AX3500 Motor Controller User’s Manual | RoboteQ guide

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AX3500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

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RoboteQ user manual AX3500 Motor Controller User’s Manual, Version 1.9b. June 1

Contents

Dual Channel High Power Digital Motor Controller AX3500User’s Manual AX3500 Motor Controller User’s Manual Version 1.9b. June 1 Date Revision HistoryRevision History Version AX3500 Motor Controller User’s Manual Revision History General Operation SECTION SECTIONSECTION SECTION SECTION SECTION Programming using built-in Switches and Display AX3500 Motor Controller User’s Manual Do not Connect to a RC Radio with a Battery Attached Important SafetyAvoid Shorts when Mounting Board against Chassis Warnings Important Safety Warnings Quick Start Locating the Switches and ConnectorsAX3500 What you will need AX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Signal Connecting to the 15-pin ConnectorImportant Warning RC Mode Connecting the R/C Radio Powering On the ControllerConnecting the R/C Radio Button Operation Prog and Set button statusFunction Default Values Default Controller ConfigurationDefault Controller Configuration Parameter Connecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision Number Exploring further = Software version 1.9b SECTION 3AX3500 Motor Controller Overview Product Description Automatic Joystick Command Corrections Technical featuresMultiple Command Modes AX3500 Motor Controller Overview High Efficiency Motor Power Outputs Technical featuresLow Power Consumption Optical Encoder Inputs Advanced Safety Features Data Logging CapabilitiesCompact Open Frame PCB Design Connecting Power and Motors to the Controller Power ConnectionsPower Connections Controller Power Connecting Power and Motors to the Controller And Main Battery Controller PowerPower Control input is 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 Single Channel Operation Converting the AX3500 to Single ChannelSingle Channel Operation Power Fuses Electrical Noise Reduction Techniques Wire Length LimitsPower Regeneration Considerations Wire Length Limits Overvoltage Protection Undervoltage Protection Using the Controller with a Power Supply Using the Controller with a Power Supply Connecting Power and Motors to the Controller Basic Operation Input Command ModesGeneral Operation Basic Operation Open Loop, Mixed Speed Control Selecting the Motor Control ModesOpen Loop, Separate Speed Control General Operation Closed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes Position Feedback Position Sensor Gear box User Selected Current Limit SettingsTemperature-Based Current Limitation Setting Motor Current = Battery Current / PWM ratio Battery Current vs. Motor CurrentBattery Current vs. Motor Current Temperature Regeneration Current Limiting Motor Current = Battery Current / PWM Ratio Switches Programmable AccelerationSetting Using Programmable Acceleration 17.97% Command Control Curves15 Hex 0.089 second Exponentiation Parameter Value Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Selected Curve Speed Adjustment Parameter Value Activating Brake Release or Separate Motor Excitation Emergency Shut Down Using Controller SwitchesEmergency Stop using External Switch Activating Brake Release or Separate Motor Excitation Using the Inputs to turn Off/On the Power MOSFET transistors Special Use of Accessory Digital InputsUsing the Inputs to Activate the Buffered Output Inverted Operation Self-Test Mode Self-Test Mode Encoder Speed or Position Connecting Sensors and Actuators to Input/Outputs AX3500 ConnectionsAX3500 Connections AX3500’s Inputs and Outputs Connecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and Outputs I/O typeActivated Signal depending Pin1I/O List and Pin Assignment Input or Connecting devices to Output C Connecting devices to Output C Connecting Switches or Devices to Input F Important warning Connecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert Input Connecting Position Potentiometers to Analog Inputs Analog Inputs Ana2 Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Operating Mode Ana 3 p12 Ana 1 p11Ana2 p10 Ana 4 p8 Temp oC Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Resistance kOhm Using the Analog Inputs to Monitor External Voltages Internal Heatsink Temperature Sensors Connecting User Devices to Analog InputsInternal Voltage Monitoring Sensors Connecting User Devices to Analog Inputs Temperature Conversion C Source Code ValueAnalog LoTemp = i * 5 Internal Heatsink Temperature Sensorselse HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1 Connecting Sensors and Actuators to Input/Outputs RC Pulses Output RC Pulse Output OverviewRC Pulse Output Overview Servo Connection to RevA Controllers Connector Location and PinoutConnecting Servos to Controllers RC Pulses Output Connecting to Slave Controllers Servo Connection to RevB ControllersConnecting to Slave Controllers Pulse Width 1.00ms Pulse Timing InformationCommand Value 1.50ms RC Channel Testing Using the PC Utility RC Channel Testing Using the PC Utility RC Pulses Output Connecting and Using the Encoder Function Optical Incremental Encoders OverviewOptical Incremental Encoders Overview Recommended Encoder Types Connecting and Using the Encoder Function Connecting the Encoder Connecting the EncoderPulse Frequency in Hz = RPM / 60 * PPR Name Cable Length and Noise ConsiderationsMotor - Encoder Polarity Matching Cable Color Voltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Wiring Limit Switches Without Encoders Wiring Limit Switches Without EncodersEffect of Limit Switches Motor 1 Fwd Motor 2 Fwd Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Motor 2 Rev Using the Encoder to Track Position Important NoticeUsing the Encoder to Track Position The actual formula is as follows Distance = Destination - Counter value / Divider Encoder Testing and Setting Using the PC Utility RS232 Communication with the Encoder ModuleRS232 Communication with the Encoder Module Connecting and Using the Encoder Function Selecting the Position Mode Closed Loop Position ModeMode Description Mode Description Position Feedback Position Sensor Gear box Position Sensor SelectionSensor Mounting Closed Loop Position Mode Feedback Potentiometer wiring Feedback Potentiometer wiring in RC or RS232 ModeFeedback Potentiometer wiring Feedback Potentiometer wiring in Analog Mode Analog Feedback on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersFeedback Wiring in Analog Mode on Single Channel Controllers Analog Feedback on Single Channel Controllers Using Optical Encoders in Position Mode Sensor and Motor Polarity Adding Safety Limit Switches Important Safety WarningEncoder Error Detection and Protection Encoder Error Detection and Protection FIGURE 62. Safety limit switches interrupting power to motors Using Current Limiting as Protection Control Loop DescriptionUsing Current Limiting as Protection PID tuning in Position Mode PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional Gain Closed Loop Position Mode Closed Loop Speed Mode Selecting the Speed Mode Tachometer or Encoder Mounting Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer wiring Closed Loop Speed Mode 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 In 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 Use of the LED DisplayUse of the LED Display Possible Display Motor Direction StatusNormal and Fault Condition LED Messages Motor Fault Messages Fault MessagesNo Control Rapidly Flashing Temporary Faults Permanent FaultsSelf-Test Display = Software version 1.9b Self-Test Display Normal and Fault Condition LED Messages SECTION 12 R/C Operation Pin1 Connector I/O Pin Assignment R/C ModeSelecting the R/C Input Mode R/C Operation R/C Input Circuit Description Supplied Cable DescriptionR/C Input Circuit Description Powering the Radio from the controller FIGURE 74. RC Cable wiring diagramFIGURE 75. RC connection cable Powering the Radio from the controller Connecting to a Separately Powered Radio Operating the Controller in R/C mode Reception Watchdog Reception Watchdog Important Notice about PCM Radios R/C Transmitter/Receiver Quality Considerations Deadband Parameter Value Joystick Deadband ProgrammingJoystick Deadband Programming Deadband as Percent of full Joystick Travel Left/Right Tuning Adjustment Joystick Calibration Automatic Joystick Calibration Automatic Joystick Calibration Data Logging in R/C Mode On before entering joystick calibration Data Logging in R/C Mode DB15 MaleTo Controller R/C Operation Analog Control and Operation Connector I/O Pin Assignment Analog Mode Analog Control and Operation Connecting to a Voltage Source Connecting a PotentiometerConnecting to a Voltage Source Selecting the Potentiometer Value Analog Deadband Adjustment Data Logging in Analog Mode Power-On SafetyUnder Voltage Safety Motor Power at 0% Data Logging in Analog Mode Analog Control and Operation Serial RS-232 Controls and Operation Use and benefits of RS232Use and benefits of RS232 Connector I/O Pin Assignment RS232 Mode Serial RS-232 Controls and Operation Cable configuration Extending the RS232 CableCable configuration Communication Settings 9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even ParityEstablishing Manual Communication with a PC RS232 Communication with the Encoder Module Establishing Manual Communication with a PCRoboteq v1.9b 06/01/07 s Entering RS232 from R/C or Analog mode Data Logging String in R/C or Analog mode Command Acknowledgement Commands Acknowledge and Error MessagesRS232 Mode if default Command Error Command Controller Commands and QueriesRS-232 Watchdog Type Query Power Applied to Motors Set Motor Command ValueSet Accessory Output Controller Commands and Queries Query Amps from Battery to each Motor Channel Syntax ?r or ?R Query Analog InputsQuery Heatsink Temperatures ?m or ?M Query Digital Inputs Query Battery VoltagesReset Controller Examples Accessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameter Flash Configuration Parameters List LocationActive after Access Input Control ModeMotor Control Mode After Reset Amps Limit AccelerationDefinition Input Switches Function Exponentiation on Channel 1 and Channel Left/Right AdjustRC Joystick or Analog Deadband 08 - Channel 0B - Encoder Default Encoder Time Base 1 andDefault Encoder Distance Divider 0C - Encoder 0F - Proportional Gain Default PID GainsJoystick Min, Max and Center Values 10 - Integral Gain Reading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime Access Read/Write Effective Instantly Operating Modes RegistersRead/Change PID Values 80 - Channel Address Access Read/Write Effective Instantly PWM Frequency RegisterController Status Register Fault Condition Model or Function Controller Identification RegisterCurrent Amps Limit Registers 8B - Channel Read Encoder Counter RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers RS232 Encoder Command Set 7 Set Encoder 1 destination register with value in buffer Read Speedq or !Q n 8 Set Encoder 2 destination register with value in buffer Read Encoder Limit Switch Status Read DistanceRead Speed/Distance Switch Important NoteRead / Modify Encoder Module Registers and Parameters n Value Parameter Description Size Encoder Hardware ID code Switch StatusRegister Description Address *84 Counter 1 and Speed or Distance 1 orCounter Read/Write Mailbox Destination Register 1 and Time Base 1 and Distance 1 andSpeed 1 and Encoder Threshold Default Value Counter Read Data FormatRC Pulse Outputs Activation Counter Read Data Format Decimal 32-bit HexController Output Automatic Switching from RS232 to RC Mode Automatic 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 Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual SECTION 15 Configuring the Controller using the Switches Programming using built-in Switches and DisplayProgramming Methods Entering Programming Mode Configuring the Controller using the SwitchesProgram Changing parameters The Special Case of Joystick CalibrationProgramming using built-in Switches and Display Programmable Parameters List Restoring factory defaultsExiting the Parameter Setting Mode This manual is for software version 1.9b cannot be selected using the switches Possible Values defaultFor safety reasons, the modes below Programmable Parameters List Order SECTION 16 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements Connecting the Controller to the PC Using the Roborun Configuration Utility 1- Program Revision Number Roborun Frame, Tab and Menu DescriptionsRoborun Frame, Tab and Menu Descriptions 2- Controller and Communication Link Information 4- File and Program Management Commands Getting On-Screen Help3- Parameter Selection and Setting and Special Functions 5- View Controller Connector Pinout Loading, Changing Controller Parameters Control SettingsLoading, Changing Controller Parameters 1- Controller Input 4- Emergency Stop or Invert Switch Select Power Settings3- Input Command Adjustment 5- Effect of Digital Inputs 3- Acceleration Setting Analog or R/C Specific SettingsLoading, Changing Controller Parameters 2- Left/Right Adjust 1- Deadband Encoder Setting and Testing Closed Loop Parameters Encoder Module Parameters Setting Encoder Setting and Testing RC Output Testing Exercising the MotorsViewing Encoder Data Running the Motors Running the Motors 2- Motor Power setting 1- Run/Stop Button3- Measurement 4- Real-Time Strip Chart Recorder 6- Input Status and Output Setting5- Transmit and Receive Data 8- Joystick Enable Logging Data to Disk7- Data Logging and Timer 4- Reset Timer button Data type/range Connecting a JoystickParameter Header Measured Parameter Using the Console 2- Command Entry1- Terminal Screen 4- Send Reset String Viewing and Logging Data in Analog and R/C ModesLoading and Saving Profiles to Disk Viewing and Logging Data in Analog and R/C Modes Operating the AX3500 over a Wired or Wireless LAN Updating the Controller’s Software Updating the Controller’s Software Creating Customized Object Files Updating the Encoder Software Creating Customized Object Files Using the Roborun Configuration Utility Mechanical Specifications Mechanical DimensionsMechanical Dimensions Mounting Considerations Thermal ConsiderationsMechanical Specifications Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions WeightWire Dimensions Mechanical Specifications AX3500 Motor Controller User’s ManualVersion 1.9b. June 1