ADLINK PCI-8144 User Manual

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.

Copyright 2008 ADLINK TECHNOLOGY INC.
All Rights Reserved.

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.

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

ADLINK TECHNOLOGY INC.

Web Site: http://www.adlinktech.com
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Product Information

Product Model

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Environment

M/B: CPU:
Chipset: BIOS:

Please give a detailed description of the problem(s):

Table of Contents

Table of Contents..................................................................... i

List of Tables........................................................................... v

List of Figures........................................................................ vi

1 Introduction ........................................................................ 1

1.1 Features............................................................................... 5

1.2 Specifications....................................................................... 6

1.3 Supported Software............................................................. 7

Programming Library ........................................ ... ...........7

MotionCreatorPro ........................................................... 7

2 Installation .......................................................................... 9

2.1 Package Contents ............................................................... 9

2.2 PCI-8144 Outline Drawing................................................. 10

2.3 PCI-8144 Hardware Installation......................................... 11

Hardware configuration .................................................11

PCI slot selection ................. ... ... .... ... ... ... ......................11

Installation Procedures .................................................11

Troubleshooting: ............................... ............................11

2.4 Software Driver Installation................................................ 13

2.5 SW1 Card Index Selection................................................. 13

2.6 J1-J8 Pulse Output Type: Differential / Open Collector..... 14

2.7 JP2 Direct Control to Stepper ........................................... 14

2.8 CN1 Pin Assignments: Main connector ............................. 15

3 Signal Connections.......................................................... 17

3.1 Pulse Output Signals CW and CCW.................................. 18

3.2 Origin Signal ORG............................................................. 21

3.3 Slow Down input signal........................ ... ... ... ... .... ... ... ... .... . 22

3.4 End-Limit Signals PEL and MEL........................................ 23

3.5 Simultaneously Start/Stop Signals STA and STP.............. 24

3.6 Termination Board............................................................. 25

3.7 General Purpose DIO........................................................ 25

Isolated Input channels .................................................26

Isolated Output channels .............................................. 26

Example of input connection .........................................26

Table of Contents i

Example of output connection ......................................27

3.8 JP2 pin define for stepping singal (Optional)..................... 27

4 Operation Theory.............................................................. 29

4.1 Classifications of Motion Controller.................................... 29

Voltage motion control interface ................................... 29

Pulse motion control interface ......................................30

Network motion control interface .................................. 30

Software real-time motion control kernel ..................... .31

DSP motion control kernel ............................................31

ASIC motion control kernel ...........................................31

Compare Table of all motion control types ...................32

PCI-8144 motion controller type ...................................32

4.2 Motion Control Modes........................................................ 33

Coordinate system ........................................................33

Absolute and relative position move .............................34

Trapezoidal speed profile .............................................35

S-curve and Bell-curve speed profile .................. .......... 36

Velocity mode ...............................................................38

One axis position mode ................................................39

Home Return Mode ......................................................40

Synchronous Start Function .........................................41

Auto Home Move Mode ................................................42

4.3 The motor driver interface.................................................. 44

Pulse Command Output Interface ................................44

4.4 Mechanical switch interface............................................... 46

Original or home signal .................................................46

End-Limit switch signal .................................................46

Slow down switch ..................................... ... ... .... ... ... ... .46

4.5 The Counters..................................................................... 47

Preset Command position counter ...............................47

4.6 Interrupt Control.......... .... ... ... ... .......................................... 47

4.7 Multiple Card Operation..................................................... 50

5 MotionCreatorPro ............................................................. 51

5.1 Run MotionCreatorPro....................................................... 51

5.2 About MotionCreatorPro....................................... .... ... ... ... 52

5.3 MotionCreatorPro Form Introducing .................................. 53

Main Menu ...................................................... .... ... ... ... .53

Select Menu ................................. ... .... ... ... ... ... .... ... ... ....54

ii Table of Contents

Card Information Menu .................................. ............... 55

Configuration Menu .......... ... ... ... .... ... ... ... ... .... ... ... ... .... .. 56

Single Axis Operation Menu .........................................59

Four-Axis Operation Menu ............................................ 63

Help Menu ....................................................................65

6 Function Library............................................................... 67

6.1 List of Functions................................................................. 68

6.2 C/C++ Programming Library.............................................. 71

6.3 System and Initialization.................................................... 72

_8144_initial ................................................................. 72

_8144_close ................................................................. 74

_8144_get_version ....................................................... 75

_8144_set_security_key ................................... ............ 76

_8144_check_security_key ..........................................78

_8144_reset_security_key ................................... .........80

_8144_config_from_file ................................................ 82

6.4 Motion Interface I/O ........................................................... 83

_8144_set_limit_logic ................................................... 83

_8144_get_limit_logic ....................................... ............ 85

_8144_get_mio_status .................................................87

_8144_set_mio_sensitivity ............................. ... ... ... .... .. 89

_8144_set_pls_outmode .............................................. 91

_8144_set_pls_outmode2 ............................................ 93

6.5 Motion................................................................................ 94

_8144_tv_move ............................................................ 94

_8144_sv_move ........................................................... 96

_8144_start_tr_move ..................................... ............... 98

_8144_start_sr_move .................................................101

_8144_enable_get_command .................................... 104

_8144_get_command ....................................... .......... 105

_8144_set_command ................................................. 106

_8144_set_external_start ........................................... 107

_8144_emg_stop ........................................................109

_8144_dec_stop ......................................................... 111

_8144_speed_up .................................... .................... 113

_8144_slow_down ............................... ....................... 114

_8144_enable_org_stop ...................................... ....... 116

_8144_enable_sd_signal ........................................ ....118

_8144_home_move .......................................... .......... 120

Table of Contents iii

_8144_home_status ................................................... 122

6.6 Motion status.................................................................... 125

_8144_motion_done ................................................... 125

_8144_motion_status .................................................127

6.7 Interrupt ................ ... ... .... ... ... .......................................... . 129

_8144_set_motion_interrupt_factor ............................ 129

_8144_wait_single_motion_interrupt ..........................131

_8144_set_gpio_interrupt_factor ................................ 134

_8144_wait_single_gpio_interrupt ..............................136

_8144_wait_multiple_gpio_interrupt ........................... 138

6.8 General purpose input/output ...................................... ... . 141

_8144_get_gpio_input ................................................ 141

_8144_get_gpio_input_channel ..................................142

_8144_set_gpio_output .............................................. 143

_8144_set_gpio_output_channel ................................144

_8144_get_gpio_output .............................................. 145

_8144_get_gpio_output_channel ............................... 146

6.9 Speed profile calculation.................................................. 147

_8144_get_tv_move_profile .......................................147

_8144_get_sv_move_profile ..................................... ..149

_8144_get_start_tr_move_profile ............................... 151

_8144_get_start_sr_move_profile .............................. 153

7 Function Return Code.................................................... 155

iv Table of Contents

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

DC

±5%, 500mA,

DC

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

R

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