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RoboteQ AX3500 Motor Controller Overview, Advanced Safety Features, Data Logging Capabilities

Models: AX3500

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Advanced Safety Features

AX3500 Motor Controller Overview

•60A up to 15 seconds (per channel)

•50A up to 30 seconds

•40A extended

•High current operation may be extended with forced cooling

•250A peak Amps per channel

•16kHz Pulse Width Modulation (PWM) output

•Auxiliary output for brake, clutch or armature excitation

•Heat sink on PCB

•Optional Bottom Aluminum place for conduction cooling (BP version)

Advanced Safety Features

•Safe power on mode

•Optical isolation on R/C control inputs

•Automatic Power stage off in case of electrically or software induced program fail- ure

•Overvoltage and Undervoltage protection

•Regeneration current limiting

•Watchdog for automatic motor shutdown in case of command loss (R/C and RS232 modes)

•Large, bright run/failure diagnostics on 7 segment LED display

•Programmable motor acceleration

•Built-in controller overheat sensor

•Emergency Stop input signal and button

Data Logging Capabilities

•13 internal parameters, including battery voltage, captured R/C command, tempera- ture and Amps accessible via RS232 port

•Data may be logged in a PC, PDA or microcomputer

Compact Open Frame PCB Design

•Surface mount PCB design

•Efficient heat sinking. Operates without a fan in most applications.

•6.75” (171.5mm) long x 4.20” (106.7mm) wide

•-20o to +85o C heatsink operating environment

•7.5oz (220g)

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AX3500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

Image 28

RoboteQ user manual AX3500 Motor Controller Overview, Advanced Safety Features, Data Logging Capabilities

Contents

AX3500 Dual Channel High Power Digital Motor ControllerUser’s Manual AX3500 Motor Controller User’s Manual Version 1.9b. June 1Revision History Revision HistoryDate VersionAX3500 Motor Controller User’s Manual Version 1.9b. June 1Revision History General Operation SECTION SECTIONSECTION SECTION SECTION SECTION Programming using built-in Switches and Display AX3500 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 WarningsAX3500 Motor Controller User’s Manual Important Safety WarningsVersion 1.9b. June 1 Locating the Switches and Connectors AX3500Quick Start What you will needAX3500 Quick Start AX3500 Motor Controller User’s ManualConnecting to the Batteries and Motors Connecting to the Batteries and MotorsAX3500 Motor Controller User’s Manual Connecting to the 15-pin Connector Important WarningSignal RC ModeConnecting the R/C Radio Powering On the ControllerConnecting the R/C Radio Important WarningButton Operation AX3500 Quick StartProg and Set button status FunctionDefault Controller Configuration Default Controller ConfigurationDefault Values Prog and Set button statusAX3500 Quick Start Connecting the controller to your PC using RoborunAX3500 Motor Controller User’s Manual Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision NumberAX3500 Motor Controller User’s Manual Exploring further = Software version 1.9bAX3500 Quick Start AX3500 Motor Controller User’s ManualProduct Description SECTION 3AX3500 Motor Controller OverviewAX3500 Motor Controller User’s Manual Technical features Multiple Command ModesAutomatic Joystick Command Corrections AX3500 Motor Controller OverviewTechnical features Low Power ConsumptionHigh Efficiency Motor Power Outputs Optical Encoder InputsAdvanced Safety Features AX3500 Motor Controller OverviewData Logging Capabilities Compact Open Frame PCB DesignConnecting Power and Motors to the Controller Power ConnectionsPower Connections Important WarningConnecting Power and Motors to the Controller Controller PowerAX3500 Motor Controller User’s Manual 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 AX3500 Motor Controller User’s ManualConnecting the Motors Connecting Power and Motors to the ControllerImportant Warning Important WarningSingle Channel Operation Converting the AX3500 to Single ChannelSingle Channel Operation AX3500 Motor Controller User’s ManualPower Fuses Connecting Power and Motors to the ControllerImportant Warning AX3500 Motor Controller User’s ManualWire Length Limits Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Wire Length LimitsOvervoltage Protection Undervoltage ProtectionConnecting Power and Motors to the Controller Important WarningUsing the Controller with a Power Supply Using the Controller with a Power SupplyAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Connecting Power and Motors to the ControllerVersion 1.9b. June 1 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 AX3500 Motor Controller User’s ManualUser Selected Current Limit Settings Temperature-Based Current LimitationPosition Feedback Position Sensor Gear box SettingBattery Current vs. Motor Current Battery Current vs. Motor CurrentTemperature Motor Current = Battery Current / PWM ratioRegeneration 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 Shut Down Using Controller Switches Emergency Stop using External SwitchActivating Brake Release or Separate Motor Excitation 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 Inverted OperationSelf-Test Mode Self-Test Mode= Software version 1.9b AX3500 Motor Controller User’s ManualImportant Warning General OperationEncoder Speed or Position AX3500 Motor Controller User’s ManualConnecting Sensors and Actuators to Input/Outputs AX3500 ConnectionsAX3500 Connections AX3500 Motor Controller User’s ManualConnecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and OutputsAX3500 Motor Controller User’s Manual Signal AX3500’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 F Important warningConnecting Sensors and Actuators to Input/Outputs AX3500 Motor Controller User’s ManualConnecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert InputAX3500 Motor Controller User’s Manual Connecting Position Potentiometers to Analog Inputs Analog InputsConnecting Sensors and Actuators to Input/Outputs AX3500 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 kOhmConnecting Sensors and Actuators to Input/Outputs Using the Analog Inputs to Monitor External VoltagesAX3500 Motor Controller User’s Manual 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/OutputsAX3500 Motor Controller User’s Manual ValueInternal Heatsink Temperature Sensors AX3500 Motor Controller User’s Manualelse LoTemp = i * 5AX3500 Motor Controller User’s Manual Connecting Sensors and Actuators to Input/OutputsVersion 1.9b. June 1 RC Pulses Output RC Pulse Output OverviewRC Pulse Output Overview AX3500 Motor Controller User’s ManualConnector Location and Pinout Connecting Servos to ControllersServo Connection to RevA Controllers RC Pulses OutputConnecting to Slave Controllers Servo Connection to RevB ControllersConnecting to Slave Controllers AX3500 Motor Controller User’s ManualPulse Timing Information Command ValuePulse Width 1.00ms 1.50msRC Channel Testing Using the PC Utility RC Channel Testing Using the PC UtilityImportant Warning AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual RC Pulses OutputVersion 1.9b. June 1 Connecting and Using the Encoder Function Optical Incremental Encoders OverviewOptical Incremental Encoders Overview AX3500 Motor Controller User’s ManualConnecting and Using the Encoder Function Recommended Encoder TypesAX3500 Motor Controller User’s Manual Connecting the Encoder Connecting the EncoderPulse Frequency in Hz = RPM / 60 * PPR AX3500 Motor Controller User’s ManualCable Length and Noise Considerations Motor - Encoder Polarity MatchingConnecting and Using the Encoder Function Important WarningVoltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit SwitchesAX3500 Motor Controller User’s Manual Wiring Optional Limit Switches Connecting and Using the Encoder FunctionImportant Warning AX3500 Motor Controller User’s ManualWiring 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 SpeedConnecting and Using the Encoder Function Motor 2 FwdUsing the Encoder to Track Position Important NoticeUsing the Encoder to Track Position AX3500 Motor Controller User’s ManualConnecting and Using the Encoder Function Important NoticeThe actual formula is as follows Distance = Destination - Counter value / DividerEncoder Testing and Setting Using the PC Utility RS232 Communication with the Encoder ModuleRS232 Communication with the Encoder Module AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Connecting and Using the Encoder FunctionVersion 1.9b. June 1 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 AX3500 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 ProtectionFIGURE 62. Safety limit switches interrupting power to motors Closed Loop Position ModeAX3500 Motor Controller User’s Manual Using Current Limiting as Protection Control Loop DescriptionUsing Current Limiting as Protection Important WarningClosed Loop Position Mode PID tuning in Position ModeAX3500 Motor Controller User’s Manual Applied Power = Command Value - Actual Position * Proportional Gain PID tuning in Position ModeAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Closed Loop Position ModeVersion 1.9b. June 1 Closed Loop Speed Mode Selecting the Speed ModeMode Description Mode DescriptionUsing Optical Encoder for Speed FeedbackDigital Optical Encod Tachometer wiringTachometer or Encoder Mounting Closed Loop Speed ModeSpeed Sensor and Motor Polarity Important WarningSpeed Sensor and Motor Polarity AX3500 Motor Controller User’s ManualAdjust Offset and Max Speed Closed Loop Speed ModeImportant Warning Control Loop DescriptionPID tuning in Speed Mode PID tuning in Speed ModeAX3500 Motor Controller User’s Manual 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 Closed Loop Speed ModeAX3500 Motor Controller User’s Manual Normal and Fault Condition LED Messages Use of the LED DisplayUse of the LED Display AX3500 Motor Controller User’s ManualMotor Direction Status Normal and Fault Condition LED MessagesPossible Display MotorFault Messages No ControlFault Messages Possible DisplayTemporary Faults Permanent FaultsSelf-Test Display Normal and Fault Condition LED MessagesSelf-Test Display = Software version 1.9bAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Normal and Fault Condition LED MessagesVersion 1.9b. June 1 SECTION 12 R/C Operation Mode DescriptionMode Description AX3500 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 74. RC Cable wiring diagramR/C Operation FIGURE 75. 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 AX3500 Motor Controller User’s ManualReception Watchdog Reception WatchdogAX3500 Motor Controller User’s Manual Important Notice about PCM Radios R/C Transmitter/Receiver Quality ConsiderationsR/C Operation AX3500 Motor Controller User’s ManualJoystick Deadband Programming Joystick Deadband ProgrammingDeadband Parameter Value Deadband as Percent of full Joystick TravelLeft/Right Tuning Adjustment Joystick CalibrationCommand Control Curves R/C OperationAutomatic Joystick Calibration Automatic Joystick CalibrationAX3500 Motor Controller User’s Manual Data Logging in R/C Mode Important NoticeR/C Operation On before entering joystick calibrationData Logging in R/C Mode AX3500 Motor Controller User’s ManualDB15 Male To ControllerAX3500 Motor Controller User’s Manual R/C OperationVersion 1.9b. June 1 Analog 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 AX3500 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 AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Analog Control and OperationVersion 1.9b. June 1 Serial RS-232 Controls and Operation Use and benefits of RS232Use and benefits of RS232 AX3500 Motor Controller User’s ManualConnector I/O Pin Assignment RS232 Mode SignalPin1 Serial RS-232 Controls and OperationCable configuration Extending the RS232 CableCable configuration AX3500 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 AX3500 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 AX3500 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 OutputQuery Power Applied to Motors Controller Commands and QueriesQuery Amps from Battery to each Motor Channel Important NoticeImportant Notice Serial RS-232 Controls and OperationQuery Heatsink Temperatures Query Analog InputsController Commands and Queries ?r or ?RQuery Battery Voltages Reset ControllerQuery Digital Inputs Serial RS-232 Controls and OperationAccessing & 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 AccelerationAccess After Reset or FFInput Switches Function Accessing & Changing Configuration Parameter in FlashAccess After Reset or FFLeft/Right Adjust RC Joystick or Analog DeadbandExponentiation on Channel 1 and Channel AccessDefault Encoder Time Base 1 and Default Encoder Distance DividerAccessing & Changing Configuration Parameter in Flash AccessDefault PID Gains Joystick Min, Max and Center ValuesAccess After Reset or FFReading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at RuntimeDefinition See pagesOperating Modes Registers Read/Change PID ValuesAccess Access Read/Write Effective InstantlyPWM Frequency Register Controller Status RegisterAddress Access Read/Write Effective Instantly AccessController Identification Register Current Amps Limit RegistersAccess AccessRS232 Encoder Command Set Set/Reset Encoder Counters and Destination RegistersRead Encoder Counter RS232 Encoder Command SetRead Speed q or !Q nSyntax AX3500 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 AccessSpeed or Distance 1 or Counter Read/Write MailboxCounter 1 and Destination Register 1 andDistance 1 and Speed 1 andTime Base 1 and Encoder ThresholdCounter Read Data Format RC Pulse Outputs ActivationDefault Value AccessEncoder Testing and Setting Using the PC Utility Decimal32-bit Hex Controller OutputAutomatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeAX3500 Motor Controller User’s Manual 00 11 22 33 44 55 66 77 88 99 AA BB CC Analog and R/C Modes Data Logging String FormatData Logging Cables AX3500 Motor Controller User’s ManualDecimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Version 1.9b. June 1SECTION 15 Configuring the Controller using the Switches Programming using built-in Switches and DisplayProgramming Methods AX3500 Motor Controller User’s ManualEntering Programming Mode Configuring the Controller using the SwitchesProgram AX3500 Motor Controller User’s ManualChanging parameters The Special Case of Joystick CalibrationProgramming using built-in Switches and Display Important WarningRestoring factory defaults Exiting the Parameter Setting ModeProgrammable Parameters List Configuring the Controller using the SwitchesPossible Values default For safety reasons, the modes belowcannot be selected using the switches Programmable Parameters ListConfiguring the Controller using the Switches Possible Values defaultOrder LetterSECTION 16 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements AX3500 Motor Controller User’s ManualUsing the Roborun Configuration Utility Connecting the Controller to the PCAX3500 Motor Controller User’s Manual Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions1- Program Revision Number 2- Controller and Communication Link InformationGetting On-Screen Help Using the Roborun Configuration Utility3- Parameter Selection and Setting and Special Functions 4- File and Program Management CommandsControl Settings Loading, Changing Controller Parameters2- Motor Control Mode Loading, Changing Controller ParametersPower Settings Using the Roborun Configuration Utility3- Input Command Adjustment 4- Emergency Stop or Invert Switch SelectAnalog or R/C Specific Settings Loading, Changing Controller Parameters 2- Left/Right Adjust3- Acceleration Setting 1- DeadbandEncoder Setting and Testing Closed Loop ParametersUsing the Roborun Configuration Utility AX3500 Motor Controller User’s ManualEncoder Setting and Testing Encoder Module Parameters SettingAX3500 Motor Controller User’s Manual RC Output Testing Exercising the MotorsViewing Encoder Data Using the Roborun Configuration UtilityRunning the Motors Running the MotorsAX3500 Motor Controller User’s Manual Using the Roborun Configuration Utility 2- Motor Power setting1- Run/Stop Button 3- Measurement4- Real-Time Strip Chart Recorder 6- Input Status and Output SettingRunning the Motors 5- Transmit and Receive DataLogging Data to Disk Using the Roborun Configuration Utility7- Data Logging and Timer 8- Joystick EnableConnecting a Joystick Running the MotorsParameter Header Data type/rangeUsing the Console Using the Roborun Configuration Utility2- Command Entry 1- Terminal ScreenViewing 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 ModesUsing the Roborun Configuration Utility Operating the AX3500 over a Wired or Wireless LANAX3500 Motor Controller User’s Manual Updating the Controller’s Software Important WarningUpdating the Controller’s Software AX3500 Motor Controller User’s ManualCreating Customized Object Files Updating the Encoder SoftwareUsing the Roborun Configuration Utility Important WarningCreating Customized Object Files AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Using the Roborun Configuration UtilityVersion 1.9b. June 1 Mechanical Specifications Mechanical DimensionsMechanical Dimensions AX3500 Motor Controller User’s ManualMounting Considerations Thermal ConsiderationsMechanical Specifications AX3500 Motor Controller User’s ManualAttaching the Controller Directly to a Chassis Attaching the Controller Directly to a ChassisAX3500 Motor Controller User’s Manual Mechanical Specifications Precautions to observeAX3500 Motor Controller User’s Manual Wire Dimensions WeightWire Dimensions AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Mechanical SpecificationsVersion 1.9b. June 1