ADLINK Technology PCI-8254 User manual

Advance Technologies; Automate the World.
Version: 2.00
Updated: August 13, 2014
P/N: 50-15085-1000
PCI-8254 / PCI-8258
DSP-Based 4/8
Advanced Motion Control Card
User manual

ii
Revision History
Revision Date Description
2.00 2014-08-13 First release

Preface iii
PCI-8254 / PCI-8258
Preface
Copyright 2014 ADLINK Technology, Inc.
This document contains proprietary information protected by
copyright. All rights are reserved. No part of this manual may be
reproduced by any mechanical, electronic, or other means in any
form without prior written permission of the manufacturer.
Disclaimer
The information in this document is subject to change without prior
notice in order to improve reliability, design, and function and does
not represent a commitment on the part of the manufacturer.
In no event will the manufacturer be liable for direct, indirect,
special, incidental, or consequential damages arising out of the
use or inability to use the product or documentation, even if
advised of the possibility of such damages.
Environmental responsibility
ADLINK is committed to fulfill its social responsibility to global
environmental preservation through compliance with the
European Union's Restriction of Hazardous Substances (RoHS)
directive and Waste Electrical and Electronic Equipment (WEEE)
directive. Environmental protection is a top priority for ADLINK.We
have enforced measures to ensure that our products,
manufacturing processes, components, and raw materials have as
little impact on the environment as possible. When products are at
their end of life, our customers are encouraged to dispose of them
in accordance with the product disposal and/or recovery programs
prescribed by their nation or company.
Trademark
Product names mentioned herein are used for identification
purposes only and may be trademarks and/or registered
trademarks of their respective companies.

iv Preface
Conventions
Take note of the following conventions used throughout this
reference to make sure that users perform certain tasks and
instructions properly.
NOTE
NOTE
Additional information, aids, and tips that help users perform
tasks.
CAUTION
Information to prevent minor physical injury, component
damage, data loss, and/or program corruption when trying to
complete a task.
WARNING
Information to prevent serious physical injury, component
damage, data loss, and/or program corruption when trying to
complete a specific task.

Table of Contents v
PCI-8254 / PCI-8258
Table of Contents
Revision History...................................................................... ii
Preface .................................................................................... iii
List of Figures ........................................................................ ix
List of Tables........................................................................ xiii
1 Introduction ........................................................................ 1
1.1 Product Specifications ......................................................... 4
1.2 Software Support ................................................................. 8
Software Support Library ................................................ 8
MotionCreatorPro 2 ........................................................ 8
1.3 Terminal Board .................................................................... 8
2 Getting Start with The Installation.................................. 11
2.1 Package Contents ............................................................. 11
2.2 PCI-8254/PCI-8258 Exterior Profile Diagram .................... 12
2.3 Hardware Installation ......................................................... 14
Hardware Configuration ................................................ 14
Installation Procedures ................................................. 14
Troubleshooting ............................................................ 15
2.4 Software Installation Procedure......................................... 16
2.5 Definitions to Key Connector Signal .................................. 18
PCI-8254:
Connector ..................................................................... 18
PCI-8258: P1-A/B Connector ........................................ 20
PCI-8254/58:
P2 Connector ................................................................ 23
2.6 DIP Switch ......................................................................... 24
S1: Analog Output Mode Settings ................................ 24
SW2: Card ID Switch .................................................... 25

vi Table of Contents
2.7 IDE 44p – DSUB 37p Bus.................................................. 26
2.8 Exclusive Board - DIN-825-GP4 ........................................ 27
Definitions to Connector ............................................... 28
Connector: For Connecting to
PCI-8254/PCI-8258/AMP-204C/AMP-208C ................. 30
S1, S2: EDO/ALM_RST Selection Switch .................... 39
3 Signal Connection ............................................................ 41
3.1 Analog Control Command Signal....................................... 42
3.1.1 Single-ended Type Signal: AOUT+ .......................... 42
3.1.2 Single-ended Type Signal: AOUT+, AOUT- ............. 42
3.2 Pulse Command ................................................................ 44
3.3 Encoder Input, EA & EB & EZ............................................ 47
3.4 Emergency Stop Input ....................................................... 49
3.5 PEL/MEL Input................................................................... 50
3.6 ORG Input.......................................................................... 52
3.7 INP / ZSP Input .................................................................. 53
3.8 ALM Input .......................................................................... 54
3.9 SVON Output ..................................................................... 55
3.10 Analog Input Signals .......................................................... 56
3.11 Compare & Trigger Output................................................. 57
3.12 Digital Output/Input ............................................................ 59
4 Motion Control Theory ..................................................... 65
4.1 Motion Control Mode and Interface Overview.................... 66
4.1.1 Motion Control Interface ........................................... 66
4.1.2 Control Cycle ............................................................ 73
4.2 Closed-loop Control ........................................................... 75
4.2.1 Close-loop Control Overview .................................... 75
4.2.2 Auto Servo Tuning .................................................... 80
4.2.3 Manual Servo Tuning................................................ 84
4.2.4 Filter.......................................................................... 85
4.2.5 Bode Plot .................................................................. 93

Table of Contents vii
PCI-8254 / PCI-8258
4.3 Motion Control Operations................................................. 98
4.3.1 Coordinated System ................................................. 98
4.3.2 Unit Factor ................................................................ 99
4.3.3 Acc/Deceleration Profile ......................................... 102
4.4 Home Move ..................................................................... 108
4.4.1 OGR Signal Homing - Home Mode = 0 .................. 111
4.4.2 EL Signal Homing - Home Mode 1 ......................... 118
4.4.3 Single EZ Signal Homing........................................ 121
4.5 Velocity Move .................................................................. 124
4.6 Jog Move ......................................................................... 127
4.7 Point-to-Point Move ......................................................... 131
4.7.1 Point-to-Point Move ................................................ 131
4.7.2 Synchronous Start .................................................. 132
4.7.3 On The Fly Change ................................................ 133
4.7.4 Continuous PTP Move............................................ 133
4.8 Interpolation ..................................................................... 136
4.8.1 Linear Interpolation................................................. 136
4.8.2 Arc Interpolation ..................................................... 138
4.8.3 Continuous Interpolation......................................... 146
4.9 Motion Status Monitoring ................................................. 152
4.9.1 Motion Status.......................................................... 153
4.10 Application Functions....................................................... 162
4.10.1 Electronic Gearing .................................................. 162
4.10.2 High Speed Position Compare Trigger................... 164
4.10.3 PWM Control (Laser Control) (VAO Table Control)170
4.10.4 Motion Control and I/O Sampling Function............. 178
4.10.5 Simultaneous Move ................................................ 184
4.10.6 Point Table Movement............................................ 187
4.11 Safety Protection ............................................................. 192
4.11.1 Hardware Protection............................................... 192
4.11.2 Software Protection ................................................ 195
4.12 Host Interrupt ................................................................... 199

viii Table of Contents
Important Safety Instructions............................................. 209
Getting Service .................................................................... 211

List of Figures ix
PCI-8254 / PCI-8258
List of Figures
Figure 1-1: PCI-8254/58 system block diagram............................ 2
Figure 1-2: System installation flow chart ..................................... 3
Figure 2-1: Exterior of your PCI-8254 ......................................... 12
Figure 2-2: Exterior of your PCI-8258 ......................................... 13
Figure 2-3: Exterior of DIN-825-GP4 .......................................... 27
Figure 2-4: Exterior of DIN-825-GP4 .......................................... 28
Figure 3-1: Connection example of differential analog output signal
43
Figure 3-2: Line Driver type pulse control command signal connec-
tion example45
Figure 3-3: Open-Collector type pulse control command signal con-
nection example46
Figure 3-4: Line driver type encoder input signal connection example
48
Figure 3-5: Emergency stop signal connection example ............ 49
Figure 3-6: Mechanical limit switch signal connection example.. 51
Figure 3-7: Original position switch signal connection example . 52
Figure 3-8: Place / zero speed detection signal connection example
53
Figure 3-9: Servo alarm signal connection example................... 54
Figure 3-10: Servo-on signal connection example........................ 55
Figure 3-11: Analog input signal connection example .................. 56
Figure 3-12: Line Driver type compare trigger signal connection exam-
ple57
Figure 3-13: Open-Collector type compare trigger signal connection
example58
Figure 3-14: General purpose digital I/O signal connection example
60
Figure 3-15: General purpose digital I/O signal connection example
63
Figure 4-1: Format of pulse signal .............................................. 67
Figure 4-2: Illustration of analog command output...................... 68
Figure 4-3: Control cycle............................................................. 74
Figure 4-4: PCI-8254/PCI-8258 close loop control structure diagram
78
Figure 4-5: Gain and Gain shiftrelationship diagram .................. 78
Figure 4-6: The auto fine tuning setup page in MCP2 ................ 83
Figure 4-7: Structure of PCI-8254/8 biquad filters in serial connection

xListofFigures
86
Figure 4-8: Ideal low pass filter ................................................... 87
Figure 4-9: Simulation results of low pass filter with 1000Hz cutoff
frequency88
Figure 4-10: MCP2 low pass filter setup page .............................. 89
Figure 4-11: MCP2 notch filter setup page ................................... 89
Figure 4-12: An ideal notch filter (a) 50 Hz ................................... 90
Figure 4-13: Simulation results of notch filter with 100Hz cutoff fre-
quency92
Figure 4-14: MCP2 low pass filter setup page .............................. 92
Figure 4-15: MCP2 notch filter setup page ................................... 92
Figure 4-16: Controller coordinates system block......................... 98
Figure 4-17: Relation of trapezoidal speed profile's speed/accelera-
tion/jerk VS time102
Figure 4-18: Maximum speed by auto-planning.......................... 103
Figure 4-19: S-curve's velocity, acceleration, and jerk versus time104
Figure 4-20: Maximum speed by auto-velocity ........................... 106
Figure 4-21: Home mode 0 (Case: ORG) .................................. 112
Figure 4-22: Home mode 0 (Case: ORG) .................................. 114
Figure 4-23: Home mode 0 (Case: ORG+EZ) ............................ 115
Figure 4-24: Home mode 0 adverse (Case: ORG+EZ).............. 116
Figure 4-25: Home mode 0 decelerate to stop (Case: ORG)..... 117
Figure 4-26: Home mode 1 (Case: EL) ...................................... 118
Figure 4-27: Home mode 1 (Case: EL+EZ) ............................... 120
Figure 4-28: Home mode 2 (Case: EZ)...................................... 122
Figure 4-29: Home mode 2 adverse (Case: EZ) ........................ 123
Figure 4-30: Relation between V-T chart of JOG movement and
JOG-ON signal127
Figure 4-31: Jog step mode ........................................................ 128
Figure 4-32: T-curve V-T chart.................................................... 131
Figure 4-33: Dynamically change position and velocity .............. 133
Figure 4-34: Continuous three position V-T chart ....................... 134
Figure 4-35: Continuous three position V-T chart
(auto speed connection (1)134
Figure 4-36: Continuous three position V-T chart
(auto speed connection (2)134
Figure 4-37: Continuous three position V-T chart
(auto speed connection (3)135
Figure 4-38: Continuous three position V-T chart
(auto speed connection (4)135

List of Figures xi
PCI-8254 / PCI-8258
Figure 4-39: Two-dimension straight line interpolation ............... 137
Figure 4-40: Three-dimension arc interpolation (method 1)........ 139
Figure 4-41: Defining spatial normal vector ................................ 140
Figure 4-42: Determining arc direction in space ......................... 140
Figure 4-43: Three dimension arc interpolation (method 2)........ 141
Figure 4-44: Three dimension arc interpolation example............ 142
Figure 4-45: Three dimension spiral interpolation (method 1) .... 143
Figure 4-46: Three-dimension spiral interpolation (method 2) .... 144
Figure 4-47: Illustration on continuous interpolation (Buffer) move-
ment146
Figure 4-48: Velocity blending (method 1) .................................. 147
Figure 4-49: Velocity blending (method 2) .................................. 148
Figure 4-50: Velocity blending (method 3) .................................. 148
Figure 4-51: Velocity blending (method 4) .................................. 149
Figure 4-52: Velocity blending (method 5) .................................. 149
Figure 4-53: Velocity blending (method 6) .................................. 150
Figure 4-54: Velocity blending (method 7) .................................. 150
Figure 4-55: Continuous interpolation examples ........................ 151
Figure 4-56: Motion status monitoring process........................... 152
Figure 4-57: Relation of different motion signals VS motions ..... 155
Figure 4-58: Relation of motion done (MDN) signals VS motion 156
Figure 4-59: Relation of motion done (MDN), In-homing (HMV) signals
VS motion157
Figure 4-60: Relation of WAIT signals VS motion....................... 158
Figure 4-61: Relation of JOG and motion done(MDN) signals VS mo-
tion159
Figure 4-62: Relation of ASTP VS motion .................................. 159
Figure 4-63: Relation of blending (BLD) signal VS motion ......... 160
Figure 4-64: Relation between pre- and post distance event signals
and movement161
Figure 4-65: Adjust electronic gear's auto engagement speed... 163
Figure 4-66: Compare trigger block diagram .............................. 165
Figure 4-67: Linear compare trigger example............................. 167
Figure 4-68: Table compare trigger example.............................. 168
Figure 4-69: Table compare trigger block diagram ..................... 169
Figure 4-70: Signal sampling structure diagram ......................... 178
Figure 4-71: Interruption flow chart ............................................. 199

xii List of Figures

List of Tables xiii
PCI-8254 / PCI-8258
List of Tables
Table 1-1: Cross-reference table of exclusive cables for pulse servo
drive9
Table 1-2: Cross-reference table of exclusive cables for analog servo
drive9
Table 4-1: Encoder input format ..................................................... 69
Table 4-2: Encoder input format ..................................................... 70
Table 4-3: PCI-8254/8 Auto-Tuning setup ...................................... 83
Table 4-4: Board parameter table ................................................. 176
Table 4-5: Motion kernel signal table............................................ 179
Table 4-6: Closed circuit control signal table ................................ 180

xiv List of Tables

Introduction 1
PCI-8254 / PCI-8258
1 Introduction
The PCI-8254/PCI-8258, is a fully in-house developed DSP-based
advanced motion control card from ADLINK. It supports 4/8 axis
pulse type or Analog type signal commands, provides Open-loop
and closed-loop circuit control options, and supports
position/speed/torque commands for several different servo
drivers.
The PCI-8254/PCI-8258 exchanges data with operating system
through high speed PCI bus including motion control command,
feedback data, parameter, etc. Used with the ADLINK exclusive
Softmove kernel, it offers scores of move control functions
including T/S speed profile planning, point-to-point movement,
multi-dimension interpolation, and master/slave motion.
To enable absolute real time motion control, ADLINK's multi-tasks
download function helps users to program with AMC code
(ADLINK Motion Code), a programming language similar to C, for
downloading to PCI-8254/58 embedded processors for execution.
It supports up to eight different programs for concurrent download
and execution.
With up to 20MHz high speed encoder feedback support and 4/8
axes independent hardware PID control plus Feed-forward gain
design, it ensures precision control and reduce following errors in
tandem with high speed motion feedback. The programmable
servo update rate allows excellent control performance because
different PID parameter adjustments can be made for individual
applications.
The PCI-8254/58, see Figure 1 below for its system functions,
uses one digital signal processor (DSP) from Texas Instrument
(TI) as its main computing unit and integrates high speed large
volume Field Programmable Gate Array (FPGA) to provide 4/8
independent PID control, high speed encoder output unit, 2/4 high
speed position compare and trigger output, move & general
purposed I/O and logic control. It separates isolation circuit into
exclusive terminal board DIN-825-GP4 to prevent the burning out
of PCI-8254/58 from incorrect wiring. Thanks to full range of
flexing resistant wires from ADLINK, it connects with market
available popular servo drives easily.

2Introduction
Figure 1-1: PCI-8254/58 system block diagram
Graphical motion control interface – MotionCreatorPro 2 is a
Windows-based motion control software development tool for
motion control and I/O status monitoring. You may employ this
development tool for axis, PID, and feed-forward gain setup as
well as analysis on motion variation curve and data. Embedded
Setup Wizard can guide you throughout the process of hardware
installation and wiring, close circuit PID parameter adjustments
and single axis operation for reduced development time and costs.
The Windows Programming Libraries supports Windows coding
environment including: Visual Studio C++ 6.0, Microsoft .NET
framework based VB.NET and C++, and Borland's C++ Builder.
There are sample programs available in the installation folders.
FPGA
PCI Bus
DPRAM
DSP
Flash ROM
SDRAM
PCI
Bridge
4/8 PID Controllers
Motion
I/Os GPIO
Misc.
functions
CMP & TRG
A/D
circuitry
D/A
circuitry
Encoder
Input
TRG
Output
TTL I/Os
PEL
MEL
ORG
DIO
EA
EB
EZ
PCI Bus
SCSI 100P
DIN-825-GP4
Isolation
DSUB 37P

Introduction 3
PCI-8254 / PCI-8258
The flow chart below will guide you in using this manual as well as
help you to locate any required information effectively.
Figure 1-2: System installation flow chart
Hardware installation
Wiring and jumper setup
Set up card and adjust axis parameters
with MotionCreatorPro 2
Is the system running
successfully?
End
Control axis with MotionCreatorPro 2
Develop application with APS library
No
APS and ADCNC
library
Chapter IV
Chapter II and III
MotionCreatorPro 2
User's Manual
Chapter II and III
MotionCreatorPro 2
User's Manual
Yes

4Introduction
1.1 Product Specifications
Item Description
System
Bus information PCI Rev. 2.2, 33MHz
PCI bus width 32-bit
PCI bus voltage 3.3V, 5V
PCI bus IRQ settings Assigned by PCI controller
DSP
Model TI 375MHz floating DSP
Memory
(for program and data)
DDR2 SDRAM: 64Mx16bit
Flash ROM: 16M-bit
Board-to-board
interface Connector
1x SCSI-II 100P for PCI-8254
1x Dual SCSI VHDCI 100P
for PCI-8258
Closed circuit
control
Number of axes supported 4/8 axes for PCI-8254/8
Analog command output
resolution ±10 volts, resolution: 16 bit
Analog command output
interface
Difference / single end
output
Maximum servo update
rate
50us-500us
(programmable)
PID (Kp, Ki and Kd) gain
range
0 to 32,767
Speed and acceleration
feed-forward (Aff, Vff) gain
range
0 to 32,767
Position / speed command
range 32 bit
Acceleration / deceleration
range 32 bit
Encoder input frequency 20 MHz @ 4x AB
Encoder input mode CW/CCW,
1x/2x/4x AB Phase
Encoder input interface ±12 volts, TTL compatible
Filter
Biquad filter & low-pass filter

Introduction 5
PCI-8254 / PCI-8258
I/O interface
Motion control relevant I/O Plus/Minus end limitsignal
Zero-position for each axis
Drive relevant I/O
Servo ON
In-position signal /
Zero-Speed detection
Alarm
Analog input
Max. input channel 4/8, single ended input
Input voltage range ±10 V
Sampling frequency 100 kHz
Resolution 12 bits, no missing codes
Accuracy ±1.5mV for ±10V input
Overload voltage ±15 V
Analog output
Max. output channel 4/8, difference/single
ended output
Output voltage range ±10V
Output current ±50mA (Typ.)
Resolution 16 bits, no missing codes
Accuracy ±1.2mV for ±10V output
Protection circuit Earth short circuit
protection
Settling Time 15us, full-scale step
General
purpose digital
I/O
General purpose I/O
20/24-CH input & 20/24-CH
TTL output (optical
isolation design for
DIN-825-GP4)
Motion control
function
Speed Profile Planning Trapezoidal Curve and
S-Curve
Trajectory Planing Jogging
Point-to-point movement
Linear interpolation:
2-6 axes
Online position/speed
change
3 axes arc interpolation
3 axes spiral interpolation
3 axes helix interpolation
Home Return
User customizing (see
zero-position, limit switch,
EZ signals for reference)
Item Description

6Introduction
Point table
Each axis supports 50
points buffer memory
(BUFs)
Supports
point-to-point/line/arc and
spiral interpolation
Supports dwell function
Supports pause/resume
function
Supports DO function
Motion Monitoring
Motion control relevant I/O
monitoring
Motion monitoring
Synchronous move 4/8 axes corresponding
PCI-8254/PCI-8258
Industrial
application
Master-client axes control Up to 4/8 axis (including
ganty control)
Data sampling
Motion speed profile/
motion status/motion
control relevant I/O
System error diagnostics Watchdog timer
Interrupt
Motion status event/error
alarm/in position/
emergency stop
Planning in accordance
with the manual
Position
comparison
& trigger output
Pulse output interface Difference output
Trigger channel 2/4 corresponding
PCI-8254/PCI-8258
Pulse logic Programmable active-high
or active-low
Trigger output frequency
Linear compare trigger:
1MHz
FIFO compare trigger:
255K ~ 1MHz
Minimum pulse width 100ns programmable
Position comparison mode FIFO and linear
comparison
FIFO capacity 255 points
(channel independent)
Item Description