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RoboteQ AX2550, AX1500 Regeneration Current Limiting, Important Warning, General Operation

Models: AX2550 AX1500

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Motor Current = Battery Current / PWM Ratio

General Operation

Vbat

On

Motor

Off

FIGURE 17. Current flow during operation

On	Off
	I mot
	Avg
	I bat
	Avg

FIGURE 18. Instant and average current waveforms

The relation between Battery Current and Motor current is given in the formula below:

Motor Current = Battery Current / PWM Ratio

Example: If the controller reports 10A of battery current while at 10% PWM, the current in the motor is 10 / 0.1 = 100A.

Important Warning

Do not connect a motor that is rated at a higher current than the controller. While the battery current will never exceed the preset Amps limit, that limit may be reached at a PWM cycle lower than 100% resulting in a higher and potentially unsafe level through the motor and the controller.

Regeneration Current Limiting

The AX1500’s current sensor is capable of measuring current in the reverse flow (regener- ation). Using this capability, the controller will automatically relax the braking effect of the power output stage to keep the regeneration current within safe values. Because of the controller’s high current handling capabilities, this protection mechanism activates only when abrupt deceleration are applied to high-inertia, ultra-low impedance motors.

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AX1500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

Image 44

RoboteQ AX2550 Regeneration Current Limiting, Important Warning, General Operation, AX1500 Motor Controller User’s Manual

Contents

User’s Manual Dual Channel Digital Motor ControllerAX1500 AX1500 Motor Controller User’s Manual Version 1.9b. June 1Revision History Revision HistoryDate 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 1Important Safety Avoid Shorts when Mounting Board against ChassisDo not Connect to a RC Radio with a Battery Attached WarningsVersion 1.9b. June 1 Important Safety WarningsAX1500 Motor Controller User’s Manual Locating the Connectors AX1500Quick Start 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 Connecting to the 15-pin Connector Important WarningSignal RC ModeConnecting the R/C Radio Connecting the R/C RadioImportant Warning AX1500 Motor Controller User’s ManualPowering On the Controller Default Controller ConfigurationDefault Values AX1500 Quick StartAX1500 Motor Controller User’s Manual Connecting the controller to your PC using RoborunConnecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Exploring furtherAX1500 Quick Start AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual SECTION 3AX1500 Motor Controller OverviewProduct Description Technical features Multiple Command ModesAutomatic Joystick Command Corrections AX1500 Motor Controller OverviewTechnical features Low Power ConsumptionHigh Efficiency Motor Power Outputs Optical Encoder Inputs optionalAdvanced Safety Features AX1500 Motor Controller OverviewData Logging Capabilities Compact Open Frame PCB DesignConnecting Power and Motors to the Controller Power ConnectionsPower Connections Important WarningAX1500 Motor Controller User’s Manual Controller PowerConnecting Power and Motors to the Controller Controller Power Power Control input isAnd Main Battery mended Off ConfigurationController Powering Schemes Powering the Controller from a single BatteryConnecting Power and Motors to the Controller Power Control input isPowering the Controller Using a Main and Backup Battery Controller Powering SchemesImportant Warning AX1500 Motor Controller User’s ManualConnecting the Motors Connecting Power and Motors to the ControllerImportant Warning Important WarningSingle Channel Operation Converting the AX1500 to Single ChannelSingle Channel Operation AX1500 Motor Controller User’s ManualPower Fuses Wire Length LimitsConnecting Power and Motors to the Controller Important WarningPower Regeneration Considerations Electrical Noise Reduction TechniquesImportant Warning Electrical Noise Reduction TechniquesUsing the Controller with a Power Supply Overvoltage ProtectionUndervoltage 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 Input Command Modes General OperationBasic Operation Basic OperationSelecting the Motor Control Modes Open Loop, Separate Speed ControlOpen Loop, Mixed Speed Control General OperationClosed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes AX1500 Motor Controller User’s ManualUser Selected Current Limit Settings Temperature-Based Current LimitationTemperature Position Feedback Position Sensor Gear boxBattery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio AX1500 Motor Controller User’s ManualRegeneration Current Limiting Motor Current = Battery Current / PWM RatioImportant Warning General OperationProgrammable Acceleration Setting UsingSetting Using SwitchesCommand Control Curves Setting UsingSetting Using SwitchesLeft / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected CurveSpeed Adjustment Speed AdjustmentGeneral Operation Parameter ValueEmergency Stop using External Switch Activating Brake Release or Separate Motor ExcitationInverted Operation Speed AdjustmentSpecial Use of Accessory Digital Inputs Using the Inputs to Activate the Buffered OutputUsing the Inputs to turn Off/On the Power MOSFET transistors General OperationConnecting Sensors and Actuators to Input/Outputs AX1500 ConnectionsAX1500 Connections AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual AX1500’s Inputs and OutputsConnecting Sensors and Actuators to Input/Outputs Signal AX1500’s Inputs and OutputsI/O type ActivatedPin1 I/O List and Pin AssignmentConnecting Sensors and Actuators to Input/Outputs Signal dependingConnecting devices to Output C Connecting devices to Output CSignal depending on ModeConnecting Switches or Devices to Input E Connecting Switches or Devices to Input FImportant warning 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 Position Potentiometers to Analog Inputs Analog InputsConnecting Sensors and Actuators to Input/Outputs AX1500 Motor Controller User’s ManualConnecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsOperating Mode Important WarningConnecting Sensors and Actuators to Input/Outputs Operating ModeImportant Warning Ana 1 p11Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhmAX1500 Motor Controller User’s Manual Using the Analog Inputs to Monitor External VoltagesConnecting Sensors and Actuators to Input/Outputs Connecting User Devices to Analog Inputs Internal Heatsink Temperature SensorsInternal Voltage Monitoring Sensors Connecting User Devices to Analog InputsTemperature Conversion C Source Code Connecting Sensors and Actuators to Input/OutputsAX1500 Motor Controller User’s Manual ValueInternal Heatsink Temperature Sensors AX1500 Motor Controller User’s Manualelse LoTemp = i * 5Version 1.9b. June 1 Connecting Sensors and Actuators to Input/OutputsAX1500 Motor Controller User’s Manual Installing Connecting and Using the Encoder Module Optical Incremental Encoders OverviewOptical Incremental Encoders Overview AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Recommended Encoder TypesInstalling, Connecting and Using the Encoder Mod Installing the Encoder Module Installing the Encoder ModulePulse Frequency in Hz = RPM / 60 * PPR AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Connecting the EncoderInstalling, Connecting and Using the Encoder Mod Cable Length and Noise Considerations Cable Length and Noise ConsiderationsName Cable ColorVoltage Levels, Thresholds and Limit Switches Motor - Encoder Polarity MatchingInstalling, Connecting and Using the Encoder Mod Important WarningWiring Optional Limit Switches Wiring Optional Limit SwitchesImportant Warning 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 Effect of Limit SwitchesWiring Limit Switches Without Encoders Motor 1 FwdUsing the Encoder Module to Measure Distance Using the Encoder to Measure SpeedInstalling, Connecting and Using the Encoder Mod Motor 2 FwdUsing the Encoder to Track Position Important NoticeUsing the Encoder to Track Position AX1500 Motor Controller User’s ManualRS232 Communication with the Encoder Module Installing, Connecting and Using the Encoder ModImportant Notice 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 Closed Loop Position Mode Mode DescriptionSelecting the Position Mode Mode DescriptionPosition Sensor Selection Sensor MountingClosed Loop Position Mode Position Feedback Position Sensor Gear boxFeedback Potentiometer wiring Feedback Potentiometer wiring in RC or RS232 ModeFeedback Potentiometer wiring Important NoticeFeedback Potentiometer wiring in Analog Mode Closed Loop Position ModeImportant Notice AX1500 Motor Controller User’s ManualFeedback Wiring in RC or RS232 Mode on Single Channel Controllers Feedback Wiring in Analog Mode on Single Channel ControllersAnalog Feedback on Single Channel Controllers Important NoticeUsing Optical Encoders in Position Mode Sensor and Motor PolarityClosed Loop Position Mode Important WarningImportant Safety Warning Encoder Error Detection and ProtectionAdding Safety Limit Switches 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 Control Loop DescriptionUsing Current Limiting as Protection 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 Closed Loop Speed Mode Selecting the Speed ModeUsing Optical Encoder for Speed FeedbackDigital Optical Encod Mode DescriptionTachometer wiring Tachometer or Encoder MountingClosed Loop Speed Mode AX1500 Motor Controller User’s ManualSpeed Sensor and Motor Polarity Important WarningSpeed Sensor and Motor Polarity AX1500 Motor Controller User’s ManualAdjust Offset and Max Speed Closed Loop Speed ModeImportant Warning 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 Normal and Fault Condition LED Messages Power On LEDDiagnostic LED Normal Operation Flashing PatternAX1500 Motor Controller User’s Manual Output Off / Fault ConditionNormal and Fault Condition LED Messages SECTION 11 R/C Operation Mode DescriptionMode Description AX1500 Motor Controller User’s ManualSelecting the R/C Input Mode Connector I/O Pin Assignment R/C ModeSignal Pin1R/C Input Circuit Description Supplied Cable DescriptionSignal R/C Input Circuit DescriptionPowering the Radio from the controller FIGURE 64. RC Cable wiring diagramR/C Operation FIGURE 65. RC connection cablePowering the Radio from the controller 3 Channel 1 Command Pulses 4 Channel 2 Command Pulses6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command Pulses Wire loop bringing power from controller to RC radioConnecting to a Separately Powered Radio Operating the Controller in R/C modeR/C Operation AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Reception WatchdogReception Watchdog Important Notice about PCM Radios R/C Transmitter/Receiver Quality ConsiderationsJoystick Deadband Programming R/C OperationCommand Control Curves Command Control CurvesDeadband Parameter Value Deadband as Percent of full Joystick TravelLeft/Right Tuning Adjustment Activating the Accessory OutputsJoystick Calibration R/C OperationAX1500 Motor Controller User’s Manual Data Logging in R/C ModeData Logging in R/C Mode R/C Operation AX1500 Motor Controller User’s ManualDB15 Male To ControllerAnalog Control and Operation Mode DescriptionMode Description Important NoticeConnector I/O Pin Assignment Analog Mode SignalPin1 Analog Control and OperationConnecting to a Voltage Source Connecting a PotentiometerConnecting to a Voltage Source AX1500 Motor Controller User’s ManualSelecting the Potentiometer Value Important NoticeAnalog Deadband Adjustment Power-On Safety Under Voltage SafetyData Logging in Analog Mode 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 Serial RS-232 Controls and Operation Use and benefits of RS232Use and benefits of RS232 AX1500 Motor Controller User’s ManualConnector I/O Pin Assignment RS232 Mode SignalPin1 Serial RS-232 Controls and OperationCable configuration Extending the RS232 CableCable configuration AX1500 Motor Controller User’s ManualCommunication Settings 9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even ParityEstablishing Manual Communication with a PC Serial RS-232 Controls and OperationRS232 Communication with the Encoder Module Establishing Manual Communication with a PCRoboteq v1.9b 06/01/07 s AX1500 Motor Controller User’s ManualEntering RS232 from R/C or Analog mode Data Logging String in R/C or Analog modeSerial RS-232 Controls and Operation AX1500 Motor Controller User’s ManualCommands Acknowledge and Error Messages RS232 Mode if defaultCommand Acknowledgement Command ErrorController Commands and Queries RS-232 WatchdogCommand Serial RS-232 Controls and OperationSet Motor Command Value Set Accessory OutputController Commands and Queries CommandQuery Power Applied to Motors Query Amps from Battery to each Motor ChannelImportant Notice Important NoticeQuery Heatsink Temperatures Query Battery VoltagesQuery Analog Inputs Controller Commands and QueriesReset Controller Query Digital InputsSerial RS-232 Controls and Operation SyntaxAccessing & Changing Configuration Parameter in Flash Apply Parameter ChangesAccessing & Changing Configuration Parameter in Flash Read parameterFlash Configuration Parameters List Serial RS-232 Controls and OperationLocation DescriptionInput Control Mode Motor Control ModeAccessing & Changing Configuration Parameter in Flash AccessAmps Limit AccessAfter Reset or FF Serial RS-232 Controls and OperationInput Switches Function AccelerationAccessing & Changing Configuration Parameter in Flash AccessRC Joystick or Analog Deadband Exponentiation on Channel 1 and ChannelAccess After Reset or FFLeft/Right Adjust Default Encoder Time Base 1 andAccessing & Changing Configuration Parameter in Flash AccessDefault Encoder Distance Divider Default PID GainsJoystick Min, Max and Center Values AccessReading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime1C - Joystick Max 2 MS 1D - Joystick Max 2 LS Effective Instantly DefinitionOperating Modes Registers Read/Change PID ValuesAccess Important NoticePWM Frequency Register Controller Status Register87 - D2 Access Read/Write Effective Instantly Address Access Read/Write Effective InstantlyController Identification Register Current Amps Limit RegistersFault Condition AccessRS232 Encoder Command Set Set/Reset Encoder Counters and Destination RegistersRead Encoder Counter RS232 Encoder Command SetRead Speed q or !Q nSyntax AX1500 Motor Controller User’s ManualRead Encoder Limit Switch Status Read DistanceRead Speed/Distance RS232 Encoder Command SetImportant Note Read / Modify Encoder Module Registers and ParametersSwitch SwitchRS232 Encoder Command Set AccessModify parameter AddressSwitch Status Register DescriptionEncoder Hardware ID code Speed or Distance 1 orCounter Read/Write Mailbox Counter 1 andDestination Register 1 and Register DescriptionDistance 1 and Speed 1 andTime Base 1 and Encoder ThresholdCounter Read Data Format Encoder Testing and Setting Using the PC UtilityCounter Read Data Format 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 00 11 22 33 44 55 66 77 88 99 AA BB CC Analog and R/C Modes Data Logging String FormatData Logging Cables 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 1SECTION 14 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements 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 3- Parameter Selection and Setting and Special FunctionsRoborun Frame, Tab and Menu Descriptions 1- Program Revision NumberGetting On-Screen Help Loading, Changing Controller ParametersUsing the Roborun Configuration Utility 4- File and Program Management CommandsControl Settings 2- Motor Control Mode3- Input Command Adjustment Loading, Changing Controller ParametersPower Settings Using the Roborun Configuration Utility4- Emergency Stop or Invert Switch Select 2- Left/Right AdjustAnalog or R/C Specific Settings Loading, Changing Controller Parameters1- Deadband 2- Joystick TimingEncoder Setting and Testing Closed Loop ParametersUsing the Roborun Configuration Utility AX1500 Motor Controller User’s ManualAX1500 Motor Controller User’s Manual Encoder Module Parameters SettingEncoder Setting and Testing Running the Motors Exercising the MotorsViewing Encoder Data Using the Roborun Configuration Utility2- Motor Power setting Running the Motors1- Run/Stop Button 3- MeasurementUsing the Roborun Configuration Utility 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting 5- Transmit and Receive DataLogging Data to Disk Running the Motors 7- Data Logging and Timer8- Joystick Enable 4- Reset Timer buttonUsing the Console Connecting a JoystickUsing the Roborun Configuration Utility Parameter HeaderUsing the Console 2- Command Entry1- Terminal Screen 3- Keep Watchdog AliveOperating the AX1500 over a Wired or Wireless LAN Viewing and Logging Data in Analog and R/C ModesLoading and Saving Profiles to Disk Using the Roborun Configuration Utility 4- Send Reset StringOperating the AX1500 over a Wired or Wireless LAN AX1500 Motor Controller User’s ManualUpdating the Controller’s Software Updating the Encoder SoftwareUsing the Roborun Configuration Utility 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 Specifications Mechanical DimensionsMechanical Dimensions AX1500 Motor Controller User’s ManualMounting Considerations Thermal ConsiderationsMechanical Specifications 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 WeightWire Dimensions AX1500 Motor Controller User’s ManualVersion 1.9b. June 1 Mechanical SpecificationsAX1500 Motor Controller User’s Manual