading, Changing Controller Parameters Power Settings Deadband Analog or R/C Specific SettingsJoystick Timing Closed Loop Parameters Encoder Setting and Testing Encoder Setting and Testing Encoder Module Parameters Setting Exercising the Motors Running the MotorsViewing Encoder Data Running the Motors Motor Power settingRun/Stop Button Measurement Input Status and Output Setting Real-Time Strip Chart RecorderTransmit and Receive Data Logging Data to Disk Connecting a Joystick Using the Console Command Entry Using the ConsoleTerminal Screen Keep Watchdog Alive Using the Roborun Configuration Utility Send Reset String Operating the AX1500 over a Wired or Wireless LANViewing and Logging Data in Analog and R/C Modes Loading and Saving Profiles to Disk Roboserver screenshot when idle Operating the AX1500 over a Wired or Wireless LAN Updating the Encoder Software Updating the Controller’s Software Creating Customized Object Files Objectmaker creates controller firmware with custom defaults 180 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mounting Considerations Mechanical SpecificationsThermal Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Weight Wire DimensionsWire Dimensions 186