ADLINK Technology PCI-8102 User manual

Advance Technologies; Automate the World.
Manual Rev. 2.01
Revision Date: February 26, 2009
Part No: 50-11136-1010
PCI-8102
Advanced 2-Axis Servo/Stepper
Motion Control Card
User’s Manual

Copyright 2009 ADLINK TECHNOLOGY INC.
All Rights Reserved.
The information in this document is subject to change without prior
notice in order to improve reliability, design, and function and does
not represent a commitment on the part of the manufacturer.
In no event will the manufacturer be liable for direct, indirect, spe-
cial, incidental, or consequential damages arising out of the use or
inability to use the product or documentation, even if advised of
the possibility of such damages.
This document contains proprietary information protected by copy-
right. All rights are reserved. No part of this manual may be repro-
duced by any mechanical, electronic, or other means in any form
without prior written permission of the manufacturer.
Trademarks
NuDAQ, NuIPC, DAQBench are registered trademarks of ADLINK
TECHNOLOGY INC.
Product names mentioned herein are used for identification pur-
poses only and may be trademarks and/or registered trademarks
of their respective companies.

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Table of Contents i
Table of Contents
Table of Contents..................................................................... i
List of Figures......................................................................... v
1 Introduction ........................................................................ 1
1.1 Features............................................................................... 4
1.2 Specifications....................................................................... 5
1.3 Supported Software............................................................. 6
Programming Library ......................................................6
MotionCreatorPro ...........................................................6
1.4 Available Terminal Board..................................................... 7
2 Installation .......................................................................... 9
2.1 Package Contents ............................................................... 9
2.2 PCI-8102 Outline Drawing................................................. 10
2.3 PCI-8102 Hardware Installation......................................... 11
Hardware Configuration ................................................11
PCI Slot Selection .........................................................11
Installation Procedures .................................................11
Troubleshooting ............................................................12
2.4 Software Driver Installation................................................ 12
2.5 P1 Pin Assignments: Main connector................................ 13
P2 Pin Assignment: 16 Digital Inputs /
16 Digital Outputs................................................14
2.6 K1/K2 Pin Assignments: Simultaneous Start/Stop ............ 16
2.7 Jumper Setting for Pulse Output........................................ 16
2.8 Switch Setting for card index............................................. 17
3 Signal Connections.......................................................... 19
3.1 Pulse Output Signals OUT and DIR .................................. 20
3.2 Encoder Feedback Signals EA, EB and EZ....................... 22
3.3 Origin Signal ORG............................................................. 25
3.4 End-Limit Signals PEL and MEL........................................ 26
3.5 In-Position Signal INP........................................................ 27
3.6 Alarm Signal ALM.............................................................. 28
3.7 Deviation Counter Clear Signal ERC................................. 29
3.8 General-Purpose Signal SVON......................................... 30
3.9 General-Purpose Signal RDY............................................ 31

ii Table of Contents
3.10 Position Compare Output pin: CMP................................... 32
3.11 Multi-Functional Input Pin: LTC/SD/PCS/CLR................... 33
3.12 Pulser Input Signals PA and PB ........................................ 34
3.13 Simultaneously Start/Stop Signals STA and STP.............. 35
3.14 General Purpose TTL Output............................................. 37
3.15 Additional 16 Digital Input / 16 Digital Output .................... 38
3.16 Termination Board ............................................................. 40
4 Operation Theory.............................................................. 41
4.1 Classifications of Motion Controller.................................... 41
Voltage Type Motion Control Interface .........................41
Pulse Type Motion Control Interface ............................42
Network Type Motion Control Interface ........................42
Software Real-time Motion Control Kernel ...................43
DSP Based Motion Control Kernel ...............................43
ASIC Based Motion Control Kernel ..............................43
Compare Table of All Motion Control Types .................44
PCI-8102’s Motion Controller Type ...............................44
4.2 Motion Control Modes........................................................ 45
Coordinate System .......................................................45
Absolute and Relative Position Move ...........................46
Trapezoidal Speed Profile ............................................47
S-Curve and Bell-Curve Speed Profile .........................48
Velocity Mode ...............................................................50
One Axis Position Mode ...............................................50
Two Axes Linear Interpolation Position Mode ..............51
Two Axes Circular Interpolation Mode ..........................52
Continuous Motion ........................................................53
Home Return Mode ......................................................56
Home Search Function .................................................62
Manual Pulser Function ................................................63
Simultaneous Start Function .........................................64
Speed Override Function ..............................................64
Position Override Function ...........................................65
4.3 Motor Driver Interface........................................................ 66
Pulse Command Output Interface ................................66
Pulse Feedback Input Interface ....................................68
In Position Signal ..........................................................70
Servo Alarm Signal .......................................................71
Error Clear Signal .........................................................71

Table of Contents iii
Servo ON/OFF Switch ..................................................72
Servo Ready Signal ......................................................72
Servo Alarm Reset Switch ............................................72
4.4 Mechanical Switch Interface.............................................. 73
Original or Home Signal ................................................73
End-Limit Switch Signal ................................................73
Slow Down Switch ........................................................73
Positioning Start switch .................................................74
Counter Clear switch ....................................................74
Counter Latch Switch ....................................................74
Emergency Stop Input ..................................................74
4.5 Counters ............................................................................ 75
Command Position Counter ..........................................75
Feedback Position Counter ..........................................75
Command and Feedback Error Counter .......................76
General Purpose Counter .............................................76
Target Position Recorder ..............................................76
4.6 Comparaters...................................................................... 77
Soft End-Limit Comparators .........................................77
Command and Feedback Error Counter Comparators .77
General Comparator .....................................................78
Trigger Comparator ......................................................78
4.7 Other Motion Functions ..................................................... 79
Backlash Compensation and Slip Corrections ..............79
Vibration Restriction Function .......................................79
Speed Profile Calculation Function ...............................80
4.8 Interrupt Control................................................................. 81
4.9 Multiple Card Operation..................................................... 84
5 MotionCreatorPro............................................................. 85
5.1 Execute MotionCreatorPro ................................................ 85
5.2 About MotionCreatorPro.................................................... 85
5.3 MotionCreatorPro Form Introduction ................................. 87
Main Menu ....................................................................87
Select Menu ..................................................................88
Card Information Menu .................................................89
Configuration Menu ......................................................90
Single Axis Operation Menu .........................................96
Two-Axis Operation Menu ..........................................103
2D_Motion Menu ........................................................107

iv Table of Contents
Help Menu ..................................................................113
6 Function Library.............................................................. 115
6.1 List of Functions............................................................... 116
6.2 C/C++ Programming Library............................................ 123
6.3 Initialization...................................................................... 124
6.4 Pulse Input/Output Configuration..................................... 127
6.5 Velocity mode motion....................................................... 130
6.6 Single Axis Position Mode ............................................... 133
6.7 Linear Interpolated Motion............................................... 137
6.8 Circular Interpolation Motion............................................ 140
6.9 Home Return Mode.......................................................... 143
6.10 Manual Pulser Motion...................................................... 146
6.11 Motion Status................................................................... 149
6.12 Motion Interface I/O ......................................................... 151
6.13 Interrupt Control............................................................... 158
6.14 Position Control and Counters......................................... 162
6.15 Position Compare and Latch............................................ 167
6.16 Continuous Motion........................................................... 171
6.17 Multiple Axes Simultaneous Operation............................ 173
6.18 General-Purposed DIO.................................................... 176
6.19 Soft Limit.......................................................................... 179
6.20 Backlash Compensation / Vibration Suppression............ 181
6.21 Speed Profile Calculation................................................. 183
6.22 Return Code..................................................................... 187
7 Connection Example ...................................................... 189
7.1 General Description of Wiring.......................................... 189
7.2 Wiring with DIN-68M-J3A................................................. 189
PIN Assignments: .......................................................191
Signal Connections of Interface Circuit .......................194
Mechanical Dimensions: .............................................197
Appendix.............................................................................. 199
8.1 Color code of Mitsubishi servo J3A cable
(MRJ3CN1 xM-OPEN)........................................... 199

List of Figures v
List of Figures
Figure 1-1: PCI-8102 Block Diagram........................................... 2
Figure 1-2: Flow Chart for Building an Application....................... 3
Figure 2-1: PCB Layout of the PCI-8102................................... 10

vi List of Figures

Introduction 1
1 Introduction
The PCI-8102 is an advanced 2-axis motion controller card with a
PCI interface. It can generate high frequency pulses (6.55MHz) to
drive stepper or servomotors. As a motion controller, it can provide
2-axis linear and circular interpolation and continuous interpolation
for continuous velocity. Also, changing position/speed on the fly is
available with a single axis operation.
Multiple PCI-8102 cards can be used in one system. Incremental
encoder interface on all four axes provide the ability to correct
positioning errors generated by inaccurate mechanical transmis-
sions. PCI-8102 features the postion compare and trigger output
function which users can put the comparing points with ADLINK
library and sending the triggering pulse to other device. In addi-
tion, a mechanical sensor interface, servo motor interface, and
general-purposed I/O signals are provided for easy system inte-
gration.
Figure 1-1 shows the functional block diagram of the PCI-8102
card. The motion control functions include trapezpoidal and S-
curve acceleration/deceleration, linear and circular interpolation
between two axes and continuous motion positioning, and 13
home return modes. All these functions and complex computa-
tions are performed internally by the ASIC, thus it can save CPU
loading.
The PCI-8102 also offers three user-friendly functions. The PCI-
8102 can let users assign the card index with the DIP switch set-
ting. The value is within 0 to 15. It is useful for machine makers to
recognize the card index if the whole control system is very huge.
The emergency input pin can let users wire the emergency botton
to trigger this board to stop sending pulse output once there is any
emgergency sitiuation happened. For security protection design,
users can set the 16-bit value into EEPROM. Users’ interface pro-
gram can uses this EEPROM to secure the software and hard-
ware in order to prevent piracy.

2Introduction
Figure 1-1: PCI-8102 Block Diagram
MotionCreatorPro is a Windows-based application development
software package included with the PCI-8102. MotionCreatorPro
is useful for debugging a motion control system during the design
phase of a project. An on-screen display lists all installed axes
information and I/O signal status of the PCI-8102.
Windows programming libraries are also provided for C++ com-
piler and Visual Basic. Sample programs are provided to illustrate
the operations of the functions.
Figure 1-2 illustrates a flow chart of the recommended process in
using this manual in developing an application. Refer to the
related chapters for details of each step.
P
C
I B
us
PLX905
2
ASIC
SCS
I
68
P1
STA/STP K1&
2
CPLD
ROM
Digital I/O Isolation
16 DI/O P2
VCC
DC/D
C
VDD +24V
CardID S1

Introduction 3
Figure 1-2: Flow Chart for Building an Application

4Introduction
1.1 Features
The following list summarizes the main features of the PCI-8102
motion control system.
X32-bit PCI bus Plug and Play
X2 axes of step and direction pulse output for controlling
stepping or servomotor
XMaximum output frequency of 6.55 MPPS
XPulse output options: OUT/DIR, CW/CCW
XProgrammable acceleration and deceleration time for all
modes
XTrapezoidal and S-curve velocity profiles for all modes
X2 axes linear / circular interpolation
XContinuous interpolation for contour following motion
XChange position and speed on the fly
X13 home return modes with auto searching
XHardware backlash compensator and vibration suppression
X2 software end-limits for each axis
X28-bit up/down counter for incremental encoder feedback
XHome switch, index signal (EZ), positive, and negative end
limit switches interface on all axes
X2-axis high speed position latch input
X2-axis position compare trigger output with 4k FIFO auto-
loading
XAll digital input and output signals are 2500Vrms isolated
XProgrammable interrupt sources
XSimultaneous start/stop motion on multiple axes
XManual pulser input interface
XCard index selection
XSecurity protection on EERPOM
XDedicated emergency input pin for wiring
XSoftware supports a maximum of up to 12 PCI-8102 cards
operation in one system
XCompact PCB design

Introduction 5
XIncludes MotionCreatorPro, a Microsoft Windows-based
application development software
XPCI-8102 libraries and utilities for Windows 2000/XP
1.2 Specifications
XApplicable Motors:
ZStepping motors
ZAC or DC servomotors with pulse train input servo driv-
ers
XPerformance:
ZNumber of controllable axes: 2
ZMaximum pulse output frequency: 6.55MPPS, linear,
trapezoidal, or S-Curve velocity profile drive
ZInternal reference clock: 19.66 MHz
Z28-bit up/down counter range: 0-268,435,455 or –
134,217,728 to +134,217,727
ZPosition pulse setting range (28-bit): -134,217,728 to
+134,217,728
ZPulse rate setting range (Pulse Ratio = 1: 65535):
0.1 PPS to 6553.5 PPS. (Multiplier = 0.1)
1 PPS to 65535 PPS. (Multiplier = 1)
100 PPS to 6553500 PPS. (Multiplier = 100)
XI/O Signales:
ZInput/Output signals for each axis
ZAll I/O signal are optically isolated with 2500Vrms isola-
tion voltage
ZCommand pulse output pins: OUT and DIR
ZIncremental encoder signals input pins: EA and EB
ZEncoder index signal input pin: EZ
ZMechanical limit/switch signal input pins: ±EL, SD/PCS,
and ORG
ZServomotor interface I/O pins: INP, ALM, and ERC
ZPosition latch input pin: LTC

6Introduction
ZPosition compare output pin: CMP
ZGeneral-purposed digital output pin: SVON
ZGeneral-purposed digital input pin: RDY
ZPulse signal input pin: PA and PB (with isolation)
ZSimultaneous Start/Stop signal: STA and STP
ZEmergency input signal: EMG
XGeneral-Purpose Output
Z20 digital inputs / 18 digital outputs
XGeneral Specifications
ZConnectors: 68-pin SCSI-type connector
ZOperating Temperature: 0°C - 50°C
ZStorage Temperature: -20°C - 80°C
ZHumidity: 5 - 85%, non-condensing
XPower Consumption
ZSlot power supply (input): +5V DC ±5%, 900mA max
ZExternal power supply (input): +24V DC ±5%, 500mA
max
ZExternal power supply (output): +5V DC ±5%, 500mA,
max
XPCI-8102 Dimension (PCB size): 120mm(L) X 100mm(W)
1.3 Supported Software
Programming Library
Windows 2000/XP DLLs are provided for the PCI-8102 users.
These function libraries are shipped with the board.
MotionCreatorPro
This Windows-based utility is used to setup cards, motors, and
systems. It can also aid in debugging hardware and software prob-
lems. It allows users to set I/O logic parameters to be loaded in
their own program. This product is also bundled with the card.
Refer to Chapter 5 for more details.

Introduction 7
1.4 Available Terminal Board
DIN-68S and DIN-68M-J3A are available for PCI-8102 wiring.
DIN-68S is general purposed pin-to-pin terminal board. Users can
use this to connect servos and steppers. DIN-68M-J3A is
designed for Mitsubishi servo J3A amplifer. Users can user this
board to connect Mitsubishi servo J3A and steppers.

8Introduction

Installation 9
2 Installation
This chapter describes how to install the PCI-8102 series. Please
follow these steps below:
XCheck what you have (section 2.1)
XCheck the PCB (section 2.2)
XInstall the hardware (section 2.3)
XInstall the software driver (section 2.4)
XUnderstanding the I/O signal connections (chapter 3) and
their operation (chapter 4)
XUnderstanding the connector pin assignments (the remain-
ing sections) and wiring the connections
2.1 Package Contents
In addition to this User’s Guide, the package also includes the fol-
lowing items:
XPCI-8102: advanced 2-Axis Servo / Stepper Motion Control
Card
XADLINK All-in-one Compact Disc
If any of these items are missing or damaged, contact the dealer
from whom you purchased the product. Save the shipping materi-
als and carton to ship or store the product in the future.

10 Installation
2.2 PCI-8102 Outline Drawing
Figure 2-1: PCB Layout of the PCI-8102
P1: Input / Output Signal Connector (68-pin)
P2: 16 Digital Input / Output Signals Connector
K1 / K2: Simultaneous Start / Stop Connector
SW1: DIP switch for card index selection (0-15)
J8-J11: Pulse output selection jumper
119.91
121.75
106.68
100.33
126.35