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

User’s Manual Dual Channel High Power Digital Motor ControllerAX3500 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 Connecting the R/C RadioPowering On the Controller Function Button OperationProg and Set button status 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 Compact Open Frame PCB Design Advanced Safety FeaturesData Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower 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 Single Channel OperationConverting the AX3500 to Single Channel 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 Version 1.9b. June 1 Basic Operation Input Command ModesGeneral Operation Basic Operation Open Loop, Mixed Speed Control Selecting the Motor Control ModesOpen Loop, Separate Speed Control General Operation Selecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control 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 AX3500 Connections Connecting Sensors and Actuators to Input/OutputsAX3500 Connections AX3500’s Inputs and Outputs Connecting Sensors and Actuators to Input/Outputs Activated AX3500’s Inputs and OutputsI/O type 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 Analog Temperature Conversion C Source CodeValue LoTemp = i * 5 Internal Heatsink Temperature Sensorselse HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1 Version 1.9b. June 1 RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview Servo Connection to RevA Controllers Connector Location and PinoutConnecting Servos to Controllers RC Pulses Output Connecting to Slave Controllers Connecting to Slave ControllersServo Connection to RevB 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 Version 1.9b. June 1 Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview Recommended Encoder Types Connecting and Using the Encoder Function Pulse Frequency in Hz = RPM / 60 * PPR Connecting the EncoderConnecting the Encoder 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 Using the Encoder to Track PositionImportant Notice The actual formula is as follows Distance = Destination - Counter value / Divider RS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC UtilityRS232 Communication with the Encoder Module Version 1.9b. June 1 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 wiringFeedback Potentiometer wiring in RC or RS232 Mode 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 Using Current Limiting as ProtectionControl Loop Description PID tuning in Position Mode PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional Gain Version 1.9b. June 1 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 Use of the LED Display Normal and Fault Condition LED MessagesUse of the LED Display Possible Display Motor Direction StatusNormal and Fault Condition LED Messages Motor Fault Messages Fault MessagesNo Control Rapidly Flashing Self-Test Display Temporary FaultsPermanent Faults = Software version 1.9b Self-Test Display Version 1.9b. June 1 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 R/C Input Circuit DescriptionSupplied Cable Description FIGURE 75. RC connection cable Powering the Radio from the controllerFIGURE 74. RC Cable wiring diagram 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 To Controller Data Logging in R/C ModeDB15 Male Version 1.9b. June 1 Analog Control and Operation Connector I/O Pin Assignment Analog Mode Analog Control and Operation Connecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer 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 Version 1.9b. June 1 Use and benefits of RS232 Serial RS-232 Controls and 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 Establishing Manual Communication with a PC Communication Settings9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Roboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC 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 Active after Flash Configuration Parameters ListLocation Access Input Control ModeMotor Control Mode After Reset Definition Amps LimitAcceleration 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 Speed/Distance Read Encoder Limit Switch StatusRead 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 Controller Output Decimal32-bit Hex Automatic Switching from RS232 to RC Mode Automatic 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 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 Programming Methods SECTION 15 Configuring the Controller using the SwitchesProgramming using built-in Switches and Display Program Entering Programming ModeConfiguring the Controller using the Switches Programming using built-in Switches and Display Changing parametersThe Special Case of Joystick Calibration 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 System Requirements SECTION 16 Using the Roborun Configuration UtilityDownloading and Installing the Utility 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 Viewing Encoder Data RC Output TestingExercising the Motors Running the Motors Running the Motors 3- Measurement 2- Motor Power setting1- Run/Stop Button 5- Transmit and Receive Data 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting 8- Joystick Enable Logging Data to Disk7- Data Logging and Timer 4- Reset Timer button Data type/range Connecting a JoystickParameter Header Measured Parameter 1- Terminal Screen Using the Console2- Command Entry 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 Version 1.9b. June 1 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mechanical Specifications Mounting ConsiderationsThermal Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions Wire DimensionsWeight Version 1.9b. June 1 Mechanical SpecificationsAX3500 Motor Controller User’s Manual