Delta Tau Power PMAC User Manual

Single Source Machine Control

……………………………………………..…...……………….

Power // Flexibility // Ease of Use

21314 Lassen St. Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // www.deltatau.com

^1 USER’S MANUAL

^2 Power PMAC

^3 Power PMAC User’s Manual

^4 050-PRPMAC-0U0

^5 January 6, 2015

DELTA TAU

Data Systems, Inc.

NEW IDEAS IN MOTION …

Power PMAC User’s Manual

Copyright Information

© 2015 Delta Tau Data Systems, Inc. All rights reserved.

This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses
are unauthorized without written permission of Delta Tau Data Systems, Inc.
Information contained in this manual may be updated from time-to-time due to product
improvements, etc., and may not conform in every respect to former issues.

To report errors or inconsistencies, call or email:

Delta Tau Data Systems, Inc. Technical Support

Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.deltatau.com

Operating Conditions

All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers
contain static sensitive components that can be damaged by incorrect handling. When
installing or handling Delta Tau Data Systems, Inc. products, avoid contact with highly
insulated materials. Only qualified personnel should be allowed to handle this
equipment.

In the case of industrial applications, we expect our products to be protected from
hazardous or conductive materials and/or environments that could cause harm to the
controller by damaging components or causing electrical shorts. When our products are
used in an industrial environment, install them into an industrial electrical cabinet or
industrial PC to protect them from excessive or corrosive moisture, abnormal ambient
temperatures, and conductive materials. If Delta Tau Data Systems, Inc. products are
directly exposed to hazardous or conductive materials and/or environments, we cannot
guarantee their operation.

Power PMAC User’s Manual

A Warning identifies hazards that could result in personal injury or
death. It precedes the discussion of interest.

Warning

!

Caution

A Caution identifies hazards that could result in equipment damage. It
precedes the discussion of interest.

Note

A Note identifies information critical to the understanding or use of
the equipment. It follows the discussion of interest.

Safety Instructions

Qualified personnel must transport, assemble, install, and maintain this equipment. Properly qualified
personnel are persons who are familiar with the transport, assembly, installation, and operation of
equipment. The qualified personnel must know and observe the following standards and regulations:

IEC364resp.CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DIN VDE 0110
National regulations for safety and accident prevention or VBG 4

Incorrect handling of products can result in injury and damage to persons and machinery. Strictly adhere
to the installation instructions. Electrical safety is provided through a low-resistance earth connection. It
is vital to ensure that all system components are connected to earth ground.

This product contains components that are sensitive to static electricity and can be damaged by incorrect
handling. Avoid contact with high insulating materials (artificial fabrics, plastic film, etc.). Place the
product on a conductive surface. Discharge any possible static electricity build-up by touching an
unpainted, metal, grounded surface before touching the equipment.

Keep all covers and cabinet doors shut during operation. Be aware that during operation, the product has
electrically charged components and hot surfaces. Control and power cables can carry a high voltage,
even when the motor is not rotating. Never disconnect or connect the product while the power source is
energized to avoid electric arcing.

Power PMAC User’s Manual

REVISION HISTORY

REV.

DESCRIPTION

DATE

CHG

APPVD

1

New Manual Generated

11/28/2011

SS

Curt Wilson

2

Updating Table of Contents

01/19/2012

SS

Curt Wilson

3

Updating the manual for firmware version 1.5 release

08/10/2012

SS

Curt Wilson

4

Updating the manual for firmware version 1.6 release

03/17/2014

SS

Curt Wilson

5

Updating the manual for firmware version 2.0 release

01/06/2015

SS

Curt Wilson

Power PMAC User’s Manual

TABLE OF CONTENTS

Contents

POWER PMAC FAMILY OVERVIEW ................................................................................................ 27

What Is Power PMAC? ............................................................................................................................... 27

Power PMAC Configurations ..................................................................................................................... 27

Power UMAC......................................................................................................................................... 27

Compact Power UMAC ......................................................................................................................... 28

Power PMAC Etherlite .......................................................................................................................... 28

Power Brick Configurations .................................................................................................................. 28

Power Clipper ........................................................................................................................................ 29

Soft Power PMAC .................................................................................................................................. 30

What Power PMAC Does ........................................................................................................................... 30

Execute Sequenced Motion Programs ................................................................................................... 30

Execute Asynchronous PLC Programs .................................................................................................. 30

Perform Kinematic Transformations ..................................................................................................... 30

Process Feedback and Master Position Data ........................................................................................ 31

Compute Commanded Motor Trajectories ............................................................................................ 31

Calculate Compensation Table Corrections .......................................................................................... 31

Close Motor Position/Velocity Servo Loops .......................................................................................... 31

Perform Electronic Phase Commutation ............................................................................................... 31

Close Motor Current Loops ................................................................................................................... 31

Provide Synchronous Data Gathering ................................................................................................... 32

Perform General Housekeeping and Safety Checks .............................................................................. 32

Respond to Host Computer Commands ................................................................................................. 32

Execute Independent C Applications ..................................................................................................... 32

Key Hardware Components ........................................................................................................................ 33

CPU Section........................................................................................................................................... 33

Machine Interface ICs ........................................................................................................................... 34

TALKING TO POWER PMAC .............................................................................................................. 39

Physical Interface ........................................................................................................................................ 39

Use of the Internet Protocol Suite ............................................................................................................... 39

Layers of the Internet Protocol Suite ..................................................................................................... 39

Low-Level Terminal Communications ....................................................................................................... 40

Terminal Emulator Programs ................................................................................................................ 41

Establishing First Communications....................................................................................................... 41

Table of Contents vi

Power PMAC User’s Manual

Communicating with the Power PMAC Control Application ................................................................ 42

Establishing Communications with the IDE ............................................................................................... 44

Startup Communications Control Window ............................................................................................ 44

Embedded Communications Control Window ....................................................................................... 45

Changing the Power PMAC IP Address ................................................................................................ 46

Finding an Unknown IP Address ........................................................................................................... 47

Power PMAC Commands ........................................................................................................................... 48

On-Line (Immediate) Commands........................................................................................................... 48

Buffered Program Commands ............................................................................................................... 50

Power PMAC Processing of Commands ............................................................................................... 51

POWER PMAC SYSTEM CONFIGURATION ................................................................................... 55

Physical Configuration Status Reporting .................................................................................................... 55

General Configuration ........................................................................................................................... 55

Interface ICs Present ............................................................................................................................. 56

Interface IC Addresses ........................................................................................................................... 56

Interface IC Configuration Information ................................................................................................ 56

Change in Configuration ....................................................................................................................... 57

Power PMAC System Clock Source ........................................................................................................... 57

Default Clock Source ............................................................................................................................. 57

IC Clock Generation Facilities .............................................................................................................. 57

Distribution of Clock Signals ................................................................................................................. 58

Re-Initialization Clock Actions .............................................................................................................. 59

Normal Reset Clock Actions .................................................................................................................. 59

Changing the Clock Source from Default .............................................................................................. 60

Setting System Clock Frequencies .............................................................................................................. 60

Phase and Servo-Clock Hardware Tasks .............................................................................................. 60

Phase-Clock Software Tasks .................................................................................................................. 61

Servo-Clock Software Tasks .................................................................................................................. 61

Real-Time Interrupt Software Tasks ...................................................................................................... 62

Background Tasks .................................................................................................................................. 63

Multi-Tasking Example .......................................................................................................................... 64

Using the IDE to Set Phase and Servo Clock Frequencies ................................................................... 65

Setting Phase and Servo Clock Frequencies in PMAC2-Style ICs ........................................................ 65

Setting Phase and Servo Clock Frequencies in PMAC3-Style ICs ........................................................ 68

Clock-Related Software Settings ............................................................................................................ 69

Setting the Phase and Servo Clock Period in the CPU ......................................................................... 70

Diagnosing Issues with Clock Settings ....................................................................................................... 71

Missing Clock Signals ............................................................................................................................ 71

Task Priority Duty Cycles ...................................................................................................................... 71

Table of Contents vii

Power PMAC User’s Manual

SETTING UP THE MACRO RING ....................................................................................................... 75

MACRO Ring Overview ............................................................................................................................ 75

Power PMAC MACRO Interfaces .............................................................................................................. 75

ACC-5E MACRO Interface for UMAC .................................................................................................. 75

ACC-5E3 MACRO Interface for UMAC ................................................................................................ 75

ACC-5EP3 MACRO Interface for Etherlite ........................................................................................... 76

MACRO Interface for Power Brick ....................................................................................................... 76

Configuring Master and Slave Devices ...................................................................................................... 76

PMAC2-Style MACRO IC ...................................................................................................................... 76

PMAC3-Style MACRO IC ...................................................................................................................... 77

Setting the Ring Frequency ......................................................................................................................... 79

PMAC2-Style MACRO IC ...................................................................................................................... 79

PMAC3-Style MACRO IC ...................................................................................................................... 80

Extending the Phase Software Update ................................................................................................... 80

Enabling MACRO Nodes ........................................................................................................................... 82

Node Allocation ..................................................................................................................................... 82

Typical Mapping of MACRO Nodes to Motors ..................................................................................... 82

Enabling Nodes in a PMAC2-Style MACRO IC .................................................................................... 83

Enabling Nodes in a PMAC3-Style MACRO IC .................................................................................... 84

Ring Check Function .................................................................................................................................. 85

Ring Check Parameters ......................................................................................................................... 85

MACRO Node Register Organization ........................................................................................................ 85

Standard Use of Registers in a Servo Node ........................................................................................... 85

Data Elements in a PMAC2-Style MACRO IC ...................................................................................... 85

Data Elements in a PMAC3-Style MACRO IC ...................................................................................... 86

Processing Position Feedback from the MACRO Ring .............................................................................. 86

Encoder Table Entry Method: EncTable[n].type .................................................................................. 86

Encoder Table Entry Source Address: EncTable[n].pEnc .................................................................... 87

Intermediate Processing: EncTable[n].index1, index2 ......................................................................... 88

Change Limiting: EncTable[n].index3, MaxDelta ................................................................................ 89

Setting Up Motor Addressing Elements ..................................................................................................... 90

Command Output Address ..................................................................................................................... 90

Position Feedback Address .................................................................................................................... 91

Interface Type ........................................................................................................................................ 91

Input Flag Addresses ............................................................................................................................. 91

Input Flag Bits ....................................................................................................................................... 91

Output Flag Addresses .......................................................................................................................... 92

Output Flag Bits .................................................................................................................................... 92

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Power PMAC User’s Manual

Commutation Addresses ........................................................................................................................ 93

Setting Up a Motor as a Network Slave ...................................................................................................... 95

Command Modes ................................................................................................................................... 95

Coordinating Power PMAC Motor Setup .............................................................................................. 96

Network-Slave Power PMAC Motor Setup ............................................................................................ 99

SETTING UP FEEDBACK AND MASTER POSITION SENSORS ................................................ 102

Setting Up Digital Quadrature Encoders .................................................................................................. 102

Signal Format ...................................................................................................................................... 102

Hardware Setup ................................................................................................................................... 103

Hardware-Control Parameter Setup ................................................................................................... 105

Using the Resulting Position Information ........................................................................................... 107

Setting Up Digital Hall Sensors ................................................................................................................ 110

Signal Format ...................................................................................................................................... 110

Hardware Setup ................................................................................................................................... 111

Hardware-Control Parameter Setup ................................................................................................... 111

Using the Resulting Position Information ........................................................................................... 112

Setting Up Serial Encoders ....................................................................................................................... 113

Signal Format ...................................................................................................................................... 113

Hardware Setup ................................................................................................................................... 113

Hardware-Control Parameter Setup ................................................................................................... 113

Using the Resulting Position Information ........................................................................................... 123

Setting Up Analog Sinusoidal Encoders ................................................................................................... 127

Signal Format ...................................................................................................................................... 127

Sinusoidal Encoder Interfaces ............................................................................................................. 128

Hardware Setup ................................................................................................................................... 129

Hardware Control Parameter Setup .................................................................................................... 131

Using the Resulting Position Information ........................................................................................... 143

Setting Up Resolvers ................................................................................................................................. 149

Signal Format ...................................................................................................................................... 149

Hardware Setup ................................................................................................................................... 150

Hardware-Control Parameter Setup ................................................................................................... 150

Using the Resulting Position Information ........................................................................................... 153

Setting Up MLDTs ................................................................................................................................... 157

Signal Format ...................................................................................................................................... 157

Hardware Setup ................................................................................................................................... 158

Hardware-Control Parameter Setup ................................................................................................... 158

Using the Resulting Position Information ........................................................................................... 161

Setting Up Parallel Data Position Inputs ................................................................................................... 163

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Power PMAC User’s Manual

Signal Format ...................................................................................................................................... 163

Hardware Setup ................................................................................................................................... 163

Hardware Control Parameter Setup .................................................................................................... 163

Using the Resulting Position Information ........................................................................................... 164

Setting Up Analog Data Position Inputs ................................................................................................... 166

Signal Format ...................................................................................................................................... 166

Hardware Setup ................................................................................................................................... 167

Hardware Control Parameter Setup .................................................................................................... 168

Using the Resulting Position Information ........................................................................................... 171

SETTING UP THE ENCODER CONVERSION TABLE.................................................................. 177

What the Encoder Conversion Table Does ............................................................................................... 177

Conversion Table Execution ..................................................................................................................... 178

Conversion Table Structure ...................................................................................................................... 178

Conversion Method Overview .................................................................................................................. 179

IDE Table Configuration Window ............................................................................................................ 179

Scaling of Entry Results ............................................................................................................................ 180

Using Conversion Table Results ............................................................................................................... 181

Default Conversion Table Setup ............................................................................................................... 182

Conversion Method Details ...................................................................................................................... 182

Type 0: End of (Active) Table .............................................................................................................. 182

Type 1: Single-Register Read .............................................................................................................. 183

Type 2: Double-Register Read ............................................................................................................. 189

Type 3: Software 1/T Encoder Extension ............................................................................................ 191

Type 4: Software Arctangent Sinusoidal Encoder Extension .............................................................. 192

Type 5: Four-Byte Read ....................................................................................................................... 196

Type 6: Resolver Arctangent Direct Conversion ................................................................................. 197

Type 7: Extended Hardware Arctangent Interpolation ....................................................................... 198

Types 8 and 9: Addition and Subtraction ............................................................................................ 199

Type 10: Triggered Time Base............................................................................................................. 200

Type 11: Floating-Point Register Read ............................................................................................... 201

Type 12: Single Register Read with Error Check ................................................................................ 203

BASIC MOTOR SETUP ........................................................................................................................ 206

IDE Interactive Setup ................................................................................................................................ 207

Parameters to Set Up Basic Motor Operation ........................................................................................... 207

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Power PMAC User’s Manual

Initial Setup Parameters ............................................................................................................................ 209

Activating the Motor: Motor[x].ServoCtrl .......................................................................................... 209

Activating PMAC Motor Commutation: Motor[x].PhaseCtrl ............................................................. 209

Motor Address Setup Parameters .............................................................................................................. 210

Command Output Address: Motor[x].pDac ........................................................................................ 210

Motor vs. Load Feedback .................................................................................................................... 211

Outer (Position) Loop Feedback: Motor[x].pEnc, PosSf .................................................................... 212

Inner (Velocity) Loop Feedback: Motor[x].pEnc2, Pos2Sf ................................................................. 212

Changing Feedback on the Fly ............................................................................................................ 213

Feedback Source and Type: Motor[x].EncType .................................................................................. 213

Encoder Status Address: Motor[x].pEncStatus ................................................................................... 214

Position-Capture Flag Address: Motor[x].pCaptFlag, CaptFlagBit .................................................. 214

Limit Flag Address: Motor[x].pLimits, LimitBits ................................................................................ 214

Amplifier Fault Flag Address: Motor[x].pAmpFault, AmpFaultBit ................................................... 215

Amplifier Enable Flag Address: Motor[x].pAmpEnable, AmpEnableBit............................................ 215

Absolute Power-On Position Address: Motor[x].pAbsPos ................................................................. 216

Is Power PMAC Commutating or Closing the Current Loop for This Motor? ......................................... 217

Setting Up Power PMAC for Velocity or Torque Control ....................................................................... 217

Hardware Setup ................................................................................................................................... 217

ASIC Programmable Signal Setup ....................................................................................................... 220

Setting Up Power PMAC for Pulse-and-Direction Control ...................................................................... 222

Hardware Setup ................................................................................................................................... 223

Signal Timing ....................................................................................................................................... 223

Power PMAC Parameter Setup ........................................................................................................... 224

Setting Up Power PMAC for Position-Output Control............................................................................. 230

Power PMAC Parameter Setup ........................................................................................................... 230

SETTING UP POWER PMAC-BASED COMMUTATION AND/OR CURRENT LOOP ............ 232

Selection of Phase Update Frequency ....................................................................................................... 232

Beginning Setup of Commutation............................................................................................................. 232

Commutation Enable: Motor[x].PhaseCtrl ......................................................................................... 233

Commutation Position Feedback Source: Motor[x].pPhaseEnc ......................................................... 234

Commutation Position Source Processing: Motor[x].PhaseEncRightShift, Motor[x].PhaseEncLeftShift

............................................................................................................................................................. 235

Commutation Position Scale Factor: Motor[x].PhasePosSf ............................................................... 235

Current Loop in Power PMAC or Not: Motor[x].pAdc ...................................................................... 236

Setting Up for Sine-Wave Output Control ................................................................................................ 238

Hardware Setup ................................................................................................................................... 238

Motor Software Setup .......................................................................................................................... 240

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Power PMAC User’s Manual

Setting Up For Direct PWM Control ........................................................................................................ 244

Introduction ......................................................................................................................................... 244

Digital Current Loop Principle of Operation ...................................................................................... 244

Hardware Setup ................................................................................................................................... 247

Motor Software Setup .......................................................................................................................... 251

Direct PWM Control of Brush Motors ..................................................................................................... 261

Direct Microstepping with Direct PWM Control...................................................................................... 264

Principle of Operation ......................................................................................................................... 264

Speed Limitations................................................................................................................................. 265

Hardware Setup ................................................................................................................................... 265

Encoder Conversion Table Entry Setup ............................................................................................... 265

Simulated Servo Loop Setup ................................................................................................................ 266

Commutation and Current-Loop Setup ................................................................................................ 267

Limiting Parameters ............................................................................................................................ 269

Establishing a Phase Reference (Synchronous Motors)............................................................................ 270

Absolute Phasing Reads ...................................................................................................................... 272

Correcting an Approximate Phase Reference...................................................................................... 278

Finishing Setting Up Power PMAC Commutation (Direct PWM or Sine Wave), Asynchronous

(Induction) Motors .................................................................................................................................... 279

Calculating Motor[x].DtOverRotorTc Slip Constant .......................................................................... 279

Setting Motor[x].IdCmd Magnetization Current ................................................................................. 281

SETTING UP THE SERVO LOOP ...................................................................................................... 283

Servo Update Rate .................................................................................................................................... 283

Choosing an Update Rate .................................................................................................................... 283

Ramifications of Changing the Rate .................................................................................................... 283

Setting the Servo Clock Frequency/Period .......................................................................................... 284

Extending the Servo Update Period for a Motor ................................................................................. 284

Closing the Servo Loop Under the Phase Interrupt for a Motor ......................................................... 284

Types of Amplifiers .................................................................................................................................. 285

Amplifiers for Which Servo Produces Position Command .................................................................. 286

Amplifiers for Which Servo Produces Velocity Command .................................................................. 286

Amplifiers for Which Servo Produces Torque/Force Command ......................................................... 287

Selecting a Servo Algorithm ..................................................................................................................... 288

Position Command Output Algorithm ...................................................................................................... 289

Basic PID Algorithm ................................................................................................................................. 289

Feedback Terms ................................................................................................................................... 290

Feedforward Filter .............................................................................................................................. 292

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Power PMAC User’s Manual

Standard Servo Algorithm ........................................................................................................................ 293

Polynomial Filters ............................................................................................................................... 293

Integration Mode ................................................................................................................................. 296

Friction Feedforward .......................................................................................................................... 296

Acceleration Feedback ........................................................................................................................ 296

Input Deadband Compensation ........................................................................................................... 296

Output Hysteretic Deadband ............................................................................................................... 298

Adaptive Servo Control ............................................................................................................................ 299

Selecting the Adaptive Control Algorithm ........................................................................................... 300

Establishing the Reference System ...................................................................................................... 300

Software Setup for Adaptive Control ................................................................................................... 300

Gain Scheduled Adaptive Control ....................................................................................................... 301

Executing the Adaptive Control Algorithm .......................................................................................... 302

Cross-Coupled Gantry Control ................................................................................................................. 304

Selecting the Cross-Coupled Control Algorithm ................................................................................. 305

Tuning the Non-Coupled Terms ........................................................................................................... 305

Tuning the Cross-Coupled Terms ........................................................................................................ 306

Custom User Servo Algorithms ................................................................................................................ 306

Tuning the Servo Loop in the IDE ............................................................................................................ 307

Automatic Tuning................................................................................................................................. 308

Sample Interactive Tuning Process ..................................................................................................... 310

Cascading Servo Loops ............................................................................................................................. 315

Strategies for Coupling the Loops ....................................................................................................... 315

To Integrate Outer Loop Command or Not ......................................................................................... 316

Inner Loop General Setup ................................................................................................................... 316

Outer Loop General Setup ................................................................................................................... 317

Joining the Loops through Position Following Function .................................................................... 317

Joining the Loops through Compensation Table ................................................................................. 319

Tuning the Outer Loop ......................................................................................................................... 321

Programming the Outer-Loop Motor .................................................................................................. 322

Setup Examples .................................................................................................................................... 322

Changing the Operational Mode of Control ........................................................................................ 324

Trajectory Pre-Filter .................................................................................................................................. 325

Typical Uses of the Pre-Filter ............................................................................................................. 325

Overview .............................................................................................................................................. 326

Saved Setup Elements .......................................................................................................................... 327

Filter DC Gain ..................................................................................................................................... 327

Spliner Reconstruction ......................................................................................................................... 328

Automated Filter Setup ........................................................................................................................ 328

Manual Filter Calculations ................................................................................................................. 329

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Power PMAC User’s Manual

SETTING UP COMPENSATION TABLES ........................................................................................ 332

Table Data Structure ................................................................................................................................. 332

Reserving Memory for the Tables ............................................................................................................ 333

Defining the Table Structure ..................................................................................................................... 334

Dimension Indices ............................................................................................................................... 334

Number of Active Dimensions: Nx[n] > 0 ........................................................................................... 334

Source Motors for Each Dimension: Source[n] .................................................................................. 336

Source Position Used for Each Dimension: SourceCtrl ...................................................................... 336

Number of Data Zones in Each Active Dimension: Nx[n] .................................................................. 336

Starting Source Location for Each Active Dimension: X0[n] ............................................................. 337

Source Span for Each Active Dimension: Dx[n] ................................................................................. 337

Interpolation-Order and Boundary-Mode Control: Ctrl ..................................................................... 338

Target Register Addresses: Target[q] ................................................................................................. 340

Target Output Scale Factors: Sf[q] ..................................................................................................... 343

Overwriting vs. Additive Outputs: OutCtrl .......................................................................................... 343

Entering the Table Data Points ................................................................................................................. 344

Enabling Compensation Tables ................................................................................................................ 345

Action of the Compensation Tables .......................................................................................................... 345

Use of “0D” Compensation Tables ........................................................................................................... 346

Sample Compensation Tables ................................................................................................................... 347

1D “Leadscrew Compensation” Table................................................................................................ 347

2D “Planar” Position Compensation Table ....................................................................................... 347

SETTING UP ELECTRONIC CAM TABLES ................................................................................... 349

Uses of Electronic Cam Tables ................................................................................................................. 349

Position Commands ............................................................................................................................. 349

Torque Offset Commands .................................................................................................................... 349

Direct Output Commands .................................................................................................................... 349

Comparison to External Time Base Techniques ....................................................................................... 350

Table Design Techniques .......................................................................................................................... 351

Table Data Structure ................................................................................................................................. 352

Reserving Memory for the Tables ............................................................................................................ 353

Defining the Table Structure ..................................................................................................................... 353

Source Motor Number: Source ............................................................................................................ 353

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Power PMAC User’s Manual

Number of Data Zones: Nx .................................................................................................................. 354

Starting Source Location: X0, SlewX0 ................................................................................................ 354

Source Span: Dx .................................................................................................................................. 355

Target Motor Number: Target ............................................................................................................. 355

Target Position Scale Factor: PosSf ................................................................................................... 355

Target Position Offset Slew: SlewPosOffset ........................................................................................ 355

Target Torque Offset Enable Control: DacEnable .............................................................................. 355

Target Torque Scale Factor: DacSf ..................................................................................................... 355

Output Address: pOut .......................................................................................................................... 355

Buffered Output Address: pOutBuf ...................................................................................................... 356

Output Shifting:OutLeftShift ................................................................................................................ 356

Output Masking: OutBits ..................................................................................................................... 356

Entering the Table Data Points ................................................................................................................. 356

Returning vs. Non-Returning Position Tables .......................................................................................... 357

Returning Position Tables ................................................................................................................... 357

Non-Returning Position Tables ........................................................................................................... 358

Enabling the Cam Tables .......................................................................................................................... 359

Action of the Cam Tables ......................................................................................................................... 359

Adjusting of the Table Action ................................................................................................................... 361

Adjusting on Source Motor Position .................................................................................................... 361

Adjusting on Target Motor Position .................................................................................................... 361

Phasing the Cam Cycle on a Source Motor Trigger ........................................................................... 361

Rollover of the Table ................................................................................................................................ 363

Position Output at Rollover ................................................................................................................. 363

Torque Offset Output at Rollover ........................................................................................................ 363

General Purpose Outputs at Rollover ................................................................................................. 364

Iterative Learning Control ......................................................................................................................... 364

Combining Cam Motion with Other Motion ............................................................................................ 364

Reporting Motor Position with Cam Table Motion .................................................................................. 365

Disabling the Cam Tables ......................................................................................................................... 365

Switching Between Cam Tables ............................................................................................................... 365

MAKING YOUR POWER PMAC APPLICATION SAFE ............................................................... 366

Watchdog Timer ....................................................................................................................................... 366

Soft Watchdog Trips ............................................................................................................................ 366

Hard Watchdog Trips .......................................................................................................................... 368

Global Abort-All Input ............................................................................................................................. 369

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Power PMAC User’s Manual

Software Setup ..................................................................................................................................... 369

Action on Trip ...................................................................................................................................... 369

Voltage Interlock Circuits ......................................................................................................................... 370

Following Error Limits ............................................................................................................................. 370

Fatal Following Error Limit ................................................................................................................ 370

Warning Following Error Limit .......................................................................................................... 372

Position (Overtravel) Limits ..................................................................................................................... 372

Software Overtravel Limit Parameters ................................................................................................ 372

Hardware Overtravel Limit Switches .................................................................................................. 374

Encoder Loss Detection ............................................................................................................................ 376

Signal Loss Detection Circuits ............................................................................................................ 377

Software Setup for Loss Detection ....................................................................................................... 379

Auxiliary Fault Detection ......................................................................................................................... 381

Software Setup for Auxiliary Fault Detection ...................................................................................... 381

Automatic Brake Control .......................................................................................................................... 383

Specifying the Brake Control Output ................................................................................................... 383

Specifying the Brake Timing ................................................................................................................ 383

Amplifier Enable and Fault Lines ............................................................................................................. 384

Current Limits ........................................................................................................................................... 385

Intermittent Current Limits .................................................................................................................. 385

Time-Integrated Current Limits ........................................................................................................... 386

RMS Current Calculations .................................................................................................................. 389

Reference Frame Conversions ............................................................................................................. 392

Torque Control Mode .......................................................................................................................... 393

Sinewave Output Mode ........................................................................................................................ 395

Direct PWM Output Mode ................................................................................................................... 397

Velocity Limits ......................................................................................................................................... 400

Programmed Vector Velocity Limit ..................................................................................................... 400

Programmed Motor Velocity Limit ...................................................................................................... 401

Position-Following Velocity Limit ....................................................................................................... 401

Acceleration Limits ................................................................................................................................... 401

Programmed Vector Acceleration Limits ............................................................................................ 401

Programmed Motor Acceleration Limits ............................................................................................. 402

Motor Move Acceleration Command ................................................................................................... 403

Position-Following Acceleration Limit ............................................................................................... 403

Jerk Limits ................................................................................................................................................ 403

Programmed Motor Jerk Limit ............................................................................................................ 403

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Power PMAC User’s Manual

Motor Move Jerk Command ................................................................................................................ 403

Commanded Safety Stops ......................................................................................................................... 404

Abort: Controlled Stop ........................................................................................................................ 404

Disable: Uncontrolled Stop ................................................................................................................. 404

Hybrid Abort/Disable .......................................................................................................................... 405

EXECUTING INDIVIDUAL MOTOR MOVES ................................................................................. 406

Jogging Move Control .............................................................................................................................. 406

Jog Speed Control ................................................................................................................................ 406

Jog Acceleration Control ..................................................................................................................... 406

Example Jog Move Profile ................................................................................................................... 410

Jog Commands..................................................................................................................................... 410

Triggered Motor Moves ............................................................................................................................ 412

Types of Triggered Moves ................................................................................................................... 412

Trigger Conditions............................................................................................................................... 413

Capturing the Position at Trigger ....................................................................................................... 417

Processing the Hardware-Captured Position ...................................................................................... 421

Processing the Software-Captured Position ........................................................................................ 430

Post-Trigger Move ............................................................................................................................... 430

Homing-Search Moves ......................................................................................................................... 430

Jog-Until-Trigger Moves ..................................................................................................................... 435

Program Move-Until-Trigger .............................................................................................................. 436

Open-Loop Moves .................................................................................................................................... 436

SETTING UP COORDINATE SYSTEMS .......................................................................................... 437

What is a Coordinate System? .................................................................................................................. 437

Number of Coordinate Systems ........................................................................................................... 437

Strategy for Assigning Coordinate Systems ......................................................................................... 437

Fault Sharing ....................................................................................................................................... 438

What is an Axis? ....................................................................................................................................... 438

Single-Motor Axes ............................................................................................................................... 438

Multiple-Motor Axes ............................................................................................................................ 438

Phantom Axes ...................................................................................................................................... 439

Axis Definition Statements ....................................................................................................................... 439

Matching Motor to Axis ....................................................................................................................... 440

Scaling and Offset ................................................................................................................................ 440

The Null Definition .............................................................................................................................. 440

Defining a Motor to Multiple Axes ...................................................................................................... 440

Cartesian Axis Sets .............................................................................................................................. 442

The Spindle Axis Definition ................................................................................................................. 443

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Conversion from Axis to Motor Position ............................................................................................. 444

Conversion from Motor to Axis Positions ............................................................................................ 444

Coordinate-System Kinematic Subroutines .............................................................................................. 446

Creating the Kinematic Program Buffers ............................................................................................ 447

Generalizing the Routines to Multiple Coordinate Systems ................................................................ 457

Axis Transformation Matrices .................................................................................................................. 460

Transformation Matrix Data Structures .............................................................................................. 461

Using the Matrices ............................................................................................................................... 462

Examples .............................................................................................................................................. 463

Rescaling Feedrate and Tool Radius ................................................................................................... 464

Segmentation Mode .................................................................................................................................. 464

Time-Base Control and Override Techniques........................................................................................... 466

Time-Base Control ............................................................................................................................... 466

Segmentation Override ........................................................................................................................ 469

Axis Target Position and Distance-to-Go Reporting ................................................................................ 472

Setting Up the Target Position Buffer .................................................................................................. 472

Querying the Target Position Data ..................................................................................................... 473

POWER PMAC COMPUTATIONAL FEATURES ........................................................................... 476

Computational Priorities ........................................................................................................................... 476

Phase (Commutation) Update ............................................................................................................. 476

Servo Update ....................................................................................................................................... 476

Real-Time Interrupt Tasks ................................................................................................................... 477

Background Tasks ................................................................................................................................ 477

Monitoring Processing Time ............................................................................................................... 477

Numerical Values ...................................................................................................................................... 478

Internal Formats .................................................................................................................................. 478

Pre-Defined Data Structures ..................................................................................................................... 481

Specifying Data Structure Indices ....................................................................................................... 482

User Variables ........................................................................................................................................... 483

Direct Access to User Variables .......................................................................................................... 483

User-Specified Variable Names Through IDE .................................................................................... 484

Automatically Assigned Declared Variables ....................................................................................... 484

System Global (“P”) Variables ........................................................................................................... 486

Coordinate System Global (“Q”) Variables ....................................................................................... 487

User Pointer (“M”) Variables ............................................................................................................. 488

Pre-Defined Setup Pointer (“I”) Variables ......................................................................................... 488

Local (“L”) Variables ......................................................................................................................... 489

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Return/Stack (“R”) Variables .............................................................................................................. 490

Coordinate System Kinematic Axis (“C”) Variables........................................................................... 491

Non-Stack Local (“D”) Variables ....................................................................................................... 492

User Shared Memory Buffer Variables ............................................................................................... 493

Operators ................................................................................................................................................... 495

Arithmetic Operators ........................................................................................................................... 495

Bit-Wise Operators .............................................................................................................................. 495

Standard Assignment Operators .......................................................................................................... 496

Synchronous Assignment Operators .................................................................................................... 496

Functions ................................................................................................................................................... 497

Scalar Functions .................................................................................................................................. 497

Vector Functions .................................................................................................................................. 497

Matrix Functions ................................................................................................................................. 498

Expressions ............................................................................................................................................... 499

The {data} Syntax ..................................................................................................................................... 500

Standard Variable Value Assignment ....................................................................................................... 500

Synchronous Variable Value Assignment ................................................................................................ 501

Variables That Can Be Assigned Synchronously ................................................................................. 501

Why Needed in Motion Programs ........................................................................................................ 502

Why Needed in PLC Programs ............................................................................................................ 503

The Synchronous Assignment Buffer ................................................................................................... 503

Execution Details ................................................................................................................................. 504

Comparators .............................................................................................................................................. 504

Conditions ................................................................................................................................................. 505

Explicit Comparisons ........................................................................................................................... 505

Compound Conditions ......................................................................................................................... 505

Condition Negation .............................................................................................................................. 506

USING GENERAL-PURPOSE DIGITAL I/O WITH POWER PMAC ........................................... 507

Note on Using “Dedicated” I/O for General Purpose Use ........................................................................ 507

Digital I/O Hardware and Configuration .................................................................................................. 507

UMAC Digital I/O Boards ................................................................................................................... 507

Compact UMAC ACC-11C Digital I/O ............................................................................................... 508

UMAC ACC-5E Digital I/O ................................................................................................................. 509

UMAC ACC-5E3 Digital I/O ............................................................................................................... 509

Power Brick Digital I/O ....................................................................................................................... 510

Power Clipper Digital I/O ................................................................................................................... 510

ACC-34 Family Multiplexed Digital I/O ............................................................................................. 511

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Software Configuration for Digital I/O Use ............................................................................................. 513

UMAC Digital I/O Boards ................................................................................................................... 513

Compact UMAC ACC-11C Digital I/O ............................................................................................... 515

UMAC ACC-5E Digital I/O ................................................................................................................. 515

UMAC ACC-5E3 Digital I/O ............................................................................................................... 517

Power Brick Digital I/O ....................................................................................................................... 518

Power Clipper Digital I/O ................................................................................................................... 518

ACC-34 Family Multiplexed Digital I/O ............................................................................................. 519

Accessing Digital I/O Points in the Script Environment .......................................................................... 523

Accessing Output Points at Different Priority Levels .......................................................................... 523

UMAC Digital I/O Boards ................................................................................................................... 524

Compact UMAC ACC-11C Digital I/O ............................................................................................... 525

UMAC ACC-5E Digital I/O ................................................................................................................. 525

UMAC ACC-5E3 Digital I/O ............................................................................................................... 526

Power Brick Digital I/O ....................................................................................................................... 526

Power Clipper Digital I/O ................................................................................................................... 527

ACC-34 Family Multiplexed Digital I/O ............................................................................................. 528

Accessing Digital I/O Points in the C Environment ................................................................................. 529

Accessing Output Points at Different Priority Levels .......................................................................... 529

Volatile Variable Declarations ............................................................................................................ 529

Using Data Structures ......................................................................................................................... 529

Using Direct Pointer Variables ........................................................................................................... 530

UMAC Digital I/O Boards ................................................................................................................... 531

Compact UMAC ACC-11C Digital I/O ............................................................................................... 532

UMAC ACC-5E Digital I/O ................................................................................................................. 532

UMAC ACC-5E3 Digital I/O ............................................................................................................... 534

Power Brick Digital I/O ....................................................................................................................... 535

Power Clipper Digital I/O ................................................................................................................... 537

ACC-34 Family Multiplexed Digital I/O ............................................................................................. 538

USING GENERAL-PURPOSE ANALOG I/O WITH POWER PMAC ........................................... 539

Note on Using “Dedicated” I/O for General Purpose Use ........................................................................ 539

Analog I/O Hardware and Configuration .................................................................................................. 539

UMAC ACC-28E ADC Board ............................................................................................................. 539

UMAC ACC-36E ADC Board ............................................................................................................. 540

UMAC ACC-59E ADC/DAC Board .................................................................................................... 541

UMAC ACC-59E3 ADC/DAC Board .................................................................................................. 541

Power Brick Optional Analog I/O ....................................................................................................... 543

Power Clipper Optional On-Board Analog I/O................................................................................... 544

Power Clipper with ACC-28B ADC Board ......................................................................................... 545

Power Clipper with ACC-8AS True DAC Board ................................................................................. 545

Software Configuration for Analog I/O Use ............................................................................................. 546

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UMAC ACC-28E ADC Board ............................................................................................................. 546

UMAC ACC-36E, ACC-59E ADC Inputs ............................................................................................ 546

UMAC ACC-59E DAC Outputs ........................................................................................................... 547

UMAC ACC-59E3 ADC Inputs ........................................................................................................... 547

UMAC ACC-59E3 DAC Outputs ......................................................................................................... 548

Power Brick Optional ADC Inputs ...................................................................................................... 548

Power Brick Optional Filtered-PWM Analog Outputs ........................................................................ 549

Power Brick Optional True DAC Outputs ........................................................................................... 550

Power Clipper Optional On-Board Analog Inputs .............................................................................. 550

Power Clipper Optional On-Board Analog Outputs ........................................................................... 550

Power Clipper with ACC-28B Analog Inputs ...................................................................................... 551

Power Clipper with ACC-8AS Analog Outputs ................................................................................... 551

Accessing Analog I/O Points in the Script Environment .......................................................................... 552

UMAC ACC-28E ADCs ....................................................................................................................... 552

UMAC ACC-36E and ACC-59E ADCs ............................................................................................... 552

UMAC ACC-59E DACs ....................................................................................................................... 552

UMAC ACC-59E3 ADCs ..................................................................................................................... 553

UMAC ACC-59E3 DACs ..................................................................................................................... 554

Power Brick Optional ADCs ............................................................................................................... 555

Power Brick Optional Filtered-PWM Analog Outputs ........................................................................ 557

Power Brick Optional True-DAC Analog Outputs .............................................................................. 558

Power Clipper Optional On-Board ADCs ........................................................................................... 559

Power Clipper Optional On-Board Analog Output ............................................................................. 560

Power Clipper with ACC-28B ADCs ................................................................................................... 561

Power Clipper with ACC-8AS True DAC Outputs .............................................................................. 562

Accessing Analog I/O Points in the C Environment ................................................................................. 564

Volatile Variable Declarations ............................................................................................................ 564

Using Data Structures ......................................................................................................................... 564

Using Direct Pointer Variables ........................................................................................................... 564

UMAC ACC-28E ADCs ....................................................................................................................... 565

UMAC ACC-36E and ACC-59E ADCs ............................................................................................... 566

UMAC ACC-59E DACs ....................................................................................................................... 566

UMAC ACC-59E3 ADCs ..................................................................................................................... 567

UMAC ACC-59E3 DACs ..................................................................................................................... 568

Power Brick Optional ADCs ............................................................................................................... 569

Power Brick Optional Filtered PWM Analog Outputs ........................................................................ 571

Power Brick Optional True-DAC Analog Outputs .............................................................................. 572

Power Clipper Optional On-Board ADCs ........................................................................................... 573

Power Clipper Optional On-Board Filtered-PWM Analog Output .................................................... 574

Power Clipper with ACC-28B ADCs ................................................................................................... 575

Power Clipper with ACC-8AS True-DAC Analog Outputs ................................................................. 577

WRITING AND EXECUTING SCRIPT PROGRAMS IN THE POWER PMAC ......................... 579

Classes of Script Programs ....................................................................................................................... 579

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Motion Programs ................................................................................................................................. 579

Rotary Motion Programs ..................................................................................................................... 579

PLC Programs ..................................................................................................................................... 579

Subprograms ........................................................................................................................................ 580

Kinematic Subroutines ......................................................................................................................... 580

Script Language Syntax Features .............................................................................................................. 580

Mathematical Capabilities ................................................................................................................... 580

Program Flow Control ........................................................................................................................ 581

Motion Specification ............................................................................................................................ 585

Program Direct Commands ................................................................................................................. 588

Downloading Rules for Script Programs .................................................................................................. 590

Motion Programs ................................................................................................................................. 590

Rotary Motion Programs ..................................................................................................................... 590

PLC Programs ..................................................................................................................................... 591

Subprograms ........................................................................................................................................ 591

Kinematic Subroutines ......................................................................................................................... 592

Implementing Script Programs in the IDE ................................................................................................ 592

Organizing Your Program Files .......................................................................................................... 592

User Variable Names ........................................................................................................................... 593

IDE Program Enhancements ............................................................................................................... 595

Execution Rules for Script Programs ........................................................................................................ 599

Motion Programs ................................................................................................................................. 599

Rotary Motion Programs ..................................................................................................................... 604

PLC Programs ..................................................................................................................................... 604

Subprograms ........................................................................................................................................ 605

Kinematic Subroutines ......................................................................................................................... 605

Starting and Stopping Script Program Execution ..................................................................................... 606

Coordinate System Addressing for Motion Programs ......................................................................... 606

Starting Script Motion Program Execution ......................................................................................... 606

Stopping Script Motion Program Execution ........................................................................................ 609

Starting Script PLC Program Execution ............................................................................................. 614

Stopping Script PLC Program Execution ............................................................................................ 615

Implementing an RS-274 Style Motion Program ..................................................................................... 617

G, M, T, and D-Codes .......................................................................................................................... 617

Standard G-Codes ............................................................................................................................... 618

POWER PMAC MOVE MODE TRAJECTORIES ............................................................................ 626

Modal Move-Rule Commands .................................................................................................................. 626

Move Commands ...................................................................................................................................... 626

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Rapid Move Mode .................................................................................................................................... 627

Rapid Mode Declaration ..................................................................................................................... 627

Position or Distance Specification ...................................................................................................... 627

Velocity Specification .......................................................................................................................... 627

Acceleration Specification ................................................................................................................... 627

Sample Move Profile ............................................................................................................................ 631

Multi-Axis Path Options ...................................................................................................................... 632

Rapid-Mode Move-Until-Trigger ........................................................................................................ 632

Breaking into a Rapid-Mode Move ...................................................................................................... 634

Executing Rapid-Style Moves with Linear Mode ................................................................................. 634

Linear Move Mode ................................................................................................................................... 635

Optional Segmentation Mode .............................................................................................................. 635

Linear Mode Declaration .................................................................................................................... 635

Position or Distance Specification ...................................................................................................... 635

Feedrate or Move-Time Specification ................................................................................................. 636

Acceleration Specification ................................................................................................................... 638

Linear Move Examples ........................................................................................................................ 640

Blending Moves Together .................................................................................................................... 642

Special Linear Contouring Mode ........................................................................................................ 646

Using Linear Mode for “Rapid” Moves .............................................................................................. 647

Circle Move Mode .................................................................................................................................... 648

Enabling Move Segmentation .............................................................................................................. 648

Specifying the Interpolation Plane ...................................................................................................... 648

Circle Mode Declaration ..................................................................................................................... 650

Position or Distance Specification ...................................................................................................... 650

Center Specification ............................................................................................................................. 650

Motion of Other Axes ........................................................................................................................... 653

Feedrate or Move-Time Specification ................................................................................................. 653

Acceleration Specification ................................................................................................................... 655

Blending Moves Together .................................................................................................................... 655

Blended Move “Cornering” Control ................................................................................................... 656

Tool (Cutter) Radius Compensation ......................................................................................................... 665

Two-Dimensional Tool Radius Compensation .................................................................................... 665

Three-Dimensional Tool Radius Compensation .................................................................................. 679

PVT Move Mode ...................................................................................................................................... 686

PVT Mode Declaration ........................................................................................................................ 686

Position or Distance Specification ...................................................................................................... 686

Velocity Specification .......................................................................................................................... 686

Power PMAC Calculations .................................................................................................................. 686

Use of PVT Mode in Contouring ......................................................................................................... 688

Lookahead with PVT Moves ................................................................................................................ 689

Blending PVT Moves with Linear and Circle Moves........................................................................... 689

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Issues with Single-Stepping ................................................................................................................. 691

Spline Move Mode .................................................................................................................................... 692

Spline Mode Declaration ..................................................................................................................... 692

Position or Distance Specification ...................................................................................................... 692

Uniform-Time Calculations ................................................................................................................. 692

Non-Uniform-Time Calculations ......................................................................................................... 694

Use of Spline Mode for Contouring ..................................................................................................... 695

Power PMAC Special Lookahead Function ............................................................................................. 696

Principle of Operation ......................................................................................................................... 696

Sample Effect Diagrams ...................................................................................................................... 697

Interactions with Kinematics ............................................................................................................... 698

Transparent Operation ........................................................................................................................ 698

Quick Instructions: Setting Up Lookahead .......................................................................................... 698

Detailed Instructions: Setting Up to use Lookahead ........................................................................... 699

Running a Program with Lookahead ................................................................................................... 705

Stopping While in Lookahead .............................................................................................................. 706

Reversal While in Lookahead .............................................................................................................. 708

Feedrate Override with Lookahead ..................................................................................................... 709

SYNCHRONIZING POWER PMAC TO EXTERNAL EVENTS .................................................... 711

A Note on “Master/Slave” Techniques ..................................................................................................... 711

Processing the Master Position Signal ...................................................................................................... 712

Processing a Quadrature Encoder with a PMAC2-Style IC ............................................................... 713

Processing an External Clock Signal with a PMAC2-Style IC ............................................................ 713

Processing a Sinusoidal Encoder with a PMAC2-Style IC ................................................................. 713

Processing a Quadrature Encoder with a PMAC3-Style IC ............................................................... 714

Processing an External Clock Signal with a PMAC3-Style IC ............................................................ 714

Processing a Sinusoidal Encoder with a PMAC3-Style IC ................................................................. 714

Processing a Serial Encoder with a PMAC3-Style IC ......................................................................... 715

Position Following (Electronic Gearing) .................................................................................................. 715

Position Following Master Address .................................................................................................... 716

Position Following “Gear Ratio” ....................................................................................................... 716

Enabling and Disabling Following...................................................................................................... 717

Following Mode: Normal vs. Offset .................................................................................................... 717

Speed and Acceleration Limiting in Following ................................................................................... 718

Custom Following Algorithms ............................................................................................................. 722

Tuning the Servo Loop of the Slave Motor .......................................................................................... 722

External Time-Base Control ..................................................................................................................... 722

What is External Time-Base Control? ................................................................................................. 722

Comparison to Electronic Cam Tables ................................................................................................ 723

How External Time-Base Works .......................................................................................................... 723

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Time-Base Entry in the Encoder Conversion Table ............................................................................ 724

Using the Scaled Master Value ............................................................................................................ 724

Writing the Motion Program ............................................................................................................... 725

Simple Time-Base Example: Crosscut on Moving Web ....................................................................... 726

Triggered Time Base ............................................................................................................................ 726

Electronic Cam Tables .............................................................................................................................. 730

Hardware Position-Capture Functions ...................................................................................................... 731

Requirements for Hardware Capture .................................................................................................. 731

Setting the Trigger Condition .............................................................................................................. 731

Automatic Move-Until-Trigger Functions ........................................................................................... 732

Manual Use of the Hardware-Capture Feature .................................................................................. 732

Position-Capture Monitoring Function ............................................................................................... 735

Manually Converting to Motor and Axis Positions ............................................................................. 736

Hardware Position-Compare Functions .................................................................................................... 739

Setup on a PMAC2-Style IC................................................................................................................. 739

Setup on a PMAC3-Style IC................................................................................................................. 742

Handling Fractional Count Values ...................................................................................................... 748

Converting from Motor and Axis Coordinates .................................................................................... 748

WRITING C FUNCTIONS AND PROGRAMS IN POWER PMAC ............................................... 751

Priorities for C Programs and Routines in Power PMAC ......................................................................... 751

Creating C Functions and Programs ......................................................................................................... 752

Accessing Shared Memory and Structures ............................................................................................... 753

Accessing ASIC Hardware Registers ....................................................................................................... 753

Using the Data Structures ................................................................................................................... 754

Using Direct Pointer Variables ........................................................................................................... 755

Capture/Compare Interrupt Service Routine ............................................................................................. 756

ASIC Interrupt Control Register .......................................................................................................... 756

Writing a Capture/Compare Interrupt Service Routine ....................................................................... 757

Executing the Capture/Compare Interrupt Service Routine ................................................................ 757

Capture Interrupt Routine Example .................................................................................................... 757

Compare Interrupt Routine Example ................................................................................................... 758

User-Written Phase Routines .................................................................................................................... 760

Declaration .......................................................................................................................................... 760

Automatic Preparation for Routine ..................................................................................................... 760

Input/Output Access ............................................................................................................................. 760

Basic Example Routine ........................................................................................................................ 761

Compiling and Downloading ............................................................................................................... 761

User-Written Servo Routines .................................................................................................................... 762

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Declaration .......................................................................................................................................... 762

Automatic Preparation of Input Values ............................................................................................... 763

Automatic Processing of Returned Value ............................................................................................ 763

Basic Example Routine ........................................................................................................................ 763

Multi-Motor Routines .......................................................................................................................... 764

Compiling and Downloading ............................................................................................................... 765

Real-Time Interrupt C PLC Routine ......................................................................................................... 765

Background C PLC Routines .................................................................................................................... 766

CfromScript Function ............................................................................................................................... 767

Declaring CfromScript() ...................................................................................................................... 767

Calling CfromScript from Script Programs ......................................................................................... 768

Using Local Data Variables within CfromScript ................................................................................ 768

Calling CfromScript from Multiple Script Programs .......................................................................... 769

Background C Application Programs ....................................................................................................... 773

EXAMPLE SCRIPT PROGRAMS ....................................................................................................... 774

Simple Motion Programs .......................................................................................................................... 774

Example 1: Basic Moves ...................................................................................................................... 774

Example 2: A More Complex Move Sequence ..................................................................................... 775

Example 3: Moves with Looping, Branching, and I/O ........................................................................ 776

Example 4: Coordinated and Blended Moves with Linear and Circular Interpolation ...................... 777

Example 5: Coordinated Path Motion ................................................................................................. 779

A Move with Separate Acceleration and Deceleration ........................................................................ 784

Motion with Related Machine I/O ....................................................................................................... 785

Interactive Jog Control PLC Programs ............................................................................................... 786

SCARA Robot Kinematics .................................................................................................................... 789

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POWER PMAC FAMILY OVERVIEW

The Power PMAC family of controllers is the latest generation of motion and machine controllers
from Delta Tau Data Systems, Inc. It is available in a large and increasing number of
configurations, permitting the user to configure controller hardware and software to particular
application needs. This chapter provides a brief overview of the Power PMAC structure; all items
mentioned here are covered in more detail elsewhere in the Users Manual or in related reference
manuals.

What Is Power PMAC?

Power PMAC is a general-purpose embedded computer with a built-in motion and machine­control application. It also provides a wide variety of hardware machine interface circuitry that
permits connection to common servo and stepper drives, feedback sensors, and analog and digital
I/O points.

Power PMAC Configurations

Power PMAC is available in multiple physical configurations, optimized for different styles of
applications. Each configuration shares the same core software capabilities, but the hardware
interfaces differ between configurations.

Power UMAC

The Power UMAC is a modular rack-mounted configuration of the Power PMAC. It consists of a
set of 3U-format (100mm x 160mm) boards in a Euro-Card rack. Along with the required Power
PMAC CPU board, a customized set of interface boards can be added, communicating over a
common backplane. These include digital and analog servo interface boards, digital and analog
general-purpose I/O boards, machine network interface boards, and industrial fieldbus interface
boards. A power supply installed in the rack can be used, or an external supply.

Example Power UMAC Configuration

Because of its modular nature, the Power UMAC provides the most flexible configuration for
Power PMAC systems.

Power PMAC Family Overview 27

Power PMAC User’s Manual

Compact Power UMAC

Starting in early 2014, the Power PMAC will also be available in the “Compact Power UMAC”

configuration. This is similar to the standard Power UMAC, with 3U-format (100mm x 160mm)
boards on a common backplane. However, the field wiring is distributed behind the backplane, as
in the Compact PCI format (but there is no PCI interface). This requires a customized and
engineered distribution scheme, so this format is intended for high-volume OEMs who have the
capability and financial justification for such a distribution scheme.

Power PMAC Etherlite

The Power PMAC Etherlite is a compact and cost-effective configuration intended for control
through industrial networks and fieldbuses. It consists of a Power PMAC CPU board, a network
interface board that can be configured for the MACROTM fiber optic network, the EtherCATTM
electrical network, or both. Optionally, a fieldbus interface board for buses such as ProfibusTM,
DeviceNetTM, or CCLinkTM can be installed.

Power PMAC Etherlite Controller

The Power PMAC Etherlite is commonly used for large systems where networked connections
are important to simplify system wiring.

Power Brick Configurations

The Power Brick controllers are integrated “boxed” configurations of Power PMAC. The come in

three configurations: Power Brick AC, Power Brick LV, and Power Brick Controller.

All of these configurations can support multiple styles of position feedback: digital incremental
(quadrature) encoders, serial encoders, analog incremental (sinusoidal) encoders, and resolvers.

All configurations provide a standard set of “flags” (e.g. limit, home, and user) for each axis, with

a set of general-purpose digital I/O. General-purpose analog I/O is also available.

Power Brick AC

The Power Brick AC combines a Power PMAC controller with integrated 3-phase motor
amplifier circuits for 4, 6 or 8 axes. The AC power input for the amplifiers can be up to 240VAC.

Power PMAC Family Overview 28

Power PMAC User’s Manual

Power Brick AC 4-Axis Configuration

Power Brick LV

The Power Brick LV combines a Power PMAC controller with integrated motor amplifier circuits
for 2-phase and 3-phase motors for 4 or 8 axes. It accepts a DC power input for the amplifiers of
up to 60VDC. Each axis can be configured by the user for 2-phase or 3-phase motors, open-loop
(stepper) or closed-loop (servo).

Power Brick Controller

The Power Brick Controller combines a Power PMAC controller with an integrated multi-axis
amplifier-interface board in a single boxed package. Both analog and digital amplifier interface
boards are available, and each can be provided in 4-axis and 8-axis configurations.

Power Clipper

The Power Clipper is a compact and cost-effective configuration of the Power PMAC for
embedded applications. It combines the Power PMAC CPU, 4 channels of axis interface circuitry,
32 general-purpose digital I/O points, and 4 optional analog inputs onto a single small circuit
board. A second Clipper board, built without the CPU, provides another set of axis and general­purpose I/O.

Power Clipper Controller Board (without fan assembly)

Power PMAC Family Overview 29

Power PMAC User’s Manual

Soft Power PMAC

The Power PMAC software has also been configured to run on multi-core PCs, using one core for
Power PMAC interrupt-driven foreground tasks, and a second core for its background tasks.
Remaining cores are available for other uses such as HMI and network interfaces, with a choice
of operating systems to execute in these cores. Presently supported for these other cores are Linux
and Microsoft Windows.

OEMs can qualify a PC of their choosing with Delta Tau, then simply purchase the software on a
per-seat license basis. Delta Tau can also provide the software pre-installed on several different
industrial PC designs.

Interface to the machine on these PC-based systems is generally done through networks such as
EtherCAT or MACRO.

What Power PMAC Does

Power PMAC can handle all of the tasks required for machine control, constantly switching back
and forth between the different tasks thousands of times per second. The major tasks involved in
machine control are summarized here.

Execute Sequenced Motion Programs

The most obvious task of Power PMAC is executing sequences of motions given to it in a motion
program written in the Power PMAC Script language. When told to execute a motion program,
Power PMAC works through the program one move at a time, performing all the calculations up
to that move command (including non-motion tasks) to prepare for actual execution of the move.
Power PMAC is always working ahead of the actual move in progress, so it can blend properly
into the upcoming move(s), if required. See the chapter Writing and Executing Script Programs
for more details.

Execute Asynchronous PLC Programs

The sequential nature of the motion program suits it well for commanding a series of moves and
other coordinated actions but these programs are not good at performing actions that are not
directly coordinated with the sequence of motions. For those types of tasks, Power PMAC

provides the capability for users to write “PLC programs”. These are named after Programmable

Logic Controllers because they operate in a similar manner, continually scanning through their
operations as processor time allows. These programs are very useful for any task that is
asynchronous to the motion sequences. PLC programs can be written both in the Power PMAC
Script language and in C. Both types of programs can execute either as interrupt-driven
foreground tasks, or as background tasks. See the chapters Writing and Executing Script
Programs and Writing C Functions and Programs for more details.

Perform Kinematic Transformations

Power PMAC can automatically perform user-specified transformations between “tool-tip” (axis)
coordinates in a geometry that the user finds easy to work with (e.g. a Cartesian reference frame)
and the underlying “joint/actuator” (motor) coordinates in which the machine is built. The
transformation can be a basic, mathematically linear, scaling and offset transformation, permitting
scaling and offsetting into user engineering units and a flexible programming origin for each axis.
This can be accomplished with simple “axis-definition” equations.

Power PMAC Family Overview 30