ADLINK PCI-8144 User Manual

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PCI-8144

4-Axis Stepper

Motion Control Card

User’s Manual

Manual Rev. 2.01 Revision Date: September 2, 2008 Part No: 50-11144-1010

Advance Technologies; Automate the World.

The information in this document is subject to change without prior notice in order to improve reliability , design, and function and does not represent a commitment on the part of the manufacturer.

In no event will the manufacturer be liable for direct, indirect, special, incidental, or consequential damages arising out of the use or inability to use the product or documentation, even if advised of the possibility of such damages.

This document contains proprietary information protected by copyright. All rights are reserved. No part of this manual may be reproduced by any mechanical, elec tronic, or other means in a ny form without prior written permission of the manufacturer.

Trademarks NuDAQ, NuIPC, DAQBench are registered trademarks of ADLINK

Technology Inc. Product names mentioned herein are used for identification pur-

poses only and may be trademarks and/or registered trademarks of their respective companies.

Getting Service from ADLINK

Customer Satisfaction is top priority for ADLINK Technology Inc. Please contact us should you require any service or assistance.

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Web Site: http://www.adlinktech.com Sales & Service: Service@adlinktech.com TEL: +886-2-82265877 FAX: +886-2-82265717 Address: 9F, No. 166, Jian Yi Road, Chungho City,

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Please email or FAX this completed service form for prompt and satisfactory service.

List of Tables

Table 2-1: SW1 Card Index ..................................................... 13

Table 2-2: JP2 Direct Control to Stepper ................................. 14

Table 2-3: CN1 Pin Assignments ............................................. 15

Table 6-1: Data type definitions .............................................. 71

List of Tables v

List of Figures

Figure 1-1: PCI-8144 Block Diagram ........................................... 2

Figure 1-2: Flow chart for building an application ........................ 4

Figure 2-1: PCB Layout of the PCI-8144 ................................... 10

vi List of Figures

1 Introduction

The PCI-8144 is a cost-effective 4-axis motion controller card with a PCI interface that can generate a pulse train up to 2.4MHz to control a stepper motor. As a motion controller, it provides nonsymmetric acceleration and deceleration speed profile settings, Tcurve and S-surve speed profile control, and simultaneously start/ stop. Changing speed on the fly is also available with a single axis operation.

Multiple PCI-8144 cards can be installed in one system. The onboard switch can be used to the set a specific index for each board in order to manage multiple cards.

Figure 1 shows the functional block diagram of the PCI-8144 card. All functions and computations are performed internally by the ASIC, thus limiting the impact on the PC’s CPU.

Introduction 1

Figure 1-1: PCI-8144 Block Diagram

2Introduction

MotionCreatorPro is a Windows-based application development software package included with the PCI-8144 and is useful for debugging a motion control system during the design phase of a project. An on-screen display lists information of all installed axes and I/O signal status of the PCI-8144.

Windows programming libraries are also included for C++ and Visual Basic. Sample programs are provided to illustrate the operations of the functions.

Introduction 3

Figure 1-2 illustrates a flow chart of the recommended process in using this manual in developing an application. Refer to the related chapters for details of each step.

Figure 1-2: Flow chart for building an application

4Introduction

1.1 Features

The following list summarizes the main features of the PCI-8144 motion control system.

X 32-bit PCI bus Plug and Play X 4 pulse train channel for stepping motors X Maximum output frequency: up to 2.4MPPS X Pulse output options: CW/CCW X Programmable acceleration and deceleration time for all

modes

X Trapezoidal and S-curve velocity profiles for all modes X Change speed on the fly X Home return modes with ORG & SD signal X Hardware backlash compensator and vibration suppression X Card index setting by switch X All digital input and output signals are 2500Vrms isolated X Programmable interrupt sources X Simultaneous start/stop X Software supports a maximum of up to 12 PCI-8144 cards

operation in one system

X Includes MotionCreatorPro, a Microsoft Windows-based

application development software

X PCI-8144 libraries and utilities for Windows 2000/XP.

Introduction 5

1.2 Specifications

Applicable Motors

Z Stepping motors Z Excitation sequencing output for 2-phase stepping motor

with JP2 connector

Performance

Z Number of controllable axes: 4 Z Maximum pulse output frequency: 2.4MPPS, trapezoi-

dal, or S-Curve speed profile

Z Internal reference clock: 4.9MHz Z Position pulse setting range (28-bit): -134,217,728 to

+134,217,728

I/O Signales

Z Input/Output signals for each axis Z All I/O signal are optically isolated with 2500Vrms isola-

tion voltage

Z Command pulse output pins: CW and CCW Z Mechanical limit/switch signal input pins: ±EL, PSD/

MSD, and ORG

Z Digital input/output: DIN & DOUT Z Simultaneous Start/Stop signal: STA and STP

General Specifications

Z Connectors: 68-pin SCSI-type connector Z Operating Temperature: 0°C - 50°C Z Storage Temperature: -20°C - 80°C Z Humidity: 5 - 85%, non-condensing

Power Consumption

Z Slot power supply (input): +5V DC ±5%, 900mA max Z External power supply (input): +24V

max

Z External power supply (output): +5V

max

±5%, 500mA

±5%, 500mA,

6Introduction

PCI-8144 Dimensions

Z 159mm(L) X 126 mm(W)

1.3 Supported Software

1.3.1 Programming Library

Windows 2000/XP DLLs are provided for the PCI-8144. These function libraries are shipped with the board.

1.3.2 MotionCreatorPro

This Windows-based utility is used to setup cards, motors, and systems. It can also aid in debugging hardware and sof tware problems. It allows for the setting of I/O logic parameters to be loaded in custom program. This product is also bundled with the card.

Refer to Chapter 5 for more details.

Introduction 7

8Introduction

2 Installation

This chapter describes how to install PCI-8144. Please follow these steps below:

X Check what you have (section 2.1) X Check the PCB (section 2.2) X Install the hardware (section 2.3) X Install the software driver (section 2.4) X Understanding the I/O signal connections (chapter 3) and

their operation (chapter 4)

X Understanding the connector pin assignm e nts (the rem a in-

ing sections) and wiring the connections

2.1 Package Contents

In addition to this User’s Guide, the package also includes the following items:

X PCI-8144: 4-Axis Stepper Motion Control Card X ADLINK All-in-one Compact Disc X An optional terminal board for wiring purposes if a different

model is ordered.

If any of these items are missing or damaged, contact the dealer from whom you purchased the product. Save the shipping materials and carton to ship or store the product in the future.

Installation 9

2.2 PCI-8144 Outline Drawing

Figure 2-1: PCB Layout of the PCI-8144

X CN1: Input/Output signal connector X JP2: Direct control to stepper X SW1: Card ID selection X J1-J8: Pulse output selection jumper

10 Installation

2.3 PCI-8144 Hardware Installation

2.3.1 Hardware configuration

The PCI-8144 is fully Plug-and-Play compliant. Hence, memory allocation (I/O port locations) and IRQ channel of the PCI card are assigned by the system BIOS. The address assignment is done on a board-by-board basis for all PCI cards in the system.

2.3.2 PCI slot selection

Some computer system may hav e both PC I and ISA slots. Do not force the PCI card into a PC/AT slot. The PCI-8144 can be used in any PCI slot.

2.3.3 Installation Procedures

1. Read through this manual and setup the jumper according to your application

2. Turn off your computer. Turn off all accessories (printer, modem, monitor, etc.) connected to computer. Remove the cover from the computer.

3. Select a 32-bit PCI expansion slot. PCI slots are shorter than ISA or EISA slots and are usually white or ivory.

4. Before handling the PCI-8144, discharge any static buildup on your body by touching the metal case of the computer. Hold the edge of the card and do not touch the components.

5. Position the board into the PCI slot you have selected.

6. Secure the card in place at the rear panel of the system unit using screws removed from the slot.

2.3.4 Troubleshooting:

If your system doesn’t boot or if you experience erratic operation with your PCI board in place, it’s most likely caused by an interrupt conflict (possibly an incorrect ISA setup). In general, the solution, once determined it is not a simple oversight, is to consult the BIOS documentation that comes with your system.

Installation 11

Check the control panel of the Windows system if the card is listed by the system. If not, check the PCI settings in the BIOS or use another PCI slot.

12 Installation

2.4 Software Driver Installation

1. Auto run the ADLINK All-In-One CD. Choose Driver Installation -> Motion Control -> PCI-8144.

2. Follow the procedures of the installer.

3. After setup installation is completed, restart windows.

Note: Please download the latest software from ADLINK website if

necessary.

2.5 SW1 Card Index Selection

The SW1 switch is used to set the card index. For example, if 1 is set to ON and the others are OFF, that card index is 1. The index value can be from 0 to 15. Refer to the following table for details.

Card ID Switch Setting (ON=1)

00000 10001 20010 3 0011 40100 50101 60110 7 0111 81000

91001 10 1010 11 1011 12 1100 13 1101 14 1110 15 1111

Table 2-1: SW1 Card Index

Installation 13

2.6 J1-J8 Pulse Output Type: Differential / Open Collector

Jumpers J1-J8 are used to set the ty pe of pulse output signals. The output signal type can either be differential line driver or open collector output. Refer to section 3.1 for detail jumper settings.

J1 & J2 Axis 0 J3 & J4 Axis 1 J5 & J6 Axis 2 J7 & J8 Axis 3

2.7 JP2 Direct Control to Stepper

No. Name Function No. Name Function

1 DGND Bus power ground 2 PB4 Axis 3 Pulser PHB 3 PA4 Axis 4 Pulser PHA 4 PB3 Axis 2 Pulser PHB 5 PA3 Axis 3 Pulser PHA 6 VCC Bus Power +5V 7 DGND Bus power ground 8 PB2 Axis 1 Pulser PHB

9 PA2 Axis 1 Pulser PHA 10 PB1 Axis 0 Pulser PHB 11 PA1 Axis 0 Pulser PHA 12 VCC Bus Power +5V 13 -- N/A 14 -- N/A 15 -- N/A 16 -- N/A 17 -- N/A 18 -- N/A 19 -- N/A 20 -- N/A

Table 2-2: JP2 Direct Control to Stepper

14 Installation

2.8 CN1 Pin Assignments: Main connector

CN1 is the major connector for the motion control I/O signals.

No. Name I/O Function No. Name I/O Function

1 VDD O I solated +5V Output 35 VDD O Isolated +5V Output 2 EGND - Ext. power ground 36 EGND - Ext. power ground 3 CW+ O Positive pulse (+) 37 CW+ O Positive pulse (+) 4 CW- O Positive pulse (-) 38 CW- O Positive pulse (-) 5 CCW+ O Negative pulse (+) 39 CCW+ O Negative pulse (+) 6 CCW- O Negative pulse (- ) 40 CCW- O Negative pulse (-) 7 PEL0 I Positive end limit signal 41 PEL2 I Positive end limit signal 8 MEL0 I Negative end limit signal 42 MEL2 I Negative end limit signal

9 PSD0 I Positive slow down signal 43 PSD2 I Positive slow down signal 10 MSD0 I Negative slow down signal 44 MSD2 I Negative slow down signal 11 ORG0 I Origin signal 45 ORG2 I Origin signal 12 EGND - Ext. power ground 46 EGND - Ext. power ground 13 CW+ O Positive pulse (+) 47 CW+ O Positive pulse (+) 14 CW- O Positive pulse (-) 48 CW- O Positive pulse (-) 15 CCW+ O Negative pulse (+) 49 CCW+ O Negative pulse (+) 16 CCW- O Negative pulse (-) 50 CCW- O Negative pulse (-) 17 PEL1 I Positive end limit signal 51 PEL3 I Positive end limit signal 18 MEL1 I Negative end limit signal 52 MEL3 I Negative end limit signal 19 PSD1 I Positive slow down signal 53 PSD3 I Positive slow down signal 20 MSD1 I Negative slow down signal 54 MSD3 I Negative slow down signal 21 ORG1 I Origin signal 55 ORG3 I Origin signal 22 STP/EMG I Forced stop signal 56 STA I External start signal 23 DIN0 I Digital Input 0 57 DOUT0 O Digital Output 0 24 DIN1 I Digital Input 1 58 DOUT1 O Digital Output 1 25 DIN2 I Digital Input 2 59 DOUT2 O Digital Output 2 26 DIN3 I Digital Input 3 60 DOUT3 O Digital Output 3 27 DIN4 I Digital Input 4 61 DOUT4 O Digital Output 4 28 DIN5 I Digital Input 5 62 DOUT5 O Digital Output 5 29 DIN6 I Digital Input 6 63 DOUT6 O Digital Output 6 30 DIN7 I Digital Input 7 64 DOUT7 O Digital Output 7 31 VDD - Isolated +5V Output 65 DO_COM - Common for DO 32 VDD - Isolated +5V Output 66 DO_COM - Common for DO 33 EGND - Ext. power ground 67 EGND - Ext. power ground 34 EX+24V I +24V isolation power input 68 EX+24V I +24V isol ation power input

Table 2-3: CN1 Pin Assignments

Installation 15

16 Installation

3 Signal Connections

Signal connections of all I/O’s are described in this chapter. Refer to the contents of this chapter before wiring any cables between the PCI-8144 and any stepper drivers.

This chapter contains the following sections: Section 3.1 Pulse Output Signals CW and CCW

Section 3.2 Orig in Sign al ORG Section 3.3 Slow Down input signal Section 3.4 End- Lim it Signa ls PEL an d MEL Section 3.5 Simultaneous start/stop signals STA and STP Section 3.6 Termination Board Section 3.7 General-purposed DIO Section 3.8 JP2 pin definition for stepping singal (Optional)

Signal Connections 17

3.1 Pulse Output Signals CW and CCW

There are 4 axis pulse output signals on the PCI-8144. For each axis, two pairs of CW and CCW signals are used to transmit the pulse train and to indicate the direction. In this section, the electrical characteristics of the CW and CCW signals are detailed. Each signal consists of a pair of differential signals. For example, CW2 consists of CW2+ and CW2- signals. The following table shows all pulse output signals on CN1.

CN1 Pin No. Signal Name Description Axis #

3 CW0+ Pulse signals (+) 1 4 CW0- Pulse signals (-) 1 5 CCW0+ Direction signal (+) 1

6 CCW0- Direction signal (-) 1 13 CW1+ Pulse signals (+) 2 14 CW1- Pulse signals (-) 2 15 CCW1+ Direction signal (+) 2 16 CCW1- Direction signal (-) 2 17 CW2+ Pulse signals (+) 3 18 CW2- Pulse signals (-) 3 39 CCW2+ Direction signal (+) 3 40 CCW2- Direction signal (-) 3 47 CW3+ Pulse signals (+) 4 48 CWT3- Pulse signals (-) 4 49 CCW3+ Direction signal (+) 4 50 CCW3- Direction signal (-) 4

18 Signal Connections

The output of the CW or CCW signals can be configured by jumpers as either differential line drivers or open collector output. Users can select the output mode either by closing breaks between 1 and 2 or 2 and 3 of jumpers J1-J8 as follows:

Output Signal

CW0- J1 J1

CCW0- J2 J2

CW1- J3 J3

CCW1- J4 J4

CW2- J5 J5

CCW2- J6 J6

CW3- J7 J7

CCW3- J8 J8

For differential line driver output,

close breaks between 1 and 2 of:

For open collector output, close

breaks between 2 and 3 of:

The default setting of CW and CCW is set to differ ential line driver mode.

The following wiring diagram is for CW and CCW signals on the 4 axes.

PCI-8144:

J1~J8

VDD

CW+, CCW+

CW-, CCW-

CW/CCW

D5V

HP0631

26LS31

EGND

Note: If the pulse output is set to open collector output mode, CW-

and CCW- are used to transmit CW and CCW signals. The sink current must not exceed 20mA on the CW- and CCWpins. The default setting of jumper is 1-2 shorted.

Suggest Usage: Jumper 2-3 shorted and conn ect CW+/CCW+ to a 470 ohm pulse input interface’s COM of driver. See the following figure.

Signal Connections 19

Choose one of CW/CCW+ and CW/CCW- to connec t to driver’s OUT/DIR

Warning: The sink current must not exc eed 20mA or t he 2631 will

be damaged!

20 Signal Connections

3.2 Origin Signal ORG

The origin signals (ORG1-ORG4) are used as input signals for the origin of the mechanism. The following table lists signal names, pin numbers, and axis numbers:

CN1 Pin No Signal Name Axis #

11 ORG0 1 21 ORG1 2 45 ORG2 3 55 ORG3 4

The input circuit of the ORG signals is shown below. Usually, a limit switch is used to indicate the origin on one axis. The specifications of the limit switch should have contact capacity of +24V @ 10mA minimum. An internal filter circuit is used to filter out any high frequency spikes, which may cause errors in the operation.

When the motion controller is operated in the home return mode, the ORG signal is used to inhibit the control output signals (CW and CCW). For detailed operations of the ORG signal, refer to Section 4.

Signal Connections 21

3.3 Slow Down input signal

The PCI-8144 provides slow down function through SD input pin. The signal names, pin numbers, and axis numbers are shown in the following table:

CN1 Pin No Signal Name Axis # CN1 Pin No Signal Name Axis #

9 PSD0 1 43 PSD2 3 10 MSD0 1 44 MSD2 3 19 PSD1 2 53 PSD3 4 20 MSD1 2 54 MSD3 4

The SD input pin wiring diagram is as follows:

22 Signal Connections

3.4 End-Limit Signals PEL and MEL

There are two end-limit signals PEL and MEL for each axis. PEL indicates the end limit signal is in the plus direction and ME L indicates the end limit signal is in the minus direction. The signal names, pin numbers, and axis numbers are shown in the table below:

CN1 Pin No Signal Name Axis # CN1 Pin No Signal Name Axis #

7 PEL0 1 41 PEL2 3

8 MEL0 1 42 MEL2 3 17 PEL1 2 51 PEL3 4 18 MEL1 2 52 MEL3 4

A circuit diagram is shown in the diagram below. The external limit switch should have a contact capacity of +24V @ 10mA minimum. EL logical can be configured by registers controlling. For more details on EL operation, refer to Section 4.

Signal Connections 23

3.5 Simultaneously Start/Stop Signals STA and STP

The PCI-8144 provides STA and STP signals, which enable simultaneous start/stop of motions on multiple axes. The STA and STP signals are on CN1, STP @ pin 22 and STA @ pin 56.

The diagram below shows the onboard circuit. The STA and STP signals of the four axes are tied together respectively.

The STP and STA signals are input signals. To operate the start and stop action simultaneously, both software control and external control are needed. With software control, the signals must be generated from external event to the chip of PCD4541. Users can also use an external open collector or switch to drive the STA/STP signals for simultaneous start/stop.

If there are two or more PCI-8144 cards, tie all STA and all STP signals of all cards resepectively for simultaneous start/stop control on all concerned axes. In this case, connect CN1 as below:

24 Signal Connections

3.6 Termination Board

CN1 of the PCI-8144 can be connected with a DIN-68S, including the ACL-10569-1 cable (a 68-pin SCSI-SCSI cable). The DIN-68S is a general purpose 68-pin SCSI-II DIN-socket. It has easy wiring screw terminals and an easily installed DIN socket that can be mounted onto the DIN rails

3.7 General Purpose DIO

PCI-8144 has 8 opto-isolated digital outputs and 8 open collector digital inputs for general purpose use. Pin assignments are illustrated in the table below:

CN1 Pin No Signal Name CN1 Pin No Signal Name

23 DIN0 57 DOUT0 24 DIN1 58 DOUT1 25 DIN2 59 DOUT2 26 DIN3 60 DOUT3 27 DIN4 61 DOUT4 28 DIN5 62 DOUT5 29 DIN6 63 DOUT6 30 DIN7 64 DOUT7

65 DO_COM 66 DO_COM

Signal Connections 25

3.7.1 Isolated Input channels

3.7.2 Isolated Output channels

3.7.3 Example of input connection

DIN

26 Signal Connections

3.7.4 Example of output connection

3.8 JP2 pin define for stepping singal (Optional)

Signal Connections 27

PCI-8144 provides another optional JP2 pins for stepping motor signal. Pin definitions of JP2 and connection example are described as follow:

JP2 Pin No Signal Name JP2 Pin No Signal Name

10 12 14 16

2 4 6 8

Φ2x Φ4x Φ2y Φ4y Φ2z Φ4z Φ2u Φ4u

11 13 15

1 3 5 7 9

Φ1x Φ3x Φ1y Φ3y Φ1z Φ3z Φ1u Φ3u

Pins 17 to 26 are not used Connection example:

28 Signal Connections

4 Operation Theory

This chapter describes the detail operation of the motion controller card. Contents of the following sections are as follows:

Section 4.1: Classifications of Motion Controller Section 4.2: Motion Control Modes Section 4.3: M ot or Drive r Int er face Section 4.4: M ec ha n ical switch Interface Section 4.5: T he Cou n ter s Section 4.6: The Comparators Section 4.7: Other Motion Functions Section 4.8: Interrupt Control Section 4.9: Multiple Cards Operation

4.1 Classifications of Motion Controller

When motor/stepper control first started, motion control was widely discussed instead of motor control. Motor control was separated into two layers: motor control and motion control. Motor control relates to PWM, power stage, closed loop, hall sensors, vector space, etc. Motion control relates to speed profile generating, trajectory following, multi-axes synchronizat ion , an d co ordin a ting .

4.1.1 Voltage motion control interface

The interfaces between motion and motor control are changing rapidly. Early on, a voltage singal was used as a command to the motor controller. The amplitude of the signal means how fast a motor is rotating and the time duration of the voltage changes means how fast a motor acceleration from one speed to the other speed. Voltage signal as a command to motor driver is so called “analog” motion controller. It is much eaiser to integrate into an analog circuit of motor controller; however noise is sometimes a big problem for this type of motion control. Also, to do positioning control of a motor, the analog motion controller must ha ve a feedback signal with position information and use a closed loop control algorithm to make it possible. This increased the complexity of motion control and not easy to use for a beginner.

Operation Theory 29

4.1.2 Pulse motion control interface

The second interface of motion and motor control is a pulse train type. As a trend of digital world, pulse trains represent a new concept to motion control. The counts of pulses show how many ste ps of a motor rotates and the frequency of pulses show how fast a motor runs. The time duration of frequency changes represent the acceleration rate of a motor. Because of this interface, a servo or stepper motor can be easier than an analog type for positioning applications. It means that motion and motor control can be separated more easily by this way.

Both of these two interfaces need to provide for gains tuning. For analog position controllers, the control loops are built inside and users must tune the gain from the controller. For pulse type position controllers, the control loops are built outside on the motor drivers and users must tune the gains on drivers.

For more than one axes’ operation, motion control seems more important than motor control. In industial applications, reliable is a very important factor. Motor driver vendors make good performance products and a motion controller vendors make powerful and variety motion software. Integrated two products make our machine go into perfect.

4.1.3 Network motion control interface

Recently, there was a new control interface was introduced--a network motion controller. The command between motor driver and motion controller is not analog or pulses signal any more. It is a network packet which contents position information and motor information. This type of controller is more reliable because it is digitized and packetized. Because a motion controller must be real-time, the nerowrk must have real-time capacity around a cycle time below 1 mini-second. This means that non-commercial networks cannot do this job. It must have a specific network, such as Mitsubishi SSCNET. The network may also be built with fiberoptics to increase communication reliability.

30 Operation Theory

4.1.4 Software real-time motion control kernel

For motion control kernel, there are three ways to accomplish it: DSP, ASIC, and software real-time.

A motion control system needs an absolutely real-time control cycle and the calculation on controller must provide a control data at the same cycle. If not, the motor will not run smoothly. Many machine makers will use PC’s computing power to do this. A feedback counter card can simply be used and a voltage output or pulse output card to make it. This method is very low-end and takes much software effort. For sure their realtime performance, they will use a real-time software on the system. It increases the complexity of the system too. But this method is the most flexible way for a professional motion control designers. Most of these methods are on NC machines.

4.1.5 DSP motion control kernel

A DSP-based motion controller kernel solves real-time software problem on computer. DSP is a micro-processer itself and all motion control calculations can be done on it. There is no real-time software problem because DSP has its own OS to arrange all the procedures. There is no interruption from other inputs or context switching problem like Windows based computer. Although it has such a perfect performance on real-time requirements, its calculation speed is not as fast as PC’s CPU at this age. The software interfacing between DSP controller’s vendors and users is not easy to use. Some controller vendors provide some kind of assembly languages for users to learn and some controller vendors provide only a handshake documents for users to use. Both ways are not easy to use. DSP based controller provide a bette r way than software kernel for machine makers to build they applications.

4.1.6 ASIC motion control kernel

An ASIC motion control kernel is falls between software kernel and DSP kernel in terms of difficulty. It has no real-time problem because all motion functions are done via the ASIC. Users or controller’s vendors just need to set some parameters which the ASIC requires and the motion control will be done easily. This kind of

Operation Theory 31

motion control separates all system integration problems into 4 parts: Motor driver’s performance, ASIC outputting profile, vendor’s software parameters to the ASIC, and users’ command to vendors’ software. It makes motion controller co-operated more smoothly between devices.

4.1.7 Compare Table of all motion control types

Software ASIC DSP

Price Fair Cheap Expensive

Functionality Highest Low Normal

Maintenance Hard Easy Fair

Analog Pulses Network

Price High Low Normal

Signal Quality Fair Good Reliable

Maintenance Hard Easy Easy

4.1.8 PCI-8144 motion controller type

The PCI-8144 is an ASIC based, pulse type motion controller made into three blocks: motion ASIC, PCI card, software motion library. The motion ASIC can be accessed via our software motion libray under many kinds of Windows NT/2000/XP, Linux, and RTX driver. Our software motion library provides one-stop-function for controlling motors. All the speed parameter calculations are done via our library.

For example, to perform a one-axis point to point moition with a trapezoidal speed profile, only fill the target position, speed, and acceleration time in one function. Then the motor will run as the profile. It takes no CPU resources because every control cycle pulse generation is done by the ASIC. The precision of target position depends on motor drivers’ closed loop control performance and mechnical parts, not on motion controller’s command because the motion controller is only responsible for sending correct pulses counts via a desired speed profile. So it is much e asier for programmers, mechnical or electrical engineers to find out problems.

32 Operation Theory

4.2 Motion Control Modes

Motion control makes the motors run according to a specific speed profile, path trajectory and synchronous condition with other axes. The following sections describe the motion control modes of this motion controller could be performed.

4.2.1 Coordinate system

The Cartesian coordinate is used and pulses are in the unit of length. The physical length depends on mechanical parts and motor’s resolution. For example, if a motor is on a screw ball, and the pitch of screw ball is 10mm and the pulses needed for a round of motor are 10,000 pulses. One pulse’s physical unit is equal to 10mm/10,000p =1 mm.

Just set a command with 15,000 pulses for motion controller if we want to move 15mm. How about if we want to move 15.0001mm?

Simple! The motion controller will keep the residue value less than 1 pulse and add it to next command.

The motion controller sends incremental pulses to motor drive rs. It means that we can only send relative command to motor driver. But we can solve this problem by calculating the difference between current position and target position first. Then send the differences to motor driver. For example, if current position is 1000 and we want to move a motor to 9000, you can use an absolute command to set a target position of 9000. Inside the motion controller, it will get current position 1000 first then calculate the difference from target position. The result is +8000. So, the motion controller will send 8000 pulses to motor driver to move the position of 9000.

Sometimes, users need to install a linear scale or external encoder to check machine’s position. But how do you to build this coordinate system? If the resolution of external encoder is 10,000

Operation Theory 33

pulses per 1mm and the motor will move 1mm if the motion controller send 1,000 pulses, It means that when we want to move 1 mm, we need to send 1,000 pulses to motor driver then we will get the encoder feedback value of 10,000 pulses. If we want to use an absolute command to move a motor to 10,000 pulses position and current position read from encoder is 3500 pulses, how many pulses will it send to motor driver? The answer is (10000 – 3500 ) / (10,000 / 1,000)=650 pulses. The motion controller will calculate it automatically if users set “move ratio” already. The “move ratio” means the (feedback resolution/command resolution)

Note: The PCI-8144 provides only one dimension motion function.

4.2.2 Absolute and relative position move

In the coordinate system, we have two kinds command for users to locate the target position. One is absolute and the other is relative. Absolute command means that user give the motion controller a position, then the motion controller will move a motor to that position from current position. Relative command means that user give the motion controller a distance, then the motion controller will move motor by the distance from current position. During the movement, users can specify the speed profile. It means user can define how fast and at what speed to reach the position.

The PCI-8144 provides only relative position move because it is designed for stepper motor. It is meaningless for a stepper

motor controller to have the encoder feedback interface for absolute motion.

34 Operation Theory

4.2.3 Trapezoidal speed profile

Trapezodial speed profile means the acceleration/deceleration area follows a 1st order linear velocity profile (constant acceleration rate). The profile chart is shown as below:

The area of the velocity profile represents the distance of this motion. Sometimes, the profile looks like a triangle because the desired distance from user is smaller than the area of given speed parameters. When this situation happens, the motion controller will lower the maximum velocity but keep the acceleration rate to meet user’s distane requirement. The chart of this situation is shown as below:

This kind of speed profile could be applied on velocity mode, position mode in one axis or multi-axes linear interpolation and two axes circular interpolation modes.

The PCI-8144 Tacc and Tdec are always the same.

Operation Theory 35

4.2.4 S-curve and Bell-curve speed profile

S-curve means the speed profile in accelerate/decelerate area follows a 2nd order curve. It ca n reduce vibration at the beginning of motor start and stop. In order to speed up the acceleration/deceleration during motion, we need to insert a linear part into these areas. We call this shape as “Bell” curve. It adds a linear curve between the upper side of s-curve and lower side of s-curve. This shape improves the speed of acceleration and also reduces the vibration of acceleration.

a) For a purse S-curve, we define its shape ’ s parameter as below:

X Tacc: Acceleration time in second X Tdec: Deceleration time in second X StrVel: Starting velocity in PPS X MaxVel: Maximum velocity in PPS

The PCI-8144 Tacc and Tdec are always the same.

36 Operation Theory

b) For a bell curve, we define its shape parameters as below: (the PCI-8144 dosen’t support this mode)

X Tacc: Acceleration time in second X Tdec: Deceleration time in second X StrVel: Starting velocity in PPS X MaxVel: Maximum velocity in PPS X VSacc: S-curve part of a bell curve in deceleration in PPS X VSdec: S-curve part of a bell curve in deceleration in PPS

If VSacc or VSdec=0, it means acceleration or deceleration use pure S-curve without linear part. The Acceleration chart of bell curve is shown below:

Operation Theory 37

4.2.5 Velocity mode

Veloctiy mode means the pulse command is continuously outputing until a stop command is issued. The motor will run without a target position or desired distance unless it is stopped by other reasons. The output pulse accelerates from a starting velocity to a specified maximum velocity. It can be follow a linear or S-curve acceleration shape. The pulse output rate is kept at maximum velocity until another velocity command is set or a stop command is issued. The velocity could be overrided by a new speed setting. Notice that the new speed could not be a reversed speed of original running speed. The speed profile of this kind of motion is shown as below:

38 Operation Theory

4.2.6 One axis position mode

Position mode means the motion controller will output a specific amount of pulses which is equal to users’ desired position or distance. The unit of distance or position is pulse internally on the motion controller. The minimum length of distance is one pulse. However, in PCI-8144, we provide a floating point function for users to transform a physical length to pulses. Inside our software library, we will keep those distance less than one pulse in register and apply them to the next motion function. Besides positioning via pulse counts, our motion controller provides three types of speed profile to accomplish positioning. There are 1st order trapezoidal, 2nd order S-curve, and mixed bell curve. Users can call respective functions to perform that. The following char shows the relationship between distance and speed profile. We use trapezoidal shape to show it.

The distance is the area of the V-t diagram of this profile. The PCI-8144 Tacc and Tdec are always the same.

Operation Theory 39

4.2.7 Home Return Mode

Home return means searching a zero p osition po int on the co ordinate. Sometimes, users use ORG pin as a zero position on the coordinate. At the beginning of machine power on, the program needs to find a zero point of this machine. Our motion controller provides following functions to make it.

_8144_enable_sd_signal _8144_enable_org_stop, _8144_tv_move, _8144_sv_move.

When ORG signal control is enabled (home return operation), the ORG signal is turned ON and the motor will stop immediately. After that, if the ORG signal goes OFF, the motor will remain stopped. Those signal statues can be used by the function, “_8144_get_mio_status”.

X When SD is not installed

X When SD is installed and SD is not latched

40 Operation Theory

Example.

_8144_enable_sd_signal( AxisNo, Enable); //Enable

SD signal control

_8144_enable_org_stop( AxisNo, Enable); //Enable

ORG signal stop

_8144_sv_move(AxisNo, StrVel, MaxVel, Tacc); //

perform a sv-move

4.2.8 Synchronous Start Function

Synchronous motion means more than one axis can be started by a synchronous signal (STA) which could be external or internal signals. For external signal, users must set move parameters first for all axes then these axes will wait an extern start/stop command to start or stop. For internal signal, the start command could be from a software start function. Once it is issued, all axes which are in waiting synchronous mode will start at the same time.

The PCI-8144 card suports external start function. When the user sets the external start by _8144_external_start function for each axis which the user want to perform external start, then set the move function for those axes. Thoes axis will start at the same time when STA signal goes ON.

Operation Theory 41

4.2.9 Auto Home Move Mode

Depending on the software homing mode design, the PCI-8144 offers an auto homing move function which means the axis will move to a zero position point on the coordinate. This mod e is used to add an auto home moving function on the normal home return mode described in the previous section no matter which position the axis is. The following diagram shows an example for normal home mode usage for which the start point is between the ORG and EL signal or exists in the ORG signal. The ORG offset can’t b e zero because the motion ASIC of the PCI-8144 offers a level trigger for the ORG signal. The suggested value is the double length of the ORG area. A homing status function can be used to monitor the current status of the homing operation .

Case 1: SD (Slow down) Case 2: EL (End Limit) Case 3: Inversed direction moving

(Slow down)

Case 4: Stop at ORG Case 5: SD (Slow down) Case 6: EL (End Limit) Case 7: Inversed dir ect ion movin g

(Slow down)

> Stop at ORG

> SD (Slow down) > Stop at ORG

> EL (End Limit) > Return > SD

> Stop at ORG

> SD (Slow down) > Stop at ORG

> EL (End Limit) > Return > SD

> Stop at ORG

42 Operation Theory

Case 1

Case 2

Case 3

Case 4

Case 5

Case 6

Case 7

SD signal

ORG signal

EL signal

Operation Theory 43

4.3 The motor driver interface

We provide several dedicated I/Os which can be connected to motor driver directly and have their own functions. Motor drivers have many kinds of I/O pins for external motion controller to use. We classify them to two groups. One is pulse I/O signals including pulse command and encoder interface. The other is digital I/O signals including servo ON, alarm, INP, servo ready, alarm reset and emergency stop inputs. The following sections will describe the functions these I/O pins.

The PCI-8144 has only pulse command interface.

4.3.1 Pulse Command Output Interface

The motion controller uses pulse command to control servo/stepper motors via motor drivers. Please set the drivers to position mode which can accept pulse trains as position command. The pulse command consists of two signal pairs. It is defined as CW and CCW pins on connector . Each signal has two p ins as a pair for differential output.

Dual Pulse Output Mode (CW/CCW Mode)

The waveform of the CW and CCW pins represent CW (clockwise) and CCW (counter clockwise) pulse ou tput respectively. The numbers of pulse represent distance in pulse. The frequency of the pulses represents speed in pulse per second. Pulses output from the CW pin makes the motor move in positive direction, whereas pulse output from the CCW pin makes the motor move in negative direction. The following diagram shows the output waveform of positive (+) commands and negative (-) commands.

44 Operation Theory

Pulse outmode = 0: (Pulse is normally high)

Pulse outmode = 1: (Pulse is normally low)

The command pulses are counted by a 24-bit preset countdown counter. The preset counter can store a value of total pulses outputting from controller.

Operation Theory 45

4.4 Mechanical switch interface

We provide some dedicated input pins for mechanical switches like original switch (ORG), plus and minus end-limit switch ( slow down switch (SD). These switches’ response time is very fast, only a few ASIC clock times. There is no re al-time problem when using these signals. All functions are done by motion ASIC. The software can just do nothing an d o nly need to wait the resu lts.

4.4.1 Original or home signal

Our controller provides one original or home signal for each axis. This signal is used for defining zero position of this axis. The logic of this signal must be set properly before doing home procedure. Please refer to home mode section for details.

4.4.2 End-Limit switch signal

The end-limit switches are usually installed on both ending sides of one axis. We must install plus EL at the positive position of the axis and minus EL at the negative position of the axis. These two signals are for safty reason. If they are installed reversely, the protection will be invalid. Once the motor’s moving part touches one of the end-limit signals, the motion controller will stop sending pulses and output an ERC signal. It can prevent machine crash when miss operation.

±EL),

4.4.3 Slow down switch

The slow down signals are used to force the command pulse to decelerate to the starting velocity when it is active. This signal is used to protect a mechanical moving part under hig h speed movement toward the mechanism’s limit. The SD signal is effective for both plus and minus directions.

46 Operation Theory

4.5 The Counters

4.5.1 Preset Command position counter

The preset command position counter is a 24-bit binary downcount counter. It provides the information of the current command counts which are not outputted.

4.6 Interrupt Control

The motion controller can generate an interrupt signal to the host PC. It is much useful for event-driven software application. There are two kinds of interrupt sources on PCI-8144. One is motion interrupt source and the other is GPIO interrupt sources. Motion and GPIO interrupt sources can be maskable. Motion interrupt sources can be maskable by _8144_set_motion_interrupt_factor(). Its mask bits are shown as following table:

Motion Interrupt Source Bit Settings (1=Enable,0=Disable)

Bit Description

0 Motion Stop

1-15 (reserve)

Operation Theory 47

The GPIO interrupt sources are maskable. The mask bits table is shown below:

GPIO Interrupt Source Bit Settings (1=Enable,0=Disable)

Bit Description

0 DI0 falling edge 1 DI1 falling edge 2 DI2 falling edge 3 DI3 falling edge 4 DI4 falling edge 5 DI5 falling edge 6 DI6 falling edge 7 DI7 falling edge 8 DI0 rising edge

9 DI1 rising edge 10 DI2 rising edge 11 DI3 rising edge 12 DI4 rising edge 13 DI5 rising edge 14 DI6 rising edge 15 DI7 rising edge

After seting the factors of interrupt, users can use wait functions to wait the interrupts, it uses no processor time while waiting for the specified interrupt to become signaled or the time-out interval to elapse.

48 Operation Theory

The steps for using interrupts:

1. Set interrupt sources for Motion or GPIO interrupts.

_8144_set_motion_interrupt_facor(AXIS0, 0x01);

// Axis0 stop

_8144_set_gpio_interrupt_factor(CARD0, 0x01);

// DI0 falling edge

2. Using wait function to wait the specified interrupt

_8144_wait_single_motion_interrupt(AXIS0, 0x01,

1000); // Wait 1000ms for normally stop interrupt

_8144_wait_single_gpio_interrupt(CARD0, 0x01,

1000) // Wait 1000ms for DI0 falling edge interrupt

3. Disable interrupt sources

_8144_set_motion_interrupt_facor(AXIS0, 0x0); _8144_set_gpio_interrupt_factor(CARD0, 0x0);

Operation Theory 49

4.7 Multiple Card Operation

The motion controller allows more than one card in one system. Since the motion controller is plug-and-p lay compatible, the base address and IRQ setting of the card are automatically assigned by the PCI BIOS at the beginning of system booting. Users don’t need and can’t change the resource settings.

When multiple cards are applied to a system, the number of card must be noted. The card number depends on the card ID switch setting on the the board. The axis number is depends on the card ID. For example, if three motion controller cards are plugged in to PCI slots, and the corresponding card ID is set, then the axis number on each card will be:

Axis No. X Y Z U

Card ID

0 0123 2 891011 3 12 13 14 15

Notice that if there has the same card ID on multiple cards, the function will not work correctly.

50 Operation Theory

5 MotionCreatorPro

After installing the hardware (Chapters 2 and 3), it is necessary to correctly configure all cards and double check the system before running. This chapter gives guidelines for establishing a control system and manually testing the 8144 cards to verify correct operation. The MotionCreatorPro software provides a simple yet powerful means to setup, configure, test, and debug a motion control system that uses 8144 cards.

Note that MotionCreatorPro is only available for Windows 2000/ XP with a screen resolution higher than 1024x768. Recommended screen resolution is 1024x768. It cannot be executed under the DOS environment.

5.1 Run MotionCreatorPro

After installing the software drivers for the 8144 in Windows 2000/ XP, the MotionCreatorPro program can be located at <chosen path> \PCI-Motion\MotionCreatorPro. To execute the program, double click on the executable file or use Start>Program Files>PCI-Motion>MotionCreatorPro.

MotionCreatorPro 51

5.2 About MotionCreatorPro

Before Running MotionCreatorPro, the following issues should be kept in mind.

1. MotionCreatorPro is a prog ram written in VB.NET 2003, and is available only for Windows 2000/XP with a screen resolution higher than 1024x768. It cannot be run under DOS.

2. MotionCreatorPro allows users to save settings and configurations for 8144 cards. Saved configurations will be automatically loaded the next time MotionCreatorPro is executed. Two file s, 8144.ini and 8144MC.ini, in the windows root directory are used to save all settings and configurations.

3. To duplicate configurations from one system to another, copy 8144.ini and 8144MC.ini into the windows root directory.

4. If multiple 8144 cards use the same MotionCreatorPro saved configuration files, the DLL function call _8144_config_from_file() can be invoked within a user developed program. This function is available in a DOS environment as well.

52 MotionCreatorPro

5.3 MotionCreatorPro Form Introducing

5.3.1 Main Menu

The main menu appears after running Motion CreatorPro. It is used to:

MotionCreatorPro 53

5.3.2 Select Menu

The select menu appears after running MotionCreatorPro. It is used to:

54 MotionCreatorPro

5.3.3 Card Information Menu

This menu shows Information about this card.

MotionCreatorPro 55

5.3.4 Configuration Menu

In this menu, users can configure EL, M_IO_Sensitivity, PulseLogic, SD_Singal and ORG_Stop.

1. EL Logic: Select the logic of the EL signal. The related function call is _8144_set_limit_logic().

2. M_IO_Sensitivity: Select the configurations of the IO Sensitivity. The related function call is _8144_set_mio_sensitivity().

3. Pulse Logic: Select the logic of the pulse mode. The related function call is _8144_set_pls_outmode().

4. SD_Singal: Select the configuration of the SD singal. The related function call is _8144_enable_sd_signal().

5. ORG_Stop: Select the configurations of the ORG_Stop.

56 MotionCreatorPro

The related function call is _8144_enable_org_stop().

6. Buttons:

Z Next Card: Change operating card. Z Next Axis: Change operating axis. Z Save Config: Save current configuration to 8144.ini

and 8144MC.ini.

MotionCreatorPro 57

In this menu, users can configure motion INT factor and gpio INT factor.

1. GPIO INT Factor: Select factors to initiate the gpio event interrupt. The related function call is _8144_set_gpio_interrupt_factor().

2. Motion INT Factor: Select factors to initiate the event interrupt. The related function call is _8144_set_motion_interrupt_factor().

3. Buttons:

Z Next Card: Change operating card. Z Next Axis: Change operating axis. Z Save Config: Save current configuration to 8144.ini

and 8144MC.ini.

58 MotionCreatorPro

5.3.5 Single Axis Operation Menu

In this menu, users can change the settings a selected axis, including velocity mode motion, preset relative motion.

1. Get Remain Pulse: Display the value of the remaining

pulse. The related function is

_8144_get_remaining_pulse()

2. Set Remain Pulse: Set the value of the remaining pulse.

The related function is

_8144_set_remaining_pulse()

3. Set Factor bit No:Set int_factor bit for normal motion

interrupt. The related function call is

_8144_set_motion_interrupt_factor()

4. Int Occur: Display if the interrupt happened. Show

“Yes” If happened. Otherwise, show “No”.

MotionCreatorPro 59

5. Int Count: The counter would plus 1 if interrupt happened.

6. Set Factor bit No: Set int_factor bit for GPIO interrupt. The related function call is _8144_set_gpio_interrupt_factor().

7. Int Occur: Display if the interrupt happened. Show “Yes” If happened. Otherwise, show “No”.

8. Int Count: The counter plus 1 if interrupt happened.

9. Operation Mode: Select operation mode.

Z Relative Mode: “Distance” will be used as relative dis-

placement for motion. The related function is

_8144_start_tr_move(), _8144_start_sr_move().

Z Cont. Move: V e locity mo tion mode. T he relate d functi on

is _8144_tv_move(), _8144_start_sv_move().

10.Distance: Set the relative distance fo r “Relative Mode.” It is only effective when “Relative Mode” is selected.

11.Repeat Mode: When “On” is selected, the motion will become repeat mode (forward<-->backward). It is only effective when “Relative Mode” is selected.

12.Vel. Profile: Select the velocity profile. Both Trapezoidal and S-Curve are available for “Relative Mode,” and “Cont. Move.”

13.Motion Parameters: Set the parameters for single axis motion.

Z Start Velocity: Set the start velocity of motion in units of

PPS. In “Relative Mode,” only the value is effective. For example, -100.0 is the same as 100.0. In “Cont. Move,” both the value and sign are effective. –100.0 means

100.0 in the minus direction.

Z Maximum Velocity: Set the maximum velocity of motion

in units of PPS. In “Relative Mode,” only the value is effective. For example, -5000.0 is the same as 5000.0.

60 MotionCreatorPro

In “Cont. Move,” both the value and sing is effective. –

5000.0 means 5000.0 in the minus direction.

Z Accel. Time: Set the acceleration time in units of sec-

ond. Tdec is the same as tacc.

Z Move Delay: This setting is effective only when repeat

mode is set “On.” It will cause the 8144 to delay for a specified time before it continues to the next motion.

14.Play Key:

X Left play button: Clicking this button will cause the 8144

start to outlet pulses according to previous settin g.

Z In “Relative Mode,” it causes the axis to move forward. Z In “Cont. Move,” it causes the axis to start to move

according to the velocity setting.

X Right play button: Clicking this button will cause the 8144

start to outlet pulses according to previous settin g.

Z In “Relative Mode,” it causes the axis to move back-

wards.

Z In “Cont. Move,” it causes the axis to start to move

according to the velocity setting, but in the opposite direction.

15.Stop Button: Clicking this button will cause the 8144 to

stop. The related function is _8144_emg_stop().

16.I/O Status: The status of motion I/O. Light-On means

Active, while Light-Off indicates inactive. The related function is _8144_get_mio_status().

17.Motion Status: The status of motion when running.

Light-On means Active, while Light-Off indicates inactive. The related function is _8144_motion_status().

MotionCreatorPro 61

18.Digital I/O: Display and set Digital I/O. The related function is:

_8144_get_gpio_output(), _8144_get_gpio_input(), _8144_set_gpio_output().

19.Buttons:

Z Next Card: Change operating card. Z Next Axis: Change operating axis. Z Save Config: Save current configuration to 8144.ini

and 8144MC.ini.

62 MotionCreatorPro

5.3.6 Four-Axis Operation Menu

In this menu, users can change the settings four selected axis, including velocity mode motion, preset relative motion.

1. Distance: Set the relative distance for “Relative Mode.”

It is only effective when “Relative Mode” is selected.

2. Motion Parameters: Set the parameters for single axis

motion.

Z Start Velocity: Set the start velocity of motion in units of

PPS. In “Relative Mode”, only the value is effective. For example, -100.0 is the same as 100.0.

Z Maximum Velocity: Set the maximum velocity of motion

in units of PPS. In “Relative Mode”, only the value is effective. For example, -5000.0 is the same as 5000.0.

MotionCreatorPro 63

Z Tacc: Set the acceleration time in units of second and

tdec is the same as tacc.

3. Operation Mode: Select operation mode.

Z Relative Mode: “Distance” will be used as relative dis-

placement for motion. The related function is

_8144_start_tr_move(), _8144_start_sr_move().

4. Repeat Mode: When “On” is selected, the motion will become repeat mode (forward<-->backward). It is only effective when “Relative Mode” is selected

5. Vel. Profile: Select the velocity profile. Both Trapezoidal and S-Curve are available for Relative Mode.

6. Motion Status: The status of motion. Light-On means Active, while Light-Off indicates inactive. The related function is _8144_motion_status().

7. I/O Status: The status of motion I/O. Light-On means Active, while Light-Off indicates inactive. The related function is _8144_get_mio_status().

8. Remaining Pulse: Display the value of the remaining pulse. The related function is

_8144_get_remaining_pulse()

9. Play Key:

X Left play button: Clicking this button will cause the 8144

start to outlet pulses according to previous setting.

Z In “Relative Mode,” it causes the axis to move forward.

X Right play button: Clicking this button will cause the 8144

start to outlet pulses according to previous setting.

Z In “Relative Mode,” it causes the axis to move back-

wards.

X Stop Button: Clicking this button will cause the 8144 to

stop. The related function is _8144_emg_stop().

64 MotionCreatorPro

10.Buttons:

Z Next Card: Change operating card. Z Save Config: Save current configuration to 8144.ini and

8144MC.ini.

5.3.7 Help Menu

In this menu, users can Click Mouse Right Key to show Help Information.

MotionCreatorPro 65

66 MotionCreatorPro

6 Function Library

This chapter describes the supporting software for the 8144 card. User can use these functions to develop programs in C, C++, or Visual Basic. If Delphi is used as the progra mm ing e nviro nme nt, it is necessary to transform the header files, 8144.h manually.

Function Library 67

6.1 List of Functions

Sec. Function name Description Page

System & Initialization 72

_8144_initial Device initialization _8144_close Device close _8144_get_version Get version numbers

6.3

_8144_set_security_key Set the security password _8144_check_security_key Varily the security password _8144_reset_security_key Reset the security password to default value _8144_config_from_file Configure settings from file

Motion Interface I/O 83

_8144_set_limit_logic Set the logic of PEL/MEL input signals _8144_get_limit_logic Get the logic of PEL/MEL input signals _8144_get_mio_status Get the status of motion I/O signals

6.4

_8144_set_mio_sensitivity Set the sensitive of motion I/O signals _8144_set_pls_outmode Set the logic of pulse output signal _8144_set_pls_outmode2 Set the output pulse mode and it’s logic

72 74 75 76 78 80 82

83 85 87 89 91 93

68 Function Library

Sec. Function name Description Page

Motion 94

_8144_tv_move

_8144_sv_move _8144_start_tr_move Begin a relative trapezoidal profile move

_8144_start_sr_move Begin a relative S-curve profile move _8144_set_external_start Set inhibit start by STA input signal _8144_emg_stop Immediately stop _8144_dec_stop Decelerate to stop _8144_slow_down Slow down

6.5

_8144_enable_org_stop Enable the stop when org signal active _8144_enable_sd_signal

_8144_speed_up _8144_enable_get_command Enable the “get_command()” function

_8144_get_command Get command position of an axis _8144_set_command Set command position of an axis

_8144_home_move _8144_home_status Get homing status

Accelerate an axis to a constant vel oc it y wit h trapezoidal profile

Accelerate an axis to a constant vel oc it y wit h S-curve profile

Enable the slow down when SD signal is active

Re-accelerate an axis to maximum velocity with a trapezoidal or S-curve profile

Perform a software based home return operation

94 96

98 101 107 109 111 114 116

118 113

104 105 106

120 122

Motion status 125

_8144_motion_done Get the motion stop or not

6.6

_8144_motion_status Get the motion status

125 127

Interrupt 129

_8144_set_motion_interrupt_factor Set factors of motion related interrupts _8144_wait_single_motion_interrupt Wait a single motion related interrupt

6.7

_8144_set_gpio_interrupt_factor Set factors of digital input interrupt _8144_wait_single_gpio_interrupt Wait a single digital input interrupt _8144_wait_multiple_gpio_interrupt Wait multiple digital input interrupts

129 131 134 136 138

Function Library 69

Sec. Function name Description Page

General purpose I/O 141

_8144_get_gpio_input Get all DIN digital input signals _8144_get_gpio_input_channel Get a specified DINn digital input signal _8144_set_gpio_output Set all DOUT digital output signal

6.8

_8144_set_gpio_output_channel Set a specified DOUTn digital output signal _8144_get_gpio_output Get all DOUT digital output signal _8144_get_gpio_output_channel Get a specified DOUTn digital output signal

141 142 143 144 145 146

Speed profile calculation 147

_8144_get_tv_move_profile Get tv_move speed profile _8144_get_sv_move_profile Get sv_move speed profile

6.9

_8144_get_start_tr_move_profile Get start_tr_move speed profile _8144_get_start_sr_move_profile Get start_sr_move speed profile

147 149 151 153

70 Function Library

6.2 C/C++ Programming Library

This section details all the functions. The function prototypes and some common data types are declared in pci_814 4.h. We suggest you use these data types in your applica tion pr ograms. T he following table shows the data type names and their range.

Typ e Name Description Range

U8 8-bit ASCII character 0 to 255

I16 16-bit signed integer -32768 to 32767

U16 16-bit unsigned integer 0 to 65535

I32 32-bit signed long integer -2147483648 to 2147483647 U32 32-bit unsigned long integer 0 to 4294967295 F32 32-bit single-precision floating-point -3.402823E38 to 3.402823E38

F64 64-bit doub le-precision floating-point

Boolean Boolean logic value TRUE, FALSE

T able 6-1: Data type definitions

The functions of the PCI-8144 software drivers use full-names to represent the functions real meaning. The naming convention rules are:

In a ‘C’ programming environment: _{hardware_model}_{action_name}. e.g. _8144_initial(). In order to recognize the difference between a C library and a VB

library, a capital “B” is placed at the beginning of each function name e.g. B_8144_initial().

-1.797683134862315E308

to 1.797683134862315E309

Function Library 71

6.3 System and Initialization

_8144_initial

Device initialization

Description:

This function is used to initialize PCI-8144 cards and assign hardware resources. All 8144 cards must be initialized by this function before calling other functions in your applications. By setting the parameter “ManualId”, user can choose the type that the card’s ID is assigned manually or automatically. In the end of your application, you should use the function, _8144_close(), to release its resources.

Syntax:

I16 _8144_initial( I32 *CardIdInBit, I16 ManualId

);

B_8144_initial( CardIdInBit As Long, ByVal

ManualId As Integer) As Integer

Parameters:

I32 *CardIdInBit: Card ID information in bit format.

Note: if the value of CardIdInBit is 0x3, that means there are 2 cards in your system and those card ID are 0 and 1 respectively.

I16 ManualId: Enable the On board dip switch (SW1) to decide theCard ID. [0:By system assigned, 1:By dip switch]

Return Values:

ERR_NoError ERR_OpenDriverFailed ERR_InsufficientMemory ERR_CardIdDuplicate ERR_NoDeviceFound

Example:

I16 ret; // return value I32 CardIdInBit;

72 Function Library

I16 ManualId = 0; //By system assigned ret = _8144_initial( &CardIdInBit, ManualId ); …// Do something ret = _8144_close(); //Close all PCI-8144 cards

in the system

See also:

_8144_close();

Function Library 73

_8144_close

Devices close

Description:

This function is used to close all PCI-8144 cards in the system and release its’ resources, which must be called at the end of your applications.

Syntax:

I16 _8144_close() B_8144_close() As Integer

Parameters:

Return Values:

ERR_NoError : Success.

Example:

I16 ret; // return value I32 CardIdInBit; I16 ManualId = 0; //By system assigned ret = _8144_initial( &CardIdInBit, ManualId ); …// Your applications ret = _8144_close(); //Close all PCI-8144 cards

in the system

See also:

_8144_initial();

74 Function Library

_8144_get_version

Get software and hardware version numbers

Description:

The user can get software and ha rdware v ersions by this function.

Syntax:

I16 _8144_get_version( I16 CardId, I32 *Dll_1,

I32 *Dll_2, I32 *FirmwareVersion, I32 *DriverVersion );

B_8144_get_version( ByVal CardId As Integer,

Dll_1 As Long, Dll_2 As Long, FirmwareVersion As Long, DriverVersion As Long ) As Integer

Parameters:

I16 CardId: The card ID number I32 *Dll_1: The 8144.DLL version information I32 *Dll_2: The MC4541.DLL version information I32 *FirmwareVersion: The information of 8144 card firm-

ware version I32 *DriverVersion: The information of WDM driver.

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_Win32Error ERR_NoError

Example:

I16 CardId = 0; I32 DLL_1, DLL_2, FirmwareVersion, DriverVersion; I16 ret = _8144_get_version(CardId, &Dll_1,

&Dll_2, &FirmwareVersion, &DriverVersion );

…

See also:

Function Library 75

_8144_set_security_key

Set the security password

Description:

This function is used to set a security code to the PCI card in EEPROM. The security code will never dispear even if the system is powered off.

Syntax:

I16 _8144_set_security_key(I16 CardId, U16

OldPassword, U16 NewPassword)

B_8144_set_security_key(ByVal CardId As Integer,

ByVal OldPassword As Integer, ByVal NewPassword As Integer)As Integer

Parameters:

I16 CardId: The card ID number. U16 OldPassword: The current password stored in card. U16 NewPassword: New password.

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_GetEEPROM ERR_SetEEPROM ERR_NoError

Example:

I16 ret; //return code I16 CardId = 0; // card ID U16 OldPassword = 0; // current password stored

in card U16 NewPassword = 0x1234; //new password If(_8144_reset_security_key(CardId)) //reset the

password to default value (0) {// return error} if(_8144_set_security_key( CardId, OldPassword,

NewPassword)) //set a new password {//return error}

76 Function Library

ret = _8144_check_security_key(CardId,

NewPassword); //verify the new password if( ret == ERR_NoError ) // security pass else // security failed

See also:

_8144_check_security_key _8144_reset_security_key

Function Library 77

_8144_check_security_key

Varily the security password

Description:

This funciton is used to verify the security code which the user set by the function “_8144_set_security_key”.

Syntax:

I16 _8144_check_security_key(I16 CardId, U16

Password)

B_8144_check_security_key(ByVal CardId As

Integer, ByVal Password As Integer) As Integer

Parameters:

I16 CardId: The card ID number. U16 Password: The password number

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_GetEEPROM ERR_NoError

Example:

I16 ret; //return code I16 CardId = 0; // card ID U16 OldPassword = 0; // current password stored

in card U16 NewPassword = 0x1234; //new password If(_8144_reset_security_key(CardId)) //reset the

password to default value (0) {// return error} if(_8144_set_security_key( CardId, OldPassword,

NewPassword)) //set a new password {//return error} ret = _8144_check_security_key(CardId,

NewPassword); //verify the new password if( ret == ERR_NoError ) // security pass

78 Function Library

else // security failed

See also:

_8144_set_security_key _8144_reset_security_key

Function Library 79

_8144_reset_security_key

Reset the security password to default value

Description:

By this function, Users can reset the security code which is stored on the PCI card to default value. The default security code is0.

Syntax:

I16 _8144_reset_security_key(I16 CardId) B_8144_reset_security_key(ByVal CardId As

Integer) As Integer

Parameters:

I16 CardId: The card ID number

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_SetEEPROM ERR_NoError

Example:

I16 ret; //return code I16 CardId = 0; // card ID U16 OldPassword = 0; // current password stored

in card U16 NewPassword = 0x1234; //new password If(_8144_reset_security_key(CardId)) //reset the

password to default value (0) {// return error} if(_8144_set_security_key( CardId, OldPassword,

NewPassword)) //set a new password {//return error} ret = _8144_check_security_key(CardId,

NewPassword); //verify the new password if( ret == ERR_NoError ) // security pass else // security failed

80 Function Library

See also:

_8144_set_security_key _8144_check_security_key

Function Library 81

_8144_config_from_file

Configure settings from file

Description:

This function is used to load the configeration of the PCI-8144 according to specified file. By using Motion Creater Rro, user could test and configure the 8144 correctly. After saving the configuration, the file would be existed in user’s system directory as 8144.ini.

When this function is executed, all 8144 cards in the system will be configured as the following functions were called according to parameters recorded in 8144.ini.

_8144_set_limit_logic _8144_set_mio_sensitivity _8144_set_pls_outmode, _8144_enable_sd_signal

Syntax:

I16 _8144_config_from_file() B_8144_config_from_file()As Integer

Parameters:

Return Values:

ERR_NoError

Example:

See also:

_8144_set_limit_logic _8144_set_mio_sensitivity _8144_set_pls_outmode _8144_enable_sd_signal

82 Function Library

6.4 Motion Interface I/O

_8144_set_limit_logic

Set the logic of PEL/MEL input signals

Description:

Set the active logic of specified axis’s PEL/MEL input signal.

Syntax:

I16 _8144_set_limit_logic(I16 AxisNo, I16

LimitLogic )

B_8144_set_limit_logic(ByVal AxisNo As Integer,

ByVal LimitLogic As Integer ) As Integer

Parameters:

I16 AxisNo: Axis number of Target Axis.

Card ID Physical axis AxisNo

11 22 33 04 15 26 37 08

... ...

I16 LimitLogic: The logic of PEL/MEL input signal

Z 0: Negative logic Z 1: Positive logic

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_NoError

Function Library 83

Example:

I16 ret; // return value I16 AxisNo = 0; //Axis number I16 LimitLogic = 1; //Positive logic ret = _8144_set_limit_logic(AxisNo, LimitLogic);

//EL logic setting

See also:

_8144_get_limit_logic _8144_get_mio_status _8144_set_mio_sensitivity

84 Function Library

_8144_get_limit_logic

Get the logic of PEL/MEL input signals

Description:

Get the information of PEL/MEL input signal logic setting.

Syntax:

I16 _8144_get_limit_logic(I16 AxisNo, I16

*LimitLogic )

B_8144_get_limit_logic(ByVal AxisNo As Integer,

LimitLogic As Integer )

Parameters:

I16 AxisNo: Axis number of Target Axis.

Card ID Physical axis AxisNo

11 22 33 04 15 26 37 08

... ...

I16 *LimitLogic: Theinformation of logic of PEL/MEL input signal.

Z 0: Negative logic Z 1: Positive logic

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_NoError

Function Library 85

Example:

I16 ret; //return code I16 AxisNo = 0; I16 LimitLogic; ret = _8144_get_limit_logic(I16 AxisNo,

&LimitLogic );

See also:

_8144_set_limit_logic _8144_get_mio_status _8144_set_mio_sensitivity

86 Function Library

_8144_get_mio_status

Get the status of motion I/O signals

Description:

Get all of motion I/O, status of each axis

Syntax:

I16 _8144_get_mio_status(I16 AxisNo, I16

*MotionIoStatusInBit )

B_8144_get_mio_status(ByVal AxisNo As Integer,

MotionIoStatusInBit As Integer ) As Integer

Parameters:

I16 AxisNo: Axis number of Target Axis.

Card ID Physical axis AxisNo

11 22 33 04 15 26 37 08

... ...

I16 *MotionIoStatusInBit: Statuses of Motion I/O. The definition of each bit as follow

Bit Name Description

0 MEL Negative Limit Switch 1 PEL Positive Limit Switch 2 ORG Origin Switch 3 STP STP pin status(EMG) 4 STA STA pin status 5 MSD Negative Slow Down signal input

Function Library 87

Bit Name Description

6 PSD Positive Slow Down signal input

7~ - Reserve

Return Values:

ERR_ParametersInvalid ERR_DeviceNotInitial ERR_NoError

Example:

I16 ret; I16 AxisNo = 0; //axis number I16 MotionIoStatusInBit; //The information of

motion I/O in bit ret = _8144_get_mio_status(AxisNo,

&MotionIoStatusInBit ); …

See also:

_8144_get_limit_logic _8144_set_ limit_logic _8144_set_mio_sensitivity

88 Function Library

_8144_set_mio_sensitivity

Set the sensitive of motion I/O signals

Description:

By this function, to set “low sensitivity” to reduce the sensitivity to signals on the ORG, P/MEL and STP signal. Pulse signals shorter than 4 reference clock cycles( approx. 800ns) will be ignored.

Syntax:

I16 _8144_set_mio_sensitivity( I16 AxisNo, I16

HighOrLow )

B_8144_set_mio_sensitivity( ByVal AxisNo As

Integer, ByVal HighOrLow As Integer ) As Integer

Parameters:

I16 AxisNo: Axis number of Target Axis.

Card ID Physical axis AxisNo

11 22 33 04 15 26 37 08

... ...

I16 HighOrLow: Sensitivity setting

Z 0: HIGH_SENSITIVITY Z 1: LOW_SENSITIVITY

Return Values:

ERR_ParametersInvalid

Function Library 89

ERR_DeviceNotInitial ERR_NoError

Example:

I16 ret; //return value I16 AxisNo = 0; //axis number I16 HighOrLow = 1; //set to low sensitivity ret = _8144_set_mio_sensitivity(AxisNo, HighOrLow

); …

See also:

_8144_get_limit_logic _8144_set_ limit_logic _8144_get_mio_status

90 Function Library

ADLINK PCI-8144 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

List of Tables

List of Figures

1 Introduction

1.1 Features

1.2 Specifications

1.3 Supported Software

1.3.1 Programming Library

1.3.2 MotionCreatorPro

2 Installation

2.1 Package Contents

2.2 PCI-8144 Outline Drawing

2.3 PCI-8144 Hardware Installation

2.3.1 Hardware configuration

2.3.2 PCI slot selection

2.3.3 Installation Procedures

2.3.4 Troubleshooting:

2.4 Software Driver Installation

2.5 SW1 Card Index Selection

2.7 JP2 Direct Control to Stepper

2.8 CN1 Pin Assignments: Main connector

3 Signal Connections

3.1 Pulse Output Signals CW and CCW

3.2 Origin Signal ORG

3.3 Slow Down input signal

3.4 End-Limit Signals PEL and MEL

3.5 Simultaneously Start/Stop Signals STA and STP

3.6 Termination Board

3.7 General Purpose DIO

3.7.1 Isolated Input channels

3.7.2 Isolated Output channels

3.7.3 Example of input connection

3.7.4 Example of output connection

3.8 JP2 pin define for stepping singal (Optional)

4 Operation Theory

4.1 Classifications of Motion Controller

4.1.1 Voltage motion control interface

4.1.2 Pulse motion control interface

4.1.3 Network motion control interface

4.1.4 Software real-time motion control kernel

4.1.5 DSP motion control kernel

4.1.6 ASIC motion control kernel

4.1.7 Compare Table of all motion control types

4.1.8 PCI-8144 motion controller type

4.2 Motion Control Modes

4.2.1 Coordinate system

4.2.2 Absolute and relative position move

4.2.3 Trapezoidal speed profile

4.2.4 S-curve and Bell-curve speed profile

4.2.5 Velocity mode

4.2.6 One axis position mode

4.2.7 Home Return Mode

4.2.8 Synchronous Start Function

4.2.9 Auto Home Move Mode

4.3 The motor driver interface

4.3.1 Pulse Command Output Interface

4.4 Mechanical switch interface

4.4.1 Original or home signal

4.4.2 End-Limit switch signal

4.4.3 Slow down switch

4.5 The Counters

4.5.1 Preset Command position counter

4.6 Interrupt Control

4.7 Multiple Card Operation

5 MotionCreatorPro

5.1 Run MotionCreatorPro

5.2 About MotionCreatorPro

5.3 MotionCreatorPro Form Introducing

5.3.1 Main Menu

5.3.2 Select Menu

5.3.3 Card Information Menu

5.3.4 Configuration Menu

5.3.5 Single Axis Operation Menu

5.3.6 Four-Axis Operation Menu

5.3.7 Help Menu

6 Function Library