Aerotech UNIDEX 600 Series User manual

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THE UNIDEX600 SERIES
USER’S GUIDE
P/N: EDU157 (V1.4)
AEROTECH, Inc. •101 Zeta Drive •Pittsburgh, PA. 15238-2897 •USA
Phone [phone] •Fax [phone]
Product Service: [phone]; [phone] (Fax)
www.aerotechinc.com

If you should have any questions about the UNIDEX 600 or comments regarding the documentation, please refer to
Aerotech online at:
http://www.aerotechinc.com
For your convenience, a product registration form is available at our web site.
Our web site is continually updated with new product information, free downloadable software and special pricing on
selected products.
UNIDEX 600 and UNIDEX 650 are products of Aerotech, Inc.
Windows, Windows 95, and Windows NT are registered trademarks of Microsoft.
Windows, Windows NT, and Visual Basic are products of Microsoft Corporation.
Visual Basic is a registered trademark of Microsoft.
The Aerdebug User’s Manual Revision History:
Rev 1.0 October 14, 1996
The UNIDEX 600 User’s Guide (previously the AerDebug User’s Manual) Revision History:
Rev 1.1 May 5, 1997
Rev 1.2 September, 1997
Rev 1.3 July 10, 2000
Rev 1.4 December 5, 2000

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION AND OVERVIEW........................................... 1-1
1.1. Introduction........................................................................................ 1-1
1.2. Installation.......................................................................................... 1-1
1.3. Programming...................................................................................... 1-2
1.4. Architecture Overview........................................................................ 1-3
1.4.1. Axis Processor...................................................................... 1-4
1.4.1.1. The Motion Controller Execution Unit..................1-4
1.4.1.2. Library Servicer..................................................... 1-5
1.4.1.3. CNC Engine........................................................... 1-5
1.4.2. The PC ................................................................................. 1-5
1.4.2.1. The PC Interrupt .................................................... 1-5
1.5. Motion................................................................................................ 1-6
1.5.1. The Servo Loop.................................................................... 1-6
1.5.2. Generating Motion ............................................................... 1-6
1.5.3. Monitoring Motion............................................................... 1-7
1.5.4. Multi-Axis Motion ............................................................... 1-7
1.5.5. Motion Resolution................................................................ 1-7
1.6. Faults.................................................................................................. 1-8
1.6.1. Axis Faults ........................................................................... 1-8
1.6.2. Task Faults........................................................................... 1-9
1.7. Option Ordering Information............................................................ 1-10
CHAPTER 2: GETTING STARTED...................................................................... 2-1
2.1. Introduction........................................................................................ 2-1
2.1.1. Minimum Requirements....................................................... 2-2
2.1.2. Fundamentals ....................................................................... 2-3
2.1.2.1. Parameters.............................................................. 2-3
2.1.2.2. Bit Masks............................................................... 2-4
2.1.2.3. Faults...................................................................... 2-4
2.2. Software Installation........................................................................... 2-5
2.2.1. UTIL600-NT Installation..................................................... 2-5
2.2.2. MMI Software Installation...................................................2-5
2.2.3. WinNT/Win95 Registration................................................. 2-5
2.2.4. Software Installation Testing................................................ 2-6
2.3. Axis Configuration ............................................................................. 2-7
2.3.1. Servo Loop Modes...............................................................2-7
2.3.2. Configuring Closed-Loop (Torque or Velocity)................... 2-8
2.3.2.1. Motor Types........................................................... 2-8
2.3.2.2. Feedback Devices .................................................. 2-8
2.3.2.3. Digital-to-Analog Conversion (Output to the
Amplifier) .............................................................. 2-9
2.3.3. Configuring a Spindle (Open-Loop Velocity Mode)............ 2-9
2.4. Motor Units (Resolution and Direction).......................................... 2-10
2.4.1. Linear vs. Rotary type ........................................................ 2-10
2.4.2. Motor Resolution ............................................................... 2-10
2.4.3. Motor Direction.................................................................. 2-10
2.5. Drive Signals.................................................................................... 2-11
2.6. Axis Faults........................................................................................ 2-11

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iv Aerotech, Inc. Version 1.4
2.6.1. FAULT...............................................................................2-12
2.6.1.1. Axis Faults and Programming..............................2-12
2.6.2. Fault Masks........................................................................2-14
2.6.2.1. FAULTMASK.....................................................2-15
2.6.2.2. DISABLEMASK .................................................2-15
2.6.2.3. HALTMASK .......................................................2-15
2.6.2.4. AUXMASK .........................................................2-15
2.6.2.5. ABORTMASK.....................................................2-16
2.6.2.6. INTMASK ...........................................................2-16
2.6.2.7. BRAKEMASK.....................................................2-16
2.6.2.8. Example ...............................................................2-16
2.7. Task Faults........................................................................................2-18
2.8. Emergency Stop (ESTOP)................................................................2-18
2.9. Axis Testing......................................................................................2-19
2.9.1. Axis Limits.........................................................................2-19
2.9.2. Axis Feedback....................................................................2-19
2.9.3. Axis Loop Closure..............................................................2-19
2.10. Accelerations....................................................................................2-20
2.11. Axis Tuning......................................................................................2-20
2.12. Jogging .............................................................................................2-20
2.13. Homing.............................................................................................2-21
2.14. Programmed Moves..........................................................................2-22
2.15. Digital I/O.........................................................................................2-22
2.15.1. Associating Virtual I/O with Physical I/O..........................2-22
2.16. Other Manuals ..................................................................................2-24
2.16.1. Hardware Manuals (UNIDEX 600)....................................2-24
2.16.2. Programming Manuals .......................................................2-24
2.16.3. MMI Interface....................................................................2-24
CHAPTER 3: PROGRAMMING............................................................................3-1
3.1. Introduction ........................................................................................3-1
3.1.1. Combination Programming ..................................................3-2
3.1.2. Multi-Tasking.......................................................................3-2
3.2. The Library Programming Interface...................................................3-3
3.2.1. Basic Elements of a Library Interface Program....................3-4
3.3. CNC G-code Programming.................................................................3-5
3.3.1. CNC Tasks and Programs ....................................................3-6
3.3.2. CNC Program Execution......................................................3-7
3.3.3. Motion from a CNC Program...............................................3-8
CHAPTER 4: AERDEBUG......................................................................................4-1
4.1. Introduction ........................................................................................4-1
4.2. The Screen..........................................................................................4-2
4.3. The Prompt.........................................................................................4-3
4.3.1. Entering Commands.............................................................4-3
4.3.2. Special Keys.........................................................................4-4
4.3.3. Help......................................................................................4-5
4.4. Axis and Faultmask Configurations....................................................4-6
4.4.1. Configuring an Axis .............................................................4-7
4.4.1.1. CONFIGRESOLVER - Resolver or Inductosyn
Feedback................................................................4-7

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. v
4.4.1.2. CONFIGENCODER - Encoder Feedback............. 4-8
4.4.1.3. CONFIGHENCODER - Encoder and Hall
Effect Sensor Feedback.......................................... 4-8
4.4.1.4. CONFIGHRESOLVER - Resolver and Hall
effect sensor feedback............................................ 4-9
4.4.1.5. ConfigD2A - Configure a DAC (D/A) Channel
for Use by This Axis.............................................. 4-9
4.4.1.6. ConfigRead - Read an Axis Configuration From
a File .................................................................... 4-10
4.4.1.7. ConfigWrite - Write an Axis Configuration to a
File....................................................................... 4-10
4.4.2. Faults, Errors, and Faultmasks ........................................... 4-11
4.4.2.1. Acknowledging (and Clearing) Faults.................. 4-11
4.5. Programming Errors ......................................................................... 4-12
4.5.1. Running CNC Programs..................................................... 4-12
4.6. Programming Commands ................................................................. 4-15
4.6.1. ? or (command) ? ............................................................... 4-18
4.6.2. ! (memory_command)........................................................ 4-18
4.6.3. ! TI ..................................................................................... 4-18
4.6.4. AX (axis_number).............................................................. 4-18
4.6.5. CMDERR (axis_number)................................................... 4-19
4.6.6. CMDLAST (axis_number)................................................. 4-19
4.6.7. CONFIGD2A (D2A_channel_number).............................. 4-19
4.6.8. CONFIGENCODER (encoder_ch)
(lines_per_revolution) (bounded)...................................... 4-20
4.6.9. CONFIGHENCODER (encoder_ch) (lines_per_rev)
(hall_lines) (com_offset) (comm_ch) (bounded)............... 4-21
4.6.10. CONFIGHRESOLVER (resolver_ch) (resolution)
(hall_lines) (com_offset) (comm_ch)(bounded)................. 4-22
4.6.11. CONFIGREAD (filespec).................................................. 4-23
4.6.12. CONFIGRESOLVER (resolver_ch) (resolution)
(poles) (com_offset)(bounded).......................................... 4-23
4.6.13. CONFIGWRITE (filespec) ................................................ 4-24
4.6.14. DB (address) ...................................................................... 4-24
4.6.15. DCAX ................................................................................ 4-24
4.6.16. DIR..................................................................................... 4-24
4.6.17. DOWNLOAD .................................................................... 4-24
4.6.18. DRVINFO.......................................................................... 4-25
4.6.19. DUMPTABLE (table number)........................................... 4-25
4.6.20. DUMPERROR (table number) .......................................... 4-25
4.6.21. DW (address) ..................................................................... 4-25
4.6.22. DL (address)....................................................................... 4-25
4.6.23. ENABLEPENDANT (channel) (mode 1).......................... 4-25
4.6.24. EXELINE (“command string”) .......................................... 4-26
4.6.25. EXEPRG (filespec)............................................................ 4-26
4.6.26. EXIT .................................................................................. 4-26
4.6.27. GETPROG......................................................................... 4-26
4.6.28. INFO .................................................................................. 4-26
4.6.29. IOGET (type) (point_number) ........................................... 4-27
4.6.30. IOMON (type) (point_number).......................................... 4-27
4.6.31. IOSET (type) (point_number) (value)................................ 4-28

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vi Aerotech, Inc. Version 1.4
4.6.32. MABORT...........................................................................4-28
4.6.33. MABSOLUTE (position) (speed) ......................................4-29
4.6.34. MALTHOME (direction) (speed) ......................................4-29
4.6.35. MFREERUN (direction) (speed)........................................4-30
4.6.36. MHALT..............................................................................4-30
4.6.37. MHOLD.............................................................................4-30
4.6.38. MHOME (direction) (speed)..............................................4-31
4.6.39. MINCREMENTAL (distance) (speed) ..............................4-31
4.6.40. MINFEEDSLAVE (distance) (speed)...............................4-32
4.6.41. MNOLIMITHOME (direction) (speed).............................4-32
4.6.42. MOSCILLATE (distance) (speed).....................................4-32
4.6.43. MQABSOLUTE (position) (velocity)................................4-33
4.6.44. MQFLUSH.........................................................................4-33
4.6.45. MQHOLD ..........................................................................4-33
4.6.46. MQINCREMENTAL (distance) (speed)............................4-33
4.6.47. MQUICKHOME (direction) (speed) .................................4-34
4.6.48. MQRELEASE....................................................................4-34
4.6.49. MRELEASE.......................................................................4-34
4.6.50. MB (address)......................................................................4-34
4.6.51. MEM..................................................................................4-34
4.6.52. ML (address)......................................................................4-35
4.6.53. MW (address).....................................................................4-35
4.6.54. OUTON (filespec)..............................................................4-35
4.6.55. OUTOFF [Z]......................................................................4-35
4.6.56. OUTPAUSE.......................................................................4-35
4.6.57. PARMGET (type) (parameter_name) ................................4-36
4.6.58. PARMMON (type) (parameter_name)...............................4-36
4.6.59. PARMSET (type) (parameter_name) (value).....................4-36
4.6.60. PLAY (filespec) [S] [P]......................................................4-36
4.6.61. PLYREWIND ....................................................................4-37
4.6.62. PRG1 (“command string”) .................................................4-37
4.6.63. PRGCMPL (filespec) (option) ...........................................4-37
4.6.64. PRGDUMP (filespec) ........................................................4-38
4.6.65. PRGERRS (filespec)..........................................................4-38
4.6.66. PRGINFO (filespec)...........................................................4-38
4.6.67. PRGLOAD (filespec) [num_lines] [userline_offset]..........4-38
4.6.68. PRGRUN (filespec) [line_number]....................................4-39
4.6.69. PRGSTATS (filespec)........................................................4-39
4.6.70. PRGTYPE (filespec)..........................................................4-39
4.6.71. PRGUNLOAD (filespec) ...................................................4-39
4.6.72. PSODOWNLOAD.............................................................4-39
4.6.73. QUIT..................................................................................4-39
4.6.74. RB (address).......................................................................4-40
4.6.75. RDO ...................................................................................4-40
4.6.76. RESET ...............................................................................4-40
4.6.77. RGINFO [device_id] [card_num] ......................................4-40
4.6.78. RL (address).......................................................................4-40
4.6.79. RW (address)......................................................................4-40
4.6.80. SPENDANTTEXT (channel) (line #) (text).......................4-41
4.6.81. TK (task_number) ..............................................................4-41
4.6.82. TSKASSOC (filespec) .......................................................4-41

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. vii
4.6.83. TSKDEASSOC.................................................................. 4-41
4.6.84. TSKINFO........................................................................... 4-41
4.6.85. TSKPRG (mode) (execution_type or line_number)........... 4-42
4.6.86. TSKRESET........................................................................ 4-42
4.6.87. VAGET (type) (number).................................................... 4-42
4.6.88. VCGET .............................................................................. 4-42
4.6.89. VDGET (type) (number).................................................... 4-43
4.6.90. VDMON (type) (number) .................................................. 4-43
4.6.91. VDSET (type) (number) (value) ........................................4-44
4.6.92. VSGET (type) (number)..................................................... 4-44
4.6.93. VSMON (type) (number)................................................... 4-44
4.6.94. VSSET (type) (number) (“string”)..................................... 4-45
4.6.95. WAIT ([!] condition).......................................................... 4-45
4.6.96. WB (address) (value) ......................................................... 4-46
4.6.97. WRITESERIAL (channel) (text)........................................ 4-46
4.6.98. WW (address) (value)........................................................ 4-46
4.6.99. WL (address) (value).......................................................... 4-46
4.6.105. ZMONITOR....................................................................... 4-47
4.6.106. ZONGOSUB...................................................................... 4-47
4.7. Command to Library Cross Reference.............................................. 4-48
CHAPTER 5: AERTUNE ........................................................................................ 5-1
5.1. Introduction........................................................................................ 5-1
5.2. The Main Window of the AerTune Program...................................... 5-2
5.2.1. The Help Menu .................................................................... 5-2
5.2.2. The File Menu...................................................................... 5-2
5.2.3. The Plot Menu...................................................................... 5-3
5.2.4. The Collect Menu................................................................. 5-3
5.2.5. The Graph Options Menu..................................................... 5-3
5.2.6. The Trigger Menu................................................................ 5-3
5.2.7. The Axis Menu..................................................................... 5-4
5.2.8. The Tools Menu................................................................... 5-4
5.3. Using AerTune ................................................................................... 5-4
5.3.1. Step Move Parameters.......................................................... 5-5
5.3.2. FFT Analysis........................................................................ 5-6
5.3.2.1. The FFT Analysis Window Menu Description...... 5-6
5.3.3. Determining the Maximum Acceleration of an Axis............ 5-7
5.3.4. Identifying an Instability within the Servo Loop.................. 5-8
5.3.5. Minimizing Position Error due to Torque Ripple or
Amplifier Offsets.................................................................. 5-8
5.3.6. AC Brushless Motor Tuning Tip.......................................... 5-9
5.3.7. Computing Torque (Closed-Loop Torque Mode).............. 5-10
5.4. Servo Loop Auto Tuning.................................................................. 5-11
5.4.1. Setting up AutoTune Parameters........................................ 5-12
5.4.2. Excitation Parameters......................................................... 5-13
5.4.2.1. Amplitude of Excitation in AutoTune.................. 5-13
5.4.2.2. Excitation Amplitude will exceed Velocity Trap
Limit..................................................................... 5-13
5.4.2.3. Units: Inches/Degrees or Counts.......................... 5-13
5.4.2.4. Starting Frequency for Excitation in AutoTune... 5-13
5.4.2.5. Ending Frequency for Excitation in AutoTune.... 5-13

Table of Contents U600 User’s Guide
viii Aerotech, Inc. Version 1.4
5.4.2.6. # Points to Collect in AutoTune...........................5-14
5.4.3. Tuning Parameters..............................................................5-14
5.4.3.1. Velocity Bandwidth .............................................5-14
5.4.3.2. Damping...............................................................5-14
5.4.3.3. Use VFF...............................................................5-15
5.4.3.4. Calculate AFFGAIN ............................................5-15
5.5. Manual Servo Loop Tuning..............................................................5-16
5.5.1. Kp - Proportional Gain.......................................................5-18
5.5.2. Ki - Integral Gain ...............................................................5-18
5.5.3. PGain - Position Gain.........................................................5-18
5.5.4. Vff - Velocity Feedforward Gain .......................................5-18
5.5.5. AffGain - Acceleration Feedforward Gain.........................5-19
5.5.6. Alpha - AffGain Filter........................................................5-19
5.5.7. VGain - Constant Velocity Gain.........................................5-19
5.6. Tuning Procedure for Torque (Current) Mode Servo Loops............5-20
5.7. Tuning With Tachometer Feedback..................................................5-30
5.7.1. Vff - Velocity Feed Forward ..............................................5-30
5.7.2. VGain - Constant Velocity Gain.........................................5-30
5.7.3. Servo Parameter Setup for Tachometer Feedback..............5-30
5.7.4. The Servo Loop Parameters for Tachometer-Based
Systems...............................................................................5-31
5.7.4.1. PGain - Position Gain ..........................................5-31
5.7.4.2. Vff - Velocity Feedforward Gain.........................5-31
5.7.4.3. Kp - Proportional Gain.........................................5-31
5.7.4.4. Ki - Integral Gain.................................................5-31
5.7.4.5. AffGain - Acceleration Feedforward Gain...........5-31
5.7.4.6. VGain - Constant Velocity Gain ..........................5-31
5.8. Tuning Tachometer Loops................................................................5-32
CHAPTER 6: AERPLOT.........................................................................................6-1
6.1. Introduction ........................................................................................6-1
6.2. File Menu............................................................................................6-2
6.3. Plot Menu ........................................................................................... 6-2
6.4. Trigger Menu......................................................................................6-3
6.5. Collect Menu ...................................................................................... 6-3
6.6. Axis Menu ..........................................................................................6-3
6.7. Graph Options Menu .......................................................................... 6-3
6.8. Tools Menu.........................................................................................6-4
6.8.1. The FFT Analysis Window Menu Description.....................6-5
6.9. Help Menu..........................................................................................6-5
CHAPTER 7: AERSTAT.........................................................................................7-1
7.1. Introduction ........................................................................................7-1
7.2. Overview ............................................................................................7-2
CHAPTER 8: AERREG...........................................................................................8-1
8.1. Introduction ........................................................................................8-1
8.2. Editing Registry Entries......................................................................8-1
8.2.1. Finding and/or Creating a “Card 1” Entry............................8-1
8.2.2. Modifying the “Card 1” Entry..............................................8-2

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. ix
CHAPTER 9: AERPLOT3D.................................................................................... 9-1
9.1. Introduction........................................................................................ 9-1
9.1.1. File Menu............................................................................. 9-1
9.1.1.1. Writing a Plot Data File......................................... 9-2
9.1.1.2. Reading and Displaying a Plot Data File............... 9-2
9.1.2. Plot Type Menu.................................................................... 9-2
9.1.3. Setup Menu .......................................................................... 9-2
9.1.4. Colors Menu......................................................................... 9-3
9.1.5. Grid Lines Menu .................................................................. 9-3
9.1.6. Units Menu........................................................................... 9-3
9.1.7. Start Menu............................................................................ 9-3
9.1.8. Stop Menu............................................................................ 9-4
9.1.9. Resume Menu....................................................................... 9-4
9.1.10. Suspend Menu...................................................................... 9-4
9.1.11. Help Menu............................................................................ 9-4
9.2. Auto Scaling the Display in AerPlot3D.............................................. 9-4
CHAPTER 10: AERPLOTIO.................................................................................. 10-1
10.1. Introduction...................................................................................... 10-1
CHAPTER 11: FILTER........................................................................................... 11-1
11.1. Introduction...................................................................................... 11-1
CHAPTER 12: SETUP WIZ.................................................................................... 12-1
12.1. Introduction...................................................................................... 12-1
12.2. Axis Names and Number.................................................................. 12-2
12.2.1. Axis Names........................................................................ 12-2
12.3. Configuring Axis Type..................................................................... 12-3
12.4. Axis Configuration ........................................................................... 12-4
12.4.1. Axis Configuration Wizard ................................................ 12-5
12.4.2. Axis & Parameter Names and Task Number
Configuration ..................................................................... 12-6
12.4.3. Configuring Axis Type....................................................... 12-7
12.4.3.1.Predefined Axis Types......................................... 12-8
12.4.4. Configuring the Primary Feedback Device ........................ 12-8
12.4.5. Configuring a DAC Channel.............................................. 12-9
12.4.6. Configuring the Secondary Feedback Device ..................12-10
12.4.6.1.Encoder Configuration....................................... 12-11
12.4.6.2.EncoderHall Configuration................................ 12-11
12.4.6.3.EncoderHall (Pole Pairs) Configuration ............ 12-13
12.4.6.4.Resolver Configuration (or Inductosyn)............. 12-15
12.4.6.5.ResolverHall Configuration ............................... 12-16
12.4.6.6.Stepper Motor Configuration............................. 12-17
12.4.6.7.Null (Virtual) Configuration.............................. 12-18
12.4.6.8.Configuring Dual Loop Axes............................. 12-18
12.4.7. Configuring Axis Calibration Data................................... 12-19
12.4.8. Saving an Axis Configuration .......................................... 12-20
12.5. Scaling and Feedrates..................................................................... 12-21
12.6. Home Cycle Configuration............................................................. 12-22
12.7. Asynchronous and G0 Accel/Decel Parameters ............................. 12-24