AX1500 Motor Controller User’s Manual | RoboteQ AX2550 guide

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AX1500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

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RoboteQ AX2550 user manual AX1500 Motor Controller User’s Manual

Contents

AX1500 Dual Channel Digital Motor Controller 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 Locating the Connectors AX1500Quick Start What you will need AX1500 Quick Start AX1500 Controller Rear View Connecting to the Batteries and Motors Connecting to the Batteries and Motors Connecting to the 15-pin Connector Signal Pin RC Mode RS232 Mode Analog Mode 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 Obtaining the Controller’s Software Revision Number Exploring further AX1500 Motor Controller Overview Product Description Technical features Technical features Low Power ConsumptionHigh 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 Controller Power Connecting Power and Motors to the Controller Controller Power Mended Off Configuration Controller Powering Schemes Powering the Controller from a single Battery Powering the Controller Using a Main and Backup Battery Controller Powering Schemes Connecting the Motors Powering the AX1500 with a Main and Backup Supply Single Channel Operation Converting the AX1500 to Single Channel Power Fuses Wire Length Limits 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 Input Command Modes General OperationBasic Operation Basic Operation Selecting the Motor Control Modes Open Loop, Separate Speed ControlOpen 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 Regeneration Current Limiting Off Programmable Acceleration Programmable Acceleration Command Control Curves Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Emergency Stop using External Switch Activating Brake Release or Separate Motor ExcitationInverted Operation Activating Brake Release or Separate Motor Excitation Special Use of Accessory Digital Inputs Using the Inputs to Activate the Buffered Output AX1500 Connections Connecting Sensors and Actuators to Input/OutputsAX1500 Connections Connecting Sensors and Actuators to Input/Outputs AX1500’s Inputs and Outputs Signal Type Use Activated AX1500’s Inputs and Outputs Pin1 List and Pin Assignment Connecting devices to Output C Connecting devices to Output C Connecting Switches or Devices to Input E Connecting Switches or Devices to Input F Connecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert Input Connecting Position Potentiometers to Analog Inputs 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 Installing, Connecting and Using the Encoder Mod Recommended Encoder Types 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 Voltage Levels, Thresholds and Limit Switches Motor Encoder Polarity Matching Wiring Optional Limit Switches Wiring Optional Limit Switches SW1 SW2 GND Wiring Limit Switches Without Encoders Effect of Limit SwitchesWiring 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 RS232 Communication with the Encoder Module Distance = Destination Counter value / Divider Encoder Testing and Setting Using the PC Utility Encoder Testing and Setting Using the PC Utility Installing, Connecting and Using the Encoder Mod Closed Loop Position Mode Mode DescriptionSelecting 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 Feedback Potentiometer wiring in Analog Mode Pot wiring for RS232 or RC Command and Analog Feedback Analog Feedback on Single Channel Controllers Analog Feedback on Single Channel Controllers Using Optical Encoders in Position Mode Sensor and Motor Polarity 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 Closed Loop Speed Mode Selecting the 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 Normal Fault Condition LED Messages Power On LEDDiagnostic LED Power On LED Output Off / Fault Condition Normal and Fault Condition LED Messages C radio control mode C Operation Selecting the R/C Input Mode Connector I/O Pin Assignment R/C ModePin Input or Number Output Signal Description Operation Supplied Cable Description Input Circuit DescriptionInput Circuit Description Powering the Radio from the controller RC Cable wiring diagram Powering the Radio from the controller Wiring for powering R/C radio from controller Connecting to a Separately Powered Radio Operating the Controller in R/C mode Reception Watchdog Reception Watchdog Transmitter/Receiver Quality Considerations Joystick Deadband Programming Command Control Curves Effect of deadband on joystick position vs. motor speed 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 Selecting the Potentiometer Value = U/R = 5V / 1000 Ohms = 0.005A = 5mA Analog Deadband Adjustment Analog Deadband Adjustment Under Voltage Safety Power-On SafetyData Logging in Analog Mode Data Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC 120 Use and benefits of RS232 Serial RS-232 Controls OperationUse and benefits of RS232 Connector I/O Pin Assignment RS232 Mode Serial RS-232 Controls and Operation 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 Entering RS232 from R/C or Analog mode Data Logging String in 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 Heatsink Temperatures Query Battery VoltagesQuery Analog Inputs ?r or ?R Reset Controller Query Digital Inputs Accessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameter Flash Configuration Parameters List Location Description Active after Input Control Mode Motor Control ModeAddress Access Read/Write Effective After Reset Value Mode See pages Amps Limit Bit Definition See pages Input Switches Function Acceleration RC Joystick or Analog Deadband Address Channel Access Read/Write Effective InstantlyExponentiation on Channel 1 and Channel Left/Right Adjust Default Encoder Time Base 1 Default PID Gains Default Encoder Distance DividerJoystick Min, Max and Center Values Reading & Changing Operating Parameters at Runtime Location Function Operating Modes Registers Read/Change PID ValuesBit Function Address 82 P1 83 I1 84 D1 85 P2 PWM Frequency Register Controller Status Register Current Amps Limit Registers Controller Identification RegisterBit Model or Function Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Encoder Counter Read Speed Or !Q n 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 Switch Status Register DescriptionEncoder Hardware ID code Speed or Distance 1 or Counter Read/Write Mailbox Counter 1Destination Register 1 Register Description Distance 1 Speed 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 Analog and R/C Modes Data Logging String Format Data Logging Cables 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 Connecting the Controller to the PC Using the Roborun Configuration Utility Roborun Frame, Tab and Menu Descriptions Parameter Selection and Setting and Special FunctionsRoborun Frame, Tab and Menu Descriptions File and Program Management Commands View Controller Connector PinoutGetting On-Screen Help Loading, Changing Controller Parameters Control Settings Motor Control ModeInput Command Adjustment Loading, Changing Controller Parameters Power Settings Deadband Analog or R/C Specific SettingsJoystick Timing Encoder Setting and Testing Closed Loop Parameters Encoder Module Parameters Setting Encoder Setting and Testing Exercising the Motors Running the MotorsViewing Encoder Data Motor Power setting Running the MotorsRun/Stop Button Measurement Input Status and Output Setting Real-Time Strip Chart RecorderTransmit and Receive Data Logging Data to Disk Using the Console Connecting a Joystick Using the Console Command EntryTerminal Screen Keep Watchdog Alive Operating the AX1500 over a Wired or Wireless LAN Using the Roborun Configuration Utility Send Reset StringViewing and Logging Data in Analog and R/C Modes Loading and Saving Profiles to Disk Operating the AX1500 over a Wired or Wireless LAN Roboserver screenshot when idle Updating the Controller’s Software Updating the Encoder Software Objectmaker creates controller firmware with custom defaults Creating Customized Object Files 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