ADLINK PCI-8164 User Manual

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PCI-8164/MPC-8164/PXI-8164 Advanced 4-Axis Servo/Stepper

Motion Control Card

User’s Manual

Manual Rev. 2.00

Revision Date: August 25, 2006

Part No: 50-11124-1050

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, electronic, or other means in any 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 purposes 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.

ADLINK TECHNOLOGY INC.

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,

Taipei, 235 Taiwan

Email or fax this completed service form for prompt and satisfactory service.

List of Tables

Table 2-1: GEME hardware configuration ................................ 22

Table 2-2: Base Addresses ...................................................... 22

vi List of Tables

List of Figures

Figure 1-1: PCI-8164 block diagram ............................................ 2

Figure 1-2: MPC-8164 block diagram .......................................... 3

Figure 1-3: PXI-8164 block diagram ............................................ 4

Figure 1-4: Application building flow chart ................................... 5

Figure 2-1: PCI-8164 PCB layout .............................................. 17

Figure 2-2: PCI-8164 face plate ................................................. 17

Figure 2-3: MPC-8164 PCB layout ............................................ 18

Figure 2-4: MPC-8164 face plate ............................................... 18

Figure 2-5: PXI-8164 layout and front panel .............................. 19

Figure 7-1: System Integration with PCI-8164 ......................... 266

Figure 7-2: Connection of PCI-8164 with Panasonic Driver .... 268

Figure 7-3: Connection of PCI-8164 with SANYO Driver......... 269

List of Figures vii

1 Introduction

The PCI-/MPC-/PXI-8164 is an advanced 4-axis motion controller card that generates high frequency pulses (6.55 MHz) to drive stepper or servomotors, and provides a 2-axis circular interpolation, 4-axis linear interpolation, or continuous interpolation for continual velocity. The PCI-/MPC-/PXI-8164 also changes position and/or speed on the fly with a single axis operation.

Multiple PCI-/MPC-/PXI-8164 cards may be installed in one system. Incremental encoder interface on all four axes provide the ability to correct positioning errors generated by inaccurate mechanical transmissions. With the aid of an onboard FIFO, the PCI-/MPC-/PXI-8164 also performs precise and extremely fast position comparison and trigger functions without compromising CPU resources. In addition, a mechanical sensor interface, a servo motor interface, and general-purposed I/O signals are provided for easy system integration.

The following figures show the functional block diagrams of the 8164 card in PCI, MPC, and PXI interfaces. The PCI-/MPC-/PXI8164 uses one ASIC (PCL6045) to perform all 4 axes motion controls. The motion control functions include linear and S-curve acceleration/deceleration, circular interpolation between two axes, linear interpolation between 2-4 axes, continuous motion positioning, and more than 13 home return modes. All these functions and complex computations are performed internally by the ASIC, thus minimizing CPU usage and eliminating real-time issues.

Introduction 1

Figure 1-1: PCI-8164 block diagram

2Introduction

The MPC-8164 is an advanced 4-axis motion controller card with a PC104 interface. All features and specification are leveraged with the PCI-8164, except for some differences in the user I/O interfaces. Figure 1-2 shows the MPC-8164 card block diagram.

Figure 1-2: MPC-8164 block diagram

Introduction 3

The PXI-8164 is an advanced 4-axis motion controller card with a PXI interface. All features and specification are the same with the PCI-8164, except for some differences in the user I/O interfaces. Figure 1-3 shows the PXI-8164 the block diagram.

Figure 1-3: PXI-8164 block diagram

4Introduction

Motion Creator is a Windows-based application development software package that comes with the card. Motion Creator is useful for debugging a motion control system during the design phase of a project. An on-screen display lists all installed axes information and the card’s I/O signal status.

DOS and Windows programming libraries for C++ and Visual Basic are included together with some sample programs to illustrate the operations of these functions.

Figure 1-4 illustrates a flow chart of application development using the contents of this manual. Refer to the related chapters for details.

Figure 1-4: Application building flow chart

Introduction 5

1.1 Features

1.1.1 PCI-8164

X 32-bit PCI bus, Plug and Play

X 4 axes of step and direction pulse output for controlling

stepping or servomotor

X 6.55 MPPS maximum output frequency

X OUT/DIR, CW/CCW pulse output options

X Programmable acceleration and deceleration time for all

modes

X Trapezoidal and S-curve velocity profiles for all modes

X Any 2 of 4 axes circular interpolation

X Any 2-4 of 4 axes linear interpolation

X Continuous interpolation for contour following motion

X Change position and speed on the fly

X Change speed by condition comparing

X 13 home return modes with auto searching

X Hardware backlash compensator and vibration suppression

X 2 software end-limits for each axis

X 28-bit up/down counter for incremental encoder feedback

X Home switch, index signal (EZ), positive, and negative end

limit switches interface on all axes

X 2-axis high speed position latch input

X 2-axis position compare trigger output with 4k FIFO auto-

X 2500V

X Programmable interrupt sources

X Simultaneous start/stop motion on multiple axes

X Manual pulser input interface (A small steering device that gen-

erates pulses when turned)

X Software supports a maximum of up to 12 PCI-8164 cards

(48 axes) operation in one system

X Compact, half-sized PCB

isolated digital input and output signals

rms

6Introduction

X Includes Motion Creator, a Microsoft Windows-based appli-

cation development software

X Libraries and utilities support DOS, Windows

9X/NT/2000/

XP, and Linux

Introduction 7

1.1.2 MPC-8164

X 16-bit PC104 bus

X 4 axes of step and direction pulse output for controlling

stepping or servomotor

X 6.55 MPPS maximum output frequency

X OUT/DIR, CW/CCW pulse output options

X Programmable acceleration and deceleration time for all

modes

X Trapezoidal and S-curve velocity profiles for all modes

X Any 2 of 4 axes circular interpolation

X Any 2-4 of 4 axes linear interpolation

X Continuous interpolation for contour following motion

X Change position and speed on the fly

X Change speed by comparator condition

X 13 home return modes with auto searching

X Hardware backlash compensator and vibration suppression

X 2 Software end-limits for each axis

X 28-bit up/down counter for incremental encoder feedback

X Home switch, index signal (EZ), positive, and negative end

limit switches interface on all axes

X 2-axis high speed position latch input

X 2-axis position compare trigger output with 4k FIFO auto-

X 2500

X Programmable interrupt sources

X 8 channels of general purpose photo-isolated digital inputs

X 8 channels of general purpose open collector digital outputs

X Software supports a maximum of up to 4 MPC-8164 cards

(16 axes) operation in one system

X Includes Motion Creator, a Microsoft Windows-based appli-

cation development software

X Libraries and utilities support DOS, Windows

XP, and Windows

X Libraries for Linux and Windows

isolated digital input and output signals

Vrms

XP/NT Embedded

CE systems

98/NT/2000/

8Introduction

1.1.3 PXI-8164

X PXI specifications Rev. 2.0-compliant

X Multiple modules synchronized via PXI trigger bus

X 3U Eurocard form factor, CompactPCI compliant (PICMG

2.0 R2.1)

X 4-CH isolated digital I/O

X 4 axes of step and direction pulse output for controlling

stepping or servomotor

X 6.55 MPPS maximum output frequency

X OUT/DIR, CW/CCW pulse output options

X Programmable acceleration and deceleration time for all

modes

X Trapezoidal and S-curve velocity profiles for all modes

X Any 2 of 4 axes circular interpolation

X Any 2-4 of 4 axes linear interpolation

X Continuous interpolation for contour following motion

X Change position and speed on the fly

X Change speed by condition comparing

X 13 home return modes with auto searching

X Hardware backlash compensator and vibration suppression

X 2 software end-limits for each axis

X 28-bit up/down counter for incremental encoder feedback

X Home switch, index signal (EZ), positive, and negative end

limit switches interface on all axes

X 2-axis high speed position latch input

X 2-axis position compare trigger output with 4k FIFO auto-

X Programmable interrupt sources

X Simultaneous start/stop motion on multiple axes

X Manual pulser input interface (A small steering device that gen-

erates pulses when turned)

X Software supports a maximum of up to 12 PXI-8164 cards

(48 axes) operation in one system

Introduction 9

X Includes Motion Creator, a Microsoft Windows-based appli-

cation development software

X Libraries and utilities DOS, Windows

9x/NT/2000/XP, and

Linux

10 Introduction

1.2 Specifications

Applicable motors

X Stepping motors

X AC or DC servomotors with pulse train input servo drivers

Performance

X 4 controllable axes

X 6.55MPPS maximum pulse output frequency, linear, trape-

zoidal, or S-Curve velocity profile drive

X 19.66 MHz internal reference clock

X 28-bit up/down counter range: 0 to 268,435,455 or

–134,217,728 to +134,217,727

X Position pulse setting range (28-bit): -134,217,728 to

+134,217,728

X Pulse rate setting ranges (pulse ratio = 1: 65535):

Z 0.1 PPS to 6553.5 PPS (multiplier = 0.1)

Z 1 PPS to 65535 PPS (multiplier = 1)

Z 100 PPS to 6553500 PPS (multiplier = 100)

Introduction 11

I/O signals

X Input/Output signals for each axis

X Opto-isolated digital input with 2500V

X OUT and DIR command pulse output pins

X EA and EB incremental encoder signals input pins

X EZ encoder index signal input pin

X ±EL, SD/PCS, and ORG mechanical limit/switch signal

isolation voltage

rms

input pins

X INP, ALM, and ERC servomotor interface I/O pins

X LTC position latch input pin

X CMP position compare output pin

X SVON general-purposed digital output pin

X RDY general-purposed digital input pin

X PA and PB (PCI-8164/PXI-8164) pulse signal input pin

X STA and STP (PCI-8164/PXI-8164) simultaneous start/stop

signal

General-purpose output

X 6 TTL level digital outputs (PCI-8164 only)

X 8 digital inputs/8 digital outputs (MPC-8164 only)

X 4 digital inputs/4 digital outputs (PXI-8164 only)

General specifications

X 100-pin SCSI-type connector

X Operating temperature: 0ºC - 50ºC

X Storage temperature: -20ºC - 80ºC

X Humidity: 5% - 85%, non-condensing

Power consumption

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

X External power supply (input): +24V DC ±5%, 500mA max

X External power supply (output): +5V DC ±5%, 500mA, max

12 Introduction

Dimensions

X PCI-8164: 185 mm (L) X 106.68 mm (W)

X MPC-8164: 152 mm (L) X 104.7 mm (W)

X PXI-8164: 3U Eurocard form factor, CompactPCI-compliant

(PICMG 2.0 R2.1)

Introduction 13

1.3 Software support

1.3.1 Programming library

Programming libraries for MS-DOS and Borland C/C++ (Version

3.1) and DLLs for Windows

95/98/NT/2000/XP come bundled with the PCI-8164/PXI-8164 card package. Support for Linuxbased systems is also included.

MPC-8164 supports DOS/Windows

98/NT/2000/XP, Windows

XP/NT Embedded, Windows® CE, and Linux.

1.3.2 Motion Creator

This Windows-based utility sets up cards, motors, and systems. It also debugs hardware and software problems and enables the user to set I/O logic parameters that can be loaded in their own programs. Refer to Chapter 5 for more details.

14 Introduction

2 Installation

Follow these steps to install the PCI-/MPC-/PXI-8164 card.

X Check the card package contents (section 2.1)

X Check the card PCB and face plate/front panel layout (sec-

tion 2.2)

X Install the card to the chassis (section 2.3)

X Install the drivers (section 2.4)

X Refer to the I/O signal connections (chapter 3) and their

operation (chapter 4)

X Refer to the connector pin assignments (the remaining sec-

tions) and wiring connections

Installation 15

2.1 Package contents

Check the package contents for the following items:

X PCI-8164/MPC-8164/PXI-8164 card

X ADLINK All-in-one CD

X +24V power input cable (for CN1) accessories (PCI-8164

only)

X Optional terminal board for wiring purposes

If any of these items are missing or damaged, contact your dealer immediately. Save the original packaging for future shipment.

16 Installation

2.2 PCI-8164 layout

Figure 2-1: PCI-8164 PCB layout

CN1: External Power Input Connector

CN2: Input / Output Signal Connector

CN3: Manual Pulse Signal Connector

CN4: Simultaneous Start / Stop Connector

CN5: General purpose TTL output

S1: End limit logic selection switch

J1-J8: Pulse output selection jumper

Figure 2-2: PCI-8164 face plate

Installation 17

2.3 MPC-8164 layout

Figure 2-3: MPC-8164 PCB layout

Figure 2-4: MPC-8164 face plate

CN2: Input / Output Signal Connector

CN3: 8 DI / 8 DO Connector

JP1: IRQ selection

SW1: Base Address Selection

18 Installation

2.4 PXI-8164 layout

Figure 2-5: PXI-8164 layout and front panel

S1: Switch setting for EL logic

S2: Card ID setting from 0-11

J3: 4-CH isolated digital Input/output

J4: 4-axis pulser input interface

Installation 19

2.5 PCI-8164/PXI-8164 hardware installation

2.5.1 Hardware configuration

Since the PCI-8164/PXI-8164 card is Plug and Play, the memory allocation (I/O port locations) and the IRQ channel are automatically assigned by the system BIOS. The address assignment is done on a board-by-board basis for all PCI cards installed in the system.

2.5.2 PCI slot selection

The PCI-8164 card may be installed in any available PCI slot. The PXI-8164 card may be installed in any PXI slot.

CAUTION Do not install the PCI card into a PC/AT (ISA) slot.

2.5.3 Installing the PCI-8164 card

1. Discharge any static buildup from your body by touching the metal case of the computer. Hold the card on its edges and avoid touching the components.

2. Set the card jumper(s) according to your requirements.

3. Turn off the computer and all connected peripherals, then open the computer chassis.

4. Locate a 32-bit PCI slot. PCI slots are shorter than ISA or EISA slots and usually comes in white or ivory.

5. Remove the metal bracket opposite the slot you want to use. Keep the bracket screw for later use.

6. Insert the PCI card connectors (golden fingers) to the slot, then press firmly until the card is properly seated on the slot.

7. Secure the card with the bracket screw you removed earlier, then replace the computer chassis.

8. Connect all peripherals, then turn the computer on.

20 Installation

Installation notes

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.

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.

2.5.4 Installing the PXI-8164 card

1. Follow steps 1 to 2 of the previous section.

2. Select an available PXI slot, then remove the metal

cover opposite the slot you want to use. Keep the metal cover and screws for later use.

3. Align the card’s top and bottom edges with the chassis

card guides, then carefully slide it into the chassis.

4. Lift the card ejector latch until it locks in place.

5. Secure the card with two screws.

6. Connect all peripherals, then turn the computer on.

Installation 21

2.6 MPC-8164 hardware installation

2.6.1 Hardware configuration

The MPC-8164 card is PC104-compliant. The onboard DIP switches and jumpers assign the card’s I/O port locations and IRQ channels.

A single-board setup has a default setting of 0x200 and IRQ5. In GEME systems, the default value varies depending on the location of the card. Refer to the following table:

GEME level Base address IRQ

1 0x300 9

2 0x200 5

30x28010

Table 2-1: GEME hardware configuration

Base address setting

The base address is set by SW1 (pins 2 to 4). Note that pin 1 is reserved. If all DIPs are set to OFF, the base address is 0x200. Default settings are dependent on the order.

DIP Switch (2 3 4) Base Address DIP Switch (2 3 4) Base Address

1 1 1 0x3C0 1 1 0 0x2C0

0 1 1 0x380 0 1 0 0x280

1 0 1 0x340 1 0 0 0x240

0 0 1 0x300 0 0 0 0x200

Table 2-2: Base Addresses

22 Installation

IRQ setting

The JP1 setting assigns the IRQ channel.

Installation note

Make sure that the system has an aqvailable I/O address and IRQ channel for the card. If there are none available, adjust the card I/O address and IRQ channel to empty.

Installation 23

2.7 Driver installation

PCI-8164/PXI-8164

1. Place the ADLINK All-In-One CD to the CD-ROM drive.

2. When the Autorun screen appears, select Driver Instal- lation > Motion Control > PCI-8164/PXI-8164.

3. Follow screen procedures to install, then restart the system after installation is completed.

NOTE When using MS-DOS, install the drivers from the \Motion

Control\PCI-8164\DOS_BC directory of the CD.

MPC-8164

1. Place the ADLINK All-In-One CD to the CR-ROM drive.

2. When the Autorun screen appears, select Driver Instal- lation > Motion Control > MPC-8164.

3. Launch the MPC-8164 Add/Remove utililty from the Start menu or installed directory to register the new card. The I/O address and IRQ channel must be the same with the settings on the board.

4. Restart the computer.

NOTES When using MS-DOS, install the drivers from the \Motion

24 Installation

Control\MPC-8164\DOS_BC directory of the CD.

You may also download the latest software from the ADLINK website (www.adlinktech.com).

2.8 CN1 pin assignments: External Power Input (PCI-

8164 only)

CN1 Pin No Name Description

1 EGND External power ground

2 CN1_24V

NOTES

X CN1 is a plug-in terminal board with no screws.

X Use the external power supply. A +24V DC is used by exter-

nal input/output signal circuits. The power circuit configuration is shown below.

X Wires for connection to CN1:

Z Solid wire: ϕ0.32 mm to ϕ0.65 mm (AWG28 to AWG22)

Z Twisted wire: 0.08 mm

Z Naked wire length: 10 mm standard

The diagram below shows the external power supply system of the PCI-8164. An external +24V power must be provided. An onboard regulator generates +5V for both internal and external use.

CAUTION The output current capacity of the +5V power source from

the onboard DC/DC is limited. DO NOT use this to drive several devices simultaneously, especially stepper motors or external encoders.

NOTE MPC-8164 and PXI-8164 do not have the CN1 for power

input. Use the E_24V and EGND pins of CN2. L is an inductor for EMI use.

+24V DC ± 5% External power supply

to 0.32 mm2 (AWG28 to AWG22)

Installation 25

2.9 CN3 pin assignments: Manual Pulse Input

(PCI-8164 only)

CN3 is for the manual pulse input.

No. Name Function (Axis)

1 DGND Bus power ground

2 PB4 Pulser B-phase signal input,

3 PA4 Pulser A-phase signal input,

4 PB3 Pulser B-phase signal input,

5 PA3 Pulser A-phase signal input,

6 VCC Bus power, +5V

7 DGND Bus power ground

8 PB2 Pulser B-phase signal input,

9 PA2 Pulser A-phase signal input,

10 PB1 Pulser B-phase signal input,

11 PA1 Pulser A-phase signal input,

12 VCC Bus power, +5V

NOTE The PCI bus provides the signals for the VCC and DGND

pins. These signals are not isolated.

26 Installation

2.10 J4 pin assignments: Manual Pulse Input

(PXI-8164 only)

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

Installation 27

2.11 CN3 pin assignments: General Purpose DIO

(MPC-8164 only)

Pin No Signal Name Pin No Signal Name

1 DOCOM 2 DOCOM

3 DOCOM 4 DOCOM

5DO06DO1

7DO28DO3

9DO410DO5

11DO612DO7

13 -- 14 DICOM

15 DICOM 16 DICOM

17 DICOM 18 DI0

19DI120DI2

21DI322DI4

23DI524DI6

25 DI7 26 --

28 Installation

2.12 J3 pin assignments: Isolated DIO

(PXI-8164 only)

No. Name Function No. Name Function

1 DICOM Digital In Common 2 DOCOM Digital Out Common

3 DI0 Input Channel 0 4 DO0 Output Channel 0

5 DI1 Input Channel 1 6 DO1 Output Channel 1

7 DICOM Digital In Common 8 DOCOM Digital Out Common

9 DI2 Input Channel 2 10 DO2 Output Channel 2

11 DI3 Input Channel 3 12 DO3 Ouput Channel 3

13 DICOM Digital In Common 14 DOCOM Digital Out Common

15 -- N/A 16 -- N/A

17 -- N/A 18 -- N/A

19 -- N/A 20 -- N/A

Installation 29

2.13 CN2 pin assignments: Main Connector

CN2 is the major connector for the motion control I/O signals.

No. Name I/O Function (axis / ) No. Name I/O Function (axis / )

1 VPP O +5V power supply output 51 VPP O +5V power supply output

2 EGND Ext. power ground 52 EGND Ext. power ground

3 OUT1+ O Pulse signal (+), 53 OUT3+ O Pulse signal (+),

4 OUT1- O Pulse signal (-), 54 OUT3- O Pulse signal (-),

5 DIR1+ O Dir. signal (+), 55 DIR3+ O Dir. signal (+),

6 DIR1- O Dir. signal (-), 56 D IR3- O Dir. signal (-),

7 SVON1 O Multi-purpose signal, 57 SVON3 O Multi-purpose signal,

8 ERC1 O Dev. ctr, clr. signal, 58 ERC3 O Dev. ctr, clr. signal,

9 ALM1 I Alarm signal, 59 ALM3 I Alarm signal,

10 INP1 I In-position signal, 60 INP3 I In-position signal,

11 RDY1 I Multi-purpose signal, 61 RDY3 I Multi-purpose signal,

12 EGND Ext. power ground 62 EGND Ext. power ground

13 EA1+ I Encoder A-phase (+), 63 EA3+ I Encoder A-phase (+),

14 EA1- I Encoder A-phase (-), 64 EA3- I Encoder A-phase (-),

15 EB1+ I Encoder B-phase (+), 65 EB3+ I Encoder B-phase (+),

16 EB1- I Encoder B-phase (-), 66 EB3- I Encoder B-phase (-),

17 EZ1+ I Encoder Z-phase (+), 67 EZ3+ I Encoder Z-phase (+),

18 EZ1- I Encoder Z-phase (-), 68 EZ3- I Encoder Z-phase (-),

19 VPP O +5V power supply output 69 VPP O +5V power supply output

20 EGND Ext. power ground 70 EGND Ext. power ground

21 OUT2+ O Pulse signal (+), 71 OUT4+ O Pulse signal (+),

22 OUT2- O Pulse signal (-), 72 OUT4- O Pulse signal (-),

23 DIR2+ O Dir. signal (+), 73 DIR4+ O Dir. signal (+),

24 DIR2- O Dir. signal (-), 74 DIR4- O Dir. signal (-),

25 SVON2 O Multi-purpose signal, 75 SVON4 O Multi-purpose signal,

26 ERC2 O Dev. ctr, clr. signal, 76 ERC4 O Dev. ctr, clr. signal,

27 ALM2 I Alarm signal, 77 ALM4 I Alarm signal,

28 INP2 I In-position signal, 78 INP4 I In-position signal,

29 RDY2 I Multi-purpose signal, 79 RDY4 I Multi-purpose signal,

30 EGND Ext. power ground 80 EGND Ext. power ground

31 EA2+ I Encoder A-phase (+), 81 EA4+ I Encoder A-phase (+),

32 EA2- I Encoder A-phase (-), 82 EA4- I Encoder A-phase (-),

33 EB2+ I Encoder B-phase (+), 83 EB4+ I Encoder B-phase (+),

34 EB2- I Encoder B-phase (-), 84 EB4- I Encoder B-phase (-),

35 EZ2+ I Encoder Z-phase (+), 85 EZ4+ I Encoder Z-phase (+),

36 EZ2- I Encoder Z-phase (-), 86 EZ4- I Encoder Z-phase (-),

37 PEL1 I End limit signal (+), 87 PEL3 I End limit signal (+),

38 MEL1 I End limit signal (-), 88 MEL3 I End limit signal (-),

39 CMP1 O Position compare o utput 89 LTC3 I Position latch input

30 Installation

40 SD/PCS1 I Ramp-down signal 90 SD/PCS3 I Ramp-down signal

41 ORG1 I Origin signal, 91 ORG3 I Origin signal,

42 EGND Ext. power ground 92 EGND Ext. po wer ground

43 PEL2 I End limit signal (+), 93 PEL4 I End limit signal (+),

44 MEL2 I End limit signal (-), 94 MEL4 I End limit signal (-),

45 CMP2 O Position compare output 95 LTC4 I Position latch input,

46 SD/PCS2 I Ramp-down signal 96 SD/PCS4 I Ramp-down signal

47 ORG2 I Origin signal, 97 ORG4 I Origin signal,

48 EGND Ext. power ground 98 GND Ext. power ground

49 EGND Ext. power ground 99 E_24V Ext. power supply, +24V

50 EGND Ext. power ground 100 E_24V Ext. power supply, +24V

Installation 31

2.14 CN4 pin assignments: Simultaneous Start/Stop

(PCI-8164 only)

CN4 is for simultaneous start/stop signals for multiple axes or multiple cards.

No. Name Function (Axis)

1 DGND Bus power ground

2 STP Simultaneous stop signal input/output

3 STA Simultaneous start signal input/output

4 STP Simultaneous stop signal input/output

5 STA Simultaneous start signal input/output

6 VCC Bus power output, +5V

Note: +5V and GND pins are provided by the PCI Bus power.

32 Installation

2.15 CN5 pin assignment: TTL Output (PCI-8164 only)

CN5 is for general-purposed TTL output signals.

Pin No. Name Function

1 DGND Digital ground

2 DGND Digital ground

3 ED0 Digital Output 0

4 ED1 Digital Output 1

5 ED2 Digital Output 2

6 ED3 Digital Output 3

7 ED4 Digital Output 4

8 ED5 Digital Output 5

9 VCC VCC +5V

10 N.C. Not used

Installation 33

2.16 Jumper setting for pulse output (PCI-8164 only)

J1 - J8 sets the type of pulse output signals (DIR and OUT). The output signal type may either be differential line driver or open collector output. Refer to section 3.1 for detailed jumper settings. The default setting is differential line driver mode.

34 Installation

2.17 Switch setting for EL Logic

The S1 switch sets the EL limit switching type. By default the EL switch is set to ON, which is the “normally open” position (or "A" contact type), while OFF is the “normally closed” position (or “B” contact type).

For safety reasons, you must set a type that will make the endlimit active when it is broken or disconnected.

NOTE MPC-8164 uses a software function for this setting.

Installation 35

2.18 CN3 pin assignment: General Purpose DI/DO ports (MPC-8164 only)

CN3 Pin No Signal Name CN3 Pin No Signal Name

1 DOCOM 2 DOCOM

3 DOCOM 4 DOCOM

5DO06DO1

7DO28DO3

9DO410DO5

11 DO 6 12 DO 7

13 -- 14 DICOM

15 DICOM 16 DICOM

17 DICOM 18 DI0

19DI120DI2

21DI322DI4

23DI524DI6

25 DI7 26 --

36 Installation

2.19 S2 card ID switch setting (PXI-8164 only)

Card ID Switch Setting (ON=1)

00000

10001

20010

3 0011

40100

50101

60110

7 0111

81000

91001

10 1010

11 1011

NOTE Other settings are invalid. In order to enable this function,

see section 6.21.

Installation 37

38 Installation

3 Signal Connections

This chapter describes the signal connections of the card I/Os. Refer to the contents of this chapter before wiring any cables between the card and any motor drivers.

This chapter contains the following sections:

X Section 3.1 Pulse Output Signals OUT and DIR

X Section 3.2 Encoder Feedback Signals EA, EB and EZ

X Section 3.3 Origin Signal ORG

X Section 3.4 End-Limit Signals PEL and MEL

X Section 3.5 Ramping-down & PCS signals

X Section 3.6 In-position signals INP

X Section 3.7 Alarm signal ALM

X Section 3.8 Deviation counter clear signal ERC

X Section 3.9 General-purposed signals SVON

X Section 3.10 General-purposed signal RDY

X Section 3.11 Position compare output pin: CMP

X Section 3.12 Position latch input pin: LTC

X Section 3.13 Pulse input signals PA and PB

X Section 3.14 Simultaneous start/stop signals STA and STP

X Section 3.15 General-purposed TTL DIO

X Section 3.16 Termination Board

X Section 3.17 General-purposed DIO

Signal Connections 39

3.1 Pulse Output Signals OUT and DIR

The PCI-/MPC-/PXI-8164 has 4 axis pulse output signals. Each axis has two pairs of OUT and DIR signals to transmit the pulse train and to indicate the direction. The OUT and DIR signals may also be programmed as CW and CCW signal pairs. Refer to section 4.1.1 for details of the logical characteristics of the OUT and DIR signals. This section details the electrical characteristics of the OUT and DIR signals. Each signal consists of a pair of differential signals. For example, OUT2 consists of OUT2+ and OUT2signals. The following table shows all pulse output signals on CN2.

CN2 Pin No. Signal Name Description Axis #

3 OUT1+ Pulse signals (+) 1

4 OUT1- Pulse signals (-) 1

5 DIR1+ Direction signal (+) 1

6 DIR1- Direction signal (-) 1

21 OUT2+ Pulse signals (+) 2

22 OUT2- Pulse signals (-) 2

23 DIR2+ Direction signal (+) 2

24 DIR2- Direction signal (-) 2

53 OUT3+ Pulse signals (+) 3

54 OUT3- Pulse signals (-) 3

55 DIR3+ Direction signal (+) 3

56 DIR3- Direction signal (-) 3

71 OUT4+ Pulse signals (+) 4

72 OUT4- Pulse signals (-) 4

73 DIR4+ Direction signal (+) 4

74 DIR4- Direction signal (-) 4

The output of the OUT or DIR signals can be configured by jumpers as either differential line drivers or open collector output. For PCI-8164 card, you can select the output mode by closing either breaks between 1 and 2 or 2 and 3 of jumpers J1-J8.

40 Signal Connections

For differential line driver

Output Signal

OUT1- J1 J1

DIR1- J2 J2

OUT2- J3 J3

DIR2- J4 J4

OUT3- J5 J5

DIR3- J6 J6

OUT4- J7 J7

DIR4- J8 J8

output, close breaks

between 1 and 2 of:

For open collector out-

put, close breaks

between 2 and 3 of:

By default, the OUT and DIR are set to differential line driver mode.

The wiring diagram below illustrates the OUT and DIR signals on the 4 axes of PCI-8164 card.

NOTE When the pulse output is set to open collector output

mode, OUT- and DIR- transmits OUT signals. The sink current must not exceed 20 mA on the OUT- and DIRpins. By default, pin 1-2 of the jumper is shorted.

USAGE Short pin 2-3 of the jumper and connect OUT+/DIR+ to a

470 ohm pulse input interface’s COM of driver. See the following figure.

Signal Connections 41

MPC-8164/PXI-8164

Non-differential type wiring example (MPC-8164/PXI-8164, or PCI-8164 when pin 2-3 of the jumper is shorted)

Choose one of OUT/DIR+ and OUT/DIR- to connect to the driver’s OUT/DIR.

WARNING The sink current must not exceed 20 mA to prevent dam-

age to the PCI-/MPC-/PXI-8164 card!

42 Signal Connections

3.2 Encoder Feedback Signals EA, EB and EZ

The encoder feedback signals include EA, EB, and EZ. Every axis has six pins for three differential pairs of phase-A (EA), phase-B (EB), and index (EZ) inputs. EA and EB are used for position counting, and EZ is used for zero position indexing. The following table shows the relative signal names, pin numbers, and axis numbers.

CN2 Pin No Signal Name Axis # CN2 Pin No Signal Name Axis #

13 EA1+ 1 63 EA3+ 3

14 EA1- 1 64 EA3- 3

15 EB1+ 1 65 EB3+ 3

16 EB1- 1 66 EB3- 3

31 EA2+ 2 81 EA4+ 4

32 EA2- 2 82 EA4- 4

33 EB2+ 2 83 EB4+ 4

34 EB2- 2 84 EB4- 4

CN2 Pin No Signal Name Axis # CN2 Pin No Signal Name Axis #

17 EZ1+ 1 67 EZ3+ 3

18 EZ1- 1 68 EZ3- 3

35 EZ2+ 2 85 EZ4+ 4

36 EZ2- 2 86 EZ4- 4

The diagram below shows the input circuit of the EA, EB, and EZ signals.

Note that the voltage across each differential pair of encoder input signals (EA+, EA-), (EB+, EB-), and (EZ+, EZ-) should be at least

3.5V. Therefore, the output current must be observed when con-

necting to the encoder feedback or motor driver feedback to avoid

Signal Connections 43

over driving the source. The differential signal pairs are converted to digital signals EA, EB, and EZ, then feed to the PCL6045 ASIC.

Below are examples of input signal connection with an external circuit. The input circuit may be connected to an encoder or motor driver if it is equipped with a differential line driver or an open collector output.

Connection to line driver output

To drive the card encoder input, the driver output must provide at least 3.5V across the differential pairs with at least 6 mA driving capacity. The grounds of both sides must be tied together. The maximum frequency will be 4 Mhz or more depending on the wiring distance and signal conditioning.

Connection to open collector output

You need an external power supply to connect with an open collector output. Some motor drivers provide the power source. The diagram below shows the connection between the card, encoder, and the power supply. Note that an external current limiting resistor R is necessary to protect the card’s input circuit. The following table lists the suggested resistor values according to the encoder power supply.

Encoder Power (V) External Resistor R

+5V

+12V

+24V

= 6 mA max

44 Signal Connections

0Ω(None)

1.8kΩ

4.3kΩ

For more operation information on the encoder feedback signals, refer to section 4.4.

Signal Connections 45

3.3 Origin Signal ORG

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

CN2 Pin No Signal Name Axis #

41 ORG1 1

47 ORG2 2

91 ORG3 3

97 ORG4 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 +24 V @ 6 mA 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 (OUT and DIR). For detailed operations of the ORG signal, refer to section 4.3.3.

46 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 MEL indicates the end limit signal is in the minus direction. The signal names, pin numbers, and axis numbers are shown in the table below.

CN2 Pin No Signal Name Axis # CN2 Pin No Signal Name Axis #

37 PEL1 1 87 PEL3 3

38 MEL1 1 88 MEL3 3

43 PEL2 2 93 PEL4 4

44 MEL2 2 94 MEL4 4

A circuit diagram is provided below. The external limit switch should have a contact capacity of +24V @ 6 mA minimum. Either ‘A-type’ (normal open) contact or ‘B-type’ (normal closed) contact switches can be used. To set the type of switch, configure dipswitch S1/SW2. By default, all bits of S1 on the card are set to ON (refer to section 2.10). For more details on EL operation, refer to section 4.3.2.

Signal Connections 47

3.5 Ramping-down and PCS

There is a SD/PCS signal for each of the 4 axes. The signal names, pin numbers, and axis numbers are shown in the table below.

CN2 Pin No Signal Name Axis #

40 SD1/PCS1 1

46 SD2/PCS2 2

90 SD3/PCS3 3

96 SD4/PCS4 4

A circuit diagram is shown below. Typically, the limit switch is used to generate a slow-down signal to drive motors operating at slower speeds. For more details on SD/PCS operation, refer to section

4.3.1.

48 Signal Connections

3.6 In-position Signal INP

The in-position signal INP from a servo motor driver indicates its deviation error. If there is no deviation error, then the servo’s position indicates zero. The signal names, pin numbers, and axis numbers are shown in the table below.

CN2 Pin No Signal Name Axis #

10 INP1 1

28 INP2 2

60 INP3 3

78 INP4 4

The diagram below shows the input circuit of the INP signals.

The in-position signal is usually generated by the servomotor driver and is ordinarily an open collector output signal. An external circuit must provide at least 5 mA current sink capabilities to drive the INP signal. For more details of INP signal operations, refer to section 4.2.1.

Signal Connections 49

3.7 Alarm Signal ALM

The alarm signal ALM indicates the alarm status from the servo driver. The signal names, pin numbers, and axis numbers are shown in the table below.

CN2 Pin No Signal Name Axis #

9ALM11

27 ALM2 2

59 ALM3 3

77 ALM4 4

The input alarm circuit diagram is provided. The ALM signal is usually generated by the servomotor driver and is ordinarily an open collector output signal. An external circuit must provide at least 5 mA current sink capabilities to drive the ALM signal. For more details of ALM signal operations, refer to section 4.2.2.

50 Signal Connections

3.8 Deviation Counter Clear Signal ERC

The deviation counter clear signal (ERC) is active for the following situations:

1. Home return is complete

2. End-limit switch is active

3. An alarm signal stops OUT and DIR signals

4. An emergency stop command is issued by software

(operator)

The signal names, pin numbers, and axis numbers are shown in the table below.

CN2 Pin No Signal Name Axis #

8 ERC1 1

26 ERC2 2

58 ERC3 3

76 ERC4 4

The ERC signal clears the deviation counter of the servomotor driver. The ERC output circuit is an open collector with a maximum of 35V at 50 mA driving capacity. For more details on ERC operation, refer to section 4.2.3.

Signal Connections 51

3.9 General-purpose Signal SVON

The SVON signal can be used as a servomotor-on control or general purpose output signal. The signal names, pin numbers, and its axis numbers are shown in the following table.

CN2 Pin No Signal Name Axis #

7 SVON1 1

25 SVON2 2

57 SVON3 3

75 SVON4 4

The output circuit for the SVON signal is shown below:

52 Signal Connections

3.10 General-purpose Signal RDY

The RDY signals can be used as motor driver ready input or general purpose input signals. The signal names, pin numbers, and axis numbers are shown in the table below.

CN2 Pin No Signal Name Axis #

11 RDY1 1

29 RDY2 2

61 RDY3 3

79 RDY4 4

The input circuit of RDY signal is shown in this diagram.

Signal Connections 53

3.11 Position compare output pin: CMP

The card provides 2 comparison output channels: CMP1 and CMP2, used by the first 2 axes, 1 and 2. The comparison output channel generates a pulse signal when the encoder counter reaches a pre-set value set by the user.

The CMP channel is located on CN2. The signal names, pin numbers, and axis numbers are shown below.

CN2 Pin No Signal Name Axis #

39 CMP1 1

45 CMP2 2

The wiring diagram below shows the CMP on the first 2 axes.

NOTE CMP trigger type may be set to normal low (rising edge)

or normal high (falling edge). Default setting is normal high. Refer to function _8164_set_trigger_type() in section 6.16 for details.

The CMP pin can be regarded as a TTL output.

54 Signal Connections

3.12 Position latch input pin: LTC

The card provides 2 position latch input channels: LTC3 and LTC4, used by the last 2 axes, 3 and 4. The LTC signal triggers the counter-value-capturing functions, which provides a precise position determination.

The LTC channel is on CN2. The signal names, pin numbers, and axis numbers are shown below.

CN2 Pin No Signal Name Axis #

89 LTC3 3

95 LTC4 4

The wiring diagram below shows the LTC of the last 2 axes.

Signal Connections 55

3.13 Pulser Input Signals PA and PB (PCI-8164 only)

The PCI-8164 accepts input pulser signals through the CN3 pins listed below. The pulses behave like an encoder. The signals generate the positioning information that guides the motor.

CN3 Pin No Signal Name Axis # CN3 Pin No Signal Name Axis #

11 PA1 1 5 PA3 3

10 PB1 1 4 PB3 3

9PA223PA44

8 PB2 2 2 PB4 4

The CN3 PA and PB pins are directly connected to PA and PB pins of the PCL6045. The interface circuit is shown below.

If the signal voltage of the pulser is not +5V or if the pulser is distantly placed, it is recommended that a photocoupler or a line driver be installed in between. Note that the CN3 +5V and DGND lines are provided from the PCI bus, and that this source is not isolated.

56 Signal Connections

3.14 Simultaneously Start/Stop Signals STA and STP

(PCI-8164 only)

The PCI-8164 provides STA and STP signals that enable simultaneous start/stop of motions on multiple axes. The STA and STP signals are located on CN4.

The diagram below shows the tied STA and STP signals of the four axes.

Both STP and STA signals are input and output signals. To operate the start and stop action simultaneously, both software control and external control are needed. With software control, the signals can be generated from any one of the PCL6045. You 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-8164 cards, cascade the CN4 connectors of all cards for simultaneous start/stop control on all concerned axes. In this case, connect CN4 as shown below.

The following diagram shows how to allow an external signal to initiate the simultaneous start/stop connect a 7406 (open collector) or an equivalent circuit.

Signal Connections 57

58 Signal Connections

3.15 General Purpose TTL Output (PCI-8164 only)

The PCI-8164 provides six general purpose TTL digital outputs. The TTL output is located on CN5. The signal names, pin numbers, and axis numbers are listed below.

Pin No. Name Function

1 DGND Digital ground

2 DGND Digital ground

3 ED0 Digital Output 0

4 ED1 Digital Output 1

5 ED2 Digital Output 2

6 ED3 Digital Output 3

7 ED4 Digital Output 4

8 ED5 Digital Output 5

9 VCC VCC +5V

The diagram shows the LTC of the last 2 axes.

Signal Connections 59

3.16 Termination board

The card’s CN2 can be connected with a DIN-100M15, including the ACL-102100 — a 100-pin SCSI-II cable. The DIN-100M15 is a general purpose 100-pin, SCSI-II DIN socket. It has convenient wiring screw terminals and an easy-install DIN socket that can be mounted to the DIN rails.

ADLINK also provides DIN-814M termination boards for Mitsubishi J2S servo motor drivers, DIN-814PA termination board for Panasonic Minas A servo motor drivers, DIN-814M-J3A termination board for Mitsubishi J3A Servo motor drviers, and DIN-814Y termination board for Yaskawa sigma-II servo motor driver.

60 Signal Connections

3.17 General Purpose DIO (MPC-8164/PXI-8164 only)

MPC-8164 has eight opto-isolated digital outputs and eight open collector digital inputs for general purpose use. Pin assignments are listed in the table below.

CN3 Pin No Signal Name CN3 Pin No Signal Name

1 DOCOM 2 DOCOM

3 DOCOM 4 DOCOM

5DO06DO1

7DO28DO3

9DO410DO5

11 DO 6 12 DO 7

13 -- 14 DICOM

15 DICOM 16 DICOM

17 DICOM 18 DI0

19DI120DI2

21DI322DI4

23DI524DI6

25 DI7 26 --

PXI-8164 has four opto-isolated digital outputs and four open collector digital inputs for general purpose use. Pin assignments are listed in the following table.

No. Name Function No. Name Function

1 DICOM Digital In Common 2 DOCOM Digital Out Common

3 DI0 Input Channel 0 4 DO0 Output Channel 0

5 DI1 Input Channel 1 6 DO1 Output Channel 1

7 DICOM Digital In Common 8 DOCOM Digital Out Common

9 DI2 Input Channel 2 10 DO2 Output Channel 2

11 DI3 Input Channel 3 12 DO3 Ouput Channel 3

13 DICOM Digital In Common 14 DOCOM Digital Out Common

15 -- N/A 16 -- N/A

17 -- N/A 18 -- N/A

19 -- N/A 20 -- N/A

Signal Connections 61

3.17.1 Isolated input channels

3.17.2 Isolated output channels

62 Signal Connections

3.17.3 Example of input connection

Signal Connections 63

3.17.4 Example of output connections

64 Signal Connections

4 Operation Theory

This chapter describes the detailed operation of the 8164PCI-/ MPC-/PXI-8164 card via the following sections:

X Section 4.1: The motion control modes

X Section 4.2: The motor driver interface (INP, ERC, ALM,

SVON, RDY)

X Section 4.3: The limit switch interface and I/O status (SD/

PCS, EL, ORG)

X Section 4.4: The counters (EA, EB, EZ)

X Section 4.5: Multiple card operation

X Section 4.6: Change position or speed on the fly

X Section 4.7: Position compare and latch

X Section 4.8: Hardware backlash compensator

X Section 4.9: Software limit function

X Section 4.10: Interrupt control

X Section 4.11: PXI Trigger Bus

Operation Theory 65

4.1 Motion Control Modes

This section describes the pulse output signal configuration and motion control modes.

X 4.1.1 Pulse command output

X 4.1.2 Velocity mode motion for one axis

X 4.1.3 Trapezoidal motion for one axis

X 4.1.4 S-Curve profile motion for one axis

X 4.1.5 Linear interpolation for 2-4 axes

X 4.1.6 Circular interpolation for 2 axes

X 4.1.7 Circular interpolation with acc/dec time

X 4.1.8 Relationship between velocity and acceleration time

X 4.1.9 Continuous motion for multiple-axis

X 4.1.10 Home return mode for one axis

X 4.1.11 Home Search mode for one axis

X 4.1.12 Manual pulse mode for one axis

X 4.1.13 Synchronous starting modes

66 Operation Theory

4.1.1 Pulse Command Output

The PCI-/MPC-/PXI-8164 uses pulse commands to control servo/ stepper motors via the drivers. A pulse command has two signals: OUT and DIR. There are two command types: (1) single pulse output mode (OUT/DIR), and (2) dual-pulse output mode (CW/CCW type pulse output). The software function, _8164_set_pls_outmode(), is used to program the pulse command mode. The modes vs. signal type of OUT and DIR pins are listed in the table below.

Mode Output of OUT pin Output of DIR pin

Dual pulse output (CW/CCW)

Single pulse output (OUT/DIR) Pulse signal

Pulse signal in plus

(or CW) direction

The interface characteristics of these signals can be differential line driver or open collector output. Refer to section 3.1 for the jumper setting for different signal types.

Single Pulse Output Mode (OUT/DIR Mode)

In this mode, the OUT signal is for the command pulse (position or velocity) chain. The numbers of OUT pulse represent the relative distance or position. The frequency of the OUT pulse represents the command for speed or velocity. The DIR signal represents direction command of positive (+) or negative (-). This mode is most commonly used. The diagrams below

Pulse signal in

minus (or CCW)

direction

Direction signal

(level)

Operation Theory 67

show the output waveform. It is possible to set the polarity of the pulse chain.

Dual Pulse Output Mode (CW/CCW Mode)

In this mode, the waveform of the OUT and DIR pins represent CW (clockwise) and CCW (counter clockwise) pulse output, respectively. 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 dia-

68 Operation Theory

gram shows the output waveform of positive (+) commands and negative (-) commands.

A/B Phase Pulse Output Mode (A/B phase Mode)

In this mode, the waveform of the OUT and DIR pins represent Aphase and B-phase pulse output, respectively. Pulses output from the OUT pin leading makes the motor move in positive direction, whereas pulse output from the DIR pin leading makes the motor move in negative direction. The following diagram shows the out-

Operation Theory 69

put waveform of positive (+) commands and negative (-) commands. This mode is not available in older version boards.

Related function:

X _8164_set_pls_outmode(): Refer to section 6.4.

70 Operation Theory

4.1.2 Velocity mode motion

This mode is used to operate a one-axis motor with velocity mode motion. The output pulse accelerates from a starting velocity (StrVel) to a specified maximum velocity (MaxVel). The _8164_tv_move() function is used for constant linear acceleration while the _8164_sv_move() function is use for acceleration according to the S-curve. The pulse output rate is kept at maximum velocity until another velocity command is set or a stop command is issued. The _8164_v_change() is used to change the speed during an operation. Before this function is applied, make sure to call _8164_fix_speed_range(). Refer to section 4.6 for more information. The _8164_sd_stop() function is used to decelerate the motion until it stops. The _8164_emg_stop() function is used to immediately stop the motion. These change or stop functions follow the same velocity profile as its original move functions, tv_move or sv_move. The velocity profile is shown below.

NOTE The v_change and stop functions can also be applied to

Preset Mode (both trapezoidal, refer to 4.1.3, and S-curve Motion, refer to 4.1.4) or Home Mode (refer to 4.1.8).

Related functions:

X _8164_tv_move(), _8164_sv_move(), _8164_v_change(),

_8164_sd_stop(), _8164_emg_stop(), _8164_fix_speed_range(), _8164_unfix_speed_range(): Refer to section 6.5

Operation Theory 71

4.1.3 Trapezoidal motion

This mode moves a singe axis motor to a specified position (or distance) with a trapezoidal velocity profile. The single axis is controlled from point to point. An absolute or relative motion can be performed. In absolute mode, the target position is assigned. In relative mode, the target displacement is assigned. In both cases, the acceleration and deceleration may be different. The function _8164_motion_done() is used to check whether the movement is completed.

The diagram shows the trapezoidal profile.

The card supports 2 trapezoidal point-to-point functions. In the _8164_start_ta_move() function, the absolute target position must be given in units of pulses. The physical length or angle of one movement is dependent on the motor driver and mechanism (including the motor). Since absolute move mode needs the information of current actual position, the “External encoder feedback (EA, EB pins)” should be set in _8164_set_feedback_src() function. The ratio between command pulses and external feedback pulse input must be appropriately set by the _8164_set_move_ratio() function.

In the _8164_start_tr_move() function, the relative displacement must be given in units of pulses. Unsymmetrical trapezoidal velocity profile (Tacc is not equal Tdec) can be specified with both _8164_start_ta_move() and _8164_start_tr_move() functions.

72 Operation Theory

The StrVel and MaxVel parameters are given in units of pulses per second (PPS). The Tacc and Tdec parameters are in units of second to represent accel./decel. time respectively. You must know the physical meaning of “one pulse” to calculate the physical value of the relative velocity or acceleration parameters. The following formula gives the basic relationship between these parameters:

X MaxVel = StrVel + accel*Tacc;

X StrVel = MaxVel + decel *Tdec;

Where accel/decel represents the acceleration/deceleration rate in units of pps/sec^2. The area inside the trapezoidal profile represents the moving distance.

Units of velocity setting are pulses per second (PPS). Usually, units of velocity of the manual of motor or driver are in rounds per minute (RPM). A simple conversion is necessary to match between these two units. Here we use an example to illustrate the conversion:

A servomotor with an AB phase encoder is used in a X-Y table. The resolution of encoder is 2000 counts per phase. The maximum rotating speed of motor is designed to be 3600 RPM. What is the maximum pulse command output frequency that you have to set on 8164?

Answer: MaxVel = 3600/60*2000*4 = 480000 PPS

Multiplying by 4 is necessary because there are four states per AB phase (See Section 4.4).

Usually, the axes need to set the move ratio if their mechanical resolution is different from the resolution of command pulse. For example, if an incremental encoder is mounted on the working table to measure the actual position of moving part. A servomotor is used to drive the moving part through a gear mechanism. The gear mechanism is used to convert the rotating motion of the motor into linear motion (see the following diagram). If the resolution of the motor is 8000 pulses/round, then the resolution of the gear mechanism is 100 mm/round (i.e., part moves 100 mm if the motor turns one round). Then, the resolution of the command pulse will be 80 pulses/mm. If the resolution of the encoder mounting on the table is 200 pulses/mm, then you have to set the move

Operation Theory 73

ratio to 200/80=2.5 using the function _8164_set_move_ratio (axis, 2.5).

If this ratio is not set before issuing the start moving command, it will cause problems when running in “Absolute Mode” because the 8164 won’t recognize the actual absolute position during motion.

Related functions:

X _8164_start_ta_move(), _8164_start_tr_move(): Refer to

section 6.6

X _8164_motion_done(): Refer to section 6.11

X _8164_set_feedback_src(): Refer to section 6.4

X _8164_set_move_ratio(): Refer to section 6.6

74 Operation Theory

4.1.4 S-curve profile motion

This mode moves a single-axis motor to a specified position (or distance) with an S-curve velocity profile. S-curve acceleration profiles are useful for both stepper and servomotors. The smooth transitions between the start of the acceleration ramp and transition to constant velocity produce less wear and tear than a trapezoidal profile motion. The smoother performance increases the life of the motor and the mechanics of the system.

There are several parameters that need to be set in order to make a S-curve move. These include:

Pos: target position in absolute mode, in units of pulses

Dist: moving distance in relative mode, in units of pulses

StrVel: start velocity, in units of PPS

MaxVel: maximum velocity, in units of PPS

Tacc: time for acceleration (StrVel -> MaxVel), in units of seconds

Tdec: time for deceleration (MaxVel -> StrVel), in units of seconds

VSacc: S-curve region during acceleration, in units of PPS

VSdec: S-curve region during deceleration, in units of PPS

Normally, the accel/decel period consists of three regions: two VSacc/VSdec curves and one linear. During VSacc/VSdec, the jerk (second derivative of velocity) is constant, and during the linear region, the acceleration (first derivative of velocity) is constant. In the first constant jerk region during acceleration, the velocity

Operation Theory 75

goes from StrVel to (StrVel + VSacc). In the second constant jerk region during acceleration, the velocity goes from (MaxVel – StrVel) to MaxVel. Between them, the linear region accelerates velocity from (StrVel + VSacc) to (MaxVel - VSacc) constantly. The deceleration period is similar in fashion.

Special case:

If you want to disable the linear region, the VSacc/VSdec must be assigned 0 rather than 0.5 (MaxVel-StrVel).

Remember that the VSacc/VSdec is in units of PPS and it should always keep in the range of [0 to (MaxVel - Strvel)/2 ], where “0” means no linear region.

The S-curve profile motion functions are designed to always produce smooth motion. If the time for acceleration parameters combined with the final position don’t allow an axis to reach the maximum velocity (i.e. the moving distance is too small to reach MaxVel), then the maximum velocity is automatically lowered (see the figure below).

The rule is to lower the value of MaxVel and the Tacc, Tdec, VSacc, VSdec automatically, and keep StrVel, acceleration, and jerk unchanged. This is also applicable for trapezoidal profile motion.

76 Operation Theory

Related functions:

X _8164_start_sr_move(),_8164_start_sa_move(): Refer to

section 6.6

X _8164_motion_done(): Refer to section 6.11

X _8164_set_feedback_src(): Refer to section 6.4

X _8164_set_move_ratio(): Refer to section 6.6

The following table shows the differences between all single axis motion functions, including preset mode (both trapezoidal and Scurve motion) and constant velocity mode.

4.1.5 Linear interpolation for 2-4 axes

In this mode, any two of four, three of four, or all four axes may be chosen to perform linear interpolation. Interpolation between multi-axes means these axes start simultaneously, and reach their ending points at the same time. Linear means the ratio of speed of every axis is a constant value.

Note that you cannot use two groups of two axes for linear interpolation on a single card at the same time. You can however, use one 2-axis linear and one 2-axis circular interpolation at the same time. If you want to stop an interpolation group, use the _8164_sd_stop() or _8164_emg_stop() function.

Operation Theory 77

2 axes linear interpolation

In the diagram below, 2-axis linear interpolation means to move the XY position (or any two of the four axis) from P0 to P1. The 2 axes start and stop simultaneously, and the path is a straight line.

The speed ratio along X-axis and Y-axis is ( tively, and the vector speed is:

When calling 2-axis linear interpolation functions, the vector speed needs to define the start velocity, StrVel, and maximum velocity, MaxVel. Both trapezoidal and S-curve profiles are available.

Example:

_8164_start_tr_move_xy(0, 30000.0, 40000.0, 1000.0, 5000.0,

0.1, 0.2) will cause the XY axes (axes 0 & 1) of Card 0 to perform a linear interpolation movement, in which:

∆X: ∆Y), respec-

∆X = 30000 pulses; ∆Y = 40000 pulses

Start vector speed=1000pps, X speed=600pps, Y speed = 800pps

Max. vector speed =5000pps, X speed=3000pps, Y speed = 4000pps

Acceleration time = 0.1sec; Deceleration time = 0.2sec

There are two groups of functions that provide 2-axis linear interpolation. The first group divides the four axes into XY (axis 0 & axis 1) and ZU (axis 2 & axis 3). By calling these functions, the target axes are already assigned.

_8164_start_tr_move_xy(), _8164_start_tr_move_zu(),

78 Operation Theory

_8164_start_ta_move_xy(), _8164_start_ta_move_zu(),

_8164_start_sr_move_xy(), _8164_start_sr_move_zu(),

_8164_start_sa_move_xy(), _8164_start_sa_move_zu()

(Refer to section 6.7)

The second group allows you to freely assign the two target axes.

_8164_start_tr_line2(), _8164_start_sr_line2(),

_8164_start_ta_line2(), _8164_start_sa_line2()

(Refer to section 6.7)

The characters “t”, “s”, “r”, and “a” after _8164_start mean:

t – Trapezoidal profile

s – S-Curve profile

r – Relative motion

a – Absolute motion

3-axis linear interpolation

Any three of the four axes of the card may perform 3-axis linear interpolation. As shown the figure below, 3-axis linear interpolation means to move the XYZ (if axes 0, 1, 2 are selected and assigned to be X, Y, Z, respectively) position from P0 to P1, starting and stopping simultaneously. The path is a straight line in space.

Operation Theory 79

The speed ratio along X-axis, Y-axis, and Z-axis is (∆X: ∆Y:

∆Z), respectively, and the vector speed is:

When calling 3-axis linear interpolation functions, the vector speed is needed to define the start velocity, StrVel, and maxi- mum velocity, MaxVel. Both trapezoidal and S-curve profiles are available.

Example

_8164_start_tr_line3(….,1000.0 /*

∆X */ , 2000.0/*∆Y */, 3000.0 /

*DistZ*/, 100.0 /*StrVel*/, 5000.0 /* MaxVel*/, 0.1/*sec*/, 0.2 /*sec*/ )

∆X = 1000 pulse; ∆Y = 2000 pulse; ∆Z = 3000 pulse

Start vector speed=100pps,

X X speed = 100/ = 26.7pps

X Y speed = 2*100/ = 53.3pps

X Z speed = 3*100/ = 80.1pps

Max. vector speed =5000pps,

X X speed= 5000/ = 1336pps

X Y speed = 2*5000/ = 2672pps

X Z speed = 3*5000/ = 4008pps

The following functions are used for 3-axis linear interpolation:

_8164_start_tr_line3(), _8164_start_sr_line3()

_8164_start_ta_line3() , _8164_start_sa_line3()

(Refer to section 6.7)

The characters “t”, “s”, “r”, and “a” after _8164_start mean:

t – Trapezoidal profile

s – S-Curve profile

r – Relative motion

80 Operation Theory

a – Absolute motion

4-axis linear interpolation

With 4-axis linear interpolation, the speed ratio along X-axis, Yaxis, Z-axis and U-axis is ( the vector speed is:

The following functions are used for 4-axis linear interpolation:

_8164_start_tr_line4(), _8164_start_sr_line4()

_8164_start_ta_line4(),_8164_start_sa_line4()

(Refer to section 6.7)

The characters “t”, “s”, “r”, and “a” after _8164_start mean:

t – Trapezoidal profile

s – S-Curve profile

r – Relative motion

a – Absolute motion

∆X: ∆Y: ∆Z: ∆U), respectively, and

Operation Theory 81

4.1.6 Circular interpolation for 2 axes

Any 2 of the 4 axes of the card can perform circular interpolation. In the example below, circular interpolation means XY (if axes 0, 1 are selected and assigned to be X, Y respectively) axes simultaneously start from initial point, (0,0) and stop at end point,(1800,600). The path between them is an arc, and the MaxVel is the tangential speed. Notice that if the end point of arc is not at a proper position, it will move circularly without stopping.

Example

_8164_start_a_arc_xy(0 /*card No*/, 1000,0 /*center X*/, 0 /*cen- ter Y*/, 1800.0 /* End X */, 600.0 /*End Y */ ,1000.0 /* MaxVel */)

To specify a circular interpolation path, the following parameters must be clearly defined:

Center point: The coordinate of the center of arc (In absolute mode)

or the off_set distance to the center of arc (In relative mode)

End point: The coordinate of end point of arc (In absolute mode)

Direction: The moving direction, either CW or CCW.

It is not necessary to set radius or angle of arc, since the information above gives enough constrains. The arc motion is stopped when either of the two axes reached end point.

There are two groups of functions that provide 2-axis circular interpolation. The first group divides the four axes into XY (axis 0 and

or the off_set distance to center of arc (In relative mode)

82 Operation Theory

axis 1) and ZU (axis 2 and axis 3). By calling these functions, the target axes are already assigned.

_8164_start_r_arc_xy(), _8164_start_r_ arc _zu(),

_8164_start_a_ arc _xy(), _8164_start_a_ arc _zu(),

(Refer to section 6.8)

The second group allows user to freely assign any targeted two axes.

_8164_start_r_arc2(),_8164_start_a_arc2(): Refer to section 6.8

Operation Theory 83

4.1.7 Circular interpolation with Acc/Dec time

In section 4.1.6, the circular interpolation functions do not support acceleration and deceleration parameters. Therefore, they cannot perform a T or S curve speed profile during operation. However, sometimes the need for an Acc/Dec time speed profile will help a machine to make more accurate circular interpolation. The 8164 card has another group of circular interpolation functions to perform this type of interpolation, but requires the use of Axis3 as an aided axis, which means that Axis3 cannot be used for other purposes while running these functions. For example, to perform a circular interpolation with a T-curve speed profile, the function _8164_start_tr_arc_xyu() is used. This function will use Axis0 and Axis1, and also Axis3 (Axis0=x, Axis1=y, Axis2=z, Axis3=u). For the full lists of functions, refer to section 6.8.

To check if the card supports these functions use the _8164_version_info() function. If hardware information for the card returns a value with the 4th digit greater then 0, for example '1003', users can use this group of circular interpolation to perform S or T-curve speed profiles. If the hardware version returns a value with the 4th digit being 0, then the card does not support these functions.

84 Operation Theory

4.1.8 Relationship between velocity and acceleration

time

The maximum velocity parameter of a motion function will eventually have a minimum acceleration value. This means that there is a range for acceleration time over one velocity value. Under this relationship, to obtain a small acceleration time, a higher maximum velocity value to match the smaller acceleration time is required. Function _8164_fix_speed_range() will provide such operation. This function will raise the maximum velocity value, which in turn results in a smaller acceleration time. Note it does not affect the actual end velocity. For example, to have a 1ms acceleration time from a velocity of 0 to 5000 (pps), the function can be inserted before the motion function as shown.

_8164_fix_speed_range(AxisNo,OverVelocity);

_8164_start_tr_move(AxisNo,5000,0,5000,0.001,0.001);

How do users decide an optimum value for “OverVelocity” in the _8164_fix_speed_range() function? The _8164_verify_speed() function is provided to calculate such value. The inputs to this function are the start velocity, maximum velocity and over velocity values. The output value will be the minimum and maximum values of the acceleration time.

For example, if the original acceleration range for the command is:

Operation Theory 85

_8164_start_tr_move(AxisNo,5000,0,5000,0.001,0.001),

then use the following function:

_8164_verify_speed(0,5000,&minAccT, &maxAccT,5000);

The value miniAccT will be 0.0267sec and maxAccT will be

873.587sec. This minimum acceleration time does not meet the requirement of 1mS. To achieve such a low acceleration time the over speed value must be used.

By changing the OverVelocity value to 140000,

_8164_verify_speed(0,5000,&minAccT, &maxAccT,140000);

The value miniAccT will be 0.000948sec and maxAccT will be

31.08sec. This minimum acceleration time meets the requirements. So, the motion command can be changed to:

_8164_fix_speed_range(AxisNo,140000);

_8164_start_tr_move(AxisNo,5000,0,5000,0.001,0.001);

Notes:

X The return value of _8164_verify_speed() is the mini-

mum velocity of motion command, it does not always equal to your start velocity setting. In the above example, it will be 3pps more than the 0pps setting.

X To disable the fix speed function

_8164_fix_speed_range() use _8164_unfix_speed_range()

X Minimize the use of the OverVelocity operation. the more it

is used, the coarser the speed interval is.

86 Operation Theory

Example:

User’s Desired Profile: (MaxV2, Target T) is not possible under MaxV2 according to the (MaxV, MiniT) relationship. So one must change the (MaxV, MiniT) relationship to a higher value, (MaxV1, MiniT1). Finally, the command would be:

_8164_fix_speed_range(AxisNo, MaxV1);

_8164_start_tr_move(AxisNo,Distance, 0 , MaxV2 , Target T, Target T);

Related functions:

X _8164_fix_speed_range(),

_8164_unfix_speed_range(),_8164_verify_speed()

Refer to section 6.5

Operation Theory 87

4.1.9 Continuous motion

The card allows you to perform continuous motion. Both single axis movement (section 4.1.3: Trapezoidal, section 4.1.4: SCurve) and multi-axis interpolation (4.1.5: linear interpolation,

4.1.6: circular interpolation) can be extended to be continuous motion.

For example, if a user calls the following function to perform a single axis preset motion:

1) _8164_set_continuous_move(0, 1)

It enables the continuous move function by keeping current position in internal variable. If this function is not enabled, the second motion function will return busy status and can not do continuous motion.

2) _8164_start_ta_move(0, 50000, 100, 30000, 0.1, 0.0)

It causes the axis “0” to move to position “50000.0.” Before the axis arrives, the user can call a second motion (refer to the next function). Notice that the deceleratin of this function is set to 0. It means that deceleration is not needed in this command in order to smoothly link the next command velocity.

3) _8164_start_tr_move(0, 20000, 100, 30000, 0.0, 0.2)

The second function call does not affect the first one. Actually, it will be executed and written into the card pre-register. After the first move is finished, the card will continue with the second move according to the pre-registered value. The time interval between these two moves can be seen as a continuous move and pulses will be continuously be generated at the “50000.0” position. Notice that the acceleration time is set to 0. It means that we do not need acceleration in this command in order to smoothly link the previous command velocity.

4) _8164_set_continuous_move(0, 0)

Return to normal move mode.

The theory of continuous motion is described below:

Theory of continuous motion (FIFO architecture)

88 Operation Theory

ADLINK PCI-8164 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

1.1.1 PCI-8164

1.1.2 MPC-8164

1.1.3 PXI-8164

1.2 Specifications

1.3 Software support

1.3.1 Programming library

1.3.2 Motion Creator

2 Installation

2.1 Package contents

2.2 PCI-8164 layout

2.3 MPC-8164 layout

2.4 PXI-8164 layout

2.5 PCI-8164/PXI-8164 hardware installation

2.5.1 Hardware configuration

2.5.2 PCI slot selection

2.5.3 Installing the PCI-8164 card

2.5.4 Installing the PXI-8164 card

2.6 MPC-8164 hardware installation

2.6.1 Hardware configuration

2.7 Driver installation

2.13 CN2 pin assignments: Main Connector

2.15 CN5 pin assignment: TTL Output (PCI-8164 only)

2.16 Jumper setting for pulse output (PCI-8164 only)

2.17 Switch setting for EL Logic

2.18 CN3 pin assignment: General Purpose DI/DO ports (MPC-8164 only)

2.19 S2 card ID switch setting (PXI-8164 only)

3 Signal Connections

3.1 Pulse Output Signals OUT and DIR

3.2 Encoder Feedback Signals EA, EB and EZ

3.3 Origin Signal ORG

3.4 End-Limit Signals PEL and MEL

3.5 Ramping-down and PCS

3.6 In-position Signal INP

3.7 Alarm Signal ALM

3.8 Deviation Counter Clear Signal ERC

3.9 General-purpose Signal SVON

3.10 General-purpose Signal RDY

3.11 Position compare output pin: CMP

3.12 Position latch input pin: LTC

3.13 Pulser Input Signals PA and PB (PCI-8164 only)

3.15 General Purpose TTL Output (PCI-8164 only)

3.16 Termination board

3.17 General Purpose DIO (MPC-8164/PXI-8164 only)

3.17.1 Isolated input channels

3.17.2 Isolated output channels

3.17.3 Example of input connection

3.17.4 Example of output connections

4 Operation Theory

4.1 Motion Control Modes

4.1.1 Pulse Command Output

4.1.2 Velocity mode motion

4.1.3 Trapezoidal motion

4.1.4 S-curve profile motion

4.1.5 Linear interpolation for 2-4 axes

4.1.6 Circular interpolation for 2 axes

4.1.7 Circular interpolation with Acc/Dec time

4.1.9 Continuous motion