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USER MANUAL

DMC-1500

Manual Rev. 2.0xf

By Galil Motion Control, Inc.

Galil Motion Control, Inc.

270 Technology Way

Rocklin, California 95765

Phone: (916) 626-0101

Fax: (916) 626-0102

Internet Address: support@galilmc.com

URL: www.galilmc.com

Rev 05-06

Using This Manual

This user manual provides information for proper operation of the DMC-1500 controller. A separate supplemental manual, the Command Reference, contains a description of the commands available for use with this controller.

Your DMC-1500 motion controller has been designed to work with both servo and stepper type motors. In addition, the DMC-1500 has a daughter board for controllers with more than 4 axes. Installation and system setup will vary depending upon whether the controller will be used with stepper motors, or servo motors, and whether the controller has more than 4 axes of control. To make finding the appropriate instructions faster and easier, icons will be next to any information that applies exclusively to one type of system. Otherwise, assume that the instructions apply to all types of systems. The icon legend is shown below.

1580

Attention: Pertains to servo motor use.

Attention: Pertains to stepper motor use.

Attention: Pertains to controllers with more than 4 axes.

Please note that many examples are written for the DMC-1540 four-axis controller or the DMC-1580 eight axes controller. Users of the DMC-1530 3-axis controller, DMC-1520 2-axis controller or DMC-1510 1-axis controller should note that the DMC-1530 uses the axes denoted as XYZ, the DMC-1520 uses the axes denoted as XY, and the DMC-1510 uses the X-axis only.

Examples for the DMC-1580 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-1550 5-axis controller, DMC-1560 6-axis controller or DMC-1570, 7-axis controller should note that the DMC1550 denotes the axes as A,B,C,D,E, the DMC-1560 denotes the axes as A,B,C,D,E,F and the DMC1570 denotes the axes as A,B,C,D,E,F,G. The axes A,B,C,D may be used interchangeably with X,Y,Z,W.

This manual was written for the DMC-1500 firmware revision 2.0 and later. For controllers with firmware previous to revision 2.0, please consult the original manual for your hardware. The later revision firmware was previously specified as DMC-1500-18.

WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design effective error handling and safety protection as part of the machine. Galil shall not responsible for any incidental or consequential damages.

be liable or

Firmware Updates

New feature for Rev 2.0h April 1998:

Feature Description

1. CMDERR enhanced to support multitasking: If CMDERR occurs on thread 1,2 or 3, thread will be holted. Thread can be re-started with

XQ _ED2, _ED1, 1 for retry XQ _ED3, _ED1, 1 for next instruction

2. _VM returns instantaneous commanded vector velocity

3. FA resolution increased to 0.25.

New feature for Rev 2.0g November 1997:

Feature Description

1. CR radius now has range of 16 million Allows for large circular interpolation radii

2. _AB returns abort input Allows for monitoring of abort input

3. CW,1 When output FIFO full application program will not

pause but data will be lost

4. List Variable (LV), List Array (LA), List app program labels (LL)

New feature for Rev 2.0e May 1997:

Feature Description

1. ER now accepts argument < 0 Disables error output (LED and Error Output does not turn on

2. During a PR decel can now be changed on an unnatural stop Allows for monitoring of abort input

New feature for Rev 2.0d February 1997:

Feature Description

1. AP, MF, MR in stepper now uses _DE instead of _RP Trippoints based on register after buffer

2. \ now terminates QD Download array no longer requires control sequence to end

3. KS can now be fraction (down to .5) Allows for smaller stepper motor smoothing delay (due to filter)

4. New arguments for MT of 2.5 and -2.5 Reverses the direction of motion from MT 2 and MT -2

5. MG now can go to 80 characters

New feature for Rev 2.0c October 1996:

Feature Description

1. MC now works for steppers More accurate trippoint for stepper motor completion

New feature for Rev 2.0b September 1996:

Allows for output FIFO buffer to fill up without affecting the execution of a program

Allows for the user to interrogate RAM

for that axis)

Increased message size

Feature Description

1. Operand ‘&’ and ‘|’ for conditional statements Allows for multiple conditional statements in jump routines IE. (A>=3) & (B<55) | (C=78)

New feature for Rev 2.0 March 1996. (This revision is also designated DMC-1500-18).

DAC resolution increased to 16-bits. Step motor control method improved.

Command Description KS Step Motor Smoothing

New feature for Rev 1.1

Electronic Cam

New commands: Command Description EA Choose ECAM master EM Cam Cycle Command EP Cam table interval and starting point ET ECAM table entry EB Enable ECAM EG Engage ECAM cycle EQ Disengage ECAM

New features added Jan 1995:

Allow circular array recording.

New commands added July 1994 Rev 1.4:

Command Description

RI,N N is a new interrupt mask which allows changing the interrupt

mask

QU Upload array QD Download array MF x,y,z,w Trippoint for motion - forward direction MR x,y,z,w Trippoint for motion - reverse direction MC XYZW In position trippoint TW x,y,z,w Sets timeout for in position VR r Sets speed ratio for VS

New commands added January 1994 Rev 1.3:

Can specify parameters with axis designator. For example:

Command Description

KPZ=10 Set Z axis gain to 10 KP*=10 Set all axes gains to 10

(KPXZ=10 is invalid. Only one or all axes can be specified at a time).

New commands added July 1993 Rev 1.2:

Command Description

_UL Gives available variables _DL Give available labels @COM[n] 2's complement function

New commands added March 1993: Rev 1.2

Command Description

_CS Segment counter in LM, VM and CM modes _AV Return distance travelled in LM and VM modes _VPX

VP x,y<n Can specify vector speed with each vector segment Where <n

Return the coordinate of the last point in a motion sequence, LM or VM

sets vector speed

New commands added January 1993:

Command Description

HX Halt execution for multitasking

AT At time trippoint for relative time from reference ES Ellipse scale factor OB n,expression Defines output n where expression is logical operation, such as

I1 & I6, variable or array element XQ#Label,n Where n = 0 through 3 and is program thread for multitasking DV Dual velocity for Dual Loop

Feature Description

1. Allows gearing and coordinated move simultaneously

2. Multitasking for up to four independent programs

3. Velocity Damping from auxiliary encoder for dual loop

Chapter 1 Overview 1

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

Overview of Motor Types .........................................................................................................2

DMC-1500 Functional Elements...............................................................................................2

Standard Servo Motors with +/- 10 Volt Command Signal........................................2

Stepper Motor with Step and Direction Signals..........................................................2

Microcomputer Section...............................................................................................3

Motor Interface............................................................................................................3

Communication...........................................................................................................3

General I/O..................................................................................................................3

System Elements .........................................................................................................3

Motor...........................................................................................................................4

Amplifier (Driver).......................................................................................................4

Encoder or Position Sensor.........................................................................................4

Watch Dog Timer........................................................................................................4

Chapter 2 Getting Started 7

Elements You Need...................................................................................................................7

Installing the DMC-1500...........................................................................................................8

Step 1. Determine Overall Motor Configuration.........................................................8

Step 2. Install Jumpers on the DMC-1500..................................................................8

Step 3. Configure DIP switches on the DMC-1500....................................................9

Step 4. Connect AC Power to the Controller ..............................................................9

Step 5. Install Communications Software...................................................................9

Step 6. Establish Communications with Galil Software............................................10

Step 7. Connect Amplifiers and Encoders.................................................................11

Step 8a. Connect Standard Servo Motors..................................................................13

Step 8b. Connect Step Motors...................................................................................16

Step 9. Tune the Servo System..................................................................................17

Design Examples.....................................................................................................................18

Example 1 - System Set-up.......................................................................................18

Example 2 - Profiled Move.......................................................................................18

Example 3 - Multiple Axes........................................................................................19

Example 4 - Independent Moves...............................................................................19

Example 5 - Position Interrogation............................................................................19

Example 6 - Absolute Position..................................................................................20

Example 7 - Velocity Control....................................................................................20

Example 8 - Operation Under Torque Limit.............................................................20

DMC-1500 Contents • i

Example 9 - Interrogation..........................................................................................21

Example 10 - Operation in the Buffer Mode .............................................................21

Example 11 - Motion Programs.................................................................................21

Example 12 - Motion Programs with Loops..............................................................22

Example 13 - Motion Programs with Trippoints.......................................................22

Example 14 - Control Variables................................................................................22

Example 15 - Linear Interpolation.............................................................................23

Example 16 - Circular Interpolation..........................................................................23

Chapter 3 Connecting Hardware

Overview..................................................................................................................................25

Using Opto-isolated Inputs......................................................................................................25

Limit Switch Input.....................................................................................................25

Home Switch Input....................................................................................................26

Abort Input................................................................................................................26

Uncommitted Digital Inputs......................................................................................27

Wiring the Optoisolated Inputs................................................................................................27

Using an Isolated Power Supply................................................................................ 28

Bypassing the Opto-Isolation:...................................................................................29

Changing Optoisolated Inputs From Active Low to Active High.............................30

Amplifier Interface ..................................................................................................................30

TTL Inputs...............................................................................................................................31

Analog Inputs...........................................................................................................................31

TTL Outputs ............................................................................................................................32

Offset Adjustment....................................................................................................................32

Chapter 4 Communication 33

Introduction..............................................................................................................................33

RS232 Ports.............................................................................................................................33

RS232 - Main Port {P1} DATATERM................................................................33

RS232 - Auxiliary Port {P2} DATASET..............................................................33

*RS422 - Main Port {P1}..........................................................................................33

*RS422 - Auxiliary Port {P2}...................................................................................34

Configuration...........................................................................................................................34

Baud Rate Selection ..................................................................................................34

Daisy-Chaining..........................................................................................................35

Daisy Chain Example:...............................................................................................35

Synchronizing Sample Clocks...................................................................................36

Controller Response to DATA ................................................................................................36

Galil Software Tools and Libraries..........................................................................................36

Chapter 5 Command Basics 37

Introduction..............................................................................................................................37

Command Syntax.....................................................................................................................37

Coordinated Motion with more than 1 axis...............................................................38

Program Syntax.........................................................................................................38

Controller Response to DATA ................................................................................................38

Interrogating the Controller.....................................................................................................39

Interrogation Commands...........................................................................................39

Summary of Interrogation Commands ......................................................................39

Additional Interrogation Methods.............................................................................40

Operands....................................................................................................................40

Command Summary ..................................................................................................40

ii • Contents DMC-1500

Chapter 6 Programming Motion 41

Overview .................................................................................................................................41

Independent Axis Positioning..................................................................................................41

Command Summary - Independent Axis ..................................................................42

Operand Summary - Independent Axis.....................................................................42

Independent Jogging................................................................................................................44

Command Summary - Jogging..................................................................................44

Operand Summary - Independent Axis.....................................................................44

Linear Interpolation Mode.......................................................................................................45

Specifying Linear Segments......................................................................................45

Specifying Vector Acceleration, Deceleration and Speed:........................................46

Additional Commands...............................................................................................46

Command Summary - Linear Interpolation...............................................................47

Operand Summary - Linear Interpolation .................................................................48

Vector Mode: Linear and Circular Interpolation Motion........................................................50

Specifying Vector Segments.....................................................................................50

Specifying Vector Acceleration, Deceleration and Speed:........................................51

Additional Commands...............................................................................................51

Command Summary - Vector Mode Motion.............................................................53

Operand Summary - Vector Mode Motion................................................................53

Electronic Gearing...................................................................................................................54

Command Summary - Electronic Gearing................................................................55

Operand Summary - Electronic Gearing...................................................................55

Electronic Cam ........................................................................................................................57

Command Summary - ECAM Mode.........................................................................61

Operand Summary - ECAM Mode............................................................................61

Contour Mode..........................................................................................................................63

Specifying Contour Segments...................................................................................63

Additional Commands...............................................................................................64

Command Summary - Contour Mode.......................................................................64

Teach (Record and Play-Back)..................................................................................66

Stepper Motor Operation.........................................................................................................67

Specifying Stepper Motor Operation.........................................................................68

Using an Encoder with Stepper Motors ....................................................................69

Command Summary - Stepper Motor Operation.......................................................69

Operand Summary - Stepper Motor Operation.........................................................69

Dual Loop (Auxiliary Encoder)...............................................................................................70

Backlash Compensation ............................................................................................70

Command Summary - Using the Auxiliary Encoder.................................................72

Operand Summary - Using the Auxiliary Encoder ...................................................72

Motion Smoothing...................................................................................................................72

Using the IT and VT Commands (S curve profiling):...............................................72

Using the KS Command (Step Motor Smoothing):...................................................74

Homing....................................................................................................................................74

High Speed Position Capture (The Latch Function)................................................................77

Chapter 7 Application Programming

Overview .................................................................................................................................79

Using the DMC-1500 Editor to Enter Programs.....................................................................79

Edit Mode Commands...............................................................................................80

Program Format.......................................................................................................................81

Using Labels in Programs .........................................................................................81

Special Labels............................................................................................................81

DMC-1500 Contents • iii

Commenting Programs..............................................................................................82

Executing Programs & Multitasking .......................................................................................83

Debugging Programs...............................................................................................................84

Debugging Programs...............................................................................................................86

Commands.................................................................................................................86

Operands....................................................................................................................86

Program Flow Commands.......................................................................................................87

Event Triggers & Trippoints .....................................................................................87

DMC-1500 Event Triggers........................................................................................88

Event Trigger Examples:...........................................................................................88

Conditional Jumps.....................................................................................................91

Subroutines................................................................................................................94

Stack Manipulation....................................................................................................94

Auto-Start Routine.....................................................................................................95

Automatic Subroutines for Monitoring Conditions...................................................95

Mathematical and Functional Expressions..............................................................................98

Mathematical Expressions.........................................................................................98

Bit-Wise Operators....................................................................................................99

Functions.................................................................................................................100

Variables................................................................................................................................100

Assigning Values to Variables:...............................................................................101

Operands................................................................................................................................102

Special Operands (Keywords).................................................................................103

Arrays ....................................................................................................................................103

Defining Arrays.......................................................................................................103

Assignment of Array Entries...................................................................................104

Automatic Data Capture into Arrays.......................................................................105

Command Summary - Automat ic Data Capture......................................................105

Data Types for Recording: ......................................................................................105

Operand Summary - Automatic Data Capture.........................................................106

Deallocating Array Space........................................................................................106

Input of Data (Numeric and String).......................................................................................107

Input of Data............................................................................................................107

Operator Data Entry Mode......................................................................................108

Using Communication Interrupt..............................................................................108

Output of Data (Numeric and String)....................................................................................110

Sending Messages ...................................................................................................110

Specifying the Serial Port for Messages:.................................................................111

Formatting Messages...............................................................................................111

Using the MG Command to Configure Terminals ..................................................112

Summary of Message Functions:.............................................................................112

Displaying Variables and Arrays.............................................................................112

Interrogation Commands.........................................................................................112

Formatting Variables and Array Elements..............................................................114

Converting to User Units.........................................................................................115

Programmable Hardware I/O.................................................................................................115

Digital Outputs ........................................................................................................115

Digital Inputs...........................................................................................................116

Input Interrupt Function ..........................................................................................117

Analog Inputs..........................................................................................................118

Example Applications............................................................................................................119

Wire Cutter..............................................................................................................119

X-Y Table Controller ..............................................................................................120

Speed Control by Joystick.......................................................................................122

Position Control by Joystick....................................................................................123

iv • Contents DMC-1500

Backlash Compensation by Sampled Dual-Loop....................................................123

Chapter 8 Hardware & Software Protection 126

Introduction ...........................................................................................................................126

Hardware Protection..............................................................................................................126

Output Protection Lines...........................................................................................126

Input Protection Lines.............................................................................................126

Software Protection ...............................................................................................................127

Programmable Position Limits................................................................................127

Off-On-Error ...........................................................................................................127

Automatic Error Routine.........................................................................................128

Limit Switch Routine ..............................................................................................128

Chapter 9 Troubleshooting

Overview ...............................................................................................................................130

Installation .............................................................................................................................130

Communication......................................................................................................................131

Stability..................................................................................................................................131

Operation...............................................................................................................................131

130

Chapter 10 Theory of Operation 132

Overview ...............................................................................................................................132

Operation of Closed-Loop Systems.......................................................................................134

System Modeling...................................................................................................................135

Motor-Amplifier......................................................................................................136

Encoder....................................................................................................................138

DAC ........................................................................................................................139

Digital Filter............................................................................................................139

ZOH.........................................................................................................................139

System Analysis.....................................................................................................................140

System Design and Compensation ........................................................................................142

The Analytical Method............................................................................................142

Appendices

Electrical Specifications ........................................................................................................146

Performance Specifications...................................................................................................147

Card Level Layout.................................................................................................................148

Connectors for DMC-1500 Main Board................................................................................149

Connectors for Auxiliary Board (Axes E,F,G,H)..................................................................152

146

Servo Control ..........................................................................................................146

Stepper Control .......................................................................................................146

Input/Output............................................................................................................146

Power.......................................................................................................................147

J2 - Main (60 pin IDC)............................................................................................149

J5 - General I/O (26 pin IDC) .................................................................................150

J3 - Aux Encoder (20 pin IDC)...............................................................................150

J4 - Driver (20 pin IDC)..........................................................................................151

J6 - Daughter Board Connector (60 pin )................................................................151

J7 - 10 pin................................................................................................................151

JD2 - Main (60 pin IDC).........................................................................................152

JD5 - I/O (26 pin IDC)...........................................................................................153

JD3 - 20 pin IDC - Auxiliary Encoders...................................................................153

DMC-1500 Contents • v

JD4 - 20 pin IDC - Amplifiers.................................................................................154

JD6 - Daughterboard Connector (60 pin)................................................................154

Cable Connections for DMC-1500........................................................................................154

Standard RS-232 Specifications..............................................................................154

DMC-1500 Serial Cable Specifications...................................................................155

Pin-Out Description for DMC-1500......................................................................................157

Configuration Description for DMC-1500............................................................................159

Jumpers....................................................................................................................159

Address Configuration Jumpers..............................................................................159

Front Panel Baud Rate Switches .............................................................................159

Adjustment Pots.......................................................................................................160

Dip Switch Settings ...............................................................................................................160

Offset Adjustments for DMC-1500.......................................................................................160

Accessories and Options........................................................................................................161

ICM-1100 Interconnect Module............................................................................................162

AMP/ICM-1100 Connections................................................................................................162

J2 - Main (60 pin IDC)............................................................................................165

J3 - Aux Encoder (20 pin IDC)...............................................................................165

J4 - Driver (20 pin IDC)..........................................................................................165

J5 - General I/O (26 pin IDC)..................................................................................165

JX6, JY6, JZ6, JW6 - Encoder Input (10 pin IDC).................................................165

ICM-1100 Drawing ...............................................................................................................166

AMP-11x0 Mating Power Amplifiers...................................................................................167

TERM-1500 Operator Terminal............................................................................................167

DB-15072 OPTO-22 Expansion Option................................................................................175

Configuring the I/O for the DB-15072....................................................................175

Connector Description of the DB-15072.................................................................176

Coordinated Motion - Mathematical Analysis.......................................................................179

DMC-700/DMC-1500 Comparison.......................................................................................182

List of Other Publications......................................................................................................184

Contacting Us ........................................................................................................................184

WARRANTY ........................................................................................................................185

Index 191

vi • Contents DMC-1500

Chapter 1 Overview

Introduction

The DMC-1500 Series are packaged motion controllers designed for stand-alone operation. Features include coordinated motion profiling, uncommitted inputs and outputs, non-volatile memory for stand-alone operation and RS232/RS422 communication. Extended performance capability over the previous generation of controllers includes: fast 8 MHz encoder input frequency, precise 16-bit motor command output DAC, +/-2 billion counts total travel per move, faster sample rate, and multitasking of up to four programs. The controllers provide increased performance and flexib ility and yet are smaller in size and lower in cost than the previous generation. The DMC-1500 is also available as a cost-effective, card-level product making it ideal for OEM applications.

Designed for maximum system flexibility, the DMC-1500 is available for one to eight axes and can be interfaced to a variety of motors and drives including step motors, servo motors and hydraulics.

Each axis accepts feedback from a quadrature linear or rotary encoder with input frequencies up to 8 million quadrature counts per second. For dual-loop applications that require one encoder on both the motor and the load, auxiliary encoder inputs are included for each axis.

The powerful controller provides many modes of motion including jogging, point-to-point positioning, linear and circular interpolation with infinite vector feed, electronic gearing and user-defined path following. Several motion parameters can be specified including acceleration and deceleration rates, and slew speed. The DMC-1500 also provides S-curve acceleration for motion smoothing.

For synchronizing motion with external events, the DMC-1500 includes 8 opto-isolated inputs, 8 programmable outputs and 7 analog inputs. For controllers with 5 or more axes, the DMC-1500 has an additional 8 opto-isolated inputs and 8 TTL inputs. I/O expansion boards provide additional inputs and outputs or interface to OPTO 22 racks. Event triggers can automatically check for elapsed time, distance and motion complete.

Despite its full range of sophisticated features, the DMC-1500 is easy to program. Instructions are represented by two letter commands such as BG for Begin and SP for Speed. Conditional Instructions, Jump Statements, and arithmetic functions are included for writing self-contained applications programs. An internal editor allows programs to be quickly entered and edited, and support software such as the Servo Design Kit allows quick system set-up and tuning.

To prevent system damage during machine operation, the DMC-1500 provides several error handling features. These include software and hardware limits, automatic shut-off on excessive error, abort input, and user-definable error and limit routines.

DMC-1500 Chapter 1 Overview • 1

Overview of Motor Types

The DMC-1500 can provide the following types of motor control: Standard servo motors with +/- 10 volt command signals Step motors with step and direction signals Other actuators such as hydraulics - For more information, contact Galil. The user can configure each axis for any combination of motor types, providing maximum flexibility.

Standard Servo Motors with +/- 10 Volt Command Signal

The DMC-1500 achieves superior precision through use of a 16-bit motor command output DAC and a sophisticated PID filter that features velocity and acceleration feedforward, an extra pole filter and integration limits.

The controller is configured by the factory for standard servo motor operation. In this configuration, the controller provides an analog signal (+/- 10Volt) to connect to a servo amplifier. This connection is described in Chapter 2.

Stepper Motor with Step and Direction Signals

The DMC-1500 can control stepper motors. In this mode, the controller provides two signals to connect to the stepper motor: Step and Direction. For stepper motor operation, the controller does not require an encoder and operates the stepper motor in an open loop fashion. Chapter 2 describes the proper connection and procedure for using stepper motors.

DMC-1500 Functional Elements

The DMC-1500 circuitry can be divided into the following functional groups as shown in Figure 1.1 and discussed in the following.

RS-232 / RS-422

Communication

8 Digital

8 Analog

8 TTL

Interfac

Figure 1.1 - DMC-1500 Functional Elements

6834

Microcompute

256K

64K

128K EEPROM

Watch

Timer

GL-

Motor/Encode

Interfac

Fro

Limit

Fro

Encoder

2 • Chapter 1 Overview DMC-1500

Microcomputer Section

The main processing unit of the DMC-1500 is a specialized 32-bit Motorola 68340 Series Microcomputer with 256K RAM, 64 K EPROM and 128 K bytes EEPROM. The RAM provides memory for variables, array elements and application programs. The EPROM stores the firmware of the DMC-1500. The EEPROM allows parameters and programs to be saved in non-volatile memory upon power down.

Motor Interface

For each axis, a GL-1800 custom gate array performs quadrature decoding of the encoders at up to 8 MHz, generates the +/-10 Volt analog signal (16 Bit DAC) for input to a servo amplifier, and generates step and direction signal for step motor drivers.

Communication

Communication to the DMC-1500 is via two separately addressable RS232 ports. The ports may also be configured by the factory for RS422. The serial ports may be daisy-chained to other DMC-1500 controllers.

General I/O

The DMC-1500 provides interface circuitry for eight optoisolated inputs, eight general outputs and seven analog inputs (12 Bit ADC with option for 16 Bit ADC).

1580

An auxiliary board, the DB-15072 provides interface to up to three OPTO 22 racks with 24 I/O modules each. 24 bits can be configured for interface to output or input modules and the remaining 48 for input modules.

Controllers with 5 or more axes provide 24 inputs and 16 outputs.

System Elements

As shown in Fig. 1.2, the DMC-1500 is part of a motion control system which includes amplifiers, motors and encoders. These elements are described below

Power Supply

Computer DMC-1500 Controller Driver

Encoder Motor

Figure 1.2 - Elements of Servo systems

DMC-1500 Chapter 1 Overview • 3

Motor

A motor converts current into torque which produces motion. Each axis of motion requires a motor sized properly to move the load at the desired speed and acceleration. Galil's Motion Component Selector software can help you calculate motor size and drive size requirements. Contact Galil at 800377-6329 if you would like this product.

The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step motors, the controller can be configured to control full-step, half-step, or microstep drives.

Amplifier (Driver)

For each axis, the power amplifier converts a +/-10 Volt signal from the controller into current to drive the motor. The amplifier should be sized properly to meet the power requirements of the motor. For brushless motors, an amplifier that provides electronic commutation is required. The amplifiers may be either pulse-width-modulated (PWM) or linear. They may also be configured for operation with or without a tachometer. For current amplifiers, the amplifier gain should be set such that a 10 Volt command generates the maximum required current. For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V. For velocity mode amplifiers, 10 Volts should run the motor at the maximum speed.

For stepper motors, the amplifier converts step and direction signals into current.

Encoder or Position Sensor

An encoder translates motion into electrical pulses which are fed back into the controller. The DMC1500 accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels in quadrature, known as CHA and CHB. This type of encoder is known as a quadrature encoder. Quadrature encoders may be either single-ended (CHA and CHB) or differential (CHA,CHA,CHB,CHB-). The DMC-1500 decodes either type into quadrature states or four times the number of cycles. Encoders may also have a third channel (or index) for synchronization.

The DMC-1500 can also interface to encoders with pulse and direction signals. There is no limit on encoder line density, however, the input frequency to the controller must not

exceed 2,000,000 full encoder cycles/second or 8,000,000 quadrature counts/sec. For example, if the encoder line density is 10,000 cycles per inch, the maximum speed is 200 inches/second.

The standard voltage level is TTL (zero to five volts), however, voltage levels up to 12 Volts are acceptable. If using differential signals, 12 Volts can be input directly to the DMC-1500. Singleended 12 Volt signals require a bias voltage input to the complementary inputs.

The DMC-1500 can accept analog feedback instead of an encoder for any axis. Note: the DMC-1580 controller must be modified by the factory to allow for analog feedback on axis H. For more information see description of analog feedback in Chapter 2 under section entitled "Test the encoder operation".

To interface with other types of position sensors such as resolvers or absolute encoders, Galil can customize the controller and command set. Please contact Galil to talk to one of our applications engineers about your particular system requirements.

Watch Dog Timer

The DMC-1500 provides an internal watch dog timer which checks for proper microprocessor operation. The timer toggles the Amplifier Enable Output (AEN) which can be used to switch the amplifiers off in the event of a serious DMC-1500 failure. The AEN output is normally high. During power-up and if the microprocessor ceases to function properly, the AEN output will go low. The

4 • Chapter 1 Overview DMC-1500

error light for each axis will also turn on at this stage. A reset is required to restore the DMC-1500 to normal operation. Consult the factory for a Return Materials Authorization (RMA) Number if your DMC-1500 is damaged.

DMC-1500 Chapter 1 Overview • 5

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6 • Chapter 1 Overview DMC-1500

Chapter 2 Getting Started

Elements You Need

Before you start, you will need the following system elements:

1. DMC-1500 Motion Controller and included cables, RS232, 60 pin ribbon cable and 26-pin ribbon cable.

1a. For stepper motor operation, you will need an additional 20-pin ribbon cable, J4.

2. Servo motors with Optical Encoder (one per axis) or step motors

3. Power Amplifiers for motors

4. Power Supply for Amplifiers

5. PC (Personal Computer with RS232 port) Software from Galil (Optional - but strongly recommended for first time users) Communication Disk (COMMdisk)

-AND WSDK-16 Servo Design Software for Windows 3.1, and 3.11 for Workgroups

-OR WSDK-32 for Windows 95 or NT ICM-1100 Interface Module (Optional, but strongly recommended). The Galil ICM-1100 is an

interconnect module with screw type terminals that directly interfaces to the DMC-1500 controller. Note: An additional ICM-1100 is required for the DMC-1550 through DMC-1580.

The motors may be servo (brush type or brushless) or steppers. The amplifiers should be suitable for the motor and may be linear or pulse-width-modulated. An amplifier may have current feedback or voltage feedback.

For servo motors, the amplifiers should accept an analog signal in the +/-10 Volt range as a command. The amplifier gain should be set so that a +10V command will generate the maximum required current. For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V. For velocity mode amplifiers, a command signal of 10 Volts should run the motor at the maximum required speed.

For step motors, the amplifiers should accept step and direction signals.

The WSDK software is highly recommended for first time users of the DMC-1500. It provides stepby-step instructions for system connection, tuning and analysis.

DMC-1500 Chapter 2 Getting Started • 7

Installing the DMC-1500

Installation of a complete, operational DMC-1500 system consists of 9 steps.

Step 1. Determine overall motor configuration.

Step 2. Install jumpers on the DMC-1500.

Step 3. Configure the DIP switches on the DMC-1500.

Step 4. Connect AC power to controller

Step 5. Install communications software.

Step 6. Establish communications with Galil Software.

Step 7. Connect amplifiers and Encoders.

Step 8a. Connect standard servo motors.

Step 8b. Connect step motors.

Step 9. Tune the servo system

Step 1. Determine Overall Motor Configuration

Before setting up the motion control system, the user must determine the desired motor configuration. The DMC-1500 can control any combination of standard servo motors, and stepper motors. Other types of actuators, such as hydraulics can also be controlled, please consult Galil.

The following configuration information is necessary to determine the proper motor configuration:

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Standard Servo Motor Operation:

The DMC-1500 has been setup by the factory for standard servo motor operation providing an analog command signal of +/- 10V. No hardware or software configuration is required for standard servo motor operation.

Stepper Motor Operation:

To configure the DMC-1500 for stepper motor operation, the controller requires a jumper for each stepper motor and the command, MT, must be given. The installation of the stepper motor jumper is discussed in the following section entitled "Installing Jumpers on the DMC-1500". Further instruction for stepper motor connections are discussed in Step 8b.

Step 2. Install Jumpers on the DMC-1500

The DMC-1500 has jumpers inside the controller box which may need to be installed. To access these jumpers, the cover of the controller box must be removed. The following describes each of the jumpers.

WARNING: Never open the controller box when AC power is applied to it. For each axis that will be driving a stepper motor, a stepper mode (SM) jumper must be connected.

If you using a controller with more than 4 axis, you will have two pc-cards inside the controller box. In this case, you will have 2 sets of stepper motor jumpers, one on each card. The jumpers on the bottom card will be for axes X,Y,Z and W (or A,B,C, and D) and the top will be E,F,G and H. To access the bottom card, the top card must be carefully removed.

8 • Chapter 2 Getting Started DMC-1500

The stepper mode jumpers are located next to the GL-1800 which is the largest IC on the board. The jumper set is labeled JP40 and the individual stepper mode jumpers are labeled SMX, SMY, SMZ, SMW. The fifth jumper of the set, OPT, is for use by Galil technicians only.

The jumper set, J41, can be used to connect the controllers internal power supply to the optoisolated inputs. This may be desirable if your system will be using limit switches, home inputs digital inputs, or hardware abort and optoisolation is not necessary for your system. For a further explanation, see section Bypassing the Opto-Isolation in Chapter 3.

Step 3. Configure DIP switches on the DMC-1500

Located on the outside of the controller box is a set of 5 DIP switches. Switch 1 is the Master Reset switch. When this switch is on, the controller will perform a master reset

upon PC power up. Whenever the controller has a master reset, all programs and motion control parameters stored in EEPROM will be ERASED. During normal operation, this switch should be off.

Switch 2,3 and 4 are used to configure the baud rate of the main RS232 serial port. See section Configuration in Chapter 4.

Switch 5 is used to configure both serial ports for hardware handshake mode. Set this switch on for handshake mode. Please note that the Galil communication software requires that hardware handshake mode be enabled.

Step 4. Connect AC Power to the Controller

Before applying power, connect the 60-pin and 26-pin ribbons between the DMC-1500 and ICM-1100 interconnect module. The DMC-1500 requires a single AC supply voltage, single phase, 50 Hz or 60 Hz. from 90 volts to 260 volts.

WARNING: Dangerous voltages, current, temperatures and energy levels exist in this product and in its associated amplifiers and servo motor(s). Extreme caution should be exercised in the application of this equipment. Only qualified individuals should attempt to install, set up and operate this equipment.

WARNING: Never open the controller box when AC power is applied to it.

Applying power will turn on the green light power indicator.

Step 5. Install Communications Software

After you have installed the DMC-1500 controller and turned the power on to your computer, you should install software that enables communication between the controller and PC. There are several ways to do this. The easiest way is to use the communication disks available from Galil (COMMDISK VOL1 FOR DOS AND VOL2 FOR WINDOWS).

Using the COMMdisk Vol1 for Dos:

To use this disk, insert the COMMDISK VOL 1 in drive A. Type INSTALL and follow the directions.

Using the COMMdisk Vol2 for Windows (16 bit and 32 bit versions):

For Windows3.x, run the installation program, setup16.exe. For Windows 95 or Windows NT, run the installation program, setup32.exe.

DMC-1500 Chapter 2 Getting Started • 9

Step 6. Establish Communications with Galil Software

Use the supplied 9-pin RS232 ribbon cable to connect the MAIN DMC-1500 serial port to your computer or terminal at COMPORT 1. The DMC-1500 main serial port is configured as DATASET. Your computer or terminal must be configured as a DATATERM for full duplex, no parity, 8 bits data, one start bit and one stop bit.

Select the baud rate switches for 19.2 KB, 9600 B or 1200 B. The default setting is 19.2 KB. Your computer needs to be configured as a "dumb" terminal which sends ASCII characters as they are

typed to the DMC-1500. The COMMdisk from Galil provides a terminal emulator program for your computer. Follow the steps below to install and run the terminal emulator.

Dos Users:

To communicate with the DMC-1500, type TALK2DMC at the prompt. Once you have established communication, the terminal display should show a colon, :. If you do not receive a colon, press the carriage return. If a colon prompt is not returned, there is most likely an incorrect setting of the serial communications port. The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller. Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software. The user must also insure that the proper serial cable is being used, see appendix for pin-out of serial cable.

Windows Users:

In order for the windows software to communicate with a Galil controller, the controller must be registered in the Galil Registry. The Galil Registry is simply a list of controllers. Registration consists of telling the software the model of the controller, the address of the controller, and other information. To do this, run the program DMCREG16 for Windows 3.x or DMCREG32 for Windows 95 and NT. The DMCREG window will appear. Select Registry from the menu.

Note: If you are using DMCREG for the first time, no controllers will exist in the Ga lil Register. This is normal.

The registry window is equipped with buttons to Add, Change, or Delete a controller. Pressing any of these buttons will bring up the Set Registry Information window. (It should be noted that if you wish to change information on any existing controller, it should be selected before clicking Change, even if it is the only controller listed in the Registry.)

Use the Add button to add a new entry to the Registry. You will need to supply the Galil Controller type. For any address changes to take effect, a model number must be entered. If you are changing an existing controller, this field will already have an entry. If you are adding a controller, it will not. Pressing the down arrow to the right of this field will reveal a menu of valid controller types. You should choose DMC-1500. The registry information will show a default comm port of 2 and a default baud rate of 9600 appears. This information should be changed as necessary to reflect the computers comm port and the baud rate as set by the controller's DIP switches. The registry entry also displays timeout and delay information. These are advanced parameters which should only be modified by advanced users (see software documentation for more information).

Once you have set the appropriate Registry information for your controller, exit from the DMCREG program. You will now be able to run communication software.

If you are using Windows 3.x, run the program DTERM16.EXE and if you are using Windows 95 or Windows NT, run the program DTERM32.EXE. From the file menu, select Startup. You will now see the registry information. Select the entry for your controller. Note: If you have only one entry, you still must select this controller for the software to establish communications. Once the entry has been selected, click on the OK button. If the software has successfully established communications with the controller, the registry entry will be displayed at the top of the screen.

10 • Chapter 2 Getting Started DMC-1500

If you are not properly communicating with the controller, the program will pause for 3-15 seconds. The top of the screen will display the message “Status: not connected with Galil motion controller” and the following error will appear: “STOP - Unable to establish communication with the Galil controller. A time-out occurred while waiting for a response from the Galil controller.” If this message appears, you must click OK. In this case, there is most likely an incorrect setting of the serial communications port. The user must ensure that the correct communication port and baud rate are specified when attempting to communicate with the controller. Please note that the serial port on the controller must be set for handshake mode for proper communication with Galil software. The user must also insure that the proper serial cable is being used, see appendix for pin-out of serial cable.

Once you establish communications, click on the menu for terminal and you will receive a colon prompt. Communicating with the controller is described in later sections.

Sending Test Commands to the Terminal:

After you connect your terminal, press <carriage return> or the <enter> key on your keyboard. In response to carriage return (CR), the controller responds with a colon, :

Now type TPX (CR) This command directs the controller to return the current position of the X axis. The controller should

respond with a number such as 0000000 The RS232 communication is established.

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Step 7. Connect Amplifiers and Encoders.

Once you have established communications between the software and the DMC-1500, you are ready to connect the rest of the motion control system. The motion control system typically consists of an ICM-1100 Interface Module, an amplifier for each axis of motion, and a motor to transform the current from the amplifier into torque for motion. Galil also offers the AMP-11X0 series Interface Modules which are ICM-1100’s equipped with servo amplifiers for brush type DC motors.

If you are using an ICM-1100, connect the 100-pin ribbon cable to the DMC-1500 and to the connector located on the AMP-11X0 or ICM-1100 board. The ICM-1100 provides screw terminals for access to the connections described in the following discussion.

Motion Controllers with more than 4 axes require a second ICM-1100 or AMP-11X0 and second 100pin cable.

System connection procedures will depend on system components and motor types. Any combination of motor types can be used with the DMC-1500.

Here are the first steps for connecting a motion control system:

Step A. Connect the motor to the amplifier with no connection to the controller. Consult the

amplifier documentation for instructions regarding proper connections. Connect and

turn-on the amplifier power supply. If the amplifiers are operating properly, the motor

should stand still even when the amplifiers are powered up.

Step B. Connect the amplifier enable signal. Before making any connections from the amplifier to the controller, you need to verify

that the ground level of the amplifier is either floating or at the same potential as earth.

WARNING: When the amplifier ground is not isolated from the power line or when it has a different potential than that of the computer ground, serious damage may result to the computer controller and amplifier.

DMC-1500 Chapter 2 Getting Started • 11

If you are not sure about the potential of the ground levels, connect the two ground

signals (amplifier ground and earth) by a 10 KΩ resistor and measure the voltage across the resistor. Only if the voltage is zero, connect the two ground signals directly.

The amplifier enable signal is used by the controller to disable the motor. It will disable

the motor when the watchdog timer activates, the motor-off command, MO, is given, or the position error exceeds the error limit with the "Off-On-Error" function enabled (see the command OE for further information).

The standard configuration of the AEN signal is TTL active high. In other words, the AEN signal will be high when the controller expects the amplifier to be enabled. The polarity and the amplitude can be changed if you are using the ICM-1100 interface board. To change the polarity from active high (5 volts = enable, zero volts = disable) to active low (zero volts = enable, 5 volts = disable), replace the 7407 IC with a 7406. Note that many amplifiers designate the enable input as ‘inhibit’.

To change the voltage level of the AEN signal, note the state of the resistor pack on the ICM-1100. When Pin 1 is on the 5V mark, the output voltage is 0-5V. To change to 12 volts, pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side. If you remove the resistor pack, the output signal is an open collector, allowing the user to connect an external supply with voltages up to 24V.

On the ICM-1100, the amplifier enable signal is labeled AENX for the X axis. Connect

this signal to the amplifier (figure 2.3) and issue the command, MO, to disable the motor amplifiers - often this is indicated by an LED on the amplifier.

Step C. Connect the encoders For stepper motor operation, an encoder is optional. For servo motor operation, if you have a preferred definition of the forward and reverse

directions, make sure that the encoder wiring is consistent with that definition.

The DMC-1500 accepts single-ended or differential encoder feedback with or without an

index pulse. If you are not using the AMP-11X0 or the ICM-1100 you will need to consult the appendix for the encoder pinouts for connection to the motion controller. The AMP-11X0 and the ICM-1100 can accept encoder feedback from a 10-pin ribbon cable or individual signal leads. For a 10-pin ribbon cable encoder, connect the cable to the protected header connector labeled X ENCODER (repeat for each axis necessary). For individual wires, simply match the leads from the encoder you are using to the encoder feedback inputs on the interconnect board. The signal leads are labeled XA+ (channel A), XB+ (channel B), and XI+. For differential encoders, the complement signals are labeled XA-, XB-, and XI-.

Note: When using pulse and direction encoders, the pulse signal is connected to CHA

and the direction signal is connected to CHB. The controller must be configured for pulse and direction with the command CE. See the command summary for further information on the command CE.

Step D. Verify proper encoder operation. Start with the X encoder first. Once it is connected, turn the motor shaft and interrogate

the position with the instruction TPX <return>. The controller response will vary as the motor is turned.

At this point, if TPX does not vary with encoder rotation, there are three possibilities:

1. The encoder connections are incorrect - check the wiring as necessary.

2. The encoder has failed - using an oscilloscope, observe the encoder signals. Verify that both channels

A and B have a peak magnitude between 5 and 12 volts. Note that if only one encoder channel fails,

12 • Chapter 2 Getting Started DMC-1500

the position reporting varies by one count only. If the encoder failed, replace the encoder. If you cannot observe the encoder signals, try a different encoder.

3. There is a hardware failure in the controller- connect the same encoder to a different axis. If the

problem disappears, you probably have a hardware failure. Consult the factory for help.

Step 8a. Connect Standard Servo Motors

The following discussion applies to connecting the DMC-1500 controller to standard servo motor amplifiers:

The motor and the amplifier may be configured in the torque or the velocity mode. In the torque mode, the amplifier gain should be such that a 10 Volt signal generates the maximum required current. In the velocity mode, a command signal of 10 Volts should run the motor at the maximum required speed.

Step by step directions on servo system setup are also included on the WSDK (Windows Servo Design Kit) software offered by Galil. See section on WSDK for more details.

Step A. Check the Polarity of the Feedback Loop

It is assumed that the motor and amplifier are connected together and that the encoder is

operating correctly (Step B). Before connecting the motor amplifiers to the controller,

read the following discussion on setting Error Limits and Torque Limits. Note that this

discussion only uses the X axis as an examples.

Step B. Set the Error Limit as a Safety Precaution Usually, there is uncertainty about the correct polarity of the feedback. The wrong

polarity causes the motor to run away from the starting position. Using a terminal

program, such as DMCTERM, the following parameters can be given to avoid system

damage:

Input the commands: ER 2000 <CR> Sets error limit on the X axis to be 2000 encoder counts OE 1 <CR> Disables X axis amplifier when excess position error exists If the motor runs away and creates a position error of 2000 counts, the motor amplifier

will be disabled. Note: This function requires the AEN signal to be connected from the

controller to the amplifier.

Step C. Set Torque Limit as a Safety Precaution To limit the maximum voltage signal to your amplifier, the DMC-1500 controller has a

torque limit command, TL. This command sets the maximum voltage output of the

controller and can be used to avoid excessive torque or speed when initially setting up a

servo system.

When operating an amplifier in torque mode, the voltage output of the controller will b e

directly related to the torque output of the motor. The user is responsible for determining

this relationship using the documentation of the motor and amplifier. The torque limit

can be set to a value that will limit the motors output torque.

When operating an amplifier in velocity or voltage mode, the voltage output of the

controller will be directly related to the velocity of the motor. The user is responsible for

determining this relationship using the documentation of the motor and amplifier. The

torque limit can be set to a value that will limit the speed of the motor.

For example, the following command will limit the output of the controller to 1 volt on

the X axis:

DMC-1500 Chapter 2 Getting Started • 13

TL 1 <CR> Note: Once the correct polarity of the feedback loop has been determined, the torque limit

should, in general, be increased to the default value of 9.99. The servo will not operate properly if the torque limit is below the normal operating range. See description of TL in the command reference.

Step D. Connect the Motor Once the parameters have been set, connect the analog motor command signal (ACMD)

to the amplifier input. To test the polarity of the feedback, command a move with the instruction: PR 1000 <CR> Position relative 1000 counts BGX <CR> Begin motion on X axis When the polarity of the feedback is wrong, the motor will attempt to run away. The

controller should disable the motor when the position error exceeds 2000 counts. If the

motor runs away, the polarity of the loop must be inverted.

Note: Inverting the Loop Polarity

When the polarity of the feedback is incorrect, the user must invert the loop polarity and

this may be accomplished by several methods. If you are driving a brush-type DC motor,

the simplest way is to invert the two motor wires (typically red and black). For example,

switch the M1 and M2 connections going from your amplifier to the motor. When

driving a brushless motor, the polarity reversal may be done with the encoder. If you are

using a single-ended encoder, interchange the signal CHA and CHB. If, on the other

hand, you are using a differential encoder, interchange only CHA+ and CHA-. The loop

polarity and encoder polarity can also be affected through software with the MT, and CE

commands. For more details on the MT command or the CE command, see the

Command Reference section.

Note: Reversing the Direction of Motion

If the feedback polarity is correct but the direction of motion is opposite to the desired

direction of motion, reverse the motor leads AND the encoder signals.

When the position loop has been closed with the correct polarity, the next step is to adjust the PID filter parameters, KP, KD and KI. It is necessary to accurately tune your servo system to ensure fidelity of position and minimize motion oscillation as described in the next section .

14 • Chapter 2 Getting Started DMC-1500

ICM-1100

Pin 2

Pin 1

red wire

black wire

CPS Power Supply

Screw Terminals

Encoder Ribbon Cable

(Typically Black Connector)

Galil

DC Servo Motor

Encoder

(Typically Red Connector)

W Encoder Z Encoder Y Encoder X Encoder

Figure 2-2 - System Connections with the AMP-1100Amplifier. Note: this figure shows a Galil Motor and Encoder which uses a flat ribbon cable to connect to the AMP-1100 unit.

DMC-1500 Chapter 2 Getting Started • 15

ICM-1100

ACMDX

GND

AENX

Pin 2

Pin 1

Screw Terminals

Encoder Wire Connections Encoder: ICM-1100: Channel A(+) XA+ Channel B(+) XB+ Channel A- XAChannel B- XBIndex Pulse XI+ Index Pulse - XI-

+Ref In 4

Inhibit* 11

Signal Gnd 2

MSA 12-80

Motor + 1

Motor - 2

Power Gnd 4

High Volt 5

XI+ (81)

XB+ (79)

XA+ (77)

Encoder Wires

black wire

red wire

+5V (103)

GND (104)

XI- (82) XB- (80)

XA- (78)

(Typically Red Connector)

DC Servo Motor

Encoder

(Typically Black Connector)

CPS Power Supply

W Encoder Z Encoder Y Encoder X Encoder

Figure 2-3 System Connections with a separate amplifier (MSA 12-80). This diagram shows the connections for a standard DC Servo Motor and encoder.

Step 8b. Connect Step Motors

In Stepper Motor operation, the pulse output signal has a 50% duty cycle. Step motors operate open loop and do not require encoder feedback. When a stepper is used, the auxiliary encoder for the corresponding axis is unavailable for an external connection. If an encoder is used for position feedback, connect the encoder to the main encoder input corresponding to that axis. The commanded position of the stepper can be interrogated with RP or DE. The encoder position can be interrogated with TP.

The frequency of the step motor pulses can be smoothed with the filter parameter, KS. The KS parameter has a range between 0.5 and 8, where 8 implies the largest amount of smoothing. See Command Reference regarding KS.

The DMC-1500 profiler commands the step motor amplifier. All DMC-1500 motion commands apply such as PR, PA, VP, CR and JG. The acceleration, deceleration, slew speed and smoothing are also used. Since step motors run open-loop, the PID filter does not function and the position error is not generated.

16 • Chapter 2 Getting Started DMC-1500

To connect step motors with the DMC-1500 you must follow this procedure:

Step A. Install SM jumpers

Each axis of the DMC-1500 that will operate a stepper motor must have the

corresponding stepper motor jumper installed. For a discussion of SM jumpers, see step

Step B. Connect step and direction signals.

Make connections from controller to motor amplifiers. (These signals are labeled

PULSX and DIRX for the x-axis on the ICM-1100). Consult the documentation for your step motor amplifier.

Step C. Configure DMC-1500 for motor type using MT command. You can configure the

DMC-1500 for active high or active low pulses. Use the command MT 2 for active high step motor pulses and MT -2 for active low step motor pulses. See description of the MT command in the Command Reference.

Step 9. Tune the Servo System

Adjusting the tuning parameters is required when using servo motors. The system compensation provides fast and accurate response. The following presentation suggests a simple and easy way for compensation. More advanced design methods are available with software design tools from Galil, such as the Servo Design Kit (SDK software )

The filter has three parameters: the damping, KD; the proportional gain, KP; and the integrator, KI. The parameters should be selected in this order.

To start, set the integrator to zero with the instruction KI 0 (CR) Integrator gain and set the proportional gain to a low value, such as KP 1 (CR) Proportional gain KD 100 (CR) Derivative gain For more damping, you can increase KD (maximum is 4095). Increase gradually and stop after the

motor vibrates. A vibration is noticed by audible sound or by interrogation. If you send the command TE X (CR) Tell error a few times, and get varying responses, especially with reversing polarity, it indicates system

vibration. When this happens, simply reduce KD. Next you need to increase the value of KP gradually (maximum allowed is 1023). You can monitor the

improvement in the response with the Tell Error instruction KP 10 (CR) Proportion gain TE X (CR) Tell error As the proportional gain is increased, the error decreases. Again, the system may vibrate if the gain is too high. In this case, reduce KP. Typically, KP should

not be greater than KD/4. (Only when the amplifier is configured in the current mode). Finally, to select KI, start with zero value and increase it gradually. The integrator eliminates the

position error, resulting in improved accuracy. Therefore, the response to the instruction TE X (CR) becomes zero. As KI is increased, its effect is amplified and it may lead to vibrations. If this occurs,

simply reduce KI. Repeat tuning for the Y, Z and W axes.

DMC-1500 Chapter 2 Getting Started • 17

For a more detailed description of the operation of the PID filter and/or servo system theory, see Chapter 10 - Theory of Operation.

Design Examples

Here are a few examples for tuning and using your controller. These examples have remarks next to each command - these remarks must not be included in the actual program.

Example 1 - System Set-up

This example assigns the system filter parameters, error limits and enables the automatic error shut-off.

Instruction Interpretation

KP10,10,10,10,10,10,10,10 Set gains for A,B,C,D,E,and H axes KP10,10,10,10,10,10,10,10 Set gains for A,B,C,D,E,and H axes KP*=10 Alternate method for setting gain on all axes KPX=10 Alternate method for setting X (or A) axis gain KPA=10 Alternate method for setting A (or X) axis gain

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The X,Y,Z and W axes can also be referred to as the A,B,C, and D axes.

Instruction Interpretation

OE 1,1,1,1,1,1,1,1 Enable automatic Off on Error function for all axes ER*=1000 Set error limit for all axes to 1000 counts KP10,10,10,10,10,10,10,10 Set gains for A,B,C,D,E,and H axes KP*=10 Alternate method for setting gain on all axes KPX=10 Alternate method for setting X (or A) axis gain KPA=10 Alternate method for setting A (or X) axis gain KPZ=10 Alternate method for setting Z axis gain KPD=10 Alternate method for setting D axis gain KPH=10 Alternate method for setting H axis gain

Example 2 - Profiled Move

Objective: Rotate the X axis a distance of 10,000 counts at a slew speed of 20,000 counts/sec and an acceleration and deceleration rates of 100,000 counts/s2. In this example, the motor turns and stops:

Instruction Interpretation

PR 10000 Distance SP 20000 Speed DC 100000 Deceleration AC 100000 Acceleration BG X Start Motion

18 • Chapter 2 Getting Started DMC-1500

Example 3 - Multiple Axes

Objective: Move the four axes independently.

Instruction Interpretation

PR 500,1000,600,-400 Distances of X,Y,Z,W SP 10000,12000,20000,10000 Slew speeds of X,Y,Z,W AC 100000,10000,100000,100000 Accelerations of X,Y,Z,W DC 80000,40000,30000,50000 Decelerations of X,Y,Z,W BG XZ Start X and Z motion BG YW Start Y and W motion

Example 4 - Independent Moves

The motion parameters may be specified independently as illustrated below.

Instruction Interpretation

PR ,300,-600 Distances of Y and Z SP ,2000 Slew speed of Y DC ,80000 Deceleration of Y AC, 100000 Acceleration of Y SP ,,40000 Slew speed of Z AC ,,100000 Acceleration of Z DC ,,150000 Deceleration of Z BG Z Start Z motion BG Y Start Y motion

Example 5 - Position Interrogation

The position of the four axes may be interrogated with the instruction, TP.

Instruction Interpretation

TP Tell position all four axes TP X Tell position - X axis only TP Y Tell position - Y axis only TP Z Tell position - Z axis only TP W Tell position - W axis only

The position error, which is the difference between the commanded position and the actual position can be interrogated with the instruction TE.

Instruction Interpretation

TE Tell error - all axes

DMC-1500 Chapter 2 Getting Started • 19

TE X Tell error - X axis only TE Y Tell error - Y axis only TE Z Tell error - Z axis only TE W Tell error - W axis only

Example 6 - Absolute Position

Objective: Command motion by specifying the absolute position.

Instruction Interpretation

DP 0,2000 Define the current positions of X,Y as 0 and 2000 PA 7000,4000 Sets the desired absolute positions BG X Start X motion BG Y Start Y motion

After both motions are complete, the X and Y axes can be command back to zero:

PA 0,0 Move to 0,0 BG XY Start both motions

Example 7 - Velocity Control

Objective: Drive the X and Y motors at specified speeds.

Instruction Interpretation

JG 10000,-20000 Set Jog Speeds and Directions AC 100000, 40000 Set accelerations DC 50000,50000 Set decelerations BG XY Start motion

after a few seconds, send the following command:

JG -40000 New X speed and Direction TV X Returns X speed

and then

JG ,20000 New Y speed TV Y Returns Y speed

These cause velocity changes including direction reversal. The motion can be stopped with the instruction

ST Stop

Example 8 - Operation Under Torque Limit

The magnitude of the motor command may be limited independently by the instruction TL.

Instruction Interpretation

TL 0.2 Set output limit of X axis to 0.2 volts JG 10000 Set X speed BG X Start X motion

In this example, the X motor will probably not move since the output signal will not be sufficient to overcome the friction. If the motion starts, it can be stopped easily by a touch of a finger.

20 • Chapter 2 Getting Started DMC-1500

Increase the torque level gradually by instructions such as

Instruction Interpretation

TL 1.0 Increase torque limit to 1 volt. TL 9.98 Increase torque limit to maximum, 9.98 Volts.

The maximum level of 10 volts provides the full output torque.

Example 9 - Interrogation

The values of the parameters may be interrogated. Some examples …

Instruction Interpretation

KP ? Return gain of X axis. KP ,,? Return gain of Z axis. KP ?,?,?,? Return gains of all axes.

Many other parameters such as KI, KD, FA, can also be interrogated. The command reference denotes all commands which can be interrogated.

Example 10 - Operation in the Buffer Mode

The instructions may be buffered before execution as shown below.

Instruction Interpretation

PR 600000 Distance SP 10000 Speed WT 10000 Wait 10000 milliseconds before reading the next instruction BG X Start the motion

Example 11 - Motion Programs

Motion programs may be edited and stored in the controllers on-board memory. The instruction

ED Edit mode

moves the operation to the editor mode where the program may be written and edited. The ed itor provides the line number. For example, in response to the first ED command, the first line is zero.

Line # Instruction Interpretation

000 #A Define label 001 PR 700 Distance 002 SP 2000 Speed 003 BGX Start X motion 004 EN End program

To exit the editor mode, input <cntrl>Q. The program may be executed with the command.

XQ #A Start the program running

DMC-1500 Chapter 2 Getting Started • 21

Example 12 - Motion Programs with Loops

Motion programs may include conditional jumps as shown below.

Instruction Interpretation

#A Label DP 0 Define current position as zero V1=1000 Set initial value of V1 #Loop Label for loop PA V1 Move X motor V1 counts BG X Start X motion AM X After X motion is complete WT 500 Wait 500 ms TP X Tell position X V1=V1+1000 Increase the value of V1 JP #Loop,V1<10001 Repeat if V1<10001 EN End

After the above program is entered, quit the Editor Mode, <cntrl>Q. To start the motion, command:

XQ #A Execute Program #A

Example 13 - Motion Programs with Trippoints

The motion programs may include trippoints as shown below.

Instruction Interpretation

#B Label DP 0,0 Define initial positions PR 30000,60000 Set targets SP 5000,5000 Set speeds BGX Start X motion AD 4000 Wait until X moved 4000 BGY Start Y motion AP 6000 Wait until position X=6000 SP 2000,50000 Change speeds AP ,50000 Wait until position Y=50000 SP ,10000 Change speed of Y EN End program

To start the program, command:

XQ #B Execute Program #B

Example 14 - Control Variables

Objective: To show how control variables may be utilized.

Instruction Interpretation

#A;DP0 Label; Define current position as zero PR 4000 Initial position

22 • Chapter 2 Getting Started DMC-1500

SP 2000 Set speed BGX Move X AMX Wait until move is complete WT 500 Wait 500 ms #B V1 = _TPX Determine distance to zero PR -V1/2 Command X move 1/2 the distance BGX Start X motion AMX After X moved WT 500 Wait 500 ms V1= Report the value of V1 JP #C, V1=0 Exit if position=0 JP #B Repeat otherwise #C Label #C EN End of Program

To start the program, command

XQ #A Execute Program #A

This program moves X to an initial position of 1000 and returns it to zero on increments of half the distance. Note, _TPX is an internal variable which returns the value of the X position. Internal variables may be created by preceding a DMC-1500 instruction with an underscore, _.

Example 15 - Linear Interpolation

Objective: Move X,Y,Z motors distance of 7000,3000,6000, respectively, along linear trajectory. Namely, motors start and stop together.

Instruction Interpretation

LM XYZ Specify linear interpolation axes LI 7000,3000,6000 Relative distances for linear interpolation LE Linear End VS 6000 Vector speed VA 20000 Vector acceleration VD 20000 Vector deceleration BGS Start motion

Example 16 - Circular Interpolation

Objective: Move the XY axes in circular mode to form the path shown on Fig. 2-4. Note that the vector motion starts at a local position (0,0) which is defined at the beginning of any vector motion sequence. See application programming for further information.

Instruction Interpretation

VM XY Select XY axes for circular interpolation VP -4000,0 Linear segment CR 2000,270,-180 Circular segment VP 0,4000 Linear segment

DMC-1500 Chapter 2 Getting Started • 23

CR 2000,90,-180 Circular segment VS 1000 Vector speed VA 50000 Vector acceleration VD 50000 Vector deceleration VE End vector sequence BGS Start motion

(-4000,4000) (0,4000)

R=2000

Figure 2-4 Motion Path for Example 16

(0,0) local zero(-4000,0)

24 • Chapter 2 Getting Started DMC-1500

Chapter 3 Connecting Hardware

Overview

The DMC-1500 provides optoisolated digital inputs for forward limit, reverse limit, home, and abort signals. The controller also has 8 optoisolated, uncommitted inputs (for general use) as well as 8 TTL outputs and 7 analog inputs configured for voltages between +/- 10 volts.

1580

Controllers with 5 or more axes have an additional 8 TTL level inputs and 8 TTL level outputs.

This chapter describes the inputs and outputs and their proper connection. To access the analog inputs or general inputs 5-8 or all outputs except OUT1, connect the 26-pin

ribbon cable to the 26-pin J5 IDC connector from the DMC-1500 to the AMP-11X0 or ICM-1100 board.

If you plan to use the auxiliary encoder feature of the DMC-1500, you must also connect a 20-pin ribbon cable from the 20-pin J3 header connector on the DMC-1500 to the 26-pin J3 header connector on the AMP-11X0 or ICM-1100. This cable is not shipped unless requested when ordering.

Using Opto-isolated Inputs

Limit Switch Input

The forward limit switch (FLSx) inhibits motion in the forward direction immediately upon activation of the switch. The reverse limit switch (RLSx) inhibits motion in the reverse direction immediately upon activation of the switch. If a limit switch is activated during motion, the controller will make a decelerated stop using the deceleration rate previously set with the DC command. The motor will remain in a servo state after the limit switch has been activated and will hold motor position.

When a forward or reverse limit switch is activated, the current application program that is running will be interrupted and the controller will automatically jump to the #LIMSWI sub routine if one exists. This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch.

After a limit switch has been activated, further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to an inactive state. This usually involves physically opening the tripped switch. Any attempt at further motion before the logic state has been reset will result in the following error: “022 - Begin not possible due to limit switch” error.

The operands, _LFx and _LRx, return the state of the forward and reverse limit switches, respectively (x represents the axis, X,Y,Z,W etc.). The value of the operand is either a ‘0’ or ‘1’ corresponding to the logic state of the limit switch. Using a terminal program, the state of a limit switch can be printed to the screen with the command, MG _LFx or MG _LFx. This prints the value of the limit switch operands for the 'x' axis. The logic state of the limit switches can also be interro gated with the TS command. For more details on TS see the Command Reference.

DMC-1500 Chapter 3 Connecting Hardware • 25

Home Switch Input

The Home inputs are designed to provide mechanical reference points for a motion control application. A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system. A reference point can be a point in space or an encoder index pulse.

The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition. A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user.

There are three homing routines supported by the DMC-1500: Find Edge (FE), Find Index (FI), and Standard Home (HM).

The Find Edge routine is initiated by the command sequence: FEX <return>, BGX <return>. The Find Edge routine will cause the motor to accelerate, then slew at constant speed until a transition is detected in the logic state of the Home input. The motor will then decelerate to a stop. The acceleration rate, deceleration rate and slew speed are specified by the user, prior to the movement, using the commands AC, DC, and SP. It is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch.

The Find Index routine is initiated by the command sequence: FIX <return>, BGX <return>. Find Index will cause the motor to accelerate to the user-defined slew speed (SP) at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high. The motor then decelerates to a stop at the rate previously specified by the user with the DC command. Although Find Index is an option for homing, it is not dependent upon a transition in

the logic state of the Home input, but instead is dependent upon a transition in the level of the index pulse signal.

The Standard Homing routine is initiated by the sequence of commands HMX <return>, BGX <return>. Standard Homing is a combination of Find Edge and Find Index homing. Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input. The motor will accelerate at the rate specified by the command, AC, up to the slew speed. After detecting the transition in the logic state on the Home Input, the motor will decelerate to a stop at the rate specified by the command, DC. After the motor has decelerated to a stop, it switches direction and approaches the transition point at the speed of 256 counts/sec. When the logic state changes again, the motor moves forward (in the direction of increasing encoder count) at the same speed, until the controller senses the index pulse. After detection, it decelerates to a stop and defines this position as 0. The logic state of the Home input can be interrogated with the command MG _HMX. This command returns a 0 or 1 if the logic state is low or high, respectively. The state of the Home input can also be interrogated indirectly with the TS command.

For examples and further information about Homing, see command HM, FI, FE of the Command Reference and the section entitled ‘Homing’ in the Programming Motion Section of this manual.

Abort Input

The function of the Abort input is to immediately stop the controller upon transition of the logic state. NOTE: The response of the abort input is significantly different from the response of an activated

limit switch. When the abort input is activated, the controller stops generating motion commands immediately, whereas the limit switch response causes the controller to make a decelerated stop.

NOTE: The effect of an Abort input is dependent on the state of the off-on-error function for each axis. If the Off-On-Error function is enabled for any given axis, the motor for that axis will be turned off when the abort signal is generated. This could cause the motor to ‘coast’ to a stop since it is no longer under servo control. If the Off-On-Error function is disabled, the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state.

26 • Chapter 3 Connecting Hardware DMC-1500

All motion programs that are currently running are terminated when a transition in the Abort input is detected. For information on setting the Off-On-Error function, see the Command Reference, OE.

NOTE: The error LED does not light up when the Abort Input is active.

Uncommitted Digital Inputs

The DMC-1500 has 8 uncommitted opto-isolated inputs. These inputs are specified as INx where x specifies the input number, 1 through 24. These inputs allow the user to monitor events external to the controller. For example, the user may wish to have the x-axis motor move 1000 counts in the positive direction when the logic state of IN1 goes high.

1580

Controllers with 5 or more axes have 16 opto-isolated inputs and 8 TTL level inputs. . For controllers with more than 4 axes, the inputs 9-16 and the limit switch inputs for the additional

axes are accessed through the second 100-pin connector.

IN9-IN16 INCOM FLE,RLE,HOMEE FLF,RLF,HOMEF FLG,RLG,HOMEG FLH,RLH,HOMEH

A logic zero is generated when at least 1mA of current flows from the common to the input. A positive voltage (with respect to the input) must be supplied at the common. This can be accomplished by connecting a voltage in the range of +5V to +28V into INCOM of the input circuitry from a separate power supply.

Wiring the Optoisolated Inputs

The default state of the controller configures all inputs to be interpreted as a logic one without any connection. The inputs must be brought low to be interpreted as a zero. With regard to limit switches, a limit switch is considered to be activated when the input is brought low (or a switch is closed to ground). Some inputs can be configured to be active when the input is high - see section Changing

Optoisolated Inputs from Active High to Active Low.

The optoisolated inputs are organized into groups. For example, the general inputs, IN1-IN8, and the ABORT input are one group. Each group has a common signal which supplies current for the inputs in the group. In order to use an input, the associated common signal must be connected to voltage between +5 and +28 volts, see discussion below.

LSCOM

The optoisolated inputs are connected in the following groups (these inputs are accessed through the 26-pin J5 header).

Group Common Signal

IN1-IN8, ABORT INCOM FLX,RLX,HOMEX FLY,RLY,HOMEY FLZ,RLZ,HOMEZ FLW,RLW,HOMEW

LSCOM

1580

For controllers with more than 4 axes, the inputs 9-16 and the limit switch inputs for the additional axes are accessed through a separate connector, JD5.

Group Common Signal

DMC-1500 Chapter 3 Connecting Hardware • 27

IN9-IN16 INCOM FLE,RLE,HOMEE FLF,RLF,HOMEF FLG,RLG,HOMEG FLH,RLH,HOMEH

A logic zero is generated when at least 1mA of current flows from the common signal to the input. A positive voltage (with respect to the input) must be supplied at the common. This can be accomplished by connecting a voltage in the range of +5V to +28V into INCOM of the input circuitry from a separate power supply

LSCOM

FLSX

RLSX

HOMEX

FLSY

RLSY

HOMEY

INCOM

IN1 IN2 IN3 IN4 IN5 IN6

Figure 3-1. The Optoisolated Inputs

IN7 IN8 ABORT

Using an Isolated Power Supply

To take full advantage of opto-isolation, an isolated power supply should be used to provide the voltage at the input common connection. When using an isolated power supply, do not connect the ground of the isolated power to the ground of the controller. A power supply in the voltage range between 5 to 28 Volts may be applied directly (see Figure 3-2). For voltages greater than 28 Volts, a resistor, R, is needed in series with the input such that

28 • Chapter 3 Connecting Hardware DMC-1500

1 mA < V supply/(R + 2.2KΩ) < 15 mA

(For Voltages > +28V)

LSCOM

2.2K

FLS

Figure 3-2. Connecting a single Limit or Home Switch to an Isolated Supply

Isolated

Suppl

NOTE: As stated in Chapter 2, the wiring is simplified when using the ICM-1100 or AMP-11x0 interface board. This board accepts the signals from the ribbon cables of the DMC-1500 and provides phoenix-type screw terminals. A picture of the ICM-1100 can be seen on pg. 2-14. The user must wire the system directly off the ribbon cable if the ICM-1100 or equivalent breakout board is not available.

Bypassing the Opto-Isolation:

If no isolation is needed, the internal 5 Volt supply may be used to power the switches, as shown in Figure 3-3. This can be done by connecting a jumper between the pins LSCOM or INCOM and 5V, labeled J9. These jumpers can be added on either the ICM-1100 or the DMC-1500. This can also be done by connecting wires between the 5V supply and common signals using the screw terminals on the ICM-1100 or AMP-11x0.

To close the circuit, wire the desired input to any ground (GND) terminal.

DMC-1500 Chapter 3 Connecting Hardware • 29

LSCOM

FLS

GND

Figure 3-3 - Connecting Limit switches to the internal 5V supply

Changing Optoisolated Inputs From Active Low to Active High

Some users may prefer that the optoisolated inputs be active high. For example, the user may wish to have the inputs be activated with a logic one signal. The limit, home and latch inputs can be configured through software to be active high or low with the CN command. For more details on the CN see Command Reference manual.

The Abort input cannot be configured in this manner.

Amplifier Interface

The DMC-1500 analog command voltage, ACMD, ranges between +/-10V. This signal, along with GND, provides the input to the power amplifiers. The power amplifiers must be sized to drive the motors and load. For best performance, the amplifiers should be configured for a current mode of operation with no additional compensation. The gain should be set such that a 10 Volt input results in the maximum required current.

The DMC-1500 also provides an amplifier enable signal, AEN. This signal changes under the following conditions: the watchdog timer activates, the motor-off command, MO, is given, or the OE1command (Enable Off-On-Error) is given and the position error exceeds the error limit. As shown in Figure 3-4, AEN can be used to disable the amplifier for these conditions.

The standard configuration of the AEN signal is TTL active high. In other words, the AEN signal will be high when the controller expects the amplifier to be enabled. The polarity and the amplitude can be changed if you are using the ICM-1100 interface board. To change the polarity from active high (5 volts = enable, zero volts = disable) to active low (zero volts = enable, 5 volts= disable), replace the 7407 IC with a 7406. Note that many amplifiers designate the enable input as ‘inhibit’.

30 • Chapter 3 Connecting Hardware DMC-1500

To change the voltage level of the AEN signal, note the state of the resistor pack on the ICM-1100.

When Pin 1 is on the 5V mark, the output voltage is 0-5V. To change to 12 volts, pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side. If you remove the resistor pack, the output signal is an open collector, allowing the user to connect an external supply with voltages up to 24V.

7407 Open Collector

Buffer. The Enable signal

can be inverted by using

a 7406.

100-PIN RIBBON

ICM-1100DMC-1500

+5V+12V

Connection to +5V or +12V made through Resistor pack RP1. Removing the resistor pack allows the user to connect their own resistor to the desired voltage level ( Up to24V).

SERVO

AMPENX

MOTOR

AMPLIFIER

GND

ACMDX

Analog Switch

Figure 3-4 - Connecting AEN to the motor amplifier

TTL Inputs

1580

As previously mentioned, the DMC-1500 has 8 uncommitted TTL level inputs for controllers with 5 o more axes. These are specified as INx where x ranges from 17 thru 24. The reset input is also a TTL level, non-isolated signal and is used to locally reset the DMC-1500 without resetting the PC.

Analog Inputs

The DMC-1500 has seven analog inputs configured for the range between -10V and 10V. The inputs are decoded by a 12-bit A/D converter giving a voltage resolution of approximately .005V. The impedance of these inputs is 10 KΩ. The analog inputs are specified as AN[x] where x is a number 1 thru 7. Galil can supply the DMC-1500 with a 16-bit A/D converter as an option.

DMC-1500 Chapter 3 Connecting Hardware • 31

TTL Outputs

The DMC-1500 provides eight general use outputs and an error signal output. The general use outputs are TTL and are accessible by connections to OUT1 thru OUT8. These

outputs can be turned On and Off with the commands, SB (Set Bit), CB (Clear Bit), OB (Output Bit), and OP (Output Port). For more information about these commands, see the Command Summary. The value of the outputs can be checked with the operand _OP and the function @OUT[] (see Chapter 7, Mathematical Functions and Expressions).

1580

Controllers with 5 or more axes have an additional eight general use TTL outputs (connector JD5).

The error signal output is available on the main connector (J2, pin 3). This is a TTL signal which is low when the controller has an error. This signal is not available through the phoenix connectors of the ICM-1100.

Note: When the error signal is active, the LED on the controller will be on. An error condition indicates one of the following conditions:

1. At least one axis has a position error greater than the error limit. The error limit is set by using the

command ER.

2. The reset line on the controller is held low or is being affected by noise.

3. There is a failure on the controller and the processor is resetting itself.

4. There is a failure with the output IC which drives the error signal.

Offset Adjustment

For each axis, the DMC-1500 provides offset correction potentiometers to compensate for any offset in the analog output. These potentiometers have been adjusted at the factory to produce 0 Volts output for a zero digital motor command. Before making any adjustment to the offset, send the motor off command, MO, to the DMC-1500. This causes a zero digital motor command. Connect an oscilloscope or voltmeter to the motor command pin. You should measure zero volts. If not, adjust the offset potentiometer on the DMC-1500 until zero volts is observed.

32 • Chapter 3 Connecting Hardware DMC-1500

Chapter 4 Communication

Introduction

The DMC-1500 has two RS232 ports. The main port is the data set and the auxiliary port is the data term. The main port can be configured through the switches on the front panel, and the auxiliary port can be configured with the software command CC. The auxiliary port can either be configur ed as a general port or for daisy-chain communications. The auxiliary port configuration can be saved using the Burn (BN) instruction. The RS232 ports also have a clock synchronizing line that allows synchronization of motion on more than one controller.

RS232 Ports

The RS232 pin-out description for the main and auxiliary port is given below. Note, the auxiliary port is essentially the same as the main port except inputs and outputs are reversed. The DMC-1500 may also be configured by the factory for RS422. These pin-outs are also listed below.

Note: If you are connecting the RS232 auxiliary port to a terminal or any device which is a DATATERM, it is necessary to use a connector adapter, which changes a dataterm to a dataset . This cable is also known as a 'null' modem cable.

RS232 - Main Port {P1} DATATERM

1 CTS - output 6 CTS - output 2 Transmit Data - output 7 RTS - input 3 Receive Data - input 8 CTS - output 4 RTS - input 9 No connect (Can be connected to +5V or sample clock with jumpers) 5 Ground

RS232 - Auxiliary Port {P2} DATASET

1 CTS - input 6 CTS - input 2 Transmit Data - input 7 RTS - output 3 Receive Data - output 8 CTS - input 4 RTS - output 9 5V (Can be disconnected or connected to sample clock with jumpers) 5 Ground

*RS422 - Main Port {P1}

1 CTS - output 6 CTS+ output 2 Transmit Data - output 7 Transmit+ output

DMC-1500 Chapter 4 Communication • 33

3 Receive Data - input 8 Receive+ input 4 RTS - input 9 RTS+ input 5 Ground

*RS422 - Auxiliary Port {P2}

1 CTS - input 6 CTS+ input 2 Receive Data - input 7 Receive+ input 3 Transmit Data - output 8 Transmit+ output 4 RTS - output 9 RTS+ output 5 Ground

*Default configuration is RS232. RS422 configuration available by factory.

Configuration

Configure your PC for 8-bit data, one start-bit, one stop-bit, full duplex and no parity. The baud rate for the RS232 communication can be selected by setting the proper switch configuration on the front panel according to the table below.

Baud Rate Selection

Switch Setting Interpretation

1200 9600 19.2K ON ON OFF 300 Baud rate ON OFF OFF 1200 Baud rate ON OFF ON 4800 Baud rate OFF ON OFF 9600 Baud rate OFF OFF ON 19200 Baud rate OFF ON ON 38400 Baud ON ON ON SELF TEST

The RS232 main port can be configured for handshake or non-handshake mode. Set the HSHK switch to ON to select the handshake mode. In this mode, the RTS and CTS lines are used. The CTS line will go high whenever the DMC-1500 is not ready to receive additional characters. The RTS line will inhibit the DMC-1500 from sending additional characters. Note, the RTS line goes high for inhibit. The handshake should be turned on to ensure proper communication especially at higher baud rates.

The auxiliary port of the DMC-1500 can be configured either as a general port or for the daisy-chain. When configured as a general port, the port can be commanded to send ASCII messages to another DMC-1500 controller or to a display terminal or panel.

(Configure Communication ) at port 2. The command is in the format of: CC m,n,r,p where m sets the baud rate, n sets for either handshake or non-handshake mode, r sets for general port

or the auxiliary port, and p turns echo on or off.

m - Baud Rate - 300,1200,4800,9600,19200,38400 n - Handshake - 0=No; 1=Yes r - Mode - 0=General Port; 1=Daisy-chain

34 • Chapter 4 Communication DMC-1500

p - Echo - 0=Off; 1=On; Valid only if r=0

Note, for the handshake of the auxiliary port, the roles for the RTS and CTS lines are rev ersed . Example:

CC 1200,0,0,1

Configure auxiliary communication port for 1200 baud, no handshake, general port mode and echo turned on.

Daisy-Chaining

Up to eight DMC-1500 controllers may be connected in a daisy-chain allowing for multiple controllers to be commanded from a single serial port. One DMC-1500 is connected to the host terminal via the RS232 at port 1 or the main port. Port 2 or the auxiliary port of that DMC-1500 is then brought into port 1 of the next DMC-1500, and so on. The address of each DMC-1500 is configured by setting the three address jumpers (ADR4,ADR2,ADR1) located inside the box near the main processor IC.

When connecting multiple controllers in a daisy-chain, the cable between controllers should be made to female 0.89 with all wires connected straight through.

ADR1 represents the eight possible addresses, 0 through 7, are set as follows:

ADR4 ADR2 ADR1 ADDRESS

bit, ADR2 represents 21 bit, and ADR4 represents 22 bit of the address. The

OFF OFF OFF 0 OFF OFF ON 1 OFF ON OFF 2 OFF ON ON 3

ON OFF OFF 4 ON OFF ON 5 ON ON OFF 6 ON ON ON 7

To communicate with any one of the DMC-1500 units, give the command “%A”, where A is the address of the board. All instructions following this command will be sent only to the board with that address. Only when a new %A command is given will the instruction be sent to another board. The only exception is "!" command. To talk to all the DMC-1500 boards in the daisy-chain at one time, insert the character "!" before the software command. All boards receive the command, but only address 0 will echo.

Note: The CC command must be specified to configure the port P2 of each unit.

Daisy Chain Example:

Objective: Control a 7-axis motion system using two controllers, a DMC-1540 4 axis controller and a DMC-1530 3 axis controller. Address 0 is the DMC-1540 and address 1 is the DMC-1530.

Desired motion profile:

Address 0 (DMC-1540) X Axis is 500 counts

Y Axis is 1000 counts Z Axis is 2000 counts W Axis is 1500 counts

Address 1 (DMC-1530) X Axis is 700 counts

Y Axis is 1500 counts

DMC-1500 Chapter 4 Communication • 35

Command Interpretation

%0 Talk only to controller 0 (DMC-1540) PR 500,1000,2000,1500 Specify X,Y,Z,W distances %1 Talk only to controller board 1 (DMC-1530) PR 700,1500,2500 Specify X,Y,Z distances !BG Begin motion on both controllers

Synchronizing Sample Clocks

It is possible to synchronize the sample clocks of all DMC-1500's in the daisy-chain. This involves burning in the command, TM-1, in all DMC-1500's except for one DMC-1500 which will be the source. It is also necessary to put a jumper on pins 7 and 9 of the JP30 and JP31 jumper blocks.

Controller Response to DATA

Most DMC-1500 instructions are represented by two characters followed by the appropriate parameters. Each instruction must be terminated by a carriage return or semicolon.

Instructions are sent in ASCII, and the DMC-1500 decodes each ASCII character (one byte) one at a time. It takes approximately .5 msec for the controller to decode each command. However, the PC can send data to the controller at a much faster rate because of the FIFO buffer.

Z Axis is 2500 counts

After the instruction is decoded, the DMC-1500 returns a colon (:) if the instruction was valid or a question mark (?) if the instruction was not valid.

For instructions that return data, such as Tell Position (TP), the DMC-1500 will return the data followed by a carriage return, line feed and : .

It is good practice to check for : after each command is sent to prevent errors. An echo function is provided to enable associating the DMC-1500 response with the data sent. The echo is enabled by sending the command EO 1 to the controller.

Galil Software Tools and Libraries

API (Application Programming Interface) software is available from Galil. The API software is written in C and is included in the Galil COMM disks. They can be used for development under DOS and Windows environments (16 and 32 bit Windows). With the API's, the user can incorporate already existing library functions directly into a C program.

Galil has also developed a Visual Basic Toolkit. This provides VBXs, 16-bit OCXs and 3 2-bit OCXs for handling all of the DMC-1500 communications including support of interrupts. These objects install directly into Visual Basic and are part of the run-time environment. For more information, contact Galil.

36 • Chapter 4 Communication DMC-1500

Chapter 5 Command Basics

Introduction

The DMC-1500 provides over 100 commands for specifying motion and machine parameters. Commands are included to initiate action, interrogate status and config ure the digital filter.

The DMC-1500 instruction set is BASIC-like and easy to use. Instructions consist of two uppercase letters that correspond phonetically with the appropriate function. For example, the instruction BG begins motion, and ST stops the motion.

Commands can be sent "live" over the bus for immediate execution by the DMC-1500, or an entire group of commands can be downloaded into the DMC-1500 memory for execution at a later time. Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter.

This section describes the DMC-1500 instruction set and syntax. A summary of commands as well as a complete listing of all DMC-1500 instructions is included in the Command Reference Manual.

Command Syntax

DMC-1500 instructions are represented by two ASCII upper case characters followed by applicable arguments. A space may be inserted between the instruction and arguments. A semicolon or <enter> is used to terminate the instruction for processing by the DMC-1500 command interpreter. Note: If you are using a Galil terminal program, commands will not be processed until an <enter> command is given. This allows the user to separate many commands on a single line and not begin execution until the user gives the <enter> command.

IMPORTANT: All DMC-1500 commands must be sent in upper case.

For example, the command PR 4000 <enter> Position relative PR is the two character instruction for position relative. 4000 is the argument which represents the

required position value in counts. The <enter> terminates the instruction. The space between PR and 4000 is optional.

For specifying data for the X,Y,Z and W axes, commas are used to separate the axes. If no data is specified for an axis, a comma is still needed as shown in the examples below. If no data is specified for an axis, the previous value is maintained. The space between the data and instruction is optional. For controllers with 5 or more axes, the axes are referred to as A,B,C,D,E,F,G,H where X,Y,Z,W and A,B,C,D may be used interchangeably.

The DMC-1500 provides an alternative method for specifying data. Here data is specified individually using a single axis specifier such as X,Y,Z or W (or A,B,C,D,E,F,G or H for the DMC-1580). An equals sign is used to assign data to that axis. For example:

DMC-1500 Chapter 5 Command Basics • 37

PRX=1000 Specify a position relative movement for the X axis of 1000 ACY=200000 Specify acceleration for the Y axis as 200000

Instead of data, some commands request action to occur on an axis or group of axes. For example, ST XY stops motion on both the X and Y axes. Commas are not required in this case since the particular axis is specified by the appropriate letter X Y Z or W. If no parameters follow the instruction, action will take place on all axes. Here are some examples of syntax for requesting action:

BG X Begin X only BG Y Begin Y only BG XYZW Begin all axes BG YW Begin Y and W only BG Begin all axes

1580

For controllers with 5 or more axes, the axes are referred to as A,B,C,D,E,F,G,H. The specifiers X,Y,Z,W and A,B,C,D may be used interchangeably:

BG ABCDEFGH Begin all axes BG D Begin D only

Coordinated Motion with more than 1 axis

When requesting action for coordinated motion, the letter S is used to specify the coordinated motion. For example:

BG S Begin coordinated sequence BG SW Begin coordinated sequence and W axis

Program Syntax

Chapter 7 explains the how to write and execute motion control programs.

Controller Response to DATA

The DMC-1500 returns a : for valid commands. The DMC-1500 returns a ? for invalid commands. For example, if the command BG is sent in lower case, the DMC-1500 will return a ?.

:bg <enter> invalid command, lower case ? DMC-1500 returns a ?

When the controller receives an invalid command the user can request the error code. The error code will specify the reason for the invalid command response. To request the error code type the command: TC1 For example:

38 • Chapter 5 Command Basics DMC-1500

?TC1 <enter> Tell Code command 1 Unrecognized command Returned response

There are many reasons for receiving an invalid command response. The most common reasons are: unrecognized command (such as typographical entry or lower case), command given at improper time (such as during motion), or a command out of range (such as exceeding maximum speed). A complete list of all error codes can be found with the description of the TC command in the Command Reference Manual.

Interrogating the Controller

Interrogation Commands

The DMC-1500 has a set of commands that directly interrogate the controller. When the command is entered, the requested data is returned in decimal format on the next line followed by a carriage return and line feed. The format of the returned data can be changed using the Position Format (PF), Variable Format (VF) and Leading Zeros (LZ) command. See Chapter 7 and the Command Reference Manual.

Summary of Interrogation Commands

RP Report Command Position RL Report Latch

∧R ∧

V SC Stop Code TB Tell Status TC Tell Error Code TD Tell Dual Encoder TE Tell Error TI Tell Input TP Tell Position TR Trace TS Tell Switches TT Tell Torque TV Tell Velocity

Firmware Revision Information

For example, the following example illustrates how to display the current position of the X axis:

TP X <enter> Tell position X 0000000000 Controllers Response TP XY <enter> Tell position X and Y 0000000000,0000000000 Controllers Response

DMC-1500 Chapter 5 Command Basics • 39

Additional Interrogation Methods.

Most commands can be interrogated by using a question mark. For information specific to a particular axis, type the command followed by a ? for each axis requested.

PR ?,?,?,? Request X,Y,Z,W values PR ,? Request Y value only

The controller can also be interrogated with operands.

Operands

Most DMC-1500 commands have corresponding operands that can be used for interrogation. Operands must be used inside of valid DMC expressions. For example, to display the value of an operand, the user could use the command:

MG ‘operand’ where 'operand' is a valid DMC operand All of the command operands begin with the underscore character (_). For example, the value of the

current position on the X axis can be assigned to the variable, V, with the command: V=_TPX The Command Reference denotes all commands which have an equivalent operand as "Used as an

Operand". For further information, see description of operands in Chapter 7.

Command Summary

For a complete command summary, see Command Reference manual.

40 • Chapter 5 Command Basics DMC-1500

Chapter 6 Programming Motion

Overview

The DMC-1500 can be commanded to do the following modes of motion: Absolute and relative independent positioning, jogging, linear interpolation (up to 8 axes), linear and circular interpolation (2 axes with 3 These modes are discussed in the following sections.

The DMC-1510 is a single axis controller and uses X-axis motion only. Likewise, the DMC-1520 uses X and Y, the DMC-1530 uses X,Y and Z, and the DMC-1540 uses X,Y,Z and W. The DMC1550 uses A,B,C,D, and E. The DMC-1560 uses A,B,C,D,E, and F. The DMC-1570 uses A,B,C,D,E,F and G. The DMC-1580 uses the axes A,B,C,D,E,F,G, and H.

The example applications described below will help guide you to the appropriate mode of motion.

axis of tangent motion), electronic gearing, electronic cam motion and contouring.

1580

For controllers with 5 or more axes, the specifiers, ABCDEFGH, are used. XYZ and W may be interchanged with ABCD.

Independent Axis Positioning

In this mode, motion between the specified axes is independent, and each axis follows its own profile. The user specifies the desired absolute position (PA) or relative position (PR), slew speed (SP), acceleration ramp (AC), and deceleration ramp (DC), for each axis. On begin (BG), the DMC-1500 profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory. The controller determines a new command position along the trajectory every sample period until the specified profile is complete. Motion is complete when the last position command is sent by the DMC-1500 profiler. Note: The actual motor motion may not be complete when the profile has been completed, however, the next motion command may be specified.

The Begin (BG) command can be issued for all axes either simultaneously or independently. XYZ or W axis specifiers are required to select the axes for motion. When no axes are specified, this causes motion to begin on all axes.

The speed (SP) and the acceleration (AC) can be changed at any time during motion, however, the deceleration (DC) and position (PR or PA) cannot be changed until motion is complete. Remember, motion is complete when the profiler is finished, not when the actual motor is in position. The Stop command (ST) can be issued at any time to decelerate the motor to a stop before it reaches its final position.

An incremental position movement (IP) may be specified during motion as long as the additional move is in the same direction. Here, the user specifies the desired position increment, n. The new target is equal to the old target plus the increment, n. Upon receiving the IP command, a revised profile will be generated for motion towards the new end position. The IP command does not require a begin. Note: If the motor is not moving, the IP command is equivalent to the PR and BG command combination.

DMC-1500 Chapter 6 Programming Motion • 41

Command Summary - Independent Axis

COMMAND DESCRIPTION

PR X,Y,Z,W Specifies relative distance PA x,y,z,w Specifies absolute position SP x,y,z,w Specifies slew speed AC x,y,z,w Specifies acceleration rate DC x,y,z,w Specifies deceleration rate BG XYZW Starts motion ST XYZW Stops motion before end of move IP x,y,z,w Changes position target IT x,y,z,w Time constant for independent motion smoothing AM XYZW Trippoint for profiler complete MC XYZW Trippoint for "in position"

The lower case specifiers (x,y,z,w) represent position values for each axis. For controllers with more than 4 axes, the position values would be represented as a,b,c,d,e,f,g,h.

Operand Summary - Independent Axis

OPERAND DESCRIPTION

_ACx Return acceleration rate for the axis specified by ‘x’ _DCx Return deceleration rate for the axis specified by ‘x’ _SPx Returns the speed for the axis specified by ‘x’ _PAx Returns current destination if ‘x’ axis is moving, otherwise returns the current commanded

position if in a move.

_PRx Returns current incremental distance specified for the ‘x’ axis

Example - Absolute Position Movement

PA 10000,20000 Specify absolute X,Y position AC 1000000,1000000 Acceleration for X,Y DC 1000000,1000000 Deceleration for X,Y SP 50000,30000 Speeds for X,Y BG XY Begin motion

42 • Chapter 6 Programming Motion DMC-1500

Example - Multiple Move Sequence

Required Motion Profiles:

X-Axis 500 counts Position 10000 count/sec Speed 500000 counts/sec2 Acceleration Y-Axis 1000 counts Position 15000 count/sec Speed 500000 counts/sec2 Acceleration Z-Axis 100 counts Position 5000 counts/sec Speed 500000 counts/sec Acceleration

This example will specify a relative position movement on X, Y and Z axes. The movement on each axis will be separated by 20 msec. Fig. 6.1 shows the velocity profiles for the X,Y and Z axis.

#A Begin Program PR 2000,500,100 Specify relative position movement of 1000, 500 and 100 counts for X,Y and Z

axes. SP 15000,10000,5000 Specify speed of 10000, 15000, and 5000 counts / sec AC 500000,500000,500000 Specify acceleration of 500000 counts / sec DC 500000,500000,500000 Specify deceleration of 500000 counts / sec BG X Begin motion on the X axis WT 20 Wait 20 msec BG Y Begin motion on the Y axis WT 20 Wait 20 msec BG Z Begin motion on Z axis EN End Program

VELOCITY (COUNTS/SEC)

for all axes

X axis velocity profile

20000

Y axis velocity profile

15000

Z axis velocity profile

10000

5000

TIME (ms)

40 60

100

Figure 6.1 - Velocity Profiles of XYZ

DMC-1500 Chapter 6 Programming Motion • 43

Notes on fig 6.1: The X and Y axis have a ‘trapezoidal’ velocity profile, while the Z axis has a ‘triangular’ velocity profile. The X and Y axes accelerate to the specified speed, move at this constant speed, and then decelerate such that the final position agrees with the command position, PR. The Z axis accelerates, but before the specified speed is achieved, must begin deceleration such that the axis will stop at the commanded position. All 3 axes have the same acceleration and deceleration rate, hence, the slope of the rising and falling edges of all 3 velocity profiles are the same.

Independent Jogging

The jog mode of motion allows the user to change speed, direction and acceleration during motion. The user specifies the jog speed (JG), acceleration (AC), and the deceleration (DC) rate for each axis. The direction of motion is specified by the sign of the JG parameters. When the begin command is given (BG), the motor accelerates up to speed and continues to jog at that speed until a new speed or stop (ST) command is issued. If the jog speed is changed during motion, the controller will make a accelerated (or decelerated) change to the new speed.

An instant change to the motor position can be made with the use of the IP command. Upon receiving this command, the controller commands the motor to a position which is equal to the specified increment plus the current position. This command is useful when trying to synchronize the position of two motors while they are moving.

Note that the controller operates as a closed-loop position controller while in the jog mode. The DMC-1500 converts the velocity profile into a position trajectory and a new position target is generated every sample period. This method of control results in precise speed regulation with phase lock accuracy.

Command Summary - Jogging

COMMAND DESCRIPTION

AC x,y,z,w Specifies acceleration rate BG X,Y,Z,W Begins motion DC x,y,z,w Specifies deceleration rate IP x,y,z,w Increments position instantly IT x,y,z,w Time constant for independent motion smoothing JG +/-x,y,z,w Specifies jog speed and direction ST XYZW Stops motion

Parameters can be set with individual axes specifiers such as JGY+2000(set jog speed for X axis to

2000) or ACYH=40000 (set acceleration for Y and H axes to 400000) .

Operand Summary - Independent Axis

OPERAND DESCRIPTION

_ACx Return acceleration rate for the axis specified by ‘x’ _DCx Return deceleration rate for the axis specified by ‘x’ _SPx Returns the jog speed for the axis specified by ‘x’ _TVx Returns the actual velocity of the axis specified by ‘x’ (averaged over.25 sec)

44 • Chapter 6 Programming Motion DMC-1500

Example - Jog in X Only

Jog X motor at 50000count/s. After X motor is at its jog speed, begin jogging Z in reverse direction at 25000 count/s.

#A AC 20000,,20000 Specify X,Z acceleration of 20000 cts/sec DC 20000,,20000 Specify X,Z deceleration of 20000 cts/sec JG 50000,,-25000 Specify jog speed and direction for X and Z axis BG XY Begin X motion AS X Wait until X is at speed BG Z Begin Z motion EN

Example - Joystick Jogging

The jog speed can also be changed using an analog input such as a joystick. Assume that for a 10 Volt input the speed must be 50000 counts/sec.

#JOY Label JG0 Set in Jog Mode BGX Begin motion #B Label for Loop V1 = @AN[1] Read analog input VEL = V1*50000/2047 Compute speed JG VEL Change JG speed JP #B Loop

Linear Interpolation Mode

The DMC-1500 provides a linear interpolation mode for 2 or more axes (up to 8 axes for the DMC-

1580). In linear interpolation mode, motion between the axes is coordinated to maintain the prescribed vector speed, acceleration, and deceleration along the specified path. The motion path is described in terms of incremental distances for each axis. An unlimited number of incremental segments may be given in a continuous move sequence, making the linear interpolation mode ideal for following a piece-wise linear path. There is no limit to the total move length.

The LM command selects the Linear Interpolation mode and axes for interpolation. For example, LM YZ selects only the Y and Z axes for linear interpolation.

When using the linear interpolation mode, the LM command only needs to be specified once unless the axes for linear interpolation change.

Specifying Linear Segments

The command LI x,y,z,w or LI a,b,c,d,e,f,g,h specifies the incremental move distance for each axis. This means motion is prescribed with respect to the current axis position. Up to 511 incremental move segments may be given prior to the Begin Sequence (BGS) command. Once motion has begun, additional LI segments may be sent to the controller.

The clear sequence (CS) command can be used to remove LI segments stored in the buffer prior to the start of the motion. To stop the motion, use the instructions STS or AB. The command, ST, causes a decelerated stop. The command, AB, causes an instantaneous stop and aborts the program, and the command AB1 aborts the motion only.

DMC-1500 Chapter 6 Programming Motion • 45

The Linear End (LE) command must be used to specify the end of a linear move sequence. This command tells the controller to decelerate to a stop following the last LI command. If an LE command is not given, an Abort AB1 must be used to abort the motion sequence.

It is the responsibility of the user to keep enough LI segments in the DMC-1500 sequence buffer to ensure continuous motion. If the controller receives no additional LI segments and no LE command, the controller will stop motion instantly at the last vector. There will be no controlled deceleration. LM? or _LM returns the available spaces for LI segments that can be sent to the buffer. 511 returned means the buffer is empty and 511 LI segments can be sent. A zero means the buffer is full and no additional segments can be sent. As long as the buffer is not full, additional LI segments can be sent at PC bus speeds.

The instruction _CS returns the segment counter. As the segments are processed, _CS increases, starting at zero. This function allows the host computer to determine which segment is being processed.

Specifying Vector Acceleration, Deceleration and Speed:

The commands VS n, VA n, and VD n are used to specify the vector speed, acceleration and deceleration. The DMC-1500 computes the vector speed based on the axes specified in the LM mode. For example, LM XYZ designates linear interpolation for the X,Y and Z axes. The vector speed for this example would be computed using the equation:

VS2=XS2+YS2+ZS2, where XS, YS and ZS are the speed of the X,Y and Z axes. The controller always uses the axis specifications from LM, not LI, to compute the speed. In cases where the acceleration causes the system to 'jerk', the DMC-1500 provides a vector motion

smoothing function. VT is used to set the S-curve smoothing constant for coordinated moves.

Additional Commands

The DMC-1500 provides commands for additional control of vector motion and program control. Note: Many of the commands used in Linear Interpolation motion also applies Vector motion described in the next section.

Trippoints

The command AV n is the ‘After Vector’ trippoint, which halts program execution until the vector distance of n has been reached.

In this example, the XY system is required to perform a 90 the corner, we use the AV 4000 trippoint, which slows the speed to 1000 count/s. Once the motors reach the corner, the speed is increased back to 4000 cts / s.

Instruction Interpretation

#LMOVE Label DP ,,0,0 Define position of Z and W axes to be 0 LMXY Define linear mode between X and Y axes. LI 5000,0 Specify first linear segment LI 0,5000 Specify second linear segment LE End linear segments VS 4000 Specify vector speed BGS Begin motion sequence

° turn. In order to slow the speed around

46 • Chapter 6 Programming Motion DMC-1500

AV 4000 Set trippoint to wait until vector distance of 4000 is reached VS 1000 Change vector speed AV 5000 Set trippoint to wait until vector distance of 5000 is reached VS 4000 Change vector speed EN Program end

Specifying Vector Speed for Each Segment

The instruction VS has an immediate effect and, therefore, must be given at the required time. In some applications, such as CNC, it is necessary to attach various speeds to different motion segments. This can be done by the instruction

LI x,y,z,w < n This instruction attaches the vector speed, n, to the motion segment LI. As a consequence, the

program #LMOVE can be written in the alternative form:

Instruction Interpretation

#ALT Label for alternative program DP 0,0 Define Position of X and Y axis to be 0 LMXY Define linear mode between X and Y axes. LI 4000,0 <4000 Specify first linear segment with a vector speed of 4000 LI 1000,0 < 1000 Specify second linear segment with a vector speed of 1000 LI 0,5000 < 4000 Specify third linear segment with a vector speed of 4000 LE End linear segments BGS Begin motion sequence EN Program end

Changing Feedrate:

The command VR n allows the feedrate, VS, to be scaled between 0 and 10 with a resolution of .0001. This command takes effect immediately and causes VS to be scaled. VR also applies when the vector speed is specified with the ‘<’ operator. This is a useful feature for feedrate override. VR does not ratio the accelerations. For example, VR .5 results in the specification VS 2000 to be divided in half.

Command Summary - Linear Interpolation

COMMAND DESCRIPTION

LM xyzw LM abcdefgh LM? Returns number of available spaces for linear segments in DMC-1500 sequence buffer.

LI x,y,z,w < n LI a,b,c,d,e,f,g,h < n VS n Specify vector speed VA n Specify vector acceleration VD n Specify vector deceleration VR n Specify the vector speed ratio BGS Begin Linear Sequence CS Clear sequence

Specify axes for linear interpolation (same) controllers with 5 or more axes

Zero means buffer full. 512 means buffer empty. Specify incremental distances relative to current position, and assign vector speed n.

DMC-1500 Chapter 6 Programming Motion • 47

LE Linear End- Required at end of LI command sequence

LE? Returns the length of the vector (resets after 2147483647) AMS Trippoint for After Sequence complete AV n Trippoint for After Relative Vector Distance, n VT S curve smoothing constant for vector moves

Operand Summary - Linear Interpolation

OPERAND DESCRIPTION

_AV Return distance traveled _CS Segment counter - returns number of the segment in the sequence, starting at zero. _LE Returns length of vector (resets after 2147483647) _LM Returns number of available spaces for linear segments in DMC-1500 sequence buffer.

Zero means buffer full. 512 means buffer empty.

_VPm Return the absolute coordinate of the last data point along the trajectory.

(m=X,Y,Z or W or A,B,C,D,E,F,G or H)

To illustrate the ability to interrogate the motion status, consider the first motion segment of our example, #LMOVE, where the X axis moves toward the point X=5000. Suppose that when X=3000, the controller is interrogated using the command ‘MG _AV’. The returned value will be 3000. The value of _CS, _VPX and _VPY will be zero.

Now suppose that the interrogation is repeated at the second segment when Y=2000. The value of _AV at this point is 7000, _CS equals 1, _VPX=5000 and _VPY=0.

Example - Linear Move

Make a coordinated linear move in the ZW plane. Move to coordinates 40000,30000 counts at a vector speed of 100000 counts/sec and vector acceleration of 1000000 counts/sec2.

Instruction Interpretation

#TEST Label LM ZW Specify axes for linear interpolation LI,,40000,30000 Specify ZW distances LE Specify end move VS 100000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration BGS Begin sequence AMS After motion sequence ends EN End program

Note that the above program specifies the vector speed, VS, and not the actual axis speeds VZ and VW. The axis speeds are determined by the DMC-1500 from:

48 • Chapter 6 Programming Motion DMC-1500

VZ VW=+

The resulting profile is shown in Figure 6.2.

30000

27000

POSITIO N W

3000

FEEDRATE

VELOCITY

Z-AXIS

VELOCITY

W-AXIS

0 40000

0 0.1 0.5 0.6

4000 36000

POSITIO N Z

TIME (sec)

Figure 6.2 - Linear Interpolation

Example - Multiple Moves

This example makes a coordinated linear move in the XY plane. The Arrays VX and VY are used to store 750 incremental distances which are filled by the program #LOAD.

Instruction Interpretation

DMC-1500 Chapter 6 Programming Motion • 49

#LOAD Load Program DM VX [750],VY [750] Define Array COUNT=10 Initialize Counter N=10 Initialize position increment #LOOP LOOP VX [COUNT]=N Fill Array VX VY [COUNT]=N Fill Array VY N=N+10 Increment position COUNT=COUNT+1 Increment counter JP #LOOP,COUNT<750 Loop if array not full #A Label LM XY Specify linear mode for XY COUNT=0 Initialize array counter #LOOP2;JP#LOOP2,_LM=0 If sequence buffer full, wait JS#C,COUNT=500 Begin motion on 500th segment LI

VX[COUNT],VY[COUNT] COUNT=COUNT+1 Increment array counter JP #LOOP2,COUNT<750 Repeat until array done LE End Linear Move AMS After Move sequence done MG "DONE" Send Message EN End program #C;BGS;EN Begin Motion Subroutine

Specify linear segment

Vector Mode: Linear and Circular Interpolation Motion

The DMC-1500 allows a long 2-D path consisting of linear and arc segments to be prescribed. Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments. The DMC-1500 performs all the complex computations of linear and circular interpolation, freeing the host PC from this time intensive task.

The coordinated motion mode is similar to the linear interpolation mode. Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments. In addition, a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes. Note that only one pair of axes can be specified for coordinated motion at any given time.

The command VM m,n,p where ‘m’ and ‘n’ are the coordinated pair and p is the tangent axis (Note: the commas which separate m,n and p are not necessary). For example, VM XWZ selects the XW axes for coordinated motion and the Z-axis as the tangent.

Specifying Vector Segments

The motion segments are described by two commands; VP for linear segments and CR for circular segments. Once a set of linear segments and/or circular segments have been specified, the sequence is ended with the command VE. This defines a sequence of commands for coordinated motion. Immediately prior to the execution of the first coordinated movement, the controller defines the current position to be zero for all movements in a sequence. Note: This ‘local’ definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences.

50 • Chapter 6 Programming Motion DMC-1500

The command, VP xy specifies the coordinates of the end points of the vector movement with respect to the starting point. Non-sequential axes do not require comma delineation. The command, CR r,q,d define a circular arc with a radius r, starting angle of q, and a traversed angle d. The notation for q is that zero corresponds to the positive horizontal direction, and for both q and d, the counter-clockwise (CCW) rotation is positive.

Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE. The motion can be initiated with a Begin Sequence (BGS) command. Once motion starts, additional segments may be added.

The Clear Sequence (CS) command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion. To stop the motion, use the in structions STS or AB1. ST stops motion at the specified deceleration. AB1 aborts the motion instantaneously.

The Vector End (VE) command must be used to specify the end of the coordinated motion. This command requires the controller to decelerate to a stop following the last motion requirement. If a VE command is not given, an Abort (AB1) must be used to abort the coordinated motion sequence.

It is the responsibility of the user to keep enough motion segments in the DMC-1500 sequence buffer to ensure continuous motion. If the controller receives no additional motion segments and no VE command, the controller will stop motion instantly at the last vector. There will be no controlled deceleration. LM? or _LM returns the available spaces for motion segments that can be sent to the buffer. 511 returned means the buffer is empty and 511 segments can be sent. A zero means the buffer is full and no additional segments can be sent. As long as the buffer is not full, additional segments can be sent at PC bus speeds.

The operand _CS can be used to determine the value of the segment counter.

Specifying Vector Acceleration, Deceleration and Speed:

The commands VS n, VA n, and VD n are used to specify the vector speed, acceleration and deceleration. The DMC-1500 computes the vector speed based on the two axes specified in the VM mode. For example, VM YZ designates vector mode for the Y and Z axes. The vector speed for this example would be computed using the equation:

VS2=YS2+ZS2, where YS and ZS are the speed of the Y and Z axes. In cases where the acceleration causes the system to 'jerk', the DMC-1500 provides a vector motion

smoothing function. VT is used to set the S-curve smoothing constant for coordinated moves.

Additional Commands

The DMC-1500 provides commands for additional control of vector motion and program control. Note: Many of the commands used in Vector Mode motion also applies Linear Interpolation motion described in the previous section.

Trippoints

The command AV n is the ‘After Vector’ trippoint, which halts program execution until the vector distance of n has been reached.

Specifying Vector Speed for Each Segment

The vector speed may be specified by the immediate command VS. It can also be attached to a motion segment with the instructions

VP x,y, < n CR r,

DMC-1500 Chapter 6 Programming Motion • 51

θ,δ < n

Both cases assign a vector speed of n count/s to the corresponding motion segment.

Changing Feedrate:

The command VR n allows the feedrate, VS, to be scaled between 0 and 10 with a resolution of .0001. This command takes effect immediately and causes VS scaled. VR also applies when the vector speed is specified with the ‘<’ operator. This is a useful feature for feedrate override. VR does not ratio the accelerations. For example, VR .5 results in the specification VS 2000 to be divided in half.

Compensating for Differences in Encoder Resolution:

By default, the DMC-1500 uses a scale factor of 1:1 for the encoder resolution when used in vector mode. If this is not the case, the command, ES can be used to scale the encoder counts. The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion. The smaller ratio of the two numbers will be multiplied by the higher resolution encoder. For more information, see ES command in Chapter 11, Command Summary.

Tangent Motion:

Several applications, such as cutting, require a third axis (i.e. a knife blade), to remain tangent to the coordinated motion path. To handle these applications, the DMC-1500 allows one axis to be specified as the tangent axis. The VM command provides parameter specifications for describing the coordinated axes and the tangent axis.

VM m,n,p m,n specifies coordinated axes p specifies tangent axis such as X,Y,Z,W or

A,B,C,D,E,F,G,H p=N turns off tangent axis

Before the tangent mode can operate, it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m,n command. m defines the scale factor in counts/degree and n defines the tangent position that equals zero degrees in the coordinated motion plane. The _TN can be used to return the initial position of the tangent axis.

Example - XY Table Control

Assume an XY table with the Z-axis controlling a knife. The Z-axis has a 2000 quad counts/rev encoder and has been initialized after power-up to point the knife in the +Y direction. A 180

cut is desired, with a radius of 3000, center at the origin and a starting point at (3000,0). The motion is CCW, ending at (-3000,0). Note that the 0

corresponds to the position -500 in the Z-axis, and defines the offset. The motion has two parts. First, X,Y and Z are driven to the starting point, and later, the cut is performed. Assume that the knife is engaged with output bit 0.

Instruction Interpretation

#EXAMPLE Example program VM XYZ XY coordinate with Z as tangent TN 2000/360,-500 2000/360 counts/degree, position -500 is 0 degrees in XY plane CR 3000,0,180 3000 count radius, start at 0 and go to 180 CCW VE End vector CB0 Disengage knife PA 3000,0,_TN Move X and Y to starting position, move Z to initial tangent position BG XYZ Start the move to get into position

° position in the XY plane is in the +X direction. This

° circular

52 • Chapter 6 Programming Motion DMC-1500

AM XYZ When the move is complete SB0 Engage knife WT50 Wait 50 msec for the knife to engage BGS Do the circular cut AMS After the coordinated move is complete CB0 Disengage knife MG "ALL DONE" EN End program

Command Summary - Vector Mode Motion

COMMAND DESCRIPTION

VM m,n Specifies the axes for the planar motion where m and n represent the planar axes and p is

the tangent axis. VP m,n Return coordinate of last point, where m=X,Y,Z or W. CR r,Θ, ±ΔΘ Specifies arc segment where r is the radius, Θ is the starting angle and ΔΘ is the travel

angle. Positive direction is CCW. VS n Specify vector speed or feedrate of sequence. VA n Specify vector acceleration along the sequence. VD n Specify vector deceleration along the sequence. VR n Specify vector speed ratio BGS Begin motion sequence. CS Clear sequence. AV n Trippoint for After Relative Vector distance, n. AMS Holds execution of next command until Motion Sequence is complete. TN m,n Tangent scale and offset. ES m,n Ellipse scale factor. VT S curve smoothing constant for coordinated moves LM? Return number of available spaces for linear and circular segments in DMC-1500

sequence buffer. Zero means buffer is full. 512 means buffer is empty.

Operand Summary - Vector Mode Motion

OPERAND DESCRIPTION

_VPM The absolute coordinate of the axes at the last intersection along the sequence. _AV Distance traveled. _LM Number of available spaces for linear and circular segments in DMC-1500 sequence

buffer. Zero means buffer is full. 512 means buffer is empty. _CS Segment counter - Number of the segment in the sequence, starting at zero. _VE Vector length of coordinated move sequence.

When AV is used as an operand, _AV returns the distance traveled along the sequence. The operands _VPX and _VPY can be used to return the coordinates of the last point specified along

the path.

DMC-1500 Chapter 6 Programming Motion • 53

Example:

Traverse the path shown in Fig. 6.3. Feedrate is 20000 counts/sec. Plane of motion is XY

Instruction Interpretation

VM XY Specify motion plane VS 20000 Specify vector speed VA 1000000 Specify vector acceleration VD 1000000 Specify vector deceleration VP -4000,0 Segment AB CR 1500,270,-180 Segment BC VP 0,3000 Segment CD CR 1500,90,-180 Segment DA VE End of sequence BGS Begin Sequence

The resulting motion starts at the point A and moves toward points B, C, D, A. Suppose that we interrogate the controller when the motion is halfway between the points A and B.

The value of _AV is 2000 The value of _CS is 0 _VPX and _VPY contain the absolute coordinate of the point A Suppose that the interrogation is repeated at a point, halfway between the points C and D.

The value of _AV is 4000+1500 The value of _CS is 2 _VPX,_VPY contain the coordinates of the point C

C (-4000,3000)

R = 1500

B (-4000,0)

Figure 6.3 - The Required Path

Electronic Gearing

π+2000=10,712

D (0,3000)

A (0,0)

This mode allows up to 8 axes to be electronically geared to one master axis. The master may rotate in both directions and the geared axes will follow at the specified gear ratio. The gear ratio may be different for each axis and changed during motion.

54 • Chapter 6 Programming Motion DMC-1500

The command GAX or GAY or GAZ or GAW (or GAA or GAB or GAC or GAD or GAE or GAF or GAG or GAH for DMC-1580) specifies the master axis. There may only be one master. GR x,y,z,w specifies the gear ratios for the slaves where the ratio may be a number between +/-127.9999 with a fractional resolution of .0001. GR 0,0,0,0 turns off electronic gearing for any set of axes. A limit switch will also disable electronic gearing for that axis. GR causes the specified axes to be geared to the actual position of the master. The master axis is commanded with motion commands such as PR, PA or JG.

When the master axis is driven by the controller in the jog mode or an independent motion mode, it is possible to define the master as the command position of that axis, rather than the actual position. The designation of the commanded position master is by the letter, C. For example, GACX indicates that the gearing is the commanded position of X.

An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS. For example, if the X and Y motor form a circular motion, the Z axis may move in proportion to the vector move. Similarly, if X,Y and Z perform a linear interpolation move, W can be geared to the vector move.

Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing. For example, when a geared motor follows a master at a ratio of 1:1, it may be advanced an additional distance with PR, or JG, commands, or VP, or LI.

Command Summary - Electronic Gearing

COMMAND DESCRIPTION

GA n Specifies master axis for gearing where:

n = X,Y,Z or W or A,B,C,D,E,F,G,H for main encoder as master

n = XC,YC,ZC or WC or AC, BC, CC, DC, EC, FC,GC,HC for commanded position. n = DX,DY,DZ or DW or DA, DB, DC, DD, DE, DF,DG,DH for auxiliary encoders n = S vector move as master GR x,y,z,w Sets gear ratio for slave axes. 0 disables electronic gearing for specified axis. GR a,b,c,d,e,f,g,h Sets gear ratio for slave axes. 0 disables electronic gearing for specified axis. MR x,y,z,w Trippoint for reverse motion past specified value. Only one field may be used. MF x,y,z,w Trippoint for forward motion past specified value. Only one field may be used.

Operand Summary - Electronic Gearing

COMMAND DESCRIPTION

GA n Specifies master axis for gearing where:

n = X,Y,Z or W or A,B,C,D,E,F,G,H for main encoder as master

DMC-1500 Chapter 6 Programming Motion • 55

Example - Simple Master Slave

Master axis moves 10000 counts at slew speed of 100000 counts/sec. Y is defined as the master. X,Z,W are geared to master at ratios of 5,-.5 and 10 respectively.

Instruction Interpretation

GAY Specify master axes as Y GR 5,,-.5,10 Set gear ratios PR ,10000 Specify Y position SP ,100000 Specify Y speed BGY Begin motion

Example - Electronic Gearing

Objective: Run two geared motors at speeds of 1.132 and -0.045 times the speed of an external master. The master is driven at speeds between 0 and 1800 RPM (2000 counts/rev encoder).

Solution: Use a DMC-1530 controller, where the Z-axis is the master and X and Y are the geared axes.

MO Z Turn Z off, for external master GA Z Specify master axis GR 1.132,-.045 Specify gear ratios

Now suppose the gear ratio of the X-axis is to change on-the-fly to 2. This can be achieved by commanding:

GR 2 Specify gear ratio for X axis to be 2

In applications where both the master and the follower are controlled by the DMC-1500 controller, it may be desired to synchronize the follower with the commanded position of the master, rather than the actual position. This eliminates the coupling between the axes which may lead to oscillations.

For example, assume that a gantry is driven by two axes, X,Y, on both sides. The X-axis is the master and the Y-axis is the follower. To synchronize Y with the commanded position of X, use the instructions:

GA XC Specify master as commanded position of X GR,1 Set gear ratio for Y as 1:1 PR 3000 Command X motion BG X Start motion on X axis

You may also perform profiled position corrections in the electronic gearing mode. Suppose, for example, that you need to advance the slave 10 counts. Simply command

IP ,10 Specify an incremental position movement of 10 on Y axis.

Under these conditions, this IP command is equivalent to:

PR,10 Specify position relative movement of 10 on Y axis BGY Begin motion on Y axis

Often the correction is quite large. Such requirements are common when synchronizing cutting knives or conveyor belts.

Example - Synchronize two conveyor belts with trapezoidal velocity correction.

Instruction Interpretation

56 • Chapter 6 Programming Motion DMC-1500

GAX Define master axis as X GR,2 Set gear ratio 2:1 for Y PR,300 Specify correction distance SP,5000 Specify correction speed AC,100000 Specify correction acceleration DC,100000 Specify correction deceleration BGY Start correction

Electronic Cam

The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion. Up to 7 axes can be slaved to one master axis. The master axis encoder must be input through a main encoder port.

The electronic cam is a more general type of electronic gearing which allows a table-based relationship between the axes. It allows synchronizing all the controller axes. For example, the DMC-1580 controller may have one master and up to seven slaves. To simplify the presentation, we will limit the description to a 4-axis controller.

To illustrate the procedure of setting the cam mode, consider the cam relationship for th e slave axis Y, when the master is X. Such a graphic relationship is shown in Figure 6.8.

Step 1. Selecting the master axis The first step in the electronic cam mode is to select the master axis. This is done with the instruction

EAp where p = X,Y,Z,W p is the selected master axis

Step 2. Specify the master cycle and the change in the slave axis(es). In the electronic cam mode, the position of the master is always expressed modulo one cycle. In this

example, the position of x is always expressed in the range between 0 and 6000. Similarly, the slave position is also redefined such that it starts at zero and ends at 1500. At the end of a cycle when the master is 6000 and the slave is 1500, the positions of both x and y are redefined as zero. To specify the master cycle and the slave cycle change, we use the instruction EM.

EM x,y,z,w

where x,y,z,w specify the cycle of the master and the total change of the slaves over one cycle.

The cycle of the master is limited to 8,388,607 whereas the slave change per cycle is limited to 2,147,483,647. If the change is a negative number, the absolute value is specified. For the given example, the cycle of the master is 6000 counts and the change in the slave is 1500. Therefore, we use the instruction:

DMC-1500 Chapter 6 Programming Motion • 57

EM 6000,1500

Step 3. Specify the master interval and starting point. Next we need to construct the ECAM table. The table is specified at uniform intervals of master

positions. Up to 256 intervals are allowed. The size of the master interval and the starting point are specified by the instruction:

EP m,n

where m is the interval width in counts, and n is the starting point.

For the given example, we can specify the table by specifying the position at the master points of 0, 2000, 4000 and 6000. We can specify that by

EP 2000,0

Step 4. Specify the slave positions. Next, we specify the slave positions with the instruction

ET[n]=x,y,z,w

where n indicates the order of the point.

The value, n, starts at zero and may go up to 256. The parameters x,y,z,w indicate the corresponding slave position. For this example, the table may be specified by

ET[0]=,0 ET[1]=,3000 ET[2]=,2250 ET[3]=,1500

This specifies the ECAM table.

Step 5. Enable the ECAM To enable the ECAM mode, use the command

EB n

58 • Chapter 6 Programming Motion DMC-1500

where n=1 enables ECAM mode and n=0 disables ECAM mode.

Step 6. Engage the slave motion To engage the slave motion, use the instruction

EG x,y,z,w

where x,y,z,w are the master positions at which the corresponding slaves must be engaged.

If the value of any parameter is outside the range of one cycle, the cam engages immediately. When the cam is engaged, the slave position is redefined, modulo one cycle.

Step 7. Disengage the slave motion To disengage the cam, use the command

EQ x,y,z,w

where x,y,z,w are the corresponding slave axes are disengaged.

3000 2250

1500

This disengages the slave axis at a specified master position. If the parameter is outside the master cycle, the stopping is instantaneous.

2000 6000

Figure 6.8: Electronic Cam Example

Master X4000

Programmed start and stop can be used only when the master moves forward. Some Examples To illustrate the complete process, consider the cam relationship described by

DMC-1500 Chapter 6 Programming Motion • 59

the equation: Y = 0.5 * X + 100 sin (0.18*X) where X is the master, with a cycle of 2000 counts. The cam table can be constructed manually, point by point, or automatically by a program. The

following program includes the set-up. The instruction EAX defines X as the master axis. The cycle of the master is

2000. Over that cycle, X varies by 1000. This leads to the instruction EM 2000,1000. Suppose we want to define a table with 100 segments. This implies increments of 20 counts each. If

the master points are to start at zero, the required instruction is EP 20,0. The following routine computes the table points. As the phase equals 0.18X and X varies in

increments of 20, the phase varies by increments of 3.6°. The program then computes the values of Y according to the equation and assigns the values to the table with the instruction ET[N] = ,Y.

Instruction Interpretation

#SETUP Label EAX Select X as master EM 2000,1000 Cam cycles EP 20,0 Master position increments N = 0 Index #LOOP Loop to construct table from equation P = N

∗

3.6 Note 3.6 = 0.18∗20 S = @SIN [P] *100 Define sine position Y = N *10+S Define slave position ET [N] =, Y Define table N = N+1 JP #LOOP, N<=100 Repeat the process EN

Now suppose that the slave axis is engaged with a start signal, input 1, but that both the engagement and disengagement points must be done at the center of the cycle: X = 1000 and Y = 500. This implies that Y must be driven to that point to avoid a jump.

This is done with the program:

Instruction Interpretation

#RUN Label EB1 Enable cam PA,500 starting position SP,5000 Y speed BGY Move Y motor AM After Y moved AI1 Wait for start signal EG,1000 Engage slave AI - 1 Wait for stop signal EQ,1000 Disengage slave EN End

60 • Chapter 6 Programming Motion DMC-1500

Command Summary - ECAM Mode

command description

EA ABCDEFG or H Specify ECAM master axis EB n (n = 0 or 1) Enable ECAM EG a,b,c,d,e,f,g,h ECAM go - Specifies position for engaging ECAM EM a,b,c,d,e,f,g,h Specify cam cycle EP m,n Specifies cam table interval and starting point EQ a,b,c,d,e,f,g,h Quit ECAM ET[n] Specify ECAM table entry

Operand Summary - ECAM Mode

operand Description

_EB Contains the state of ECAM mode (0 = disabled, 1 = enabled) _EGx Contains ecam status for specified axis (0 = engaged, 1= disengaged) _EMx Contains the cycle of the specified axis _EP Contains the value of the interval _EQx Contains status of ECAM mode for specified axis

Example - Using ECAM

The following example illustrates a cam program with a master axis, Z, and two slaves, X and Y.

Instruction Interpretation

#A;V1=0 PA 0,0;BGXY;AMXY EA Z EM 0,0,4000 EP400,0 ET[0]=0,0 ET[1]=40,20 ET[2]=120,60 ET[3]=240,120 ET[4]=280,140 ET[5]=280,140 ET[6]=280,140 ET[7]=240,120 ET[8]=120,60 ET[9]=40,20 ET[10]=0,0 EB 1 JGZ=4000 EG 0,0 BGZ #LOOP;JP#LOOP,V1=0

Label; Initialize variable Go to position 0,0 on X and Y axes Z axis as the Master for ECAM Change for Z is 4000, zero for X, Y ECAM interval is 400 counts with zero start When master is at 0 position; 1st point. 2nd point in the ECAM table 3rd point in the ECAM table 4th point in the ECAM table 5th point in the ECAM table 6th point in the ECAM table 7th point in the ECAM table 8th point in the ECAM table 9th point in the ECAM table 10th point in the ECAM table Starting point for next cycle Enable ECAM mode Set Z to jog at 4000 Engage both X and Y when Master = 0 Begin jog on Z axis Loop until the variable is set

DMC-1500 Chapter 6 Programming Motion • 61

EQ2000,2000 MF,, 2000 ST Z EB 0 EN

Disengage X and Y when Master = 2000 Wait until the Master goes to 2000 Stop the Z axis motion Exit the ECAM mode End of the program

The above example shows how the ECAM program is structured and how the commands can be given to the controller. The next page provides the results captured by the WSDK program. This shows how the motion will be seen during the ECAM cycles. The first graph is for the X axis, the second graph shows the cycle on the Y axis and the third graph shows the cycle of the Z axis.

62 • Chapter 6 Programming Motion DMC-1500

Contour Mode

The DMC-1500 also provides a contouring mode. This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes. This is ideal for following computer generated paths such as parabolic, spherical or user-defined profiles. The path is not limited to straight line and arc segments and the path length may be infinite.

Specifying Contour Segments

The Contour Mode is specified with the command, CM. For example, CMXZ specifies contouring on the X and Z axes. Any axes that are not being used in the contouring mode may be operated in other modes.

A contour is described by position increments which are described with the command, CD x,y,z,w over a time interval, DT n. The parameter, n, specifies the time interval. The time interval is defined as 2n ms, where n is a number between 1 and 8. The controller performs linear interpolation between the specified increments, where one point is generated for each millisecond.

Consider, for example, the trajectory shown in Fig. 6.4. The position X may be described by the points:

Point 1 X=0 at T=0ms Point 2 X=48 at T=4ms Point 3 X=288 at T=12ms Point 4 X=336 at T=28ms

The same trajectory may be represented by the increments

Increment 1 DX=48 Time=4 DT=2 Increment 2 DX=240 Time=8 DT=3 Increment 3 DX=48 Time=16 DT=4

When the controller receives the command to generate a trajectory along these points, it interpolates linearly between the points. The resulting interpolated points include the position 12 at 1 msec, position 24 at 2 msec, etc.

The programmed commands to specify the above example are:

Instruction Interpretation

#A CMX Specifies X axis for contour mode DT 2 Specifies first time interval, 2 CD 48;WC Specifies first position increment DT 3 Specifies second time interval, 2 CD 240;WC Specifies second position increment DT 4 Specifies the third time interval, 2 CD 48;WC Specifies the third position increment DT0;CD0 Exits contour mode EN

DMC-1500 Chapter 6 Programming Motion • 63

POSITION (COUNTS)

336 288

240 192

96 48

TIME (ms)

SEGMENT 1 SEGMENT 2 SEGMENT 3

Figure 6.4 - The Required Trajectory

20 24

Additional Commands

The command, WC, is used as a trippoint "When Complete". This allows the DMC-1500 to use the next increment only when it is finished with the previous one. Zero parameters for DT followed by zero parameters for CD exit the contour mode.

If no new data record is found and the controller is still in the contour mode, the controller waits for new data. No new motion commands are generated while waiting. If bad data is received, the controller responds with a ?.

Command Summary - Contour Mode

COMMAND DESCRIPTION CM XYZW Specifies which axes for contouring mode. Any non-contouring axes may be operated in

other modes.

CM ABCDEFGH

CD x,y,z,w Specifies position increment over time interval. Range is +/-32,000. Zero ends contour

CD a,b,c,d,e,f,g,h

DT n Specifies time interval 2n msec for position increment, where n is an integer between 1 and

WC Waits for previous time interval to be complete before next data record is processed.

64 • Chapter 6 Programming Motion DMC-1500

Contour axes for DMC-1580

mode. Position increment data for DMC-1580

8. Zero ends contour mode. If n does not change, it does not need to be specified with each CD.

General Velocity Profiles

The Contour Mode is ideal for generating any arbitrary velocity profiles. The velocity profile can be specified as a mathematical function or as a collection of points.

The design includes two parts: Generating an array with data points and running the program.

Generating an Array - An Example

Consider the velocity and position profiles shown in Fig. 6.5. The objective is to rotate a motor a distance of 6000 counts in 120 ms. The velocity profile is sinusoidal to reduce the jerk and the system vibration. If we describe the position displacement in terms of A counts in B milliseconds, we can describe the motion in the following manner:

ωπ

Note:

In the given example, A=6000 and B=120, the position and velocity profiles are:

=−

()

ATBA

Χ= −

sin( )

ω is the angular velocity; X is the position; and T is the variable, time, in milliseconds.

Β12cos( )

X = 50T - (6000/2 Note that the velocity,

ω = 50 [1 - cos 2π T/120]

ω, in count/ms, is

Figure 6.5 - Velocity Profile with Sinusoidal Acceleration

π) sin (2π T/120)

The DMC-1500 can compute trigonometric functions. However, the argument must be expressed in degrees. Using our example, the equation for X is written as:

X = 50T - 955 sin 3T A complete program to generate the contour movement in this example is given below. To generate

an array, we compute the position value at intervals of 8 ms. This is stored at the array POS. Then,

DMC-1500 Chapter 6 Programming Motion • 65

the difference between the positions is computed and is stored in the array DIF. Finally the motors are run in the contour mode.

Contour Mode Example

Instruction Interpretation

#POINTS Program defines X points DM POS[16] Allocate memory DM DIF[15] C=0 Set initial conditions, C is index T=0 T is time in ms #A V1=50*T V2=3*T Argument in degrees V3=-955*@SIN[V2]+V1 Compute position V4=@INT[V3] Integer value of V3 POS[C]=V4 Store in array POS T=T+8 C=C+1 JP #A,C<16 #B Program to find position differences C=0 #C D=C+1 DIF[C]=POS[D]-POS[C] Compute the difference and store C=C+1 JP #C,C<15 EN End first program #RUN Program to run motor CMX Contour Mode DT3 4 millisecond intervals C=0 #E CD DIF[C] Contour Distance is in DIF WC Wait for completion C=C+1 JP #E,C<15 DT0 CD0 Stop Contour EN End the program

Teach (Record and Play-Back)

Several applications require teaching the machine a motion trajectory. Teaching can be accomplished using the DMC-1500 automatic array capture feature to capture position data. The captured data may then be played back in the contour mode. The following array commands are used:

66 • Chapter 6 Programming Motion DMC-1500

DM C[n] Dimension array RA C[] Specify array for automatic record (up to 8 arrays) RD _TPX Specify data for capturing (such as _TPX or _TPZ) RC n,m Specify capture time interval where n is 2n msec, m is number of records to be captured RC? or _RC Returns a 1 if recording

Record and Playback Example:

Instruction Interpretation

#RECORD Begin Program DP0 Define position for X axis to be 0 DA*[ ] De-allocate all arrays DM XPOS [501] Dimension 501 element array called XPOS RA XPOS [ ] Record Elements into XPOS array RD_TPX Element to be recorded is encoder position of X axis MOX Motor off for X axis RC2 Begin Recording with a sample rate of 2 msec #LOOP1;JP#LOOP1,_RC=1 Loop until all elements have been recorded #COMPUTE Routine to determine the difference between consecutive points DM DX [500] Dimension a 500 element array to hold contour points I = 0 Set loop counter #LOOP2 Loop to calculate the difference DX[I]=XPOS[I+1]-XPOS[I] Calculate difference I=I+1 Update loop counter JP#LOOP2,I<500 Continue looping until DX is full #PLAYBK Routine to play back motion that was recorded SHX Servo Here WT1000 Wait 1 sec (1000 msec) CMX Specify contour mode on X axis DT2 Set contour data rate to be 2 msec I=0 Set array index to 0 #LOOP3 Subroutine to execute contour points CD DX[I];WC Contour data command; Wait for next contour point I=I+1 Update index JP#LOOP3,I<500 Continue until all array elements have been executed DT0 Set contour update rate to 0 CD0 Disable the contour mode (combination of DT0 and CD0) EN End program

For additional information about Automatic Array Capture, see Chapter 7, Arrays.

Stepper Motor Operation

When configured for stepper motor operation, several commands are interpreted differently than from servo mode. The following describes operation with stepper motors.

DMC-1500 Chapter 6 Programming Motion • 67

Specifying Stepper Motor Operation

In order to command stepper motor operation, the appropriate stepper mode jumpers must be installed. See chapter 2 for this installation.

Stepper motor operation is specified by the command MT. The argument for MT is as follows: 2 specifies a stepper motor with active low step output pulses

-2 specifies a stepper motor with active high step output pulses

2.5 specifies a stepper motor with active low step output pulses and reversed direction

-2.5 specifies a stepper motor with active high step output pulse and reversed direction

Stepper Motor Smoothing

The command, KS, provides stepper motor smoothing. The effect of the smoothing can be thought of as a simple Resistor-Capacitor (single pole) filter. The filter occurs after the motion profiler and has the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor. Use of KS is most applicable when operating in full step or half step operation. KS will cause the step pulses to be delayed in accordance with the time constant specified.

When operating with stepper motors, you will always have some amount of stepper motor smoothing, KS. Since this filtering effect occurs after the profiler, the profiler may be ready for additional moves before all of the step pulses have gone through the filter. It is important to consider this effect since steps may be lost if the controller is commanded to generate an additional move before the previous move has been completed. See the discussion below,

Pulses.

Monitoring Generated Pulses vs Commanded

The general motion smoothing command, IT, can also be used. The purpose of the command, IT, is to smooth out the motion profile and decrease 'jerk' due to acceleration.

Monitoring Generated Pulses vs Commanded Pulses

For proper controller operation, it is necessary to make sure that the controller has completed generating all step pulses before making additional moves. This is most particularly important if you are moving back and forth. For example, when operating with servo motors, the trippoint AM (After Motion) is used to determine when the motion profiler is complete and is prepared to execute a new motion command. However when operating in stepper mode, the controller may still be generating step pulses when the motion profiler is complete. This is caused by the stepper motor smoothing filter, KS. To understand this, consider the steps the controller executes to generate step pulses:

First, the controller generates a motion profile in accordance with the motion commands. Second, the profiler generates pulses as prescribed by the motion profile. The pulses that are

generated by the motion profiler can be monitored by the command, RP (Reference Position). RP gives the absolute value of the position as determined by the motion profiler. The command, DP, can be used to set the value of the reference position. For example, DP 0, defines the reference position of the X axis to be zero.

Third, the output of the motion profiler is filtered by the stepper smoothing filter. This filter adds a delay in the output of the stepper motor pulses. The amount of delay depends on the parameter which is specified by the command, KS. As mentioned earlier, there will always be some amount of stepper motor smoothing. The default value for KS is 2 which corresponds to a time constant of 6 sample periods.

Fourth, the output of the stepper smoothing filter is buffered and is available for input to the stepper motor driver. The pulses which are generated by the smoothing filter can be monitored by the command, TD (Tell Dual). TD gives the absolute value of the position as determined by actual output

68 • Chapter 6 Programming Motion DMC-1500

of the buffer. The command, DP sets the value of the step count register as well as the value of the reference position. For example, DP 0, defines the reference position of the X axis to be zero.

Motion Profiler

Stepper Smoothing Filter

(Adds a Delay)

Output Buffer

Output

(To Stepper Driver)

Step Count Register (TD)Reference Position (RP)

Motion Complete Trippoint

When used in stepper mode, the MC command will hold up execution of the proceeding commands until the controller has generated the same number of steps out of the step count register as specified in the commanded position. The MC trippoint (Motion Complete) is generally more useful than AM trippoint (After Motion) since the step pulses can be delayed from the commanded position due to stepper motor smoothing.

Using an Encoder with Stepper Motors

An encoder may be used on a stepper motor to check the actual motor position with the commanded position. If an encoder is used, it must be connected to the main encoder input. Note: The auxiliary encoder is not available while operating with stepper motors. The position of the encoder can be interrogated by using the command, TP. The position value can be defined by using the command, DE. Note: Closed loop operation with a stepper motor is not possible.

Command Summary - Stepper Motor Operation

COMMAND DESCRIPTION DE Define Encoder Position (When using an encoder) DP Define Reference Position and Step Count Register IT Motion Profile Smoothing - Independent Time Constant KS Stepper Motor Smoothing MT Motor Type (2,-2,2.5 or -2.5 for stepper motors) RP Report Commanded Position TD Report number of step pulses generated by controller TP Tell Position of Encoder

Operand Summary - Stepper Motor Operation

OPERAND DESCRIPTION _DEx Contains the value of the step count register _DPx Contains the value of the main encoder _ITx Contains the value of the Independent Time constant for the 'x' axis _KS Contains the value of the Stepper Motor Smoothing Constant for the 'x' axis _MT Contains the motor type value for the 'x' axis _RP Contains the commanded position generated by the profiler _TD Contains the value of the step count register

DMC-1500 Chapter 6 Programming Motion • 69

_TP Contains the value of the main encoder

Dual Loop (Auxiliary Encoder)

The DMC-1500 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation. When used, the second encoder is typically mounted on the motor or the load, but may be mounted in any position. The most common use for the second encoder is backlash compensation, described below.

The auxiliary encoder may also be used for gearing. In this case, the auxiliary encoder input is used to monitor an encoder which is not under control of the DMC-1500. To use the auxiliary encoder for gearing, the master axis is specified as the auxiliary encoder and GR is used to specify the gear ratios. For more information, see previous section

The second encoder may be a standard quadrature type, or it may provide pulse and direction. The controller also offers the provision for inverting the direction of the encoder rotation. The main and the auxiliary encoders are configured with the CE command. The command form is CE x,y,z,w (or a,b,c,d,e,f,g,h for controllers with more than 4 axes) where the parameters x,y,z,w each equal the sum of two integers m and n. m configures the main encoder and n configures the auxiliary enco der.

Using the CE Command

m= Main Encoder n= Second Encoder

0 Normal quadrature 0 Normal quadrature 1 Pulse & direction 4 Pulse & direction 2 Reverse quadrature 8 Reversed quadrature 3 Reverse pulse & direction 12 Reversed pulse & direction

Electronic Gearing on page 54.

For example, to configure the main encoder for reversed quadrature, m=2, and a second encoder of pulse and direction, n=4, the total is 6, and the command for the X axis is

CE 6

Additional Commands for the Auxiliary Encoder

The command, DE x,y,z,w, can be used to define the position of the auxiliary encoders. For example, DE 0,500,-30,300 sets their initial values. The positions of the auxiliary encoders may be interrogated with the command, DE?. For example DE ?,,? returns the value of the X and Z auxiliary encoders. The auxiliary encoder position may be assigned to variables with the instructions V1= _DEX The command, TD XYZW, returns the current position of the auxiliary encoder. The command, DV XYZW, configures the auxiliary encoder to be used for backlash compensation.

Backlash Compensation

There are two methods for backlash compensation using the auxiliary encoders:

70 • Chapter 6 Programming Motion DMC-1500

Continuous dual loop Sampled dual loop

To illustrate the problem, consider a situation in which the coupling between the motor and the load has a backlash. To compensate for the backlash, position encoders are mounted on both the motor and the load.

The continuous dual loop combines the two feedback signals to achieve stability. This method requires careful system tuning, and depends on the magnitude of the backlash. However, once successful, this method compensates for the backlash continuously.

The second method, the sampled dual loop, reads the load encoder only at the end point and performs a correction. This method is independent of the size of the backlash. However, it is effective only in point-to-point motion systems which require position accuracy only at the endpoint.

Example - Continuous Dual Loop

Note: In order to have a stable continuous dual loop system, the encoder on the motor must be of equal or higher resolution than the encoder on the load.

Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder port. The dual loop method splits the filter function between the two encoders. It applies the KP (proportional) and KI (integral) terms to the position error, based on the load encoder, and applies the KD (derivative) term to the motor encoder. This method results in a stable system.

The dual loop method is activated with the instruction DV (Dual Velocity), where DV 1,1,1,1 activates the dual loop for the four axes and DV 0,0,0,0 disables the dual loop. Note that the dual loop compensation depends on the backlash magnitude, and in extreme cases will

not stabilize the loop. The proposed compensation procedure is to start with KP=0, KI=0 and to maximize the value of KD under the condition DV1. Once KD is found, increase KP gradually to a maximum value, and finally, increase KI, if necessary.

Example - Sampled Dual Loop

In this example, we consider a linear slide which is run by a rotary motor via a lead screw. Since the lead screw has a backlash, it is necessary to use a linear encoder to monitor the pos ition of the slide. For stability reasons, it is best to use a rotary encoder on the motor.

Connect the rotary encoder to the X-axis and connect the linear encoder to the auxiliary encoder of X. Assume that the required motion distance is one inch, and that this corresponds to 40,000 counts of the rotary encoder and 10,000 counts of the linear encoder.

The design approach is to drive the motor a distance, which corresponds to 40,000 rotary counts. Once the motion is complete, the controller monitors the position of the linear encoder and performs position corrections.

This is done by the following program.

Instruction Interpretation

#DUALOOP Label CE 0 Configure encoder DE0 Set initial value PR 40000 Main move

DMC-1500 Chapter 6 Programming Motion • 71

BGX Start motion #Correct Correction loop AMX Wait for motion completion V1=10000-_DEX Find linear encoder error V2=-_TEX/4+V1 Compensate for motor error JP#END,@ABS[V2]<2 Exit if error is small PR V2*4 Correction move BGX Start correction JP#CORRECT Repeat #END EN

Command Summary - Using the Auxiliary Encoder

COMMAND DESCRIPTION CE Configure Encoder Type DE Define dual (auxiliary) encoder position DV Set continuous dual loop mode - see description below GA Set master axis for gearing - the auxiliary encoder input can be used for gearing GR Set gear ratio for gearing - the auxiliary encoder input can be used for gearing TD Tell dual (auxiliary) encoder input position.

Operand Summary - Using the Auxiliary Encoder

OPERAND DESCRIPTION _CEx Contains the encoder configuration for the specified axis _DEx Contains the current position of the specified auxiliary encoder _DVx Contains a '1' or '0' if the specified axis is in continuous dual loop operation. _GRx Contains the value of the gear ratio for the specified axis _TDx Contains the position of the specified auxiliary encoder.

Motion Smoothing

The DMC-1500 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system.

Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value. The discontinuous acceleration results in jerk which causes vibration. The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration.

Using the IT and VT Commands (S curve profiling):

When operating with servo motors, motion smoothing can be accomplished with the IT and VT command. These commands filter the acceleration and deceleration functions to produce a smooth velocity profile. The resulting velocity profile, known as S curve, has continuous acceleration and results in reduced mechanical vibrations.

72 • Chapter 6 Programming Motion DMC-1500

The smoothing function is specified by the following commands:

IT x,y,z,w Independent time constant VT n Vector time constant

The command, IT, is used for smoothing independent moves of the type JG, PR, PA and the command, VT, is used to smooth vector moves of the type VM and LM.

The smoothing parameters, x,y,z,w and n are numbers between 0 and 1 and determine the degree of filtering. The maximum value of 1 implies no filtering, resulting in trapezoidal velocity prof iles. Smaller values of the smoothing parameters imply heavier filtering and smoother moves.

The following example illustrates the effect of smoothing. Fig. 6.6 shows th e trapezoidal velocity profile and the modified acceleration and velocity.

Note that the smoothing process results in longer motion time.

Example - Smoothing

Instruction Interpretation

PR 20000 Position AC 100000 Acceleration DC 100000 Deceleration SP 5000 Speed IT .5 Filter for S-curve BG X Begin

ACCELERATION

VELOCITY

ACCELERATION

VELOCITY

DMC-1500 Chapter 6 Programming Motion • 73

Figure 6.6 - Trapezoidal velocity and smooth velocity profiles

Using the KS Command (Step Motor Smoothing):

When operating with step motors, motion smoothing can be accomplished with the command, KS. The KS command smoothes the frequency of step motor pulses. Similar to the commands, IT and VT, this produces a smooth velocity profile.

The step motor smoothing is specified by the following command:

KS x,y,z,w where x,y,z,w is an integer from 1 to 16 and represents the amount of smoothing

The command, IT, is used for smoothing independent moves of the type JG, PR, PA and the command, VT, is used to smooth vector moves of the type VM and LM.

The smoothing parameters, x,y,z,w and n are numbers between 0 and 16 and determine the degree of filtering. The minimum value of 1 implies no filtering, resulting in trapezoidal velocity profiles. Larger values of the smoothing parameters imply heavier filtering and smoother moves.

Note that KS is valid only for step motors.

Homing

The Find Edge (FE) and Home (HM) instructions may be used to home the motor to a mechanical reference. This reference is connected to the Home input line. The HM command initializes the motor to the encoder index pulse in addition to the Home input. The configure command (CN) is used to define the polarity of the home input.

The Find Edge (FE) instruction is useful for initializing the motor to a home switch. The home switch is connected to the Homing Input. When the Find Edge command and Begin is used, the motor will accelerate up to the slew speed and slew until a transition is detected on the Homing line. The motor will then decelerate to a stop. A high deceleration value must be input before the find edge command is issued for the motor to decelerate rapidly after sensing the home switch. The velocity profile generated is shown in Fig. 6.7.

The Home (HM) command can be used to position the motor on the index pulse after the home switch is detected. This allows for finer positioning on initialization. The command sequence HM and BG causes the following sequence of events to occur.

Upon begin, motor accelerates to the slew speed. The direction of its motion is determined

by the state of the homing input. A zero (GND) will cause the motor to start in the forward direction; +5V will cause it to start in the reverse direction. The CN command is

used to define the polarity of the home input. Upon detecting the home switch changing state, the motor begins decelerating to a stop. The motor then traverses very slowly back until the home switch toggles again. The motor then traverses forward until the encoder index pulse is detected. The DMC-1500 defines the home position (0) as the position at which the index was detected.

74 • Chapter 6 Programming Motion DMC-1500

Example 1 - Using Home Command

Instruction Interpretation

#HOME Label AC 1000000 Acceleration Rate DC 1000000 Deceleration Rate SP 5000 Speed for Home Search HM X Home X BG X Begin Motion AM X After Complete MG "AT HOME" Send Message EN End

Example 2 - Using Find Edge Command

Instruction Interpretation

#EDGE Label AC, 2000000 Acceleration rate DC, 2000000 Deceleration rate SP, 8000 Speed FE Y Find edge command BG Y Begin motion AM Y After complete MG "FOUND HOME" Print message DP,0 Define position as 0 EN End

MOTION BEGINS TOWARD HOME DIRECTION

MOTION REVERSE TOWARD HOME DIRECTION

POSITION

DMC-1500 Chapter 6 Programming Motion • 75

MOTION TOWARD INDEX DIRECTION

Figure 6.7 - Motion intervals in the Home sequence

76 • Chapter 6 Programming Motion DMC-1500

High Speed Position Capture (The Latch Function)

Often it is desirable to capture the position precisely for registration applications. The DMC-1500 provides a position latch feature. This feature allows the position of X,Y,Z or W to be captured within 25 microseconds of an external low input signal. The general inputs 1 through 4, and 9 through 12 correspond to each axis.

IN1 X-axis latch IN 9 E-axis latch IN2 Y-axis latch IN10 F-axis latch IN3 Z-axis latch IN11 G-axis latch IN4 W-axis latch IN12 H-axis latch Note: To insure a position capture within 25 microseconds, the input signal must be a transition from

high to low. The DMC-1500 software commands, AL and RL, are used to arm the latch and report the latched

position. The steps to use the latch are as follows:

Give the AL XYZW command, or ABCDEFGH for DMC-1580, to arm the latch for the

specified axis or axes.

Test to see if the latch has occurred (Input goes low) by using the _AL X or Y or Z or W

command. Example, V1=_ALX returns the state of the X latch into V1. V1 is 1 if the latch has not occurred.

After the latch has occurred, read the captured position with the RL XYZW command or _RL

XYZW.

Note: The latch must be re-armed after each latching event.

Example - Using Position Capture Function

Instruction Interpretation

#Latch Latch program JG,5000 Jog Y BG Y Begin motion on Y axis AL Y Arm Latch for Y axis #Wait #Wait label for loop JP #Wait,_ALY=1 Jump to #Wait label if latch has not occurred Result=_RLY Set value of variable ‘Result’ equal to the report position of y axis Result= Print result EN End

DMC-1500 Chapter 6 Programming Motion • 77

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78 • Chapter 6 Programming Motion DMC-1500

Chapter 7 Application Programming

Overview

The DMC-1500 provides a powerful programming language that allows users to customize the controller for their particular application. Programs can be downloaded into the DMC-1500 memory freeing the host computer for other tasks. However, the host computer can send commands to the controller at any time, even while a program is being executed.

In addition to standard motion commands, the DMC-1500 provides commands that allow the DMC1500 to make its own decisions. These commands include conditional jumps, event triggers and subroutines. For example, the command JP#LOOP, n<10 causes a jump to the label #LOOP if the variable n is less than 10.

For greater programming flexibility, the DMC-1500 provides user-defined variables, arrays and arithmetic functions. For example, with a cut-to-length operation, the length can be specified as a variable in a program which the operator can change as necessary.

The following sections in this chapter discuss all aspects of creating applications programs.

Using the DMC-1500 Editor to Enter Programs

Application programs for the DMC-1500 may be created and edited either locally using the DMC1500 editor or remotely using another editor and then downloading the program into the controller. (Galil's Terminal and SDK software provides an editor and UPLOAD and DOWNLOAD utilities).

The DMC-1500 provides a line Editor for entering and modifying programs. The Edit mode is entered with the ED instruction. The ED command can only be given when the controller is not running a program.

In the Edit Mode, each program line is automatically numbered sequentially starting with 000. If no parameter follows the ED command, the editor prompter will default to the last line of the program in memory. If desired, the user can edit a specific line number or label by specifying a line number or label following ED.

Instruction Interpretation

ED Puts Editor at end of last program ED 5 Puts Editor at line 5 ED #BEGIN Puts Editor at label #BEGIN

The program memory space for the DMC-1500 is 1000 lines x 80 characters per line

DMC-1500 Chapter 7 Application Programming • 79

Line numbers appear as 000,001,002 and so on. Program commands are entered following the line numbers. Multiple commands may be given on a single line as long as the total number of characters doesn't exceed the limits given above.

While in the Edit Mode, the programmer has access to special instructions for saving, inserting and deleting program lines. These special instructions are listed below:

Edit Mode Commands

<RETURN> Typing the return or enter key causes the current line of entered instructions to be saved. The editor

will automatically advance to the next line. Thus, hitting a series of <RETURN> will cause the ed itor to advance a series of lines. Note, changes on a program line will not be saved unless a <return> is given.

<cntrl>P The <cntrl>P command moves the editor to the previous line. <cntrl>I The <cntrl>I command inserts a line above the current line. For example, if the editor is at line

number 2 and <cntrl>I is applied, a new line will be inserted between lines 1 and 2. This new line will be labeled line 2. The old line number 2 is renumbered as line 3.

<cntrl>D The <cntrl>D command deletes the line currently being edited. For example, if the editor is at line

number 2 and <cntrl>D is applied, line 2 will be deleted. The previous line number 3 is now renumbered as line number 2.

<cntrl>Q The <cntrl>Q quits the editor mode. In response, the DMC-1500 will return a colon. After the Edit session is over, the user may list the entered program using the LS command. If no

number or label follows the LS command, the entire program will be listed. The user can start listing at a specific line or label. A range of program lines can also be displayed. For example;

Instruction Interpretation

LS List entire program LS 5 Begin listing at line 5 LS 5,9 List lines 5 through 9 LS #A,9 List line label #A through line 9

80 • Chapter 7 Application Programming DMC-1500

Program Format

A DMC-1500 program consists of DMC-1500 instructions combined to solve a machine control application. Action instructions, such as starting and stopping motion, are combined with Program Flow instructions to form the complete program. Program Flow instructions evaluate real-time conditions, such as elapsed time or motion complete, and alter program flow accordingly.

Each DMC-1500 instruction in a program must be separated by a delimiter. Valid delimiters are the semicolon (;) or carriage return. The semicolon is used to separate multiple instructions on a single program line where the maximum number of instructions on a line is limited by 38 characters. A carriage return enters the final command on a program line.

Using Labels in Programs

All DMC-1500 programs must begin with a label and end with an End (EN) statement. Labels start with the pound (#) sign followed by a maximum of seven characters. The first character must be a letter; after that, numbers are permitted. Spaces are not permitted.

The maximum number of labels allowed on the DMC-1500 series controller is 254.

Valid Labels

Label

#BEGIN #SQUARE #X1 #Begin1

Invalid Labels

Label Problem

#1Square Can not use number to begin a label #SQUAREPEG Can not use more than 7 characters in a label

Program Example:

Instruction Interpretation

#START Beginning of the Program PR 10000,20000 Specify relative distances on X and Y axes BG XY Begin Motion AM Wait for motion complete WT 2000 Wait 2 sec JP #START Jump to label START EN End of Program

The above program moves X and Y 10000 and 20000 units. After the motion is complete, the motors rest for 2 seconds. The cycle repeats indefinitely until the stop command is issued.

Special Labels

The DMC-1500 has some special labels, which are used to define input interrupt subroutines, limit switch subroutines, error handling subroutines, and command error subroutines. See section on

Automatic Subroutines for Monitoring Conditions” on page 95.

”

DMC-1500 Chapter 7 Application Programming • 81

#AUTO Label for auto program start #ININT Label for Input Interrupt subroutine #LIMSWI Label for Limit Switch subroutine #POSERR Label for excess Position Error subroutine #MCTIME Label for timeout on Motion Complete trip point #CMDERR Label for incorrect command subroutine #COMINT Label for communication interrupt subroutine

Commenting Programs

There are two methods for commenting programs. The first method uses the NO command and allows for comments to be embedded into Galil programs. The second method used the REM statement and requires the use of Galil software.

Using the Command, NO

The DMC-1500 provides a command, NO, for commenting programs. This command allows the user to include up to 77 characters on a single line after the NO command and can be used to include comments from the programmer as in the following example:

#PATH NO 2-D CIRCULAR PATH VMXY NO VECTOR MOTION ON X AND Y VS 10000 NO VECTOR SPEED IS 10000 VP -4000,0 NO BOTTOM LINE CR 1500,270,-180 NO HALF CIRCLE MOTION VP 0,3000 NO TOP LINE CR 1500,90,-180 NO HALF CIRCLE MOTION VE NO END VECTOR SEQUENCE BGS NO BEGIN SEQUENCE MOTION EN NO END OF PROGRAM

Note: The NO command is an actual controller command. Therefore, inclusion of the NO commands will require process time by the controller.

Using REM Statements with the Galil Terminal Software.

If you are using Galil software to communicate with the DMC-1500 controller, you may also include REM statements. ‘REM’ statements begin with the word ‘REM’ and may be followed by any comments which are on the same line. The Galil terminal software will remove these statements when the program is downloaded to the controller. For example:

82 • Chapter 7 Application Programming DMC-1500

#PATH REM 2-D CIRCULAR PATH VMXY REM VECTOR MOTION ON X AND Y VS 10000 REM VECTOR SPEED IS 10000 VP -4000,0 REM BOTTOM LINE CR 1500,270,-180 REM HALF CIRCLE MOTION VP 0,3000 REM TOP LINE CR 1500,90,-180 REM HALF CIRCLE MOTION VE REM END VECTOR SEQUENCE BGS REM BEGIN SEQUENCE MOTION EN REM END OF PROGRAM

These REM statements will be removed when this program is downloaded to the controller.

Executing Programs & Multitasking

The DMC-1500 can run up to four independent programs simultaneously. These programs are called threads and are numbered 0 through 3, where 0 is the main one. Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion.

The main thread differs from the others in the following ways:

1. Only the main thread may use the input command, IN.

2. When input interrupts are implemented for limit switches, position errors or command

errors, the automatic subroutines, #LIMSWI, #POSERR, and #CMDERR are executed in thread 0. For more information, see section "

Conditions" on page To begin execution of the various programs, use the following instruction: XQ #A, n Where n indicates the thread number. If the XQ command is given with no parameters, the first

program in memory will be executed in thread 0. To halt the execution of any thread, use the instruction HX n where n is the thread number.

95.

Automatic Subroutines for Monitoring

Note that both the XQ and HX commands can be performed by an executing program.

DMC-1500 Chapter 7 Application Programming • 83

Multitasking Example: Producing Waveform on Output 1 Independent of a Move.

Instruction Interpretation

#TASK1 Task1 label AT0 Initialize reference time CB1 Clear Output 1 #LOOP1 Loop1 label AT 10 Wait 10 msec from reference time SB1 Set Output 1 AT -40 Wait 40 msec from reference time, then initialize reference CB1 Clear Output 1 JP #LOOP1 Repeat Loop1 #TASK2 Task2 label XQ #TASK1,1 Execute Task1 #LOOP2 Loop2 label PR 1000 Define relative distance BGX Begin motion AMX After motion done WT 10 Wait 10 msec JP #LOOP2,@IN[2]=1 Repeat motion unless Input 2 is low HX Halt all tasks

The program above is executed with the instruction XQ #TASK2,0 which designates TASK2 as the main thread (i.e. Thread 0). #TASK1 is executed within TASK2.

Debugging Programs

The DMC-1500 provides commands and operands which are useful in debugging application programs. These commands include interrogation commands to monitor program execution, determine the state of the controller and the contents of the controllers program, array, and variable space. Operands also contain important status information which can help to debug a program.

Trace Commands

The trace command causes the controller to send each line in a program to the host computer immediately prior to execution. Tracing is enabled with the command, TR1. TR0 turns the trace function off. Note: When the trace function is enabled, the line numbers as well as the command line will be displayed as each command line is executed.

Data which is output from the controller is stored in an output FIFO buffer. The output FIFO buffer can store up to 512 characters of information. In normal operation, the controller places output into the FIFO buffer. The software on the host computer monitors this buffer and reads information as needed. When the trace mode is enabled, the controller will send information to the FIFO buffer at a very high rate. In general, the FIFO will become full since the software is unable to read the information fast enough. When the FIFO becomes full, program execution will be delayed until it is cleared. If the user wants to avoid this delay, the command CW,1 can be given. This command causes the controller to throw away the data which can not be placed into the FIFO. In this case, the controller does not delay program execution.

84 • Chapter 7 Application Programming DMC-1500

Error Code Command

When there is a program error, the DMC-1500 halts the program execution at the point where the error occurs. To display the last line number of program execution, issue the command, MG _ED.

The user can obtain information about the type of error condition that occurred by using the command, TC1. This command reports back a number and a text message which describes the error condition. The command, TC0 or TC, will return the error code without the text message. For more information about the command, TC, see the Command Reference.

Stop Code Command

The status of motion for each axis can be determined by using the stop code command, SC. This can be useful when motion on an axis has stopped unexpectedly. The command SC will return a number representing the motion status. See the command reference for further information. The command SC1 will return the number and the textual explanation of the motion status.

RAM Memory Interrogation Commands

For debugging the status of the program memory, array memory, or variable memory, the DMC-1500 has several useful commands. The command, DM ?, will return the number of array elements currently available. The command, DA ?, will return the number of arrays which can be currently defined. For example, a standard DMC-1500 controller will have a maximum of 8000 array elements in up to 30 arrays. If an array of 100 elements is defined, the command DM ? will return the value 7900 and the command DA ? will return 29.

To list the contents of the variable space, use the interrogation command LV (List Variables). To list the contents of array space, use the interrogation command, LA (List Arrays). To list the contents of the Program space, use the interrogation command, LS (List). To list the application program labels only, use the interrogation command, LL (List Labels).

Operands

In general, all operands provide information which may be useful in debugging an application program. Below is a list of operands which are particularly valuable for program debugging. To display the value of an operand, the message command may be used. For example, since the operand, _ED contains the last line of program execution, the command MG _ED will display this line number.

_ED contains the last line of program execution. Useful to determine where program stopped. _DL contains the number of available labels. _UL contains the number of available variables. _DA contains the number of available arrays. _DM contains the number of available array elements. _AB contains the state of the Abort Input _FLx contains the state of the forward limit switch for the 'x' axis _RLx contains the state of the reverse limit switch for the 'x' axis

Debugging Example:

The following program has an error. It attempts to specify a relative movement while the X-axis is already in motion. When the program is executed, the controller stops at line 003. The user can then query the controller using the command, TC1. The controller responds with the corresponding explanation:

DMC-1500 Chapter 7 Application Programming • 85

:ED Edit Mode 000 #A Program Label 001 PR1000 Position Relative 1000 002 BGX Begin 003 PR5000 Position Relative 5000 004 EN End <cntrl> Q Quit Edit Mode :XQ #A Execute #A ?003 PR5000 Error on Line 3 :TC1 Tell Error Code ?7 Command not valid

while running. :ED 3 Edit Line 3 003 AMX;PR5000;BGX Add After Motion Done <cntrl> Q Quit Edit Mode :XQ #A Execute #A

Debugging Programs

Command not valid while running

Commands

The DMC-1500 provides trace and error code commands which are used in debugging programs. The trace command causes the controller to send each line in a program to the host computer immediately prior to execution. Tracing is enabled with the command, TR1. TR0 turns the trace function off. Note: When the trace function is enabled, the line numbers as well as the command line will be displayed as each command line is executed.

When there is a program error, the DMC-1500 halts the program execution at the point where the error occurs. The line number is then displayed.

The DMC-1500 provides the capability to check the available program memory and array memory. The command, DM ?, will return the number of array elements currently available. The command, DA ?, will return the number of arrays currently available. For example, a standard DMC-1510 will have a maximum of 8000 array elements in up to 30 arrays. If an array of 100 elements is defined, the command DM ? will return the value 1500 and the command DA ? will return 13.

Operands

The operand _ED will return the value of the last line executed and can be used to determine where an error occurred. For example, the command MG _ED will display the line number in the program that failed.

The operand _DL returns the number of available labels. The operand _UL returns the number of available variables. The operand _DA returns the number of available arrays.

86 • Chapter 7 Application Programming DMC-1500

The operand _DM returns the number of available array elements.

Debugging Example:

Instruction Interpretation

while running. :ED 3 Edit Line 3 003 AMX;PR5000;BGX Add After Motion Done <cntrl> Q Quit Edit Mode :XQ #A Execute #A

Command not valid while running

Program Flow Commands

The DMC-1500 provides instructions to control program flow. The DMC-1500 program sequencer normally executes program instructions sequentially. The program flow can be altered with the use of event triggers, trippoints, and conditional jump statements.

Event Triggers & Trippoints

To function independently from the host computer, the DMC-1500 can be programmed to make decisions based on the occurrence of an event. Such events include waiting for motion to be complete, waiting for a specified amount of time to elapse, or waiting for an input to change logic levels.

The DMC-1500 provides several event triggers that cause the program sequencer to halt until the specified event occurs. Normally, a program is automatically executed sequentially one line at a time. When an event trigger instruction is decoded, however, the actual program sequence is halted. The program sequence does not continue until the event trigger is "tripped". Fo r example, the motion complete trigger can be used to separate two move sequences in a program. The commands for the second move sequence will not be executed until the motion is complete on the first motion sequence. In this way, the DMC-1500 can make decisions based on its own status or external events without intervention from a host computer.

DMC-1500 Chapter 7 Application Programming • 87

DMC-1500 Event Triggers

Command Function

AM X Y Z W or S (A B C D E F G H)

AD X or Y or Z or W (A or B or C or D or E or F or G or H)

AR X or Y or Z or W (A or B or C or D or E or F or G or H)

AP X or Y or Z or W (A or B or C or D or E or F or G or H) MF X or Y or Z or W (A or B or C or D or E or F or G or H)

MR X or Y or Z or W (A or B or C or D or E or F or G or H)

MC X or Y or Z or W (A or B or C or D or E or F or G or H)

AI +/- n Halts program execution until after specified input is at

AS X Y Z W S (A B C D E F G H) AT +/-n Halts program execution until n msec from reference time.

AV n Halts program execution until specified distance along a

WT n Halts program execution until specified time in msec has

Halts program execution until motion is complete on the specified axes or motion sequence(s). AM with no parameter tests for motion complete on all axes. This command is useful for separating motion sequences in a program.

Halts program execution until position command has reached the specified relative distance from the start of the move. Only one axis may be specified at a time.

Halts program execution until after specified distance from the last AR or AD command has elapsed. Only one axis may be specified at a time.

Halts program execution until after absolute position occurs. Only one axis may be specified at a time.

Halt program execution until after forward motion reached absolute position. Only one axis may be specified. If position is already past the point, then MF will trip immediately. Will function on geared axis.

Halt program execution until after reverse motion reached absolute position. Only one axis may be specified. If position is already past the point, then MR will trip immediately. Will function on geared axis.

Halt program execution until after the motion profile has been completed and the encoder has entered or passed the specified position. TW x,y,z,w sets timeout to declare an error if not in position. If timeout occurs, then the trippoint will clear and the stopcode will be set to 99. An application program will jump to label #MCTIME.

specified logic level. n specifies input line. Positive is high logic level, negative is low level. n=1 through 24.

Halts program execution until specified axis has reached its slew speed.

AT 0 sets reference. AT n waits n msec from reference. AT n waits n msec from reference and sets new reference after elapsed time.

coordinated path has occurred.

elapsed.

Event Trigger Examples:

Event Trigger - Multiple Move Sequence

The AM trippoint is used to separate the two PR moves. If AM is not used, the controller returns a ? for the second PR command because a new PR cannot be given until motion is complete.

88 • Chapter 7 Application Programming DMC-1500

Galil DMC-1510, DMC-1540, DMC-1520, DMC-1550, DMC-1570 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Using This Manual

Contents

Chapter 1 Overview

Introduction

Overview of Motor Types

Standard Servo Motors with +/- 10 Volt Command Signal

Stepper Motor with Step and Direction Signals

DMC-1500 Functional Elements

Microcomputer Section

Motor Interface

Communication

General I/O

System Elements

Motor

Amplifier (Driver)

Encoder or Position Sensor

Watch Dog Timer

Chapter 2 Getting Started

Elements You Need

Installing the DMC-1500

Step 1. Determine Overall Motor Configuration

Standard Servo Motor Operation:

Stepper Motor Operation:

Step 2. Install Jumpers on the DMC-1500

Step 3. Configure DIP switches on the DMC-1500

Step 4. Connect AC Power to the Controller

Step 5. Install Communications Software

Using the COMMdisk Vol1 for Dos:

Using the COMMdisk Vol2 for Windows (16 bit and 32 bit versions):

Step 6. Establish Communications with Galil Software

Dos Users:

Windows Users:

Sending Test Commands to the Terminal:

Step 7. Connect Amplifiers and Encoders.

Step 8a. Connect Standard Servo Motors

Step 8b. Connect Step Motors

Step 9. Tune the Servo System

Design Examples

Example 1 - System Set-up

Example 2 - Profiled Move

Example 3 - Multiple Axes

Example 4 - Independent Moves

Example 5 - Position Interrogation

Example 6 - Absolute Position

Example 7 - Velocity Control

Example 8 - Operation Under Torque Limit

Example 9 - Interrogation

Example 10 - Operation in the Buffer Mode

Example 11 - Motion Programs

Example 12 - Motion Programs with Loops

Example 13 - Motion Programs with Trippoints

Example 14 - Control Variables

Example 15 - Linear Interpolation

Example 16 - Circular Interpolation

Chapter 3 Connecting Hardware

Overview

Using Opto-isolated Inputs

Limit Switch Input

Home Switch Input

Abort Input

Uncommitted Digital Inputs

Wiring the Optoisolated Inputs

Using an Isolated Power Supply

Bypassing the Opto-Isolation:

Changing Optoisolated Inputs From Active Low to Active High

Amplifier Interface

TTL Inputs

Analog Inputs

TTL Outputs

Offset Adjustment

Chapter 4 Communication

Introduction

RS232 Ports

Configuration

Baud Rate Selection

Daisy Chain Example: