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RoboteQ AX2550 user manual AX1500 Motor Controller Overview, Advanced Safety Features

Models: AX2550 AX1500

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Advanced Safety Features

AX1500 Motor Controller Overview

•20A extended

•High current operation may be extended with forced cooling

•125A peak Amps per channel

•16kHz Pulse Width Modulation (PWM) output

•Auxiliary output for brake, clutch or armature excitation

•Heat sink on PCB

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)

•Diagnostic LED

•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.

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

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

•4.0oz(120g)

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AX1500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

Image 26

RoboteQ AX2550 user manual AX1500 Motor Controller Overview, Advanced Safety Features, Data Logging Capabilities

Contents

User’s Manual Dual Channel Digital Motor ControllerAX1500 AX1500 Motor Controller User’s Manual Version 1.9b. June 1Date Revision HistoryRevision History VersionAX1500 Motor Controller User’s Manual Version 1.9b. June 1Revision History General Operation Recommended Encoder Types SECTION Connector I/O Pin Assignment RS232 Mode Controller Identification Register Logging Data to Disk AX1500 Motor Controller User’s Manual Version 1.9b. June 1Do not Connect to a RC Radio with a Battery Attached Important SafetyAvoid Shorts when Mounting Board against Chassis WarningsVersion 1.9b. June 1 Important Safety WarningsAX1500 Motor Controller User’s Manual Quick Start Locating the ConnectorsAX1500 What you will needAX1500 Quick Start AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Connecting to the Batteries and MotorsConnecting to the Batteries and Motors Signal Connecting to the 15-pin ConnectorImportant Warning RC ModeImportant Warning Connecting the R/C RadioConnecting the R/C Radio AX1500 Motor Controller User’s ManualDefault Values Powering On the ControllerDefault Controller Configuration AX1500 Quick StartAX1500 Motor Controller User’s Manual Connecting the controller to your PC using RoborunConnecting the controller to your PC using Roborun AX1500 Quick Start Obtaining the Controller’s Software Revision NumberExploring further AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual SECTION 3AX1500 Motor Controller OverviewProduct Description Automatic Joystick Command Corrections Technical featuresMultiple Command Modes AX1500 Motor Controller OverviewHigh Efficiency Motor Power Outputs Technical featuresLow Power Consumption Optical Encoder Inputs optionalData Logging Capabilities Advanced Safety FeaturesAX1500 Motor Controller Overview Compact Open Frame PCB DesignPower Connections Connecting Power and Motors to the ControllerPower Connections Important WarningAX1500 Motor Controller User’s Manual Controller PowerConnecting Power and Motors to the Controller And Main Battery Controller PowerPower Control input is mended Off ConfigurationConnecting Power and Motors to the Controller Controller Powering SchemesPowering the Controller from a single Battery Power Control input isImportant Warning Powering the Controller Using a Main and Backup BatteryController Powering Schemes AX1500 Motor Controller User’s ManualImportant Warning Connecting the MotorsConnecting Power and Motors to the Controller Important WarningSingle Channel Operation Single Channel OperationConverting the AX1500 to Single Channel AX1500 Motor Controller User’s ManualConnecting Power and Motors to the Controller Power FusesWire Length Limits Important WarningImportant Warning Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Electrical Noise Reduction TechniquesUndervoltage Protection Using the Controller with a Power SupplyOvervoltage Protection Connecting Power and Motors to the ControllerUsing the Controller with a Power Supply AX1500 Motor Controller User’s ManualVersion 1.9b. June 1 Connecting Power and Motors to the ControllerAX1500 Motor Controller User’s Manual Basic Operation Input Command ModesGeneral Operation Basic OperationOpen Loop, Mixed Speed Control Selecting the Motor Control ModesOpen Loop, Separate Speed Control General OperationSelecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control AX1500 Motor Controller User’s ManualTemperature User Selected Current Limit SettingsTemperature-Based Current Limitation Position Feedback Position Sensor Gear boxMotor Current = Battery Current / PWM ratio Battery Current vs. Motor CurrentBattery Current vs. Motor Current AX1500 Motor Controller User’s ManualImportant Warning Regeneration Current LimitingMotor Current = Battery Current / PWM Ratio General OperationSetting Using Programmable AccelerationSetting Using SwitchesSetting Using Command Control CurvesSetting Using SwitchesExponentiation Parameter Value Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Selected CurveGeneral Operation Speed AdjustmentSpeed Adjustment Parameter ValueInverted Operation Emergency Stop using External SwitchActivating Brake Release or Separate Motor Excitation Speed AdjustmentUsing the Inputs to turn Off/On the Power MOSFET transistors Special Use of Accessory Digital InputsUsing the Inputs to Activate the Buffered Output General OperationAX1500 Connections Connecting Sensors and Actuators to Input/OutputsAX1500 Connections AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual AX1500’s Inputs and OutputsConnecting Sensors and Actuators to Input/Outputs I/O type SignalAX1500’s Inputs and Outputs ActivatedConnecting Sensors and Actuators to Input/Outputs Pin1I/O List and Pin Assignment Signal dependingSignal depending Connecting devices to Output CConnecting devices to Output C on ModeImportant warning Connecting Switches or Devices to Input EConnecting Switches or Devices to Input F Connecting Sensors and Actuators to Input/OutputsAX1500 Motor Controller User’s Manual Connecting Switches or Devices to EStop/Invert InputConnecting Switches or Devices to EStop/Invert Input Connecting Sensors and Actuators to Input/Outputs Connecting Position Potentiometers to Analog InputsAnalog Inputs AX1500 Motor Controller User’s ManualOperating Mode Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Important WarningImportant Warning Connecting Sensors and Actuators to Input/OutputsOperating Mode Ana 1 p11Temp oC Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Resistance kOhmAX1500 Motor Controller User’s Manual Using the Analog Inputs to Monitor External VoltagesConnecting Sensors and Actuators to Input/Outputs Internal Voltage Monitoring Sensors Connecting User Devices to Analog InputsInternal Heatsink Temperature Sensors Connecting User Devices to Analog InputsAX1500 Motor Controller User’s Manual Temperature Conversion C Source CodeConnecting Sensors and Actuators to Input/Outputs Valueelse Internal Heatsink Temperature SensorsAX1500 Motor Controller User’s Manual LoTemp = i * 5Version 1.9b. June 1 Connecting Sensors and Actuators to Input/OutputsAX1500 Motor Controller User’s Manual Optical Incremental Encoders Overview Installing Connecting and Using the Encoder ModuleOptical Incremental Encoders Overview AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Recommended Encoder TypesInstalling, Connecting and Using the Encoder Mod Pulse Frequency in Hz = RPM / 60 * PPR Installing the Encoder ModuleInstalling the Encoder Module AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Connecting the EncoderInstalling, Connecting and Using the Encoder Mod Name Cable Length and Noise ConsiderationsCable Length and Noise Considerations Cable ColorInstalling, Connecting and Using the Encoder Mod Voltage Levels, Thresholds and Limit SwitchesMotor - Encoder Polarity Matching Important WarningImportant Warning Wiring Optional Limit SwitchesWiring Optional Limit Switches AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Installing, Connecting and Using the Encoder ModWhen the switch is activated, the module’s input is pulled to Wiring Limit Switches Without Encoders Wiring Limit Switches Without EncodersEffect of Limit Switches Motor 1 FwdInstalling, Connecting and Using the Encoder Mod Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Motor 2 FwdUsing the Encoder to Track Position Using the Encoder to Track PositionImportant Notice AX1500 Motor Controller User’s ManualImportant Notice RS232 Communication with the Encoder ModuleInstalling, Connecting and Using the Encoder Mod Distance = Destination - Counter value / DividerAX1500 Motor Controller User’s Manual Encoder Testing and Setting Using the PC UtilityEncoder Testing and Setting Using the PC Utility Version 1.9b. June 1 Installing, Connecting and Using the Encoder ModAX1500 Motor Controller User’s Manual Selecting the Position Mode Closed Loop Position ModeMode Description Mode DescriptionClosed Loop Position Mode Position Sensor SelectionSensor Mounting Position Feedback Position Sensor Gear boxFeedback Potentiometer wiring Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode Important NoticeImportant Notice Feedback Potentiometer wiring in Analog ModeClosed Loop Position Mode AX1500 Motor Controller User’s ManualAnalog Feedback on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersFeedback Wiring in Analog Mode on Single Channel Controllers Important NoticeClosed Loop Position Mode Using Optical Encoders in Position ModeSensor and Motor Polarity Important WarningAdding Safety Limit Switches Important Safety WarningEncoder Error Detection and Protection Encoder Error Detection and ProtectionAX1500 Motor Controller User’s Manual Closed Loop Position ModeFIGURE 53. Safety limit switches interrupting power to motors Using Current Limiting as Protection Using Current Limiting as ProtectionControl Loop Description Important WarningAX1500 Motor Controller User’s Manual PID tuning in Position ModeClosed Loop Position Mode AX1500 Motor Controller User’s Manual PID tuning in Position ModeApplied Power = Command Value - Actual Position * Proportional Gain Version 1.9b. June 1 Closed Loop Position ModeAX1500 Motor Controller User’s Manual Using Optical Encoder for Speed FeedbackDigital Optical Encod Closed Loop Speed ModeSelecting the Speed Mode Mode DescriptionClosed Loop Speed Mode Tachometer wiringTachometer or Encoder Mounting AX1500 Motor Controller User’s ManualSpeed Sensor and Motor Polarity Speed Sensor and Motor PolarityImportant Warning AX1500 Motor Controller User’s ManualImportant Warning Adjust Offset and Max SpeedClosed Loop Speed Mode Control Loop DescriptionAX1500 Motor Controller User’s Manual PID tuning in Speed ModePID tuning in Speed Mode AX1500 Motor Controller User’s Manual Closed Loop 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 Diagnostic LED Normal and Fault Condition LED MessagesPower On LED Normal Operation Flashing PatternAX1500 Motor Controller User’s Manual Output Off / Fault ConditionNormal and Fault Condition LED Messages Mode Description SECTION 11 R/C OperationMode Description AX1500 Motor Controller User’s ManualSignal Selecting the R/C Input ModeConnector I/O Pin Assignment R/C Mode Pin1Signal R/C Input Circuit DescriptionSupplied Cable Description R/C Input Circuit DescriptionR/C Operation Powering the Radio from the controllerFIGURE 64. RC Cable wiring diagram FIGURE 65. RC connection cable6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command Pulses Powering the Radio from the controller3 Channel 1 Command Pulses 4 Channel 2 Command Pulses Wire loop bringing power from controller to RC radioR/C Operation Connecting to a Separately Powered RadioOperating the Controller in R/C mode AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Reception WatchdogReception Watchdog Joystick Deadband Programming Important Notice about PCM RadiosR/C Transmitter/Receiver Quality Considerations R/C OperationDeadband Parameter Value Command Control CurvesCommand Control Curves Deadband as Percent of full Joystick TravelJoystick Calibration Left/Right Tuning AdjustmentActivating the Accessory Outputs R/C OperationAX1500 Motor Controller User’s Manual Data Logging in R/C ModeData Logging in R/C Mode DB15 Male R/C OperationAX1500 Motor Controller User’s Manual To ControllerMode Description Analog Control and OperationMode Description Important NoticePin1 Connector I/O Pin Assignment Analog ModeSignal Analog Control and OperationConnecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer AX1500 Motor Controller User’s ManualSelecting the Potentiometer Value Important NoticeAnalog Deadband Adjustment Data Logging in Analog Mode Power-On SafetyUnder Voltage Safety Motor Power at 0%Data Logging in Analog Mode AX1500 Motor Controller User’s ManualVersion 1.9b. June 1 Analog Control and OperationAX1500 Motor Controller User’s Manual Use and benefits of RS232 Serial RS-232 Controls and OperationUse and benefits of RS232 AX1500 Motor Controller User’s ManualPin1 Connector I/O Pin Assignment RS232 ModeSignal Serial RS-232 Controls and OperationCable configuration Cable configurationExtending the RS232 Cable AX1500 Motor Controller User’s ManualEstablishing Manual Communication with a PC Communication Settings9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Serial RS-232 Controls and OperationRoboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC AX1500 Motor Controller User’s ManualSerial RS-232 Controls and Operation Entering RS232 from R/C or Analog modeData Logging String in R/C or Analog mode AX1500 Motor Controller User’s ManualCommand Acknowledgement Commands Acknowledge and Error MessagesRS232 Mode if default Command ErrorCommand Controller Commands and QueriesRS-232 Watchdog Serial RS-232 Controls and OperationController Commands and Queries Set Motor Command ValueSet Accessory Output CommandImportant Notice Query Power Applied to MotorsQuery Amps from Battery to each Motor Channel Important NoticeQuery Analog Inputs Query Heatsink TemperaturesQuery Battery Voltages Controller Commands and QueriesSerial RS-232 Controls and Operation Reset ControllerQuery Digital Inputs SyntaxAccessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameterLocation Flash Configuration Parameters ListSerial RS-232 Controls and Operation DescriptionAccessing & Changing Configuration Parameter in Flash Input Control ModeMotor Control Mode AccessAfter Reset or FF Amps LimitAccess Serial RS-232 Controls and OperationAccessing & Changing Configuration Parameter in Flash Input Switches FunctionAcceleration AccessAccess RC Joystick or Analog DeadbandExponentiation on Channel 1 and Channel After Reset or FFAccessing & Changing Configuration Parameter in Flash Left/Right AdjustDefault Encoder Time Base 1 and AccessJoystick Min, Max and Center Values Default Encoder Distance DividerDefault PID Gains Access1C - Joystick Max 2 MS 1D - Joystick Max 2 LS Effective Instantly Reading & Changing Operating Parameters at RuntimeReading & Changing Operating Parameters at Runtime DefinitionAccess Operating Modes RegistersRead/Change PID Values Important Notice87 - D2 Access Read/Write Effective Instantly PWM Frequency RegisterController Status Register Address Access Read/Write Effective InstantlyFault Condition Controller Identification RegisterCurrent Amps Limit Registers AccessRead Encoder Counter RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetSyntax Read Speedq or !Q n AX1500 Motor Controller User’s ManualRead Speed/Distance Read Encoder Limit Switch StatusRead Distance RS232 Encoder Command SetSwitch Important NoteRead / Modify Encoder Module Registers and Parameters SwitchModify parameter RS232 Encoder Command SetAccess AddressEncoder Hardware ID code Switch StatusRegister Description Speed or Distance 1 orDestination Register 1 and Counter Read/Write MailboxCounter 1 and Register DescriptionTime Base 1 and Distance 1 andSpeed 1 and Encoder ThresholdCounter Read Data Format Counter Read Data FormatEncoder Testing and Setting Using the PC Utility DecimalAX1500 Motor Controller User’s Manual Version 1.9b. June 1AX1500 Motor Controller User’s Manual Automatic Switching from RS232 to RC ModeAutomatic Switching from RS232 to RC Mode Data Logging Cables 00 11 22 33 44 55 66 77 88 99 AA BB CCAnalog and R/C Modes Data Logging String Format AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion TableDecimal to Hexadecimal Conversion Table AX1500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Version 1.9b. June 1System Requirements SECTION 14 Using the Roborun Configuration UtilityDownloading and Installing the Utility AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Connecting the Controller to the PCUsing the Roborun Configuration Utility Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions3- Parameter Selection and Setting and Special Functions 1- Program Revision NumberUsing the Roborun Configuration Utility Getting On-Screen HelpLoading, Changing Controller Parameters 4- File and Program Management Commands3- Input Command Adjustment Control Settings2- Motor Control Mode Loading, Changing Controller Parameters4- Emergency Stop or Invert Switch Select Power SettingsUsing the Roborun Configuration Utility 2- Left/Right Adjust1- Deadband Analog or R/C Specific SettingsLoading, Changing Controller Parameters 2- Joystick TimingUsing the Roborun Configuration Utility Encoder Setting and TestingClosed Loop Parameters AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Encoder Module Parameters SettingEncoder Setting and Testing Viewing Encoder Data Running the MotorsExercising the Motors Using the Roborun Configuration Utility1- Run/Stop Button 2- Motor Power settingRunning the Motors 3- Measurement6- Input Status and Output Setting Using the Roborun Configuration Utility4- Real-Time Strip Chart Recorder 5- Transmit and Receive Data8- Joystick Enable Logging Data to DiskRunning the Motors 7- Data Logging and Timer 4- Reset Timer buttonUsing the Roborun Configuration Utility Using the ConsoleConnecting a Joystick Parameter Header1- Terminal Screen Using the Console2- Command Entry 3- Keep Watchdog AliveLoading and Saving Profiles to Disk Operating the AX1500 over a Wired or Wireless LANViewing and Logging Data in Analog and R/C Modes Using the Roborun Configuration Utility 4- Send Reset StringOperating the AX1500 over a Wired or Wireless LAN AX1500 Motor Controller User’s ManualUsing the Roborun Configuration Utility Updating the Controller’s SoftwareUpdating the Encoder Software Important WarningAX1500 Motor Controller User’s Manual Creating Customized Object FilesCreating Customized Object Files Version 1.9b. June 1 Using the Roborun Configuration UtilityAX1500 Motor Controller User’s Manual Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions AX1500 Motor Controller User’s ManualMechanical Specifications Mounting ConsiderationsThermal Considerations AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Attaching the Controller Directly to a ChassisAttaching the Controller Directly to a Chassis AX1500 Motor Controller User’s Manual Precautions to observeMechanical Specifications Wire Dimensions Wire DimensionsWeight AX1500 Motor Controller User’s ManualVersion 1.9b. June 1 Mechanical SpecificationsAX1500 Motor Controller User’s Manual