Mounting Considerations, Thermal Considerations | RoboteQ AX3500

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RoboteQ AX3500 user manual Mounting Considerations, Thermal Considerations, Mechanical Specifications, 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 Revision History Revision HistoryDate 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 Important Safety Avoid Shorts when Mounting Board against ChassisDo not Connect to a RC Radio with a Battery Attached Warnings Important Safety Warnings Locating the Switches and Connectors AX3500Quick Start What you will need AX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Connecting to the 15-pin Connector Important WarningSignal RC Mode Connecting the R/C Radio Powering On the ControllerConnecting the R/C Radio Button Operation Prog and Set button statusFunction Default Controller Configuration Default Controller ConfigurationDefault Values 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 Technical features Multiple Command ModesAutomatic Joystick Command Corrections AX3500 Motor Controller Overview Technical features Low Power ConsumptionHigh Efficiency Motor Power Outputs 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 Controller Power Power Control input isAnd Main Battery 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 Wire Length Limits Power Regeneration ConsiderationsElectrical Noise Reduction Techniques 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 Input Command Modes General OperationBasic Operation Basic Operation Selecting the Motor Control Modes Open Loop, Separate Speed ControlOpen Loop, Mixed Speed Control General Operation Closed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes User Selected Current Limit Settings Temperature-Based Current LimitationPosition Feedback Position Sensor Gear box Setting Battery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio Temperature Regeneration Current Limiting Motor Current = Battery Current / PWM Ratio Programmable Acceleration Setting UsingSwitches Programmable Acceleration Command Control Curves 15 Hex17.97% 0.089 second Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Speed Adjustment Parameter Value Emergency Shut Down Using Controller Switches Emergency Stop using External SwitchActivating Brake Release or Separate Motor Excitation Activating Brake Release or Separate Motor Excitation Special Use of Accessory Digital Inputs Using the Inputs to Activate the Buffered OutputUsing the Inputs to turn Off/On the Power MOSFET transistors 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 Pin1 I/O List and Pin AssignmentSignal depending 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 Connecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsAna2 Operating Mode Ana 1 p11 Ana2 p10Ana 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 Connecting User Devices to Analog Inputs Internal Voltage Monitoring SensorsInternal Heatsink Temperature Sensors Connecting User Devices to Analog Inputs Temperature Conversion C Source Code ValueAnalog Internal Heatsink Temperature Sensors elseLoTemp = i * 5 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 Connector Location and Pinout Connecting Servos to ControllersServo Connection to RevA Controllers RC Pulses Output Connecting to Slave Controllers Servo Connection to RevB ControllersConnecting to Slave Controllers Pulse Timing Information Command ValuePulse Width 1.00ms 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 Cable Length and Noise Considerations Motor - Encoder Polarity MatchingName Cable Color Voltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Wiring Limit Switches Without Encoders Effect of Limit SwitchesWiring Limit Switches Without Encoders Motor 1 Fwd Using the Encoder Module to Measure Distance Using the Encoder to Measure SpeedMotor 2 Fwd 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 Closed Loop Position Mode Mode DescriptionSelecting the Position Mode Mode Description Position Sensor Selection Sensor MountingPosition Feedback Position Sensor Gear box Closed Loop Position Mode Feedback Potentiometer wiring Feedback Potentiometer wiring in RC or RS232 ModeFeedback Potentiometer wiring Feedback Potentiometer wiring in Analog Mode Feedback Wiring in RC or RS232 Mode on Single Channel Controllers Feedback Wiring in Analog Mode on Single Channel ControllersAnalog Feedback on Single Channel Controllers Analog Feedback on Single Channel Controllers Using Optical Encoders in Position Mode Sensor and Motor Polarity Important Safety Warning Encoder Error Detection and ProtectionAdding Safety Limit Switches 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 Using Optical Encoder for Speed FeedbackDigital Optical Encod Tachometer wiringTachometer or Encoder Mounting 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 Motor Direction Status Normal and Fault Condition LED MessagesPossible Display Motor Fault Messages No ControlFault Messages 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 Connector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin1 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 Joystick Deadband Programming Joystick Deadband ProgrammingDeadband Parameter Value 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 Power-On Safety Under Voltage SafetyData Logging in Analog Mode 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 Commands Acknowledge and Error Messages RS232 Mode if defaultCommand Acknowledgement Command Error Controller Commands and Queries RS-232 WatchdogCommand Type Set Motor Command Value Set Accessory OutputQuery Power Applied to Motors Controller Commands and Queries Query Amps from Battery to each Motor Channel Syntax Query Analog Inputs Query Heatsink Temperatures?r or ?R ?m or ?M Query Battery Voltages Reset ControllerQuery Digital Inputs Examples Accessing & Changing Configuration Parameter in Flash Apply Parameter ChangesAccessing & Changing Configuration Parameter in Flash Read parameter Flash Configuration Parameters List LocationActive after Input Control Mode Motor Control ModeAccess After Reset Amps Limit AccelerationDefinition Input Switches Function Left/Right Adjust RC Joystick or Analog DeadbandExponentiation on Channel 1 and Channel 08 - Channel Default Encoder Time Base 1 and Default Encoder Distance Divider0B - Encoder 0C - Encoder Default PID Gains Joystick Min, Max and Center Values0F - Proportional Gain 10 - Integral Gain Reading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime Operating Modes Registers Read/Change PID ValuesAccess Read/Write Effective Instantly 80 - Channel PWM Frequency Register Controller Status RegisterAddress Access Read/Write Effective Instantly Fault Condition Controller Identification Register Current Amps Limit RegistersModel or Function 8B - Channel RS232 Encoder Command Set Set/Reset Encoder Counters and Destination RegistersRead Encoder Counter RS232 Encoder Command Set Read Speed q or !Q n7 Set Encoder 1 destination register with value in buffer 8 Set Encoder 2 destination register with value in buffer Read Encoder Limit Switch Status Read DistanceRead Speed/Distance Important Note Read / Modify Encoder Module Registers and ParametersSwitch n Value Parameter Description Size Switch Status Register DescriptionEncoder Hardware ID code Address *84 Speed or Distance 1 or Counter Read/Write MailboxCounter 1 and Destination Register 1 and Distance 1 and Speed 1 andTime Base 1 and Encoder Threshold Counter Read Data Format RC Pulse Outputs ActivationDefault Value 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 Restoring factory defaults Exiting the Parameter Setting ModeProgrammable Parameters List This manual is for software version 1.9b Possible Values default For safety reasons, the modes belowcannot be selected using the switches Programmable Parameters List Configuring the Controller using the Switches SECTION 16 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements Connecting the Controller to the PC Using the Roborun Configuration Utility Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions1- Program Revision Number 2- Controller and Communication Link Information Getting On-Screen Help 3- Parameter Selection and Setting and Special Functions4- File and Program Management Commands 5- View Controller Connector Pinout Control Settings Loading, Changing Controller ParametersLoading, Changing Controller Parameters 1- Controller Input Power Settings 3- Input Command Adjustment4- Emergency Stop or Invert Switch Select 5- Effect of Digital Inputs Analog or R/C Specific Settings Loading, Changing Controller Parameters 2- Left/Right Adjust3- Acceleration Setting 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 Logging Data to Disk 7- Data Logging and Timer8- Joystick Enable 4- Reset Timer button Connecting a Joystick Parameter HeaderData type/range Measured Parameter Using the Console 2- Command Entry1- Terminal Screen Viewing and Logging Data in Analog and R/C Modes Loading and Saving Profiles to Disk4- Send Reset String 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