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RoboteQ AX3500 user manual Regeneration Current Limiting, Important Warning, General Operation

Models: AX3500

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Motor Current = Battery Current / PWM Ratio

General Operation

Vbat

On

Motor

Off

FIGURE 19. Current flow during operation

On	Off
	I mot
	Avg
	I bat
	Avg

FIGURE 20. 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 AX3500’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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AX3500 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

Image 46

RoboteQ Regeneration Current Limiting, Important Warning, General Operation, AX3500 Motor Controller User’s Manual

Contents

AX3500 Dual Channel High Power Digital Motor ControllerUser’s Manual AX3500 Motor Controller User’s Manual Version 1.9b. June 1Date Revision HistoryRevision History 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 1Do not Connect to a RC Radio with a Battery Attached Important SafetyAvoid Shorts when Mounting Board against Chassis WarningsAX3500 Motor Controller User’s Manual Important Safety WarningsVersion 1.9b. June 1 Quick Start Locating the Switches and ConnectorsAX3500 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 Signal Connecting to the 15-pin ConnectorImportant Warning RC ModeConnecting the R/C Radio Connecting the R/C RadioPowering On the Controller Important WarningProg and Set button status Button OperationAX3500 Quick Start FunctionDefault Values Default Controller ConfigurationDefault Controller Configuration 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 AX3500 Quick Start Exploring further= Software version 1.9b AX3500 Motor Controller User’s ManualProduct Description SECTION 3AX3500 Motor Controller OverviewAX3500 Motor Controller User’s Manual Automatic Joystick Command Corrections Technical featuresMultiple Command Modes AX3500 Motor Controller OverviewHigh Efficiency Motor Power Outputs Technical featuresLow Power Consumption Optical Encoder InputsData Logging Capabilities Advanced Safety FeaturesAX3500 Motor Controller Overview Compact Open Frame PCB DesignPower Connections Connecting Power and Motors to the ControllerPower Connections Important WarningConnecting Power and Motors to the Controller Controller PowerAX3500 Motor Controller User’s Manual And Main Battery Controller PowerPower Control input is mended Off ConfigurationConnecting Power and Motors to the Controller Controller Powering SchemesPowering the Controller from a single Battery Power Control input isImportant Warning Powering the Controller Using a Main and Backup BatteryController Powering Schemes AX3500 Motor Controller User’s ManualImportant Warning Connecting the MotorsConnecting Power and Motors to the Controller Important WarningSingle Channel Operation Single Channel OperationConverting the AX3500 to Single Channel AX3500 Motor Controller User’s ManualImportant Warning Power FusesConnecting Power and Motors to the Controller AX3500 Motor Controller User’s ManualElectrical Noise Reduction Techniques Wire Length LimitsPower Regeneration Considerations Wire Length LimitsConnecting Power and Motors to the Controller Overvoltage ProtectionUndervoltage Protection 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 Basic Operation Input Command ModesGeneral Operation Basic OperationOpen Loop, Mixed Speed Control Selecting the Motor Control ModesOpen Loop, Separate Speed Control General OperationSelecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control AX3500 Motor Controller User’s ManualPosition Feedback Position Sensor Gear box User Selected Current Limit SettingsTemperature-Based Current Limitation SettingTemperature Battery Current vs. Motor CurrentBattery Current vs. Motor Current Motor Current = Battery Current / PWM ratioImportant Warning Regeneration Current LimitingMotor Current = Battery Current / PWM Ratio General OperationSetting Using Programmable AccelerationSetting Using SwitchesSetting Using Command Control CurvesSetting Using SwitchesExponentiation Parameter Value Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Selected CurveGeneral Operation Speed AdjustmentSpeed Adjustment Parameter ValueActivating Brake Release or Separate Motor Excitation Emergency Shut Down Using Controller SwitchesEmergency Stop using External Switch Speed AdjustmentUsing 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= Software version 1.9b Self-Test ModeSelf-Test Mode AX3500 Motor Controller User’s ManualEncoder Speed or Position Important WarningGeneral Operation AX3500 Motor Controller User’s ManualAX3500 Connections Connecting Sensors and Actuators to Input/OutputsAX3500 Connections AX3500 Motor Controller User’s ManualConnecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and OutputsAX3500 Motor Controller User’s Manual I/O type SignalAX3500’s Inputs and Outputs ActivatedConnecting Sensors and Actuators to Input/Outputs Pin1I/O List and Pin Assignment Signal dependingSignal depending Connecting devices to Output CConnecting devices to Output C on ModeConnecting Sensors and Actuators to Input/Outputs Connecting Switches or Devices to Input FImportant warning 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 Sensors and Actuators to Input/Outputs Connecting Position Potentiometers to Analog InputsAnalog Inputs AX3500 Motor Controller User’s ManualOperating Mode Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Important WarningImportant Warning Connecting Sensors and Actuators to Input/OutputsOperating Mode Ana 1 p11Temp oC Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Resistance kOhmConnecting Sensors and Actuators to Input/Outputs Using the Analog Inputs to Monitor External VoltagesAX3500 Motor Controller User’s Manual Internal Voltage Monitoring Sensors Connecting User Devices to Analog InputsInternal Heatsink Temperature Sensors Connecting User Devices to Analog InputsAX3500 Motor Controller User’s Manual Temperature Conversion C Source CodeConnecting Sensors and Actuators to Input/Outputs Valueelse Internal Heatsink Temperature SensorsAX3500 Motor Controller User’s Manual LoTemp = i * 5AX3500 Motor Controller User’s Manual Connecting Sensors and Actuators to Input/OutputsVersion 1.9b. June 1 RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview AX3500 Motor Controller User’s ManualServo Connection to RevA Controllers Connector Location and PinoutConnecting Servos to Controllers RC Pulses OutputConnecting to Slave Controllers Connecting to Slave ControllersServo Connection to RevB Controllers AX3500 Motor Controller User’s ManualPulse Width 1.00ms Pulse Timing InformationCommand Value 1.50msImportant Warning RC Channel Testing Using the PC UtilityRC Channel Testing Using the PC Utility AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual RC Pulses OutputVersion 1.9b. June 1 Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview AX3500 Motor Controller User’s ManualConnecting and Using the Encoder Function Recommended Encoder TypesAX3500 Motor Controller User’s Manual Pulse Frequency in Hz = RPM / 60 * PPR Connecting the EncoderConnecting the Encoder AX3500 Motor Controller User’s ManualConnecting and Using the Encoder Function Cable Length and Noise ConsiderationsMotor - Encoder Polarity Matching Important WarningVoltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit SwitchesAX3500 Motor Controller User’s Manual Important Warning Wiring Optional Limit SwitchesConnecting and Using the Encoder Function AX3500 Motor Controller User’s ManualWiring Limit Switches Without Encoders Wiring Limit Switches Without EncodersEffect of Limit Switches Motor 1 FwdConnecting and Using the Encoder Function Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Motor 2 FwdUsing the Encoder to Track Position Using the Encoder to Track PositionImportant Notice AX3500 Motor Controller User’s ManualThe actual formula is as follows Connecting and Using the Encoder FunctionImportant Notice Distance = Destination - Counter value / DividerRS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC UtilityRS232 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 Selecting the Position Mode Closed Loop Position ModeMode Description Mode DescriptionClosed Loop Position Mode Position Sensor SelectionSensor Mounting Position Feedback Position Sensor Gear boxFeedback Potentiometer wiring Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode Important NoticeImportant Notice Feedback Potentiometer wiring in Analog ModeClosed Loop Position Mode AX3500 Motor Controller User’s ManualAnalog Feedback on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersFeedback Wiring in Analog Mode on Single Channel Controllers Important NoticeClosed Loop Position Mode Using Optical Encoders in Position ModeSensor and Motor Polarity Important WarningAdding Safety Limit Switches Important Safety WarningEncoder Error Detection and Protection 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 Using Current Limiting as ProtectionControl Loop Description 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 Mode Description Closed Loop Speed ModeSelecting the Speed Mode Mode DescriptionTachometer or Encoder Mounting Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer wiring Closed Loop Speed ModeSpeed Sensor and Motor Polarity Speed Sensor and Motor PolarityImportant Warning AX3500 Motor Controller User’s ManualImportant Warning Adjust Offset and Max SpeedClosed Loop Speed Mode 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 Use of the LED Display Normal and Fault Condition LED MessagesUse of the LED Display AX3500 Motor Controller User’s ManualPossible Display Motor Direction StatusNormal and Fault Condition LED Messages MotorFault Messages Fault MessagesNo Control Possible DisplaySelf-Test Display Temporary FaultsPermanent Faults 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 Mode Description SECTION 12 R/C OperationMode Description AX3500 Motor Controller User’s ManualSignal Selecting the R/C Input ModeConnector I/O Pin Assignment R/C Mode Pin1Signal R/C Input Circuit DescriptionSupplied Cable Description R/C Input Circuit DescriptionR/C Operation Powering the Radio from the controllerFIGURE 74. RC Cable wiring diagram FIGURE 75. RC connection cable6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command Pulses Powering the Radio from the controller3 Channel 1 Command Pulses 4 Channel 2 Command Pulses Wire loop bringing power from controller to RC radioR/C Operation Connecting to a Separately Powered RadioOperating the Controller in R/C mode AX3500 Motor Controller User’s ManualReception Watchdog Reception WatchdogAX3500 Motor Controller User’s Manual R/C Operation Important Notice about PCM RadiosR/C Transmitter/Receiver Quality Considerations AX3500 Motor Controller User’s ManualDeadband Parameter Value Joystick Deadband ProgrammingJoystick Deadband Programming Deadband as Percent of full Joystick TravelCommand Control Curves Left/Right Tuning AdjustmentJoystick Calibration R/C OperationAutomatic Joystick Calibration Automatic Joystick CalibrationAX3500 Motor Controller User’s Manual R/C Operation Data Logging in R/C ModeImportant Notice On before entering joystick calibrationDB15 Male Data Logging in R/C ModeAX3500 Motor Controller User’s Manual To ControllerAX3500 Motor Controller User’s Manual R/C OperationVersion 1.9b. June 1 Mode Description Analog Control and OperationMode Description Important NoticePin1 Connector I/O Pin Assignment Analog ModeSignal Analog Control and OperationConnecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer AX3500 Motor Controller User’s ManualSelecting the Potentiometer Value Important NoticeAnalog Deadband Adjustment Data Logging in Analog Mode Power-On SafetyUnder Voltage Safety 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 Use and benefits of RS232 Serial RS-232 Controls and OperationUse and benefits of RS232 AX3500 Motor Controller User’s ManualPin1 Connector I/O Pin Assignment RS232 ModeSignal Serial RS-232 Controls and OperationCable configuration Cable configurationExtending the RS232 Cable AX3500 Motor Controller User’s ManualEstablishing Manual Communication with a PC Communication Settings9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Serial RS-232 Controls and OperationRoboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC AX3500 Motor Controller User’s ManualSerial RS-232 Controls and Operation Entering RS232 from R/C or Analog modeData Logging String in R/C or Analog mode AX3500 Motor Controller User’s ManualCommand Acknowledgement Commands Acknowledge and Error MessagesRS232 Mode if default Command ErrorCommand Controller Commands and QueriesRS-232 Watchdog Serial RS-232 Controls and OperationQuery Power Applied to Motors Set Motor Command ValueSet Accessory Output Controller Commands and QueriesImportant Notice Query Amps from Battery to each Motor ChannelImportant Notice Serial RS-232 Controls and OperationController Commands and Queries Query Heatsink TemperaturesQuery Analog Inputs ?r or ?RQuery Digital Inputs Query Battery VoltagesReset Controller Serial RS-232 Controls and OperationAccessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameterLocation Flash Configuration Parameters ListSerial RS-232 Controls and Operation DescriptionAccessing & Changing Configuration Parameter in Flash Input Control ModeMotor Control Mode AccessAccess Amps LimitAcceleration After Reset or FFAccess Input Switches FunctionAccessing & Changing Configuration Parameter in Flash After Reset or FFExponentiation on Channel 1 and Channel Left/Right AdjustRC Joystick or Analog Deadband AccessAccessing & Changing Configuration Parameter in Flash Default Encoder Time Base 1 andDefault Encoder Distance Divider AccessAccess Default PID GainsJoystick Min, Max and Center Values After Reset or FFDefinition Reading & Changing Operating Parameters at RuntimeReading & Changing Operating Parameters at Runtime See pagesAccess Operating Modes RegistersRead/Change PID Values Access Read/Write Effective InstantlyAddress Access Read/Write Effective Instantly PWM Frequency RegisterController Status Register AccessAccess Controller Identification RegisterCurrent Amps Limit Registers AccessRead Encoder Counter RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetSyntax Read Speedq or !Q n AX3500 Motor Controller User’s ManualRead Speed/Distance Read Encoder Limit Switch StatusRead Distance RS232 Encoder Command SetSwitch Important NoteRead / Modify Encoder Module Registers and Parameters SwitchModify parameter RS232 Encoder Command SetAccess AddressEncoder Hardware ID code Switch StatusRegister Description AccessCounter 1 and Speed or Distance 1 orCounter Read/Write Mailbox Destination Register 1 andTime Base 1 and Distance 1 andSpeed 1 and Encoder ThresholdDefault Value Counter Read Data FormatRC Pulse Outputs Activation Access32-bit Hex Encoder Testing and Setting Using the PC UtilityDecimal Controller OutputAutomatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeAX3500 Motor Controller User’s Manual Data Logging Cables 00 11 22 33 44 55 66 77 88 99 AA BB CCAnalog and R/C Modes Data Logging String Format 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 1Programming Methods SECTION 15 Configuring the Controller using the SwitchesProgramming using built-in Switches and Display AX3500 Motor Controller User’s ManualProgram Entering Programming ModeConfiguring the Controller using the Switches AX3500 Motor Controller User’s ManualProgramming using built-in Switches and Display Changing parametersThe Special Case of Joystick Calibration Important WarningProgrammable Parameters List Restoring factory defaultsExiting the Parameter Setting Mode Configuring the Controller using the Switchescannot be selected using the switches Possible Values defaultFor safety reasons, the modes below Programmable Parameters ListOrder Configuring the Controller using the SwitchesPossible Values default LetterSystem Requirements SECTION 16 Using the Roborun Configuration UtilityDownloading and Installing the Utility AX3500 Motor Controller User’s ManualUsing the Roborun Configuration Utility Connecting the Controller to the PCAX3500 Motor Controller User’s Manual 1- Program Revision Number Roborun Frame, Tab and Menu DescriptionsRoborun Frame, Tab and Menu Descriptions 2- Controller and Communication Link Information3- Parameter Selection and Setting and Special Functions Getting On-Screen HelpUsing the Roborun Configuration Utility 4- File and Program Management Commands2- Motor Control Mode Control SettingsLoading, Changing Controller Parameters Loading, Changing Controller Parameters3- Input Command Adjustment Power SettingsUsing the Roborun Configuration Utility 4- Emergency Stop or Invert Switch Select3- Acceleration Setting Analog or R/C Specific SettingsLoading, Changing Controller Parameters 2- Left/Right Adjust 1- DeadbandUsing the Roborun Configuration Utility Encoder Setting and TestingClosed Loop Parameters AX3500 Motor Controller User’s ManualEncoder Setting and Testing Encoder Module Parameters SettingAX3500 Motor Controller User’s Manual Viewing Encoder Data RC Output TestingExercising the Motors Using the Roborun Configuration UtilityRunning the Motors Running the MotorsAX3500 Motor Controller User’s Manual 1- Run/Stop Button Using the Roborun Configuration Utility2- Motor Power setting 3- MeasurementRunning the Motors 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting 5- Transmit and Receive Data7- Data Logging and Timer Logging Data to DiskUsing the Roborun Configuration Utility 8- Joystick EnableParameter Header Connecting a JoystickRunning the Motors Data type/range2- Command Entry Using the ConsoleUsing the Roborun Configuration Utility 1- Terminal Screen4- 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 ModesUsing the Roborun Configuration Utility Operating the AX3500 over a Wired or Wireless LANAX3500 Motor Controller User’s Manual Updating the Controller’s Software Updating the Controller’s SoftwareImportant Warning AX3500 Motor Controller User’s ManualUsing the Roborun Configuration Utility Creating Customized Object FilesUpdating the Encoder Software 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 Dimensions Mechanical SpecificationsMechanical Dimensions AX3500 Motor Controller User’s ManualMechanical Specifications Mounting ConsiderationsThermal Considerations 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 Wire DimensionsWeight AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Mechanical SpecificationsVersion 1.9b. June 1